Transcript APQP (Advanced Product Quality Planning) STA Version

APQP (Advanced Product Quality
Planning)
Supplier Version
Supplier Technical Assistance
Business Office
Training Purpose
• It is intended to be an overview of the APQP process.
• It is not intended to be a detailed training instruction in the use
of the APQP Assessment.
• Basic Industry Tools (e.g. FMEA & PPAP) are unchanged.
However, the format of the APQP assessment has changed.
• Important to focus on the tools not just the format
• Where to find additional information is given at the end of this
presentation
Contents
•
Background
 APQP - Key Features when considering GPDS
 JLR & Supply Base Integration
 Process overview
 PMST: Key Deliverables
Contents (continued)
•
Reporting Process Overview
 APQP Assessment
 APQP Reporting
•
Priority / High Impact Supplier Engagement Overview
 Priority / High Impact Supplier Selection
 Team Make up
 Supplier Evaluations
Note: The terms Priority supplier & High Impact
supplier are interchangeable.
APQP – Key Features when considering
GPDS
•
Emphasis on “Front-End Loading” of a programme to support earlier
activities
•
Failure Mode Avoidance through Compatibility before Completion
•
Powertrain (PT), Under Body (UN) & Upper Body (UP) start at different
points
•
Higher reliance on Virtual Engineering, Virtual Builds
•
Virtual Prove-Out = early & cheap: before FDJ
•
Physical Prove-Out = late & expensive…
•
Synchronised Compatibility Check at FDJ
•
Single Point of Release
•
VP Build to verify total vehicle Specs.
•
Shorter launch period
JLR & Supply Base Integration
PMST Compatibility verification with
the supplier’s manufacturing site:
Product Design  Process Design
Ongoing Communication of
requirements, changes, effects,
issues, solutions, re-planning
= PMST Core Business
Supplemented by STA Site
activities ~ (Priority Supplier
Manufacturing sites)
APQP: Approach
• Suppliers are required to use Advanced Product Quality Planning &
Production Part Approval Process (TS16949 & Customer Specifics)
• From Sourcing to Launch APQP is the prime method of planning &
communication between JLR & Supplier: Status is critical to JLR
• Some Suppliers will be designated Priority Suppliers. Degree of
engagement will be determined by
> Supplier Manufacturing Site Capability
> Part Criticality
• Designation will be reviewed during the course of the programme
• Jaguar Land Rover multifunctional teams will evaluate Priority
suppliers a minimum of four (4) times
> PMST Deep Dive Confirmation
APQP – PMST Additional emphasis
•
STA Role: Confirming programme viability at each
Milestone based upon Supplier Readiness
•
STA’s involvement is critical in Failure Mode
detection & countermeasure development =
compatibility of Product Design & Process Design
(Feasibility)
•
Facilitated by:
• Formalised Cross-functional Team Engagement
• Early Supplier Manufacturing involvement
APQP Process Overview
Topic:
APQP process overview
Principles:
Agree Priority
Supplier
Manufacturing Sites
PD, STA & Purchase
Sourcing
Early cross functional engagement, integrates GPDS, APQP & PPAP
Enter Plan Dates into APQP.
Rate actual & predicted status of Deliverables &
Expectations.
Specify corrective actions where not Green
or not Complete. Complete Summary for Reds
All Suppliers
Communicate to all Suppliers
directing use of Supplier APQP
Assessment as planning and
status reporting tool
Programme STA
Programme
Start
Achieve consensus that
status is accurate
Supplier, PD, STA & other
team members as required
Submit APQP
Assessment Monthly
All Suppliers
215 Timed Expectations
49 Timed APQP
Deliverables
31 APQP
Elements
Unit
PTC
Unit
PA
PTCC
Mail box
Element Summary
Report - All Suppliers
Deliverables: Completion
vs Due GPDS Milestone
Each Function
responsible for
their Lead Items
Supplier Scorecard
Summary by Supplier of Status,
Issues & Action Plans
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
For Priority Suppliers
PTC/
M1DJ
M1
PA
FDJ
VP
PEC
LR/
FEC
TT
PP
MP1
For Priority suppliers, engagement will be centred around a series of
evaluations by a cross-functional team that includes the PD Engineer,
Buyer, STA Site Engineer and representatives from other JLR
functions as required
CrossFunctional
Teams Formed
Team KickOff
Meetings
Begin
PD Lead
Share Assessment Document with
PD Engineer & STA Site Engineer
(and other team members as
required)
All Suppliers
Resolve Open Issues
Evaluation #1:
Verify FMA Strategy
& M/f Plan. PD Lead
Evaluation
#2: Verify
Launch Prep
& VP Parts.
Joint Lead
Decision
to Proceed to
Run-atRate
Evaluation
#3: Verify
Supplier
Capability.
STA Lead
Monthly Update of APQP Assessment
Evaluation
#4: Confirm
Supplier
Capacity.
STA Lead
APQP Process Overview:
Team Consensus of Status
liers
er
ent
status
/
Enter Plan Dates into Assessment Document.
Review & Assess due Expectations and rate Due
& Forecast Deliverables. Specify corrective
actions where not Green
or not Complete. Complete Summary for Reds
All Suppliers
Achieve consensus that
status is accurate
Supplier, PD, Site STA & other
team members as req'd
Share Assessment Document with
PD Engineer & STA Site Engineer
(and other team members as
required)
All Suppliers
For Priority Suppliers
M1
LR/
APQP Process Overview
Topic:
APQP process overview
Principles:
Agree Priority
Supplier
Manufacturing Sites
PD, STA & Purchase
Sourcing
Early cross functional engagement, integrates GPDS, APQP & PPAP
Enter Plan Dates into APQP.
Rate actual & predicted status of Deliverables &
Expectations.
Specify corrective actions where not Green
or not Complete. Complete Summary for Reds
All Suppliers
Communicate to all Suppliers
directing use of Supplier APQP
Assessment as planning and
status reporting tool
Programme STA
Programme
Start
Achieve consensus that
status is accurate
Supplier, PD, STA & other
team members as required
Submit APQP
Assessment Monthly
All Suppliers
215 Timed Expectations
49 Timed APQP
Deliverables
31 APQP
Elements
Unit
PTC
Unit
PA
PTCC
Mail box
Element Summary
Report - All Suppliers
Deliverables: Completion
vs Due GPDS Milestone
Each Function
responsible for
their Lead Items
Supplier Scorecard
Summary by Supplier of Status,
Issues & Action Plans
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
For Priority Suppliers
PTC/
M1DJ
M1
PA
FDJ
VP
PEC
LR/
FEC
TT
PP
MP1
For Priority suppliers, engagement will be centred around a series of
evaluations by a cross-functional team that includes the PD Engineer,
Buyer, STA Site Engineer and representatives from other JLR
functions as required
CrossFunctional
Teams Formed
Team KickOff
Meetings
Begin
PD Lead
Share Assessment Document with
PD Engineer & STA Site Engineer
(and other team members as
required)
All Suppliers
Resolve Open Issues
Evaluation #1:
Verify FMA Strategy
& M/f Plan. PD Lead
Evaluation
#2: Verify
Launch Prep
& VP Parts.
Joint Lead
Decision
to Proceed to
Run-atRate
Evaluation
#3: Verify
Supplier
Capability.
STA Lead
Monthly Update of APQP Assessment
Evaluation
#4: Confirm
Supplier
Capacity.
STA Lead
APQP Process Overview
Unit
PTC
Unit
PA
PTCC
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
PTC/
M1DJ
M1
PA
FDJ
PEC
LR/
FEC
TT
PP
MP1
For Priority suppliers, engagement will be centred around a series of
evaluations by a cross-functional team that includes the PD Engineer,
Buyer, STA Site Engineer and representatives from other JLR
functions as required
CrossFunctional
Teams Formed
Team KickOff
Meetings
Begin
PD Lead
VP
Resolve Open Issues
Evaluation #1:
Verify FMA Strategy
& M/f Plan. PD Lead
Evaluation
#2: Verify
Launch Prep
& VP Parts.
Joint Lead
Decision
to Proceed to
Run-atRate
Evaluation
#3: Verify
Supplier
Capability.
STA Lead
Monthly Update of APQP Assessment
Evaluation
#4: Confirm
Supplier
Capacity.
STA Lead
APQP Process Overview
Topic:
APQP process overview
Principles:
Agree Priority
Supplier
Manufacturing Sites
PD, STA & Purchase
Sourcing
Early cross functional engagement, integrates GPDS, APQP & PPAP
Enter Plan Dates into APQP.
Rate actual & predicted status of Deliverables &
Expectations.
Specify corrective actions where not Green
or not Complete. Complete Summary for Reds
All Suppliers
Communicate to all Suppliers
directing use of Supplier APQP
Assessment as planning and
status reporting tool
Programme STA
Programme
Start
Achieve consensus that
status is accurate
Supplier, PD, STA & other
team members as required
Submit APQP
Assessment Monthly
All Suppliers
215 Timed Expectations
49 Timed APQP
Deliverables
31 APQP
Elements
Unit
PTC
Unit
PA
PTCC
Mail box
Element Summary
Report - All Suppliers
Deliverables: Completion
vs Due GPDS Milestone
Each Function
responsible for
their Lead Items
Supplier Scorecard
Summary by Supplier of Status,
Issues & Action Plans
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
For Priority Suppliers
PTC/
M1DJ
M1
PA
FDJ
VP
PEC
LR/
FEC
TT
PP
MP1
For Priority suppliers, engagement will be centred around a series of
evaluations by a cross-functional team that includes the PD Engineer,
Buyer, STA Site Engineer and representatives from other JLR
functions as required
CrossFunctional
Teams Formed
Team KickOff
Meetings
Begin
PD Lead
Share Assessment Document with
PD Engineer & STA Site Engineer
(and other team members as
required)
All Suppliers
Resolve Open Issues
Evaluation #1:
Verify FMA Strategy
& M/f Plan. PD Lead
Evaluation
#2: Verify
Launch Prep
& VP Parts.
Joint Lead
Decision
to Proceed to
Run-atRate
Evaluation
#3: Verify
Supplier
Capability.
STA Lead
Monthly Update of APQP Assessment
Evaluation
#4: Confirm
Supplier
Capacity.
STA Lead
Principles of APQP Priority Supplier Engagement
1.
Supplier launch success is a cross-functional, shared
responsibility – PD, STA, Buyers are core team members
(Other JLR team members, e.g. MP&L and AME can be called
upon as and when necessary)
2.
JLR cross-functional teams will work proactively with the
highest leverage suppliers on a programme
