Apqp Forms

Table of ContentsTable of ContentsAppendix ReferenceRevision1APQP Open IssuesAppendix_84/27/072APQP Timing PlanAppendix_94/27/073APQP Contact ListAppendix_216/9/064AIAG APQP ChecklistsAppendix_1111/3/085Program Review - Paper & ElectronicAppendix_6_111/21/086Program Review - ExpressAppendix_6_13/12/087All Run@Rate Forms (R@R forms not included in the APQP forms due to size)Appendix_152/20/088Delphi PFMEA Severity RankingsQFP Training Website9/6/059Delphi PFMEA Occurrence RankingsQFP Training Website9/6/0510Delphi PFMEA Detection RankingsQFP Training Website9/6/05

Click on the title below and you will be linked to the appropriate worksheet. To get back to the Table of Contents, use the worksheet tab keys at the bottom or click on the back key at the top.&L8/04APQP Open IssuesAPQP Timing PlanAPQP Contact ListAIAG APQP ChecklistsDelphi PFMEA Severity RankingsDelphi PFMEA Occurrence RankingsDelphi PFMEA Detection RankingsProgram Review - Paper & ElectronicProgram Review - Express

APQP Open IssuesAPQP Open IssuesSupplier/MfgLocation:Part Number(s):Supplier Contact:Program(s):Delphi SQE Contact:Part Name:Issue No.Issue Origin/DateIssues Description and/or SketchResponsibilityAssigned Date/Status DateAction PlanForecast Completion DateProgress1.2.3.4.5.6.7.8.9.10.Progress Key:

Issue IdentifiedAction Plan ProposedAction Plan ImplementedIssue Resolved

APQP Timing PlanAPQP Timing PlanSupplier Duns:Part Number(s):Supplier/Mfg Location:(CL)(CL)(CL)PPAP Date:Supplier Contact:Description:Supplier Telephone:Tool SupplierAQE/SQE Contact:(If applicable):AQE/SQE Telephone:MY/Program:SOP Date:Program EventStartFinishStatusCommentsPlanned(mm/dd/yy)Actual (mm/dd/yy)PlannedActual1) Submit Team Feasibility Commitment Form2) Source Selection by Delphi P.O. Issued3) Initiate APQP Activity4) Develop Product Quality Timing Plan5) Complete Preliminary Process Flow Diagram6) Complete Preliminary Listing of Special Product and Process Characteristics7) Design FMEA- Develop or Obtain Copy8) Design Review9) Review Specifications:Engineering, Material, Drawing10) Review Subcontractor APQP Status11) Complete Facility & Layout12) Complete Machinery & Equipment , Tooling Design & Build13) Prototype Builds14) Gage Reviews- Design, Build, R&R15) Submit Team Feasibility Commitment Form - Design16) Review Quality Systems-Procedures and Operator Work Instructions17) Complete Final Production Process Flow Chart18) Complete Process FMEA19) Complete Pre-Launch Control Plan20) Define Packaging Specifications21) Complete PPAP Production Run, Capability Studies, Production Control Plan22) Submit Supplier PPAP23) Conduct Run @ Rate24) Complete Early Production Containment PlanPotential Issues exists (comments must be noted)

APQP Contact ListSupplier Quality APQP Project Contact ListSupplier CodeManufacturing AddressSupplier NameContactsName and TitleMailing Address and E-Mail AddressContact NumbersSales ContactProduct EngineerQuality ResidentProgram Managerin Sales OfficeProgram Managerin Manufacturing FacilityAPQP ContactQuality ManagerQuality Engineer1st Shift Contact2nd Shift Contact3rd Shift ContactPRR ResponseResponsibilityDelphi EngineeringDelphi BuyerDelphi SQE

&RRevised08/11/04

AIAG ChecklistsA-1 DESIGN FMEA CHECKLISTCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate1Was the DFMEA prepared using the Chrysler, Ford and General Motors Potential Failure Mode and Effects Analysis (FMEA) reference manual, and applicable customer specific requirements?2Have historical campaign and warranty data been reviewed?3Have best practices and lessons learned from similar part DFMEAs been considered?4Does the DFMEA identify Special Characteristics?5Have pass-through characteristics (glossary) been identified and reviewed with affected suppliers for FMEA alignment and appropriate controls in the supply base?6Have special characteristics designated by the customer or organization been reviewed with affected suppliers to assure FMEA alignment?7Have design characteristics that affect high risk priority failure modes been identified?8Have appropriate corrective actions been assigned to high risk priority numbers?9Have appropriate corrective actions been assigned to high severity numbers?10Have risk priorities been revised when corrective actions have been completed and verified?Revision Date:Pg. 1 of 1Prepared By:A-2 DESIGN INFORMATION CHECKLISTCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDateA. General1Does the design require:a- New materials?b- Special tooling?c- New technology or process?2Has assembly build variation analysis been considered?3Has Design of Experiments been considered?4Is there a plan for prototypes in place?5Has a DFMEA been completed?6Has a DFMA (Design for Manufacturability and Assembly) been completed?7Have service and maintenance issues been considered?8Has the Design Verification Plan been considered?9If yes, was it completed by a cross functional team?10Are all specified tests, methods, equipment and acceptance criteria clearly defined and understood?11Have Special Characteristics been selected?12Is bill of material complete?13Are Special Characteristics properly documented?Revision Date:Pg. 1 of 3A-2 DESIGN INFORMATION CHECKLIST - CONTINUEDCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDateB. Engineering Drawings14Are reference dimensions identified to minimize inspection layout time?15Are sufficient control points and datum surfaces identified to design functional gages?16Are tolerances compatible with accepted manufacturing standards?17Can existing and available inspection technology measure all design requirements?18Is the customer designated engineering change management process used to manage engineering changes?C. Engineering Performance Specifications19Have special characteristics been identified?20Are test parameters sufficient to address required use conditions, i.e., production validation and end use?21Have parts manufactured at minimum and maximum specifications been tested as required?22Will all product testing be done in-house?23If not, is it done by an approved supplier?24Is the specified in-process performance test sampling size and/or frequency consistent with manufacturing volumes?25Has customer approval been obtained, e.g., for testing and documentation, as required?Revision Date:Pg. 2 of 3A-2 DESIGN INFORMATION CHECKLIST - CONTINUEDCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDateD. Material Specification26Are special material characteristics identified?27Where the organization is design responsible, are specified materials, heat treat and surface treatments compatible with the durability requirements in the identified environment?28Where required, are the material suppliers on the customer approved list?29Has the organization developed and implemented a process to control incoming material quality?30Have material characteristics requiring inspection been identified?If so,a- Will characteristics be checked in-house?b- If checked in-house, is test equipment available?c- If checked in-house, are competent people available to assure accurate testing?31Will outside laboratories be used?a- Does the organization have a process in place to assure laboratory competency such as accreditation? NOTE: Competency needs to be assured, regardless of the organization's relationship with the laboratory.32Have the following material requirements been considered:a- Handling, including environmental aspects?b- Storage, including environmental aspects?c- Have the materials/substance composition been reported in accordance with customer requirements e.g., IMDS?d- Have polymeric parts been identified/marked per customer requirements?Revision Date:Pg. 3 of 3Prepared By:A-3 NEW EQUIPMENT, TOOLING AND TEST EQUIPMENT CHECKLISTCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate1Does the design require:a- New materials?b- Quick change?c- Volume fluctuations?d- Mistake proofing?2Have lists been prepared identifying: (Include all suppliers)a- New equipment?b- New tooling?c- New test equipment (including checking aids)?3Have acceptance criteria been agreed upon for: (Include all suppliers)a- New equipment?b- New tooling?c- New test equipment (including checking aids)?4Will a preliminary capability study be conducted at the tooling and/or equipment manufacturer?5Has test equipment feasibility and accuracy been established?6Is a preventative maintenance plan complete for equipment and tooling?Revision Date:Pg. 1 of 2A-3 NEW EQUIPMENT, TOOLING AND TEST EQUIPMENT CHECKLIST - CONTINUEDCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate7Are setup instructions for new equipment and tooling complete and understandable?8Will capable gages be available to run preliminary process capability studies at the equipment supplier's facility?9Will preliminary process capability studies be run at the processing plant?10Have process characteristics that affect special product characteristics been identified?11Were special product characteristics used in determining acceptance criteria?12Does the manufacturing equipment have sufficient capacity to handle forecasted production and service volumes?13Is testing capacity sufficient to provide adequate testing?14Has the measurement equipment been verified and documented showing qualification for the required scope of measurement and testing?Revision Date:Pg. 2 of 2Prepared By:A-4 PRODUCT/PROCESS QUALITY CHECKLISTCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate1Is customer assistance or approval required for the development of the control plan?2Has the organization identified who will be the quality liaison with the customer?3Has the organization identified who will be the quality liaison with its suppliers?4Has the quality management system been reviewed and approved per customer specific requirements?5Are there sufficient personnel identified to cover:a- Control plan requirements?b- Layout inspection?c- Engineering performance testing?d- Problem reaction and resolution analysis?6Is there a documented training program that:a- Includes all employees?b- Lists whose been trained?c- Provides a training schedule?7Has training been completed for:a- Statistical Process Control?b- Capability studies?c- Problem solving?d- Mistake proofing?e- Reaction plans?f- Other topics as identified?8Is each operation provided with process instructions that are keyed to the control plan?Revision Date:Pg. 1 of 4A-4 PRODUCT/PROCESS QUALITY CHECKLIST - CONTINUEDCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate9Are standard operator instructions accessible at each work station?10Do operator instructions include pictures and diagrams?11Were operator/team leaders involved in developing standard operator instructions?12Do inspection instructions include:a- Easily understood engineering performance specifications?b- Test frequencies?c- Sample sizes?d- Reaction plans?e- Documentation requirements?13Are visual aids:a- Appropriate, easily understood and legible?b- Available?c- Accessible?d- Approved?e- Dated and current?14Is there a procedure to implement, maintain, and establish reaction plans, for issues such as out of control conditions based on statistical process control?15Is there an identified problem solving process that includes root cause analysis?16Are the latest drawings and specifications available for the operator, in particular at the points of the inspection?a- Have engineering tests (dimensional, material, appearance, and performance) been completed and documented as required in accordance with customer requirements?Revision Date:Pg. 2 of 4A-4 PRODUCT/PROCESS QUALITY CHECKLIST - CONTINUEDCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate17Are the current forms/logs available for appropriate personnel to record inspection results?18Are the following available and placed at the appropriate points of the operation?a- Monitoring and measurement devices?b- Gage instructions?c- Reference samples?d- Inspection logs?19Have provisions been made to certify and calibrate gages and test equipment at a defined frequency that is appropriate?20Have required measurement system capability studies been:a- Completed?b- Accepted?21Have initial process capability studies been conducted per customer requirements?22Are layout inspection equipment and facilities adequate to provide initial and ongoing layout of all details and components in accordance with customer requirements?23Is there a documented procedure for controlling incoming material that may include, for example, the following items:a- Characteristics to be inspected?b- Frequency of inspection?c- Sample size?d- Designated location for approved product?e- Disposition of nonconforming products?24Have sample production parts been provided per customer requirements?Revision Date:Pg. 3 of 4A-4 PRODUCT/PROCESS QUALITY CHECKLIST - CONTINUEDCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate25Is there a procedure to identify, segregate, and control nonconforming products to prevent shipment?26Are rework/repair procedures available to assure conforming product?27Is there a procedure to requalify repaired/reworked material?28Has a master sample, if required, been retained as part of the part approval process?29Is there an appropriate lot traceability procedure?30Are periodic audits of outgoing products planned and implemented?31Are periodic assessments of the quality system planned and implemented?32Has the customer approved the packaging and the packaging specification?Revision Date:Pg. 4 of 4Prepared By:A-5 FLOOR PLAN CHECKLISTCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate1Have lean concepts been applied in considering material flow?2Does the floor plan identify all required process and inspection points?3Have clearly marked areas for all material, tools, and equipment at each operation been considered?4Has sufficient space been allocated for all equipment?5Are process and inspection areas:a- Of adequate size?b- Properly lighted?6Do inspection areas contain necessary equipment and record storage?7Are there adequate:a- Staging areas?b- Impound areas?8Are inspection points located to prevent shipment of nonconforming products?9Are there controls for each process to eliminate contamination or inappropriate mixing of product?10Is material protected from overhead or air handling systems contamination?11Have facilities been provided for final product audit?12Are facilities adequate to control movement of nonconforming incoming material?Revision Date:Pg. 1 of 1Prepared By:A-6 PROCESS FLOW CHART CHECKLISTCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate1Does the floor chart illustrate the entire process from receiving through shipping, including outside processes and services?2In the development of the process flow chart, was the DFMEA used, if available, to identify specific characteristics that may be critical?3Is the flow chart keyed to product and process checks in the control plan and PFMEA?4Does the flow chart describe how the product will move, i.e., roller conveyor, slide containers, etc.?5Has the pull system/optimization been considered for this process?6Have provisions been made to identify and inspect reworked product before being used?7Are material controls for movement and staging of product including appropriate identification properly defined and implemented? The controls should address incoming supplier product as well as subcontracted processes?Revision Date:Pg. 1 of 1Prepared By:A-7 PROCESS FMEA CHECKLISTCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate1Was the Process FMEA prepared by a cross functional team? Has the team taken into account all customer specific requirements, including FMEA methodologies as shown in the current edition of FMEA?2Have all operations including subcontracted, or outsourced processes and services been considered?3Have all operations affecting customer requirements including fit, function, durability, governmental regulations and safety been identified and listed sequentially?4Were similar part/process FMEA's considered?5Have historical campaign and warranty data been reviewed and used in the analysis?6Have you applied the appropriate controls to address all of the identified failure modes?7Were severity, detection and occurrence revised when corrective action was completed?8Do the effects consider the customer in terms of the subsequent operation, assembly, and product?9Were customer plant problems used as an aid in developing PFMEA?10Have the causes been described in terms of something that can be corrected or controlled?11Have provisions been made to control the cause of the failure mode prior to subsequent or the next operation?Revision Date:Pg. 1 of 1Prepared By:A-8 CONTROL PLAN CHECKLISTCustomer or Internal Part No.Revision LevelQuestionYesNoN/AComment/Action RequiredPersonDueResponsibleDate1Was the control plan developed according to the methodology described in Chapter 6 of this APQP manual?2Have all the controls identified in the PFMEA been included in the control plan?3Are all special product/process characteristics included in the control plan?4Were DFMEA and PFMEA used to prepare the control plan?5Are material specifications requiring inspection identified?6Does the control plan address incoming (material/components) through processing/assembly including packaging?7Are engineering performance testing and dimensional requirements identified?8Are gages and test equipment available as required by the control plan?9If required, has the customer approved the control plan?10Are the gage methodology and compatibility appropriate to meet customer requirements?11Have measurement systems analysis been completed in accordance with customer requirements?12Are sample sizes based upon industry standards, statistical sampling plan tables, or other statistical process control methods or techniques?Revision Date:Pg. 1 of 1Prepared By:

Meeting InputsMeeting Plan ChecklistAQE InputUtilize Program Review Form -or -Utlize Express Program Review FormPPAP RequirementsR@R Timing and RequirementsDelphi's Customer Specific RequirementsIntroduction/Instructions to all Delphi Supplier Websites.Engineering InputLatest part prints and specificationsProgram Timing / Critical CharacteristicsTechnical Documents including sub-component drawings.Program Information such as estimated annual usage, PPAP dates, SOP dates, etc.Pilot and Prototype requirements and timing.Key/Critical characteristics for PPAPBuyer Input (from quote)Packaging planQuoted Tool CapacityEstimated Annual VolumeSupplier InputSupplier Scorecard, be prepared to discussUpdated supplier information (Supplier Profile) including contact list.Program Timing including tooling, PPAP, R@RSupplier issues/concerns caused by Delphi Delphi.Supplier issues/concerns not associated with Delphi.Questions/concerns needing to be addressed by DelphiOther Potential Supplier InputInformation on the manufacturing facility (Location, Capacity, etc.)Preliminary Process Flow Diagram (PFD)Preliminary Control PlanPreliminary Timing ChartsManufacturing Site Organizational chartSubcontractors/Sub-Tier MgtCapability studies on similar parts.Major disruptions, Problem Cases, PPM/Total Defects Reduction PlanTooling / Equipment PlansChecking Fixture PlanPrototype PlanOn-Going Product Assurance TestingPreliminary PFMEAProof of Delphi required quality certifications or transition plans(Should be posted in Supplier Profile)Description of Operator Training programPlan for communication between technical support and manufacturing plant.Completed Team Feasibility CommitmentError Proofing/ Poke-Yoke Techniques

