Doc. No.

:- OPPL/TM/PM-13
Process No-13 Rev No :-'03

Rev Date: 22.10.2020

Title : Advance Product Quality Planning IATF CLAUSE NO.:-8.3.1.1

Process Name :- Process for Advance Product Quality Planning.

Purpose :- To establish a system for carrying out advance product quality planning and development of control plans.

Scope :- It covers all New product and changes in New Product and existing product to be developed and manufactured by the company.
This procedure is applicable from development to till sop at customer end.

Process Owner :-NPD

Performance Criteria Project Review Frequency:-

Sr No. Project CFT TOP Mangement

1. Time Overrun from target time

Less Than 1
1 Phase Wise Phase Wise
2. First time ok at customer line trial Months

2 1 Month Phase Wise 15 Days

3. New Product Development
Greater Than
3 Phase Wise 15 Days
4. ECN/PCN Change 1 Months

Documents :

Sr. No. Document No. Document Name Indexing Special Protection Control Authority

----- ----- -------- ------ -------- --------

Records :-

Special
Sr. No. Record No. Record Name Retention Period Indexing Disposal Authority
Protection

APQP/New Product 3 Year for general parts &

1 OPPL/F/MKT/09 Product wise No NPD & QA - Head
Developmnet Plan 11 year for Maru-A parts

3 Year for general parts &

2 OPPL/F/MKT/16 Project Review Meeting Product wise No NPD & QA - Head
11 year for Maru-A parts

3 Year for general parts &

3 OPPL/F/MKT/08 Feasibility Report Product wise No NPD & QA - Head
11 year for Maru-A parts

3 Year for general parts &

4 OPPL/F/MKT/13 Bill of Material Product wise No NPD & QA - Head
11 year for Maru-A parts

3 Year for general parts &

5 OPPL/F/MKT/12 Past Problem History Sheet Product wise No NPD & QA - Head
11 year for Maru-A parts

6 OPPL/F/MKT/10 APQP Matrix 3 Year Product wise No NPD & QA - Head

7 OPPL/F/QA/08 MSA / Gauge R & R Study 3 Year Monthly No QA Head

8 OPPL/F/MKT/17 NPD Register 3 Year Enq.Wise No NPD

Prepared By: Approved By:

 Doc. No.:- OPPL/TM/PM-13
Process No-13 Rev No :-'03
Rev Date: 22.10.2020
Title : Advance Product Quality Planning IATF CLAUSE NO.:-8.3.1.1
Sr. Reference /
Input Activity Output Resp. Checkpoint
No. Format
1st Phase
( Plan & Define The Programme )

Receipt of Enquiry along with specification / Drawing/ RFQ , Customer approved RFQ , Customer approved NPD register
Customer Dwg., sample,
1 Reference sample etc. drawing Drawing, applicable std., Marketting drawing Drawing, applicable OPPL/F/MKT/17
ECN & RFQ
sample, ECN , std., sample, ECN ,

Consider Man Power planning Feasibility Report

2 Feasibility Study Report Make Feasibility Report Feasibility Report NPD (New joinee, Special Training OPPL/F/MKT/08
Req. Etc.)

Inform to Customer Feasibility Report

Is it Feasible by Mail Or Viability Report NPD Consider all Parameters OPPL/F/MKT/08
Telephonically

Inform To Customer by Mail / Letter Mail for Feasibility/ Viability NPD

3 Quotation Sheet Quatation of Part NPD Check quotation Quotation on Letter Head/as per format
Send the Qutation to the Customer

4 Receving Of LOI P.O LOI / P.O NPD LOI / P.O from Customer
Reveview the LOI ( letter of Intent ) / P.O ( Purchase
Order ) by Mail / Hard Copy

CFT chart
Nomination of CFT Team With Role & Responsibility should
NPD OPPL/F/MKT/11
Preparation of CFT Leader Clear of CFT Members
5 Making of CFT
Team

Traninig Of APQP / Training about APQP / FMEA / Cp & Cpk / PPAP to the Cocerrn
6 FMEA / MSA / SPC & person who will handle the APQP or Project Development Training Attandence Sheet
&Training of Testing Equipment Trainings Record NPD/HR
Spl Measuring Tools OPPL/F/HR/05

