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APQP Internal Assessment Checklist: Development Phase

This document is an internal assessment checklist used during the Process Design and Development phase of APQP (Advanced Product Quality Planning). It contains 18 requirements that must be met during this phase, including forming project teams, ensuring adequate training, updating Process FMEAs, finalizing tooling and equipment needs, conducting pilot builds, validation testing, and identifying potential process failure modes. The checklist is used to audit a specific customer, project, department, and area to ensure all critical elements are addressed during early production process planning and development.

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Randhir Kanwar
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Download as PDF, TXT or read online on Scribd
236 views

APQP Internal Assessment Checklist: Development Phase

This document is an internal assessment checklist used during the Process Design and Development phase of APQP (Advanced Product Quality Planning). It contains 18 requirements that must be met during this phase, including forming project teams, ensuring adequate training, updating Process FMEAs, finalizing tooling and equipment needs, conducting pilot builds, validation testing, and identifying potential process failure modes. The checklist is used to audit a specific customer, project, department, and area to ensure all critical elements are addressed during early production process planning and development.

Uploaded by

Randhir Kanwar
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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APQP Internal Assessment Checklist

Customer: Audit Date:


Audit Type: APQP Internal Assessment Auditor:
APQP Phase / Support Process: Process Design and Project / Platform:
Development Phase Department:
Checklist: Page 1 of 3 Area:

Author: Quality-One Date Created:

Requirements: Finding:
1. Are system and/or component level Project Teams
formed?

Deliverables may include: Team roles and


responsibilities, organizational charts, etc.
2. Is adequate training or skill available to team
members for this phase?

Deliverables may include: skill assessments, training


plans.
Skills and Training may include: Product Development
Systems, Reliability, Assembly Variation Analysis,
Block Diagrams, Quality Function Deployment (QFD),
Benchmarking, Design of Experiments (DOE), Failure
Mode Analysis (FMA), Pugh Concept, Design for
Manufacturing and Assembly (DFMA), Flow Charting,
Design Verification Planning and Reporting,
Serviceability, Supplier Feasibility Assessment, Error
/Mistake Proofing, Design Failure Mode and Effects
Analysis (DFMEA), Process Failure Mode Effects
Analysis (PFMEA) Finite Element Analysis (FEA),
Geometric Dimensioning and Tolerancing (GD&T),
Statistical Process Control (SPC), Process Capability
Analysis, Process Mapping, Fault Tree Analysis (FTA),
Control Plans, Measurement Systems Analysis
(GR&R), Reliability and Maintainability (R&M), Total
Productive Maintenance (TPM), etc.
3. Have Process FMEA’s been updated from Design
phase activities? Have Key Process Characteristics
been finalized? Are Actions followed up and are
Process FMEA’s updated to reflect actions taken?

4. Have Mistake Proofing requirements been updated for


high-risk operations?

5. Are Supplier Product Development Plans and


supporting documentation available and reviewed?

6. Are Special Characteristic Matrixes utilized? Do they


identify Special Characteristic to Manufacturing
Process operation relationships?

7. Are Pre-Launch Control Plans utilized and do they


include:
o Specific additional actions / reactions which must
occur to assure error-free output?
o Linkage to key Design and Process FMEA’s and
Process Flow charts?
o Statistical evaluation of the process
o Reaction plans if problems are encountered in
builds?
o Quality Assurance vs. Quality Control
Methodology?
APQP Internal Assessment Checklist

Customer: Audit Date:


Audit Type: APQP Internal Assessment Auditor:
APQP Phase / Support Process: Process Design and Project / Platform:
Development Phase Department:
Checklist: Page 2 of 3 Area:

Author: Quality-One Date Created:

Requirements: Finding:

8. Are Product Level Predictive Indicators established?

Deliverable may include: First Time Capability (FTC) vs


Product Quality Assessments, FTC vs Warranty, etc.
9. Have Tooling, Equipment, Gage, Fixture, and Test
Equipment requirements been finalized to include:

o Comparison to key process characteristics?


o Comparison to Control Plan to identify any new
requirements?

10. Have Process Capability Estimates been finalized for


each process characteristic? Are reaction plan
developed for each characteristic that does not meet
capability targets?

11. Are Component Packaging and Shipping Design and


Test Plans available which include:

o Packaging and shipping instruction?


o Shipping and Part identification label?
o Lab and Shipping Test requirements for
expendable packaging and/or returnable
containers?
o Returnable container management program?

12. Have Operator Process Instructions been finalized


and do they reflect FMEA’s, Control Plan(s),
Engineering requirements, Process Flow Chart, Floor
Plan Layout, Characteristic Matrix, etc.?

13. Is Operator Training performed and are training plans


available?

14. Are Pilot Builds conducted that include:

o Components from Hard Tooled processes?


o Reviews that Components meet design intent for
Process Capability?

15. Is System and/or Component Production Validation


Testing conducted that include:

o Test results that include descriptive statistics,


capability statistics, etc.?
o Identification of any test Failures on Design and
Process FMEA’s?

16. Are Supplier Process Sign-off’s performed and


include:

o A procedure for Process Sign-off’s?


APQP Internal Assessment Checklist

Customer: Audit Date:


Audit Type: APQP Internal Assessment Auditor:
APQP Phase / Support Process: Process Design and Project / Platform:
Development Phase Department:
Checklist: Page 3 of 3 Area:

Author: Quality-One Date Created:

Requirements: Finding:
o A systematic and sequential review of the
manufacturing process at quoted peak daily line
rate, including manpower, facilities, equipment,
material, methods, procedures, etc.?
17. Are Potential Process Failure Modes identified with
the use of Process FMEA’s at the product level,
system, and component level designs? Are high-risk
failure modes identified by station and are lists
available?

18. Are Measurement Systems Analysis plans developed


and do they include:

o The responsibility for gage linearity, accuracy,


repeatability, reproducibility?
o Correlation for duplicate gages?
o Inclusion of measuring devices on Manufacturing
calibration systems?

Auditor Additional Notes:

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