Advanced Product Quality Planning (APQP) and Production Part Approval

Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP) Training Material Nordin Mimouni – Supplier Quality Manager Rev. 01 – Nov 29th 2018 1

Training Outline APQP introduction APQP timing chart and phases APQP application APQP sum up & key take aways 2 PPAP introduction When is PPAP required? PPAP submission level PPAP status Camso application of PPAP PPAP sum up & key take aways Camso 2019

What is APQP? Advanced Product Quality Planning Cycle Advanced Product Quality Planning method to assure that a product satisfies the customer (both internal and external) The goal of APQP is to: Plan before acting Anticipate and prevent issues Validate before moving forward Facilitate communication Each Advanced Product Quality Plan is unique and is a living document Particular emphasis should be placed on identifying critical path activities and ensuring those are fully resourced 3 Camso 2019

APQP at Camso 4 PDP: Product Development Process Same approach: Plan, Do, Check, Act Phases: Portfolio, Project proposal, Feasibility till Project Closure Milestones: scope approval, tech solution approval Roles and Responsibilities: deliverables per project function Camso 2019

APQP Background Automotive and Non Automotive industries challenges: Innovation, product complexity Reduce NPD times (Time to Market!) Complicated Supply chain (Global presence) Increasing customer and quality requirements (Zero Defect!) Solution: Ford, GM, Chrysler APQP Task Force jointly developed in the late 80’s to standardize their respective supplier quality systems. Continuous Improvement: Many industries outside the Automotive industry have embraced the AIAG APQP process to achieve similar benefits Camso 2019

APQP – timing chart and phases - AIAG 6 The Advanced Product Quality Planning process consists of four phases and five major activities and has some 20 supporting tools (e.g. DFMEA, PFMEA, CTQ, Special Characteristics, Control Plan, SPC) along with ongoing feedback assessment and corrective action. Camso 2019

Phase 1: Plan and Define Program 7 OUTPUTS: INPUTS: Assure that customer needs and expectations are clearly understood and assessed Voice of the Customer Market Research (ie IHS Markit) Historical Warranty and Quality Information Team Experience Business Plan/Marketing Strategy Product/Process Benchmark Data Product/Process Assumptions Product Reliability Studies Customer Inputs * The inputs and outputs applicable to the process may vary according to the product process and customer needs and expectations. Design Goals Reliability & Quality goals CONC targets Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary list of Special Product and Process Characteristics Product Assurance Plan Management Support Camso 2019

Phase 2: Product Design and Development 8 OUTPUTS: INPUTS: Develop design into a near final form. Prototype and feasibility studies – volumes, schedule, manufacturing. Design Goals Reliability & Quality goals Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary list of Special Product and Process Characteristics Product Assurance Plan Design Failure Mode and Effects Analysis (DFMEA) Design For Manufacturability and Assembly Design Verification Design Reviews Prototype Build – Control plan Engineering Drawings (Including Math Data) Engineering Specifications Material Specifications Drawing and Specification Changes Cont. next slide Camso 2019

Phase 2: Product Design and Development 9 OUTPUTS: INPUTS: Develop design into a near final form. Prototype and feasibility studies – volumes, schedule, manufacturing. Design Goals Reliability & Quality goals Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary list of Special Product and Process Characteristics Product Assurance Plan New Equipment, Tooling and Facilities Requirements Special Product and Process Characteristics Gages/Testing Equipment Requirements Team Feasibility Commitment Management Support Camso 2019

Phase 3: Process Design and Development 10 OUTPUTS: INPUTS: Develop a manufacturing system and its related control plans to achieve quality products. Design Failure Mode and Effects Analysis (DFMEA) Design For Manufacturability and Assembly Design Verification Design Reviews Prototype Build – Control Plan Engineering Drawings (Including Math Data) Engineering Specifications Material Specifications Drawing and Specification Changes New Equipment, Tooling and Facilities Requirements Special Product and Process Characteristics Gages/Testing Equipment Requirements Team Feasibility Commitment Management Support Packaging Standards Product/Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis (PFMEA) Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Management Support Camso 2019

Phase 4. Product and Process Validation 11 OUTPUTS: INPUTS: Validate manufacturing process through production trial run. Validate that the control plan and process flow chart are effective and that the product meets customer expectation. Packaging Standards Product/Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis (PFMEA) Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Management Support Measurement Systems Evaluation Significant Production Run Preliminary Process Capability Study Production Part Approval Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off - formal Management Support Camso 2019

Feedback, Assessment, Corrective actions 12 OUTPUTS: INPUTS: Evaluate outputs, effectiveness of the product quality planning efforts. Production Trial Run Measurement Systems Evaluation Preliminary Process Capability Study Production Part Approval Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off and Management Support Reduced Variation Improved Customer Satisfaction Improved Delivery and Service Effective use of best practice, lessons learned Maximum ROI Minimum Waste Camso 2019

Application to Different Mfg. Environments 13 High Volume APQP plans and activities are organized by part number and are very specific to the part Low Volume APQP plans may be specific to part families with activities focused on the parent part More limited validation would be done on child parts Family part differences should be understood and higher risk differences incorporated into APQP plans Camso 2019

APQP Summary: What we do: Design Quality DFMEA / PFMEA / DFM/A Manufacturing Quality Control Plans Process Flows Measurement System Analysis Capability Analysis Process Validation Run at rate Supplier Qualification & Quality Requirements Product Qualification 1st Article Inspection PPAP Tooling & Gauges Testing What we get: How we do it: APQP UP FRONT DETAILED QUALITY PLANNING Leadership Engagement is Critical Defect Free Launches Reduced Warranty Claims Zero Spills Customer Satisfaction Robust Products Greater Supplier Control Reduced supplier cost 14

