Advance Product Quality Planning

Status Report
Supplier Program
Location Model Year
Supplier Code Lead Part No.
Risk Assessment Part Name
New : Site Technology Process Notice Level
Other Risks User Plant(s)

Team Members Company/Title Phone/Fax

Build Level Material Quantity Concurred P.I.S.T P.I.P.C.

Required Date No. SCs No. CCs % %
- - - -
- - - -

APQP Elements GYR Review Focus Program Supplier Closed Champion Remarks or
Status Type Element Need Timing Date Initials Assistance Required
Rating Date Date
1) Sourcing Decision - -
2) Customer Input Requirements - -
3) Design FMEA - -
4) Design Review(s) - -
5) Design Verification Plan - -
6) Subcontractor APQP Status - -
7) Facilities, Tools, and Gages - -
8) Prototype Build Control Plan - -
9) Prototype Builds - -
10) Drawings and Specifications - -
11) Team Feasibility Commitment - -
12) Manufacturing Process Flow Chart - -
13) Process FMEA - -
14) Measurement Systems Evaluation - -
15) Pre-Launch Control Plan - -
16) Operator Process Instructions - -
17) Packaging Specifications - -
18) Production Control Plan - -
19) Production Trial Run / Run at Rate - -
20) Preliminary Process Capability Study - -
21) Production Validation Testing - -
22) Production Part Approval (PSW) - -
23) PSW Part Delivery at MRD - -

COMMENTS
 Program Need Date Breakdown

Element Questions/Formula Program

Need Date
(PND)
23) Part Submission Warrant What is the Production Validation MRD? 1-Mar-05 1-Mar-05
(PSW), Part Delivery at
Material Required Date
(MRD)

22) Production Part Approval. a) How many days to ship parts once PSW is approved? 5 17-Feb-05
PSW must be submitted b) How many days does Dana need to review the Production Part 7
and approved prior to Approval Package?
PSW parts being delivered Formula:
to customer plant #23 PND - (a) - (b)
Production Part Validation 1-Mar-05 5 7 = 17-Feb-05
MRD

21) Production Validation (PV) a) How many days are needed to compile the Production Part 7 10-Feb-05
Testing. PV Testing must Approval (PSW) submission once all requirements are completed
be completed, analyzed, (i.e. testing, control plans, etc.)?
and formatted for inclusion Formula
into the PSW package. #22 PND - (a)
17-Feb-05 7 = 10-Feb-05

20) Preliminary Process a) How many days to complete PV Testing? 21 13-Jan-05

Capability Studies. These b) How many days does the customer require to review data? 7
must be analyzed and Formula:
formatted for inclusion into #21 PND - (a) - (b)
the PSW package. This 10-Feb-05 21 7 = 13-Jan-05
should be done prior to
PV testing

19) Production Control Plan. a) How many days will it take to analyze data specifically for the 7 6-Jan-05
This must be completed capability studies?
and signed off for inclusion Formula:
into the PSW package. #20 PND - (a)
13-Jan-05 7 = 6-Jan-05

18) Production Trial Run. This a) How many days to compile PSW information once completed? 7 24-Feb-05
build generates data for Formula:
Ppk Studies and parts for #22 PND - (a)
PV Testing 17-Feb-05 -7 = 24-Feb-05

17) Packaging Specifications. a) How many days to receive sufficient quantities for the capability 7 15-Feb-05
This must be complete in studies?
order to ship PSW parts b) How many days to ship parts for packaging? 7
to PV MRD. Formula:
#23 PND - (a) - (b)
1-Mar-05 7 7 = 15-Feb-05
 Program Need Dates (PND)

Element Questions/Formula Program

Need Date
(PND)
16) Operator Process a) How many days required to train and post instructions for 21 20-Jan-05
Instructions. This must operators?
be in place for Production b) How many days to build PTR parts? 14
Trial Run. Formula:
#18 PND - (a) - (b)
24-Feb-05 21 14 = 20-Jan-05

15) Pre-Launch Control Plan. a) How many days to post control plan? 3 31-Jan-05
This must be completed b) How many days to build PTR parts? 14
signed by customer prior c) How many days for customer to review? 7
to PTR. Formula:
#18 PND - (a) - (b) - (c) =
24-Feb-05 3 14 7 31-Jan-05

14) Measurement System a) How many days to include GR&R data for Pre-Launch 7 24-Jan-05
Evaluation. This must be Control Plan?
completed prior to Formula:
finalization of the Pre- #15 PND - (a)
Launch Control Plan/ 31-Jan-05 7 = 24-Jan-05

13) Process Failure Modes & a) How many days does it take to include added controls or 14 17-Jan-05
Effects Analysis (FMEA). process actions from the FMEA in the Pre-Launch
This must be completed Control Plan or Operator Process Instructions?
prior to PND for Pre- Formula:
Launch Control Plan and #15 PND - (a)
Operator Process 31-Jan-05 14 = 17-Jan-05
Instructions to ensure
FMEA is updated in the
PLCP or OPI prior to PTR.

12) Manufacturing Process a) How many days to complete PFMEA? 21 27-Dec-04

Flow Chart. This must be Formula:
completed prior to PFMEA. #13 PND - (a)
(used to start the PFMEA 17-Jan-05 21 = 27-Dec-04
Process)

11) Team Feasibility a) How many days to build PTR parts? 14 22-Nov-04
Commitment. b) How many days will it take to train operators on tools? 14
c) How many days to order tooling? 7
Formula:
#18 PND - (a) - (b) - (c) =
27-Dec-04 14 14 7 22-Nov-04
 Program Need Date (PND)

Element Questions/Formula Program

Need Date
(PND)
10) Drawings and a) How many days will it take to build or revise tools, deliver 168 9-Sep-04
Specifications. This must and prove out?
be finalized to build or Formula:
revise production tooling #18 PND - (a)
for Production Trial Run 24-Feb-05 168 = 9-Sep-04

9) Prototype Builds. This a) What is the next Prototype Build date? 1-Jun-05 1-Jun-05
changes throughout the
program.

8)
Prototype Build Control Plan a) When is the earliest MRD for Prototype Build? 1-Jun-05 11-May-05
This must be completed b) How many days will it take to build and test prototype 14
and signed-off prior to first build?

Prototype Build. (Update as c) How many days required for reviewing and approving 7
necessary.) Prototype Build Control Plan?
Formula:
(a) - (b) - (c)
1-Jun-05 14 7 = 11-May-05

7) Facilities, Tools and a) How many days to build parts? 7 27-Jan-05

Gauges. This must be in b) How many days will it take to train operators and perform 21
place and proven out for Trial Runs?
PTR Formula:
#18 PND - (a) - (b)
24-Feb-05 7 21 = 27-Jan-05

6) Subcontractor APQP No Program Need Date. 5-Jan-05 5-Jan-05

Status. This is an ongoing
activity.

5) Design Verification Plan a) When is the earliest Prototype Build MRD? 1-Jun-05 25-May-05
(DVP). This must be in b) How many days will it take to communicate requirements 7

place for the first Prototype on DVP necessary personnel?

Build. Formula:
(a) - (b)
1-Jun-05 7 = 25-May-05

4) Design Review PND could be date of next scheduled review. 1-Jan-05 1-Jan-05

3)
Design FMEA. This must be a) How many days will it take to develop DVP? 7 18-May-05
completed prior to DVP Formula:
#5 PND - (a)
25-May-05 7 = 18-May-05
 Program Need Dates (PND)

Element Questions/Formula Program

Need Date
(PND)
2) Customer Input These will vary from supplier and from commodities. No 1-Jan-05 1-Jan-05
Requirements formula works for all. commodity to commodity.

1) Sourcing Decision Suppliers should keep in mind they are communicating 1-Jan-05 1-Jan-05
last possible dates these elements can be completed
(or delivered to them in this case) and not adversely
affect the program.
 Advance Product Quality Planning
Work Plan
Element / Activity Issue(s) for Red / Yellow Elements Corrective Action / Resolution Plan Timing Reponsibility
# Activity (summarize the concern & resulting risk) (e.g. revise timing, allocate resources) Open Closed Dana Supplier
 APQP Focus Element Rating Checklist
Design Failure Modes and Effects Analysis

Expectations Yes

1) A design responsible cross-functional team must develop the Design FMEA

2) The Design FMEA must be prepared using the approved Ford (1696A), Chrysler-
Ford-GM FMEA (1995 or later edition), or Society of Automotive Engineers (J1739)
Manual.
3) Lessons learned from campaigns, recalls, user plant concerns, similar part design
FMEAs. Things gone wrong and warranty data must be addressed during current
part design FMEA development
4) Every component design function must be clearly included in the Design FMEA

5) Failure modes must be listed and described in physical, technical and measurable
terms
6) The effects of failures must address the impact on each part, next higher assembly,
system, vehicle, customer wants and government regulations.
7) Corrective actions, responsibilities and completion dates must be assigned to high
severity numbers and high risk priority numbers.
8) Risk priority numbers must be revised to reflect verified corrective actions
9) The Design FMEA must identify potential special product characteristics.
10) Potential causes and/or mechanisms of failure must be identified for all failure
modes.

Note: If an "Expectations" checklist item is not applicable, the team shall note reason in comments section and check the "yes" box upon customer approval
 APQP Focus Element Rating Checklist
Design Failure Modes and Effects Analysis

Exceeds Expectations Yes

1) A Concept (System) FMEA was completed prior to starting the design FMEA.
2) Fault tree analysis, failure mode analysis, or other analytical methods were used in
preparing the Design FMEA.
3) Robust design techniques were used in developing corrective actions.
4) Other innovations (please detail in "Innovations" box Below)

Rating

0 Less than 5 boxes checked in "Expectations"

1 5 to 10 boxes checked in "Expectations"
2 All 10 boxes checked in "Expectations" plus specific "Exceeds Expectations" designated by Dana Program Management
3 All "Expectations" complete with one or more boxes in "Exceeds Expectations" excluding those designated as "Expectations" by Dana Program

Innovations
is

Comments

ion and check the "yes" box upon customer approval

s

Comments

designated by Dana Program Management

s" excluding those designated as "Expectations" by Dana Program
 APQP Focus Element Rating Checklist
Design Verification Plan and Report

Expectations Yes

1) A cross functional team must be used in the completion of the design verification
plan
2) Specified tests, methods, equipment, acceptance criteria, sample sizes, design
level and timing must be clearly documented in the design verification plan
3) Tests must include variation within tolerance on selected product characteristics
chosen by the team
4) The design verification plan must include retest requirements for design, material,
or manufacturing process changes that occur prior to the production trial run

5) Design verification plan must include tests that address environmental again,
dimensional wear, and material fatigue
6) Design verification plan must include tests that address the "90th percentile"
customer usage profile and duty cycle
7) Design verification plan must include tests that address the useful life (10 yr./ 150k
miles) of the product
8) Design verification plan must include tests that address the effects of the external
environment (climate, road surface conditions, etc.)
9) Design verification plan must include tests that address the effects of the internal
environment created by the neigbouring sub-systems
10) Design verification plan must include tests that address the effects that the physical
interfaces components and sub-systems
11) Design verification plan should include tests that are designed to detect a failure
using variables data. Note: a failure is a significant event; partial, degraded,
intermittent, or total product failure.
12) The team must agree upon operating definitions of failure and success.
13) Design verification plan must include a procedure to document and react when the
distribution of product failures does not meet design and reliability goals.

