TRAINER FOLDER

for exercises related to APQP & PPAP by PSA:

PHASE 1:
RFQ. Plan & define program.

v3.1
1
 EN J1_Kick off meeting
E
N
Starting of product and process design

Milestone date: specific for each part

To cross the milestone at the latest 6 weeks after SUP choice.

Thème Résultats attendus / Expected results

RI01 (SUP)
Supplier's project team and PSA's project team are identified by name and
trained. Resources are allocated.
The name of each project team member, SUP and PSA, is registered in
APQP grid.
RI02 (SUP)
The Project PMR (Risks Management Plan) and the PED (Defects
Project management Eradication Plan) built during supplier bid phase have been updated to take
into account the constraints of the project schedule. They are registered in
APQP grid.
If necessary:
- The finalize Safety plan is registered in APQP grid.
- The DIA (Development Interfaces Agreement) integrates supplier
proposals and registered in APQP grid.
For sofware: Sofware safety plan is available in APQP grid
RI03 (SUP)

The development and industrial schedules of the supplier take into

account all APQP deliverables on PSA expected dates.
Supplier development schedule
These schedules are registered in APQP grid.
For Software: Software development plan is vailable in APQP grid

RI04 (SUP)

Technical specifications + The requirements coverage matrix takes into account: 1/ all PSA technical
Requirements coverage matrix, requirements (included quality targets), 2/ the related justifications and
including after sale action plans for not compliant items.
requirements The matrix is registered in APQP grid.

RI05 (SUP)
List of Product Functional and
The supplier has taken into account the changes brought to the CTF list
Technical Characteristics (CTF)
provided during the bid phase.
and Parts Inspection Standard
. (PCP)
The CTF list is registered in the PLM.

RI06 (SUP)

The parts and validation means required for both Supplier and PSA Design
Validation Plans are identified and taken into account.
Design Validation Plan and The Supplier Design Validation Plan and its planning are registered in APQP
results grid.
For Software - APQP-RI06-SW: Sofware validation plan is available in
APQP grid.

RI07 (SUP)

Process flow diagram The estimated process flow diagram is registered in APQP grid. (SUP)

RI08 (SUP)

Measurement and checking means are taken into account and planned.
Measurement processes The list and a preliminary description of these checking equipement are
registered in APQP grid.

RI09 (SUP)
The supplier has taken into account the customer-specific requirements of
the PPAP file.
For Software:
Software development plan is available in APQP grid.
Software quality plan is available in APQP grid. Software configuration
Customer-Specific plan is available in APQP grid. Supplier answer about Software Guidelines
requirements is available in APQP grid. Supplier answer about PSA software
development rules and ISO 26262 is available in APQP grid.
Software requirements coverage matrix contains PSA technicals
requirements including prooves and actions plans for thoses which are
not compliant. It is available in APQP grid.

v3.1
2
 CASE STUDY : CORPALU

CORPALU is specialized in the design, production of aluminium parts for vehicle transmissions as a tier 1
supplier, and for different applications for the aviation industry.
Its main customers are European and American OEM, with a market fully growing each year for
STELLANTIS.
CORPALU has different production sites and locations, close to its customers:
Headquarters and design centre: REIMS
Production sites: Lillebonne (France)
Novomesto (Slovenia)
Miranda (Brazil)
Chen Yang (China)
CORPALU is IATF 16949 and ISO 14001 certified.

CORPALU has sent a bid / quotation to a request for quotation by STELLANTIS related to a new bearing
transmission (part number AB12).

v3.1
3
INSTRUCTION: you take part to the first gate / milestone review « kick-off meeting».

You have to give a status on the maturity level on deliverables for the milestone 1 (GREEN, RED, GREY).

You have at your disposal 3 deliverables:

Achie
 APQP-RI01: the list of project team members of CORPALU
ving
 APQP-RI03: the master design and industrialisation plan of CORPALU
the

milestAPQP-RI09: the conformance of STELLANTS (ex-PSA) specific requirements by CORPALU

one 1
«
KICK
YOUR CONTRIBUTION:
-OFF
Within groups, at paperboard, you have to analyse the 3 supplied deliverables, then give a status.
MEE
TING
YOUR DECISION :
»
Deliverable status (red, Why ? Give the explanation Required Action (if necessary)
green, grey)
APQP-RI01: the
list of project
team members of
CORPALU

