KSS Global Standard

Supplier Advanced Product Quality Planning

KSS GLOBAL STANDARD

Supplier Advanced Product Quality

Planning (APQP) Procedure

KSS 704
Document No: 1005484

Author: Alexandru Iedu

Approved by: Hubert Ross
Mike Rawson
Frank Lin
Fred Heegan
Brian Schantz

Document History
Revision: Release Date ECP No. Modification
1 2/17/05 84019A Release for production.
2 5/05/05 84331A Release APQP Checklist.
3 1/10/06 84924A Revised APQP Checklist.
4 8/06/07 28797 Added Risk Assessment form.
5 10/20/08 32773 Revised Documents and roles.
Fully revised procedure according to the
6 01/09/14 65040
APQP SharePoint Portal system.

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Supplier Advanced Product Quality Planning

Table of Contents

INTRODUCTION ..................................................................................................................................................3
1 PURPOSE ...................................................................................................................................................3
2 SCOPE ........................................................................................................................................................3
3 RESPONSIBILITY.......................................................................................................................................3
4 DEFINITIONS / ABBREVIATIONS .............................................................................................................5
5 PROCESS MAP ..........................................................................................................................................5
6 PROCEDURE..............................................................................................................................................6
6.1 KSS APQP SHAREPOINT PORTAL AND APQP TRACKING ..................................................................... 6
6.2 KSS APQP SHAREPOINT PORTAL ITEMS ............................................................................................. 6
6.3 KSS APQP SHAREPOINT PORTAL REVIEW .......................................................................................... 8
6.4 DOCUMENTS REVIEW ........................................................................................................................... 8
6.4.1 Core Documentation review ......................................................................................................... 8
6.4.2 Tool Progress Report (TPR)......................................................................................................... 9
6.5 REVIEW OF FIRST OFF TOOL (FOT) PARTS AND DIMENSIONAL RESULTS ................................................ 9
6.6 RUN AT RATE ...................................................................................................................................... 9
6.7 PPAP SUBMISSION AND DISPOSITION .................................................................................................. 9
6.8 PPAP APPROVAL STATUS REPORTING ................................................................................................. 9
6.9 PPAP INTERIM APPROVAL OR REJECTION..........................................................................................10
6.10 APQP CLOSURE ...............................................................................................................................10
7 REFERENCES (RELATED DOCUMENTS) ............................................................................................ 10
8 APPENDICES .......................................................................................................................................... 10

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Supplier Advanced Product Quality Planning

Introduction
1 Purpose
This document describes how Key Safety Systems, Inc. manages the Advanced
Product Quality Planning (APQP) process.

After supplier approval through the Sourcing Council and update of the Supplier
Launch Tracker (SLT), the Early Supplier Involvement (ESI, #1012767) meeting is
the starting point for the APQP process and it ends with the full approval for the
PPAP initial submission. The objective of these activities is to ensure successful
and timely PPAP approval in accordance with program timing requirements.

2 Scope
The “Supplier Advanced Product Quality Planning (APQP) Procedure” applies to all
new and carry-over modified components that Key Safety Systems, Inc. procures
from outside sources. APQP can apply also for relocated or replacement/capacity
tool(s) if requested by the KSS Program Management, Commodity Buyer, or SQE
Manager.

3 Responsibility
The following are the roles and responsibilities for the Supplier APQP process.

Supplier:
• Attend ESI Meeting
• Upload signed feasibility form into folder in folder on APQP SharePoint Portal.
• Based off on KSS required dates for tool completion, first off tool & PPAP the
supplier is responsible to enter the required tool kick off date to meet KSS
program timing.
• Establish target timing for all APQP activities on the KSS Supplier APQP
SharePoint Portal.
• Update APQP status in a timely manner but as a minimum on a bi-weekly
(weekly for CLD3) basis or as defined by KSS SQE representative and maintain
related documentation.
• Upload core documentation (Process Flow, PFMEA, Control Plan, and Tool
Progress Report) as required, to the APQP Portal.
• Communicate any concerns through the Supplier comments area of the APQP
SharePoint Portal.
• Upon completion of tool apply KSS tool tags, take pictures and upload into
folder in APQP SharePoint Portal.

