Supplier Name: Supplier Location: Supplier Code:

Part Number: Part Name: Revision Level:

Component Priority Level: Lead Customer/Program: Report Date:
Supplier APQP Workbook
Date: 16 Jan 2008
Revision: D
Doc No: D_020_4_03
Page 1 of 28
Cover
Process Owner / Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Supplier APQP: Five Phases
GSQM
MANAGEMENT MESSAGE
APQP
OTHER SUPPLIER
REQUIREMENTS
SUPPLIER
REQUIREMENTS &
SELECTION
PHASE 3
Product/Process
Realization
Supplier Packaging
Requirements
Analysis of process failures
and effects
Process Flow Chart
Use PCM for Pre-Launch
Control Plan
Process Instructions
Finalize process capability
study plan
Validation review of off-tool
condition
Floor plan layout
Pre-qualify equipment /
tooling / gauging at supplier
Review Key Supplier
Metrics
PHASE 4
Pre-PPAP
Pre-Production Run
Process Capability Study
Finalize PCM; Prepare for
Safe Launch
Finalize PFMEA and Control
Plan
Launch Readiness Audit;
document in Key Metrics
Re-qualify equipment /
tooling/ gauging at supplier
Supplier participates in Plant
Readiness Review
Review Key Supplier Metrics
Update previous phase open
issues/key documents
PHASE 2
Equipment & Tool
Design
Conduct cross-functional
component design review
Preliminary Process Flow,
PFMEA & Control Plan review
Review Supplier DFMEA
(when applicable)
Create PCM; Identify sub-
supplier value chain
Supplier master schedule
review
Review Key Supplier Metrics
Update previous phase open
issues/key documents
PHASE 5
Product/Process
Validation & Launch
Finalize complete PPAP
submission package
Cross-functional Key Metrics
review; OK to launch sign-off
Launch Readiness Audit
Confirmation of full volume
Run at Rate
Initiate Safe Launch Practice
Final component packaging
review
Update previous phase
open issues/key documents
Review Key Supplier Metrics
Close out previous phase
open issues/key documents
PHASE 1
Supplier Kick-
off & Planning
Identify TRW & Supplier team
contacts/roles/responsibilities
Communicate & initiate Key
Supplier Metrics
Initial supplier program plan
and timing
APQP requirements
Create APQP Progress
Report
Initiate Open Issues
document
Review Preliminary Capacity
Study
Review Manufacturing
Feasibility
SUPPLIER SENIOR MANAGEMENT SUPPORT
Supplier Ramp Plan
Appearance Approval
(when applicable)
Equipment, tooling & gage
design review
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 2 of 28
5 Phases Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Progress Report Reporting form for suppliers to track progress on all APQP deliverables.
Supply Chain Map
Example
An example of how a Supply Chain Map may appear for a typical metal component.
Other APQP Tools Embedded copies of the Component Design Review, Product Characterisitics Matrix, and Launch
Readiness Audit.
Supply Chain Map Form for showing multi-tier suppy chain relationships involved in providing the component/assembly to
TRW. The information documented here will also be used in the creation of the Product Characteristics
Matrix.
Lists all of the forms and examples included in this workbook.
Key Metrics Report Key Metrics contain those elements that contribute to a successful launch. This form allows for five
reviews. The minimum requirement is to use it at APQP-5. The APQP-5 report is generated at the
time product is manufactured for the PPAP submission. The additional columns would either be used
at the discretion of the SDE or based on circumstances that require additional reviews.
Key Metrics Graph Visually displays and compares the results of the Key Metrics reports generated during APQP-4 and/or
APQP-5.
Key Metrics Definitions Operational definitions for the twelve key metrics. Explains the metric and its method of calculation.
Supplier APQP: Table of Contents
Introduction Displays a pictorial representation of APQP elements tracked in the Progress Report in relationship to
TRW's launch profile.
Blank Time Line Suppliers are required to create a Master Time Line for the launch of the awarded component(s). It is
expected that a Gantt chart is used as the format. For those suppliers who do not have software
available to meet this requirement, a blank time line is provided for their use.
Shows the 5 APQP Phases and the activities that occur within them. Cover
Table of Contents
Product
Characteristics Matrix -
Tier II
The PCM is used initially to define and determine appropriate controls for special characteristics, other
process critical features and customer touch points. This tab is used to define the process at TRW's
direct supplier. Throughout the APQP phase of launch this form is used as the Pre-Launch Control
Plan and also forms the basis for Safe Launch Planning.
Product
Characteristics Matrix -
Sub-Supplier
The use of this tab is identical to the functionality define above, with the exception that this is used to
document the remaining supply chain's, below the Tier II supplier, impact on the critical features.
In Cell Check (Blank) This form is used document inspection results for those characteristics and features identified on the
Product Characteristics Matrix during the Safe Launch Plan implementation period.
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 3 of 28
Table of Contents Process Owner/Department:
R. Sparisou / Supplier Development
Approved by:
R. Spariosu / Global Director, SDE
Supplier APQP: Table of Contents
Contacts Lists the individuals involved in the component(s) launch, for both TRW and the supplier, and their
respective contact information. This tab is optional and may be used as needed.
Open Issues The action plan format used to document open issues, their actions and resolution throughout the
APQP process. This combines several different action plans generated by different, individual tools into
a single document.
Format to be used for a weekly summary of the inspection results from the Safe Launch Plan.
In Cell Check
(Example)
SLP - Weekly QOS
Report
An example of the In Cell Check.
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 4 of 28
Table of Contents Process Owner/Department:
R. Sparisou / Supplier Development
Approved by:
R. Spariosu / Global Director, SDE
A
P
Q
P


P
H
A
S
E
1.1 Design FMEA
1.2 Preliminary Capacity Study reviewed
1.3 Manufacturing Feasibility reviewed
1.4 Component Design Review
1.5 Key Supplier Metrics initiated
1.6 Supplier Project timing plan
1.7 Open Issues Action Plan created
2.1 Sub contractor PPAP approval
2.2 Product Characteristic Matrix initiated
2.3 Process flow chart
2.4 PFMEA
2.5 Control Plan
2.6 Appearance Approval Process (when applicable)
2.7 Key Supplier Metrics reviewed
3.1 Measurement/ Testing equipment
3.2 Tooling
3.3 Capital equipment
3.4 Training
3.5 Process instructions
3.6 Quality System and Plan review
3.7 Packaging
3.8 Launch Readiness Audit
3.9 Key Supplier Metrics reviewed
4.1 ELV/IMDS
4.2 Safe Launch Plan finalized
4.3 Supplier Ramp Plan
4.4 Plant Readiness Review
4.5 Launch Readiness Audit
4.6 Key Supplier Metrics reviewed
5.1 PPAP
5.2 Launch Readiness Audit
5.3 Run at Rate
5.4 Key Supplier Metrics reviewed
5.5 OK to Launch Sign-Off
Supplier APQP: Five Phase Time Line
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The TRW Automotive Supplier Advanced Product Quality Planning (APQP) process consists of 5 Phases. Essential to this process are 12 Key Supplier Metrics (KSM). These metrics are established in the initial phase and then updated and
reviewed during each of the following phases. The time line below illustrates the relationship between the 5 Phases, their deliverables and the Global Development & Product Introduction Management process.
This workbook consists of 10 forms in support of this process. Suppliers are expected to use this process regardless of the priority ranking assigned components/materials requiring submission of a PPAP package.
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Date: 16 Jan 2005
Revision: D
Doc No.: D_020_4_03
Page 5 of 28
Introduction Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
0
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1.1 Design FMEA
1.2 Preliminary Capacity Study reviewed
1.3 Manufacturing Feasibility reviewed
1.4 Component Design Review
1.5 Key Supplier Metrics initiated
1.6 Supplier Project timing plan
1.7 Open Issues Action Plan created
2.1 Sub contractor PPAP approval
2.2 Product Characteristic Matrix initiated
2.3 Process flow chart
2.4 PFMEA
2.5 Control Plan
2.6 Key Supplier Metrics reviewed
3.1 Measurement/ Testing equipment
3.2 Tooling
3.3 Capital equipment
3.4 Training
3.5 Process instructions
3.6 Packaging
3.7 Key Supplier Metrics reviewed
4.1 ELV/IMDS
4.2 Safe Launch Plan finalized
4.3 Supplier Ramp Plan
4.4 Plant Readiness Review
4.5 Launch Readiness Audit
4.6 Appearance Approval Process (when applicable)
4.7 Key Supplier Metrics reviewed
5.1 PPAP
5.2 Launch Readiness Audit
5.3 Run at Rate
5.4 Key Supplier Metrics reviewed
5.5 OK to Launch Sign-Off
6.1
6.2
6.3
6.4
6.5
6.6
6.7
KEY: X Planned start O Planned completion + Actual start > Actual end
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Supplier APQP: Blank Time Line
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OUTPUT
Year 1 Year 2
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 6 of 28
Blank Time Line Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Supplier Name: Supplier Location: Supplier Code:
Part Number: Part Name: Revision Level:
Component Priority Level: Lead Customer/Program: Report Date:
CLICK ON THE BUTTON TO UPDATE THE "KEY METRICS STATUS" GRAPH:
Supplier APQP: Key Metrics Elements Graph
0
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Key Metrics Status
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APQP Readiness
Instructions
FTC
Process Efficiency
Capability
Testing
% Process Complete
LRA
Sub-Tier PPAP
PPAP Completion
Ramp Plan
GSQM 220
Key Metric Values at Review
0-Jan-00 0-Jan-00 0-Jan-00 0-Jan-00 0-Jan-00
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 7 of 28
APQP Element Graphs Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Supplier Name: Supplier Location: Supplier Code:
Part Number: Part Name: Revision Level:
Component Priority Level: Lead Customer/Program: Report Date:
SUPPLIER SIGN-OFF (MANAGER LEVEL)
TRW SIGN-0FF
Signature
4. Process Efficiency
K
E
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M
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Supplier APQP: Key Supplier Metrics Report
Signature
Signature
0
0
Name (print)
Name (print)
Name (print)
0
12. GSQM 220 Deployment
TRW Internal Use only Commodity Mgr/Buyer
SDE
SQA
Function Project Leader
D
L
N
8. Launch Readiness Audit
5. Process Capability
0
0 0-Jan-1900
0 0
0
Manufacturing
9. Sub-Component PPAP
Approvals
10. PPAP Package
Completion
11. Supplier Ramp Plan
Signature
Name (print)
Production Control Purch/Sales Quality Design Engineering
5
Total number of instructions needed.
Production volumes provided off production intent process
High volulme process or Interim Process with Concession
5
M
A
N
U
F
A
C
T
U
R
A
B
I
L
I
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Y
Total number of designated characteristics features
Results from Run at Rate, line 25
Ideal % of good parts
3. First Time Capability
1. APQP Readiness
2. Process Instructions
Number of sub-components and materials PPAP approved
6. Test Achievement
Number of tests passed
7. Process Implementation -
% Completed
% of total tests
Score achieved during event
Goal is 100%.
Number of capable designated characteristics features
State of completed supplier ramp plan
Number of PPAP required documents completed
Total number of elements from'Progress Report'
Number of 'Progress Report' elements with Green status
Overall Utilization percentage.
Maximum allowable utilization
Total number of purchased sub-components/materials
Enter completed stage of PCM (see comments)
Ramp planned completed and shipping to releases
Total number of instructions completed
Number of PPAP required documents required
Complete Stage 5 by SOP 5
Primary Indicator:
Goal
Target Production Preparation Influencing Factors
Results
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 8 of 28
Key Metrics Report Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Enter the number of GREEN elements at
the time of the report.
Enter the total number of elements being
tracked. There are 33 elements on the
APQP Progress Report. For suppliers
where the DFMEA does not apply subtract
1. For suppliers who are not providing an
Appearance item, subtract 1.
Enter number of completed process
instructions at the time of the review.
Enter total number of process instructions
needed for serial production.
Enter, as a decimal number, the ratio of
total parts produced to good parts from
the trial run.
Enter the number '1,' which represents the
production of 100% good, or usable, parts.
The Overall Utilization % from the Run at
Rate form.
Maximum allowable utilized capacity is
100% when the standard shift pattern and
CPV are used.
Enter the number of characteristics, with
a Ppk > 1.67, at the time of the review.
Enter the total number of designated
characteristics on the drawing.
This is the total number of samples that
passed all of the required testing at the
time of the review.
The should represent the total number of
individual tests required times the number
of samples, for each test, that is required.
APQP: Key Supplier Metrics Operational Definitions
First time Capability Percentage of good parts to the total
number of parts produced during the Run
at Rate.
Form No.: D_020_4_12
Test Achievement Total number of performance and
materials tests that need to be conducted
to meet the specifications shown on the
drawing. This number is a combination
of the number of unique tests multiplied
by the number of samples required for
the test.
This section defines the Key Supplier Metrics that will be tracked throughout the five APAP Phases. Reviews will be held toward the end of each of the five
phases. Review of these metrics, in the Phase 5, will take place before the final full PPAP appro
Process Capability The number of designated
characteristics with a Ppk > 1.67.
Goal Results
APQP Readiness
Definition Metric
Data is derived from the 'APQP Progress
Report'. This metric tracks the
percentage of GREEN elements
compared to the total number of
elements being tracked.
Process Instructions Total number of set-up, manufacturing
and inspection instructions needed.
Process Efficiency This is the percentage that the process is
utilized.
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 9 of 28
Key Metrics Definitions Process Owner/Department:
R. Sparisou / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
APQP: Key Supplier Metrics Operational Definitions
This section defines the Key Supplier Metrics that will be tracked throughout the five APAP Phases. Reviews will be held toward the end of each of the five
phases. Review of these metrics, in the Phase 5, will take place before the final full PPAP appro
Goal Results
APQP Readiness
Definition Metric
Data is derived from the 'APQP Progress
Report'. This metric tracks the
percentage of GREEN elements
compared to the total number of
elements being tracked.
Enter the appropriate stage of process
implementation in regard to
manufacturing for serial production.
1. Prototype process is implemented; No
released deviation of concession; No
containment plan.
2. Intermim process implemented, with
partial production intent process; No
released deviation or concession; No
containment plan.
3. Prototype or partially implemented
process; Released deviation or
concession; No containment plan.
4. Partial or fully implemented process;
Released deviation or concession;
Containment plan implemented.
5. Fully implemented process; No
deviation or concession required
5. Fully implemented process; No deviation
or concession required.
The score achieved on the Launch
Readiness Audit. Enter data as a
decimal number.
The minimum goal for full release for
production is 90%. Goal is 100% and
entered as "1".
The number of approved sub-component
and material PPAPs at the time of the
report.
The number of approved sub-component
and materials making up the shipped
component/material.
The number of elements (or documents)
completed for the PPAP package at the
time of the review.
The total number of required elements, or
documents, required to be submitted.
A comprehesive audit tool's score, which
assesses a process's state of preparation
to meet serial production requirements.
Form No.: D_020_4_09
PPAP Package
Completion
Number of PPAP submission package
elements completed compared to
required number.
Launch Readiness Audit
This metric assesses the level of
implementation of the full production
intent process. Processes that are not
fully implemented at the Start-of-
Production require a deviation, or
concession, to allow shipment. This
document needs to clearly define the
state of the process implementation,
provide a time line for completing the
implementation, list any non-conformities
to the drawing and/or specifications, and
a containment plan to keep those non-
conformances from reaching TRW.
Process Implementation -
% Completed
Sub-Component PPAP
Approvals
Number PPAPs approved for the
purchased sub-components and
materials that makes up the final shipped
component/material, and that do not have
any deviations, waivers, and/or
concessions granted by any tier below
TRW.
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 10 of 28
Key Metrics Definitions Process Owner/Department:
R. Sparisou / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
APQP: Key Supplier Metrics Operational Definitions
This section defines the Key Supplier Metrics that will be tracked throughout the five APAP Phases. Reviews will be held toward the end of each of the five
phases. Review of these metrics, in the Phase 5, will take place before the final full PPAP appro
Goal Results
APQP Readiness
Definition Metric
Data is derived from the 'APQP Progress
Report'. This metric tracks the
percentage of GREEN elements
compared to the total number of
elements being tracked.
Enter the number corresponding to the
completed stage from the list below.
1. Has not received any production
releases from using plant(s).
2. Is receiving production releases from
the using plant(s), but no production
schedule or plan documented to meet
those volumes or has ramp plan, is
receiving plant releases, but is not
shipping to plan and/or releases .
3. Has not received production releases
from plant(s), but has created a
preliminary planned based on quoted
volumes and program timing.
4. Is receiving production releases and
has created a plan, but production
schedule does not reflect the plan.
5. Is receiving production releases, has
created a ramp plan and this plan is
reflected in the production schedule.
Enter the goal, Level 5-Is receiving
production releases, has created a ramp
plan and this plan is reflected in the
production schedule.
Enter number of completed stage at time
of review.
Enter the number '5' representing the
completion of the PCM, less the exit from
the Safe Launch Plan. This applies to
situations where the PPAP will be
submitted in a span of time from before
SOP to 30 days after SOP.
Enter the number '6' for situations where
the SLP exit is required for closing APQP.
This element provides status of the
completion of the safe launch plan, on
the PCM (D_020_4_20).
Supplier Ramp Plan
GSQM 220 Deployment
This element evaluates a supplier's ability
to meet ramp-up timing and volumes.
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 11 of 28
Key Metrics Definitions Process Owner/Department:
R. Sparisou / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Supplier Name: Supplier Location: Supplier Code:
Part Number: Part Name: Revision Level:
Component Priority Level: Lead Customer/Program: Report Date:
PROGRAM MILESTONES
PHASE/ELEMENT STATUS OVERVIEW
2
0
4
0
6
0
8
0
1
0
0
0-Jan-1900
Launch Readiness Audit
Tooling
Capital equipment
Training
Process instructions
Supplier APQP: Progress Report - Status Overview
0
0 0
1.4 Component Design Review
5.5
4.7
5.1
5.2
5.3
5.4
3.3
3.4
3.5
3.8
4.1
4.2
3.7
3.6
2.3
2.4
2.5
2.6
3.1
3.2
Run at Rate
OK to Launch Sign-Off
1.1
1.2
1.3
1.5
1.6
1.7
2.1
2.2
Safe Launch Plan finalized
Plant Readiness Review
Key Supplier Metrics reviewed
PPAP
Supplier Ramp Plan
Launch Readiness Audit
PFMEA
Control Plan
Key Supplier Metrics reviewed
Measurement/ Testing equipment
Key Supplier Metrics reviewed
ELV/IMDS
5
Design FMEA
Preliminary Capacity Study
Key Supplier Metrics initiated
Supplier Project timing plan
Open Issues Action Plan created
0
0
0
0
0
4
Date Date
Subcontractor PPAP approval
Committed
Event Event
Design Freeze
Needed Committed Completed
2
3
Needed
First Off-Tool
First Off-Process
TRW PV Build
1
Completed
PPAP submission
Start of Production
Manufacturing Feasibility reviewed
Issues / Recovery Plan / Actions
Date Percent
Needed Committed Complete
APQP
Phase
S
t
a
t
u
s
Element
Process flow chart
Product Characteristic Matrix
Key Supplier Metrics reviewed
Packaging
Launch Readiness Audit
4.6 Appearance Approval Process
4.4
4.3
4.5
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_05
Page 12 of 28
Progress Report Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
CLICK HERE
CLICK HERE
CLICK HERE
CLICK HERE
Supplier APQP: Other Tools
PPAP CHECKLIST
COMPONENT DESIGN REVIEW
PRODUCT CHARACTERISTICS
MATRIX
LAUNCH READINESS AUDIT
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 13 of 28
Other APQP Tools Process Owner/Department:
R. Sparisou / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Supplier: Part Number: Date: Revision:
Supplier APQP: Supply Chain Map
Tier V Tier IV Tier III
TRW receiving
Operation
0 0
OEM
Customer
Tier Tier II
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 14 of 28
Supply Chain Map - Form Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
TRW Alfdorf
Alfdorf, Germany
OEM Z910
TRW Mesa
Mesa, AZ
OEM Z910
Saf-Store
Mesa, AZ
Warehouse Services
3rd Party
Warehouse
Supplier APQP: Supply Chain Map - Example
CUSTOMER
TIER 1 SUPPLIER
Zephyr Coatings
Austin, TX
E-Coat
Dynamic Chemical
Supplies
Tulsa, OK
Coating materials,
solvents
White & Jones
Jackson, MI
C1038 Rod
Wire Draw, Anneal
Fine Fasteners, Inc.
Benton Harbor, MI
M8x20 Weld Stud
59039813A
Cold Forming
B&C Processing
Georgetown, PA
C1024 Rod
Wire Draw, Anneal
ABC Nut Co.
Summit, NJ
M8x15 Staking Nut
59039812C
Cold Forming
AAA Heat Treat
Frederick, MD
Harden & Draw
Kojak Heat Treat
Benton Harbor, MI
Harden & Draw
Pacific Steel
Los Angeles, CA
C1024 Rod
Steel Mill
Precision Forming
Amarrillo, TX
Airbag Reaction Can
49019804A
Stamping body, end
caps, brackets
TIER 4
SUPPLIER
TIER 2
SUPPLIER
TIER 3
SUPPLIER
Anaconda Steel
Erie, PA
C1038 Rod
Steel Mill
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 15 of 28
Supplier Chain Map - Example Process Owner:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Part Name: Supplier Name: PCM Revision Date:
Part Number/ Revision: Location:
Project/ Program: TRW Using Plant(s):
Product Characteristic
Level/
Class
DFMEA
Severity
PFMEA
Severity
PFMEA
Occurance
PFMEA
Detection
RPN Control Method(s) Gauge R&R Control Method
Supplier APQP: Product Characteristic Matrix
#
Product Design Inputs
Sample Size / Frequency Sample Size / Frequency
Safe Launch Plan (SLP) Supplier Process Control Information
Date: 29 April 2008
Revision: B
Doc No: D.020.4.20
Page 16 of 28
D_020_4_20-PCM Process Owner/Department:
R. Blanchette / Supplier Development
Approved by:
/ VP Purchasing
Part Name: Supplier Name: PCM Revision Date:
Part Number/ Revision: Location:
Project/ Program: TRW Using Plant(s):
Product Characteristic
Level/
Class
DFMEA
Severity
PFMEA
Severity
PFMEA
Occurance
PFMEA
Detection
RPN Control Method(s) Gauge R&R Control Method
Supplier APQP: Product Characteristic Matrix
#
Product Design Inputs
Sample Size / Frequency Sample Size / Frequency
Safe Launch Plan (SLP) Supplier Process Control Information
Safe Launch Plan duration is for 90 days after start of production unless otherwise specified. Other:
SLP data must be sent to TRW (check one):
Safe Launch Plan must remain in effect until TRW approves SLP exit.
Date
TRWA SDE
TRWA Plant SQA
Supplier Representative
All production material sent to TRW during the SLP time period must be subjected to the agreed Safe Launch Plan. This includes material produced
during PPAP.
Signature Comments Position/ Title Name
PCM APPROVALS
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
Weekly Monthly Each Shipment Other Daily
Date: 29 April 2008
Revision: B
Doc No: D.020.4.20
Page 17 of 28
D_020_4_20-PCM Process Owner/Department:
R. Blanchette / Supplier Development
Approved by:
/ VP Purchasing
Supplier APQP: Safe Launch Plan Data and Exit Approval
Part Name: Supplier Name: PCM Revision Date:
Part Number/ Revision: Location:
Project/ Program: TRW Using Plant(s):
Date: Date: Date:
Product Characteristic
Level/
Class
Control Method
Quantity
Inspected
Quantity
Rejected
Ppk
Quantity
Inspected
Quantity
Rejected
Ppk
Quantity
Inspected
Quantity
Rejected
#
Product Design Inputs Safe Launch Plan (SLP)
Cpk from
PPAP
Sample Size / Frequency
Date: 25 Apr 2008
Revision: B
Doc No: D.020.4.20
Page 18 of 28
D_020_4_20-SLP
Process Owner/Department:
R. Blanchette / Supplier Development
Approved by:
/ VP Purchasing
Safe Launch Plan duration is for 90 days after start of production unless otherwise specified. Other:
Date
Supplier Representative
TRWA Plant SQA
Submit data to the TRW Plant per the agreed frequency on the Product Characteristic Matrix unless instructed otherwise by TRW.
To exit SLP: Sign and submit this form with all data. Acceptablilty of SLP exit request will be determined by TRW SQA.
Enter accumulated production data where specified in this form. Use of the SLP Weekly QOS Form will be directed by TRW as necessary.
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
Comments Name Position/ Title
SAFE LAUNCH PLAN EXIT APPROVALS
Signature
Date: 25 Apr 2008
Revision: B
Doc No: D.020.4.20
Page 19 of 28
D_020_4_20-SLP
Process Owner/Department:
R. Blanchette / Supplier Development
Approved by:
/ VP Purchasing
Ppk
Date: 25 Apr 2008
Revision: B
Doc No: D.020.4.20
Page 20 of 28
D_020_4_20-SLP
Process Owner/Department:
R. Blanchette / Supplier Development
Approved by:
/ VP Purchasing
Submit data to the TRW Plant per the agreed frequency on the Product Characteristic Matrix unless instructed otherwise by TRW.
To exit SLP: Sign and submit this form with all data. Acceptablilty of SLP exit request will be determined by TRW SQA.
Enter accumulated production data where specified in this form. Use of the SLP Weekly QOS Form will be directed by TRW as necessary.
Comments
SAFE LAUNCH PLAN EXIT APPROVALS
Date: 25 Apr 2008
Revision: B
Doc No: D.020.4.20
Page 21 of 28
D_020_4_20-SLP
Process Owner/Department:
R. Blanchette / Supplier Development
Approved by:
/ VP Purchasing
Total WEEK
0 Incidents
0 QTY
#DIV/0! PPM #DIV/0! #DIV/0! #DIV/0! #VALUE! #VALUE! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Fault
No.
Failure Mode Total Action Timing W14 W15 W16 W17 W18 W19 W20 W21 W22 W23 W24 W25 W26 W27 W28 W29
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Safe Launch Plan: QOS Report
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
I
n
c
i
d
e
n
t

Pareto Failures By Process
0
0
0
0
0
1
1
1
1
1
1
0
0
0
1
1
1
1
P
P
M

I
n
c
i
d
e
n
t

Touch Point Incident & PPM Monitoring
Incidents PPM
Date: 01 Aug 2005
Revision: C
Doc No: D_020_4_05
Page 22 of 28
D_020_4_20-SLP - QOS Process Owner/Department:
K. Gillis / Supplier Development
Approved by:
E. Carpenter / VP Purchasing
Part Name: Supplier Name: PCM Revision Date:
Part Number/ Revision: Location:
Project/ Program: TRW Using Plant(s):
Product Characteristic
Level/
Class
DFMEA
Severity
PFMEA
Severity
PFMEA
Occurance
PFMEA
Detection
RPN Control Method(s) Gauge R&R Control Method
Safe Launch Plan (SLP) Supplier Process Control Information
Sample Size / Frequency
Supplier APQP: Product Characteristic Matrix
#
Product Design Inputs
Sample Size / Frequency
Date: 29 April 2008
Revision: B
Doc No: D.020.4.20
Page 23 of 28
D_020_4_20-PCM Sub-Supplier Process Owner/Department:
R. Blanchette / Supplier Development
Approved by:
/ VP Purchasing
Part Name: Supplier Name: PCM Revision Date:
Part Number/ Revision: Location:
Project/ Program: TRW Using Plant(s):
Product Characteristic
Level/
Class
DFMEA
Severity
PFMEA
Severity
PFMEA
Occurance
PFMEA
Detection
RPN Control Method(s) Gauge R&R Control Method
Safe Launch Plan (SLP) Supplier Process Control Information
Sample Size / Frequency
Supplier APQP: Product Characteristic Matrix
#
Product Design Inputs
Sample Size / Frequency
Safe Launch Plan duration is for 90 days after start of production unless otherwise specified. Other:
SLP data must be sent to TRW (check one):
Safe Launch Plan must remain in effect until TRW approves SLP exit.
Date
TRWA SDE
TRWA Plant SQA
Supplier Representative
Signature Comments Position/ Title Name
SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.
PCM APPROVALS
All production material sent to TRW during the SLP time period must be subjected to the agreed Safe Launch Plan. This includes material produced
during PPAP.
Weekly Monthly Each Shipment Other Daily
Date: 29 April 2008
Revision: B
Doc No: D.020.4.20
Page 24 of 28
D_020_4_20-PCM Sub-Supplier Process Owner/Department:
R. Blanchette / Supplier Development
Approved by:
/ VP Purchasing
P
a
r
t

D
e
s
c
r
i
p
t
i
o
n
Operator Name:___________ Work Cell:_________
Quantity Inspected:____________Date:______________
Verification
Method
P
a
s
s
F
a
i
l
1
2
3
4
5
6
7
8
9
10
COMMENTS :
100% IN CELL KEY FEATURES VERIFICATION
AND CUSTOMER TOUCH POINTS
P
a
r
t

N
u
m
b
e
r
Supervisor Signature : Date :
T
h
e

I
t
e
m
s


Q
u
a
l
i
f
i
e
d

A
r
e

T
o

B
e

M
a
r
k
e
d

W
i
t
h

"
Y
E
L
L
O
W
"

P
a
i
n
t
.
FEATURES TO BE QUALIFIED
Date: 16 Jan 2008
Revision: D
Doc No: D_020_4_03
Page 25 of 28
In Cell Check Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Special Work Instruction
Customer /Project:
OPERATION OP25 SAFE LAUNCH PRODUCTION
P
a
r
t

D
e
s
c
r
i
p
t
i
o
n
B
r
a
k
e

A
s
s
y

L
H
B
r
a
k
e

A
s
s
y

R
H
Operator Name:___________ Work Cell:_________
Quantity Inspected:____________Date:______________
Verification
Method
P
a
s
s
F
a
i
l
1 * * Lining identification code Visual
2 * * Mass weight and rivet presence Visual
3 * * Date code on shoe Visual
4 * * PKB rivet crimped washer Visual
5
* *
Pkb lever hook Gap Gauge
6
* *
Wheel cylinder screw torque
Air Torque
/mark
FEATURES TO BE QUALIFIED
COMMENTS :
1
4
5
4
4
0
0
1
Safe Launch Plan: In Cell Check Example
P
a
r
t

N
u
m
b
e
r
TRW
Automotive
Supervisor Signature : Date :
T
h
e

I
t
e
m
s


Q
u
a
l
i
f
i
e
d

A
r
e

T
o

B
e

M
a
r
k
e
d

W
i
t
h

"
Y
E
L
L
O
W
"

1
4
5
4
4
0
0
2
Save lunch checking item Station15
Part No. issue Station Document No. Rev Issue date
Sheet 1/1
Part/ Process Description :
145-44001
/145-44002
ADVICS / IMV 0
2
3
1
5
4
6
15
23 April'04
Example
Date: 16 Jan 2008
Revision: D
Doc No: D_020_4_03
Page 26 of 28
In Cell (Example) Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Supplier Name: Component Manufacturing Location: Supplier Code:
TRW Part Numbe(s): Issued by:
Customer Name: Customer Platform: TRW Product: Status:
Action
Closed
Supplier APQP: Open Issues - Corrective Action Plan
Item
Number
0 0
Source
Ref
Number
Source of Issue Responsibility Status
Dates
Date scheduled Date actual
Due Opened
Concern / Problem / Open Issue
Description
0
Launch Activity Date Launch Activity Date Launch Activity Date
Date scheduled Date actual
Distribution:
Action plan review Action plan review
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 27 of 28
Open Issues Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE
Part Number
Report Date / Revision
Function Function
Name Name
Dept. Dept.
Tel. Tel.
Fax. Fax.
E-mail E-mail
Adress/
Location
Adress/
Location
Name Name
Dept. Dept.
Tel. Tel.
Fax. Fax.
E-mail E-mail
Adress/
Location
Adress/
Location
Name Name
Dept. Dept.
Tel. Tel.
Fax. Fax.
E-mail E-mail
Adress/
Location
Adress/
Location
Name Name
Dept. Dept.
Tel. Tel.
Fax. Fax.
E-mail E-mail
Adress/
Location
Adress/
Location
Name Name
Dept. Dept.
Tel. Tel.
Fax. Fax.
E-mail E-mail
Adress/
Location
Adress/
Location
Name Name
Dept. Dept.
Tel. Tel.
Fax. Fax.
E-mail E-mail
Adress/
Location
Adress/
Location
Name Name
Dept. Dept.
Tel. Tel.
Fax. Fax.
E-mail E-mail
Adress/
Location
Adress/
Location
TRW APQP: Contacts- APQP TEAM
TRW Supplier
Development
Engineering
TRW Engineering
TRW Purchasing
Product Line Mgr
Contact Information
TRW Purchasing
Commodity Mgr
TRW Receiving Plant
Logisitic &
Packaging
TRW Receiving Plant
Quality
Project management
Contact Information
Supplier
Date: 16 Jan 2008
Revision: D
Doc No.: D_020_4_03
Page 28 of 28
Contacts Process Owner/Department:
R. Spariosu / Supplier Development
Approved by:
R. Blanchette / Global Director, SDE