Doc. No.

:
Rev. No. : 01
Procedure For Advanced Product Issue Date : 01.01.2017
Quality Planning Rev Date 01.11.2017
Page 1 of 7

1. PROCESS OBJECTIVE: To define the steps needed for meeting quality requirements of the product, to
establish communication channel with everyone involved and to ensure that the process meets product quality
requirements.

2. PROCESS SCOPE: This process includes-

a. Absolutely New component: No experience of production so far.

b. Component similar to component produced so far or parts differ material grade and other chemical properties.
c. Whenever there happen to be minor deviation in the component produced so far and change like Process , Layout
, Plant shift etc
d. Whenever happen to be extremely minor changes in details related to component like ECN , dimensional
change , Process Tooling change etc.

3. PROCESS OWNER: Head Engineering supported with CFT

4. SUPPORT FUNCTION: Production, Quality, Purchase, Marketing

5. PROCESS DISCRIPTION :

SN. Description Source Document reference

1 New project register Marketing Register

2 Customer Drawing / Specification Marketing -

3 New Product Development Team CFT CFT Format

4 Contract Review Marketing Contract Review Check List

5 Team Feasibility Commitment CFT Team Feasibility Commitment
Phase A (Planning & Feasibility)

6 Product Costing Engineering Cost Estimation Sheet

7 Product Realization Time Plan CFT APQP Time Plan
8 Process Flow chart (Prototype) Engineering Process Flow Diagram
9 Control Plan (Prototype) Engineering Control Plan
Identification Of Special Identification of Special
10 Engineering
Characteristics Characteristics
List Of Equipment Tooling and
11 List of new equipment and tooling Production
Facilities
12 Bill Of Material (BOM) Purchase Bill of Material

13 List of Testing Equipment& Gauges Quality List of Testing Equipment& Gauges

14 Review Meet CFT APQP Review Meeting

SN. Description Source Document reference

 Doc. No. :
Rev. No. : 01
Procedure For Advanced Product Issue Date : 01.01.2017
Quality Planning Rev Date 01.11.2017
Page 2 of 7

Internal Product Drawing / - Document / Drawing Distribution

15 Engineering
Specification Release Record In-house Drawing

Product/Process Quality System

16 Existing quality system review CFT
review

17 Sourcing raw material Purchase Sourcing of raw material/job work

18 Micro Timing Plan (Tooling) CFT Micro Level Time Plan

19 Process Flow chart (Pre launch) Engineering Process Flow chart

Phase B (Process design & development)

20 Control Plan (Pre launch) Engineering Control Plan

21 PFMEA (Pre launch) Engineering Process FMEA

22 SPC Plan Quality SPC Plan

23 MSA Plan Quality MSA Plan

24 Packing Standard & Specification Engineering Packing Standard Sheet

25 Work Instruction Engineering Work Instruction

26 Product Trial Run Production

27 Sample Submission Report Quality Sample Inspection Report

28 Part Submission Warrant Engineering PSW (Part Submission Warrant)

Customer Feed Back Report

29 Marketing Customer Approval
(Approval)

30 Review Meet CFT APQP Review Meeting

SN Description Source Document reference

31 Pilot Lot Production Production -

Phas
 Doc. No. :
Rev. No. : 01
Procedure For Advanced Product Issue Date : 01.01.2017
Quality Planning Rev Date 01.11.2017
Page 3 of 7

32 SPC Study Quality SPC Report

33 MSA Study Quality MSA Report

e C (Product & Process Validation)

34 PPAP Final (As per list) Engineering PPAP Requirement Check Sheet

35 Layout inspection Production -

36 Operation Standard Engineering Operation Standard

37 Final Inspection Standard Engineering Final inspection standard

38 Sample Test report Quality -

39 Review Meet CFT APQP Review Meeting

40 SOP at Customer End Marketing -

41 APQP Summary & Sign Off CFT APQP Summery Sign Off

6. PROCESS FLOW:

STEP FROM ACTIVITY TO RESP. REF. DOC.

NO.
Formation of CFT
7.1 -
Formed an APQP-CFT with a Team Leader considering
following:
 Production Head
 Engineering Concerned
7.1.1 - Engineeri
 Quality Person
ng
 Marketing/ Purchase etc as appropriate

7.2 Feasibility Commitment - -

Receive Product sample and/ or drawing along with
7.2.1 Customer other specification (if any) from Customer & transfer it. CFT MKT.

Review the Customer Product input information and

7.2.2 - decide and take appropriate action - CFT
On the basis of design information review make
7.2.3 - feasibility commitment Mkt. CFT
If the Product is found feasible, prepare cost estimate
7.2.4 - and send one copy along with feasibility commitment Head Mkt. CFT
 Doc. No. :
Rev. No. : 01
Procedure For Advanced Product Issue Date : 01.01.2017
Quality Planning Rev Date 01.11.2017
Page 4 of 7

Initiate further Action as per Contract Review and get

Purchase Commitment and Inform along with
 Need for Sample / Pilot Lot
7.2.5 -  Quantity of sample / Pilot Lot CFT Mkt.
 Need for PPAP / Submission Level etc.

7.3 Preparation of APQP Time Plan - -

Initiate APQP Check List cum time Chart and Identified
the need for the following activities as appropriate:
 Sample / Prototype Development
 Process Design and Development Concerned
7.3.1 - CFT
 Process /Product Validation Person
 Feedback / Assessment /Corrective Action

7.4 Sample Development - -

Identify the need for following, as appropriate and make
Time Plan:
 Product Drawing
 Any Specific Customer Input
 Customer Return/Warranty /Rejection etc.
 Bill of Material
 List of special characteristics
 New Tooling/ equipment /measuring instrument Concerned
7.4.1 -  Prototype Control Plan CFT
Person
 Target date for Sample Development and
Submission
 Management Support / Feedback / corrective Action

Progress of development must be reviewed & recorded

at defined interval (short duration -Weekly, long
duration - monthly).
7.4.2 - - CFT
This must include the top management
recommendations.

Develop the Sample & Check it as per Drawing /

7.4.3 - Control Plan and hand it over to Marketing along with Customer CFT
report for submitting
Submit Sample (along with report), Follow up and get
7.4.4 - the Feedback/ Report from customer and transfer to Customer CFT -
production & quality
Provide identification during material movement (IPP Process
7.4.5 - Tag) Next Process -
Owner
Review the Report/ Feedback and initiate action i.e. - CFT
7.4.6 - going to next phase or any Corrective Action etc. -

7.4.7 - For fast removal of defect prepare history record of the QA & Prod CFT -
 Doc. No. :
Rev. No. : 01
Procedure For Advanced Product Issue Date : 01.01.2017
Quality Planning Rev Date 01.11.2017
Page 5 of 7

defect occurred during development from in house and

at customer end observation and take appropriate action
to eliminate the same in future.
7.5 - Process Design and Development - - -
Identify the need for the following as appropriate and
incorporate in Time-Plan:
 Product Drawing
 Specific Customer Input
 Customer Return / Warranty Rejection
 Bill of Material
 Process Bench Mark
 List of Special characteristics
 New Tool/ Equipment/ Measuring Instrument
 Product/ Process/ Quality System Review
 Development/ Review of Floor Plan Layout
 Micro Time Plan (Tooling) Concerned
7.5.1 -  Process Flow Diagram/ Chart CFT -
Person
 Process FMEA
 Pre Lunch Control Plan
 Work Instruction
 MSA Reports
 Preliminary Capability Study
 Packing Standard/ Specification
 Management Support / Feedback / Corrective
Action etc.

Progress of development must be reviewed & recorded

at defined interval (short duration -Weekly, long
7.5.2 - duration - monthly). - CFT -
This must include the top management
recommendations.
7.6 - Product and Process Validation - -
 Do Planning for Pilot Lot Production and record
 Carry out Production as per Plan/ Control as per
Prod.
Control Plan and generate Necessary Data
 Provide on the job training
 Carry out MSA/ Capabilities study
 Check Product as per Control Plan and prepare the
QA
report.
 Collect PPAP related Documents
7.6.1 - CFT -
 Submit Sample along with reports/ PPAP Customer
Documents
 Follow with Customer, get Feedback/ Report
 Development phase will be open till the start of
production at customer end.
 Review the Report and if Satisfactory, Prepare Final
CFT
Production Control Plan, APQP Summary and Sign
off
 Doc. No. :
Rev. No. : 01
Procedure For Advanced Product Issue Date : 01.01.2017
Quality Planning Rev Date 01.11.2017
Page 6 of 7

If any Corrective Action is required, identify the actions,

7.6.2 - make action plan and Implement it. - CFT -

7. PROCESS MONITORING:

Step Monitoring Criteria Responsibility REF. DOC.

(IF ANY)
Phase-A Ensure need for all inputs are identified and provided before
feasibility review CFT leader

Feasibility commitment to be signed by CFT

- Special characteristics must be finalized by CFT CFT
Time plan must include all steps (e.g. process, documents,
- verification, validation, monitoring, inspection test etc) CFT
Progress of development must be reviewed & recorded at defined
- interval (short duration -Weekly, long duration - monthly). CFT
This must include the top management recommendations.
Process control documents (e.g. control plan, drawing , FMEA etc.)
must include/refer to
 Customer Technical Specification ,
Phase B  Customer Designated special characteristics symbol or -
equivalent.

Acceptance criteria for attribute data sampling must be zero

- CFT
defects.
FMEA & CP must be developed by CFT at the place of
- manufacturing CFT

Progress of development must be reviewed & recorded at defined

interval (short duration -Weekly ,long duration - monthly).
- This must include the top management recommendations. CFT

Quantity of sample pieces & pilot lot must be produced at least as

Phase C desired by customer. CFT
Progress of development must be reviewed & recorded at defined
- interval (short duration -Weekly, long duration - monthly). CFT
This must include the top management recommendations.

8. PROCESS PERFORMANCE (EFFECTIVENESS, EFFICIENCY) INDICATOR (DATA):

PERFORMANCE INDICATOR ANALYSIS REF. DOC.

FREQUENCY RESPONSIBILITY (IF ANY)
Planned Completion Time vs. Actual Completion Every Project CFT -
No. of resubmission for Final Approval Every Project CFT -
Average Product Development Time Every Project CFT -

9. RESOURCE REQUIREMENT:
 Doc. No. :
Rev. No. : 01
Procedure For Advanced Product Issue Date : 01.01.2017
Quality Planning Rev Date 01.11.2017
Page 7 of 7

HUMAN RESOURCE/ COMPETENCE INFRA WORK REF. IF

STRUCTURE ENVIRONMENT ANY
Competent person on APQP tools & technique, bench Computer with
marking, capability study, MSA, SPC supported software - -

10. RECORDS:
Refer to List of Formats

No. Rev. Revision Detail Rev. Date Revised By

No.
1 01

Prepared by- Approved by-

Date: Date: Controlled Copy Stamp
-