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Eff.Date:-15.07.17
QUALITY MANUAL PROCEDURE Page No.: 1 of 9
APQP(Advanced Product Quality Planning)

1. PURPOSE

This Procedure is to be defining new product development and ECN Parts and to define the
process needed for the Product Quality planning process to ensure that:
1. Resources are directed to satisfy the customer.
2. To promote early identification of problems / changes to avoid late changes
3. To provide a quality product on time at the lowest cost.
4. Use of CFT approach & Simultaneous engineering during design and development of
the process.

2. SCOPE
A Absolutely new component : no Experience of Production so far
That the part happens to be similar to what had been produced so far but there
happens to be large scale difference in raw
A component similar to the component produced so far but there happens to be large
scale difference in raw material,Machining ,Methodology,In the structure or in the
B
function.
That whenever there happens to be changed in production site
That whenever the place/country of development happens to be different from the
place/country of production
That whenever there happens to be extremely Process Change in details related to the
C component ,so much so that even the inspection

Applicable to all new development parts and ECN parts

3. RESPONSIBILITY

It is the responsibility of the MR to ensure that this procedure is latest, implemented and
understood by all appropriate personnel across the organization.

It is the responsibility of the CFT & relevant functional heads to ensure that this procedure is
implemented in their respective departments.

4. PROCEDURE

Phase – I (Plan and Define the program / Pre contract review)

Prepared By: Reviewed and Approved By:

Mr.Deepak Sharma Mr.Gaurav Bansal

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APQP(Advanced Product Quality Planning)

Responsibility/ Document No
Sl. No. Activity
Authority
Receive enquiry / Customer drawing / Customer provided sample / M.D./
4.1.1 any standards and specifications from CUSTOMER, Sample --
submission time requirement (If any). PLANT HEAD
Perform enquiry review and the details will be entered in Enquiry HOD F/MKT/06
4.1.2 Register The details shall be reviewed for adequacy if engineering
(Marketing)
drawing were provided by the customer.
Identify the Customer drawing, standards, if given by putting
`MASTER COPY’ on the rear side of the drawing and standard.
Mark the date of receipt suitably handwritten on the rear side or front
4.1.3 side and update the master list of customer drawing immediately. In PLANT HEAD
case if any drawings received for reference purpose as design input, it
can be considered only for reference by putting `Reference only’ on --
the rear side of the drawing.
Photocopies of the customer drawing affixed with `CONTROLLED --
4.1.4 PLANT HEAD
COPY’ stamp can be used for reference purpose
Top management shall constitute a Manufacturing Cross Functional F/PD/13
Team consisting of members from Marketing, Production,
4.1.5 M.D
Maintenance, Quality, and Purchasing to carry out the Advanced
Product Quality Planning. List of CFT Members
Drawing Review: The drawing shall be reviewed by Manager. F/PD/15
In case of samples received from the customer, it can be used for
CFT
Comparative purpose only and does not absolve the CFT to comply
with customer requirement as stated in the drawing.
4.1.6
Clarification from customer, If required:
During drawing review if any incomplete information found, the
marketing person shall interact with customer to get the relevant
Marketing --
required information.
Additionally CFT Team shall collect information on Internal voices /
Past History based on:
a) In house rejections / Rework
b) Customer complaints
4.1.7 CFT
c) Process changes and their impact
d) SPC results

Pre – Feasibility Study: F/MKT/07

Conduct Pre-feasibility study to understand the manufacture ability of CFT
new product.
For feasible products, a final Process details shall be prepared. The
4.1.8 final Process details, and then is reviewed by MANAGER for CFT /
preparation of cost data sheet and facilitating submission of MANAGER
Quotation.
If found not feasible, CFT shall send mail/regret letter or verbally Regret Letter
MANAGER
intimating the customer the inability to service this enquiry.
4.1.9 Reliability and Quality, Goals: (If required) CFT
Prepared By: Reviewed and Approved By:

Mr.Deepak Sharma Mr.Gaurav Bansal

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APQP(Advanced Product Quality Planning)

CFT Team shall identify goals in the form of: F/PD/24

1.Product cycle time
2.In-Process Rejection PPM
3. Process capability requirement
Preliminary Process flow Chart:
4.1.10 Tentative process flow chart (Block diagram) shall be prepared by the CFT F/PD/14
CFT.
Marketing shall provide a Quotation to the customer with lead-time --
and validity of quote. Marketing shall resolve any difference with the
customer in regard to the quotation. Marketing to monitor the status
of the quote and shall be closed when reasonable period of extension
4.1.12 MARKETING
based on the interactions with the customer is over.
If at a later stage, the customer revises the same enquiry, it shall be
the prerogative / discretion of the Marketing / Top Management to
consider the enquiry at the earlier quote.
CFT Review: CFT Members will review the project status every
week & the same will be recorded in MOM. If any delay found it will F/PD/17
MR / APQP
4.1.13 be reviewed & corrective action planned. Timing plan also updated
champion
accordingly if required.

