Form No.

APQP - PRODUCT DEVELOPMENT PLAN

Name of Supplier & Location: SAROJ ENGINEERS JAYSINGPUR

Supplier Doc. No.: F/ DEV / 05 KEY CONTACT PERSON : MR. GIRMAL A.K. PHONE/FAX : 02322221049

Supplier Doc. Rev. No.:00 TEAM LEADER : KINIKAR P.R. PHONE/FAX : 02322221149 DATE: 2/11/2016

CUSTOMER : TVSM HOSUR VEHICLE MODEL : 3 Wheeler

CUSTOMER PART NO : G4080238 PRODUCT NO : G4080238
PROJECT CONTROL NO : PART NAME : GEAR FINAL DRIVEN
TEAM MEMBERS DEPT/ PROCESS PHONE/FAX:
1. BHARAMGONDA A.C DEVELOPMENT DEPT 9822874792
2. KRISHNA A.V. MAINTAINCE & ENGINEERING 9850983232
3.MAGDUM D.K. QUALITY DEPT 9850040481
4. Nirmale D.I. PRODUCTION DEPT 9881059899
5. GADGADE A.K. DEVELOPMENT DEPT 9011071054
6. MANE A.S. DEVELOPMENT DEPT 9921493098
7.
BUILD LEVEL Product required date Quantity PROJECT CLASSIFICATION :
PROTOTYPE TOTALLY NEW VARIANT UPGRADE MINOR CHANGE OTHERS
ALPHA Jan-17 50
BETA Mar-17 250
PRODUCTION TRIAL RUN Apr-17 500 REMARKS : (Regular production requirement rate to include Spares also).
REGULAR (MASS) PRODUCTION May-17 3000
 APQP - PRODUCT DEVELOPMENT PLAN Form No.
Customer: TVSM HOSUR Product: GEAR FINAL DRIVEN Part No. G4080238

Applica Respons DAY / WEEK / MONTH / YEAR (Tick mark one. Indicate Year(s))
bility ibility
PHASE APQP ELEMENTS November December January February March April May June

1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd

PHASE I - PLAN 1) STUDY PAST DEVELOPMENT RECORDS. Ex: Study historic A BAC
data of internal and external rejection and rework, warranty
AND DEFINE complaints, TGR/TGW reports of past problems in development of
PROGRAM - similar parts, etc.
INPUTS

2) COLLECT PRODUCT BENCHMARK DATA. Ex. Data NA

relating to features, operating conditions, product performance,
reliability, durability, maintainability, serviceability, life, weight,
material cost, warranty performance, etc. of similar parts

3) COLLECT PROCESS BENCHMARK DATA. Ex. Data A BAC,

relating to process capability, rejections, rework, scrap, yield, etc. for MDK,
similar parts / processes.
KPR

4) RECEIVE AND REVIEW CUSTOMER INPUTS / CUSTOMER A BAC,

REQUIREMENTS INCLUDING SPECIAL CHARACTERISTICS, KPR,
IDENTIFICATION, TRACEABILITY AND PACKAGING.
This includes review of requirements of customer's Supplier KAV
Quality Assurance Manual, Special Process Qualification, Tier-2
supplier approval, packaging standards to be followed, customer
plants where parts are required and corresponding logistics, control
over special characteristics (product and process), PPAP process,
traceability, Homologation requirements, etc.

5) OTHERS IF ANY.

Highlighted activities applicable only for suppliers having product design responsibility.

PHASE I - PLAN 1) DEFINE QUALITY GOALS. Ex. Product A KPR,

conformance and performance specs, targets for warranty (Zero), BAC,
AND DEFINE targets for rejection, rework, etc. at customer end (Zero), targets for
PROGRAM - internal rejection and rework at supplier end, yield, etc. MDK
OUTPUTS

2) DEFINE LIFE, RELIABILITY, DURABILITY, MAINTAINABILITY NA

AND COST TARGETS FOR PRODUCT DESIGN
(Targets for life, reliability, durability, etc. to be based on
customer warranty targets. Please consult customer on
maintainability target fixing for totally new designs). Cost targets are
product cost targets; include material cost, manufacturing cost and
overhead cost targets.

