JLR APQP Priority Supplier Process Manual

JLR PSM-002

IMPORTANT

This Jaguar Land Rover process is derived from the original Ford used by Jaguar Land

Rover prior to June 2008 but is unique to Jaguar Land Rover. Certain aspects of this

process will appear similar to the process currently used by Ford and which was

historically used by Jaguar Land Rover; however, the two processes are now distinct

from each other and contain important differences.

It is important to ensure that the Jaguar Land Rover version is always used for Jaguar

Land Rover business; the Jaguar Land Rover and Ford versions are NOT

interchangeable.

For any queries regarding the Jaguar Land Rover process described in this document,

please contact your Jaguar Land Rover STA Engineer.

APQP Priority Supplier

Process Manual

JLR Version 1

February 2010

Table of Contents JLR PSM-002

February 2010 Page 1 of 49 JLR Version 1

TOPICS Page

Number

I. Introduction 2

II. Process Overview 1) High Level Flow Chart 2) What is the "APQP Priority Supplier" Process? 3) Roles & Responsibilities 4) Process Leadership 5) Supplier Selection 6) GPDS Linkage and Reporting

4 5 6 8 9

11

III. Process Detail 7) Priority Supplier Selection 8) Kick-off Meeting 9) Evaluations #1 10) Evaluation #2 11) Evaluation #3 12) Evaluation #4 13) Program Reporting Processes

13.a. APQP – Assessment 13.b. APQP – Element Summary 13.c. APQP – Supplier Scorecard

15 17 20 25 30 36 39 40 46 48

I. Introduction JLR PSM-002


This manual is intended to define the internal Jaguar Land Rover process for working with the supply base to launch quality parts within Global Product Development System (GPDS). The APQP Priority Supplier strategy is first and foremost a cross-functional process that recognises supplier success as a function of the combined talents and input of many disciplines within Jaguar Land Rover. The process is governed by the following principles: � Supplier launch success is a cross-functional, shared responsibility

� Jaguar Land Rover cross-functional teams will work proactively with the highest leverage

suppliers on a programme � Supplier Engagement will begin early in a programme – immediately after sourcing � Jaguar Land Rover cross functional teams will evaluate the Priority supplier manufacturing

facility a minimum of four (4) times � The teams will provide the supplier with a single Jaguar Land Rover voice on key launch

matters � Team engagement will continue until the supplier has successfully completed all Production

Part Approval Process (PPAP) requirements and fully met all programme ramp-up volumes � Jaguar Land Rover will implement the priority supplier process consistently on a global basis

in alignment with the global makeup of the supply base

February 2010

II. Process Overview JLR PSM-002


Section II. Process Overview

1) High Level Flow Chart 2) What is the “APQP Priority Supplier" Process? 3) Roles & Responsibilities 4) Process Leadership 5) Supplier Selection

6) GPDS Linkage & Reporting



Supplier Sourcing Begins

Priority Suppliers Selected

Cross-Functional Teams Formed

Team Kick-Off Meetings

Begin

Evaluation #1

Evaluation #2

Evaluation #3

Evaluation #4

Resolve Open Issues

Decision to

Proceed to

Run-At-

Rate

Update of APQP Assessment

PTC/

M1DJ PTCC PA FDJ PEC

LR/

FEC

M1 VP TT PP

Unit

PTC

Unit

PA

MP1

II. Process Overview

What is the “APQP Supplier Engagement Process?

February 2010 Page 5 of 49 JLR PSM-002 (Version 1)

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The process begins with a Kick-Off meeting and proceeds with a minimum of 4 cross-functional deep dive Evaluations of the supplier's progress towards manufacturing readiness. An overview of the meeting requirements is listed below:

Priority Supplier Team Meeting Overview

Meeting Location Timing Duration JLR Participants

Kick-Off Meeting

Jaguar Land Rover facility, supplier facility, or teleconference (according to team preference)

PT: <Unit PTC> to <PTCC> UN: <PSC> to 3 months after PTCC UP: <PTCC> to <PTC/M1DJ>

2-3 Hours

PD Engineer (Lead) Site STA Engineer Buyer

Evaluation #1

Supplier's Manufacturing Facility or as applicable

PT/UN: <PTCC> to <PTC/M1DJ> UP: <PTC/M1DJ> to <PA>

1-2 Days

PD Engineer (Lead) Site STA Engineer Buyer Representatives from other functions as required

Evaluation #2


Prior to <VP> In Plant Date

1-2 Days

PD Engineer (co-Lead) Site STA Engineer (co-Lead) Buyer Representatives from other functions as required

Evaluation #3


UN/UP: Prior to TT Build In Plant Date PT: Prior to Production Validation In Plant Date

1-2 Days

Site STA Engineer (Lead) PD Engineer Buyer Representatives from other functions as required

Evaluation #4


Prior to MP1 Build In Plant Date 1-2 Days

Site STA Engineer (Lead) PD Engineer Buyer Representatives from other functions as required


Roles and Responsibilities


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Because the supplier interface with Jaguar Land Rover spans commercial, design, manufacturing, and logistics functions, the successful launch of a component and vehicle is dependent upon robust communication at all levels of the Company.

The Roles & Responsibilities within this process are structured around ownership of the key elements of the industry standard Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP). APQP and PPAP are existing Jaguar Land Rover processes and are both fundamental building blocks of GPDS.

FPDS GPDS

Team approachTeam approachTeam approachTeam approach Single voice / directionSingle voice / directionSingle voice / directionSingle voice / direction

Improved ResourceImproved ResourceImproved ResourceImproved Resource Utilisation Utilisation Utilisation Utilisation

Fragmented approach / multiple Fragmented approach / multiple Fragmented approach / multiple Fragmented approach / multiple directiondirectiondirectiondirection

No integration / leadershipNo integration / leadershipNo integration / leadershipNo integration / leadership

Redundant workRedundant workRedundant workRedundant work

PD

SUPPLIER

Purch. Plant

MP&L

STA

PD

Plant

MP&L

Purch. STA

Supplier


Roles and Responsibilities


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APQP Roles & Responsibilities

� For all elements, each organisation may play a key support role at certain times in the program


Priority Supplier Selection


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Over the course of the programme, leadership of the process resides with the engineer for the Kick-Off meeting and Evaluation #1. The leadership of the Evaluation #2 is shared between the PD Engineer and the STA Engineer. For Evaluations #3 and #4, leadership of the process transitions to the STA Engineer.

Jaguar Land Rover Leadership during the Program

Leadership of the process involves the following responsibilities: � Schedule the Kick-Off meetings and Evaluations � Develop the agenda for the team meetings and Evaluations � Invite JLR team members from other functions as required � Accurately record meeting outcome � Chair the Kick-Off meetings and Evaluations � Act as the spokesperson for the team when required While there is a team lead at all times, each team member still has the responsibility between meetings to resolve open concerns, to communicate with other team members including the team leader, and to bring together other team members to close out concerns as necessary.

It is recognised that the Jaguar Land Rover team members will interface with the supplier regularly between Evaluations, and in many cases, this interaction will occur at the supplier site. Further, although the process provides specific attendance requirements for each team meeting, all team members with open issues must attend an Evaluation.

Kick-Off Meetings

Evaluation #1 Evaluation #3 Evaluation #4 Evaluation #2

PD Engineer Shared PD Engineer and

STA Site Engineer

STA Site Engineer




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Application of the APQP Priority Supplier process is limited to a subset of the total New Tooled End Item (NTEI) suppliers on a programme. The programme team will target the most critical suppliers based upon a prioritization model that assesses risk related to supplier site readiness, part criticality, and programme specific concerns.

