Advanced Product Quality Planning ( APQP ) is a structured method for specifying and put to deathing the actions necessary to guarantee a merchandise satisfies the client along with cost and clip. APQP is required of all vehicle, system, subsystem and constituent fabrication locations.

1.2 Goal

The end of APQP is to ease communicating with all individuals involved in a programme and guarantee that all needed stairss are completed on clip, at acceptable cost and quality degrees.

1.3 Purpose

The intent of this guideline is to set up:

Common APQP outlooks for all M & A ; M activities.

Common APQP procedure prosodies.

Common APQP deliverables.

A common programme status-reporting format.

Lead and Support functions and duties for each APQP Element.

1.4 Approach

APQP emphasise on Up-front planning, First three portion of the P-D-C-A rhythm are devoted to up-front merchandise quality planning through merchandise / Process Validation. The Act of execution, the 4th portion is the phase where the importance of measuring the end product serves two maps ; to find if clients are satisfied, and to back up the chase of uninterrupted betterment.

This guideline focuses on 23 cardinal APQP elements. Definitions, outlooks, and deliverables for these elements are identified in Section 5.0 APQP Element Description of this guideline. The position for these subjects is summarized on the APQP Status Report. This guideline provides a direction tool for follow-up and timely completion of all 23 APQP Elementss.

1.5 Applicability

APQP position coverage is a demand of all M & A ; M activities and must be applied to the followers:

New Product launch/ relaunch.

Changed/ modified merchandise launch.

Launch of a new fabrication site.

Significant procedure alterations ( new facilities/ toolings ) .

High impact providers.

Carry over issues.

Part Submission Warrant ( PSW ) demand as per the MQS Mahindra Production Part Approval Process Manual.

2.0 APQP Fundamentalss

2.1 Teams

The first measure in the Advanced Product Quality Planning Process is to delegate lead duty for every APQP Element. This leader establishes a cross-functional squad to finish the component demands on clip. Effective Product Quality Planning requires a cross-functional squad including representatives from Product Development, Manufacturing Engineering, Manufacturing Plants, Purchasing, Quality, Field Service, Gross saless, Suppliers, and Customers, as appropriate.

2.2 Elementss

This guideline focuses on 23 Key APQP subjects, identified as APQP elements. These elements, when summarized and reported, pass on the quality planning position of a programme.

2.3 Adjustments

If the programme is considered to be low hazard, the APQP leader may jump certain APQP elements. For illustration, if the merchandise is carry-over with minor alterations, bing control programs can be used and/ or packaging ratings may non be required. The cross-functional squad must hold to all divergences from the APQP procedure. If the squad agrees that an component is non required, the map should compose “ N/A ” for “ non applicable ” in the comments subdivision of the APQP Status Report ( Annexure 1 ) .

2.4 Roles & A ; Duties

The APQP Lead/Support Responsibilities are documented in Section 5.0 APQP Element Description, of this guideline.

2.5 APQP Elementss in MPDS

The alliance of APQP elements is done utilizing the timing program of the Mahindra Product Development System ( MPDS ) .

2.6 APQP Process Flow

Figure 2 shows the generic APQP Process Flow

Figure 1

APQP Timing Plan

MPDS Gateways

Silicon: Strategic Purpose

Scandium: Strategic Confirmation

Dad: Programme Approval

VV: Virtual Validation

Personal computer: Programme Confirmation

Praseodymium: Merchandise Readiness

PP: Production Prove-out

So: Sign Off

Lawrencium: Launch Readiness

J1: Job 1

Degree fahrenheit: Concluding Status

Silicon

J 1

Degree fahrenheit

Personal computer

Praseodymium

PP

So

Lawrencium

Scandium

Dad

VV

Figure 2: Generic Process Flow – APQP

End

Green

YELLOW/RED

Risk Assessment Y/R

APQP

Appraisal

Green

APQP Status G/Y/R

Major Review Meeting including APQP Assessment Results

Start APQP Reporting

Initiate APQP Process

Management

establishes cross-functional squad

Standards for APQP

Start

3.0 The APQP Status Report

3.1 Purpose

The APQP Status Report summarises the position for the 23 APQP elements. The position study facilitates communicating between Product Development, Manufacturing Engineering, Manufacturing Plants etc. It besides provides a dated record that future programmes for mention.

3.2 Status Reporting Responsibility

For each of the 23 elements, there is a lead duty defined. This lead map obtains the necessary input/support from other affected maps and consolidates it into a G/Y/R ( Green/Yellow/Red ) position ( per component ) on the APQP position study signifier. ( MQS/APQP/F01 )

Coverage Requirements

The Project Team consolidates the APQP position study and present sum-up to senior direction at all major Programme Reviews/ Gateways. Action program is prepared for all Yellow & A ; Red position.

Evaluations and Assessment

4.1 G Y R Status

Green-Yellow-Red position communicates the advancement toward the successful undertaking completion of elements by the plan demand day of the month. Program demand day of the month is the last possible day of the month an component can be completed and non adversely affect quality, cost or timing of the plan. The “ GYR Status ” column of the study shows the appraisal for each element.Definitions/Risk factors for Red, Yellow, and Green are listed in the tabular array below.

Hazard

Coloring material

Definition

High

Red

Target day of the months and/or elements are at hazard. A recovery Action Plan is non available and/or implemented, or the Action Plan does non accomplish plan marks. Late on clip.

Moderate

Yellow

Target day of the months and/or elements are at hazard, but a recovery Action Plan has been developed to accomplish plan marks, and has been approved by the appropriate Project Team. Target day of the month can be met with direction support.