&CPage &P&RLast Revised: 8/22/07

Program ReviewDELPHIPROGRAM REVIEW SUMMARYLink to AIAG Web SiteDate of Review:New Risk Level of Product(s)Supplier :(Determine upon completion of Program Review)Supplier Duns:Sub-Tier Supplier **:Supplier/Mfg Location:** List if sub-tier supplier contributes more than 50% of manufacturing, controls a key process or directly affects a key product characteristic. A separate program review may be required for this supplier. Reference Team Feasibility document on RFQ.Critical process sub-tiers for heat treating, coating and plating must comply with the AIAG assessment requirements stated in CQ9, 11 and 12. Including qualified auditors to complete the assessments. See Section KPART NUMBERDESCRIPTIONMODELDELPHIPLATFORMHIGH VOLUMEYEARSTART OFSCENARIOPRODUCTION(Vehicles)123456CHECK IF IN ATTENDANCEDELPHI CONTACTSTITLENAMEPHONEEMAILAQESQEBUYERPROGRAM MGRPPAP COORDINATORCOMPONENT ENGINEERPRODUCT ENGINEERRESPONSE TEAMSUPPLIER CONTACTSNAMEPHONEEMAILPRESIDENTQUALITY MANAGERKEY CONTACTPPAP CONTACTQUALITY CONTACTRUN@RATE CONTACTHighlight first column in color to indicate activity requirements.LEGEND:COMPLETE(Ctrl-g)OPEN WITH RECOVERY PLAN(Ctrl-y)NO PLAN OR PLAN DOES NOT MEET PROGRAM TIMING(Ctrl-r)AProduct ApplicationDoes the supplier have working knowledge of the following items?IssuesDescription and/or SketchResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1Intended use of product.2End use application of product.3Latest Prints and Specifications, Traceability4Source restrictions specified by engineering.BDesign ReviewIdentify characteristics that will require controls. (KPC's, KCC's, CQC's, QCI's) Ideally, a six sigma capability is the goal. Note gaps between desired and actual, with action plans to close.IssuesDescription and/or SketchResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1Critical dimensions and interfaces of productKPC's, KCC's, CQC's, QCI's, Pass-Through Characteristic/Feature2Fit & Function, Safety Compliance3Part Packaging Specification4Part Labeling requirementsNote: Shipping Container Pkg & Labeling requirements (Suppliers must comply with requirements. Communicate to suppliers that they should contact their Delphi PC&L rep. if they have questions or need assistance. Information can also be found on the DelphiSupplier(SQ can note date that this Delphi PC&L requirement was reinforced with the supplier).CProgram InformationList information required belowDetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1Platform2Model Year3Delphi Estimated Annual Volume4Supplier PPAP Due Date5Delphi SOP6Delphi Manufacturing Site7Supplier Quoted Tool Capacity (5 days)DProduct Requirements & TimingRecord the following if applicable.DetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1Prototype requirements.2Pre-Production Requirements3Other Product RequirementsESupplier Tooling RequirementsDevelop a program review for the tooling supplier on critical components.DetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1Supplier Tooling Completion Dates2Tooling Supplier Name (if different)FSupplier Gage ReviewMutual Agreement on gage concept proposal.Certify Gage to product design record.DetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1Development and Approval of Gage Design Plan2Gage Evaluation including Measurement System Analysis (MSA)3Gaging Completion DatesGProduct Measurement PlanHave acceptable measurement methods been confirmed and correlated?DetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1.1Has Delphi received the suppliers plan for dimensional layout and measurement of the component? (Should include the measurement methods, layout, datums, tools, equipment and fixtures (if applicable))1.2Has engineering reviewed and approved the supplier plan for dimensional layout and measurement?1.3Has the Delphi Receiving Facility, reviewed and approved the supplier plan for dimensional layout and measurement? (Applicable for sites with a Receiving Inspection)1.4Not applicable: The supplier has received dimensional accreditation by the using division.HCapability Assessment GuidelinesList Characteristic(s) to be used in capability study.DetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1.1KPC / QCI (note details in column)1.2KPC / QCI (note details in column)1.3KPC / QCI (note details in column)2Capability Study Parameters3Can your process meet Ppk =/> 1.33? Goal is 2.04Can your process meet Cpk =/> 1.67?IMeasurement System Analysis GuidelinesAdd equipment used for Capability Assessment and MSA requirementsDetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1Measurement Equipment #1 & Methodology2Measurement Equipment #2 & Methodology3Measurement Equipment #3 & Methodology4Measurement Equipment #4 & Methodology5Measurement Equipment #5 & Methodology6Measurement Equipment #6 & MethodologyJDesign Responsible SuppliersList all issues/requirements if the supplier is design responsible.DetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1Was a Design Failure Modes & Effects Analysis (DFMEA) initiated by the supplier?2Has the Delphi PDT reviewed the DFMEA?3Are DFMEA open items addressed on an action plan and communicated to Delphi's PDT?KSpecial Process For Suppliers and Sub-Suppliers with CQI-9, 11 or 12 requirements, complete the following:Audit Completion DateResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1CQI 9 Heat Treatment assessment is required:2CQI 11 Plating assessment is required:3CQI 12 Coating assessment is required:LPPAP GuidelinesThe link below will take you to the Delphi SUPPLIER PPAP SUBMISSION CHECKLIST. Utilize the Checklist for PPAP discussions. List potential issues below for tracking purposes.DetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgressLink to SUPPLIER PPAP SUBMISSION REQUIREMENTS CHECKLIST(Use attached link or worksheet version provided.)https://delphi.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103457.xls12345MFirst Time Quality (FTQ) Improvement ProcessDetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1FTQ Improvement Process InitiationReview Delphi's FTQ procedure and training presentations as required.2FTQ Improvement Process DocumentationReview the use of Gate Charts / Step Down Charts / Alarm Charts (Appendix 31_2 & 57_3)3Check procedure or methods in place to comprehend FTQ documentation and improvement.4Determine if preliminary data from supplier accurately depicts FTQ results.NRun@Rate RequirementsThe link below will take you to the Delphi R@R Plan. Utilize the R@R Plan for discussions. List potential issues below for tracking purposes.DetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgressLink to Run@Rate Plan (Use attached link or worksheet version provided.)Run@Rate Planhttps://delphi.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103455.xlsRun@Rate Worksheethttps://delphi.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103455.xls12345OWEBSITE INFORMATIONDetermine the suppliers access and working knowledge of each Delphi database below.DetailsResponsibilityForecast Completion DateAction PlanActualCompletion DateProgress1Capability to access/update the following:1.1Supplier Profiles (Discuss Red/Yellow/Green status)1.2Supplier Suggestions Program (SSP/SCR)1.3Supplier Scorecard (Updated copy if current supplier)1.4Problem Solver1.5Customer Specific Requirements / Quality Expectations1.6Additional Forms & Procedures available on the website2Registered to the Delphi Supplier WebsiteMainly used for electronic PPAP submissions2.1Initial electronic PPAP submissions2.2SSP/SCR required PPAP submissionsEnd of file

&CPage &Phttps://delphi.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103457.xlshttps://delphi.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103455.xlshttps://delphi.portal.covisint.com/c/document_library/get_file?folderId=114313&name=DLFE-103455.xlsLink to AIAG Web Site

ProgRew InstructionsThe following instructions are intended to help the AQE/SQE in performing the Program Review. Take a moment to review theInstructions. The intent of the program review is to engage the supplier in conversations about various aspects of the currentprogram/parts and determine areas of concern that will need further action.The form is protected/locked so that users can tab through fields. To allow attachments (such as program rosters) and/orand/or additional information into any open field within the form, the form can be unprotected. The password is "unlock".This will allow each user to customize the program review to fit their needs while continuing to use a common form and process.We will start the instructions with definitions and acronyms:KPCKey Product CharacteristicsMost important product features or material properties for meeting customer requirements.The two kinds of KPCs are 1) safety and compliance, and 2) fit and function. KPCs may be attributes (present or not).It is required to target variable KPCs at nominal and reduce variation continuously because these characteristics are optimized at the nominalspecification and have a loss function associated with deviating from nominal.KCCKey Process Control CharacteristicMost important process characteristics that have a direct effect on the KPCs.Suppliers may designate additional process characteristics as KCCs.QCIQuality / Customer InterfaceA feature or property of a product that is contacted directly by the customer and has an immediate impact on their satisfactionif not within limits. Or, a characteristic that does not meet the KPC criteria, but is deemed critical to the final product or its manufacturability.QCCQuality Control CharacteristicMost important process characteristics that have a direct effect on the QCI's. Suppliers may designate additional process characteristics as QCI's.PPAPProduct Part approval process.Pass-Through CharacteristicIs a characteristic/feature where an anomoly only declares itself under certain conditions such as environmental stimulation and cannot be testedin Delphi's operations (i.e. soft tie rods, stepper motor with step loss and steering hose with incorrect rubber component.The first part of the Program Review is an informational list used by Delphi and the Supplier for better communication.Fill in the following information as thoroughly as possible:Date of ReviewSupplier-include both the facility name and parent name where applicableSupplier Duns Code-this is in reference to the manufacturing site producing the product.Supplier/Mfg LocationPart NumbersPPAP DateDescriptionPlatformModel YearSOP DateSupplier Contacts:-List key supplier contactsKey ContactPPAP ContactQuality ContactRun@Rate ContactDelphi Contacts-List key Delphi contactsAQESQEBuyerProgram ManagerPPAP CoordinatorComponent EngineerProduct EngineerResponse TeamNew Risk Level of Product-Once the review has been completed, evaluate the program risk based on your findings.Sections A through M are used to track the progress of the supplier through various aspects of building a new product. Each sectionfocuses on a specific area and is as comprehensive as possible.The first columns will be used to color code each line item. Green indicates completed, Yellow indicates Open with recovery plan, Red indicates the suppliers process will not meet Delphi requirements.The formatting for these three colors has been automated. Go to the cell you want to change, then hit the following key:for red use "Ctrl-r" for yellow use "Ctrl-y" for green us "Ctrl-g" this coding will also show up in black/white copies with patterns for each color..The columns represented in each section are used to promote communication between Delphi and the supplier. It also determines responsibility,forecasts completion dates, action plans, actual completion dates and progress. Each block is expandable to add information as necessary.The following gives an explanation of each section:Section AProduct ApplicationReview how the product will be used at Delphi and the customer, etc.Section BDesign ReviewReview prints/specs/ QCI/KPC, and pass-through characteristic/feature, packaging and labeling requirements.Section CProgram InformationReview with supplier so they understand the final product and it's requirements.Section DProduct Requirements & Timing# of parts required, type of product (saleable vs non-saleable) to be recorded.Section ESupplier Tooling RequirementsTooling completion and possible roadblocks should be discussed.Section FSupplier Gage ReviewEvaluate and approve gage designs.Section GProduct Measurement PlanConsider the measurement req't and techniques that will be used for dimensional layout on the component prior to ppap.Section HCapability Assessment GuidelinesDetermine based on the print requirements, customer requirements. Detail this section well.Section IMeasurement Systems Analysis GuidelinesBased on the item listed in section H, detail equipment and methodologies that will be used.Section JDesign Responsible SuppliersIf your supplier is responsible for the design, this section should be discussed.Section KSpecial ProcessEvidence of conformance to required CQI assessment required here.Section LPPAP GuidelinesHyperlink to Delphi's PPAP checklistSection MFirst Time Quality (FTQ) Improvement ProcessTraining and or evidence of conformance is reviewed in this section.Section NRun@Rate RequirementsHyperlink to Delphi's R@R planSection OWebsite InformationLists all websites and programs the supplier will need in working with Delphi.


