Quality System Procedure Issue date

20 July
2017

QSP-19 Revision date Nil

Procedure for APQP Issue no. 03

Page 1 of 9
Rev.no. 00

PURPOSE
The Advanced Product Quality Planning procedure (APQP) accompanies the steps necessary to
assure that a product conforms to customer expectations during the development and launch
phase.
This procedure is formulated by involving cross-functional team to prepare a guideline for
submitting the APQP to customer.

SCOPE:
The procedure applies to Bearing Races (Inner & Outer) and any other components in the form
of rings undertaken for development in following conditions: -
This procedure applies to wherever customer approval required
a. New product development.
b. Location change.
c. ECN change.
d. Major 4M changes.
e. Tooling inactive more than one year.

The procedure covers all process and activities right from receipt RFQ along with drawing from
customer till SOP at customer end.

RESPONSIBILITY:
The APQP team is responsible for the timely planning, execution and documentation of all
activities carried out within the framework of Advanced Product Quality Planning (APQP).

Top Management : Overall Responsibility to ensure effective implementation of the

Process of New Product development.

CFT : Progress follow-up, Sign-off on PPAP summary report.

MKT/SCP/PDN/ENG/QA/MET : As per the activities defined in the scope.

SCP : Announce start and end of initial supply controls.

Prepared by: Reviewed and Approved by:

 Quality System Procedure Issue date
20 July
2017

QSP-19 Revision date Nil

Procedure for APQP Issue no. 03

Page 2 of 9
Rev.no. 00

PROCEDURE:
The product development process (PEP) consists of consecutive phases that are separated by
milestones.

Sr. No. Description

1 Receiving Drawing & RFQ from customer

2 Inquiry & Feasibility Review

3 Quotation Submission to customer

4 Spec. Review meeting with customer

1.0 Plan &

5 Quotation approved by customer
Define

6 Order confirmation by customer

7 Training gap identification

Sourcing decision and initiation of supplier identification, if new

8
supplier is required

9 Status - Review

1 Raw material procurement plan & Order

2 New Equipment, Tooling's Requirements

2.0 Product 3 Define special Product and Process Characteristics

Design &
Development 4 Gauges / Testing Equipment availability

5 Sub-Contractor selection

6 Status - Review

Prepared by: Reviewed and Approved by:

 Quality System Procedure Issue date
20 July
2017

QSP-19 Revision date Nil

Procedure for APQP Issue no. 03

Page 3 of 9
Rev.no. 00

1 Manufacturing Process Flow Chart

2 Process FMEA

3 Prelaunch Control plan

3.0 Process 4 Measurement System Analysis Activity Plan

Design &
Development 5 Preliminary Process Capability Activity Plan

6 Packaging Specifications review and approval

7 Manufacturing Team Training

8 Status - Review

1 Raw material availability for PPAP batch

2 Subcontractor sample Approval

3 Production Trail Run

4 Sample summation and approval

5 Production for PPAP approval

4.0 Product &
Process 6 Measurement System Analysis Evaluation
Validation
7 Preliminary Process Capability Study

8 Review Production Control Plan

9 Submission of PPAP lot along with documents to customer.

10 Conduct Lessons Learned and Handover doc. to production.

11 Status - Review

5.0 Customer
1 Customer Approval and PSW sign off
Approval

Prepared by: Reviewed and Approved by:

 Quality System Procedure Issue date
20 July
2017

QSP-19 Revision date Nil

Procedure for APQP Issue no. 03

Page 4 of 9
Rev.no. 00

Process and
2 Status - Review
Feedback
APQP Elements
The aims, expectations and requirements associated with documenting the individual elements of
the APQP are described below:

Customer order
Formal placing of an order by the customer so that investments can be effected on schedule by
the supplier.

Customer specifications
Customer specifications include, for example, the design briefs, drawings or specifications which are
required at the start of a project.

Contract review
To carry out a commercial and technical assessment of the documents provided by the customer to
check that they are complete, up-to-date and feasible.
 The product requirements have been suitably defined and documented (e.g. drawing, specification,
design requirements)
 The defined requirements can be met. The quotation is prepared following a cross-functional
manufacturing feasibility analysis.
Documentation
 Manufacturing feasibility assessment.

Design FMEA
 Only applicable when personal responsibility for product development is of company.
 A Design FMEA is a systematic procedure used to ensure that potential development and design defects
and their respective causes have been taken into account and have been countered by preventive
measures within a technical cross-functional team.

Design Review
 To monitor the progress of measures and to ensure that objectives are met.

Design Verification Plan – DVP

 Only applicable when personal responsibility for product development is of company.
 Systematic planning of all tests or calculations to check whether the product or design is suitable
for the application.

Equipment, tools and inspection equipment

Capable / released operating materials
 Planning (monitoring of dates) and provision of all necessary operating materials
 Deadlines for the procurement or manufacture of equipment and tooling must be monitored.

Prepared by: Reviewed and Approved by:

 Quality System Procedure Issue date
20 July
2017

QSP-19 Revision date Nil

Procedure for APQP Issue no. 03

Page 5 of 9
Rev.no. 00

 The equipment and tooling should be tested prior to the production trial run.
Drawings and specifications
The term "drawings and specifications “includes all technical drawings, CAD data, material
specifications and technical specifications from the customer.
All drawings and specifications that are needed to observe the initial volume production sample
date/start of production (SOP).
Documentation
 Drawings, Specifications

Manufacturing feasibility assessment

A cross-functional team must assess the manufacturing feasibility of the intended product within the
framework of the contract review.
 The team must be convinced that the product is suitable for the intended application and can be
produced, checked, packed and delivered to the customer in sufficient quantities, at a competitive price
and to the required quality.
Documentation
 Manufacturing feasibility assessment