3.
Supplier engagement will begin early in a programme –
immediately after sourcing
Principles of APQP Priority Supplier Engagement
4.
JLR cross functional teams (PMST) will review Priority
Suppliers a minimum of four (4) times (PMST to decide if all
reviews need to be at the Supplier manufacturing site)
5. The teams will provide the supplier with a single JLR voice on
key launch matters
6. Underlying APQP and PPAP processes and roles &
responsibilities will remain the same
7. Team engagement will continue until the supplier has
successfully completed all PPAP requirements and fully met all
program ramp-up volumes
APQP Supplier Engagement – Priority Sites
• A programme’s suppliers are defined as “Priority” or “NonPriority.”
• Priority suppliers have parts that present major risks to
the launch (site, part, or programme risk).
• The list is reviewed at decision points in the programme
• Early in the programme the focus has to be on suppliers
where enhanced Failure Mode Avoidance effort is critical
• Suppliers affected by late change should join the Priority
list
The APQP Supplier Engagement Process will focus crossfunctional JLR resources on the Priority suppliers.
APQP Process Overview – 49 Key Deliverables
Reporting will focus on measurable “Deliverables” that highlight APQP
Element completion at a given programme milestone
APQP Element
1.
Lead
Sourcing decision
Pre APQP: Site STA
objective is:
If STA Approves Non-Q1
Sourcing then there is a
sound basis for viability.
Buyer
2.
Customer input requirements
3.
Craftsmanship/
appearance approval report
4.
DFMEA
Due*
<PTCC>
Deliverables
1. Required Sourcing Agreement Signed
<PA>
2. Required Supplier Commercial & Program Agreements Signed
<FDJ>
3. All Production Tool Orders Issued to Suppliers
<PA>
4. Final Mix, Maximum Weekly Volume Communicated and Agreed
PD
<PA>
5. Program Expectations Cascaded to Suppliers
PD
<TT>
6. AAR Approved
<PP>
7. Color Changes Completed Supporting Color Harmony
<PA>
8. DFMEA Completed
<PA>
9. Special Characteristics Cascaded to Suppliers
PD
5.
Design/manufacturing reviews
PD/STA
<PP>
10. Quality Issues Closed and Effective
6.
DVP&R material,
performance test results
PD
<TT>
11. DV Testing Complete
7.
Subcontractor APQP status
STA
<FDJ>
12. Sub-supplier PPAP Timing Plan Completed
<TT>
13. Sub-supplier PPAP Phase 1 (or equivalent) Completed
<MP1>
14. Sub-supplier PPAP Phase 3 (or equivalent) Completed
*UP Timing Shown
Reporting will focus on measurable “Deliverables” that highlight APQP
Element completion at a given programme milestone
APQP Element
8.
9.
10.
11.
Facilities, Tools & Gauges
Lead
STA
Due*
Deliverables
<FDJ>
15. Facility and Tooling Timing Plan Completed
<TT>
16. Facilities/Tools/Gauges are at the Final Production Location
<PTC>
17. Supplier’s OEE plan is Confirmed by Surrogate Data
<PA>
18. Gauge Plan (Including Released Gauge Drawings) Completed
<TT>
19. Supplier’s Demonstrated OEE (Phase 0) supports capacity
requirements
Prototype Control Plan
PD
<FDJ>
20. Prototype Build Control Plan Completed
Prototype Build
PD
<FDJ>
21. All Prototype Tool Orders Issued to Suppliers
<FDJ>
22. Prototype Parts Ordered
<FDJ>
23. Prototype Parts Achieve 100% of Required Print Specs.
<PSC>
24. Design Styling Confirmation
<FDJ>
25. Design Release (WERS) Completed
Drawings & Specifications
PD
12.
Engineering Change
PD
<TT>
26. All JLR Engineering Changes Approved & Recognized by the
Supplier
13.
Team Feasibility
PD/STA
<FDJ>
27. Design, Process, & Timing Feasibility Confirmation
14.
Manufacturing Process Flow
STA
<PEC>
28. Final Process Flowchart Supports PPAP Phase 0 Event
*UP Timing Shown
Reporting will focus on measurable “Deliverables” that highlight
APQP Element completion at a given programme milestone
APQP Element
Lead
Due*
Deliverables
15.
PFMEA
STA/PD
<VP>
29. Final PFMEA Completed with Linkages
16.
Measurement System Analysis
STA
<TT>
30. Gauge R&R Results <= 10% per PPAP Ford Customer Specifics
17.
Qualified Laboratory Documents
STA
<TT>
31. Supplier Internal & External Laboratory Compliance
18.
Checking Aids
STA
<TT>
32. Checking Aids Compliant With Part Specifications
19.
Pre-Launch Control Plan
STA
<PEC>
33. Pre-Launch Control Plan Completed with Linkages
20.
Operator Instructions
STA
<PEC>
34. Operator Process Instructions Completed
21.
Packaging Specifications
MP&L
<TT>
35. Packaging Approval Process Completed
22.
Production Trial Run
STA
<TT>
36. PPAP Phase 0 (Including Sub-suppliers) Completed
23.
Production Control Plan
STA
<TT>
37. Production Control Plan Complete with Linkages
24.
Initial Process Capability
STA
<TT>
38. Initial Process Capability Results (Ppk >= 1.67)
*UP Timing Shown
Reporting will focus on measurable “Deliverables” that highlight
APQP Element completion at a given programme milestone
APQP Element
Lead
Due*
Deliverables
25.
Dimensional Results
STA
<TT>
39. 100% of Required Measured Points within Tolerance
26.
PV Testing
PD
<TT>
40. PV Testing Complete
27.
PSW
STA/PD
<TT>
41. PPAP Phase 1 Completed
<PEC>
42. Demonstrate Compliance with RSMS
<PP>
43. PPAP Phase 2 Completed
<MP1>
44. PPAP Phase 3 completed
<MP1>
45. Suppliers Demonstrated OEE Support Capacity Req.
28.
Bulk Material Requirements
STA
<TT>
46. Bulk Materials Checklist Included in PPAP Submission
29.
Sample Product
STA
<TT>
47. Sample Product Produced with JLR Identification
30.
Master Sample
STA
<TT>
48. Master Sample Approved
31.
Record of Compliance
STA
<TT>
49. JLR Specific Requirements Documented
*UP Timing Shown
Supplier Sourcing
Unit
PTC
Unit
PA
PTCC
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
CrossFunctional
Teams Formed
Team
Kick-Off
Meetings
Begin
PTC/
M1DJ
M1
PA
FDJ
VP
PEC
LR/
FEC
TT
PP
The APQP process begins once the suppliers are
sourced.
GPDS breaks the vehicle into Powertrain (PT),
Underbody (UN), and Upperbody (UP). Sourcing
completion is generically required by:
PT: <PTCC>
Resolve Open Issues
UN: <PTCC>
UP: <PTCC>Evaluation
+ 90 Days
Evaluation
#1
#2
Decision
to
Proceed
to RunAt-Rate
Evaluation
#3
Update of APQP Assessment
Evaluation
#4
MP1
APQP Assessment
Principles of Use:
• Completed by all NTEI Suppliers
• Submitted to JLR monthly after <PTCC>
• Consolidated automatically to produce rolled-up supplier
deliverables & readiness reports
Summary View (OFF)
Submission
Dates
DD-MMM-YY
Program
Information
Current Milestone
Program Code:
Program Name:
Model Year:
APQP Current Date:
Click Here to Clear Entries
Final
Assessment
FDJ
FDJ
Formatted to Print A4 (EU)
Import Previous APQP
Highlight Next Deliverable (ON)
APQP JLR Version 1
Priority Site
Select Vehicle PartitionUnderbody
Underbody
Select Vehicle PMT
RANGE ROVER
2013
15/01/2010
Previous APQP Date: 18/11/2009
Supplier Contact Information
Chassis
Chassis
Program Contact Name: ASMITH
Base Part Number: AC123456
Base Part Name: WIDGET
Total Number of Parts: 99
User Plant: JLR
Manufacturing Supplier Site Code: XXXXX
Supplier Name: XXXXX
Location: XXXXX
Q1 Status: Y Y
Q1 Score: 1000
L405
Program Contact Phone: 0044 123456
e-mail Address: ASMITH@SUPP
email Address: BSMITH@SUPP
Planned
Completion
Date
DD-MMM-YY
Expectations / Deliverables
VPP Timing
Deliverable Number
Expectation Number
ELEMENT
PTCC
PTC
PA
VP
M-1DJ
AA1
AA2
UPV0
UPV1
UPV2
Dates
DD-MMM-YY
Builds
UNV0
UNV1
UNV2
FDJ
PEC
05-Feb-10
05-Feb-11
b) Commercial and
Program Agreement
c) Volume and Mix
1
All Quality, Cost, Weight, and Functional (QCWF) targets have been reviewed, documented and
agreed as part of the Sourcing Agreement Process.
2
The Preliminary Engineering, Development & Testing (ED&T) budget has been defined in the
Sourcing Agreement.
Supplier agreement letter has been issued and the supplier manufacturing site has been
identified.
1
3
Cost model has been developed and agreed, including process to manage change control.
4
There are no outstanding issues on the Final ED&T budget and QCWF targets.
C
2
All required Supplier Commercial and Program Agreements (CPA) have been signed.
Note: UN and UP due 2 months before <PA>, PTO scale 1-4 due 1 month before <PTC>, PTO
scale 5 and 6 due 2 months before <PA>.
C
3
All Production tooling orders have been issued to suppliers.
C
4
Final Mix (estimated Take Rate), Average Production Weekly (APW) and Maximum Production
Weekly (MPW) have been communicated and agreed by the supplier via the SA/CPA document.
C
2. Customer Input Requirements
5
Supplier has received a list of the key contact personnel within Jaguar Land Rover, including
names, locations, and phone numbers of the Program Managers, Product Development
Engineers, Buyer, Supplier Technical Assistance (STA) Engineer, Material Planning and Logistics
(MP&L) and others as appropriate.
6
Supplier has received specifications, as they become available, to understand Product
Assumptions, Functional Performance, Dimensions, Weights, Materials, and Craftsmanship
requirements. Requirements for service parts (if applicable) have also been cascaded.
7
Supplier has received Reliability and Quality Goals including Functional Performance Specs, 10
yr/150 mileage Useful Life Reliability Initiative (ULRI) Targets, Warranty Targets, and Incoming
Quality Targets (PPM, etc.).
8
Supplier has received the Program Timing Dates for APQP requirements, Program Status
Reviews, Design Freeze, Prototype Builds, Material Required/In Plant Dates, and Job#1. The
Supplier has used this timing information to create a timing plan in support of the APQP elements
noted in the PDP and in this APQP Assessment.
9
Supplier has received applicable affordable cost targets, as they are defined for the Program,
including capacity and peak volumes.
10
5
LS
Supplier has received and understood any related logistics and volume requirements (including
packaging concerns, density of containers and frequency of shipment).
Supplier has received all necessary information identified in the expectations of the Customer