Express"Express" Program ReviewSection A: Supplier Program ReviewPart Number:Delphi Information (From Roster Database & Request for Sourcing):Family Parent Part No. (if any):1Delphi Start Of Production DateProd. Mfg. Loc.:2Volume InformationYear:3Annual Usage:4Peak Weekly Usage:ForecastedBuilds5Type of Build:6Parts required Date:7Quantity:8PML9Build when PPAP is required:10Supplier PPAP Due Date11PPAP Level Required312CommentsSection B: Supplier Commitments (Supplier complete):13Supplier First Parts Promise Date14Estimated PPAP package delivery15Supplier Quoted 5 Day Capacity(vs. Peak Usage in question #4)16The supplier is responsible to register and use the Delphi Supplier Websites and must be capable to update and access the following:Supplier ProfilesSupplier Suggestion Program (SSP / SCR)Problem SolverCustomer Specific Requirements/ Quality ExpectationsIMDS system (reportable Chemicals)17The Supplier agrees to and understands the following:1. The only authorization to implement Delphi engineering changes (including marked up prints) must be issued by the Delphi Buyer.2. No change, of any kind, shall be made in material content, processing methods, testing methods, or location of manufacture without theprior written approval of Delphi Corporation.Agreed by:Authorized representativeDate18Supplier Comments/ Concerns:Section C: Run @ Rate :19Is Part Commodity Exempt? Y/NLetter Location:20Exemption Calc. (highest # 15 / # 4)(if less than 40%, may exempt Run @ Rate)21Approving Supplier Quality ManagerDate:22Comments:For Semiconductors Run at Rate is exempt. To ensure commitments are met a CAPACITY STUDY is required."Express" Program Review


Express InstructionsSPDP Express FormInstructionsPRINT IN PORTRAIT MODElSPDP Express forms should be filled in, transmitted, and stored electronically. For E&S - They should be stored in T:\PURCHASING\SUPL_DEV\AQE\RISK ASSESSMENTS\EXPRESS\"COMMODITY"\"SUPPLIER NAME"\"PART #" Please use the part number as the first part of the filename and put a zero in front of 9 million part numbers (to achieve 8 digits and proper sort order by Windows Explorer).lThe tab key can be used to move to the next available field in the form to enter data. Similarly, shift_tab will move to the previous available field.For filling in the SPDP Express form:lSection A: Volume Information and Scheduled Builds (lines 1 to 10) should be filled in by the Product Engineer or the Program Team Leader. Line 11 will be filled in by the AQE Analyst.lSection B should be filled in by the Supplier (lines 13 to 18). Enter the Supplier Name in the appropriate cell and enter the name and date of the authorized Supplier Representative who is filling in the form.lSection C should be filled in by the AQE. If the part commodity is exempt (see Express form for criteria), it should be listed in the Commodity Exemption letter signed by the Supplier Quality Manager. This is expected to be one letter listing all exempted commodities and stored in one location for reference by all of Supplier Quality.