Priority Supplier Selection Criteria

Site Readiness

OR =

Programme Priority Suppliers

Initial selection of Priority sites will occur between Unit <PTC> and 3 months after <PTCC>

New Technologies/Features New Mfg Process Compressed Program Timing Unconventional Operating Patterns or High Supplier Personnel Turnover

Non-Q1 Sites Excludes sites awaiting Q1 approval (“A” codes) with Q1 scores over 1000 and Non-Q1 sites with parts having low

corporate or customer impact

OR Part Criticality

Programme induced

Risk

NTEI’s /1

Axles Audio/Navigation Engines Seats Transmissions Restraints Frames Brake System Tyres Fuel System Wheels Steering Moon Roofs Latches Wiring Suspension Lighting Driveline Electronic Module Major Module Assembly

Note:

/1 Reference: “Modified” carryover components, Priority supplier selection should be considered when:

• Features or functions being changed directly impact critical characteristics or high RPN items in the DFMEA. • The modified part creates new failure modes • 25% or more of component tooling is new • A new assembly line or location is utilized. • Current assembly process/tooling is modified by more than 25%




PPrriioorriittyy SSuupppplliieerr SSeelleeccttiioonn ((ccoonntt..))::

Timeline

Select PT Priority

Suppliers

Select UN Priority

Suppliers

Select UP Priority

Suppliers

Confirm Priority

Suppliers at <PA>

Review and Modify Priority Supplier as Required

PTC/

M1DJ PTCC PA FDJ PEC

LR/

FEC

M1 VP TT PP

Unit

PTC

Unit

PA

MP1


GPDS Linkage and Reporting


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Information and data management within the APQP Priority Supplier Process will adhere to the same Lean Product Creation Principles as GPDS overall. � Understand and deliver defined value � Front load cross-functional solutions � Leverage reuse and commonality � Build in learning & continuous improvement � Integrate suppliers into the programme � Align tools and technologies with the process Supplier and Jaguar Land Rover teams globally will utilize common GPDS documents and reporting structures to maximize the availability/understanding of part status information while minimizing the effort required to maintain the data.

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Example of APQP ASSESSMENT:

Current Milestone PTCC Select Vehicle Partition Underbody Body Exterior

Program Code: Manufacturing Supplier Site Code:Program Name: Supplier Name:

Model Year: Location:

APQP Current Date: Q1 Status: Y

Previous APQP Date: Q1 Score:

PTCC PTC PA VP LR LS J1

25-Apr-10

M-1DJ AA1 AA2 FDJ PEC FEC

UNV0 UNV1 UNV2 UPV0 UPV1 UPV2 TT MRD PP MRDMP1

MRDMP2

1000

Pro

gra

m

Info

rmati

on

Su

bm

iss

ion

Da

tes

DD

-MM

M-Y

Y

RANGE ROVER

MOROCCO

18/11/2009

2013

18/12/2009

L405

Total Number of Parts:

U3NFA

User Plant:

99

JLR

AB123456

YAZAKI HARNESS

Select Vehicle PMT

Base Part Number:

Base Part Name:

APQP JLR Version 1

Dates

DD-MMM-YY

Engineering Milestones

Program Milestones

Builds

Dates

DD-MMM-YY

ELEMENT

Delivera

ble

Nu

mb

er

Dates

DD-MMM-YY

VP

P T

imin

g

Exp

ecta

tio

n N

um

ber

Expectations / Deliverables

Planned

Completion

Date

DD-MMM-YY

UnderbodyPTCC Body Exterior

Y

Summary View (OFF)

Final Assessment

Priority Site

Highlight Next Deliverable (ON)Click Here to Clear Entries Formatted to Print A4 (EU) Import Previous APQP

Using the APQP ASSESSMENT All suppliers of New Tooled End Items (NTEI's) will be required to complete and submit the APQP ASSESSMENT to Jaguar Land Rover on a monthly basis after sourcing.

PRIORITY SUPPLIERS… NON-PRIORITY SUPPLIERS…

… will agree on the APQP input with the Jaguar Land Rover cross-functional teams during site visits. The APQP update is a key output of the supplier evaluations and will reflect the team agreement for part/supplier readiness.

…will complete the APQP Assessment on their own and will submit the document to the Jaguar Land Rover engineer and STA monthly. Suppliers will engage the relevant Jaguar Land Rover team member PD, Buyer, STA, MP&L depending on the help needed.




At a minimum, all suppliers will submit the monthly APQP Assessment update to a designated programme email address so that a total programme status can be tracked.

PRIORITY SUPPLIERS… NON-PRIORITY SUPPLIERS…

… will also share the APQP status update with Jaguar Land Rover cross-functional team members to maintain communication and alignment throughout the programme development

…will use the APQP Assessment with Jaguar Land Rover team members when help is required.

Throughout the programme development cycle, the APQP ASSESSMENT is a communication and reporting tool intended to provide an up-to-date status on supplier/part health so that concerns can be resolved early and efficiently. Programme Functional Reporting Because the APQP ASSESSMENT (A) is the single repository of supplier/part status information prior to Open-to-Go, all management discussions and reporting above the working level will be derived from the information recorded in the document.

Next Milestone

FDJ G RProcess

Application

L538 2012 MY Element Summary Report Status

Review DateFinal Deliverable:

Implications of Red:

October Data

Parts Supply & Quality Risks During Launch

Supplier APQP Readiness

Process

Output

Deliverables - % On Target (Target 80%)

0

10

20

30

40

50

60

70

80

90

100

May Jul Sep Nov Jan Mar May Jul Sep Nov Jan Mar May

APQP Deliverable Red's

0

50

100

150

200

250

300

350

400

450

500


Report Submission

0

10

20

30

40

50

60

70

80

90

100


Red Assessment Complete / Green / Yellow Await Assessment

A. Monthly External APQP ASSESSMENT Submissions for all Programme NTEI Suppliers

B C




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III. Process Detail


Section III. Process Detail

7) Priority Supplier Selection

8) Kick-off Meeting

9) Evaluation #1

10) Evaluation #2

11) Evaluation #3

12) Evaluation #4

13) Programme Reporting Processes

13. a. APQP – Assessment 13. b. APQP – Element Summary Report 13. c. APQP – Supplier Scorecard

III. Process Detail



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I. Purpose: Outline the selection process for the sub-set of NTEI (new tooled end item) suppliers determined to be "priority" manufacturing sites for a given programme. Priority sites will receive specific cross-functional support from Jaguar Land Rover from the time they are sourced through to successful completion of all Phase PPAP requirements.

II. Timing:

Start Finish PT/UN/UP Unit <PTC> 3 months after <PTCC>

(Note: Actual completion timing will be dependant upon the specific needs of the programme.)

III. Participants: Lead: Chief Programme Engineer, STA Programme Manager Support: Programme PMT Leaders, STA Site Managers

IV. Initial Selection Process: 1. Chief Programme Engineer obtains programme bill of material highlighting NTEI components and

suppliers. 2. Chief Programme Engineer and STA Programme Manager apply the selection criteria to the

programme bill of material to develop a preliminary priority supplier list. If supplier satisfied any of the criteria in below:

a) Site Readiness

• Non- Q1 (R,X,W,2,Z,A with score <1000)

• Sites with high customer or corporate impact b) Part Criticality

• Part belonging to the critical list: Axles, Frames, Tyres, Wheels, Moonroofs, Wiring, Lighting, Audio Navigation, Seats, Restraints, Brake System, Fuel System, Steering, Latches, Suspension, Driveline, Electronic Modules.