Prepared By: Approved By:

 Doc. No.:- OPPL/TM/PM-13
Process No-13 Rev No :-'03
Rev Date: 22.10.2020
Title : Advance Product Quality Planning IATF CLAUSE NO.:-8.3.1.1
Sr. Reference /
Input Activity Output Resp. Checkpoint
No. Format

Phase -II
( Poduct Design & Development )

Prepare detailed APQP Matrix ,APQP Time Plan in Product New Product Development Timing
Develoment Plan sheet from Prototype to approval of SOP. New Product Development Project Leader CFT APQP plan to be review at Plan OPPL/F/MKT/09
7 Review the Project on Weekly Basis By CFT Head & Top
Preparation of APQP Timing Plan specified freq. Project Review Sheet
Management
Timing Plan & approval OPPL/F/MKT/16
for TOP Mangaement.

Process Flow Diagram

Process Flow Chart Prepare the Prototype Process Flow Diagram & Check Prototype PFD/Control OPPL/F/QA/02
8 (Prototype),Prototype Control Plan Proto type PFD/Control Plan NPD
Plan Control Plan
Control Plan
OPPL/F/QA/03

DEFECT SUMMARY FOR NEW

Prepare Prototype Do Sample Trial Run along with CFT & submitt the OK Identify the gaps / Problem
9 Sample Parts NPD PRODUCT DEVELOPMENT
sample & submission Sample to Customer along with Inspection Report . during sample preperation
OPPL/F/MKT/15

Sample Approval From Check Sample Report &

10 Sample report/customer Mail NPD Sample Report/Customer Mail
Customer Take the sample approval from customer feedback

DEFECT SUMMARY FOR NEW

11 Follow-Up from NPD Action On Customer Feedback PRODUCT DEVELOPMENT
Follow-up results from customer during product Customer Feedback
customer if no response development OPPL/F/MKT/15
within a week

As per tool design.

12 Prepare Micro level Tool Colour coding
Tools NPD Identification on tool as per
Die/Tool development Start Tool manufacturing as per Development Targets
define colour
Plan

As per Gauges & fixtures

Gauges no. & name
Prepare Micro level design. Identification on
13 Start gauges & fixtures manufacturing as per Gauges & fixture NPD/QA OPPL/F/QA/11
Gauge/Fixture Development Targets gauges & fixtures as per define
development Plan name

Prepared By: Approved By:

 Doc. No.:- OPPL/TM/PM-13
Process No-13 Rev No :-'03
Rev Date: 22.10.2020
Title : Advance Product Quality Planning IATF CLAUSE NO.:-8.3.1.1
Sr. Reference /
Input Activity Output Resp. Checkpoint
No. Format

Phase-III
(Process Design & Development)

Process Flow Diagram

OPPL/F/QA/02
Prototype Flow PFD/Control Plan NPD Check PFD/Control Plan Control Plan
14 Prepare the Process Flow Diagram & Control Plan
Diagram OPPL/F/QA/03

PFD/Past Defect As per AIAG - 4 (FMEA) Process FMEA

Prepare Process Failure Mode and Effect Analysis
15 History Sheet PFMEA NPD Guidelines OPPL/F/QA/04

Control Plan
16 PFD/PFMEA Prelaunch Control Plan NPD Check Control Plan
Preparation of Prelaunch control Plan OPPL/F/QA/03

Work Instruction,
PFD/PFMEA/CP/Drawi Preparation of WI,Operation Std. & inspection Work Instruction,Process OPPL/F/QA/18
17 NPD
ng/Std. Standard. Sheet,Process Drawing Check Work Process Sheet
Instruction,Process OPPL/F/QA/37
Sheet,Process Drawing Process Drawing

PFD/PFMEA/CP/ Prepare Sample Trial i.e.T0,T1,T2,T3.....respectively &

18 Drawing/Std./RM/ Submission Of OK Samples DEFECT SUMMARY FOR NEW
Instrument/machine Identify the gaps / Problem PRODUCT DEVELOPMENT
Do Sample Trial Run along with CFT & submitt the OK Sample Parts NPD during sample preperation OPPL/F/MKT/15
Sample to Customer along with Inspection Report .