3) DEFINE PRODUCTIVITY, PROCESS CAPABILITY AND COST BAC,

TARGETS FOR PROCESS DESIGN KPR,
Productivity target to be defined in terms of % MDK,
process-wise. Productivity targets are not cycle time targets or run- NDI
at-rate targets. Process Performance / Process Capability targets to
be fixed for all critical and major product characteristics. Cost targets
are only manufacturing cost targets, derived from 2 above.
Targets also need be defined for Measurability of products and
processes, new equipment reliability and maintainability, planned A
no. of Error-proofing devices, No. of new Gauges to be planned
based on current models, etc.

4) PREPARE PRELIMINARY PROCESS FLOW CHART. The A BAC

Preliminary PFC should as a minimum include the operation number
and name, and the equipment on which the process would be done.

5) PRELIMINARY LISTING OF SPECIAL PRODUCT NA

CHARACTERISTICS: Include identifiable Critical and Major
characteristics. All parts shall have at least a few special
characteristics.

6) PRELIMINARY LISTING OF SPECIAL PROCESS A BAC,

CHARACTERISTICS: Identify all significant process variables that MDK,
could affect identified special product characteristics. These could
be marked in Preliminary Process Flow Chart by symbols. KAV ,
GAK

7) PRELIMINARY LISTING OF APPEARANCE ITEMS: NA

Appearance items are those items that are visible when the vehicle
is assembled.

8) CONDUCT FEASIBILITY & RISK ANALYSIS: Risk Analysis to A BAC,

cover all potential risks that could lead to the supplier's inability to MDK,
meet customer's QCD performance needs at the development stage
and thereafter on an on-going basis. KAV ,
GAK

PHASE II - 1) DECIDE PRODUCT SPECIFICATIONS: These are

based on Design Goals, Quality Goals, Goals for life, reliability,
PRODUCT DESIGN durability, maintainability, cost, etc. and includes Conformance
AND Specifications (Ex. MBQ parameters, regulatory requirements) and
DEVELOPMENT Performance Specifications.

2) DECIDE MATERIAL SPECIFICATIONS

3) PREPARE DRAWINGS AND SPECIFICATION INCLUDING
REFERENCE TO PRODUCT ACCEPTANCE CRITERIA AND
CHARACTERISTICS THAT ARE ESSENTIAL FOR ITS SAFE
AND PROPER USE

4) CONDUCT DESIGN REVIEW - I CFT approach

a must. Agenda for design review to be prepared in advance.
Identify personnel with product and process technical knowledge to
take part in design reviews. The purpose of design reviews is to
assess the suitability, adequacy and effectiveness of the design to
meet established goals, to identify problems and to propose
solutions.

5) PREPARE DESIGN FMEA.

Include activities of reviewing and revising DFMEAs after Design
Review, Design Verification and Design Validation activities in the
same row.

6) REVIEW SPECIAL PRODUCT CHARACTERISTICS AND

INCORPORATE IN DRAWINGS

7) APPROVE & RELEASE DESIGN DOCUMENTS

8) PREPARE PROTO TYPE CONTROL PLAN A BAC,
MDK,
GAK
9) MAKE PROTO TYPE NA BAC,
MDK,
GAK
10) CARRY OUT DESIGN VERIFICATION Typical NA `
methods of design verification are prototype testing, comparison
with a proven design and alternate calculations. FEA / Simulation
tests may be treated as design verification activity. Reviewing the
drawings before release is a mandatory requirement and no more
treated as a design verification step.

11) CONDUCT DESIGN REVIEW - II (See note above) NA

12) TEAM FEASIBILITY COMMITMENT (TFC) : A ALL

Revisit the Risk Analysis table and modify. Identify mitigation plans TEAM
for unacceptable risks. Review and revise Team Feasibility Analysis
sheet. All CFT members to agree and sign the TFC. MEMB
ERS

Notes : 1) Steps 4 to 8 should run concurrently

2) Step 9 to be done after step 8

PHASE III - 1) DECIDE PACKAGING & MH STANDRADS A BAC

Packing Standards define numbers to be packed, how many to be
PROCESS DESIGN packed, what protection required, how to test and prove the packing,
AND what identification, etc. Also include the complete Material Handling
DEVELOPMENT and Storage facilities in this activity.

2) PREPARE PACKAGING SPECIFICATIONS; Packaging A BAC

Specifications are the drawings for the containers, cartons, labels,
etc.

3) a) REVIEW OF QUALITY SYSTEMS Review A MDK

existing QMS and identify need for new systems and revisions in
existing systems.

b) UPDATE DOCUMENTS IF REQUIRED Updation A MDK

may involve quality plans, calibration plans, preventive maintenance
plans, training needs, etc.
4) PREPARE PROCESS FLOW DIAGRAM/CHART: A BAC ,
As a minimum, PFD/PFC shall contain Process No. & Name,
Equipment & Tool No., Product Characteristics to be obtained in
GAK ,
each process step and the corresponding significant Process MDK
Characteristics to be controlled. It is not enough to indicate Process
Characteristics in the Control Plan. Control Plan derives inputs
manly from PFC, in addition to DFMEA (where applicable /
available) and PFMEA.

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 APQP - PRODUCT DEVELOPMENT PLAN Form No.
Customer: TVSM HOSUR Product: GEAR FINAL DRIVEN Part No. G4080238

Applica Respons DAY / WEEK / MONTH / YEAR (Tick mark one. Indicate Year(s))
bility ibility
PHASE APQP ELEMENTS November December January February March April May June

1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd 4th 1st 2nd 3rd
5) PREPARE PROCESS FMEA: A BAC ,
Include activities of revisiting and revising PFMEAs after gaining
experience in manufacturing the Alpha, Beta, Trial lots and
GAK ,
Production lots, in the same row. MDK

6) NEW EQUIPMENTS, TOOLING AND FACILITIES A BAC

REQUIREMENTS
a) FINALISATION (Include targets for equipment reliability,
durability, maintainability, uptime, Ppk / Cpk / Cmk targets in the
Equipment Note).
b) ORDERING

c) IMPLEMENTATION

7) TOOLS / DIES A BAC

a) FINALISATION

b) ORDERING / DESIGN / MANUFACTURING (Include targets for

tool set-up times, removal times, cleaning times, tool life, etc. in the
tool order / design).
c) TRY OUT

8) GAUGES / TESTING EQUPMENTS A MDK ,

a) FINALISATION (Study existing practices of usage of BAC
instruments & gauges. Identify measurement systems that would be
used for special product and process characteristics).

b) ORDERING / DESIGN / MANUFACTURING

c) TRY OUT

9) RESOLVE PROCESS RELATED DESIGN ISSUES A BAC

10) PREPARE PRE-LAUNCH CONTROL PLAN: Control A BAC,

Plan shall contain all details called for in Annexure . A to ISO/TS
16949-2009, including details of error-proofing and corrective
MDK ,
actions. Process variables to be controlled in each process step to GAK ,
be included, but do not write / type them in the same row as the KAV
product characteristics.

11) DECIDE PILOT LOTS There may A BAC

be more than one pilot lot production. Ex. Alpha, Beta, QP1, QP2,
QP3, SPTR etc.

12) PREPARE PROCESS INSTRUCTIONS They A MDK

derive inputs from DFMEA, PFC, PFMEA, and Control Plans.
Include Set-up Instructions and Rework Instructions.

13) CONDUCT PROCESS DESIGN REVIEW See Note A BAC,

under Design Review - 1 (Phase II).
MDK ,
GAK ,
KAV
14) PREPARE MSA STUDY PLANS Identify A MDK Plan Alpha Phase Beta Phase SPTR
and list all new instruments and gauges that are going to be used for
the part under development. If no MSA has been done so far, then Phase
identify and list all measurement systems (incl. new instruments and
gauges) that would be used.

15) PREPARE PROCESS CAPABILITY STUDY PLAN Include all A MDK Plan Alpha Phase Beta Phase SPTR
special product characteristics for Ppk / Pp study.
Phase

16) DEFINE PROCESS APPROVAL ACCEPTANCE CRITERIA: A MDK Alpha Phase Beta SPTR
Define Process Approval Acceptance Criteria for each trial run and
document.
Phase Phase

17) TRAIN OPERATORS, INSPECTORS & OTHERS: A NDI

Arrange for product-specific and process- specific training for
Operators, Inspectors and Others as required so that they achieve
the competency to carry out the activities. Maintain training records.

18) TEAM FEASIBILITY COMMITMENT (TFC) : A ALL

Revisit the Risk Analysis table and modify. Identify mitigation plans
for unacceptable risks. Review and revise Team Feasibility Analysis
TEAM
sheet. All CFT members to agree and sign the TFC. MEMB
ERS

Notes : 1) Steps 10, 12, 13 and 14 to be done after step 5 only.