• And also satisfies the sub-criteria: i. Features or functions being changed directly impact Critical Characteristics

(CCs) or high Risk Priority Number (RPNs) in DFMEA ii. The modified part creates new failure modes iii. 25% or more of component tooling is new iv. A new assembly line or location is utilized v. Current assembly process/tooling is modified by more than 25%

c) Programme Induced Risk

• New Technologies/Features

• New Manufacturing Process

• Compressed Programme Timing

• Unconventional Operating Patterns or High Supplier Personnel Turnover 3. Chief Programme Engineer reviews the list with PMT leaders to verify supplier selections for part

criticality and programme-induced design risk. 4. STA Programme Manager reviews the list with affected STA Site Managers to verify supplier site

selection for site readiness and programme-induced timing or manufacturing risk. 5. STA Programme Manager and Chief Programme Engineer reconcile input and publish final list to the

PST and impacted PD and STA Site Engineers.

III. Process Detail



V. Outputs

Deliverable Responsibility

1. Priority Supplier list

Chief Programme Engineer STA Programme Manager

2. Priority Supplier Notification STA Programme Engineer

Note: Because PT, UN, and UP sourcing occurs at different times, the process can be performed as required as each group of suppliers and parts is sourced.

6. STA Programme Manager will enter completion status in the Integrator – Engineering Status Report (ESR)

7. STA Programme Manager will notify priority suppliers on next steps

Ongoing Process – Post selection period (3 months after <PTCC>): After the selection period, the programme will select incremental* Priority NTEI suppliers for cross-functional engagement based on the following criteria:

Financial Instability:

Supplier experiences financial crisis that jeopardizes their ability to meet program timing

Mfg. Process:

APQP plan indicates significant risk to achievement PPAP timing

Late Part Release:

A part is released/sourced after the normal GPDS timing such that the supplier cannot meet the TT build with Phase 1 PPAP parts

Resourcing:

A part is resourced (a new manufacturing site identified) after <PTC> and the supplier cannot meet the TT build with Phase 1 PPAP parts

DVP/PV Failure:

A part suffers a DVP/PV failure where the supplier cannot meet the TT build with Phase 1 PPAP Parts

Compression:

A part requires significant tooling/testing compression to achieve Phase 1 PPAP at TT build

Late/Non-Submissions:

Two or more consecutive late or non-submissions of the APQP

Assessment

*Note: the team can also decide that a supplier be dropped from Priority status if the risk is eliminated

III. Process Detail

Kick Off Meeting


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I. Purpose:

The purpose of the Kick-Off meeting is to introduce Jaguar Land Rover and supplier team members, to provide them with an overview of the APQP Priority Supplier Process, and to communicate team expectations prior to Evaluation #1 for each of the Priority Suppliers. A key deliverable out of this meeting will also be Jaguar Land Rover and supplier team agreement on the required programme and process timing.

II. Timing:

Start Finish PT Unit <PTC> <PTCC> UN <PSC> 3 mths. after <PTCC> UP <PTCC> <PTC/M1DJ>

Note: Actual review timing will be dependant upon the specific needs of the component and the programme. The estimated duration for this meeting is 2-3 hours.

III. Participants: Lead: PD Engineer Support: STA Site Engineer, and Buyer

IV. Location: Jaguar Land Rover facility, supplier facility, or teleconference (according to team preference)

V. APQP/PPAP Element Focus: Because the Kick-Off meeting is focused on preparation for Evaluation #1, the team reviews assignments relative to the 5 (of the total 31) APQP elements discussed at the future supplier evaluations. The 5 elements are:

APQP Element Number

Element Description Jaguar Land Rover Lead Organization

1 Sourcing Decision Commercial Purchasing

2 Customer Input Requirements PD

4 Failure Mode Avoidance (including DFMEA)

PD

8 Facilities, Tools & Gauges STA

11 Drawings and Specifications PD

III. Process Detail

Kick Off Meeting


VI. Agenda:

1. Introduction of team members 2. Present overview of APQP Priority Supplier

Process 3. Review Perfect Drawing Plan (PDP)

a. Reconcile Vehicle Programme Plan (VPP) and component timing plan

b. Gain team agreement & understanding to timing plan

c. Agree on generic timing plan for on-site evaluations

4. Review reference material/documentation and standard forms to be used throughout the process. Functions to address functional concerns/open issues

5. Review inputs and pre-work for Supplier Evaluation #1 (see Key Areas of Focus for more detail)

6. Document Open Issues with assigned responsibilities and timing

7. Determine date for Supplier Evaluation #1

Jaguar Land Rover and Supplier Leads: 1. PD Engineer 2. PD Engineer, Site STA Engineer 3. PD Engineer 4. PD Engineer, Site STA Engineer 5. All 6. All 7. PD Engineer

VII. Key Areas of Focus: The kick off meeting is focused on the preparation for Supplier Evaluation #1 by communicating the following list of items that will be utilized during the next supplier evaluation:

1. Supplier a. Facility layout b. Process flow diagram c. Sub-supplier APQP status (if available) d. Control plan (current or surrogate process) e. Input on gauging strategy f. Input on DVP&R and in-process testing g. Supplier recommended SC/CCs h. Preliminary PFMEAs i. Packaging, shipping, and dunnage recommendations j. Draft of team feasibility form

2. Buyer

a. Capacity Planning Volumes b. Status of tool orders (prototype and production) c. Status of Purchasing Orders d. Status on piece price agreement on dunnage e. Verification of manufacturing site code f. Other commercial issues

III. Process Detail

Kick Off Meeting


3. PD

a. Customer input requirements (part history, SDS, warranty concerns, TGW expectations)

b. Latest design requirements including GD&T drawings c. Overall Failure Avoidance Mode Strategy d. DVP&R Requirements e. DFMEA including customer identified Potential Critical (YC)/ Potential Significant (YS)

Characteristics & request for supplier identified YC/YS f. Branding requirements & lot/part traceability requirements g. Feasibility study results including Digital Pre-Assembly (DPA) checks

4. STA a. Latest Manufacturing Site Assessment b. Latest SIM status and prior 8Ds c. Gauging strategy requirement for part d. Phased PPAP dates

5. MP&L a. Packaging requirements b. Dunnage plan and approval forms c. Program volumes and ramp-up curve d. Material Management Operating Guideline (MMOG) requirements

IX. Outputs:


1. Document Open Issues PD Engineer

2. Agreed upon timing/responsibilities for next on-site evaluation

All

III. Process Detail

Evaluation #1


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I. Purpose: The purpose of Evaluation #1 is to validate progress of the supplier responsible APQP elements against the corresponding GPDS block timing and to reconcile open issues and/or concerns using a structured agenda. The on-site evaluation will center on planning activities for the APQP Elements, including Failure Mode Avoidance (detailed FMEA and Control Plan review), Capacity and Manufacturing Planning.

II. Timing:

Start Finish PT/ UN <PTCC> <PTC/M1DJ>

UP <PTC/M1DJ> <PA>

Note: Actual review timing will be dependent upon the specific needs of the component and the programme.

III. Participants: Lead: PD Engineer

Support: STA Site Engineer, Buyer and other Jaguar Land Rover team members as required.