Input Requirements element, to plan, design, manufacture and ship the product.
Lead Buyer: ESMITH
C
Evidence
(Metric)
PP MRD
MP&L Analyst: FSMITH
Program Mailbox: APQPL405
J1
FEC
TT MRD
Dates
DD-MMM-YY
1. Sourcing Decision
a) Sourcing Agreement
LR
Dates
DD-MMM-YY
Engineering Milestones
LEAD PD ENGINEER: CSMIYJ
Lead STA Site Engineer: DSNITH
Plant Contact Name: BSMITH
Plant Contact Phone: 0044 234555
Program Milestones
JLR Contact Information
(Corporate Directory System ID)
MP1
MRD
MP2
Actual
Completion
Dates
DD-MMM-YY
Action Plan/
Counter Measure Description
Action Plan/
Counter Measure
Responsibility
Action Plan/
Counter
Measure
Date
DD-MMM-YY
APQP Assessment: Functionality
Functionality:
• The APQP Assessment uses Excel macros to function
properly.
• The user must always select ENABLE macros. Failure to
enable the macros will result in loss of functionality.
• The APQP assessment is designed for use with Excel 2003
and Excel 2007.
• Using previous versions of Excel will result in a loss of
functionality.
• For further guidance please refer to the APQP User Guide
APQP Assessment: Meeting cadence
Priority Suppliers:
• Submit the APQP Assessment monthly as required by the
STA programme team.
• Site STA to review the APQP Assessment with the rest of
the PMST prior to this monthly submission.
Non Priority Suppliers:
• Submit the APQP Assessment as per Priority Suppliers
• Send copy of APQP Assessment to STA and PD engineers
prior to submission to the JLR programme team
APQP Assessment -- Detail
2. Element Status Section Structure
31
Structure:
APQP
Elements
The Element Status section
of the Assessment is
structured in a hierarchy that
includes:
49
Deliverables
(minimum 1
per element)
Team
215
Expectations
Business
Summary View (OFF)
Submission
Dates
DD-MMM-YY
Program
Information
Current Milestone
Click Here to Clear Entries
Final
Assessment
FDJ
FDJ
Formatted to Print A4 (EU)
Criteria
Import Previous APQP
Highlight Next Deliverable (ON)
APQP JLR Version 1
Priority Site
Select Vehicle PartitionUnderbody
Underbody
Supplier Contact Information
Chassis
Select Vehicle PMT Chassis
Program Contact Name: ASMITH
Base Part Number: AC123456
Base Part Name: WIDGET
Total Number of Parts: 99
User Plant: JLR
Manufacturing Supplier Site Code: XXXXX
Supplier Name: XXXXX
Location: XXXXX
Q1 Status: Y Y
Q1 Score: 1000
Program Code: L405
Program Name: RANGE ROVER
Model Year: 2013
APQP Current Date: 15/01/2010
Previous APQP Date: 18/11/2009
QoE
Program Contact Phone: 0044 123456
e-mail Address: ASMITH@SUPP
email Address: BSMITH@SUPP
Planned
Completion
Date
DD-MMM-YY
Expectations / Deliverables
VPP Timing
Deliverable Number
Expectation Number
ELEMENT
PTCC
PTC
PA
VP
M-1DJ
AA1
AA2
UPV0
UPV1
UPV2
Dates
DD-MMM-YY
Builds
UNV0
UNV1
UNV2
FDJ
PEC
05-Feb-10
05-Feb-11
Dates
DD-MMM-YY
b) Commercial and
Program Agreement
c) Volume and Mix
1
All Quality, Cost, Weight, and Functional (QCWF) targets have been reviewed, documented and
agreed as part of the Sourcing Agreement Process.
2
The Preliminary Engineering, Development & Testing (ED&T) budget has been defined in the
Sourcing Agreement.
Supplier agreement letter has been issued and the supplier manufacturing site has been
identified.
1
3
Cost model has been developed and agreed, including process to manage change control.
4
There are no outstanding issues on the Final ED&T budget and QCWF targets.
C
2
All required Supplier Commercial and Program Agreements (CPA) have been signed.
Note: UN and UP due 2 months before <PA>, PTO scale 1-4 due 1 month before <PTC>, PTO
scale 5 and 6 due 2 months before <PA>.
C
3
All Production tooling orders have been issued to suppliers.
C
4
Final Mix (estimated Take Rate), Average Production Weekly (APW) and Maximum Production
Weekly (MPW) have been communicated and agreed by the supplier via the SA/CPA document.
C
2. Customer Input Requirements
5
Supplier has received a list of the key contact personnel within Jaguar Land Rover, including
names, locations, and phone numbers of the Program Managers, Product Development
Engineers, Buyer, Supplier Technical Assistance (STA) Engineer, Material Planning and Logistics
(MP&L) and others as appropriate.
6
Supplier has received specifications, as they become available, to understand Product
Assumptions, Functional Performance, Dimensions, Weights, Materials, and Craftsmanship
requirements. Requirements for service parts (if applicable) have also been cascaded.
7
Supplier has received Reliability and Quality Goals including Functional Performance Specs, 10
yr/150 mileage Useful Life Reliability Initiative (ULRI) Targets, Warranty Targets, and Incoming
Quality Targets (PPM, etc.).
8
Supplier has received the Program Timing Dates for APQP requirements, Program Status
Reviews, Design Freeze, Prototype Builds, Material Required/In Plant Dates, and Job#1. The
Supplier has used this timing information to create a timing plan in support of the APQP elements
noted in the PDP and in this APQP Assessment.
9
Supplier has received applicable affordable cost targets, as they are defined for the Program,
including capacity and peak volumes.
10
5
LS
J1
PP MRD
MP1
MRD
Supplier has received and understood any related logistics and volume requirements (including
packaging concerns, density of containers and frequency of shipment).
Supplier has received all necessary information identified in the expectations of the Customer
Input Requirements element, to plan, design, manufacture and ship the product.
FEC
TT MRD
1. Sourcing Decision
a) Sourcing Agreement
LR
Dates
DD-MMM-YY
Engineering Milestones
LEAD PD ENGINEER: CSMIYJ
Lead STA Site Engineer: DSNITH
Lead Buyer: ESMITH
Plant Contact Name: BSMITH
Plant Contact Phone: 0044 234555
Program Milestones
JLR Contact Information
(Corporate Directory System ID)
C
Evidence
(Metric)
MP2
Actual
Completion
Dates
DD-MMM-YY
Action Plan/
Counter Measure Description
MP&L Analyst: FSMITH
Program Mailbox: APQPL405
Action Plan/
Counter Measure
Responsibility
Action Plan/
Counter
Measure
Date
DD-MMM-YY
-- APQP Elements
-- Deliverables
-- Expectations
The suppliers will enter their
specific status ratings in this
section of the document
against each programme
milestone or build event.
APQP Assessment -- Detail
The APQP Assessment contains 3 sections:
1) Header Section
2) Element Status Section
3) Summary Section
Summary View (OFF)
Click Here to Clear Entries
Final
Assessment
Submission
Dates
DD-MMM-YY
Program
Information
FDJ
Current Milestone FDJ
Formatted to Print A4 (EU)
Import Previous APQP
Highlight Next Deliverable (ON)
APQP JLR Version 1
Priority Site
Select Vehicle PartitionUnderbody
Underbody
Base Part
Base Part Name: WIDGET
Total Number of Parts: 99
User Plant: JLR
Manufacturing Supplier Site
Supplier Name: XXXXX
Location: XXXXX
Q1 Status: Y Y
Q1 Score: 1000
Program Name: RANGE ROVER
Model Year: 2013
APQP Current Date: 15/01/2010
Previous APQP Date: 18/11/2009
Program Contact Name: ASMITH
Number: AC123456
Code: XXXXX
Program Code: L405
Supplier Contact Information
Chassis
Select Vehicle PMT Chassis
Program Contact Phone: 0044 123456
e-mail Address: ASMITH@SUPP
email Address: BSMITH@SUPP
DD-MMM-YY
Expectations / Deliverables
VPP Timing
Deliverable Number
Expectation Number
ELEMENT
Planned
Completion
Date
PTCC
PTC
PA
VP
M-1DJ
AA1
AA2
UPV0
UPV1
UPV2
Dates
DD-MMM-YY
Builds
UNV0
UNV1
UNV2
FDJ
PEC
05-Feb-10
05-Feb-11
b) Commercial and
Program Agreement
c) Volume and Mix
1
All Quality, Cost, Weight, and Functional (QCWF) targets have been reviewed, documented and
agreed as part of the Sourcing Agreement Process.
2
The Preliminary Engineering, Development & Testing (ED&T) budget has been defined in the
Sourcing Agreement.
Supplier agreement letter has been issued and the supplier manufacturing site has been
identified.
1
3
Cost model has been developed and agreed, including process to manage change control.
4
There are no outstanding issues on the Final ED&T budget and QCWF targets.
C
2
All required Supplier Commercial and Program Agreements (CPA) have been signed.
Note: UN and UP due 2 months before <PA>, PTO scale 1-4 due 1 month before <PTC>, PTO
scale 5 and 6 due 2 months before <PA>.
C
3
All Production tooling orders have been issued to suppliers.
C
4
Final Mix (estimated Take Rate), Average Production Weekly (APW) and Maximum Production
Weekly (MPW) have been communicated and agreed by the supplier via the SA/CPA document.
C
2. Customer Input Requirements
5
LS
5
Supplier has received a list of the key contact personnel within Jaguar Land Rover, including
names, locations, and phone numbers of the Program Managers, Product Development
Engineers, Buyer, Supplier Technical Assistance (STA) Engineer, Material Planning and Logistics
(MP&L) and others as appropriate.
6
Supplier has received specifications, as they become available, to understand Product
Assumptions, Functional Performance, Dimensions, Weights, Materials, and Craftsmanship
requirements. Requirements for service parts (if applicable) have also been cascaded.
7
Supplier has received Reliability and Quality Goals including Functional Performance Specs, 10
yr/150 mileage Useful Life Reliability Initiative (ULRI) Targets, Warranty Targets, and Incoming
Quality Targets (PPM, etc.).
8
Supplier has received the Program Timing Dates for APQP requirements, Program Status
Reviews, Design Freeze, Prototype Builds, Material Required/In Plant Dates, and Job#1. The
Supplier has used this timing information to create a timing plan in support of the APQP elements
noted in the PDP and in this APQP Assessment.
9
Supplier has received applicable affordable cost targets, as they are defined for the Program,
including capacity and peak volumes.
10
Supplier has received and understood any related logistics and volume requirements (including
packaging concerns, density of containers and frequency of shipment).
Supplier has received all necessary information identified in the expectations of the Customer