2) Step 5 to be done after step 4
3) Step 6, 7 and 8 to be done after step 5
PHASE IV - 1) CONDUCT PRODUCTION TRIAL RUN Include A NDI, Alpha Beta SPTR SOP
PRODUCT AND plans for Special Process Qualification, Alpha, Beta, Lot 1, Lot 2, Lot GAK
3 as applicable, in the same row, but at different points of time. Mark Phase
PROCESS
them as Process Qualification, Alpha, Beta, Lot 1, Lot 2.
VALIDATION

2) CONDUCT MSA STUDIES A MDK Beta Phase SPTR SOP

Phase

3) CONDUCT PROCESS PERFORMANCE STUDIES A MDK SPTR SOP

Phase

4) DO PRODUCTION VERIFICATION TESTING: The A BAC, Alpha Phase Beta SPTR

purpose is to prove that each defined Design and Quality Goal / NDI ,
Targets (product, process has been met. Compare results against
Phase Phase
goals / targets / specs. MDK
Update process performance data in Process Approval Acceptance
Criteria columns in Process Design Input Sheet. Go back to Step
No. 1 of Phase IV after each trial run till the results are satisfactory.
Activity includes Product Design Validation where supplier is
responsible for product design.

5) TEAM FEASIBILITY COMMITMENT (TFC) : Revisit A ALL Alpha Beta SPTR

the Risk Analysis table and modify. Identify mitigation plans for
unacceptable risks. Review and revise Team Feasibility Analysis
TEAM Phase Phase Phase
sheet. All CFT members to agree and sign the TFC. MEMB
ERS

6) REVISIT PROCESS CONTROL DOCUMENTS, REVISE AS A ALL Alpha Beta SPTR

APPLICABLE AFTER EACH TRIAL RUN: Revisit all Process TEAM
Control Documents (PFD, PFMEA, Control Plan, Work Instructions,
Phase Phase Phase
Checklists etc.) after each Process Trial Run, update as necessary. MEMB
ERS

7) PREPARE PPAP DOCUMENTATION, SUBMIT TO A BAC Beta SPTR SOP

CUSTOMER, OBTAIN CUSTOMER APPROVAL
Phase

8) PACKAGING EVALUATION: As the products are now available, A BAC ,

evaluate the quality of packaging to ensure no damage /
deterioration during handling, storage, transportation, unpacking,
MDK
etc.

9) DESIGN REVIEW - III (See Note under DR 1) A ALL

TEAM
MEMB
10) PROCESS DESIGN VALIDATION (3 LOTS) Observe A ALL
ERS Alpha Phase Beta SPTR
process performance over 3 lots. All design and quality targets
should be met.
TEAM Phase Phase
MEMB
ERS
11) QUALITY PLANNING SIGN-OFF (AT SITE WHERE A MDK
PRODUCTION ACTIVITIES OCCUR)

12) BRIEFING/GETTING MANAGEMENT SUPPORT

PHASE V - 1) IDENTIFY OPPORTUNITY FOR REDUCED VARIATION A BAC,

FEEDBACK, (Special emphasis on product and process special characteristics. MDK ,
ASSESSMENT AND All characteristics with Cpk less than 1.67 would require attention).
NDI ,
CORRECTIVE GAK
ACTION
2) CUSTOMER SATISFACTION PLAN Interact with A MDK,
customer and identify improvement requirements. Prepare action NDI
plans and deploy.

3) MONITOR DELIVERY AND SERVICE - About one month (or A MDK,

5,000 - 10,000 Nos.) of mass production
NDI

4) PREPARE PRODUCTION CONTROL PLANS A BAC,

Incorporate all required changes so that the process when deployed MDK,
faithfully would continue to meet and exceed the design and quality
goals. GAK

5) PREPARE TGR & TGW REPORTS - (To be done in each A BAC, Alpha Phase Beta SPTR
Phase) MDK , Phase Phase
GAK ,
KAV
6) OTHERS, IF ANY

REVIEW DATE

Symbols used : Abbreviations used : Revision details Remarks :

: Starting plan PPAP: Production Part Approval Process

Sl. No. Details Date Sign
: Started A : Applicable

: Completion plan NA : Not applicable

: Completed Prepared by : BAC
Checked by :
2 Phase planning mentioned 25/1/2017 BAC Approved by :

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