IV. Location: Supplier's Manufacturing Facility or as applicable.

V. APQP Element Focus: Evaluation #1 is focused on 5 (of the total 31) APQP elements. Each supplier is mandated to monitor and track progress of these elements by utilising the APQP Assessment. A corresponding Jaguar Land Rover lead is listed for each element. The 5 elements are:

APQP Element Number


Deliverable Number

1 Sourcing Decision Commercial Purchasing 1, 2, 4

2 Customer Input Requirements PD 5

4 Failure Mode Avoidance (including DFMEA)

PD 8, 9

8 Facilities, Tools & Gauges STA 17

11 Drawings and Specifications PD 24

III. Process Detail

Evaluation #1


VI. Agenda

1. Introduction of key team members 2. Review applicability and understanding of all

APQP expectations and deliverables. 3. Conduct plant tour/facility review (If at supplier

site) 4. Review previous Open Issues 5. Review latest APQP Assessment submission 6. Confirm Commercial Issues and Agreements

such as, Sourcing Agreement (SA), Commercial and Program Agreement (CPA).

7. Deep dive document linkage on FMEAs, Control Plans and Failure Mode Avoidance Strategy.

8. Review drawings and specifications 9. Initiate agreements on gauging strategy 10. Initiate confirmation on part feasibility

11. Review sub-supplier management plans 12. Agree on facilities, tooling, equipment and gauge

timing plan 13. Discuss Capacity Plan 14. STA Engineer updates the Manufacturing Site

Assessment as required by evaluation results 15. Document Open Issues with assigned

responsibilities and timing in the APQP Assessment

16. Update APQP Assessment Status

17. Agree on Supplier APQP Assessment rating 18. Agree on follow up schedule for evaluation #2.

Jaguar Land Rover and Supplier Leads: 1. All 2. All 3. Supplier 4. Supplier 5. Supplier 6. Buyer 7. Supplier, PD Engineer, Site STA Engineer 8. Supplier, PD Engineer 9. Supplier, PD Engineer, Site STA Engineer 10. PD Engineer, Supplier, Site STA Engineer 11. Supplier, Site STA Engineer 12. Supplier, Site STA Engineer 13. Supplier, Buyer, Site STA Engineer 14. Site STA Engineer 15. Supplier 16. Supplier 17. All 18. All

VII. Key Areas of Focus: The following key areas should be focused on during Evaluation #1. Questions listed below should serve as a starting point for key review areas. They are not, however, intended to be inclusive for all Evaluation #1 elements:

1. Sourcing (APQP Element 1) a. Does the ESOW contain the supplier Engineering Development and Test (ED&T) Budget? b. Were all quality, cost, weight, function and major sub-system attribute targets cascaded and

documented? c. Are there any outstanding issues in the CPA?

2. Customer Inputs (APQP Element 2)

a. The following programme requirements has been received and agreed by the supplier: � Annual Production Weekly (APW) and Maximum Production Weekly (MPW) Volumes � Reliability and Quality Goals, Program Timing Dates

III. Process Detail

Evaluation #1


3. DFMEA (APQP Element 4)

a. Have all Potential Critical and Significant Characteristics been identified and agreed? b. Has the team followed the Failure Mode Avoidance (FMA) Guide and has evidence that the FMA

analysis was successfully completed? Has the team utilized robustness tools, such as P-diagrams, boundary diagrams, interface diagrams, etc?

c. Was this part considered a candidate to demonstrate robustness using the Robustness Checklist? If so, has this been completed?

d. Describe the appropriate Noise Factor Management Strategy chosen for the most relevant noises.

e. Has the preliminary DFMEA and PFMEA been completed with linkages? f. Has the Tier 1 supplier cascaded the special characteristic requirements to sub-suppliers?

4. Facilities, Tools and Gauges (APQP Element 8) a. Has the supplier correctly identified in the timing plan, the critical path activities (vendor selection,

procurement, installation, validation, etc) for facility, equipment and tooling implementation? How does the plan correlate to the supplier PPAP timing? Has the plan been agreed by Jaguar Land Rover, the production supplier and tooling/facility/equipment vendors? Does the plan support Jaguar Land Rover’s volume requirements?

a. Does the gauge Measurement System Analysis (MSA) strategy (R&R calculation and index, sample collection, etc) support PPAP Jaguar Land Rover Customer Specifics and timing requirements?

III. Process Detail

Evaluation #1


5. Drawings and Specifications (APQP Element 11)

a. Does this part meet all Digital Pre-Assembly (DPA) checks for compatibility? Are the corrective actions been incorporated in the design?

b. Are all specifications documented (includes tolerances, dimensions, notes)? c. Has design styling fully finalised and requirements cascaded? d. Does the design reflect the latest PDL? e. Have service parts been addressed?

6. Additional topics for discussion: a. Preliminary discussion on Sub-supplier management plans requirements:

�� Roles and Responsibilities �� APQP requirements �� Regular reviews to assess quality-of-event

VIII. Outputs:


1. Summary Report for Evaluation Supplier/ PD Engineer

2. Confirm Deliverable status for: All

a. Required Sourcing Agreement signed. Supplier/Buyer

b. Required Supplier Commercial and Program Agreements (CPA) signed.

Supplier/Buyer

c. Final Mix, Maximum Weekly Volume communicated and agreed

Supplier/Buyer

d. Programme expectations cascaded to supplier Supplier/ PD Engineer

e. DFMEA completed Supplier/ PD Engineer

f. Special Characteristics cascaded to supplier Supplier/ PD Engineer

g. Supplier’s OEE plan is confirmed by surrogate data

Supplier/Site STA Engineer

h. Design Styling Confirmation Supplier/ PD Engineer

3. Agreement on Plan to manage sub-supplier APQP and PPAP status


4. Agreement that Capacity Plan is achievable and consistent with Jaguar Land Rover requirements


5. Agreement on Plan to achieve APQP and PPAP Supplier/Site STA Engineer

6. Agreement on Prototype Build Support (includes Prototype Control Plan and Build Plan)

Supplier/ PD Engineer

7. Agreement on Failure Mode Avoidance Strategy (Completion of DFMEA & Agreement on Special Characteristics)

All

8. Updated APQP Assessment Supplier (with cross functional team consensus)

9. Updated Manufacturing Site Assessment (MSA) Site STA Engineer

10. Agreed upon timing for next evaluations All

III. Process Detail

Evaluation #1


b. PPAP: �� Does the plan to achieve Phased PPAP requirements meet programme timing? Is it

realistic? Is the amount of work leveled throughout the plan? How are the resources being allocated to support the plan? Were valid assumptions used when developing the plan such as tolerances, process/manufacturing parameters (OEE, scrap rate, buffers), equipment/ gauge procurement, delivery and try out, etc? Is this a unique process?

�� Has the supplier identified the critical path to meet PPAP and properly addressed the concern?

c. Prototype Build �� What is the supplier’s initial plan to produce and manage the Prototype Builds? Does the

supplier have all the preliminary information (dates, quantity, and location) necessary to plan for the Prototype Builds?

IX. Reference Materials & Forms: 1. GPDS Process Sheet and Quality Document References.

III. Process Detail

Evaluation #2


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I. Purpose: The purpose of the Priority Supplier Evaluation #2 is to validate progress of the supplier responsible APQP elements against the corresponding GPDS block timing and reconcile open issues and/or concerns using a structured agenda. The evaluation will center on VP Build preparedness and extent to Run-at-Rate readiness. Because of the potential time gap between the VP Build event and the supplier Run-at-Rate activity, a second team evaluation may be required to properly assess the supplier manufacturing readiness prior to Run-at-Rate.