Low

Green

Target day of the months and elements are on path and meeting aims.

Each component shall be supported by relevant documented grounds like studies, round, filled format, quality paperss, scanned signoff transcript etc. For this intent MQS & A ; PQO recommends the usage of appropriate packages like Excel, Word, Power point, MS Project, etc with hyperlinks to the papers.

Any point one time become ruddy will stay ruddy & A ; Yellow/Green will be superimposed suitably to demo latest position.

4.2 The 8 Focus Elementss:

For all 23 elements, quality outlooks are defined in this Guideline. Out of the 23 elements, the following 8 elements are considered as Focus Elementss:

Design FMEA

Design Verification Plan

Prototype Build Control Plan

Manufacturing Process Flow Chart

Procedure FMEA

Pre-Launch Control Plan

Operator Process Instructions

Production Control Plan

These elements when completed with Quality and On Time lay the foundation for Programme success.

The 8 Focus Elementss are assessed for Quality of Event utilizing Focus Element Rating Checklist.

4.3 Status Report Descriptions:

Build Level: Indicates the degree of Build such as Engineering Prototype, Verification Prototype, Production Trial Run, Job # 1, etc.

PIST: Percentage of Inspection points that satisfy Specified Tolerance ( all points ) .

PIPC: Percentage of Indexs which are Process Capable ( Percentage of Critical & A ; Significant Characteristics with Pp & A ; Ppk greater than or equal to 1.67 for the pre-production stage and Cp and Cpk greater than or equal to 1.33 for production stage ) .

SC & A ; CC ( Special Characteristics ) : All merchandises and procedures have characteristics described by features which are of import and need to be controlled. However, some features called particular features require excess attempts to understate the hazard of possible inauspicious effects.

Particular Characteristics consist of –

1. Critical Features are those merchandise or procedure demands that affect conformity with authorities ordinance or safe vehicle/ merchandise map AND which require particular actions/ controls.

Merchandise or procedure demands can include dimension, specification, trials, procedures, assembly sequences, tooling, articulations, torsions, dyer’s rockets, attatchments, component use etc.

Symbol: & lt ; CC & gt ;

Badness Rating: 9 or 10 for any happening evaluation.

2. Significant Features are those merchandise, procedure, and/ or trial demands which are of import for client satisfaction AND for which Quality Planning actions must be summarised on a Control Plan.

Symbol: & lt ; SC & gt ;

Badness Rating: 5 to 8 Happening Evaluation: 5 and above

For farther inside informations please mention Charachteristics Classification Guideline,

MQS/CC & A ; SC/GL01

The 23 APQP Elementss

5.0 APQP Element Description Description DescriptionThe following pages include an in-depth position of the 23 APQP elements. Each component is split into six separate countries. These countries are:

Definition – identifies the motive behind the component.

Expectations – defines the demands for the component.

Lead Responsibility – identifies the map responsible for lead coverage. Identifies function that all others will back up in completion of the component.

Support map – identifies the support maps that will supply input to the Lead Responsibility.

Clocking – Identifies the initial and concluding Gateway timing for the component with regard to Total Project Work Plan ( TPWP ) .

Deliverables – indicates the points that must be completed during clip frames specified for the component.

.

11. Sourcing Decision

Definition

Sourcing Decision is a formal client committedness to work on a timely footing with internal and external providers on the programme.

Expectations

The Sourcing Decision is completed and communicated to internal and external providers before the Programme Need Date.

The sourcing demand day of the months for all constituents, systems and vehicles are established.

Lead Duty

Undertaking Team/CFT for in-house sourced constituents / sums.

Material Management. ( MM )

Support Functions

Supplier Upgradation

Merchandise Development

Strategic Sourcing

Fabrication Plant

Manufacturing Engineering

Timing

Initiate Milestone & lt ; PA & gt ;

Finalise Milestone & lt ; VV & gt ;

Deliverables

Establish a Timing Plan for completion of Sourcing Decisions.

Start communicating with possible in-house makers for “ brand parts ” and with providers for “ purchase ” parts.

Identify long -lead points ( i.e. sourcing for new installations, execution of individual sourcing schemes for Assembly Plants, etc. )

Measure the per centum of completion for the Sourcing Decision Element at the beginning of each month between & lt ; PA & gt ; and & lt ; VV & gt ; .

Sourcing Decision for long-lead points is completed and communicated.

Open issues are identified and agreed upon by Project Team/CFT.

The Soucing Decision is completed and communicated.

22. Customers Input Requirement

Definition

The Customer Input Requirements Element is used to originate the Quality Planning procedure through designation of design standards and programme demands.

Quality Function Deployment, ( QFD ) is one of the mechanisms to bring forth the Customer Input Requirements.

Expectations

Design ends ( specified through client study ) are translated into probationary and mensurable design aims.

The Project Team/CFT must have initial system and constituent designs and specifications from R & A ; D Centre including

– Merchandise Premises

Functional Performance

Weight

Material

Dependability and Quality ends are established based on

Anterior theoretical account merchandise and procedure concern history

Customer wants and outlooks

Programme aims

Reliability bench-marks

The dependability and quality ends must include the undermentioned:

Useful life Reliability Targets

Warranty Targets ( R/1000 )

Incoming quality marks ( parts per million, defect degrees, bit rates )

Functional Targets

Note: The above marks should be supplied as appropriate to the system, subsystem, or constituent.