APQP Benefits: Manufacturing process functions that are clearly planned, validated, documented and communicated that result in: Robust and reliable designs Reduced process variation Enhanced confidence in supplier’s capabilities Better controlled process changes Defect free launches Improved Customer satisfaction Improved Delivery and Service Maximum ROI Minimum Waste Minimum Cost of Non-conformance CONC Total Cost of Quality 15 Redesign Re-qualifications Escape Investigations Prevention through APQP Current state Development Production Time Camso 2019

Key Take Aways: APQP is cross-functional planning and execution to produce product that fully meets the customer’s expectations the first time AIAG APQP phases are Planning, Product Design, Process Design, Validation, Production Phase approach ensures activities are completed in the appropriate order Can be applied to different manufacturing environments – High Volume, Low Volume It’s cross-functional – Marketing/Design/Manufacturing/SCM/Quality Camso 2019

17 Production Part Approval Process (PPAP) Camso 2019

What is PPAP? 18 Production Part Approval Process Standard used to formally reduce risks prior to product or service release, in a team oriented manner using well established tools and techniques Initially developed by AIAG (Auto Industry Action Group) in 1993 with input from the Big 3 - Ford, Chrysler, and GM AIAG’s 4th edition effective June 1, 2006 is the most recent version PPAP has now spread to many different industries beyond automotive Camso 2019

PPAP at Camso 19 Aligned to AIAG PPAP Manual rev 4 Requirements set up during Camso Technical Reviews (DPAR Process*) Continuous validation approach Embedded to our APQP (output of phase 4 – Production Part Approval) *DPAR: Design, Process & Assembly Review – you can refer to DPAR Training Material for further information Camso 2019

Production Run 20 PPAP data must be submitted from a production run using: Production equipment and tooling Production employees Production rate Production process All data shall reflect the actual production process that will be used at start-up! Camso 2019

Purpose of PPAP 21 Provide evidence that all customer engineering design record and specification requirements are properly understood by the organization To demonstrate that the manufacturing process has the potential to produce product that consistently meets all requirements during an actual production run at the quoted production rate Camso 2019

When is PPAP Required? 22 New part Engineering change(s) Durable Tooling: transfer, replacement, refurbishment, or additional Tooling inactive one year Correction of discrepancy Change to optional construction or material Sub-supplier or material source change Change in part processing Parts produced at a new or additional location PPAP is required with any significant change to product or process! Camso 2019

Benefits of PPAP Submissions 23 Helps to maintain design integrity Identifies issues early for resolution Reduces warranty charges and prevents cost of poor quality Assists with managing supplier changes Prevents use of unapproved and nonconforming parts Identifies suppliers that need more development Improves the overall quality of the product & customer satisfaction Camso 2019

PPAP Submission Levels 24 Level 1 Production Warrant and Appearance Approval Report (if applicable) submitted to Camso Level 2 Production Warrant, product samples, and dimensional results submitted to Camso Level 3 Production Warrant, product samples, and complete supporting data submitted to Camso Level 4 Production Warrant and other requirements as defined by Camso Level 5 Production Warrant, product samples and complete supporting data (a review will be conducted at the supplier's manufacturing location) Camso 2019

PPAP Submission Requirements Requirement 1.Design Record 2.Engineering Change Documents, if any 3.Customer Engineering approval, if required 4.Design FMEA 5.Process Flow Diagrams 6.Process FMEA 7.Control Plan 8.Measurement System Analysis studies 9.Dimensional Results 10.Material, Performance Test Results 11.Initial Process Studies 12.Qualified Laboratory Documentation 13.Appearance Approval Report (AAR), if applicable 14.Sample Product 15.Master Sample 16.Checking Aids 17.Records of Compliance With Customer Specific Requirements 18.Part Submission Warrant 19.Bulk Material Checklist Level 1 R R R R R R R R R R R R S R R R R S S Level 2 S S R R R R R R S S R S S S R R R S S Level 3 S S S S S S S S S S S S S S R R S S S Level 4 * * * * * * * * * * * * * * * * * S S Level 5 R R R R R R R R R R R R R R R R R R R Any customer S The organization shall submit to the customer and retain a copy of records or documentation items at appropriate specific locations requestsRfall The organization shall retain at appropriate locations and make available to the customer upon request * The organization shall retain at the appropriate location and submit to the customer upon request under Element # 17 25 Note: For each level, full PPAP is required. The PPAP level simply indicates which elements you submit, and which you retain at your site. Camso 2019

PPAP Element 17: Camso Requirements 26 Depending on the specific Camso business, Camso may require: Measurement Agreement Gage Drawing Safe Launch Control Plan Annual layout Special Processes qualification Packaging Specification Data Sheet Submit Bar Code Label Packaging Approval Capacity R@R Worksheet MSDS Camso 2019

PPAP Status 27 Approved The part meets all Camso requirements Supplier is authorized to ship production quantities of the part Interim Approval Permits shipment of part on a limited time or piece quantity basis Rejected The part does not meet Camso requirements, based on the production lot from which it was taken and/or accompanying documentation Camso 2019 Production quantities shall not be shipped before Camso Approval Order!

PPAP Sum up & Take Aways 28 PPAP is a result of a good APQP! DPAR* is an important activity to determine PPAP expectations! Commitment on part and process feasibility We plan a good Control Plan: Measurement Agreement on key characteristics Camso determines PPAP level based on component risk Submission requirements are increased for higher risk components Requirements are defined and agreed during DPAR phase Camso provides a standard PPAP workbook with all necessary tools Supplier can use their own templates and tools if they meet the AIAG requirements Let’s be Smart! Going through PPAP process as a routine Identifying opportunities: Master PFMEA, Master CP *: refer to DPAR Training – DPAR Design Process & Assembly Review Camso 2019

29 Thanks Camso 2019