II. Timing:

Start Finish

Evaluation # 2 <FDJ>

Prior to <VP> In Plant Date (IPD)

Note: Actual review timing will be dependent upon the specific needs of the component and the programme. The estimated duration for this meeting is 1-2 days.

III. Participants: Co-Lead: PD Engineer and Site STA Engineer Support: Buyer and other Jaguar Land Rover team members as required.

IV. Location: Ideally, since Evaluation 2 would address the VP Build Preparedness and Run-at Rate Readiness the preferred location is the Supplier's Manufacturing Facility. However, due to the potential time gap between the VP Build event and supplier Run-at-Rate activity, separate meetings may be required. The team can choose the most appropriate location(s) providing that the focus elements can be fully verified.

III. Process Detail

Evaluation #2


V. APQP Element Focus: Evaluation #2 is focused on 8 (of the total 31) APQP elements. Each supplier is mandated per GPDS process sheets (see Reference Materials & Forms) to monitor and track progress of these elements by utilising the

APQP Assessment. A corresponding Jaguar Land Rover lead is listed for each element. The 8 elements are:

APQP Element Number


Deliverables

Number

1 Sourcing Decision Commercial Purchasing 3

7 Sub-supplier APQP STA 12

8 Facilities, Tools & Gauges STA 15, 18

9 Prototype Control Plan PD 20

10 Prototype Build PD 21, 22, 23

11 Drawings and Specifications PD 25

13 Team Feasibility PD/STA 27

15 PFMEA STA/PD 29

VI. Agenda:

1. Introduction of key team members 2. Review previous Open Issues 3. Review APQP Assessment latest submission 4. VP Build Preparedness specifics:

a. Verify that the prototype parts meet the requirements (quality, dimensional, quantity, VP Build specifications, etc)

5. Run-at-Rate Readiness specifics:

a. Conduct review of manufacturing facility: �� Review area designated for production of

parts �� Review area designated for storage of parts �� Review area designated for any repair or

containment processes �� Review area used for sequencing (if

applicable)

Jaguar Land Rover and Supplier Leads: 1. PD Engineer, Site STA Engineer 2. Supplier 3. Supplier 4. All 5. Supplier

III. Process Detail

Evaluation #2


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�� Review any equipment/processes already in place that are planned to be used

�� For equipment not in place, conduct review of similar/surrogate equipment and/or processes used for different parts

6. Document Open Issues with assigned responsibilities and timing in the APQP Assessment.

7. Update Status in the APQP Assessment 8. Agree on latest APQP Assessment rating 9. Agree on follow up evaluation schedule for

evaluation #3 10. STA Engineer updates the Manufacturing Site

Assessment as required by the evaluation results

6. Supplier

7. Supplier 8. PD Engineer, Site STA Engineer

9. Site STA Engineer 10. Site STA Engineer


1. Sourcing Decision (APQP Element 1)

a. Has the supplier received all production tool orders in time to support PPAP?

2. Sub-supplier APQP(APQP Element 7) a. Has the supplier provided a work plan timing containing all sub-supplier important

events/dates? Do all dates support supplier and Jaguar Land Rover program timing? b. Does the workplan identify PPAP dates, supplier and Jaguar Land Rover Material

Required Dates, testing completion and other items in the critical path?

3. Facilities, Tools and Gauges (APQP Element 8) a. Does the timing implementation plan still support PPAP Phase 0?

4. Prototype Control Plan (APQP Element 9) a. Does the Prototype Control Plan contain linkages to the DFMEA and PFMEA?

5. Prototype Build (APQP Element 10)

a. Have all Prototype Tools and measuring devices been in place at the Prototype location? b. Has the supplier followed the Prototype Control Plan? c. Was the latest design used to make these parts? d. Are dimensional data available for review? e. Do the parts and purchase orders meet the Prototype Build Requirements (quantity,

timing, quality, etc)? f. Do the packaging, dimensional data and labeling requirements meet the Prototype Build

Requirements? g. Has the supplier recorded and addressed all internal issues found during the Prototype

Build(s)?

III. Process Detail

Evaluation #2


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6. Drawings and Specifications (APQP Element 11)

a. Have all design and specifications resolved, implemented and recorded in the latest released design record? Have all supplier documentation been updated accordingly? Check for evidence on Control Plans, FMEAs, gauge drawings, etc.

b. How will branding requirements and environmental compliance be addressed?

7. Team Feasibility (APQP Element 13) a. Has the supplier team agreed that the part can be manufactured with the proposed

equipment, facilities, tools and gauges? Has the supplier and the Jaguar Land Rover team agreed that the part can meet customer timing, quality and logistics requirements at the specified cost in the Target Agreement?

8. PFMEA (APQP Element 15)

a. Review the PFMEA for completeness and correct linkages to the DFMEA and Control Plan.

b. Ensure all CCs have mandated special controls listed on the Control Plan (Poke-Yoke, inspections/testing, etc.)

c. Ensure all SCs have appropriate controls captured on the Control Plan.

9. Additional topics for discussion: a. Appearance Approval

�� What is the plan to achieve appearance approvals (colour, graining, gloss, surface, etc.), including dates and responsibilities?

�� Are there any outstanding issues from previous builds �� How will the supplier support any requirements on Colour Harmony?

b. PPAP �� Review Run-at-Rate input requirements to be in place for the production stream,

including operation instructions and personnel training to support PPAP Phase 0 event?

�� Ensure all gauges (including sub-assembly gauges) are tagged/labeled, calibrated and identified on the Control Plan. Verify gauge calibration records and condition of gauges.

�� What Control Plan is planned to be used during the PPAP Phase 0? �� What is the expected number of parts produced in a defined period of time? �� Are "Bottle Neck" operations identified? �� Will Phase 0 parts be used to qualify for PPAP Phase 1, including Gauge R&R?

III. Process Detail

Evaluation #2


VIII. Outputs:


1. Summary Report for Evaluation PD Engineer

2. Confirm Deliverable Status for:

a. All production tool orders issued to suppliers Supplier/Buyer

b. Sub-supplier PPAP timing plan completed Supplier/Site STA Engineer

c. Facility and Tooling timing plan completed Supplier/Site STA Engineer

d. Gauge plan (including released gauge drawings) completed


e. Prototype Build Control Plan completed Supplier/PD Engineer

f. All Prototype Tool Orders issued to suppliers Supplier/Buyer

g. Prototype Parts ordered Supplier/Buyer

h. Prototype Parts achieved 100% of required print specifications

Supplier/PD Engineer

i. Design release (WERS) completed PD Engineer

j. Design, Process and Timing Feasibility Confirmation All

k. Final PFMEA completed with linkages Supplier/ PD Engineer/Site STA Engineer

3. Acceptance of parts to support Prototype Build (prior to shipment)

All

4. Concurrence on manufacturing plans in support of Run-at-Rate event

Supplier/ Site STA Engineer

5. Agreement on PFMEA Supplier/ PD Engineer/ Site STA Engineer

6. Updated APQP Assessment – Supplier (with cross functional team consensus)

7. Updated Manufacturing Site Assessment (MSA) Site STA Engineer

8. Agreed upon timing for next on-site evaluations All

IX. Reference Materials & Forms: 1. GPDS Process Sheet and Quality Document References 2. APQP Assessment User Guide

III. Process Detail

Evaluation #3


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I. Purpose: The purpose of Supplier Engagement Evaluation #3 is to focus on validating the completion of the PPAP Phase 1:

�� Dimensional Results �� Production Validation Testing �� Process Capability �� Appearance Approval

III. Participants: Lead: Site STA Engineer Support: PD Engineer, Buyer and other Jaguar Land Rover team members as required.