Sample Approval From Check Sample Report &

19 Take the sample approval from customer Sample report/customer Mail NPD Sample Report/Customer Mail
Customer feedback

DEFECT SUMMARY FOR NEW

20 Follow-Up from Follow-up results from customer during product sample NPD Action On Customer Feedback PRODUCT DEVELOPMENT
Customer Feedback
customer if no response OPPL/F/MKT/15
within a week

Preparation of Logistic Study & displayed of packing Check Customer approved Packing Standard
21 Customer Packing Std. Packing Std. NPD & QA
Standard. Packing Std. OPPL/F/QA/33

SPC Report
Control Plan/Critical OPPL/F/QA/31
22 Preparation of MSA & SPC Plan. SPC & MSA Plan & report NPD & QA Check SPC & MSA Report
Characteristics Sheet MSA Report
OPPL/F/QA/08

Prepared By: Approved By:

 Doc. No.:- OPPL/TM/PM-13
Process No-13 Rev No :-'03
Rev Date: 22.10.2020
Title : Advance Product Quality Planning IATF CLAUSE NO.:-8.3.1.1
Sr. Reference /
Input Activity Output Resp. Checkpoint
No. Format
Phase - IV
( Product & Process Varification)

Process Sheet,Process
Training Attandance
23 Drawing,Work Training Given to Operator about Process Instruction / SOP / Process Training Attandence QA Check Attandence Record
Sheets & Process Drawing OPPL/F/HR/05
Instruction

Inprocess Inspection report

24 PFD/PFMEA/CP/ Prepare a Pilot lot with inspection report Inspection report PROD/NPD/QA Check Sample Report
OPPL/F/QA/22
Drawing/Std./RM/
Instrument/machine

Process Audit Report

OPPL/F/QA/14A
PFD/PFMEA/CP/ Conduct the Product & process Audit Check Process & Product Product Audit Report
25 Drawing/Std./RM Process & Product Audit Report QA Audit Report OPPL/F/QA/16

SPC Report
Control Plan/Critical Preparation of Preliminary Process capability Study (Cp, OPPL/F/QA/31
26 Cpk Study) & Preliminary MSA / Gauge R&R Study SPC & MSA Report QA Check SPC & MSA Report
Characteristics Sheet MSA Report
OPPL/F/QA/08

PPAP - File as per

27 Customer Requirement Prepare the Initial Pilot Lot / PPAP / SOP lot. and send To customer PPAP Documents NPD/ QA as per AIAG requirements
with Parts,including along with required documents
PSW

28 PPAP Documents List PPAP Documents approval from customer Customer Approval NPD/ QA Check PPAP PPAP as per customer

Control Plan
29 PFD,PFMEA Control Plan NPD/ QA Check Production Control Plan
Preparation of Production Control Plan. OPPL/F/QA/03

Prepared By: Approved By:

 Doc. No.:- OPPL/TM/PM-13
Process No-13 Rev No :-'03
Rev Date: 22.10.2020
Title : Advance Product Quality Planning IATF CLAUSE NO.:-8.3.1.1
Sr. Reference /
Input Activity Output Resp. Checkpoint
No. Format

Phase -V
(Feedback and Corretive Action)

Customer Things Gone Wrong (TGW) / Things Gone Right(TGR) to be MOM

30 MOM NPD Check MOM
Feedback/Mail finalized. OPPL/F/MKT/21

Customer Compilation of quality problem during trial & pilot lot in PDCA CAPA Sheet
31 Feedback/Defect Study Analysis Summery sheet & CAPA Sheet CAPA Sheet QA Check CAPA Sheet
Report during
Development

Take Sign off - PSW from Customer

32 PSW PSW QA Check Approved PSW

Start Mass Production Plan ( Initial Production Control ) - 3month / IPC Procedure
33 IPC Procedure 3Lot / 5000 Nos. Whichever Later. IPC Procedure QA/PROD Check IPC Procedure
OPPL/TM/PM-25

Rev No. Revision Date Revision Description

0 2.10.2017 Intial Release
1 2.12.2019 Point No.33 Added, IPC Procedure Added
2 28.02.2020 Performance Criteria Added
3 22.10.2020 APQP Phase Sequence Modified as per Customer Requirement

Prepared By: Approved By: