APQP Guidelines

In case of any doubt contact IFMPL QA personnel

# Programe Events Actions required from Supplier

Stage-1: Identification & Planning

1 Release of PO Acknowledge the PO

Supplier need to:

Submission of APQP Timing Plan 1. Fill-up all activities listed herein with the target date and mark "X" in appropriate block
2
(QP-1) 2. Submit the filled up copy to IFMPL QA
3. Save a copy for tacking the progress of activities listed

Supplier need to:

Submission of Supplier List
3 1. Fill-up all the column of this format and submit the copy to IFMPL QA.
(QP-2)
2. Enter the suppliers to be used for Raw Material as well as Out-sourcing operation.

Supplier need to:

4 Submission of Ballooned Print (QP-3)
1. Ballooned all the parameters mentioned on the drawing and submit to IFMPL QA

Supplier need to:

1. Define the process flow for all the process including out-source process.
Submission of Process Flow Chart 2. Define the in-coming source of variation for all the processes.
5
(QP-4) 3. Define all inspection points
4. List out Ballooned ID in product characteristic column for corresponding process step.
5. Submit the complete document to IFMPL QA

Supplier need to:

1. List out ballooned ID and machine on which those will produced.
6 Submission of Machine Plan (QP-5) 2. Provide the target date of machine procumbent if the machine is not available
3. Provide a complete details in the form provided.
4. Submit the complete document to IFMPL QA

Supplier needs to:

1. Identify the jig /fixture for parameters (ballooned ID) generated with its usage.
7 Submission of Jig / Fixture Plan (QP-6) 2. Provide the target date of jig / fixture if it is not available
3. Provide a complete details in the form provided.
4. Submit the complete document to IFMPL QA

Supplier needs to:

1. Identify the tools required to generate the parameters (ballooned ID).
8 Submission of Tool Plan (QP-7) 2. Provide the target date of the required tools are not available
3. Provide a complete details in the form provided.
4. Submit the complete document to IFMPL QA

Page 1 of 36 file:///conversion/tmp/activity_task_scratch/636072452.xlsx
 # Programe Events Actions required from Supplier

Supplier needs to:

1. Identify the gauges required to inspect the parameters (ballooned ID).
9 Submission of Gauge Plan (QP-8) 2. Provide the target date of the required gauges are not available
3. Provide a complete details in the form provided.
4. Submit the complete document to IFMPL QA

Supplier needs to:

Submission of Production Trial Run Schedule
10 1. Provide the trial run duration for all the production steps.
(QP-9)
2. Submit the complete document to IFMPL QA

Stage-2: Process Preparation

Supplier needs to:

1. Conduct the process FMEA for all the processes identified in process flow chart.
Submission of PFMEA
11 2. Use the ranking table provided.
(QP-10)
3. Identify the actions where the process control mechanism is inadequate.
4. Submit the complete document to IFMPL QA

Supplier needs to:

1. Prepare the control Plan for all the processes identified in process flow chart.
Submission of Control plan
12 2. Enter Ballooned ID# in characteristics column.
(QP-11)
3. Enter the reaction plan.
4. Submit the complete document to IFMPL QA

Supplier needs to:

Submission of list of new Process Instructions 1. Identify the new process instructions required which will be used during the production.
13
to be made (QP-12) 2. Provide the target date and list of instructions.
3. Submit the complete document to IFMPL QA

Supplier needs to:

1. Define the packaging steps to ensure the integrity of the part.
Submission of Packaging Data Sheet
14 2. Provide the details of the packaging material to be used.
(QP-13)
3. Specify the Rust Preventive mechanism to be used on the part.
4. Submit the complete document to IFMPL QA

Stage-3: Production Trial

Supplier needs to:

1. Do the layout inspection for all the parameters defined in the part drawing.
Submission of Layout Inspection Report
15 2. Inspect all samples produced.
(QP-15)
3. Prepare separate report for casting and machining operations.
4. Submit the complete document to IFMPL QA

Supplier needs to:

Submission of Samples with all required 1. Submit all the reports as listed in QAP.
16
inspection reports 2. Submit all inspected samples packed as per defined packing datasheet.
3. Submit the complete document to IFMPL QA

Page 2 of 36 file:///conversion/tmp/activity_task_scratch/636072452.xlsx
 # Programe Events Actions required from Supplier

Submission of PPAP Supplier needs to:

17
(Refer PPAP Workbook) 1. Submit PPAP documents as per PPAP workbook.

Stage-4: FAA

18 Inspection & Assembly Trail Activities are related to IFMPL

Issue of FAA report

19 Activities are related to IFMPL
(QP-14)

Page 3 of 36 file:///conversion/tmp/activity_task_scratch/636072452.xlsx
 SUPPLIER RESPONSIBILITY MATRIX
# Function Conatct Details Primary Responsible

Name
Designation
1 Quality Email
Mob. No.
Landline No

Name
Designation
2 Operations Email
Mob. No.
Landline No

Name
Designation
3 Commercial Email
Mob. No.
Landline No
PONSIBILITY MATRIX
2nd contact in absence of 3nd contact in absence of both
Primary Responsible contacts
 APQP Timing Plan
Supplier Name Contact Person Contact # Supplier Site Address

Outsource Process Outsource Supplier Name Contact Person # Contact # Site Address

Part Description MANIFOLD SUCTION ASSEMBLY Drawing No. 518.175.156E Rev. No. C
)
Submission Date Sample Status
Initial Samples Overview Remarks
Planned Actual Submitted OK Reject

Submission Date Sample Status

Initial Samples Overview Remarks
Planned Actual Submitted OK Reject

(Supplier to fill up all target dates & put "x" for the corresponding month and week nos box for all the following programe events)
Week Nos
# Programe Events Owner Target Dt. Status Comments
43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

Stage-1: Identification & Planning

1 Release of PO x

Submission of APQP Timing Plan

2 x
(QP-1)

Submission of Supplier List

3 x
(QP-2)

4 Submission of Ballooned Print (QP-3) x

Submission of Process Flow Chart

5 x
(QP-4)

6 Submission of Machine Plan (QP-5) x

7 Submission of Jig / Fixture Plan (QP-6) x

8 Submission of Tool Plan (QP-7) x

9 Submission of Gauge Plan (QP-8) x

Submission of Sample Production Trial Run

10 x
Schedule (QP-9)

Stage-2: Process Preparation

Submission of PFMEA
11 x
(QP-10)

Submission of Control plan

12 x
(QP-11)

Submission of list of new Process Instructions

13 x
to be made (QP-12)

Submission of Packaging Data Sheet

14 x
(QP-13)

Stage-3: Production Trial

Submission of Layout Inspection Report

15 x
(QP-15)

Submission of Samples with all required

16 x
inspection reports

Submission of PPAP
17 x
(Refer PPAP Workbook)

Stage-4: FAA

18 Inspection & Assembly Trail IFMPL

Issue of FAA report

19 IFMPL
(QP-16)

LEGEND:
Achieved
Behind schedule
Missed target

Page 6 of 36 file:///conversion/tmp/activity_task_scratch/636072452.xlsx
 List of Supplier: Raw Material & Out-source Operations
Supplier Name Submission Date:
Part Name: Part Number:
Drawing No: Rev. No.:

Description of Raw Supplier

Material Grade/ Supplier Approval Supplier Approval
Sr. No. Material / Out-source Remarks
Standard Date Method
operations Name Location Contact No.

4
Inspection Key Operation Key Rev.00
A=Automatic E=Equip./Machine
PROCESS FLOW CHART Date:27.09.2016

Part Name:
M=Manual M=Manual Part #
V=Visual Drawing No: Drg. Rev. No / Date :
Q=Quality Audit Prepared By:M.G.Santhosh kumar Prepared On:
Team: Supplier Name:
Operation Nos.

Operation

Store/Get
Machine,

Inspect
In-coming Product Characteristics Process
Operation Description Device, Jig,

Move
Source of (Outputs) Characteristics
Tools, for
Variation (ID# as in Balloon Drg) (Inputs)
Mfg.
E A

Raw material receiving Composition A

10 Spectro meter
inspection variation

Color Code
20 Material Storage Manual M
missing
Melting Color Code
30 Melting of Raw materials E
furnace missing

40 Casting GDC process E

50 Set up Approval Manual A

60 Continuous Production Manual E

Periodic / Visual Inspection

70 Manual
and 1.Layout A

Runner cutting E
80 Runner cutting Manual
border line missing

Sand blockage,
90 De coaring De coring gun Dent on casting E
profile
Heat
100 Heat treatment treatment Low hardness E
process

110 Fettling Manual A

Incorrect size and

Shot blasting
120 Shot Blasting hardness of the E
machine
ball

130 Machining Milling E A

Impregnation E
40 Impregnation Incomplted
setup

Hydro pum without

150 Hydro test M
with fixture impregnation

160 Final inspection Visual

E

170 Packing Manual E

Free from damage &

180 Dispatch Manual E oxidization on the As per WI
Finished parts
Approved by: S.Ranganathan Date:21.10.2019
 Machine Plan:List Of Machines
Supplier Name: Submission Date:

Part Name : Drawing no.

Part No. :

Available Machine Order Target Dt of

SL Description of Month of Ownership of
Balloon ID Machine No Make Status if not receipt if to be Remarks
NO Machine Purchase Machine
Yes No available purchased

5
 List Of Jig & Fixture

Supplier Name: Submission Date: 21.10.2019

Part Name : Drawing no. 518.175.000

Part No. : Status on : 21.10.2019

Available Supplier Name (in

Description of Jig / Calibration / Target Date of Ownership lies
SI.NO Balloon ID Identification No case need to Order Status Remarks
Fixture / Die / Pattern Inspection Date Receipt with
Yes No Purchase)

1 VMC machining fixture Yes

 LIST OF GAUGES & INSTRUMENTS

Supplier Name: Submission date:

Part Name : Drg. No. / Rev. No.:

Part No. :

Available
Name of Inspection Supplier for
# Balloon ID Characteristics Specification least Count Gauge No Calibration Date
Instrument Purchase
Yes No

GAUGES

1 22

1 1 Yes

2 2 Yes

3 3 Yes

4 4 Yes

5 5 Yes

6 6 Yes

7 7 Yes

8 8 Yes

9 9 Yes

10 11 Yes

11 12 Yes

12 13 Yes

13 16 Yes

14 17 Yes

15 19 Yes

16 20 Yes

17 21 Yes

18 23 Yes

19

20

21

22

23

24
25

26

27

28

29

30

31

32

33

34

35

36

37
ion date:

Rev. No.:

Status on:21.10.2019

Target Date of
Order Status Remarks
Receipt
 LIST OF TOOLS

Supplier Name: Submission Date:

Part Name : Drawing no.

Part No. :

Available
Supplier for Target Date of
SL NO Balloon ID Description of Tool Spec of the tool Order status Ownership lies with Remarks
purchasing the tool Receipt
Yes No

Under
1
Development
14

15

DATE: PREPARED BY APPROVED BY

Sample Production Trial Run Schedule
Supplier Name:
Part Name :
Drawing No :

Sl.No Production Steps Target Period Remarks

1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
 CONTROL PLAN
Key Contact / Phone Head- Quality Assurance/+91 887 000 6653 Date origin : 21.10.2019 Format No : R / QLA / 10

Control Plan Number Work Order Number Date Revision : Revision Number :00

Customer Name Organization Name Customer Engineering Approval Date (If Required ) :

Part Name / Description Core Team : Head - Q.A ; Head - Tool Room ; Head - Engg. ; Head - Customer Quality Approval Date (If Required ) :
Production ; Head - Operation
Part Number / Rev Level

Characteristics Methods
Part / Process Name / Machine, Device,

poka yoka
Process Operation Jigs, Tools For Product / Process Reaction Plan

Sp.Char.
Evaluation Measurement Sample Sample
Number Description Mfg No. Product Process Specification / Control Method Responsibility
technique Size Frequency
Tolerance

Receiving
10 Spectrometer
Inspection
 CONTROL PLAN
Key Contact / Phone Head- Quality Assurance/+91 887 000 6653 Date origin : 21.10.2019 Format No : R / QLA / 10

Control Plan Number Work Order Number Date Revision : Revision Number :00

Customer Name Organization Name Customer Engineering Approval Date (If Required ) :

Part Name / Description Core Team : Head - Q.A ; Head - Tool Room ; Head - Engg. ; Head - Customer Quality Approval Date (If Required ) :
Production ; Head - Operation
Part Number / Rev Level

Characteristics Methods
Part / Process Name / Machine, Device,

poka yoka
Process Operation Jigs, Tools For Product / Process Reaction Plan

Sp.Char.
Evaluation Measurement Sample Sample
Number Description Mfg No. Product Process Specification / Control Method Responsibility
technique Size Frequency
Tolerance

20 Material Storage

Melting & Holding

30 Melting
furnace

Gravity Die
40 Tools and dies
Casting
 CONTROL PLAN
Key Contact / Phone Head- Quality Assurance/+91 887 000 6653 Date origin : 21.10.2019 Format No : R / QLA / 10

Control Plan Number Work Order Number Date Revision : Revision Number :00

Customer Name Organization Name Customer Engineering Approval Date (If Required ) :

Part Name / Description Core Team : Head - Q.A ; Head - Tool Room ; Head - Engg. ; Head - Customer Quality Approval Date (If Required ) :
Production ; Head - Operation
Part Number / Rev Level

Characteristics Methods
Part / Process Name / Machine, Device,

poka yoka
Process Operation Jigs, Tools For Product / Process Reaction Plan

Sp.Char.
Evaluation Measurement Sample Sample
Number Description Mfg No. Product Process Specification / Control Method Responsibility
technique Size Frequency
Tolerance

10

11

50 Setup Approval GDC Process 12

13

14

15

16

17

18

19

20

21

22

Bal
oon
.No

22

50 Setup Approval GDC Process

42

16
 CONTROL PLAN
Key Contact / Phone Head- Quality Assurance/+91 887 000 6653 Date origin : 21.10.2019 Format No : R / QLA / 10

Control Plan Number Work Order Number Date Revision : Revision Number :00

Customer Name Organization Name Customer Engineering Approval Date (If Required ) :

Part Name / Description Customer Quality Approval Date (If Required ) :

Core Team : Head - Q.A ; Head - Tool Room ; Head - Engg. ; Head -
Production ; Head - Operation
Part Number / Rev Level

Characteristics Methods
Part / Process Name / Machine, Device,

poka yoka
Process Operation Jigs, Tools For Product / Process Reaction Plan

Sp.Char.
Evaluation Measurement Sample Sample
Number Description Mfg No. Product Process Specification / Control Method Responsibility
technique Size Frequency
Tolerance

60

70

80

90

100

110

120

130

140

Prepared By Approved By
 POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
FMEA Number :

Page :- 01
Process
Item : Responsibility :- Prepared By :-

Model No: Key Date :- FMEA Date (Orig) :-

Core Team :- (Rev.) :

Current Process Actions Results

C
Potential S l Potential D R
Process Potential Failure O Recommended Resp. & S O D R
Requirement Effect(s) of E a Causes for Control E P
Function Mode C Control Detection T Actions Target date Actions Taken E C E P
Failure V s Failure Prevention N
s C V C T N

Rejection of Composition check in

Incorrect Chemical parts due to Process defect at Spectrum Analyzer &
7 --- 1 5 35
Composition variation in Ingot manufacturer Test certificates before
specification accepting the material
Rejection of
parts due to Improper Heat number and Heat number and
Mixing up of alloys 7 1 5 35
different grade Identification. colour code colour code
material
Improper
degassing / Nitrogen degassing to Prorosity Tester and
Gas Entrapment Blow Holes 6 3 4 72
Frequency of be done as per W.I Through cut sample
degassing
Rejection of
Impurities such as parts due to Improper cleaning of Molten metal cleaning
5 2 Visual 6 60
Sand dust & slag etc Inclusions and molten metal to be done as per W.I
hard metal

Improper filling It can be ensured

Usage of different Identification number
Ladle cup of the 5 2 online during 5 50
ladle cup provided the ladle cup
components production

Injection pressure is Set as per Process Process verification

7 2 4 56
too low Parameter Card report

Periodic inspection with

Variation in metal On line temperature
7 2 Thermometer every two 4 56
temperature controller
Shrinkage & blow Rejection of hour once
holes parts
verification of Process Periodic inspection with
Variation in die
7 parameter as per 2 Thermometer every two 4 56
temperature
control plan hour once

Improper metal Current control service

As per Work
7 cleaning & 2 of furnace by operator/ 4 56
Instructions
Degassing shift in charge

Process to be
Verification of control Rejection of Periodic inspection
5 Process variation controlled by adjust 2 5 50
plan parameters parts report
the settings
 Impurities and Gas Frequency of
Low casting Cut section of
porosity 7 entrapment in degassing to be done 2 4 56
strength components
Molten metal 2hrs once

1.Chill vent and

Rejection of
overflow pads to be
High / Low parts due to Flow restriction due Temperature Indicator
7 provided 3 3 63
Temperature Non-fills , short to low temperature for furnace metal
2. Productivity to be
fill and flashes
increased

Verification with
Process to be
Machine setting Process parameter
5 controlled by adjust 3 4 60
parameter standard at beginning
Aesthetic look & the settings
Non filling of cavity by of each shift
Low strength of
metal
casting
Pyrometer /
Temperature controller
4 Low temperature 2 Temperature probe 4 32
is provided
control

Function defects Check length of

100% of Inspection until
Warpage in casting and dimensional 5 Unbalanced ejection ejector pins and 2 4 40
process stabilized
variation ejection plate angel

Improper Die
Blue matching will be
matching &
6 done before running 3 3 54
Insufficient locking
Failure in the machine
Flashes and extra force in machine
subsequent Visual Inspection
projection in casting
operation

Pressure should be
5 Core back up maintained within 2 6 60
spec

1.Process parameters
to be maitained as per
Rejection of Process variation, 100% Components
Crack 5 P.P.Card. 2 4 40
parts Under cut in die Visual Inspection
2.Under cut in the die
to be corrected

Rejection of Handling to be done 100% Components

Damage 5 Poor Handling 2 4 40
parts as per work instruction Visual Inspection

Dimensional Hardness of the pin to

Lack of hardness in 100% Components
Core hole offset variation / 5 be ensued before 2 6 60
the pin Visual Inspection
assembly error issuing

Before pouring the

Dimensional
Incorrect locking of moulten metal die 100% Components
Mismatch variation / 5 2 6 60
die and side cores assembly to e Visual Inspection
assembly error
checked

Limit samples display /

Incorrect cutting /part Fit Functional Process done by 100% Visual
2 Training course of 4 5 40
Damage problem Manual Inspection
operator

Damage & Sand Training to the 100% Visual

Part Not usable lack of training
contaminination operator Inspection
 Process cycle Training to the Follow the work
Low Harness Rework of parts 7 3 4 84
variation operator instruction

Fit Functional Training to the

Bend / Damage 7 Handling Not Proper 2 100 % Inspection 4 56
problem operator

Reworking of Training to the 100% Visual

Improper fettling 5 lack of training 3 4 60
parts operator Inspection

Aesthetic look &

Fit and Over clamping and Training to the
Bend / Damage 7 2 100% inspection 4 56
functional excess filing operator
problem

Excess parts loaded Operator to be trained

Poor surface
Improper shot blasting 5 in single cycle/ cycle and cycle time to be 2 100% visual inspection 4 40
finish
time difference maintained

Improper positioning
of the casting in the Correct fixtures and Dimensinal inspection
In correct method of Part get rejected
6 Machining cycle time to be 2 and Gauge checking as 4 48
clamping, Machining and un usable
fitxure,Incorrect tool maintained per control plan
selection ,method

Process to be
Distribution of
140 - In sufficient Vaccuum Functional Dirt, temperature, controlled by adjust Process to be validated
mass should be 7 2 4 56
Impregnation pressure and sealent problem and loose fits the settings and also as per sampling plan
centreline
Training the operator

1. Process to be
controlled by adjust
the settings and also
Part get rejected Training the operator. Process to be validated
150 -Hydro Test No Leak Leakage 6 Air holes & porosity 2 4 48
and un usable 2. After machining as per sampling plan
parts to be
impregnated double
time

Visual & Improper fettling &

160-Final 100 % visual
Dimensionally ok Appearance / Burr Rework of parts 6 visual inspection is 2 100 % visual inspection 4 48
inspection inspection
component not done

170-Packing of Quality passed Damage of Improper packing Standard packing Standard packing
Packing method 6 2 5 60
finished parts parts parts method method method

Free from damage, Damage of Improper packing Standard packing Standard packing
180 -Despatch Packing method 6 2 5 60
dent, white rust parts method method method

0 0 21.10.2019 Initial Release

S.NO Rev No Date Revision Details Remarks
Prepared By M G Santhosh kumar Checked By Approved By
SEVERITY
OCCURANCE
DETECTION
 List of New Instructions Requirement
Part Name : Submission Date:
Drawing No : Part #
Prepared By :

Sr. No. Purpose of Instruction WI Number Target Date Actual Completed

Page: 33 of 36
 Packaging Datasheet
Supplier Name:
Part Name
Drawing No

Specification of Material Used during packaging including Rust

# Packaging Steps Remarks
Preventive Oils
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
 Page 35 of 36

Layout Inspection Report- Dimensional Results Inspection Date:

Part Name: Part Number

Supplier Name Drawing No. & Rev.

Print Dimensions/Specifications Inspection Results

Balloon
ID Characterstics Inspection Method Least Count Comments / Remarks
Nominal Minimum Maximum 1 2 3 4 5 ok not ok

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47
 Page 36 of 36

PPAP will be failed if any characteristics found outside the tolerances or does not meet acceptance criteria, lot will be rejected & will not be accepted under deviation request
Name
Inspected By
Approved By