IV. Location: Supplier's Manufacturing Facility or as required

II. Timing: Note: Actual review timing will be dependent upon the specific needs of the component and the program.

Start Finish

PT <FDJ> Prior to Production

Validation (PV) In Plant Date

UN/UP <PEC> Prior to <TT> In Plant

Date (IPD)

V. APQP Element Focus: Evaluation #3 is focused on validating compliance to the PPAP requirements with emphasis on the 22 PPAP items listed below. Each supplier is mandated to ensure successful completion of all PPAP requirements by following the Jaguar Land Rover Phased Production Part Approval Process. Note: Where applicable, any APQP elements not yet closed require continued monitoring and tracking via the APQP Assessment.

III. Process Detail

Evaluation #3


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APQP Element Number

Element Description Jaguar Land Rover Lead Organisation

Deliverable

Number

3 Craftsmanship PD 6

6 DVP&R PD 11

7 Subcontractor APQP Status STA 13

8 Facilities, Tools & Gauges STA 16, 19

12 Engineering Change PD 26

14 Manufacturing Process Flow STA 28

16 Measurement System Evaluation STA 30

17 Qualified Lab. Document STA 31

18 Checking Aids STA 32

19 Pre-Launch Control Plan STA 33

20 Operator Process Instructions STA 34

21 Packaging Specifications MP&L 35

22 Production Trial Run STA 36

23 Production Control Plan STA 37

24 Initial Process Capability STA 38

25 Dimensional Results STA 39

26 PV Testing PD 40

27 PSW STA/PD 41, 42*

(*if single workstream)

28 Bulk Materials Requirement STA 45

29 Sample Product STA 46

30 Master Sample STA 47

31 Record of Compliance STA 48

III. Process Detail

Evaluation #3


VI. Agenda:

1. Introduction of key team members 2. Review previous Open Issues impacting PPAP

Phase 1 and, if single workstream, Phase 2 completion

3. Review APQP Assessment latest submission 4. Conduct review of manufacturing facility (If

evaluation at supplier site): a. Conduct Process walk with PFMEA and Control

plan checking for adequacy of control measures and accuracy of the Control Plan

b. Review each spot in the production process where an SC or CC is controlled.

c. Review repair or rework area and understand part identification strategy, gauging strategy, as well as how parts are re-entered into the normal production stream.

d. Review production gauging layout, function and calibration.

e. Review Gauge R&R results f. Review process capability results and information.

5. Update Open Issues with assigned responsibilities and timing in the APQP Assessment

6. Update Status in the APQP Assessment. 7. Agree on new APQP Assessment rating 8. Review Phase 1 submission (Phase 2 for single

workstream) 9. Agree on schedule for Evaluation #4 10. Update the Manufacturing Site Assessment as

required by evaluation results

Jaguar Land Rover and Supplier Leads:

1. Site STA Engineer 2. Supplier 3. Supplier

4. Site STA Engineer,

Supplier

5. Supplier 6. Supplier

7. All 8. Site STA Engineer, PD

Engineer 9. All

10. Site STA Engineer


1. Craftsmanship (APQP Element 3) a. Has the supplier followed the plan for obtaining Appearance Approval?

2. DVP&R (APQP Element 6) a. Has the latest design level been validated? Are there any risks and/or extraordinary

plans in place to support PPAP? 3. Sub-Contractor APQP Status (APQP Element 7)

a. Review evidence that supplier has received sub-supplier parts that were compliant to PPAP Phase 1 and 2 requirements.

4. Facilities, Tools and Gauges (APQP Element 8) a. Does the machine installation correspond to the plant layout?

III. Process Detail

Evaluation #3


VVVIIIIII... KKKeeeyyy AAArrreeeaaasss ooofff FFFooocccuuusss (((cccooonnnttt...)))::: 5. Engineering Change (APQP Element 12)

a. Ensure that all latest engineering changes are implemented in the tools and affected manufacturing process.

6. Manufacturing Process Flow (APQP Element 14)

a. Does the machine installation correspond to the flowchart?

7. Measurement System Evaluation (APQP Element 16) a. Review evidence that supplier has followed Measurement System Analysis plan and

data meets Jaguar Land Rover Customer Specific requirements. b. Check the accuracy of the calculations.

8. Qualified Laboratory Documentation (APQP Element 17) a. Review evidence that supplier has utilised a qualified internal and/or external

laboratory. Verify qualification is valid, by checking dates and results.

9. Checking Aids (APQP Element 18) a. Review evidence that gauges support latest design specifications. b. Review preventive maintenance for gauges in place for the life of the program.

10. Pre-launch Control Plan (APQP Element 19) a. Review evidence supplier followed the Pre-Launch Control Plan and all extraordinary

actions/measures have been documented. b. Agree with the rework/repair strategy. Which parts/components can be reworked/

scrapped? Has the team agree with that?

11. Operator Process Instructions (APQP Element 20) a. Verify all operators understand and follow the latest instructions.

12. Packaging Specifications (APQP Element 21) a. Has the supplier obtained packaging approval? Are there any approved provisions for

alternative packaging or shipping methods? b. Has the supplier complied with all system requirements to receive the latest Jaguar

Land Rover releases?

13. Production Trial Run (APQP Element 22) a. Review supplier’s evidence (including sub-suppliers) that PPAP Phase 0 has been

conducted successfully.

III. Process Detail

Evaluation #3


14. Production Control Plan (APQP Element 23)

a. Verify FMEA linkages in the Production Control. b. Verify if Lessons Learned from previous builds/concerns have been incorporated into the

Production Control Plan. c. Verify Reaction Plans have been accurately identified. d. Verify if supplier has enough controls to prevent defective parts (including those in the rework

areas) to be shipped to Jaguar Land Rover.

15. Initial Process Capability (APQP Element 24) a. Verify that capability studies were conducted according to Jaguar Land Rover specific

requirements. b. Check normality using a normal probability plot, three standard statistical tests (Anderson-

Darling, Kolmogorov-Smirnov and Ryan-Joiner) and a histogram.

16. Dimensional Results (APQP Element 25) a. Verify dimensional results are acceptable according to the design record.

17. PV Testing (APQP Element 26) a. Verify PV was successfully completed with parts generated during PPAP Phase 0 including

parts from repair/rework areas and alternate production intended processes.

18. PSW (APQP Element 27) a. For PPAP Phases 1 and 2 sign-off, ensure that parts from PPAP Phase 0 were used. b. Review PPAP package to validate that all Phase 1 requirements have been met. c. For single workstream, validate that all Phase 2 requirements have been met.

19. Bulk Materials Requirement (APQP Element 28) a. Verify supplier has met all the agreed items in the Bulk materials Checklist.

20. Sample Product (APQP Element 29) a. Verify supplier has followed the plan to provide a sample product to Jaguar Land Rover

containing proper identification (e.g., parts branding, part number, site code, etc). b. Verify that the Sample Product was produced during the Run-at-Rate event.

21. Master Sample (APQP Element 30) a. Verify that the Master Sample was produced during the Run-at-Rate event. b. Has the Master Sample been properly stored to prevent against damage, dirt or environmental

changes? c. If a Master Sample was required per the design record, did PD approve the Master Sample? d. Verify that an approval date is clearly recorded on the Master Sample.