Input Requirements element, to plan, design, manufacture and ship the product.
Lead Buyer: ESMITH
C
MP&L Analyst: FSMITH
Program Mailbox: APQPL405
J1
FEC
TT MRD PP MRD
Dates
DD-MMM-YY
1. Sourcing Decision
a) Sourcing Agreement
LR
Dates
DD-MMM-YY
Engineering Milestones
LEAD PD ENGINEER: CSMIYJ
Lead STA Site Engineer: DSNITH
Plant Contact Name: BSMITH
Plant Contact Phone: 0044 234555
Program Milestones
JLR Contact Information
(Corporate Directory System ID)
Evidence
(Metric)
MP1
MRD
MP2
Actual
Completion
Dates
DD-MMM-YY
Action Plan/
Counter Measure Description
Action Plan/
Counter Measure
Responsibility
Action Plan/
Counter
Measure
Date
DD-MMM-YY
APQP Assessment -- Detail
1. Header Section
Summary View (OFF)
Click Here to Clear Entries
Final
Assessment
Submission
Dates
DD-MMM-YY
Program
Information
FDJ
Current Milestone FDJ
Formatted to Print A4 (EU)
Import Previous APQP
Highlight Next Deliverable (ON)
APQP JLR Version 1
Priority Site
Select Vehicle PartitionUnderbody
Underbody
Previous APQP Date: 18/11/2009
Program Contact Name: ASMITH
Base Part Number: AC123456
Base Part Name: WIDGET
Total Number of Parts: 99
User Plant: JLR
Manufacturing Supplier Site Code: XXXXX
Supplier Name: XXXXX
Location: XXXXX
Q1 Status: Y Y
Q1 Score: 1000
Program Code: L405
Program Name: RANGE ROVER
Model Year: 2013
APQP Current Date: 15/01/2010
Supplier Contact Information
Chassis
Select Vehicle PMT Chassis
Program Contact Phone: 0044 123456
e-mail Address: ASMITH@SUPP
email Address: BSMITH@SUPP
DD-MMM-YY
Expectations / Deliverables
VPP Timing
Deliverable Number
Expectation Number
ELEMENT
Planned
Completion
Date
PTCC
PTC
PA
VP
LR
LS
M-1DJ
AA1
AA2
UPV0
UPV1
UPV2
Dates
DD-MMM-YY
Builds
UNV0
UNV1
UNV2
Lead Buyer: ESMITH
FDJ
PEC
05-Feb-10
05-Feb-11
FEC
TT MRD PP MRD
MP&L Analyst: FSMITH
Program Mailbox: APQPL405
J1
Dates
DD-MMM-YY
Engineering Milestones
LEAD PD ENGINEER: CSMIYJ
Lead STA Site Engineer: DSNITH
Plant Contact Name: BSMITH
Plant Contact Phone: 0044 234555
Program Milestones
JLR Contact Information
(Corporate Directory System ID)
Evidence
(Metric)
MP1
MRD
MP2
Actual
Completion
Dates
Action Plan/
Counter Measure Description
Action Plan/
Counter Measure
Responsibility
DD-MMM-YY
Dates
DD-MMM-YY
1. Sourcing Decision
a) Sourcing Agreement
1
All Quality, Cost, Weight, and Functional (QCWF) targets have been reviewed, documented and
agreed as part of the Sourcing Agreement Process.
2
The Preliminary Engineering, Development & Testing (ED&T) budget has been defined in the
Sourcing Agreement.
Supplier agreement letter has been issued and the supplier manufacturing site has been
identified.
1
3
C
Cost model has been developed and agreed, including process to manage change control.
There are no outstanding issues on the Final ED&T budget and QCWF targets.
The header section of the Assessment provides general information about part,
supplier, team contacts, and key programme dates.
4
b) Commercial and
Program Agreement
c) Volume and Mix
2
All required Supplier Commercial and Program Agreements (CPA) have been signed.
Note: UN and UP due 2 months before <PA>, PTO scale 1-4 due 1 month before <PTC>, PTO
scale 5 and 6 due 2 months before <PA>.
C
3
All Production tooling orders have been issued to suppliers.
C
4
Final Mix (estimated Take Rate), Average Production Weekly (APW) and Maximum Production
Weekly (MPW) have been communicated and agreed by the supplier via the SA/CPA document.
C
2. Customer Input Requirements
5
Supplier has received a list of the key contact personnel within Jaguar Land Rover, including
names, locations, and phone numbers of the Program Managers, Product Development
Engineers, Buyer, Supplier Technical Assistance (STA) Engineer, Material Planning and Logistics
(MP&L) and others as appropriate.
There are also selection boxes that indicate Priority/Non-Priority, GPDS Vehicle
Partition (Powertrain – PT, Underbody – UN, Upperbody – UP), and PMT. These
selection boxes are important because they are required for management reports, and
they will display the proper rows to reflect differences in UP and UN timing, for
example.
5
6
Supplier has received specifications, as they become available, to understand Product
Assumptions, Functional Performance, Dimensions, Weights, Materials, and Craftsmanship
requirements. Requirements for service parts (if applicable) have also been cascaded.
7
Supplier has received Reliability and Quality Goals including Functional Performance Specs, 10
yr/150 mileage Useful Life Reliability Initiative (ULRI) Targets, Warranty Targets, and Incoming
Quality Targets (PPM, etc.).
8
Supplier has received the Program Timing Dates for APQP requirements, Program Status
Reviews, Design Freeze, Prototype Builds, Material Required/In Plant Dates, and Job#1. The
Supplier has used this timing information to create a timing plan in support of the APQP elements
noted in the PDP and in this APQP Assessment.
9
Supplier has received applicable affordable cost targets, as they are defined for the Program,
including capacity and peak volumes.
10
Supplier has received and understood any related logistics and volume requirements (including
packaging concerns, density of containers and frequency of shipment).
Supplier has received all necessary information identified in the expectations of the Customer
Input Requirements element, to plan, design, manufacture and ship the product.
Denotes Selection Box
C
Action Plan/
Counter
Measure
Date
DD-MMM-YY
APQP Assessment -- Detail
2. Element Status Section -- Definitions
Planned
Completion
Date
Expectations / Deliverables
DD-MMM-YY
VPP Timing
Expectation Number
ELEMENT
Deliverable Number
Program Milestones
M-1DJ
Dates
DD-MMM-YY
Builds
Dates
DD-MMM-YY
86
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
87
Identify any specified requirements and specifications that cannot be evaluated using known
inspection techniques and request appropriate adjustments from engineering.
24
Design Styling is completed
25
Plan to complete P-Authority Release by FDJ + 4 weeks.
NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO).
Confirm with the JLR PD Engineer that the release plan supports program requirements.
12. Engineering Change Document
26
PTC
Engineering Milestones
11. Drawing & Specifications / Design Records
88
PTCC
Dates
DD-MMM-YY
Develop and implement a process to manage change to ensure that any product (either revised
or new) affected by revisions in design and process shall continue to meet all applicable
specifications. Reference can be obtained in the "Change Implementation Plan" Checklist
provided in the Supplier Request for Engineering Approval (SREA) form.
All Jaguar Land Rover engineering changes have been recorded, approved and recognised on
an authorised engineering change document.
Element:
One of the 31 unique requirements of the APQP and PPAP process
UNV0
UNV1
UNV2
UPV0
APQP Assessment -- Detail
2. Element Status Section – Deliverables
Planned
Completion
Date
Expectations / Deliverables
DD-MMM-YY
VPP Timing
Expectation Number
ELEMENT
Deliverable Number
Program Milestones
PTCC
PTC
Dates
DD-MMM-YY
Engineering Milestones
M-1DJ
Dates
DD-MMM-YY
Builds
UNV0
UNV1
UNV2
Dates
DD-MMM-YY
11. Drawing & Specifications / Design Records
86
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
87
Identify any specified requirements and specifications that cannot be evaluated using known
inspection techniques and request appropriate adjustments from engineering.
24
Design Styling is completed
25
Plan to complete P-Authority Release by FDJ + 4 weeks.
NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO).
Confirm with the JLR PD Engineer that the release plan supports program requirements.
12. Engineering Change Document
88
26
Develop and implement a process to manage change to ensure that any product (either revised
or new) affected by revisions in design and process shall continue to meet all applicable
specifications. Reference can be obtained in the "Change Implementation Plan" Checklist
provided in the Supplier Request for Engineering Approval (SREA) form.
All Jaguar Land Rover engineering changes have been recorded, approved and recognised on
an authorised engineering change document.
Deliverables are the metrics used to define the status (RED/YELLOW/GREEN/COMPLETE) of the
individual 31 elements.
There is at least one Deliverable for each element, but there can be multiple deliverables for each
element. As noted previously, there are a total of 49 Deliverables.
Deliverables are intended to reflect, where possible, quantifiable evidence of element success or
completion. Deliverables can reflect key in-process metrics like Cpk or OEE, for example.
UPV0
APQP Assessment -- Detail
2. Element Status Section -- Deliverables
Planned
Completion
Date
Expectations / Deliverables
DD-MMM-YY
VPP Timing
Expectation Number
ELEMENT
Deliverable Number
Program Milestones
PTCC
PTC
Dates
DD-MMM-YY
Engineering Milestones
M-1DJ
Dates
DD-MMM-YY
Builds
UNV0
UNV1
UNV2
UPV0
Dates
DD-MMM-YY
11. Drawing & Specifications / Design Records
86
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
87
Identify any specified requirements and specifications that cannot be evaluated using known
inspection techniques and request appropriate adjustments from engineering.
24
Design Styling is completed
25
Plan to complete P-Authority Release by FDJ + 4 weeks.
NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO).
Confirm with the JLR PD Engineer that the release plan supports program requirements.
12. Engineering Change Document
88
26
Develop and implement a process to manage change to ensure that any product (either revised
or new) affected by revisions in design and process shall continue to meet all applicable
specifications. Reference can be obtained in the "Change Implementation Plan" Checklist
provided in the Supplier Request for Engineering Approval (SREA) form.