APQP-RI03 : the
design and
industrialisation
plan of CORPALU

APQP-RI09 : the
conformance of
STELLANTIS (ex-
PSA) specific
requirements by
CORPALU

v3.1
4
 PROJECT TEAM MEMBERS LISTED FOR PROJECT PSA / BEARING AB12

Project Director
Me Soubirou A.
tel:
mail:[email protected]

Quality development Product Engineering Project leader Calculation & Tests Process Engineering
Not definedi Mr Geodeve M. Me Justine E. Mr Parlabaux Y. Mr Chaussesse G.
tel: tel: tel: tel: tel:
mail: mail:[email protected] mail:[email protected] mail:[email protected] mail:[email protected]

WORKLOAD PLAN OF PROJECT TEAMS FOR DEVELOPMENTS IN PROGRESS

function Box XCV Bowl ZT Relay ZAM PSA Bearing

AB12
Mrs Justine E. Project leader X X X X

Mr Geodeve M. Pilot of Product X X

Engineering
Mr Dessinee B. Pilot of Product X X
Engineering
Mrs Toussure S. Quality X X X
development
? Quality X
development
Mr Paralbaux Y. Calculation & X X
Tests
Mrs Victor A. Calculation & X X
Tests
Mr Chausesse G. Process X X
Engineering
Mr Zoutil X. Process X X
Engineering

COMMENTS from CORPALU:

 The team member of the project team “quality development” is not yet named and defined ; He/she will be
recruited within 6 months;
 The project leader Mrs Justine E. is already managing 3 other projects and her availability will be limited for
the new project PSA Bearing AB12 ;
 The whole STELLANTIS Team is assigned on the project: CP (Project Manager), RAP (Project Purchasing),
SQD.

v3.1
5
 THE MASTER DESIGN AND INDUSTRIALISATION PLAN OF CORPALU’s PROJECT PSA BEARING AB12
EXTRACT from plan entered in the APQP grid : PLAN of PHASE « INDUSTRIALIZATION » : milestone PSA / FOT release : 30/09/2016

Macro task activity days pilot Start End % observations

Supplier Signature of contract 15 Product E. 25/03/2016 08/04/2016
Development for Material test 30 Product E. 08/05/2016 08/06/2016
material Qualification of product 10 Product E. 08/06/2016 18/06/2016
(120 days)
Qualification of process / audit 25 Process E. 18/06/2016 13/07/2016

PPAP approval 5 Quality D. 13/07/2016 19/07/2016

Specific toolings Quotation of suppliers 15 Process E. 08/04/2016 23/04/2016

(not estimated) Supplier Selection 3 Process E. 23/04/2016 27/04/2016

Mold Realization 150 Mold Supplier 30/04/2016 25/09/2016 Too long duration (new technology)
Qualification of mold 30 Process E. 28/09/2016 28/10/2016

CTF and CSE for PCP planning ? Quality D. Tasks to be described by Quality
(to be consolidated) Implementation ? Quality D. Department
st
Data analysis (1 parts) ? Quality D.

During the gate review with STELLANTIS team “kick-off meeting”, the CORPALU’s project leader Mrs JUSTINE Eliane is explaining that she has not yet any knowledge
of the APQP grid and has not yet checked whether all PSA deliverables were included in the master plan or not.
STELLANTIS is noting in addition that the « Supplier Production Capacity Assessment» is not planned and included in the master plan after the delivery of PPAP
parts; the project leader answers that this expected deliverable will be added to the master plan in Phase 5 of the APQP; the updated plan will be provided for the
next monthly review.

V3.1
6
 CONFORMANCE TO PSA SPECIFIC REQUIREMENTS;
TAKING INTO ACCOUNT OF THE PSA REQUIREMENTS for the PPAP FILE

* STELLANTIS requests to communicate the approval status of all raw material suppliers (Aluminium)
in the PPAP file :
CORPALU is OK to provide this status of Tier 2 suppliers in the PPAP file.

* STELLANTIS requests that a specific RAMS study (reliability, availability, maintainability and safety) has
to be supplied in the PPAP file, as the part BEARING AB12 is defined as a “safety part”.
CORPALU is OK to perform and supply this study in the PPAP file ; CORPALU has integrated this
study in his own master plan in phase 2 of APQP.
These requirements have been added in the grid and this request will be included in APQP grid
(PPAP item 17).

V3.1
7