22. Records of Compliance (APQP Element 31) a. Verify all records of compliance have been submitted successfully.

III. Process Detail

Evaluation #3


VIII. Outputs:


1. Summary Report for Evaluation Site STA Engineer


a. AAR Approved Supplier/PD Engineer

b. DV Testing Completed Supplier/PD Engineer

c. Sub-supplier PPAP Phase 1 (or equivalent) completed Supplier/Site STA Engineer

d. Facilities/tools/gauges are at the final production location


e. Supplier’s demonstrated OEE (Phase 0) supports capacity requirements


f. Jaguar Land Rover Engineering changes approved and recognised by suppliers


g. Final Process Flowchart supports PPAP Phase 0 event Supplier/ PD Engineer

h. Gauge R&R results <= 10% per PPAP Jaguar Land Rover Customer Specifics


i. Supplier external and internal laboratory compliance Supplier/Site STA Engineer

j. Checking aids compliant with part specifications Supplier/Site STA Engineer/ PD Engineer

k. Pre-launch Control Plan completed with linkages Supplier/Site STA Engineer

l. Operator process instructions completed Supplier/Site STA Engineer

m. Packaging approval process completed Supplier/MP&L Analyst

n. PPAP Phase 0 (including sub-supplier) completed Supplier/Site STA Engineer

o. Production Control Plan completed with linkages Supplier/Site STA Engineer

p. Initial Process Capability Results (Ppk >= 1.67) Supplier/Site STA Engineer

q. 100% of required measurement points within tolerance Supplier/Site STA Engineer

r. PV Testing Completed Supplier/PD Engineer

s. PPAP Phase 1 completed Supplier/Site STA Engineer

t. PPAP Phase 2 completed (if single workstream) Supplier/Site STA Engineer

u. Bulk materials checklist included in PPAP submission Supplier/Site STA Engineer

v. Sample Product produced with Jaguar Land Rover identification


w. Master Sample approved Supplier/Site STA Engineer

x. Jaguar Land Rover specific-requirements documented Supplier/Site STA Engineer

3. PPAP Phase 1 approval (and Phase 2 if single workstream)

Site STA Engineer, PD Engineer

4. Updated APQP Assessment Supplier (with cross functional team consensus)

5. Updated Manufacturing Site Assessment (MSA) Site STA engineer

6. Agreed upon timing for next on-site evaluations All

IX. Reference Materials & Forms: 1. GPDS Process Sheets and Quality Document References 2. APQP Assessment User Guide

III. Process Detail

Evaluation #4


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I. Purpose: The purpose of the Priority Supplier Evaluation #4 is to verify the supplier's production system can support customer declared daily planning volumes (DPV) and launch ramp-up curve while meeting PPAP Phase 2 and 3 requirements.

II. Timing:

Start Finish

Evaluation 4 <PP> Build in Plant Date

Prior to <MP1> In Plant Date

Note: Actual review timing will be dependent upon the specific needs of the component and the programme.

III. Participants: Lead: Site STA Engineer Support: PD Engineer, Buyer and other Jaguar Land Rover team members as required.

IV. Location: Supplier's Manufacturing Facility or as required.

V. APQP Element Focus: Evaluation #4 is focused on validating the compliance of PPAP Phase 3 requirements with emphasis on 4 PPAP items listed below. Specifically, this evaluation verifies the overall production system's capacity, and ensures that the supplier achieves both the launch ramp-up curve and steady on-going production while meeting Phase 3 PPAP requirements. The responsible supplier is mandated per GPDS process sheets (see Reference Materials & Forms) to ensure successful completion of all PPAP requirements by following Jaguar Land Rover’s Phased Production Part Approval Process.

APQP Element Element Description Jaguar Land Rover Lead Organisation

Deliverable

3 Craftsmanship PD 7

5 Design/Manufacturing Reviews PD/STA 10

7 Sub-supplier APQP Status STA 14

27 PSW STA/PD 42* (*if multiple workstreams)

43,44

III. Process Detail

Evaluation #4


VI. Agenda:

1. Introduction of key team members 2. Review previous Open Issues impacting PPAP

Phase 3 completion 3. Review APQP Assessment latest submission 4. Review Capacity Analysis Report submission 5. Conduct review of manufacturing facility to verify

key constraints and evidence of Jaguar Land Rover capacity support

6. Verify personnel hiring and training 7. Update Open Issues with assigned

responsibilities and timing in the APQP Assessment

8. Update Status in the APQP Assessment. 9. Agree on new APQP Assessment rating 10. Review final PPAP Phase 3 Warrant 11. Agree on follow-up evaluation schedule, if

required. 12. Update the Manufacturing Site Assessment as

required by evaluation results

Jaguar Land Rover and/ or Supplier Leads:

1. Site STA Engineer 2. Supplier

3. Supplier 4. Supplier, Site STA Engineer 5. Supplier, Site STA Engineer

6. Supplier, Site STA Engineer 7. Supplier 8. Supplier 9. All 10. Site STA Engineer 11. All 12. Site STA Engineer


1. Craftsmanship (APQP Element 3) a. Does the part match (colour/grain) in the vehicle? Has the supplier incorporated all

colour changes according to the Colour Harmony process?

2. Design/Manufacturing Reviews (APQP Element 5) a. Have all issues/concerns been addressed in the FMEA and Control Plan? Have all

action plans implemented and proven to be effective?

3. Sub-Supplier APQP Status (APQP Element 7) a. Verify supplier’s evidence that all sub-suppliers are capable to achieve PPAP Phase

3 or equivalent.

4. PSW (APQP Element 27) a. Are all personnel (Salary, Direct and Indirect Labour) hired and trained to support

Phased PPAP, including Run-at-Rate event(s)? b. For multiple workstreams, analyse PPAP Phase 2 results. Has the supplier met all

quality requirements? c. Analyse PPAP Phase 3 results documented in the Capacity Analysis Report.

III. Process Detail

Evaluation #4


VIII. Outputs:




a. Colour changes completed in support of Colour Harmony


b. Quality issues closed and effective Supplier/Site STA Engineer

c. Sub-supplier PPAP Phase 3 (or equivalent) completed

Supplier/site STA Engineer

d. PPAP Phase 2 completed (if multiple work streams)


e. PPAP Phase 3 completed Supplier/Site STA Engineer

f. Supplier’s demonstrated OEE (Phase 3 PPAP) supports capacity requirements


3. Personnel (Salary, Direct and Indirect) hired and trained Supplier/Site STA Engineer


5. Approved PPAP Phase 3 (includes Capacity Analysis Report – C.A.R)

Site STA Engineer

6. Updated APQP Assessment if outstanding issues exist Supplier (with cross functional team consensus)

7. Updated Manufacturing Site Assessment (MSA), if required

Site STA Site Engineer

8. Agreed upon timing for next on-site evaluations, if required

All

IX. Reference Materials & Forms: 1. GPDS Process Sheets and Quality Document References 2. APQP Assessment User Guide

III. Process Detail

Programme Reporting Process


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As described in the Process Overview, reporting within the APQP Process will centre on 3 key documents:

Next Milestone

FDJ G RProcess

Application




October Data



Process

Output


0

10

20

30

40

50

60

70

80

90

100



0

50

100

150

200

250

300

350

400

450

500


Report Submission

0

10

20

30

40

50

60

70

80

90

100



B C

B. ELEMENT SUMMARY REPORT C. SUPPLIER SCORECARD

A. Monthly Supplier APQP ASSESSMENT Submissions for all Program NTEI Suppliers

III. Process Detail



1133.. aa.. AAPPQQPP AASSSSEESSSSMMEENNTT::

I. Purpose: The APQP ASSESSMENT is the single focus for suppliers and teams to rate status for individual sites/commodities against the 31 APQP elements.