The Programme Timing Plan is established to run into the client demands and outlooks by placing the Timing Requirements for the followers:

Undertakings

Assignments

Events

Programme Timing Date must be communicated for the followers:

Programme position reappraisals

APQP Plans

Design Freeze

2Prototype physiques

In Plant Dates

Job # 1

Low-cost cost marks have been communicated for the vehicle, system, sub-system and constituents.

Capacity Planning volumes have been provided to the provider ( external and internal )

A list for Key Contact Personnel within M & A ; M – the Undertaking Owner, Project Manager, Design Leader, Manufacturing Engineering Leader, Launch Leader, MM Leader, Supplier Upgradation Leader and others as appropriate – is established. The list should include name, location, e-mail reference and phone figure.

Lead duty

Merchandise Development

Support Functions

Manufacturing Engineering

Fabrication Plants

Millimeter

Selling

Undertaking Team/CFT

Assembly Plant assigns a Launch Manager to back up all necessary activities at the & lt ; PA & gt ; Milestone and beyond. The Assembly Plant prepares a want list of preferred merchandise and procedure betterments. The Wants List is prepared based on client informations and fabrication procedure capablenesss of current running production theoretical accounts. When necessary, quality, cost, and clocking informations shall be presented to take activities.

Timing

Initiate Milestone & lt ; KO & gt ;

Finalise Milestone & lt ; SC & gt ;

Deliverables

Establish Plans to develop:

Design ends

Dependability and Quality ends

Programme Timing

Cost Targets

Capacity Planning Volume

– Key Contact Personnel

2The Programme Steering Team recognizes and supports the standards identified in the outlooks.

A fabrication scheme is identified and available.

The preliminary Product and Business Targets are defined in sufficient item to originate Engineering undertakings at the & lt ; PA & gt ; Milestone.

The Programme Core Team is identified.

Resources are identified and committed by all affected maps.

The Total Programme Work Plan ( TPWP ) is developed and agreed upon by the Programme Core Team including APQP deliverables.

The fabrication demands ( must/ wants ) are available, amalgamate and submitted to the Programme Core Team.

Aims, Targets and Plans for the above desired outlooks are completed, confirmed and communicated to all beginnings and planning activities.

The TPWP ( including APQP deliverables ) is signed off.

33. Design FMEA

Definition

A Design or Concept FMEA is a systematic attack ( used by the design responsible squad ) which assures that possible design failure manners and associated causes are considered and addressed.

Expectations

DFMEAs are led by Product Engineering, prepared with a cross-functional squad, and follow the guidelines laid down in the MQS FMEA Manual.

DFMEAs prepare for new merchandise characteristics, engineerings, and merchandise development quality concerns unresolved during the old theoretical account life-time.

DFMEAs are indispensable in developing Prototype Build Control Plans and the Manufacturing P/ FMEAs.

Unanticipated failure manners encountered during design confirmation proving must be addressed in the D/ FMEA.

Potential Special Characteristics & lt ; CC & gt ; & A ; & lt ; SC & gt ; are identified.

Lead Duty

Merchandise Development

Support Functions

Manufacturing Engineering

Fabrication Plants

Customer Care

Timing

Initiate Milestone & lt ; VV & gt ;

Finalize Milestone & lt ; LR & gt ;

Deliverables

Initial

Establish a list of Concepts, Systems, Sub-systems etc on which DFMEA needs to be conducted and compose out a DFMEA Timing Plan.

Intermediate

Review per centum of DFMEA completion at all Milestones between & lt ; VV & gt ; and & lt ; LR & gt ;

Concluding

100 % of the DFMEAs are complete and all necessary actions to understate quality hazards are implemented.

Potential & lt ; CC & gt ; & A ; & lt ; SC & gt ; are identified.

4 Design Reviews

Definitions

Design Reviews are on a regular basis scheduled meetings led by the design responsible activity and must include any affected countries, such as, Manufacturing Engineering, Plant forces etc. The reappraisal procedure includes the followers:

A series of confirmation activities that are more than technology review.

An effectual method to forestall jobs and misinterpretations.

Supply a mechanism to supervise advancement and study to the direction ( including the reappraisal of APQP unfastened issues )

Expectations

The Design Feasibility concerns are resolved in clip to back up each physique In-Plant Date.

Review the advancement of the Design Verification Plan and Report ( DVP & A ; R ) ) . Unanticipated failure manners encountered during design confirmation proving must be addressed in the DFMEA.

Review any unfastened APQP issues.

Review the advancement toward accomplishing dependability, quality, cost and clocking marks.

Lead Duty

Merchandise Development

Support Functions

Manufacturing Engineering

Fabrication Plants

Customer Care

Millimeter

Timing

Initiate Milestone & lt ; SC & gt ;

Finalize Milestone & lt ; LR & gt ;

Deliverables

Develop a Design Review Plan.

Define functions and duties

Develop a Design Review work program one month prior to the initial Design Review

4

Measure the advancement of DVP & A ; Rs

Review the important and critical features identified in the Engineering Specifications.

Concerns are identified at each Milestone from & lt ; SC & gt ; to & lt ; LR & gt ;

100 % of the unfastened design issues are resolved

The Project Team/CFT present the lessons learned from the Programme.

For farther inside informations please mention Design Review Guideline,

MQS/DR/GL01

5Design Verification Plan & A ; Report

Definition

The Design Verification Plan & A ; Report ( DVP & A ; R ) is a papers naming the technology ratings, trials, and studies required to set up a design tantrum for usage in the intended environment and meets the client driven aims and the purpose with which the merchandise / procedure was designed. The design confirmation program has a correlativity with the Customer Input Requirement.

Expectations

The DVP & A ; R is a squad attack

Designation of specific trials, methods, equipment, credence standards, sample sizes, design degree and timing must be contained in the DVP & A ; R.

Trials must include fluctuation within tolerance on squad selected merchandise features.

The Design Verification must include:

Trial demands for design, stuff, or fabricating procedure that apply to the production test.

Trials, which reference for the client use profile and responsibility rhythm.

Trials which address the utile life of the merchandise.

Trials which address the effects of the external environment ( clime, route surface conditions etc )

Trials which address the effects of physical interfaces between constituents or systems.

Lead Duty

Product & A ; Reliability Engineering

Support Functions

Manufacturing Engineering

Fabrication Plants

Customer Care

Support Functions have skilled forces assigned to reexamine and corroborate the DVP & A ; R consequences and specification scenes for important and critical features.

Applicability

Design Verification Plans and Reports are used for the undermentioned agendas,

Development Prototypes.

Product Validation.

Product Life Cycle.

5Design Verification Plans and Reports include the undermentioned trials

Engineering Development Trials: Performed during merchandise design for functional development, for observing clip dependent failures.

Design Verification Tests: Performed to show that the design samples run intoing production purpose environmental, functional, dependability and lastingness demands

Production Validation Trials: Performed to show that the design samples from the production environment meet all demands similar to Design Verification trials and assure that no inauspicious variables have been introduced.

Continuous Conformity Trials: Performed on an on traveling footing to guarantee contained conformity to all Product & A ; Process demands.

Timings

Initial Gateway & lt ; VV & gt ;

Finalize Gateway & lt ; LR & gt ;

Deliverables

Develop the DVP & A ; R and appropriate reappraisal procedure

The DVP & A ; R is complete and the identified prosodies enable comparing with mark prosodies at Engineering Prototype reappraisal.

DVP & A ; R is updated and a bill of exchange of the Engineering specification is available as per MPDS Guideline.

The DVP & A ; R is complete in order to back up the Verification Prototype ( VP ) physiques.

All Engineering specifications, up to and including occupation # 1 design degree are confirmed and released.

All confirmation and proof trials are completed.

6Subcontractor APQP Status ( Tier 1 Supplier )

Definition

The Subcontractor APQP Status identifies and studies on the status of an external Supplier or Subcontractor ‘s APQP procedure. It is required of Supplier to cascade APQP demands to their providers or subcontractors and behavior APQP reviews as appropriate. The consequences of these reappraisals are summarised on the APQP Status Report.

Expectations

All providers must measure hazard and stipulate the degree of their providers APQP engagement.

Subcontractors that affect important and critical features must follow all APQP subjects.

Suppliers will apportion sufficient resources to work with their subcontractors as portion of the cross-functional APQP attempt.

Suppliers will keep on a regular basis scheduled APQP position reappraisals with their subcontractors.

Concerns are reported to the client and action programs are developed for elements that do non run into quality, cost and clocking aims.

Lead Duty

Millimeter

Support Function

Supplier Upgradation.

Timing

Initiate Gateway & lt ; VV & gt ;

Finalize Gateway & lt ; LR & gt ;

Deliverables

Communicate to all relevant providers the expected APQP deliverables in line with Programme Need Dates ( In Plant Dates ) .

Supply a Subcontractor APQP position at each Milestone

100 % of approved PSW parts delivered before & lt ; SO & gt ; Gateway

100 % of the provider ‘s unfastened issues are resolved to back up ongoing production

7 Facilities, Tools & A ; Gauges

Definition

The Facilities, Tools and Gauges component identifies the new, extra, refurbished and relocated resources necessary to fabricate the client specified merchandise at designated measure and quality degrees.

Expectations

Facilities, be aftering blessing, drawings and public-service corporations must be included on the Product Timing Plan and funding blessing must be complete.

Machinery FMEA needs to be completed before let go ofing the Design Approved Print ( DAP )

SPC & A ; MSA and credence standards must be squad approved before sourcing of Facilities, Tools or Gauges can be approved.

Trial tallies should happen at the machine builder ‘s location to measure up all Facilities, Tools and Gauges.

All disciplinary actions for Facilities, Tools and Gauges non run intoing client demands must be completed anterior to the Production Trial Run.

Facilities, Tools and Gauges must be delivered, installed and approved prior to the Production Trial Run.

Lead Duty

Manufacturing Engineering

Support Functions

Fabrication Plants

Undertaking Engineering

Asset Management

Timing

Initiate Gateway & lt ; VV & gt ;

Finalise Gateway & lt ; LR & gt ;

Deliverables

Establish a Manufacturing Strategy.

New Technologies are identified.

Difficult points for fabrication procedure installations and complexness are established.

Long lead support is identified for major Facilities, Tools and Gauges at the & lt ; VV & gt ; Milestone.

7

Tooling for the VP0 physique is confirmed and available before & lt ; PC & gt ; Gateway clearance

Readiness for PP ( Production Proveout ) assembly is confirmed at before & lt ; PP & gt ; Gateway clearance

Facilities, Tools and Gauges are installed & A ; listed in the Process Sheets.

Equipment safety is verified.

Concerns are resolved.

8Prototype Build Control Plan

Definition

Prototype Build Control Plan ( PBCP ) is a description of the control factors that will be used to fabricate and piece a paradigm physique. In the control program rating procedure, PBCP is the first drumhead papers. This papers is necessary to aline the responsible activities process stairss to both the important / critical merchandise features and client marks.

Expectations

A cross-functional squad led by the Product Engineering develops the Prototype Build Control Plan.

The Prototype Build Control Plan is to be reviewed at each Design Review and is an indispensable portion of the Team Feasibility Commitment.

All relevant records of Part Quality Inspection before Build are compulsory.

Lead Duty

Merchandise Development

Support Functions

Manufacturing Engineering

Fabrication Plants

Timing

Initiate Gateway & lt ; VV & gt ;

Finalize Gateway & lt ; PR & gt ;

Deliverables

Establish a work program for Prototype Build Control Plan development.

Review the per centum of Prototype Build Control Plan completion at each design reappraisal.

The Preliminary Prototype Build Control Plan is available at & lt ; PC & gt ; Gateway

A bill of exchange of the technology specifications needed for the PBCB is made available at Gateway & lt ; PC & gt ; .

All relevant drawing and technology specification consequences, upto and including Job 1, is summarized in the Prototype Build Control Plan.

All significant/critical features are reviewed during the paradigm physique stage.

Lessons learned are identified.

Feasibility committedness of concluding Prototype Build Control Plan features is available.

9Prototype Physiques

Definition

The Prototype Builds Element entails the industry or assembly of constituents, systems or sub-systems, and assembled vehicles that will be supplied to the client for physiques happening prior to the Verification Prototype ( VP ) Build stage.

Expectations

All client paradigm stuff will run into the undermentioned demands by the

In Plant Date.

Correct degree parts

Customer specification informations.

Customer blessing for all non conformities.

The Prototype Build Control Plan was followed in the industry or assembly of the Prototype Builds.

Lead Duty

Merchandise Development

Support Functions

Manufacturing Engineering

Fabrication Plant

Millimeter

Timing

Initiate Gateway & lt ; PC & gt ;

Finalize Gateway & lt ; PP & gt ;

Deliverables

Timing Plan for Prototype Builds is established.

100 % of the parts are available before the & lt ; PR & gt ; Milestone.

All planned Prototype Builds are in line with the Timing Plan.

Quality degree is verified based on the demands established in the Prototype Build Control Plan.

Concerns are identified and documented.

9Timing Plan for VP Prototype Builds is established.

PSW position is to the full identified for all parts necessary for each paradigm physique.

All planned Prototype Builds are in line with the Timing Plan

Quality degree is verified based on the demands established in the Prototype Build Control Plan.

Concerns are identified and documented.

For complete Build definition and its application please mention MQS website under MPDS Section.

Please refer Supplier ‘s Master Schedule for physique inside informations ( MQS/APQP/F 021 )

1010. Pulling and Specifications

Definition

The Drawing and Specifications Element refers to all technology drawings, CAD informations, material specifications and technology specifications.

Expectations

The Programme Need Dates must be communicated to the client.

Note: the Drawing and Specifications Programme Need Date is the last possible day of the month the provider can accept a design alteration and support PSW ( Part Submission Warrant ) bringing at the Material Required Date.

PPRF/PR drawings are applicable for protobuilds.

Change cutoff for concluding drawing release should take topographic point before

Pre-launch physique.

Drawings and specifications must include

Engineering specification trials

Product Validation Test demands

The Product Development / Manufacturing Engineering forces who will be assessing drawings and specifications to run into Programme Affordable Cost and Quality demands are identified.

The pulling information and technology specifications will be used as a requirement to the Prototype Build Control Plan.

Lead Duty

Merchandise Development

Support maps

Manufacturing Engineering

Fabrication Plants

Timing

Initiate Gateway & lt ; VV & gt ;

Finalize Gateway & lt ; SO & gt ;

Deliverables

Initial

Establish a Timing Plan to back up all activities and construct stages with Drawings and Specifications.

Assess the per centum of completed drawings and specifications at each Gateway between & lt ; VV & gt ; to & lt ; SO & gt ; .

The Preliminary BOM ( Bill of Materials ) is established at & lt ; PA & gt ; Gateway

CAE analysis is complete and all necessary drawings are available for the Engineering Prototype Review.

10All necessary drawings are up dated and a bill of exchange of the Engineering Specification is available.

The BOM ( Bills of Materials ) reflecting PDB content is loaded into Metaphase ( Engineering Release System ) at the & lt ; VV & gt ; Gateway

100 % of the drawings and Engineering Specifications are updated up to and including Job1 design degree, are made available at the & lt ; SO & gt ; Gateway

100 % of the Drawings and Engineering Specifications are updated.

All service parts are released.

11 Teams Feasibility Commitment

Definition

The Team Feasibility Element determines whether the proposed design can be manufactured within the guidelines. A cross-functional design reappraisal squad is charged with measuring design feasibleness. Once workability is established, the Programme Management Team undertakes the duty of following the design reappraisal procedure and reevaluating feasibleness for any design or portion alteration that may happen during portion development.

Expectations

The design reappraisal squad must be satisfied with the undermentioned conditions:

The design is fit for intended usage

The design can be manufactured, assembled, tested, packaged and delivered in sufficient quality to the client on agenda.

Major feasibleness concerns must be resolved prior to the Production Trial Run.

The fabrication or assembly works must measure hazard and determine which of their providers must finish a feasibleness appraisal. Subcontractors who affect significant/ critical features must finish a feasibleness appraisal.

A Team Feasibility Commitment is given if all activities agree to be able to bring forth a merchandise within specification of important / critical features outlined in the relevant control program.

The squad must set up a formal feasibleness papers

Lead duty

Merchandise Development

Manufacturing Engineering

Support Functions

Fabrication Plants

Undertaking Engineering

Millimeter

Timing

Initiate Gateway & lt ; VV & gt ;

Finalize Gateway & lt ; SO & gt ;

11Deliverables

The Team feasibleness committedness is scheduled in conformity with the Design Review Timing Plan.

The squad feasibleness committedness is to be reviewed at each Design Review.

Review the Prototype Build Control Plan Characteristics.

All activities agree to be able to bring forth the merchandise in line within the specification of important / critical features outlined in the relevant control program.

All feasibleness concerns are resolved and necessary merchandise and procedure alterations are scheduled to be completed anterior to the 1 PP ( First Production Proveout ) build stage.

12Manufacturing Process Flow Charts

Definition

The Manufacturing Process Flow Chart is a in writing representation of the current or proposed sequence of fabrication procedure flow.

Expectations

A Manufacturing Process Flow Chart is developed as input to PFMEAs by a cross-functional squad led by Manufacturing Engineering.

Lead Duty

Manufacturing Engineering.

Support Functions

Manufacturing Plants.

Merchandise Technology

Timing

Initiate Gateway & lt ; VV & gt ;

Finalize Gateway & lt ; LR & gt ;

Deliverables

Develop a program to set up procedure flow charts for new procedures / engineerings, in line with the PFMEA agenda.

Process sheets initiated at & lt ; VV & gt ; .

Manufacturing Process Flow Charts are available to originate PFMEAs

100 % of Manufacturing Process Flow Charts are available.

Concluding Process Sheet available before & lt ; LR & gt ; .

For further inside informations, please refer Guideline on Dynamic Control Planning,

MQS/DCP/GL01.

1313. Procedure FMEA

Definition

A Process FMEA is a systematic attack used by a fabrication responsible squad to guarantee that possible procedure related failure manners and their associated causes have been considered and addressed.

Expectations

All PFMEAs are prepared by a cross-functional squad led by Manufacturing Engineering following the MQS FMEA manual.

Quality hazards identified from DFMEAs, which can non be resolved through Product design alterations, require the induction of a PFMEA.

PFMEAs must be established for all major quality concerns non resolved during the current production theoretical account twelvemonth, all new processes/ engineerings, and new merchandise characteristics.

A finalised DFMEA is non a compulsory requirement to execute a PFMEA.

Lead Duty

Manufacturing Engineering

Support Functions

Merchandise Development

Fabrication Plants

Customer Care

Timing

Initiate Gateway & lt ; VV & gt ;

Finalize Gateway & lt ; LR & gt ;

Deliverables

Establish a PFMEA program in line with the above described outlooks.

Initial PFMEAs are established for new or critical systems.

100 % PFMEAs are performed in line with the development program and necessary actions are identified and planned before & lt ; PC & gt ; gateway clearance.

100 % PFMEAs are performed and all identified actions are implemented before & lt ; LR & gt ; .

A list of confirmed & lt ; CC & gt ; & A ; & lt ; SC & gt ; is available.

For further inside informations, please mention MQS Guideline on Potential Failure Mode & A ; Effectss Analysis, MQS/FMEA.

14Measurement System Evaluation

Definition

Measurement Systems Evaluation assesses the fluctuation of the measuring system and determines whether the measuring system is acceptable for supervising the procedure.

Expectations

The appropriate Measurement Systems Evaluation methods, standard credence degrees, and statistical and analytical demands will be performed following the MQS/MSA/GL01Guideline.

All measurement systems ( gages and trial equipment ) must be modified to reflect the latest technology portion degree prior to the Production Trial Run.

The Measurement systems development program must follow the development of the Control Plans ( Prototype, Pre-launch and Production )

The user must be given the chance to reexamine and agree with the gages and trial equipment survey consequences prior to the Production Trial Run.

The Measurement System Evaluation for & lt ; SC & gt ; & lt ; CC & gt ; is compulsory and must be repeated and approved following all gage and trial equipment alterations.

Lead Duty

Manufacturing Engineering

Support Function

Fabrication Plant

Merchandise Development

Timing

Initiate Milestone & lt ; VV & gt ;

Finalize Milestone & lt ; LR & gt ;

Deliverables

Establish measuring systems development program in line with Prototype Build Control Plan features.

Develop a Timing Plan for measurement equipment alterations and execution of new systems.

The Measurement Systems Evaluation is in line with the programme physique agenda

100 % Measurement Systems are evaluated for carry over parts and necessary alterations are identified 100 % Measurement Systems are identified.

14100 % Measurement Systems Evaluation is performed and necessary alterations are identified.

100 % measurement capableness blessing of all measuring system covering all important / critical features as outlined in the Production Control Plan.

For further inside informations, please refer Guideline on Measurement System and Equipment Capability, MQS/MSA/GL01.

1515. Pre-Launch Control Plan

Definition

The Pre-Launch Control Plan is a written description of the dimensional measurings and stuff and functional trials that will happen after paradigm physique and before full production.

Expectations

Development of the Pre-Launch Control Plan is led by Manufacturing Engineering, prepared with a cross-functional squad and will follow the lineation provided in the MQS APQP and Control Plan Manual.

The Pre-Launch Control Plan is initiated during the paradigm physique stage.

Consequences from the Prototype Build Control Plan and DFMEA provide an lineation for the Pre-Launch Control Plan.

Lead duty

Manufacturing Engineering

Support Functions

Fabrication Plants

Merchandise Development

Timing

Initiate Gateway & lt ; PR & gt ;

Finalise Gateway & lt ; PP & gt ;

Deliverables

Develop a Timing Plan to set up Pre-Launch Control Plans.

Assess the completion position of the Pre-Launch Control Plan against the Programme Need Date.

The Pre-Launch Control Plan is 100 % complete to back up the 1PP build stage.

For further inside informations, please refer Guideline on Dynamic Control Planning,

MQS/DCP/GL01.

1616 Operator Process Instructions ( SOP or SOS )

Definition

Operator Process Instructions describe the inside informations of controls and actions that operating forces must execute to bring forth quality merchandises.

Expectations

Operator Process Instructions are developed by a cross-functional squad led by Manufacturing Plant

Operator Process Instructions depict all procedure stairss necessary to bring forth a quality merchandise, and include all indispensable ocular AIDSs and/ or elaborate instructions to back up the production operators.

Lead Duty

Fabrication Plants

Support Functions

Manufacturing Engineering

Timing

Initiate Milestone & lt ; PR & gt ;

Finalise Milestone & lt ; LR & gt ;

Deliverables

Develop a Timing Plan for release of Process Instructions.

Plants begin reexamining Manufacturing Engineering processes to place necessary ocular AIDSs for production.

The Assembly Process is available for specific, critical or new systems

Assess the advancement of Operator Process Instructions in line with the Timing Plan to guarantee handiness of a Preliminary Procedure at the PP construct stage.

The period between & lt ; PR & gt ; and & lt ; LR & gt ; will be used to verify and finalize the Operator Process Instructions

Plants have all ocular AIDSs identified.

Operator Process Instructions are 100 % in topographic point before & lt ; LR & gt ;

For further inside informations, please refer Operator Process Instruction/SOP Guideline,

MQS/Operator Process Instruction/GL01.

1717. Boxing Specifications

Definition

The provider of a merchandise must guarantee that single packaging for cargo ( including interior dividers ) is designed and developed. Customer packaging criterions should be used wheresoever available.

Expectations

Packaging demands are agreed upon by the provider and the receiving works.

Boxing rating must prove the packaging under the expected conditions of conveyance and stuff handling.

The packaging design must guarantee that the merchandise public presentation and features will stay unchanged during packing, transportation and unpacking.

Feasibility of packaging is assured during Design Reviews.

Lead Duty

Manufacturing Engineering.

Support Functions

Merchandise Engineering.

Manufacturing Plants.

Timing

Initiate Gateway & lt ; VV & gt ;

Finalise Gateway & lt ; SO & gt ;

Deliverables

Develop a Timing Plan for packaging development.

At each Milestone, boxing design is reviewed for rightness to the expected portion quality degree.

All necessary packaging tests are conducted during the PP Production Trial Run

All packaging specifications are available. All packaging installations are in topographic point at the providers and/or user workss.

For further inside informations, please mention Packaging guideline for supply of production parts,

MQS/PKG/GL01.

1818. Production Trial Run

Definition

The production test tally is a proof of the effectivity of the fabrication and assembly processes utilizing production tooling, equipment, environment ( including production operators ) , installations and rhythm times. End product of the Production Trial Run is used for Production Part Approval and Manufacturing/Quality Planning Sign-Off.

Expectations

The Pre-launch Control Plan is followed during the Production Trial Run.

The Production Trial Run must be used to corroborate or add linkages between merchandise and procedure features.

Preliminary Operator Process Instructions are followed during the Production Trial Run.

Corrective design and procedure actions must be established for concerns identified during the Production Trial Run.

Lead Duty

Fabrication Plant ( Launch Manager ) .

Support Functions

Manufacturing Engineering

Merchandise Development

Timing

Initiate Gateway & lt ; PP & gt ; .

Finalize Gateway & lt ; LR & gt ; .

Deliverables

A Timing Plan for the Production Trial Run is established.

A Timing Plan for operator preparation is established.

100 % PSW Status is identified for each build test.

All merchandise and procedure concerns are resolved before the start of the FEU ( Field Evaluation Unit ) physique.

Completion of operator preparation is reviewed often between Milestones & lt ; PP & gt ; and & lt ; LR & gt ; .

Facilities, tools and gages are implemented.

All merchandise and procedure concerns are resolved.

Operator Process Instructions are finalised and in topographic point.

The Production Control Plan is finalised and in topographic point.

Production proof testing is completed.

Approved PSW parts are delivered. and Operator preparation is completed.

1919. Production Control Plan

Definition

The Production Control Plan is a written description of the systems for commanding parts and procedures during full production.

Expectations

The Production Control Plan is developed by a cross-functional squad led by Manufacturing Engineering, and is to follow the lineation provided in the MQS APQP and Control Plan Manual.

The result of the paradigm physique and the pre-launch control program provides a footing for the Production Control Plan.

Lead Duty

Fabrication Plant ( Launch Manager ) .

Support Function

Manufacturing Engineering.

Timing

Initiate Milestone & lt ; SO & gt ;

Finalize Milestone & lt ; LR & gt ;

Deliverables

Develop a Timing Plan for the development of the Production Control Plan.

Preliminary Production Control Plan is 100 % available prior to the FEU ( Field Evaluation Unit ) build stage.

Post – FEU, the Production Control Plan is ready and suitably modified and in topographic point.

The Production Control Plan is ready for ongoing production.

All technology specifications are reviewed.

All significant/critical merchandise and procedure features commanding the industry of parts and vehicle assembly ( including pigment ) are included in the Production Control Plan.

For further inside informations, please refer Guideline on Dynamic Control Planning,

MQS/DCP/GL01

2020. Preliminary Process Capability Study

Definition

The Preliminary Process Capability Study is a statistical appraisal of the ability to bring forth merchandise within specification.

Expectations

Preliminary Process Capability surveies are to be performed following the MQS Guideline.

The statistical and analytical techniques used to find capableness must be acceptable to the client.

Preliminary Process Capability surveies must be performed as documented in the Pre-Launch Control Plan.

Preliminary Process Capability surveies must be completed and the client given the chance to reexamine, before Production Part Approval.

Lead Duty

Manufacturing Engineering

Support Functions

Fabrication Plants

Timing

Initiate Milestone & lt ; PR & gt ;

Finalize Milestone & lt ; LR & gt ;

Deliverables

Get down the procedure capableness appraisal for similar procedures.

Develop a Timing Plan to execute statistical surveies

100 % necessary statistical surveies are identified and the Timing Plan is confirmed

80 % capableness appraisal is performed

100 % capableness appraisal is performed

Concerns are identified and necessary alterations for the merchandise and procedures are concerned.

The Timing Plan for confirmation at the PP physique stage is established.

For further inside informations, please refer

Guideline on Continuing Process Control & A ; Process Capability Improvement, MQS/SPC/GL01.

Guideline for Process Potential Studies ( Ppk ) for Machine & A ; Process Evaluation, MQS/Ppk/GL01.

2121. Production Validation Testing

Definition

Production Validation Testing refers to technology trials that validate that merchandises made from production tools and processes meet technology criterions.

Expectations

Partss for Production Validation Testing must be selected from the Production Trial Run, as per the sample sizes and frequences outlined in the Pre-Launch Control Plan.

All client – specified dimensional, stuff, functional and dependability trials must be completed anterior to Production Part Approval. If non, appropriate action programs and client blessings are required.

Lead Duty

Product Development / CQA

Support Function

Fabrication Plant.

Manufacturing Engineering.

Timing

Initiate Milestone & lt ; PP & gt ;

Finalize Milestone & lt ; SO & gt ;

Deliverables

Develop a Timing Plan to bring forth parts, constituents, systems, sub-systems and vehicles for proof proving in line with Engineering Specifications outlined in the Pre-Launch Control Plan.

All produced parts, constituents, systems, and sub-systems are tested prior to the FEU ( Field Evaluation Unit ) build stage

All required Engineering Specifications are tested and blessing for credence is available.

For further inside informations, please mention Production Validation proving ( Engine ) Guideline,

MQS/PV/GL01

2222. Production Part Approval

Definition

Production Part Approval is the documented confirmation that all client technology design demands are met by the internal or external provider, and the procedure has the possible to bring forth to these demands, where applicable during an existent production tally.

Expectations

All points of the MQS “ Mahindra Production Part Approval Process ” Manual must be completed and the needed certification provided to the client with the Part Submission Warrant.

Production Part Approval is complete before the Material Required Date ( MRD ) for the User Plant ‘s Production Trial Run

Lead Duty

Fabrication Plant / CQA

Support Functions

Manufacturing Engineering

Timing

Initiate Milestone & lt ; PP & gt ;

Finalize Milestone & lt ; SO & gt ;

Deliverables

A Timing Plan for the Production Part Approval Process is established.

100 % PSW blessing procedure is initiated and the entire Programme PSW ( Part Submission Warrant ) position is evaluated.

100 % PSW is approved.

2323. PSW Part Delivery at Material Required Date ( MRD )

Definition

PSW portion bringing at the Material Required Date ( MRD ) is the concluding day of the month that to the full approved ( PSW ) stuff must be received at the client ‘s works to back up their Production Trial Runs.

Expectations

The client ‘s Material Required Date must be included in the provider ‘s Timing Plan.

Production Part Approval demands must be completed anterior to the MRD of the user works.

Lead Duty

Merchandise Development

Manufacturing Engineering

Millimeter

Fabrication Plant

Timing

Initiate Milestone & lt ; PP & gt ;

Finalize Milestone & lt ; SO & gt ;

Deliverables

Develop the stuff In Plant timing for physiques between stat mi rocks & lt ; PP & gt ; to & lt ; SO & gt ;

Establish a MRD reappraisal procedure

Assess PSW portion bringing rate at each physique.

100 % approved PSW parts are available.

Abbreviations

Ad. NOVA – Degree centigrade

Advanced New Overall Vehicle Audit – Customer

CAE

Computer Aided Engineering

CED

Cause & A ; Effect Diagram

DCP

Dynamic Control Planning

DFMEA

Design Failure Mode & A ; Analysis

Department of energy

Design of Experiments

DAP

Design Approved Print

NOVA – Bacillus

New Overall Vehicle Audit – Body

NOVA – Phosphorus

New Overall Vehicle Audit – Paint

PDI

Pre Delivery Inspection

PDT

Plant Driveline Team

Pet

Plant Engine Team

Perfluorocarbon

Procedure Flow Chart

Polonium

Procedure operation sheet

PVT

Plant Vehicle Teams

QCRT

Quick response Concern Resolution Team

Sos

Standard Operating Sheet

Sop

Standard Operating Procedure

SQA

Supplier Quality Assurance

Tungsten

Work station standardisation

BWT

Basic Working Team