Note: If an "Expectations" checklist item is not applicable, the team shall note reason in comments section and check the "yes" box upon customer approval
 APQP Focus Element Rating Checklist
Design Verification Plan and Report

Exceeds Expectations Yes

1) Accelerated test models have been validated by testing to failure and field data
2) Engineering methods, supported by statistical analysis, have been used to correct
undesirable results from DV testing
3) Design verification plan includes testing the component in the customer's product in
addition to bench tests
4) Design verification tests use variables data to measure how the component or sub-
system functions within the system.
5) Other innovations (please detail in "Innovations" box Below)

Rating

0 Less than 7 boxes checked in "Expectations"

1 7 to 12 boxes checked in "Expectations"
2 All 13 boxes checked in "Expectations" plus specific "Exceeds Expectations" designated by Dana Program Management
3 All "Expectations" complete with one or more boxes in "Exceeds Expectations" excluding those designated as "Expectations" by Dana Program Management.

Innovations
 Comments

nd check the "yes" box upon customer approval

 Comments

gnated by Dana Program Management

cluding those designated as "Expectations" by Dana Program Management.
 APQP Focus Element Rating Checklist
Process Flow Diagram

Expectations Yes

1) A cross-functional team must be used in the completion of the manufacturing

process flow chart
2) The process flow chart must illustrate the sequence of production operations
including; inspection, transportation, storage, subcontracted services, and alternate
paths (rework, repair and back-up)
3) The current part Design FMEA must be used as an aid to develop the process flow
chart
4) Surrogate part process flow charts and process FMEA's must be used in
development of the current part process flow chart
5) The process flow chart must describe how the product will move within the process
(e.g. roller conveyor, slide, containers).
6) The process flow chart must have a key for symbols.
7) Each operation must be clearly described on the process flow chart.
8) All operations affecting special characteristics must be appropriately identified on
the process flow chart.
9) The desired product and process characteristic outcomes of each operation must
be identified on the process flow chart
10) There is evidence that changes have been made in the process flow to reduce
potential process variability.

Note: If an "Expectations" checklist item is not applicable, the team shall note reason in comments section and check the "yes" box upon customer approval
 APQP Focus Element Rating Checklist
Process Flow Diagram

Exceeds Expectations Yes

1) Dynamic Control Planning techniques have been used to develop the process flow
chart.
2) The controlling correlation's have been identified between product and process
characteristics or groups of product characteristics.
3) There is evidence that changes have been made in the process flow to improve
safety and ergonomics.
4) Other innovations (please detail in "Innovations" box Below)

Rating

0 Less than 5 boxes checked in "Expectations"

1 5 to 10 boxes checked in "Expectations"
2 All 10 boxes checked in "Expectations" plus specific "Exceeds Expectations" designated by Ford Program Management
3 All "Expectations" complete with one or more boxes in "Exceeds Expectations" excluding those designated as "Expectations" by Dana Program

Innovations
 Comments

ion and check the "yes" box upon customer approval

 Comments

designated by Ford Program Management

s" excluding those designated as "Expectations" by Dana Program
 APQP Focus Element Rating Checklist
Process FMEA

Expectations Yes Comments

1) A manufacturing responsible cross-functional team must be used to develop the
Process FMEA.
2) The Process FMEA must be prepared using the approved Ford (1696), Chrysler-
Ford-General Motors FMEA manual (1995 or later edition), or Society of
3) Automotive Engineers
Lessons learned (J1739) Manual.
from campaigns, recalls, user plant concerns, similar process
FMEAs, Things Gone Wrong and warranty data must be addressed during current
part process FMEA development.
4) All operations from must described in physical, technical, and measurable terms.

5) Failure modes must be described in physical, technical, and measurable terms.

6) The effects of failure must address the impact on each part, next higher assembly,
system, vehicle, customer wants, government regulations, and operator safety.

7) Potential causes and/or mechanisms of failure must be identified for all failure
modes.
8) Causes must be described in terms of something that can be corrected or
controlled.
9) Causes must consider people, material, methods, machines, measurement
systems and environment.
10) Corrective actions, responsibilities, and completion dates must be assigned to high
severity failures modes and high risk priority numbers.
11) Mistake proofing must be used in addressing corrective actions.
12) Risk priority numbers must be revised it reflect verified corrective actions.
13) Severity number cannot change unless a design a design action reduces the effect
of the failure mode and the design FMEA has been revised a design action reduces
the effect of the failure mode.
14) The process FMEA must identify potential special characteristics.

Note: If an "Expectations" checklist item is not applicable, the team shall note reason in comments section and check the "yes" box upon customer approval
 APQP Focus Element Rating Checklist
Process FMEA

Exceeds Expectations Yes Comments

1) The Dynamic Control Planning methodology was used to develop the process
FMEA
2) Fault tree analysis, failure mode analysis, or other analytical methods were used in
preparing the process FMEA.
3) Correlation has been made between sources of variation and product
characteristics or downstream operations.
4) Characteristics, other than special characteristics, have been classified as their
importance.
5) Other innovations (please detail in "Innovations" box Below)

Rating

0 Less than 7 boxes checked in "Expectations"

1 7 to 13 boxes checked in "Expectations"
2 All 14 boxes checked in "Expectations" plus specific "Exceeds Expectations" designated by Ford Program Management
3 All "Expectations" complete with one or more boxes in "Exceeds Expectations" excluding those designated as "Expectations" by Ford Program

Innovations
 APQP Focus Element Rating Checklist
Prototype and PreLaunch Control Plan

Expectations Yes

1) A cross-functional team must be used in the completion of the prototype build

control plan
2) The cross-functional team reviewed all product characteristics, identified those
required for the prototype build control plan and obtained Design Engineering
approval.
3) Potential special characteristics from the Design FMEA , the customer and other
sources must be clearly identified on the control plan
4) Inspection plans must be defined for all material and engineering specifications

5) Gauges and test equipment to be used in the prototype phase must be identified
on the prototype build control plan
6) Gauges and test equipment to be used in the prototype build control plan must be
accurate, discriminant, repeatable and reproducible
7) Documented measurement procedures, techniques and datum's must be
referenced on the control plan.
8) Reaction plans must clearly state that all non-conformance or repairs require
customer authorization.
9) The customer must be given the opportunity to approve the prototype build control
plan.
10) Prototype processes that are different from the intended production processes
must be documented on the prototype control plan

Note: If an "Expectations" checklist item is not applicable, the team shall note reason in comments section and check the "yes" box upon customer approval
 APQP Focus Element Rating Checklist
Prototype and PreLaunch Control Plan

Exceeds Expectations Yes

1) A flow chart of the prototype build process has been prepared prior to the
completion of the prototype build control plan
2) The process parameter conditions have been documented on the control plan
3) When existing production processes are used to produce prototype components,
all special characteristics are capable and in statistical control.
4) Other innovations (please detail in "Innovations" box Below)

Rating

0 Less than 5 boxes checked in "Expectations"

1 5 to 10 boxes checked in "Expectations"
2 All 10 boxes checked in "Expectations" plus specific "Exceeds Expectations" designated by Dana Program Management
3 All "Expectations" complete with one or more boxes in "Exceeds Expectations" excluding those designated as "Expectations" by
Dana Program Management.

Innovations
 Comments

ion and check the "yes" box upon customer approval

 Comments

designated by Dana Program Management

s" excluding those designated as "Expectations" by
 APQP Focus Element Rating Checklist
Production Control Plan

Expectations Yes Comments

1) A manufacturing responsible cross-functional team must be used to develop the
production control plan.
2) The production control plan must be prepared per section 6 of the Chrysler-Ford-
General Motors Advanced Product Quality Planning and Control Plan Reference
3) Manual
Special Characteristics from the process and design FMEAs, the customer, and
other sources must be identified on the production control plan
4) Inspection plans must be defined for all material and engineering specifications

5) Flow chart operations and their desired product and process characteristic
specifications must be listed on the production control plan
6) Data must be developed to show the direct relationship between special
characteristics and their controlling process parameters
7) Gauges and test equipment to be used during production must be identified on the
production control plan.
8) Evidence must be available to show that gauges and test equipment identified on
the production control plan are accurate, discriminant, repeatable and reproducible.

9) The customer must be given the opportunity to approve the production control plan.

10) Documented measurement procedures, techniques and datum's must be

referenced on the production control plan.
11) Reaction plans must specify the containment and corrective actions necessary to
avoid producing non-conforming products or operating out of control

12) Control methods must address the requirement to produce product characteristics
within specifications.
13) Current controls listed in the process FMEA must be consistent with those listed on
the production control plan.
14) Reaction plans must be written so the operator can understand and implement
them.
15) Statistical control methods must be documented on the production control plan.

16) Control methods and reactions plans must be updated to address any issues and
lessons learned during the production trial run, including counter measures for
known capability problems.
17) Appropriate sample sizes and frequencies must be documented on the production
control plan.
Note: If an "Expectations" checklist item is not applicable, the team shall note reason in comments section and check the "yes" box upon customer approval
 APQP Focus Element Rating Checklist
Production Control Plan

Exceeds Expectations Yes Comments

1) The Dynamic Control Planning methodology was used to develop the production
control plan
2) In addition to special characteristics, data has been developed to show direct
relationships between other product characteristics and their controlling process
characteristics.
3) Product characteristic relationships from the characteristic matrix have been
analyzed to determine which are the vital few requiring control.
4) Control methods and/or sampling plans were economically optimized using quality
cost methods such as Taguchi or Juran.
5) Other innovations (please detail in "Innovations" box Below)

Rating

0 Less than 5 boxes checked in "Expectations"

1 5 to 10 boxes checked in "Expectations"
2 All 10 boxes checked in "Expectations" plus specific "Exceeds Expectations" designated by Dana Program Management
3 All "Expectations" complete with one or more boxes in "Exceeds Expectations" excluding those designated as "Expectations" by
Dana Program Management.

Innovations
 APQP Focus Element Rating Checklist
Operator Instructions

Expectations Yes

1) A manufacturing responsible cross-functional team must be used to develop the

process instructions.
2) Process instructions must be accessible and visible at the work station and
communicate requirements to all employees

3) Process instructions must specify monitoring of special characteristics

4) Process instructions must list requirements for inspection, testing , gauging and
recording results, with adequate sample size and frequency.
5) Process instructions must list approval and rejection criteria
6) Process instructions must list required tools and gauges with calibration
requirements, job set-up and tool change intervals.
7) Process instruction must document the identification and handling of non-
conforming material.
8) Process instructions must specify reaction plans for unstable/ non-capable
processes, including notifications and corrective actions.
9) Process instructions must specify application of statistical methods required by
control-plans
10) Process instructions must show operation name and number, part name and
number and revision dates, engineering level, and appropriate approvals.
11) Process instruction must reference available visual aids.
12) Process instructions must be verified during the production trial run to ensure that
they can perform as intended.

Note: If an "Expectations" checklist item is not applicable, the team shall note reason in comments section and check the "yes" box upon customer approval
 APQP Focus Element Rating Checklist
Operator Instructions

Exceeds Expectations Yes

1) Dynamic Control Planning methodology was used in the development of the

process instructions
2) Diagnostic guides were developed as part of each instruction.
3) Customer usage of the product is clearly identified as part of the process
instructions.
4) Other innovations (please detail in "Innovations" box Below)

Rating

0 Less than 5 boxes checked in "Expectations"

1 5 to 10 boxes checked in "Expectations"
2 All 10 boxes checked in "Expectations" plus specific "Exceeds Expectations" designated by Dana Program Management
3 All "Expectations" complete with one or more boxes in "Exceeds Expectations" excluding those designated as "Expectations" by
Dana Program Management.

Innovations
 Comments

ion and check the "yes" box upon customer approval

 Comments

designated by Dana Program Management

s" excluding those designated as "Expectations" by