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Supplier Advanced Product Quality Planning

Supplier Quality Engineer (SQE):

• Attend ESI Meeting
• Launch APQP process into the KSS Supplier APQP SharePoint Portal, based
on the Sourcing Council approval / Supplier Launch Tracker (SLT) review.
• Conduct at a minimum bi-weekly follow-up with Suppliers to ensure APQP
SharePoint Portal updates are completed.
• Review Tool Progress Report in conjunction with Tool Engineering.
• Review core documents and provide feedback to supplier (Process Flow,
PFMEA, and Control Plan).
• Ensure Run at Rate is conducted by SQA as per the CLD requirements, and
support if needed
• Corrective Action coordination with supplier during development process.
• Monitor Supplier APQP Timing and communicate component status to the
program management team per program requirements.

Commodity Manager / Buyer:

• Provide and update part information data, program milestones and supplier
PPAP deadlines on SLT.
• Distribute released drawings to supplier.
• Schedule ESI according with policy #1012767 requirements and ensure entire
team is invited.
• Communicate supplier kick off after successful ESI meeting to all relevant
parties.
• Ensure approval of the feasibility commitment.
• Provide and update ramp up plan.
• Notify SQE and Tooling Engineer about any change relate to the program which
may affect time plan of the APQP and/or Tool Progress Report.

Engineering:
• Communicate any upcoming engineering changes.
• Timely release of component and assembly drawings.
• Resolve open SREA / drawing concerns that are hindering full PPAP approval.
• Attend ESI Meeting and provide assistance, feedback for any drawing
clarifications, adds changes.
• Review and approve of First Off Tool (FOT) samples received; all issues and
concerns to be communicated to supplier and SQE.
• Notify SQE of issues that may result in a delay of the PPAP approval.

Tool Engineering:
• Ensure supplier tool designs meet KSS Tool Design Standards.
• Approve tool concept and tool timing plan preferably during ESI meeting.
• Review Tool Progress Reports for PPAP timing compliance.
• Review and approve of First Off Tool (FOT) samples, when needed.
• Provide assistance and recommend resolutions to drawing/SREA issues with
Product Engineering related to tooling capability.

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Supplier Advanced Product Quality Planning

Supplier Quality Assurance (SQA):

• Attend ESI Meeting.
• Review core documents and provide feedback to supplier (Process Flow,
PFMEA, and Control Plan).
• Conduct Run at Rate; involve SQE when appropriate
• Update PPAP status upon approval or rejection of PPAP
• Monitor PPAPs status using the APQP SharePoint Portal and plan appropriately
• Review PPAP package and provide feedback to the supplier and SQE

4 Definitions / Abbreviations
APQP Advanced Product Quality Planning Process
CLD Control Level Definition
ESI Early Supplier Involvement
PPAP Production Part Approval Process
SLT Supplier Launch Tracker
SQE Supplier Quality Engineer (Purchasing)
SQA Supplier Quality Assurance (Quality)
TPR Tooling Progress Report
TE Tooling Engineer
QN Quality Notice

5 Process Map
EXPECTATION /
SUPPLIER INPUT PROCESS FLOW DESCRIPTION RESPONSIBLE OUTPUT CUSTOMER
MEASURE

Add Component w ith Key milestones

Component approved Add component to Component available
SQE Req. PPAP, Req. Tool Completion, SQE External Supplier
through sourcing Council APQP Portal for supplier APQP
Req. First off Tool

Supplier Program Timeline Enter applicable APQP portal complete External Supplier
External Supplier Target dates for Enter all dates into Portal. External Supplier
Customer Program Timeline co mponent w ith all timing KSS

1) APQP portal
Portal updates complete w ith all timing
Biweekly 2) Delay timing
1) Supplier to review data / timing and
Review Portal for updates received from supplier External Supplier
External Supplier update w ith all changes. External Supplier
at minimum bi-w eekly and program team. KSS
2) Communication of delay in Timing
3) Actions developed
to recover original
timing.

External Supplier PPAP data PPAP Submission Supplier submits level 3 PPAP External Supplier PPAP received by KSS SQA

Approved
PPAP SQE review s PPAP to KSS
SQA PPAP Requirements Disposition SQA PPAP Disposition External Supplier
requirements
Interim /
rejected

Feedback to SQE to uopdate portal w ith

SQA Communication to supplier Supplier PPAP SQA List PPAP issues External Supplier
no n-co nformances requirements to correct PPAP

PPAP Approval to Sign PSW and send to supplier

SQA Communication to supplier SQA PPAP Approval External Supplier
supplier Update portal to Approved status

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Supplier Advanced Product Quality Planning

6 Procedure

6.1 KSS APQP SharePoint Portal and APQP tracking

Prior to the ESI meeting the supplier shall receive and review the component drawing
including GD&T, 3D CAD model, applicable specifications, minimum requirements for
DV/PV activities and other project specific documentation.

During or after the ESI meeting the supplier will receive the APQP Portal login information.

The initial timing submission in the APQP Portal is due by the date agreed by KSS and the
supplier in the ESI meeting. The supplier is responsible for providing all information and
dates for all steps assigned to him in the APQP Portal. The information/dates should be
determined individually per task, such that the overall completion timing meets the
Supplier PPAP date agreed upon in ESI. The milestones, once provided on the initial
submission, are not to change without the approval of SQE and Program Manager.

Note: Failure to accurately update the APQP Portal by the supplier in a timely manner but
as a minimum on a bi-weekly basis (weekly for CLD3) may result in a QN being issued to
the supplier.

6.2 KSS APQP SharePoint Portal items

Steps on the APQP Portal are defined as follows:

(Responsible Party) - APQP line item - Explanation

(KSS) - Program - to be added info about OEM / Program / Project

(KSS) - Part Number - to be added part number drawing code.
(KSS) - CLD Level – Control Level Definition per the CLD assessment (1, 2 or 3).
(KSS) - Part Name - to be added part name from the drawing.
(KSS) - Job# - add the name of the SQE responsible (first name / family name).
(KSS) - KSS Plant receiving location - to be selected the manufacturing plant from the
drop-down list.
(KSS/Supplier) - PPAP status - to be selected the PPAP status from the drop-down list.
(KSS) - ESI Meeting - to select from calendar the meeting date.
(KSS/Supplier) - ESI Feasibility Form completion - to select the date of KSS feasibility
form completion.
(Supplier) - Request Kick Off date - supplier select the KSS kick-off date which allow it to
keep project timing.
(KSS) - Actual Kick Off date - to be selected real kick-off date.
(KSS) - KSS Req. PPAP Submission Date - to be selected by KSS acc. project timing.
(Supplier) - Supplier Target PPAP Date - supplier to select the feasible target date to
submit PPAP.
(KSS) - Act. PPAP completion Date - actual date of first complete PPAP documentation
and samples submittal.

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(KSS) - KSS required Production Tool completion Date - date when the serial tool need to
be completed to satisfy the other program milestones.
(Supplier) - Supplier Target Production Tool completion Date - data when supplier can
commit as feasible for serial tool availability.
(Supplier / KSS) - Supplier Actual Prod. Tool completion Date - data of tool completion.
(KSS) - KSS Req. FOT Parts Avail. - data when FOT parts should be available in KSS.
(Supplier) - Suppl. Target FOT Parts Avail. - Supplier selected target date for FOT parts
delivery to KSS.
(KSS) - Suppl. Act. FOT Parts Avail. Date - data when FOT parts were available in KSS.
(KSS) - Prototype Builds - to be selected “prototype builds” tab, if applicable.
(Supplier) - Prototype Builds Date - supplier to selected prototype build date.
(Supplier) - Prod. Manufacturing Process Flow Chart Date - to select completion date of
document.
(Supplier) - Prod. Control Plan Date - to select completion date of document.
(Supplier) - Prod. Process FMEA Date - to select completion date of document.
(Supplier) - Operator Process Instructions Date - to select completion date of document.
(Supplier) - Packaging Approval completion - To be selected the date when packaging
was approved.
(Supplier) - Packaging Approval Req. Date - to be selected the date when packaging
proposal was submitted.
(Supplier) - Preliminary Process Capability Studies Date - to select completion date of
document.
(KSS) - Facilities Tools and Gauges - to select the tab, if applicable.
(Supplier) - Facilities Tools and Gages Date - to select the date when gage(s) are
available.
(Supplier) - Req. Production Trial Run Date - to be selected date of the first serial
production run.
(Supplier) - Actual Production Trial Run - to be selected date of the first serial production
has run.
(Supplier) - Parts Verified Dimensionally Correct Date - to select completion date of
document.
(Supplier) - Production Validation Testing - to select the tab, if applicable.
(Supplier) - Production Validation Testing Date - to select date when test reports will be
available.
(KSS) - Material Validation/Certification - to select the tab, if applicable.
(Supplier) - Material Validation/Certification Date - to select date when material
validation/certification is available.
(Supplier) - Measurement Systems Evaluation Date - to select date when MSA will be
available.
(KSS) - Color/Grain Validation - to select the tab, if applicable.
(KSS) - AAR Comp. Date - to select the tab, if applicable.
(Supplier) - AAR Comp. Date - to select the date when AAR samples / report will be
submitted.
(Supplier) - Sub-Contractor 100% PPAP Approval Date - to select the target date when all
sub-suppliers will be fully PPAP approved / list with all sub-suppliers, together with a copy
of approved/signed PSW’s can be requested.
(KSS) - Process to Audit date for CLD3 components - to be selected the date for Process
Audit execution.
(Supplier) - Weekly Capacity - supplier to add the info about weekly capacity.

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(Supplier) - Unit of Measure - to select from the drop down list the units used to measure
weekly capacity.
(KSS) - SQA Comments - SQA field to add comments.
(KSS) - SQE Comments - SQE field to add comments.
(Supplier) - Supplier Comments - supplier field to add comments.
(KSS) - AAR Required - to select from the drop down list if AAR is requested by KSS.
(KSS) - Material / Color Approval Status - to select from the drop down list the status of
Material/Color approval.
(Supplier) - KSS Pre-Grain Submission - to be selected the date when preliminary grain
samples will be submitted to KSS, for review / approval.
(Supplier) - Dimensional - to be selected the target date for dimensional report availability;
KSS requires that a minimum five (5) piece dimensional layout be performed; for multiple
cavity / die tooling, a minimum of one (1) piece layout per cavity / die is required; where
are less than five (5) cavity / die, additional pieces will be measures till the number of five
(5) results.
(Supplier) - Draft Analysis - to be selected the date when draft analysis is completed.
(Supplier) - Part Submission - to be selected the target date for PPAP parts submission
(Supplier) - Grain Completion - to be selected the target date for tooling grain completion.
(Supplier) - AAR Submission - to select the date when AAR samples / report will be
submitted.

6.3 KSS APQP SharePoint Portal review

SQE is responsible for managing and controlling all supplier APQP activities from APQP
initiation at ESI until PPAP submission.

SQE shall review status updates from the suppliers to ensure all activities are progressing
on time per the target timing established. SQE shall involve cross-functional team
members from KSS and the supplier as required to address any issues that are identified
and manage the resolution of those issues.

The supplier shall maintain the current status for all items on the APQP Portal. The
supplier shall add actual completion dates for each item as soon they are completed. The
supplier is required to provide timely, but as a minimum bi-weekly (weekly for CLD3)
updates on the APQP Portal; updates are to be provided until full PPAP approval is
achieved for the part.

SQE shall confirm that supplier timing is in accordance with the program required PPAP
timing established by the Program Manager for each applicable program and notify the
cross-functional program team of any supplier related issue that may jeopardize the
program timing.

6.4 Documents review

6.4.1 Core Documentation review

For CLD 3 or as per KSS SQE request, the supplier shall provide the following Core
Documents via the control documents folder on their APQP SharePoint Portal page for
review prior to PPAP submission:

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Supplier Advanced Product Quality Planning

• Process Flow
• PFMEA
• Control Plans
SQE at their discretion will review those Core Documents. Feedback on these documents
should be provided to the supplier such that improvements can be made, if necessary,
prior to the initial PPAP Submission.

6.4.2 Tool Progress Report (TPR)

KSS SQE and Tool Engineering shall monitor the tooling progress based on the timeline
agreed latest in the ESI meeting.

The Supplier shall submit a bi-weekly TPR to the responsible SQE and to the responsible
Tooling Engineer using KSS TPR report (see Appendix). If suppliers have a dedicated
program / software to create / track project timing, this can be accepted by KSS after SQE
/ Tooling Engineering review and approval of the format. The TPR shall list all major steps
through the design, construction and qualification process, up to PPAP approval.

6.5 Review of First Off Tool (FOT) parts and dimensional results
The Supplier shall provide First Off Tool (FOT) sample parts together with the material
certification and dimensional layout results to the KSS application engineering team for
review and functional evaluation. KSS application engineering will provide feedback to the
supplier on any corrective actions required by the supplier to address dimensional or
functional non-conformances.

6.6 Run at Rate

Run at Rate should be in conjunction with the PPAP Production Run in accordance with
KSS Run at Rate Procedure #1005108. The Run at Rate will either be witnessed by KSS
on site for CLD 3 components, or be conducted by the supplier and reported to KSS for
CLD 1 and CLD 2 components using the Run at Rate worksheet #1022008.

6.7 PPAP Submission and Disposition

The supplier shall provide the PPAP Submission to the SQA of the receiving KSS Plant
location. The PPAP shall be in accordance with the AIAG PPAP current revision and
KSS-specific requirements. Upon submitting the PPAP the supplier is responsible to
change the PPAP status to “submitted” in the APQP Portal. The SQA shall review and
disposition the PPAP Package.

6.8 PPAP Approval status reporting

PPAP approval status shall be communicated by the SQA to the Supplier. SQA is
responsible to update the PPAP status in the APQP Portal.

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Supplier Advanced Product Quality Planning

6.9 PPAP Interim Approval or Rejection

SQA is responsible for the communication of reasons for rejection or interim approval.
SQA shall request corrective actions from the supplier and manage the resolution of any
open issues. SQE will support to get timely responses from the supplier.

6.10 APQP closure

Supplier APQP activities reach closure when full PPAP approval is issued for each
individual component. 30 days after receipt of full PPAP approval the part will be removed
from the APQP Portal and placed on the APQP Portal Archive.

7 References (Related Documents)

AIAG Advanced Product Quality Planning standard, latest revision
KSS Quality First Manual, Document #82000030
KSS ESI Procedure, Document #1012767
KSS Run at Rate Procedure, Document #1005108
Run at Rate worksheet, Document #1022008
Product Characteristic Classification (CC/SC Standard), Document #1033079

8 Appendices
Appendix A: Tool Progress Report Stamping
Appendix B: Tool Progress Report Molding / Die-casting

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Supplier Advanced Product Quality Planning

Appendix A: Tool Progress Report Stamping

Stampings Page #1
TOOLING PROGRESS REPORT (TPR)
STAMPING DIES, PROG. DIES, TRANSFER TOOLS, LINE DIES

Part Nam e: Supplier Nam e: Tool Kick-off Date:

Part Num ber: Supplier Contact: No. of Build Weeks :
Tool Des cription: Phone Num ber: Firs t Sam ple Date:
Date: Em ail: Buyer:

W EEK 14 03/16/09
TASKS % of % of task total % job T IMELINE CHART
total job complete complete
Tool Kick-of f 0 0 0
Concept / Strip Layout 0 0 0 100.0
Preliminary Design Approval 0 0 0
Order Material 0 0 0
Final Design 0 0 0 90.0
3D Surf acing 0 0 0
General Machining 0 0 0 80.0
Die Set w ork 0 0 0
CNC Machining: Die Chases 0 0 0
Platens 0 0 0 70.0

% JOB COMPLETE
Die Details 0 0 0
Cam Action Units 0 0 0 60.0
Forming/Bending Section 0 0 0
Stretching
Stretch & Draw
inserts
Inserts 0 0 0
Electrodes 0 0 0
50.0
Sinker EDM 0 0 0
Wire EDM 0 0 0 40.0
Grinding 0 0 0
Hydraulics 0 0 0
30.0
Heat Treat 0 0 0
Coatings 0 0 0
Assembly: Fit & Adjust 0 0 0 20.0
Benchw ork 0 0 0
Spotting 0 0 0
10.0
Tool Assembly 0 0 0
Tool Tryout 0 0 0
Dimensional Layout 0 0 0 0.0
0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
0 0 0
Total 0 WEEK
Total % job complete 0

Design Approval / OK to tool: Steel order date: Steel delivery date:

Comments:

Stampings Page #2
WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK
1 12/15/08 2 12/22/08 3 12/29/08 4 01/05/09 5 01/12/09 6 01/19/09 7 01/26/09 8 02/02/09 9 02/09/09 10 02/16/09 11 02/23/09 12 03/02/09 13 03/09/09 14 03/16/09 15 03/23/09 16 03/30/09 17 04/06/09 18 04/13/09 19 04/20/09 20 04/27/09
JOB TASKS % of % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job
total job complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete
Tool Kic k-off 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Concept / Strip Layout 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Preliminary Design Approval 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Order Material 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Final Design 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
3D Surfacing 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
General Machining 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Die Set work 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
CNC Machining: Die Chases 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Platens 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Die Details 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Cam Action Units 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Forming/Bending Section 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Stretch & Draw Inserts 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Electrodes 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Sinker EDM 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Wire EDM 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Grinding 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Hydraulic s 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Heat Treat 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Coatings 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Assembly: Fit & Adjust 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Benchw ork 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Spotting 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Tool Assembly 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Tool Tryout 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Dimensional Layout 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
TOTAL: 0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

KICK-OFF DATE (mm/dd/yy): 12/08/08

TOTAL NUMBER OF BUILD WEEKS: 14

WORK INSTRUCTIONS:
0.0 1 NOTE: ONLY CHANGE COLORED CELLS AS PER INSTRUCTIONS!! DO NOT CHANGE OR DELETE ANY WHITE CELLS
0.0 2 AT TOOL KICK-OFF:
0.0 3 1.) ON 'WORKSHEET': FILL IN GREY CELLS 'F37' and 'F38'. (Kick-off date and number of build weeks).
0.0 4 2.) ON 'WORKSHEET' PAGE: FILL IN GREEN CELLS 'E5' TO 'E33' ACCORDINGLY. THES NUMBERS MUST ADD UP TO 100%
0.0 5 WEEKLY:
0.0 6 3.) FILL IN YELLOW CELLS OF CORRESPONDING BUILD WEEK ON 'WORKSHEET' PAGE ACCORDING TO BUILD PROGRESS.
0.0 7 4.) ENTER CURRENT WEEK IN GREY CELL 'F9' ON 'MAIN SHEET'
0.0 8
0.0 9
0.0 10
0.0 11
0.0 12
0.0 13
0.0 14
0.0 15
0.0 16
0.0 17
0.0 18
0.0 19
0.0 20

Doc. No: 1005484 Rev. 06 Page 11 of 12 Uncontrolled copy printed: 09-Jan-2014

(KSS template no. 1033844 Rev. 2)
KSS Global Standard
Supplier Advanced Product Quality Planning

Appendix B: Tool Progress Report Molding / Die-casting

Molding Page # 1
TOOLING PROGRESS REPORT (TPR)
INJECTION MOLDS, DIE CAST TOOLS, POLYURETHANE MOLDS, BLOW MOLDS

Part Nam e: Supplier Nam e: Tool Kick-off Date:

Part Num ber: Supplier Contact: No. of Build Weeks :
Tool Des cription: Phone Num ber: Firs t Sam ple Date:
Date: Em ail: Buyer:

WEEK 1 12/16/08
TASKS % of % of task total % job T IMELINE CHART
total job complete complete
Surf acing 0 0 0
Mold Design 0 0 0 100.0
Square / E.B. 0 0 0
Steel Order 0 0 0
CNC: Core 0 0 0 90.0
Cavity 0 0 0
Slides 0 0 0 80.0
Lif ters 0 0 0
Core Trodes 0 0 0
Cav. Trodes 0 0 0 70.0

% JOB COMPLETE
Other 0 0 0
Ejector Box 0 0 0 60.0
EDM: Core 0 0 0
Cavity 0 0 0
Other 0 0 0
50.0
Benching 0 0 0
Spotting: Slides, Lif ters 0 0 0 40.0
Core to Cavity 0 0 0
Polishing 0 0 0
30.0
Waterlines: Core 0 0 0
Cavity 0 0 0
Slides, Lifters 0 0 0 20.0
Manif old 0 0 0
Cylinders 0 0 0
10.0
Texture / Graining 0 0 0
Other (Wirecut) 0 0 0
Toolmaking / Leading 0 0 0 0.0
A ssembly 0 0 0 1 2 3 4 5 6 7 8
Try-out 0 0 0
Total 0 WEEK
Total % job complete 0

Design Approval / OK to tool: Steel order date: Steel delivery date:

Comments:

Molding Page # 2
WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK
1 12/16/08 2 12/23/08 3 12/30/08 4 01/06/09 5 01/13/09 6 01/20/09 7 01/27/09 8 02/03/09 9 02/10/09 10 02/17/09 11 02/24/09 12 03/03/09 13 03/10/09 14 03/17/09 15 03/24/09 16 03/31/09 17 04/07/09 18 04/14/09 19 04/21/09 20 04/28/09
JOB TASKS % of % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job % of task total % job
total job complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete complete
Surfacing 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Mold Design 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Square / E.B. 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Steel Order 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
CNC: Core 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Cavity 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Slides 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Lifters 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Core Trodes 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Cav. Trodes 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Other 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Ejector Box 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
EDM: Core 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Cavity 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Other 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Benching 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Spotting: Slides, Lif ters 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Core to Cavity 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Polis hing 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Waterlines: Core 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Cavity 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Slides, Lifters 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Manif old 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Cylinders 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Texture / Graining 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Other (Wirecut) 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Toolmaking / Leading 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Assembly 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Try-out 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
TOTAL 0
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

KICK-OFF DATE (mm/dd/yy): 12/09/08

TOTAL NUMBER OF BUILD WEEKS: 8

WORK INSTRUCTIONS:
0.0 1 NOTE: ONLY CHANGE COLORED CELLS AS PER INSTRUCTIONS!! DO NOT CHANGE OR DELETE ANY WHITE CELLS
0.0 2 AT TOOL KICK-OFF:
0.0 3 1.) ON 'WORKSHEET': FILL IN GREY CELLS 'F37' and 'F38'. (Kick-off date and number of build weeks).
0.0 4 2.) ON 'WORKSHEET' PAGE: FILL IN GREEN CELLS 'E5' TO 'E33' ACCORDINGLY. THESE NUMBERS MUST ADD UP TO 100%
0.0 5 WEEKLY:
0.0 6 3.) FILL IN YELLOW CELLS OF CORRESPONDING BUILD WEEK ON 'W ORKSHEET' PAGE ACCORDING TO BUILD PROGRESS.
0.0 7 4.) ENTER CURRENT WEEK IN GREY CELL 'F9' ON 'MAIN SHEET'
0.0 8
0.0 9
0.0 10
0.0 11
0.0 12
0.0 13
0.0 14
0.0 15
0.0 16
0.0 17
0.0 18
0.0 19
0.0 20

Doc. No: 1005484 Rev. 06 Page 12 of 12 Uncontrolled copy printed: 09-Jan-2014

(KSS template no. 1033844 Rev. 2)