II. Applicability: The Assessment will be completed for each NTEI Commodity/Supplier combination in a programme (including Priority & Non-Priority sites). The Assessment will be used by the supplier and the Jaguar Land Rover team from the time of sourcing through PPAP completion. The current assumption is that the supplier will update and submit to Jaguar Land Rover the Assessment monthly. Jaguar Land Rover Management Reports will be derived from the data in the Assessment.

III. APQP ASSESSMENT - Structure: The APQP Assessment contains 3 sections: � Header Section � Element Status Section � Summary Section

1) Header Section The header section of the Assessment provides general information about part, supplier, team contacts, and key program dates. There are also selection boxes that indicate Priority/Non-Priority and GPDS Vehicle Partition (Powertrain – PT, Underbody – UN, Upperbody – UP). These selection boxes are important because they are required for management reports, and they will display the proper rows to reflect differences in UP and UN timing, for example

The header should be completed at the beginning of the programme, and will only be updated as team members or programme dates change.

III. Process Detail



1133..aa.. AAPPQQPP AASSSSEESSSSMMEENNTT –– SSttrruuccttuurree ((ccoonntt..))::

� 31 APQP Elements The Element Status Section is divided into 31 parts from the elements of the APQP and PPAP processes.

�

�

�

� 49 Deliverables (minimum 1 per element)

Within each of the 31 APQP elements are deliverables. There is at least one deliverable for each APQP/PPAP element. The status of these deliverables drives the rating (Red/Yellow/Green/Complete/NA) status for each element. Deliverables are intended to reflect, where possible, quantifiable evidence of element success or completion. For example, deliverables will reflect key in-process metrics like Cpk or OEE.

III. Process Detail



1133.. aa.. AAPPQQPP AASSSSEESSSSMMEENNTT –– SSttrruuccttuurree ((ccoonntt..))::

� 215 Expectations

Supporting each of the deliverables are sets of expectations. Expectations are guidelines used to assist team members in the successful completion of the elements, and where applicable, help rate the completion of the related deliverables.

While expectations will be rated Red/Yellow/Green/Complete, they will not drive the element rating – only deliverables will drive element ratings. The ratings for expectations are intended only for internal use and communication. The expectation section can be expected to be updated and added to over time to reflect systemic lessons learned.

III. Process Detail



3) Summary Section This part of the Assessment is intended to summarize the element status for the entire document. Currently, there are 4 parts to the summary:

1133.. aa.. AAPPQQPP AASSSSEESSSSMMEENNTT –– SSttrruuccttuurree ((ccoonntt..)):: Current Milestone Deliverable Status The spreadsheet provides a summary report of the deliverables that are required to be complete up until the milestone being reported. There are two ways current deliverables can be assessed. Because there is often a long span of time between GPDS milestones, it is not always appropriate to report that a current deliverable is Complete or Red. A deliverable may be on track to be complete at the next milestone that is more than 1 month in the future, so it is appropriate to use a different rating. The “Pre-Assessment” selection button is designed to allow the use of the proper rating. In the below example, a Chart graphically represents the number of Red, Complete, Not Submitted and Not Applicable Deliverables when using the Pre-Assessment Mode.

CURRENT MILESTONE DELIVERABLE STATUS

FORECAST MILESTONE DELIVERABLE STATUS

PPAP ELEMENT DATES

AND BUILD SUPPORT PLANS

SUPPLIER EVALUATIONS

CHART

ACTION PLAN

AREA

III. Process Detail



The Action Plan Summary box contains the 8 key parameters (Sourcing, Design, Tooling, Process, DV/PV Testing, Capacity, Logistics and Others) affected by the Red status. These key parameters are required to be addressed in the Action Plan. The text entered in the Action Plan Summary box must be succinct and objective since it populates the Supplier Scorecard report.

��Important: The action plan and ratings obtained in this section will automatically feed the

Element Summary and Supplier Scorecard Reports. Any updates must be agreed upon prior to the submission date and in time to support the creation of the two reports.

1133.. aa.. AAPPQQPP AASSSSEESSSSMMEENNTT –– SSttrruuccttuurree ((ccoonntt..)):: Forecast Milestone Deliverable Status The APQP Assessment also provides a second chart containing an outlook of all the remaining deliverables that are not yet required to be complete. This will provide a future outlook for the part(s) and allowing the teams to forecast issues, leverage workload and perform planning activities.

�Reminder:

Before starting a new assessment, confirm that the fields Current Milestone, Priority Site, Vehicle Partition, Program Code, Model Year, APQP Assessment Submission Dates are correctly selected and completed.

III. Process Detail



PPAP Element Dates and Build Support Plan The PPAP Element Dates information is a summary of the promised and actual PPAP dates in the Element Status automatically populated from the “Planned and Actual Completion Date” columns. The Build Support Plan information will be rolled up as part of the SUPPLIER SCORECARD.

Supplier Evaluation Summary The Supplier Evaluation Summary information is required for Priority Suppliers only (it appears only when the "Priority" supplier boxed is selected in the header). The team will manually track planned and actual evaluation dates along with the team’s attendance for each evaluation. Rating Criteria and Assessment Definition Against the programme milestones, Deliverables and Expectations will show two colour schemes: Light Grey With No Box – Forecast Period (activity is not expected in this time period, but the supplier must enter a rating to show whether or not they forecast risk to the deliverable completion in the future Dark Grey With Black Box – Deliverable/Expectation Start & End Points (activity is expected to begin and end between these milestones

Light Grey

with no Box

Dark Grey

with Black

Box

PPAP Element Dates

And

Build Support Plan

Supplier Evaluation

Summary

III. Process Detail



NOTE: All APQP deliverables must be rated either C (complete) or R (red) at the milestone when the deliverable is due using the FINAL ASSESSMENT Mode. Additional information on how to use and interpret results from the APQP Assessment can be found in the APQP Assessment User Guide.

III. Process Detail



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1133bb.. EElleemmeenntt SSuummmmaarryy RReeppoorrtt:: There are 4 parts of the Summary Report:

� Report Submission � Deliverables - % On Target � APQP Deliverable Reds

� Individual Element/Deliverables Roll Up

Report Submission This Section tracks the status of the Report submissions:

Deliverables - % On Target The Deliverables - % On Target chart shows the percent of the 49 Assessment deliverables complete versus the required timing.

APQP Deliverable Reds The APQP Deliverable Reds is a status of the number of Red Deliverables across the Programme.

Next Milestone

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The solid bars represent the cumulative plan for deliverable completion against the requirement at each milestone.

Note: This chart is automatically calculated from data taken from the individual APQP Assessments.

III. Process Detail



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Individual Element/Deliverable Roll-Up The individual Element/Deliverable Roll-Up shows the status of each of the 49 deliverables for all of a program’s NTEI suppliers. One line will denote the percent of suppliers who are showing completion for a specific deliverable at the given milestone.

Note: This chart is automatically calculated from data taken from the individual APQP Assessments.

III. Process Detail



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I. Purpose: The SUPPLIER SCORECARD is intended to provide individual supplier status at a milestone. The Scorecard is intended to be automatically rolled-up from the individual supplier APQP Assessments for both Priority and Non-Priority suppliers. It is a one-line summary of a supplier’s Assessment. Suppliers who have not completed the required deliverables for a given milestone will be rated “RED” and will be sorted to the top of the report.

JLR APQP Priority Supplier Process Manual

Documents

Transcript of JLR APQP Priority Supplier Process Manual