Process flow chart and volume production layout

The volume production process flow chart is a graphical representation of the planned sequence of
operations.
 To ensure the sequence of all volume production stages and inspection stages from goods inwards through
to goods issue.
Documentation
 Process flow chart

Process FMEA
A Process FMEA is a systematic procedure used to ensure that potential production defects and their
respective causes have been taken into account and have been countered by preventive measures
within a technical cross-functional team.
The Process FMEA must cover all production and inspection stages and must take into account
experiences and previous concerns.
 All production and inspection stages are listed and analyzed.
 Potential defect modes are described and evaluated and, where necessary, corrective measures are
introduced and monitored by the persons responsible.
 Significant numbers are coordinated with the customer.
Documentation
 Process FMEA

Prepared by: Reviewed and Approved by:

 Quality System Procedure Issue date
20 July
2017

QSP-19 Revision date Nil

Procedure for APQP Issue no. 03

Page 6 of 9
Rev.no. 00

Inspection equipment capability

To evaluate the suitability of the intended inspection equipment and inspection methods by means
of a capability study.
 Capability studies must be carried out in order to check the suitability of the inspection equipment.
 If modifications are made to the inspection/measuring equipment, the capability studies must be repeated.
Documentation
 Proof of capability with individual values.

Pre-Launch Control Plan

To ensure that process and product requirements are met during pre-launch,
e.g. through increased inspection frequency, additional inspection characteristics.
 The type and scope of the inspections and the corresponding inspection equipment for pre-launch are
defined and agreed with the customer.
 Reaction plans are defined for handling discrepancies.
 All "special characteristics “are included.
Documentation:
 Pre-Launch Control Plan

Process instructions
All instructions for production personnel, e.g. production plans, work instructions and inspection
instructions, maintenance plans, defect catalogues, process parameters.
 Easily understood (available in the national language of the respective production site) and accessible
instructions, at the workplace, to ensure that procedures are followed and requirements regarding the
process or the product are implemented.
 Descriptions are given of the procedures involved in controlling defective products.
Documentation with supplier:
 Process instructions

Packaging
To maintain product quality through the use of suitable packaging materials.
 Packaging specifications and corrosion protection for shipments to the customer have been agreed with
the customer.
 Related customer packaging specifications must be observed.
 It must be ensured that the quality of the product is not impaired when it is packed, dispatched, put into
storage and removed from storage.
Documentation:
 Defined packaging specifications and corrosion protection.

Prepared by: Reviewed and Approved by:

 Quality System Procedure Issue date
20 July
2017

QSP-19 Revision date Nil

Procedure for APQP Issue no. 03

Page 7 of 9
Rev.no. 00

Production Trial Run

To check the effectiveness of the volume production process.
 Verification of the required product quality and the planned nominal quantities (capacity)
 Verification of the volume production process.
 The production quantity must consist of at least one production batch size which is representative of the
process (usually daily requirement from annual requirement).
 Taking of initial volume production samples from this batch
Documentation with supplier:
 Production Records

Volume Production Control Plan

To ensure that process and product requirements are met during volume production.
 The type and scope of the inspections and the corresponding inspection equipment for volume production are
defined and agreed with the customer.
 Inspections for requalification of the product are included.
 Reaction plans are defined for handling discrepancies.
 All "special characteristics “are included.
Documentation:
 Volume Production Control Plan

Preliminary process capability study

Process capability studies use statistical methods to prove that the product can be manufactured in
line with the specification.
 Preliminary process capability under volume production conditions, at Pp/Ppk values of > 1.67 (at least 25 x 5
parts) and machine capability (50 parts) at Cm/Cmk values of > 1.67.
 In the event of incapable processes, suitable corrective measures must be introduced in order to achieve
process capability. A 100 % inspection must be carried out until process capability is achieved.
Documentation
 Capability record

Initial volume production sampling

The initial volume production samples to prepare documentation for all elements requested by the
customer in accordance with the Production Process and Product Release Procedure.
 To provide documentation on schedule; scope in accordance with defined submission level.
Documentation
 Initial sample inspection report.

Marking and packaging of initial samples.

The initial sample must be marked with "Initial sample" and TAG to be put on along with samples. If
there is any customer specific requirement related to marking and tagging then it has to be
implemented accordingly.
Prepared by: Reviewed and Approved by:
 Quality System Procedure Issue date
20 July
2017

QSP-19 Revision date Nil

Procedure for APQP Issue no. 03

Page 8 of 9
Rev.no. 00

APQP Documentation

The documents are listed as following:

1. APQP Timing Plan.

2. APQP Responsibility Matrix.
3. APQP Activities Matrix.
4. Feasibility Evaluation.
5. New Product and Process Development Requirements.
6. Cross Functional Team.
7. Management review sheet.
8. Pre-launch Control Plan.
9. Mfg. Process Flow Chart.
10. PFMEA.
11. Key Characteristics sheet.
12. PSW.
13. PPAP Verification Summary Report and Sign-off.
14. Things Gone Wrong with Product / Process.

Note:
 Additional documents may be required which will depend upon the specific customer
requirement.
 After PPAP Submission, the next 3 supplied lots will be monitored.
 APQP Development shall be reviewed with Top Management at the end of each phase
and if required will be reviewed in between as decided by CFT team.
 Initial Parts (5 Nos. Sample) must be Trace with New Part Tag(NPD) at all Stages.

Prepared by: Reviewed and Approved by:

 Quality System Procedure Issue date
20 July
2017

QSP-19 Revision date Nil

Procedure for APQP Issue no. 03

Page 9 of 9
Rev.no. 00

Record of Changes

Issue
S.No Page Change Revision Date.
Date

1 All Aligned as per IATF : 2016 requirements 20 July 2017 Nil

10

Prepared by: Reviewed and Approved by: