2007 apqp program mgmt classroom

7/25/2019 2007 APQP Program Mgmt Classroom

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Supplier APQP Overview

The Global Leader in

Automotive Safety Systems

2005TRWA

utomotive

TRWs High Performance Brake Calier!

And the life it helps protect.2005TRWA

utomotive

TRWs "lectricall# Po$ere% &teering an% "lectronic

&ta'ilit# Control stem $ork together to hel kee

vehicles on the roa%! And these lives safe!

TRWs Air'ag "lectronic Control (nit!

And the life it helps protect.

2005TRWAutomotive

TRWs &i%e )mact Rollover Protection stem!

And the lives it helps protect.

2005TRWAutomotive


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TRW Automotive Inc. 20042A ril19.2004

TRW Automotive Inc. 2006

2 01.09.2006

What is the goal of this module?What do we want toachieve?

To provide an understanding of what the SupplierDevelopment Teams responsibilities are, in terms

of the APQP process.

To provide an understanding of the roles andresponsibilities between the cross function

departments engineering, purchasing, program

management, operations!.

To provide an understanding of the importance of allcross functions working together to achieve a

flawless launch.



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3 01.09.2006

"usiness Polic# $anual "P$!

Supports goal of onecompan#, one process,

one standard.

%epositor# for both

automotive and product

line processes.

D& Suppl# $anagement

contains supplier APQP

documents.

Click on the picture to find out.

What is the BPM?


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4 01.09.2006

"usiness Polic# $anual "P$!

http://oeforums.shrluk.trw.com/bem/dispatch

.exe/bpm_docs

Click picture for links

Where can I find the BPM?

A link can be foundon the TRWAutomotive

homepage or anyother product line

website.

Or you cn type t!e "R# into your $ro%&er''re&& %in'o%(
http://oeforums.shrluk.trw.com/bem/dispatch.exe/bpm_docshttp://oeforums.shrluk.trw.com/bem/dispatch.exe/bpm_docshttp://oeforums.shrluk.trw.com/bem/dispatch.exe/bpm_docshttp://oeforums.shrluk.trw.com/bem/dispatch.exe/bpm_docs


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) 01.09.2006

'DP($

I& it t!e *lo$l +evelopment, -ro'uct Intro'uctionn/ement

What is GDPIM?

Is it the Global DesignProcess for Integration &

Management?

Click picture tostart

No, Try Again

ClickHere

ClickHere

or

Congratulations!

That is correct.


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6 01.09.2006

Checklists, phasedefinitions,priority

assessments.

Used forcustomer

specific product

launches.

Pre-definedstages with exitreviews assure

containment ofissues.

'DP($ Consists of ProgramManager, Engineering,

Operations, Qualityand Purchasing.

Cross

FunctionalTeam

PhasedApproach

Core EngrgModule

ApplicationEngrgModule

DefinedTools &

Techniques

GDPIM

Applies to development

of new products.

CLICK HERECLICK HERE

CLICK HERE CLICK HERE

CLICK HERE


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01.09.2006

'DP($

'DP($ is found in

the "usinessPolic# $anual,

Section A.

Where can I find the GDPIM procedure and relateddocuments?

Click on the compass tofind out.


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01.09.2006

'SQ$

The 'SQ$ is T%)s 'lobal SupplierQualit# $anual.

This manual documents T%)se*pectations and re+uirements from

its direct material suppl# base.

The scope of the manual includes allsuppliers who directl# affect the

+ualit# of production materials.

(t does not include& $%O (nternal suppliers

What is the GSQM?

Click on picture for answer


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9 01.09.2006

'SQ$The 'SQ$ is divided into sections&

Supplier QualificationRequirements

APQP and PPAPprocesses

Serial Production

requirements

Continuous Improvement

Links to allreferenced formsand procedures.

Definition of theapplication of thedocument.

Responsibilities andformats.

Governmental and

Environmentalregulationcompliance. Introduction Documents

Table

Automotive

Requirements


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10 01.09.2006

'SQ$W!ere i& t!e * #octe'(

Click on picture for locations

Internally it can be found athttp://vinet.livmi.trw.com/on

the Intranet, or

It can also be found at TRWAutomotive(http://www.TRWAuto.com)
http://vinet.livmi.trw.com/http://vinet.livmi.trw.com/


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11 01.09.2006

)hat is APQP-

5Alterntive -ro'uct uliiction -roce&&7 %!ic! i& &y&temticpproc!8 %!ic! re&ult& in component& pprove' --A-8 %!en t!e'r%in/ i& rele&e' lte.

5Acci'entl -ro'uction o ulity -rt&7 &upplier p!ilo&op!iclpproc! re&ultin/ in unplnne' conormnce to t!e 'r%in/.

5A'vnce' -ro'uct ulity -lnnin/7 &y&temtic pproc!8 %!ic!re&ult& in pln or controllin/ mnucturin/ proce&& n'or pro'uct inor'er to meet t!e cu&tomer& re:uirement&.

Is it???


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12 01.09.2006

OOPS! A good guess,but not the correct

answer. Click heretotry again.

)hat is APQP-


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13 01.09.2006

)hat is APQP-

(t can also be usedfor drawingchanges, supplierprocess changes

and tool moves.

Click on each sign if more information

Starts in DesignValidation phaseof GDPIM.

Finishes with

full approval,or release ofPPAP.


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14 01.09.2006

/e# 0lements of APQP

A met!o' o i'entiyin/ t!o&e componenteture& t!t ect it8 orm8 unction8&&em$ly n' mnuctur$ility.

pecial

Characteristics

Manufacturing

Feasibility

Failure modes

effects

analysis

Control plan

T!e $ility to mnucture t!e component8in &uicient :untitie& n' %it! ccept$le

:ulity8 to t!e cu&tomer;& re:uirement&.

A study of what can go wrong in amanufacturing process and what controlswill be use to reduce the risks.

The listing of controls used, based onthe FMEA, detailing characteristics,methods, frequencies, and reaction to

process non-conformances.

Click on term to see definition.


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1) 01.09.2006

1ow that #ou are prepared, lets start our overview2


)hat is the primar# form of communication in and out of T%)-

clic3 on what #ou thin3 is the correct answer!

PROPOSAL

WRONG. TRY AGAIN!The drawing is correct. It represents

the ocal point or all reiews, actiitiesand actions.


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16 01.09.2006

4ets ta3e #ou through a scenario as an e*ample22



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1 01.09.2006

APQP Scenario

I you %ere t


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1 01.09.2006

APQP Scenario

?e@t8 you %oul' nee' mp n''etermine %!ic! route you %oul'$e t


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19 01.09.2006

APQP Scenario

I 'rivin/8 you %ill nee' to/et t!e cr re'y or t!e trip.

Are ne% tire& nee'e'

W!en 'i' you l&t /et noil c!n/e

TuneDup

+on;t or/et t!e !ou&eE top t!e mil 'elivery .

T!e ne%&pper.

Click on picture


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20 01.09.2006

APQP ScenarioHow does this relate to a TRW launch?

(click on arrow for relationship)

Length of Vacation Launch Window

Road map Product drawing


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21 01.09.2006

APQP Scenario

Places we must see

Special (designated)Characteristics

(Click on arrows)

Process FlowDiagramTravel itinerary


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22 01.09.2006

APQP Scenario

Thisand

not thisDesign FMEA

Not this,but this

Process FMEA

(click on arrows)


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23 01.09.2006

APQP Scenario(click on arrow)

Control Plan

Packing, shopping,things to do lists,

agendas,itineraries, etc.


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2) 01.09.2006

Leads theteam;

responsiblefor quality oflaunch.

Supplier 5omponent APQP Process

THE KEY PLAYERS ARE:

Program

Manager

Engineer

Operations

CommodityManager

Supplier

SupplierDevelopment

Engineer

LaunchCoordinator,Logistics andManufacturingEngineeringparticipate.

Works with

supplier tovalidate

componentsmanufacturingprocess.

Responsible forproduct designand functionality.May include

both Core andApplications.

Responsiblefor supplierselection &commercial

relationship.

Responsible formanufacturingthe component tomeet the

drawingsrequirements.

(Click on picture for explanation)


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26 01.09.2006


The first step is the Component Priority Assessment (CPA)(click on picture)

What is it?

A process to identify which

component(s) and/orsupplier(s), involved in anygiven launch, require a focusedeffort from Kick-off toProduction by the SDE and/or a

cross-functional team.

Lead by:NPISupported by:Program ManagementEngineeringCommodity ManagementSDE/SQA

Operations

Who Attends?


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2 01.09.2006


Component Priority Assessment (CPA)(click on picture)

+eine& %!ic! proce&&e&8 in t!e +F tool$o@8 %!ic!re employe' $&e' on element &core&.

BENEFITS I'entiie& erly in pro/rm %!ic! component&8

e&pecilly in comple@ &&em$lie&8 re li


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2 01.09.2006



T%o &ection& one or Frly ourcin/ n' t!e ot!er orpro'uction.

corin/ i& 'ierent or Frly ourcin/.

Totl &core& re utomticlly clculte'8 %it! &ttu& or

cte/ory &!o%n.


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29 01.09.2006



FAR#> O"RCI?* AFF?T Fi/!t cte/orie&.

=ocu& i& on &upplier8 &c!e'ule n' component comple@ity.

Cn $e u&e' or core or ppliction proect&.


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30 01.09.2006



#A"?CB corin/8 $&e' on 'eine' criteri8 my $e )08 10 or 1.

Overlp o t%o cte/orie&.

Fc! prt cte/oriHe' & A8 G or C8 %!ic! 'eine& +F&

'e/ree o involvement.


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31 01.09.2006


Component Priority Assessment (CPA)(click here)

6.

.*

x

1.Select FirstPart Number

2.EvaluateAgainst EachRiskCategory

3.Form Automatically

Calculates Total Score

4.Select NextPart Number

THE PROCESS:


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32 01.09.2006


Component Priority Assessment (CPA)(click on picture) 5AT0'O%7 A 5O$PO101TS&

Bi/!e&t c!nce o lunc! i&&ue&.

Re:uire& totl &core o 200 or more.

!oul' $e e% in num$er $out 3D)J. T!e&e aret!e criticl e%.

Ge&t repre&ent& ne% tec!nolo/ie&8proce&&e& n'or &upplier&.

Re:uire& &&i/nment o upplierC!mpion $&e' on &&e&&mentcte/ory &corin/.

+oe& not inclu'e c!ronic i&&ue

&upplier&.


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33 01.09.2006



5AT0'O%7 " 5O$PO101TS&

o'erte c!nce o lunc!

i&&ue&. Totl &core i& rom 100 to 199.

!oul' $e e% in num$er $out10D1)J.

Ge&t repre&ent& c!ronic i&&ue&8tec!nolo/y evolution n'or poor:ulity perormnce.

"tiliHe& &electe' tool& $&e' on

&corin/.


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34 01.09.2006



5AT0'O%7 5 5O$PO101TS

#o% c!nce o lunc! i&&ue&.

Totl &core o le&& t!n 100. !oul' $e t!e mority o t!e

component&.

Ge&t repre&ent& current

tec!nolo/ie&8 proce&&e& n'ccept$le :ulity perormnce.

A-- con'ucte' $y &upplier--A- only &u$mi&&ion

re:uirement.


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3) 01.09.2006


Component Priority Assessment (CPA).

(click on picture)

DOCUMENTATION:

Work Instruction:

D_020_3_03Form

D_020_4_08 Assessment

Element Definitions Utilization Matrices

Location

Business Policy Manual

Section D


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36 01.09.2006


5 PHASES


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3 01.09.2006

Supplier 5omponent APQP Process& 8 Phases

PHASE 1: Supplier Kick-off and Planning

Applie& to ll Cte/ory A component&.

Applie& to Cte/ory G n' C component&$&e' on t!e +F;& c!oice.

Goals (click on picture to left) Communicte pro/rmcomponent

unctionlity.

F&t$li&! proect time line8 /ol& n'e@pecttion&.

I'entiy i&&ue& %it! t!e &upplier;&$ility to mnucture t!e component.

Scope (click on picture at right)


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3 01.09.2006


PHASE 1: Supplier Kick-off and Planning

Fn'& %it! completion o t!e Kic


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39 01.09.2006


PHASE 1: Supplier Kick-off and Planning INPUTS

Program Mgr

SDE

EngineerStarts long lead tooling early enough tomeet program timing; Process design ismore robust.

DELIVERABLE

EngineerIdentifies critical features andfunctionalities that can be incorporated intoprocess and tooling design.

IMPACTRESPONSIBILITY

Buyer

Communicates program needs anddeliverables to all participants.

Defines expectations andvalidation requirements.

Establishes capacity requirements

the suppliers process must meet.


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41 01.09.2006


PHASE 1: Supplier Kick-off and Planning OUTPUTS

Supplier

Supplier

SDEDocuments review of drawing, technicaland commercial issues.

DELIVERABLE

SupplierDisplays suppliers plan for meetingprogram deliverables.


Identifies all suppliers, regardless of sub-

tier level, who impact the final part.

Defines all special characteristics andpoint in process they are manufactured.


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43 01.09.2006

Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools-APQP Workbook

In the Business Policy Manual andthe GSQM.

D_020_4_003.xls

A collection of APQP forms thatwould be used regardless ofpriority ranking.

APQP Progress Report,SupplyChain Map,Key Metrics Report,Product Characteristics Matrixand

Open Issues Action Plan.


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44 01.09.2006

Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools-APQP Progress Report

Provides supplier timing andprogress on key APQP deliverables.

Periodic submission to SDE for allpriority A and B components.

Further detail, i.e., tool build timing,captured in supplier timeline.

Status of completion one of the KeyMetrics.


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4) 01.09.2006

Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools Supply Chain Map

Used to define deep and/or complex supply chains.

Identifies suppliers that affects quality of special characteristics.

Further defined in Product Characteristics Matrix (PCM).


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46 01.09.2006


PHASE 1: Supplier Development Tools Key Metrics Report

Focuses APQP on resultsrather than events.

Twelve key metrics allow

multiple updates todemonstrate current status andprogress over time.

Four primary indicators providea quick picture of the process.

Automatically generates agraph.

Operational definitionsprovided.


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4 01.09.2006


PHASE 1: Supplier Development Tools PCM

Ties DFMEA,Component PFMEA,Control Plan and Supply

Chain Map together.

Forms basis of SafeLaunch Plan (SLP) andis hand-off from SDE toOperations/SQA.

Engineeringparticipation essential tosuccess.

Initiated at Design

Review.


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4 01.09.2006

Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools Open Issues Action Plan

Combines all separatedaction plans into a singledocument.

Started at Kick-offmeeting.

Supplier is owner of thedocument.


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49 01.09.2006

Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools Design Review

Found in Business PolicyManual and GSQM.

Document No: D_020_4_04

Cross functional participationcritical for event success.

Includes detailed review of everydimension, note andspecification on.

Unresolved issues identified atthe Design Review often createlaunch and serial productionissues.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 1: Supplier Development Tools Launch Readiness Audit

Found in Business Policy Manualand GSQM.


Scored audit grades suppliersstate of preparation for start-of-production.

Is one of the Key Metrics.

Requires a score of 90%, or more,

to show readiness for launch.

Can be used at different pointsthroughout APQP to measureprogress.


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PHASE 2: Equipment and Tool Design



Goals (click on picture to left)

Re&olve i&&ue& i'entiie' in A-- 1.

Approve t!e &upplier;& 'e&i/n ortoolin/8 proce&& n'or /u/in/.



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PHASE 2: Equipment and Tool Design

Fn'& %it! t!e &upplier;& completion ot!eir toolin/8 e:uipment n'or /u/in/'e&i/n.

Ge/in& %it! completion o Kic


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PHASE 2: Equipment and Tool Design INPUTS

Engineer

This defines the process developmentneeded. Lack of special features andcorrect specifications will carry over intoproduction.

DELIVERABLE

EngineerIdentifies critical features andfunctionalities that can be incorporated intoprocess and tooling design.


Buyer Updated volumes assure tools ability tomeet product requirements.

SupplierCommunicates issues identified duringthe component design review andcaptures new issues as they arise.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 2: Equipment and Tool Design INPUTS

Supplier

Supplier Updated milestones for processdevelopment.

DELIVERABLE IMPACTRESPONSIBILITY

Supplier

Preliminary concepts refined based onresults of design review.

Preliminary concepts refined based onresults of design review.

Supplier Defines all special characteristics thatneed consideration in the tooling design.

SDEOpen manufacturability issues identified inprevious phase need resolution to properlycomplete tooling design.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 2: Equipment and Tool Design OUTPUTS

Supplier

DELIVERABLE

SupplierUpdated to include process build detailsand milestones. Process realizationprogress can be measured from this.


Supplier

Final designs released to suppliersvendors for build and/or procurement of

necessary manufacturing processelements.

Updated to reflect closure of completeditems and addition of new issues thathave been identified.

EngineerUpdated to reflect resolution of suppliersmanufacturability issues, latestinformation, improved design.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 2: Equipment and Tool Design OUTPUTS

Supplier Updated to reflect progress made since

Phase 2.



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PHASE 3: Product/Process Realization



Goals (click on picture to left) Guil' toolin/8 e:uipment n'or

/u/in/ nece&&ry to mnucturecomponent.

Re&olve i&&ue& i'entiie' in previou&p!&e&.



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PHASE 3: Product/Process Realization

Fn'& %it! t!e &upplier;& pprovl8 t t!eirven'or&; loction&8 to ccept t!e toolin/8e:uipment8 n'or /u/in/.

Ge/in& %it! completion o 'e&i/n&.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 3: Product/Process Realization INPUTS

EngineerUpdated drawings resulting fromcompleted tests and various buildscontinue to keep the supplier informed.


SupplierUpdated to reflect closure, or progress,on open issues and addition of any

newly identified problems.

SupplierFinal designs released to suppliersvendors for build and/or procurement ofnecessary manufacturing processelements.

SupplierContinuing definition of controls and, whenapplicable, expansion of detail to sub-tiersuppliers.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 3: Product/Process Realization INPUTS

Supplier

Supplier Continues to be updated to reflectprogress and/or timing related changes.


Suppliers Process FMEA contributesprocess knowledge, lessons learned,potential mistake proofing opportunitiesand other process controls to be used.

Supplier Document that defines all of the supplierscontrols starting with Receiving Inspectionand ending with the shipment to thecustomer.


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PHASE 3: Product/Process Realization OUTPUTS

DELIVERABLE

SupplierUpdated to include process build detailsand milestones. Process realizationprogress can be measured from this.


SupplierUpdated to reflect closure of completeditems and addition of new issues thathave been identified.


SupplierUpdated to reflect progress made sincePhase 3.


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PHASE 4: Pre-PPAP



Goals (click on picture to left) *enerte ir&t piece& o proce&&.

I'entiy toolin/e:uipment;&

mnucturin/ cp$ility.


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PHASE 4: Pre-PPAP

Fn'& %!en t!e &upplier !& &ti&ctorilycomplete' 'u&tin/ t!e proce&& topro'uce ccept$le prt&.

Ge/in& %it! &upplier;& receipt o toolin/8e:uipment n'or /u/in/ t t!eirmnucturin/ loction.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 4: Pre-PPAP INPUTS



SupplierUpdated to reflect closure of openissues and addition of any newlydiscovered problems.

Supplier The suppliers manufacturing process andany test/measurement gauges needed.

Supplier

Defines Safe Launch Plan, where required,and documents process capability

associated with special characteristics.


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PHASE 4: Pre-PPAP INPUTS

Supplier

Supplier The process developed to manufacture thematerial/component.


Document that defines all of the supplierscontrols starting with Receiving Inspectionand ending with the shipment to thecustomer.

SupplierSuppliers Process FMEA contributesprocess knowledge, lessons learned andpotential mistake proofing opportunities.


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PHASE 4: Pre-PPAP OUTPUTSDELIVERABLE IMPACTRESPONSIBILITY

SupplierUpdated to reflect closure of completeditems and addition of new issues that

have been identified.


Supplier Updated to reflect progress made sincePhase 3.

SupplierThe suppliers process thatmanufactures components for serialproduction at TRW.


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PHASE 4: Pre-PPAP OUTPUTS

Supplier


Document that defines all of the supplierscontrols starting with Receiving Inspectionand ending with the shipment to thecustomer.

Supplier Twelve QOS (Quality Operating System)measurables that indicate the status of theAPQP process and readiness for start-of-production.

SupplierSuppliers Process FMEA is updated toreflect any new failure modes discoveredor modify level of Severity, Occurrence

and/or Detection.


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PHASE 5: PPAP

Fn'& %!en t!e &upplier;& --A-&u$mi&&ion pc


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PHASE 5: PPAP INPUTS



SupplierThe process realized to manufacture thecomponent.

SDEAIAG Level 3 submission plus anyadditional needed documentation.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 5: PPAP OUTPUTS


Supplier

A collection of documents based on theAIAG PPAP Manual and additionalTRW requirements.

Supplier;

SDE

A scored audit designed to evaluate thesuppliers state of readiness for launch.

Supplier;SDE

For Category A and B components aformal Run at Rate is conducted to verifythe suppliers actual capacity.

SupplierThe suppliers production run that thePPAP submission will be based on.


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PHASE 5: PPAP OUTPUTS


Supplier Updated to reflect closure of completeditems and addition of new issues thathave been identified. All issues are tobe closed to complete the PPAP

process.

Supplier Updated to reflect progress made sincePhase 4. Full PPAP approval/releasecloses this document.

SQA;

Plant

Reviewed, and signed off on, by usingplant(s) and SQA, this initiates the SafeLaunch Plan at both the supplier andTRW.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 5: Supplier Development Tools Run at Rate

Found in Business Policy Manual and GSQM.


Detailed format incorporates Equipment Allocation to assure sufficientcapacity is in place to meet production requirements.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 5: Supplier Development Tools PPAP Requirements



Lists PPAP package elementsand their associated formnumbers (where applicable).

Establishes consistent order ofdocuments within the PPAP

package.

Defines different levels ofsubmission.


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Supplier 5omponent APQP Process& 8 PhasesPHASE 5: Supplier Development Tools PPAP Checklist



Lists in addition to the PPAPpackage elements specific thingsto look for associated with thoseelements.

Can be used by both TRW

reviewer and supplier.Intended to drive globalconsistency in acceptancestandards for PPAP packages.


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)hen things go well and we are wor3ing together as a team, wesee great results22.


8.6 5ombustion Plate 9 5ase Stud#I dont know if this was a success story, but more ofan amazing resurrection of a part that wassmoldering in the ashes

TRW Mesa Core Engineering


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8.6 5ombustion Plate

5ase Stud#

The 5.2 Inflator Combustion Plate story actually took placeafter the start-of-production.

This took place in the Summer of 2000. The OSS SDE group

had just gone through merging two different groups, Air Bagsand Seat Belts, and also had a new management team.

Many of the tools existed in pocketed areas and were notused and/or available at the programs beginning.

The component had significant issues making it virtuallyimpossible to manufacture. Demanding machiningrequirements increased cycle times to the point it wasnecessary to add several additional suppliers to meet the

requirements.


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The tools below were used to address the issues and SDE hastaken several of these and incorporated them into the globalSupplier APQP process.

Focused Design Reviews

Intensive Supplier Processing Analysis IncludingEquipment and Tool Design and Capacity

Run at Rate and Contingency Plans

Cost of Quality and Yield Analysis

Engineering Collaboration for Design for Manufacturability


5ase Stud#


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econ'ry

-ropellnt C!m$er

Retention tu'

Com$u&tion-lte

InititorRetiner

Cni&ter+iu&er

Inititor

-ropellnt

Fn!ncer-ropellnt

Rupture +i&;68

5hange B :=@ chamfer

tool to spot drill

Tool change should result in a 8 sec. advantage $S( to order tool and test b#

>;C.

(ncrease %P$ on bottom endmill

Speed change should reali;6.

"#pass autoload operation Autoload operation potentiall# less efficient than

operator positioning:estimated savings of 8 sec.

$S( to perform trial run onfifth )asino and evaluateonce machine is running.

Actions were defined based on the studys results.


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8 A ril19.2004 TRW Automotive Inc. 2006

6 01.09.2006


5ase Stud# : %esolution Activit#& Suppl# 5hain

rition intro'uce' into t!e proce&& $y &tmpin/ net or/e' prt.

"ltimtely t!i& trn&lte' into 'iiculty in mintinin/ true po&ition or t!ei/niter port&. A ne% 'tum Mpt&.N %oul' nee' to $e ''e'.

StampedFeatures

MachinedFeatures

Added additionaloperation tomachine flats to

create fixturinglocation toensure trueposition


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01.09.2006


5ase Stud# : %esolution Activit#& 'auging

100J *u/in/ %& re:uire' on t!e $uttre&& t!re'& Mn/ulr tolernceor inititor orienttionN $ecu&e o t!e lr/e mount o yiel' lo&&.

*u/in/ %& perorme' %it! t!re'e' in&ert& &!o%n $elo% %!ic!:uic


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01.09.2006


5ase Stud# : %esolution Activit#& 0*cessive "urrs

Burr Locations

-on'& M'e&i/ne' or %ei/!t re'uctionN %ere eliminte'. pecil 'e$urrin/ tool& %ere 'evelope' to llo% opertor& to rec! t!e

$urr loction& n' remove $urr&.

T!erml 'e$urrin/ met!o'& %ere e@plore'.

ec!nicl 'e$urrin/ n' relie n/le& or toolin/ %ere e@plore'.


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9 01.09.2006


5ase Stud# : %esolution Activit#& 5#cle Time Anal#sis

F@ten&ive nly&i& %it! e:uipment provi'er to i'entiy /p& in:uote' ver&u& ctul cycle time to perorm &peciicopertion&. T!i& re:uire' 'o%nlo'in/ o C?C co'e Mcnnot&ee opertion in clo&e' c!m$erN.

Anly&i& &!o%& t!t only 3 out o ) opertion& %!eree@pecte' to meet &c!e'ule t!i& %& prtly 'ue to vriou&&econ' &ource& n' t!e in$ility to clerly communicte&c!e'ule re:uirement&.

Anly&i& clerly &!o%& t!e improvement re:uire' in term& o''itionl e:uipment n' t!e u&e o improve' i@ture& toeliminte nee' or reDc!uc


90/95



90 01.09.2006



5urrent

The bottleneckoperation produces

less than the needvolume


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91 01.09.2006



5urrent


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92 01.09.2006


5ase Stud# : %esolution Activit#& 5osts

A co&t mo'el %& 'evelope' to en&ure 3r'mnucturin/ &ource %oul'inclu'e ccurcy in t!e co&t &tructure o t!e component n' oer competitive price. MI %& &


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93 01.09.2006

)hat do we need to fi*22


Supplier APQP follows the pareto principle. That is 20% of thecomponents require 80% of the effort.

Full, cross-functional participation is required at the following events: Component Priority Assessment

Supplier Kick-off Meeting Component Design Review Launch Readiness Audits

Manufacturable designs, with clearly defined special characteristics,sufficiently early in the program to assure suppliers can build and tune-

in their processes to meet drawing expectations and requirements.

Ownership of the suppliers by the launch team.

Escalation of show stopper issues to upper management within theproduct lines.


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94 01.09.2006

ucce&&ul component A-- i& cro&&Dunctionl eort.

TRW upplier +evelopment !& %ellD'eine' tool$o@ t!t i /iven

&uicient re&ource& n' &upport cn ''re&& n' re&olve &i/niicnt

i&&ue& $eore &trt o pro'uction.

=or t!e 20J o t!e component& t!t my criticlly ect ny lunc!8

lc< o &uicient inormtion or i&&ue re&olution erly in t!e proce&&%ill cu&e i&&ue& 'urin/ lunc! n' &eril pro'uction.

APQP Summar#


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QUESTIONS?

?