All Jaguar Land Rover engineering changes have been recorded, approved and recognised on
an authorised engineering change document.
All 49 Deliverables are required to be rated with every submission of the Assessment
Against the program milestones, Deliverables will show two colour schemes:
• Light Grey With No Box – Forecast Period (activity is not expected in this time period, but the
supplier must enter a rating to show whether or not they forecast risk to the deliverable completion
in the future.
• Dark Grey With Black Box – Deliverable Start & End Points (activity is expected to begin and end
between these milestones)
APQP Assessment -- Detail
Planned
Completion
Date
Expectations / Deliverables
DD-MMM-YY
VPP Timing
Expectation Number
ELEMENT
Deliverable Number
2. Element Status Section -- Deliverables
Program Milestones
PTCC
PTC
PA
Dates
DD-MMM-YY
09-Sep-09
14-Sep-09
16-Nov-09
Engineering Milestones
M-1DJ
AA1
AA2
Dates
DD-MMM-YY
FDJ
05-Feb-10
Builds
UNV0
UNV1
UNV2
Dates
DD-MMM-YY
10-Sep-09
11-Sep-09
12-Sep-09
G
G
G
UPV0
UPV1
UPV2
15-Sep-09
11. Drawing & Specifications / Design Records
86
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
87
Identify any specified requirements and specifications that cannot be evaluated using known
inspection techniques and request appropriate adjustments from engineering.
24
Design Styling is completed
25
Plan to complete P-Authority Release by FDJ + 4 weeks.
NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO).
Confirm with the JLR PD Engineer that the release plan supports program requirements.
G
G
G
G
C
Example:
This deliverable is rated GREEN in the Forecast period denoting there was no expected risk to
completion by FDJ.
The Deliverable Start & End point spans <PA> to <FDJ>. The <PA> milestone is rated GREEN, and the
<FDJ> milestone is rated COMPLETE. Per GPDS convention, the Deliverable end point can only be
rated RED (if not finished) or COMPLETE (if finished).
APQP Assessment -- Detail
Planned
Completion
Date
Expectations / Deliverables
DD-MMM-YY
VPP Timing
Expectation Number
ELEMENT
Deliverable Number
2. Element Status Section -- Expectations
Program Milestones
PTCC
PTC
PA
Dates
DD-MMM-YY
09-Sep-09
14-Sep-09
16-Nov-09
Engineering Milestones
M-1DJ
AA1
AA2
Dates
DD-MMM-YY
FDJ
05-Feb-10
Builds
UNV0
UNV1
UNV2
Dates
DD-MMM-YY
10-Sep-09
11-Sep-09
12-Sep-09
G
G
G
UPV0
UPV1
UPV2
15-Sep-09
11. Drawing & Specifications / Design Records
86
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
87
Identify any specified requirements and specifications that cannot be evaluated using known
inspection techniques and request appropriate adjustments from engineering.
24
Design Styling is completed
25
Plan to complete P-Authority Release by FDJ + 4 weeks.
NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO).
Confirm with the JLR PD Engineer that the release plan supports program requirements.
G
G
G
G
C
Expectations are guidelines used to assist team members in the successful completion of the
elements, and where applicable, help rate completion of the related deliverables.
While expectations can be rated RED/YELLOW/GREEN/COMPLETE, they will not drive the element
rating – only deliverables are rolled-up to drive element ratings.
The ratings for expectations are intended only for internal use and communication.
Expectations should be thought of as Quality of Event criteria
APQP Assessment -- Detail
Planned
Completion
Date
Expectations / Deliverables
DD-MMM-YY
VPP Timing
Expectation Number
ELEMENT
Deliverable Number
2. Element Status Section -- Expectations
Program Milestones
PTCC
PTC
PA
Dates
DD-MMM-YY
09-Sep-09
14-Sep-09
16-Nov-09
Engineering Milestones
M-1DJ
AA1
AA2
Dates
DD-MMM-YY
FDJ
05-Feb-10
Builds
UNV0
UNV1
UNV2
Dates
DD-MMM-YY
10-Sep-09
11-Sep-09
12-Sep-09
UPV0
UPV1
UPV2
15-Sep-09
11. Drawing & Specifications / Design Records
86
All Jaguar Land Rover engineering drawing requirements and specifications have been made
available to the supplier. Supplier, working jointly with JLR Engineering, has included the
following requirements on the applicable drawings: weld, dimensions, SC and CCs, Safety and
regulatory, sufficient control points and datum surfaces, tolerances and part specifications
compatible with existing manufacturing processes; special material characteristics.
87
Identify any specified requirements and specifications that cannot be evaluated using known
inspection techniques and request appropriate adjustments from engineering.
24
Design Styling is completed
25
Plan to complete P-Authority Release by FDJ + 4 weeks.
NOTE: Some long-lead parts may be required to be released earlier (T-Release for PTO).
Confirm with the JLR PD Engineer that the release plan supports program requirements.
G
Y
G
G
G
G
Y
G
C
Y
Y
G
C
G
G
G
C
G
G
C
12. Engineering Change Document
88
Develop and implement a process to manage change to ensure that any product (either revised
or new) affected by revisions in design and process shall continue to meet all applicable
specifications. Reference can be obtained in the "Change Implementation Plan" Checklist
provided in the Supplier Request for Engineering Approval (SREA) form.
Example:
These Expectations were rated YELLOW at <PTC> and AA1 showing a potential risk.
By <FDJ>, the Expectation end points, they were rated COMPLETE.
Note: Expectations are not used to drive Element status.
There is no requirement to provide a Forecast rating for an Expectation.
APQP Assessment -- Detail
3. Summary Section
This part of the Assessment is intended to summarise the element status for the entire document.
There are 4 parts to the summary:
1. Current Milestone Deliverable Status
2. Forecast Milestone Deliverable Status
3. Phased PPAP Element Dates
4. Supplier Evaluation Summary (Priority sites only)
APQP Assessment -- Detail
3. Summary Section
Current Milestone Deliverable Status:
Indicates the status for only those elements with deliverables required to be completed by the
currently assessed milestone. These fields are automatically generated based upon input in the
Element Status.
The one exception are the words for the Action Plan Summary – these must be manually entered and
should be limited to the Key Escalation Issues, and not made up from a cut
and paste of the Element status section.
APQP Assessment -- Detail
3. Summary Section
Forecast Milestone Deliverable Summary:
Indicates the status of remaining deliverables not yet required for completion at a given milestone. The
majority of these fields are automatically generated based upon input in the Element Status. The
Action Plan Summary fields must be manually entered.
This provides a forward looking view of future deliverables for use by the team.
APQP Assessment -- Detail
3. Summary Section
PPAP Element Dates:
Supplier Evaluation Summary:
A summary of PPAP dates outline in the
Element Status. The dates are automatically
populated from the deliverables, while Build
Support Plans must be manually entered
Required for Priority suppliers only. The team
manually tracks planned and actual visit dates.
The data is rolled up on Element Summary
Report.
APQP: Summary of Deliverable Rating Criteria
Summary of Deliverable Rating Criteria
Prior to Required Deliverable Completion Timing:
Deliverables can be rated RED, YELLOW, GREEN, or COMPLETE
At Required Deliverable Completion Timing:
Deliverables must be rated either COMPLETE or RED.
A deliverable must be tracked until it is complete
After Required Deliverable Timing Completion Timing (Red items only):
A deliverable will continue to be rated RED until it is COMPLETE. It will no longer
required to be rated at subsequent milestones after it is COMPLETE.
Summary of Reporting Process
•
•
•
•
APQP Assessments will be completed by every
NTEI supplier and submitted to JLR on a monthly
basis from <PTCC> to PPAP Completion
For Priority suppliers, the cross-functional team
shall achieve consensus on Deliverable ratings
Programme Reports will be generated from the
Assessments
Key Escalation Issues and Actions must be
explained in the Action Plan Summary – the
audience includes Board Members
Priority Supplier Selection
Unit
PTC
Unit
PA
PTCC
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
CrossFunctional
Teams Formed
Team
Kick-Off
Meetings
Begin
PTC/
M1DJ
M1
PA
FDJ
VP
PEC
LR/
FEC
TT
PP
MP1
Once sourcing is complete, the STA Programme
Lead and the PD Programme Lead will work with the
STA Site Managers & Engineers, and PD
Programme Leaders & PMST Leaders to complete
the Selection of “Priority” suppliers for the
Resolve Open Issues
programme.
A specific risk model is used to guide the Priority
Decision
suppliers.
to
Evaluation
Evaluation
Evaluation
Evaluation
#1
#2
Proceed
to RunAt-Rate
#3
Update of APQP Assessment
#4
Priority Supplier Selection Process – Initial Model
Supplier Selection process is led by program STA and PD and
reviewed by Site STA. This process shall take place by the following:
• Underbody: <PTCC> + 90 days
• Upperbody: <PTC>
Site
Readiness
OR
Part
Criticality
OR
Programme
Induced Risk
=
Programme
Priority
Suppliers
Team Formation
Unit
PTC
Unit
PA
PTCC
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
CrossFunctional
Teams Formed
Team
Kick-Off
Meetings
Begin
PTC/
M1DJ
M1
PA
FDJ
VP
PEC
LR/
FEC
TT
PP
The STA and PD Programme leads will notify the
appropriate PD Engineers, Buyers, and STA Site
Engineers, that their suppliers are designated as
Priority for a given programme. This notification
will include specific
timing and reporting
Resolve Open Issues
requirements for the programme.
Evaluation
#1
Evaluation
#2
Decision
to
Proceed
to RunAt-Rate
Evaluation
#3
Update of APQP Assessment
Evaluation
#4
MP1
Team Member Responsibilities
While there is a team lead at all times, each team member
still has the responsibility between meetings to:
• Resolve open concerns
• Communicate with other team members as needed
• Bring together other team members to close out concerns
as necessary
It is recognised that all team members will interface with the
supplier regularly between Evaluations, and viability issues
are raised immediately
Team Kick-Off Meetings
Unit
PTC
Unit
PA
PTCC
PTC/
M1DJ
M1
PA
FDJ
VP
PEC
LR/
FEC
TT
PP
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
CrossFunctional
Teams Formed
Team
Kick-Off
Meetings
Begin
Prior to the Evaluations, the cross-functional JLR
team members will meet with their supplier team
to review programme expectations and begin the
preparations for siteResolve
visits.
Open Issues
This is called the “Kick-Off” meeting.
Evaluation
#1
On-Site
Evaluation
#2
Decision
to
Proceed
to RunAt-Rate
On-Site
Evaluation
#3
Update of APQP Assessment
On-Site
Evaluation
#4
MP1
Team Kick-Off Meeting – Key Points
Purpose:
Introduce JLR and supplier team members
• JLR and supplier team agree on the required programme and process timing.
• Communicate team expectations in preparation for Evaluation #1.
 Plan to exploit opportunities that on-site activity will give (e.g. surrogate
process & design review)
Timing: PT: Unit <PTC> -- <PTCC>
UN: <PSC> - <PTCC>+90 Days
UP: <PTCC> – <PTC/M1DJ>
Note: Actual review timing will depend upon the specific needs of the component and program.
Participants:
Lead: PD Engineer
Support: STA Site Engineer, Buyer
Location:
JLR facility, supplier facility, or teleconference (according to team preference). Meetings will typically
last 2 – 3 hours.
Evaluation #1
Unit
PTC
Unit
PA
PTCC
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
PTC/
M1DJ
M1
PA
FDJ
PEC
LR/
FEC
TT
PP
The cross-functional team’s first detailed review is
called Evaluation #1 – Verification of Supplier
Failure Mode Avoidance Strategy, Manufacturing
Feasibility & Planning.
Timing for this visit will depend on the section of the
vehicle where the part resides – PT, UN, or UP
CrossFunctional
Teams Formed
Team
Kick-Off
Meetings
Begin
VP
Resolve Open Issues
Evaluation
#1
Evaluation
#2
Decision
to
Proceed
to RunAt-Rate
Evaluation
#3
Update of APQP Assessment
Evaluation
#4
MP1
Evaluation #1 – Key Points
Purpose:
•
•
•
•
Failure Mode Avoidance through detailed FMEA and Control Plan reviews:
Feasibility & actions to resolve by FDJ
Manufacturing Planning
Capacity Planning
Timing: PT: <PTCC> - <PTC/M1DJ>
UN : <PTCC> - <PTC/M1DJ>
UP : <PTC/M1DJ> - <PA>
Note: Actual review timing will be dependant upon the specific needs of the component and the program.
Participants:
•
JLR Lead: PD Engineer
•
JLR Support: STA Site Engineer, Buyer
Evaluation #1– APQP Focus
APQP Element Focus
5 of 31 Elements / 8 Deliverables
APQP Element + Deliverables
Lead
1
Sourcing decision
1. Required Sourcing Agreement Signed
2. Required Supplier Commercial & Program Agreements
Signed
4. Final Mix, Maximum Weekly Volume Communicated and
Agreed
Buyer
2
Customer input requirements
5. Program Expectations Cascaded to Suppliers
PD
4
DFMEA
8. DFMEA: Identify Potential Failure Modes and associated
Potential Causes. Ensure that effective Countermeasures are
defined against all Potential Causes to reduce risk to acceptable
levels
9. Special Characteristics Cascaded to Supplier
PD
8
Facilities, tools, & gauges
17. Supplier’s OEE Plan is Confirmed by Surrogate Data
STA
Drawing & specification/design records
24. Design Styling Confirmation
PD
11
These deliverables are due for completion
Others are started but not completed
APQP emphasis for supplier : Objectives for Evaluation #1
Evaluation #1 is aimed at achieving a successful FDJ event
Objective: Manufacturing Feasibility Signed off or AIMS raised
Deadline: FDJ
Why? Supplier confirming that PD has communicated the design, that the supplier
understands the design and that planned process is capable of producing the
design, and that no design changes will be requested to solve manufacturing
problems after FDJ. PD & STA confirm this within JLR.
If issues are found that have no known solution then these should be escalated to
JLR STA & PD and an AIMS raised
Assessment Expectations 90,91,92
APQP Element 13
Team feasibility
commitment/customer
engineering approval
Lead
Support
PD/STA
All
Demonstrate that the feasibility analysis gives confidence
that all of the engineering requirements and specifications
will be met and that the product can be manufactured to
meet the requirements of Ppk >= 1.67 and CPE>=1.33 for
the lifetime of the product.
Demonstrate that the manufacturing process as planned will
have the capacity to meet the volume requirements.
APQP emphasis for supplier : Objectives for Evaluation #1
Evaluation #1 is aimed at achieving a successful FDJ event
Objective: Manufacturing Installation & Validation Plan for PPAP Phase 1
@ TT has been reviewed and deliverable in APQP Assessment is shown
as complete
Deadline: FDJ
Why? Confirm that Tier 1 can support Phased PPAP requirements. Note the Facilities & Tooling timing plan must support a Phase 0: Run-at-Rate
that in turn allows Phase 1 to be achieved for TT IPD - allowing sufficient
time for activities such as PV testing, Capability Studies etc.
APQP Element 8
Facilities, tools, &
gauges
Lead STA
Support
All
Assessment Deliverable 15
Verify that Facilities & Tooling timing plan can meet
Phased PPAP requirements
Evaluation #1– Expected Outputs
Output
1
2
Updated APQP Assessment – Confirmation of 8 Required
Deliverable Status
Agreement on Failure Mode Avoidance Strategy (All DFMEA’s up to
date & Agreement on Special Characteristics): Feasibility &
actions to be resolved by FDJ
Responsibility
Supplier (with Cross
Functional Team
Consensus)
All
3
Agreement that Capacity Plan is Achievable and Consistent with
JLR Requirements, and that the Facilities & tooling timing plan can
meet Phased PPAP requirements
STA
4
Plan developed to support prototype builds (prototype control plan &
build plan)
PD
5
STA
Updated Manufacturing Site Assessment (MSA) – As required
6
Agreement of timing for next visits
All
Evaluation #2
Unit
PTC
Unit
PA
PTCC
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
PTC/
M1DJ
M1
PA
FDJ
PEC
LR/
FEC
TT
PP
The cross-functional team’s second detailed review
is called Evaluation #2 – Verification of Supplier
Launch Preparation.
This Evaluation shall occur prior to the supplier’s
shipment of parts of VP builds
CrossFunctional
Teams Formed
Team
Kick-Off
Meetings
Begin
VP
Resolve Open Issues
Evaluation
#1
Evaluation
#2
Decision
to
Proceed
to RunAt-Rate
Evaluation
#3
Update of APQP Assessment
Evaluation
#4
MP1
Evaluation #2 – Key Points
Scope:
•
•
•
•
•
•
Facilities & Tooling Planning/Installation
PFMEA & Control Plans
Gauging
Staffing & Training Planning
VP Prototype Build Readiness
Run-at-Rate Preparation
Timing: PT/UN/UP: Between <FDJ> and Prior to <VP> In Plant Date (IPD)
Participants:
•
JLR Joint Lead: PD Engineer , STA Site Engineer
•
JLR Support: Buyer
Evaluation #2– APQP Focus
APQP Element Focus
8 of 31 Elements / 11 Deliverables
APQP Element + Deliverables
1 Sourcing Decision
Lead
Buyer
3. All Production Tool Orders Issued to Suppliers
7 Subcontractor APQP Status
STA
12. Sub-supplier PPAP Timing Plan Completed
8 Facilities Tools & Gauges
STA
15. Facility and Tooling Timing Plan Completed
18. Gauge Plan (including Released Gauge Drawings) Completed
9 Prototype Build Control Plan
PD
20. Prototype Build Control Plan Completed
10 Prototype Builds
PD
21. All Prototype Tool Orders Issued to Supplier
22. Prototype Parts Ordered
23. Prototype Parts Achieve 100% of Required Print Specifications
11 Drawing & Specification Design Records
PD
25. Design Release (WERS) Completed
13 Team Feasibility Commitment/Customer Engineering
Approval
PD/STA
27. Design, Process, & Timing Feasibility Confirmation
15 PFMEA
29. Final PFMEA Completed with Linkages
STA/PD
APQP emphasis for supplier : Objectives for Evaluation #2
Evaluation #2 is aimed at achieving successful VP & Phase 0 events
Objective: Understand the current state of the assembly process, tooling
and associated equipment used to manufacture the VP parts & produce
a Future State map with timing to close off all the deviations to support
Phase 1 PPAP at TT Build
Deadline: VP
• Why? Review the manufacturing process employed for VP part supply as a failure mode
detection opportunity (if applicable to intended production process). Confirming that supplier's
execution of plan to install tools, equipment etc. is on schedule to meet Phased PPAP
requirements.
• If issues are found that have no known solution then these should be escalated in STA & PD and
an AIMS raised - these are the parts that will be tracked by the programme to PPAP sign-off (the
“exceptions”).
APQP emphasis for supplier: Objectives for Evaluation #2
Evaluation #2 is aimed at achieving successful VP & Phase 0 events
Objective: PFMEA Completed
Deadline: VP
Why? Confirm the linkages (Using the Special Characteristics Summary
Sheet) in Failure Mode Avoidance activities extend from Design through
to Process Control. Use VP part build as a Failure Mode detection event
(confirming known ones, checking new ones). If issues are found that
have no known solution then these should be escalated to STA & PD
and an AIMS raised
APQP Element 15
PFMEA
Lead
STA/PD
Support
All
Assessment Deliverable 29
PFMEA is complete and has linkages to DFMEA &
Control Plans
Evaluation #2– Expected Outputs
Output
1
Updated APQP Assessment – Confirmation of 11 Required
Deliverable Status
2
Responsibility
Supplier (with Cross
Functional Team
Consensus)
PD/STA
Acceptance of parts to support VP Prototype Build (prior to
shipment)
3
4
Concurrence on manufacturing plans in support of Run-at-Rate
event
Agreement on PFMEA
5
STA
STA/PD
STA
Updated Manufacturing Site Assessment (MSA) – As required
6
Agreement of timing for next evaluations
All
Decision to Proceed to Phase 0: Run-at-Rate
Unit
PTC
Unit
PA
PTCC
PTC/
M1DJ
M1
PA
FDJ
VP
LR/
FEC
PEC
TT
PP
This decision is a cross-functional team decision
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
Confirming that NO further changes are required to:
• Design
• Tooling & Equipment
• Process & Process Parameters
CrossFunctional
Teams Formed
Team
Kick-Off
Meetings
Begin
}
All the Inputs to
Phase 0 Shown on
the Phased PPAP
Flowchart
Resolve Open Issues
Evaluation
#1
Evaluation
#2
Decision
to
Proceed
to RunAt-Rate
Evaluation
#3
Update of APQP Assessment
Evaluation
#4
MP1
The Path to Phase 0 : Run-at-Rate
The Path to Phase 0 : Run-at-Rate
• Phase 0: Run at Rate timing is established and committed/reported to
pre-FDJ
• From Single Point of Release to achieving a successful Phase 0 the
following must be achieved:
> Off tool Development
> Off-Tool in Home Line Development
> Off Tool & Off Process in Home Line – all tooling, equipment
operating as a system
Development
> Off Tool & Off Process in Home Line – all tooling, equipment
operating as a system AND all parameters fully developed
> Only Ready for Phase 0 if there is agreement that no further
development is necessary for Job#1
• PPAP simply measures how well this was done
Why focus on PPAP & PSW?
• The activities that precede & enable Phase 0: Run-at-Rate to take
place are critical.
• Phase 0: Run-at-Rate marks the end of planning & development
• Phase 0: Run-at-Rate parts are used for confirming:
> Production Validation & Material Tests
> Dimensional Conformance (& Appearance)
> Process Stability & Capability
• The information that PPAP yields confirms that the supplier is ready
to supply parts to JLR.
• PPAP status is therefore a key measure at Launch Readiness
> At part level, at sub-assembly level, at option level.
Evaluation #3
Unit
PTC
Unit
PA
PTCC
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
PTC/
M1DJ
M1
PA
FDJ
PEC
LR/
FEC
TT
PP
The cross-functional team’s third detailed review is
called Evaluation #3 – Verification of Supplier
Capability.
This evaluation shall occur prior to the supplier’s
shipment of parts for production Tool Tryout (TT)
builds
CrossFunctional
Teams Formed
Team
Kick-Off
Meetings
Begin
VP
Resolve Open Issues
Evaluation
#1
Evaluation
#2
Decision
to
Proceed
to RunAt-Rate
Evaluation
#3
Update of APQP Assessment
Evaluation
#4
MP1
Evaluation #3 – Key Points
Purpose:
•
Completion of PPAP Phase 1
>
>
>
>
Dimensional Results
Production Validation Testing
Process Capability
Appearance Approval
Timing:
UN/UP: Between <PEC> and Prior to TT Build In Plant Date (IPD)
Participants:
•
Lead: STA Site Engineer
•
Support: PD Engineer , Buyer
Evaluation #3 – APQP Focus
APQP Element Focus
22 of 31 Elements / 24 Deliverables
APQP Element + Deliverables
3
Craftsmanship/Appearance Approval Report
Lead
PD
6. AAR Approved
6
DVP&R Material/Performance Test Results
PD
11. DV Testing Complete
7
Subcontractor APQP Status
STA
13. Sub-supplier PPAP Phase 1 (or equivalent) Completed
8
Facilities, Tools, and Gauges
16. Facilities/Tools/Gauges are at the Final Production Location
19. Suppliers Demonstrated OEE (Phase 0) Supports Capacity Requirements
12
Engineering Change Documents
STA
PD
26. All JLR Engineering Changes Approved & Recognized by the Supplier
14
Manufacturing Process Flowchart/Process Flow Diagram
STA
28. Final Process Flowchart Supports PPAP Phase 0 Event
16
Measurement System Evaluation/Measurement Systems Analysis Studies
STA
30. Gauge R&R Results <= 10% per PPAP Customer Specifics
17
Qualified Laboratory Documentation
STA
31. Supplier Internal & External Laboratory Compliance
18
Checking Aids
32. Checking Aids Compliant with Part Specifications
STA
Evaluation #3 – APQP Focus (continued)
APQP Element Focus
22 of 31 Elements / 24 Deliverables
APQP Element + Deliverables
19
Pre-Launch Control Plan
Lead
STA
33. Pre-Launch Control Plan Completed with Linkages
20
Operator Process Instructions
STA
34. Operator Process Instructions Completed
21
Packaging Specifications
MP&L
35. Packaging Approval Process Completed
22
Production Trial Run
STA
36. PPAP Phase 0 (Including Sub-Suppliers) Completed
23
Production Control Plan
STA
37. Production Control Plan Completed with Linkages
24
Initial Process Capability
STA
38. Initial Process Capability Results (Ppk >= 1.67)
25
Dimensional Results
39. 100% of Required Measurement Points within Tolerance
STA
Evaluation #3 – APQP Focus (continued)
APQP Element Focus
22 of 31 Elements / 24 Deliverables
APQP Element + Deliverables
26
Production Validation Testing
Lead
PD
40. PV Testing Complete
27
Part Submission Warrant
41.
42.
43.
28
STA/PD
PPAP Phase 1 Complete
RSMS Compliance
PPAP Phase 2 Complete (if Single Workstream)
Bulk Materials Requirement
STA
46. Bulk Materials Checklist Included in PPAP Submission
29
Sample Product
STA
47. Sample Product Produced with Ford Identification
30
Master Sample
STA
48. Master Sample Approved
31
Record of Compliance
49. Specific Requirements Documented
STA
APQP emphasis for STA : Objectives for Evaluation #3
Evaluation #3 is aimed at achieving Phase1 and hence a successful TT
event
Objective: Ensure Phase 0: Run-at-Rate is completed & Data set is
available.
Deadline: LR, & continues until completed
•
Why? Confirm that Phase 0: Run-at-Rate has taken place, that the verification activities to achieve Phase 1 can
continue, and no known problems exist that would invalidate the PPAP process - these affect Programme viability.
Exceptions must be managed.
•
If Phase 0: Run-at-Rate has been completed but Phase 1 is not yet achieved, STA must be able to state that the Runat-Rate event was successful i.e. all inputs to the event were acceptable, the Control Plan was adhered to, the cycle
time and process yield were as planned. Why? To ensure that the only obstacles to Phase 1 Approval are the
completion of the tests/studies/analyses.
•
If the signed Capacity Analysis Report shows a risk to volume it and the CCAR raised to fix the problem should be
escalated in STA. This allows known & predicted volumes to be used at LR milestone decision making (LR decisions
determine MP1 content)
APQP emphasis for STA : Objectives for Evaluation #3
Evaluation #3 is aimed at achieving Phase1 and hence a successful TT
event
Objective: Support Programme Launch Decisions for parts that are not
PPAP Phase 1 for TT (Exceptions)
Deadline: LR, continues until PPAP Phase 2 completed
•
Why? For parts that are not PPAP Phase 1 by TT, Supplier must provide quality
data to allow JLR Programme team to make a informed decision.
•
This means warranting all completed PPAP Elements, and providing a risk / confidence
statement for those PPAP Elements that are not complete
•
Data should be available to support this statement and would normally include details of a
modified Control Plan. (Basis of IPSW as mandated for saleable units - see Phased PPAP
Exception Management Process).
Evaluation #3– Expected Outputs
Output
1
Updated APQP Assessment -Confirmation of 24 Required
Deliverable Status
2
Signed Phase 1 PPAP warrant
(and Phase 2 PPAP if single production workstream)
3
4
Updated Manufacturing Site Assessment (MSA) – As
required
Agreement of timing for next evaluations
Responsibility
Supplier (with Cross
Functional Team
Consensus)
STA/PD
STA
All
Evaluation #4
Unit
PTC
Unit
PA
PTCC
Supplier
Sourcing
Begins
Priority
Suppliers
Selected
PTC/
M1DJ
M1
PA
FDJ
PEC
LR/
FEC
TT
PP
The cross-functional team’s fourth evaluation is
called Evaluation #4 – Verification of Supplier
Capacity.
This visit should always occur prior to the supplier’s
shipment of parts for Mass Production 1 (MP1)
builds. Opportunities to complete this visit before
PP should be exploited
CrossFunctional
Teams Formed
Team
Kick-Off
Meetings
Begin
VP
Resolve Open Issues
Evaluation
#1
Evaluation
#2
Decision
to
Proceed
to RunAt-Rate
Evaluation
#3
Update of APQP Assessment
Evaluation
#4
MP1
Evaluation #4 – Key Points
Purpose:
•
Completion of PPAP Phase 3
> Operators Staffed and Trained
> Ability to Meet Launch Ramp-Up Curve
> Ability to Meet Ongoing Production
> OEE Confirmation
> ToPT/UN/UP:
determine capacity
work
& monitoring
Timing:
Betweenrisks,
PECongoing
and MP1
Build
In Plant Date (IPD)
Participants:
•
Lead: STA Site Engineer
•
Support: PD Engineer, Buyer
Evaluation #4 – APQP Focus
APQP Element Focus
4 of 31 Elements / 6 Deliverables
APQP Element + Deliverables
3
Craftsmanship
Lead
PD
7. Colour Changes Completed Supporting Color Harmony
5
Design/Manufacturing Reviews
STA/PD
10. Quality Issues Closed and Effective
7
Subcontractor APQP Status
STA
14. Sub-Supplier PPAP Phase 3 (or equivalent) Completed
27
Part Submission Warrant
42.
43.
45.
RSMS Compliance
PPAP Phase 3 completed
Supplier’s Demonstrated OEE (Phase 3) Supports Capacity Requirements
STA/PD
APQP emphasis for STA : Objectives for Evaluation #4
Evaluation #4 is aimed at achieving Phase 3 and hence successful PP & J1
events
Objective: Support Programme Launch Decisions for parts that are not
PPAP Phase 3 (Exceptions)
Deadline: LR, continues until PPAP Phase 3 completed
•
Why? For parts that are not PPAP Phase 3 supplier must provide data to allow
JLR Launch to make an informed decision.
•
This means warranting all completed PPAP Elements, and providing a risk / confidence
statement for the PPAP Elements that are not complete, including making a statement of
the volume that can be achieved
•
Data should be available to support this statement and would normally include details of a
modified Control Plan. (Basis of IPSW as mandated for saleable units - see Phased PPAP
Exception Management Process).
Evaluation #4 – Expected Outputs
Output
1
Updated Supplier APQP Assessment – Confirm Required
Deliverable Status (Final Status)
2
Responsibility
Supplier (with Cross
Functional Team
Consensus)
STA
Signed Phase 3 PPAP Warrant and Capacity Analysis Report
3
STA
Updated Manufacturing Site Assessment (MSA) – As required
• And agreement on need for ongoing monitoring & analysis as required
APQP Assessments & Programme Viability

APQP Assessments are used as the inputs to JLR Programme Reports

Programme Reports allow JLR to make decisions about Programme Viability

What do the APQP Assessments tell us ?

How much of the activity has been completed (C) as a percentage of the total required?

What is the list of Work In Progress Red’s we have – CCAR’s : not Programme Critical yet

From the deliverables is there a specific area we need to deep dive, e.g. DFMEA?

What are the key escalation issues we need to take to the program team for escalation?

Enforce the use of the Action Plan Summary Section for Key Escalation Issues

Those that will affect programme viability if not fixed now or in the near future, i.e.
within the next reporting cycle.

ACCURACY & CLARITY are fundamental .

Board Members are in the audience at Programme Reviews.

Board Members will take decisions based on this information
Programme Reports – Programme Viability
90
80
70
60
50
40
30
East
West
North
20
10
0
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr
Assessment
Red List
APQP
Assessments
CCAR
1st Qtr
2nd Qtr
3rd Qtr
Metrics – to show
%age Complete as
well as list of Reds
Key Issues List
Program escalated
support plan and
actions
Deliverable list
for escalation
review
Enforce the use of the Action Plan Summary Section for Key Escalation Issues and
Actions that will affect programme viability if not fixed now or in the near future

The key escalation issues and actions are those that must be escalated to be fixed because
they are critical to the programme now, or will be by the next reporting cycle (next month).

If there are NO key escalation issues and actions state this in order to avoid doubt– make sure
we put in the +ve statement
Summary
•
APQP integrates JLR’s activities & the Supplier’s activities, and is a Team-based
process
•
Priority Suppliers require enhanced engagement. The terms Priority Supplier & High
Impact supplier are interchangeable
•
Engagement starts early to focus on Failure Mode Avoidance & Manufacturing
Feasibility
•
The APQP Assessment is a key form of communication between JLR and the supplier
in the PMST
•
JLR uses the information to assess risks, solve problems, make decisions – up to and
including Board level
•
Phase 0: Run-at-Rate with the right Quality of Event is a key point
•
PPAP is based upon the Supplier warranting that they can meet JLR’s requirements
Additional Information
The following manuals can be found on the Jaguar Land
Rover Supplier Portal on Covisint:
•
APQP Assessment User Guide
•
APQP Priority Supplier Process Manual