CFT Members shall appraise the Top Management about the status F/PD/17
and analysis for any variance to provide further appropriate supports
(Interims of Resource Requirements) and the same are minuted in CFT / APQP
4.1.14
Management Support & Review Meeting Report. For Long champion
duration project shall be reviewed month wise instead of phase
wise.

Phase –II – (Product Design & Development, Team Feasibility Commitment)

4.2.1 Marketing shall accept a Purchase Order / LOI from the customer. Marketing --
4.2.2 CFT shall also conduct Contract Review If required. MANAGER F/MKT/04
The CFT shall be specific to the product and if required representatives CFT --
4.2.3
from other functions may be inducted
CFT develops New Product Development Plan (Master & Micro) as F/PD/01 &
required by the organization, in-line with APQP Matrix F/PD/08 &
4.2.4 Master plan is prepared for overall monitoring process & Micro Plan: CFT
F/PD/25
Process were involve more time which are monitor through Micro Level
planning such as a tool / fixture development & inspection testing
establishment & process validation.
4.2.5 Identify customer defined special characteristics, Check for Availability CFT F/PD/10
Prepared By: Reviewed and Approved By:

Mr.Deepak Sharma Mr.Gaurav Bansal

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APQP(Advanced Product Quality Planning)

of published standards and record the details.

Product error proofing, as appropriate: --
CFT
4.2.6 CFT shall review for any Poke Yoke requirements to ensure the error
proofing / mistake proofing.
Engineering Drawings / Specifications / Material Specifications:
CFT shall prepare process drawings and material specifications based on
Customer Drawing input if required. In addition to the above, wherever F/PD/18
CFT
4.2.7 applicable all engineering changes shall be as per Process Manual (ECN
PROCEDURE-Pr-09) for Document Control Process. Purchase shall insist
through P.O the traceability requirements like date and month code to be
followed wherever feasible on the Brought out.
New equipment/ Tooling / Gauges / Testing equipment / Facilities F/PD/09
4.2.8 requirements:
CFT
Identify New Equipment, Tooling’s / Gauges / testing equipment and
Facilities Requirements to complete the project.
CFT shall review for other facilities, equipment’s and other resources that --
4.2.9 are required for the New product that is to be developed CFT

Appropriate personnel of CFT shall prepare Proto Control Plan for all
processes as per the preliminary Process flow Chart. Control Plan shall be F/PD/03&F/PD/06
4.2.10 CFT
prepared based on APQP Manual / customer approved methodology. (If
req.)
Evaluate feasibility through Product Data and Team Feasibility Report. F/PD/02 &
Marketing / Customer Representative shall interact with customer for any
clarifications.
F/PD/15
CFT /
4.2.11 Team feasibility Commitment Report shall be signed by the CFT and the
MANAGER
team now agrees to develop the new product. If required communicate
with customer & time fixed with customer for spec meeting or DFR
issues.
CFT Review: CFT Members will review the project status every week & F/PD/17
the same will be recorded in MOM. If any delay found it will be reviewed MR / APQP
4.2.12
& corrective action planned. Timing plan also updated accordingly if champion
required.
CFT Members shall appraise the Top Management about the status and F/PD/17
analysis for any variance to provide further appropriate supports (Interims
CFT / APQP
4.2.13 of Resource Requirements) and the same are minuted in Management
champion
Support & Review Meeting Report. For Long duration project shall
be reviewed month wise instead of phase wise.

PHASE –III (Process Design & Development)

Appropriate personnel of CFT shall ensure that the following activities are --
4.3.1 CFT
carried out thru simultaneous Engineering method
4.3.2 CFT shall prepare Packaging standards / specifications that are required Purchasing --
for the new product that is being developed personnel of
 Decide Packaging Specifications CFT
 Reflect Packaging Specifications in Work Instruction
Prepared By: Reviewed and Approved By:

Mr.Deepak Sharma Mr.Gaurav Bansal

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APQP(Advanced Product Quality Planning)

 If Customer provided the packaging specification, The same shall be

used.
CFT shall prepare Process flow diagram as per the format to cover the --
4.3.3 CFT
incoming source of variation and expected deliverables
Floor Plan Layout: --
CFT shall prepare proposed floor plan layout in-line with PFC sequence (IF
4.3.4 CFT
required) . If the product is similar to the existing no need to prepare floor
plan layout.
CFT shall prepare Characteristics matrix (if required)for the new F/PD/10
product that is being developed
4.3.5  CFT to list all special Characteristic CFT
 Identify appropriate techniques for Process Control

CFT shall conduct Process Failure Mode and Effect analysis (PFMEA) F/PD/05
4.3.6 for all value adding processes as per the PFMEA Manual / methodology CFT
given in Customer Supplier Development Manual.
Appropriate personnel of CFT shall prepare Pre-launch Control Plan for --
all processes as per the Process flow diagram. Control Plan shall be
4.3.7 prepared based on APQP Manual / customer approved methodology. CFT

Appropriate personnel of CFT shall prepare Process instructions (Work

Instructions) for all processes as the PFD.
 Develop Process Instructions based on the output of the above --
4.3.8 CFT
steps.
 Ensure Process Instruction referred in the Control Plan.
 Identify Special Characteristics Symbol in process Instructions.
Appropriate personnel of CFT shall prepare MSA plan as per the --
requirement for which MSA to be conducted.
Develop MSA Plan indicating the process, type of MME, Product and
4.3.9 CFT
Process Tolerance and the Appraiser and the time.

Appropriate personnel of CFT shall prepare Preliminary process

capability study plan
Prepare Plan indicating the process, Equipment and the qualified appraiser --
4.3.10 and Tolerances CFT
SPC Plan shall be for processes where there are special characteristics as
defined by the customer and / or as defined by the CFT.

CFT Review: CFT Members will review the project status every week & F/PD/17
the same will be recorded in MOM. If any delay found it will be reviewed MR / APQP
4.3.11
& corrective action planned. Timing plan also updated accordingly if champion
required.
4.3.12 CFT Members shall appraise the Top Management about the status and CFT / APQP F/PD/17
analysis for any variance to provide further appropriate supports (Interims champion
of Resource Requirements) and the same are minuted in Management
Support & Review Meeting Report For Long duration project shall be
Prepared By: Reviewed and Approved By:

Mr.Deepak Sharma Mr.Gaurav Bansal

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APQP(Advanced Product Quality Planning)

reviewed month wise instead of phase wise.

PHASE – IV (Product and Process Validation)

CFT shall perform Job Verification setups. Produce samples for initial --
product and process Establishment. Depending on the model the actual
4.4.1 quantity can be decided by the respective CFT / based on customer CFT
requirement.

Production Trial Run : --

 Produce samples as per pre-launch control plan for initial
sample submission to the customer with PPAP Documentation
for Customer requirements.
 Ensure significant production run quantity for PPAP run for
4.4.2 customers identified depending on the model the actual CFT
quantity can be decided by the respective CFT / Customer.
 Collect the all issues found at internal/customer end problem
during trial run. CFT shall conduct the analysis on the issues
identified & take appropriate actions to solve the issue, same
shall be recorded in the PDCA or History Sheet. F/PD/19, F/PD/20
During the Production Trial Run, CFT shall ensure that : --
 MSA study is conducted with follow-up action for
marginal/non capable system.
 Preliminary Process capability study is conducted and action
plan is established where Cpk Values do not meet customer /
Default requirements.
 Production Part Approval Process (PPAP) as per customer
requirement Production Validation testing
4.4.3  Conduct test that validate that products made from production CFT
tools and processes meet Engineering requirement
 Packaging Evaluation is carried out
 Conduct trials and assess results,
 Carry out corrective actions,
 Freeze packaging standards and specifications.
 Logistics: Marketing shall discuss with Customer on the
logistics front. Adopt the suitable & mutual agreed logistics
modem.
4.4.4 CFT shall prepare CFT --
Production Control Plan
Production Process control standard
Other documents as required
Develop production Process control standard which is a logical

Prepared By: Reviewed and Approved By:

Mr.Deepak Sharma Mr.Gaurav Bansal

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APQP(Advanced Product Quality Planning)

extension of pre-launch control plan and catering to all the requirements

of Production control plan

After completion of development part handover to production deptt. QA Manager / Refer to initial control
And start the initial control. During first trial of mass production do the Plant head Procedure (Pr-30)
4.4.5 audit for production trial & record in production readiness check sheet
& take the necessary action for observations.

CFT shall sign Quality planning sign off with production team to F/PD/16
assure that the new product developed has met the customer
4.4.6 CFT
requirements and that all tools, equipment’s, facilities, testing
requirements are in line with customer expectations.
CFT Review: CFT Members will review the project status every week F/PD/17
& the same will be recorded in MOM. If any delay found it will be MR / APQP
reviewed & corrective action planned. Timing plan also updated champion
accordingly if required.
CFT Members shall appraise the Top Management about the status and F/PD/17
analysis for any variance to provide further appropriate supports
(Interims of Resource Requirements) and the same are minuted in CFT / APQP
4.4.7
Management Support & Review Meeting Report. For Long champion
duration project shall be reviewed month wise instead of phase
wise.

PHASE V (Feedback Assessment and Corrective Action)

Track customer feedback after pilot lot (PPAP), Feedback and --
Corrective action. The overall objective of this process shall be:
Reduced variation
CFT
 Incorporate ongoing process performance meeting
Cpk>1.67 for all special characteristics.
4.5.1
 Identify CI projects to reduce variations
Customer satisfaction --
Evaluate customer Satisfaction
CFT
Delivery
Monitor 100 % delivery performance.
CFT shall prepare Things Gone Right (TGR) and Things Gone Wrong F/PD/22
4.5.2 (TGW) TGR/TGW Report and also define corrective actions that are CFT
required.
CFT Review: CFT Members will review the project status every week F/PD/17
& the same will be recorded in MOM. If any delay found it will be MR / APQP
4.5.3
reviewed & corrective action planned. Timing plan also updated champion
accordingly if required.

Prepared By: Reviewed and Approved By:

Mr.Deepak Sharma Mr.Gaurav Bansal

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APQP(Advanced Product Quality Planning)

CFT Members shall appraise the Top Management about the status and F/PD/17
analysis for any variance to provide further appropriate supports
(Interims of Resource Requirements) and the same are minuted in CFT / APQP
4.5.4
Management Support & Review Meeting Report For Long duration champion
project shall be reviewed month wise instead of phase wise.
5. REFERENCES - DOCUMENTS:

Procedure for Marketing

Procedure for Production & Maintenance

6. REFERENCES – RECORDS:

1 New Product Development Master Plan F/PD / 01

2 New Product Development Micro Plan F/PD/25
3 APQP Activities Matrix F/PD / 08
4 List of CFT Members F/PD/13
5 Enquiry Register F/MKT/06
6 Experience Sharing F/PD/23
7 Pre-Feasibility F/MKT/07
8 Management support & Review Meeting F/PD/17
9 Purchase Order Free format
10 Contract Review F/MKT/04
11 List of new equipment’s / Tooling / Gauges / Facilities F/PD/09
12 Team Feasibility Commitment F/PD/02
13 Packaging standards / specifications Free format
14 Process flow diagram F/PD/03
15 List of Special Characteristics Matrix F/PD/10
16 Potential Process FMEA F/PD/05
17 Target For Productivity, Process Capability & Cost F/PD/24
18 Control Plan- Prelaunch F/PD/06
19 Process instructions (Work Instructions) Free format
20 MSA Reports F/QA/08
21 SPC Reports F/QA/13
22 PPAP Reports Free format
23 Control Plan- Production F/PD/06
24 Checking Aids List F/PD/21
25 Quality Planning Sign Off F/PD/16
26 PDCA( Trial Report), History Sheet F/PD/19
27 Production Readiness check sheet F/PD/11
28 Drawing Feasibility Sheet F/PD/15
Prepared By: Reviewed and Approved By:

Mr.Deepak Sharma Mr.Gaurav Bansal

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APQP(Advanced Product Quality Planning)

29 Raw material specification for NPD part F/PD/18

30 Development History Card F/PD/20
31 Kakotora Sheet F/PD/23
32
33
34
35

• - Customer Representative shall maintain copies of the above records in the APQP file for
each part.

Prepared By: Reviewed and Approved By:

Mr.Deepak Sharma Mr.Gaurav Bansal