PFMEA Severity Rankings

PFMEA Occurrence Rankings

ProbabilityLikely Failure RatesPpkRankingVery High: Persistent Failures100 per thousand pieces50 per thousand pieces< 0.55> 0.55109High: Frequent Failures20 per thousand pieces10 per thousand pieces> 0.78> 0.8687Moderate: Occasional Failures5 per thousand pieces

2 per thousand pieces

1 per thousand pieces> 0.94

>1.00

>1.106

5

4Low: Relatively Few Failures0.5 per thousand pieces

0.1 per thousand pieces>1.20

> 1.303

2Remote: Failure is unlikely< 0.001 per thousand pieces *> 1.671Note: Identical to Manual except for Ranking of 1. Manual allows for .01 per thousand (10 PPM)DELPHI Supplier Quality FMEA OCCURRENCE EVALUATION RANKINGSSample calculation to determine Ppk value from a likely failure rate of 5 per thousand pieces (see FMEA third Appendix I).

PFMEA Detection Rankings

RankingEffectPFMEA10Absolute UncertaintyCannot detect or is not checked.9Very RemoteControl is achieved with indirect or random checks only.8RemoteControl is achieved with visual inspection only.7Very LowControl is achieved with double visual inspection only.6LowControl is achieved with charting methods, such as SPC (Statistical Process Control) OR gauging performed on setup and first-piece check. *5ModerateControl is based on variable or attribute gauging performed 100% of the parts after parts have left the station.4Moderately HighError detection in subsequent operation. *3HighError detection in-station, or error detection in subsequent operations by multiple layers of acceptance: supply, select, install, verify. Cannot accept discrepant part.2Very HighError detection in-station (automatic gauging with automatic stop feature). Cannot pass discrepant part.1Almost CertainDiscrepant parts cannot be made because item has been error-proofed by process/product design.* Note: Identical to Manual except for Rankings of 6 and 4. Words OR gauging performed on setup and first piece check moved from a detection of 4 to a detection of 6DELPHI Supplier Quality FMEA Detection Rankings

MBD001AC6F1.docDELPHI Supplier Quality FMEA SEVERITY RANKINGS

Note #1: Any Failure Mode affecting the Vehicle Assembly Plant MUST be ranked an 8 or higher.

Note #2: Any Failure Mode affecting a Delphi Plant MUST be ranked 5 or higher.

Select from the categories below, using the highest applicable ranking.

Ranking

Effect

End Customer

Vehicle Assembly Plant

Delphi Plant

Supplier Plant

10

Hazardous-without warning

Potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation without warning.

Potential failure mode may cause unsafe condition for plant personnel without warning.



9

Hazardous-with warning

Potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation with warning.

Potential failure mode may cause unsafe condition for plant personnel with warning.



8

Very High

Vehicle/item inoperable (loss of primary function); failure mode may cause customer walk home, field return, or durability issue.

Potential failure mode may cause a spill/major disruption, repair, assembly difficulty, rework, or sorting at the Vehicle Assembly Plant

Potential failure mode may cause a spill/major disruption at a Delphi Plant.

7

High

Vehicle/item operable but at a reduced level of performance. Customer very dissatisfied. Failure mode may cause vehicle repairs at Dealer. Includes Noise issues (squeak/rattle).

See Note #1

Potential failure mode may cause repair, assembly difficulty, rework, sorting at a Delphi plant.

6

Moderate

Vehicle/item operable but comfort/convenience item(s)) inoperable/not performing to customer expectation (e.g.. Noise)

See Note #1

Potential failure mode may cause special handling of components at Delphi-S.

5

Low

Vehicle/item operable but comfort/convenience item(s) operable at a reduced level of performance.

See Note #1

Potential failure mode may cause inconvenience to Delphi prior to assembly.

4

Very Low

Fit and finish item does not conform. Defect noticed by most customers.

See Note #1

See Note #2

3

Minor

Fit and finish item does not conform. Defect noticed by average customers.

See Note #1

See Note #2

2

Very Minor

Fit and finish item does not conform. Defect noticed by discriminating customers.

See Note #1

See Note #2

1

None

No effect.

See Note #1

See Note #2

LPHI-S FMEA DETTION RANKking

Effect

PFMEA

10

Absolute Uncertainty

Cannot detect or is not checked.

9

Very Remote

Control is achieved with indirect or random checks only.

DELPHI-S FMEA RANKINGS

k.bourassa

Revised: 11/12/01