Apqpppap

What this skill does

# APQP/PPAP - Advanced Product Quality Planning & Production Part Approval

## When to Activate This Skill
- "What APQP phase are we in?"
- "Create a phase gate checklist"
- "What PPAP elements are required?"
- "Generate a PSW for [part]"
- "Create a timing plan for [program]"
- "Track open issues for [launch]"
- "What's needed for PPAP Level [X]?"
- "Run readiness review"

## Workflow Routing

| Workflow | Trigger | File |
|----------|---------|------|
| **PhaseGate** | "phase gate review", "gate checklist" | `Workflows/PhaseGate.md` |
| **PpapPackage** | "PPAP elements", "PPAP submission" | `Workflows/PpapPackage.md` |
| **TimingPlan** | "timing plan", "launch schedule" | `Workflows/TimingPlan.md` |
| **OpenIssues** | "open issues", "issue tracker" | `Workflows/OpenIssues.md` |

---

## APQP Five Phases

### Phase 1: Plan and Define Program
**Purpose:** Determine customer needs and expectations

**Key Deliverables:**
| Deliverable | Description | Owner |
|-------------|-------------|-------|
| Voice of Customer | Customer requirements documented | Commercial |
| Business Plan | Program justification, capacity, investment | GM |
| Product/Process Assumptions | Initial feasibility assessment | Engineering |
| Product Assurance Plan | Quality objectives, reliability goals | Quality |
| Preliminary BOM | Initial bill of materials | Engineering |
| Preliminary Process Flow | High-level manufacturing concept | Mfg Eng |
| Preliminary Special Characteristics | Initial CC/SC identification | Quality |
| Management Support | Resource commitment | GM |

**Gate 1 Criteria:**
- [ ] Customer requirements documented and reviewed
- [ ] Feasibility assessment complete
- [ ] Resource plan approved
- [ ] Risk assessment performed
- [ ] Timing plan established

---

### Phase 2: Product Design and Development
**Purpose:** Develop design to near-final form

**Key Deliverables:**
| Deliverable | Description | Owner |
|-------------|-------------|-------|
| DFMEA | Design Failure Mode Effects Analysis | Design Eng |
| Design for Manufacturability (DFM) | Manufacturing input to design | Mfg Eng |
| Design Verification Plan | DVP&R creation | Design Eng |
| Engineering Drawings | Released with GD&T | Design Eng |
| Engineering Specifications | Material, performance specs | Design Eng |
| Prototype Build | Sample parts for validation | Multiple |
| Prototype Control Plan | Inspection plan for prototypes | Quality |
| Special Characteristics (Updated) | CC/SC finalized | Quality |

**Gate 2 Criteria:**
- [ ] DFMEA complete (RPN addressed)
- [ ] Design reviews completed
- [ ] Drawings released
- [ ] Prototypes built and validated
- [ ] Design verification results acceptable
- [ ] Special characteristics agreed with customer

**Note:** For contract manufacturing (MNMUK), Phase 2 is often customer-led. Focus on DFM feedback and prototype support.

---

### Phase 3: Process Design and Development
**Purpose:** Develop manufacturing process

**Key Deliverables:**
| Deliverable | Description | Owner |
|-------------|-------------|-------|
| Process Flow Diagram | All operations mapped | Mfg Eng |
| Floor Plan Layout | Equipment and flow layout | Mfg Eng |
| Characteristics Matrix | Link characteristics to operations | Quality |
| PFMEA | Process Failure Mode Effects Analysis | Quality/Mfg Eng |
| Pre-Launch Control Plan | Enhanced control for validation | Quality |
| Process Instructions | Operator work instructions | Mfg Eng |
| MSA Plan | Measurement system analysis plan | Quality |
| Preliminary Process Capability Plan | Cpk study plan | Quality |
| Packaging Standards | Pack spec developed | Logistics |
| Management Support (Updated) | Confirm resources | GM |

**Gate 3 Criteria:**
- [ ] Process flow complete and approved
- [ ] PFMEA complete (high RPNs addressed)
- [ ] Pre-launch control plan approved
- [ ] Work instructions drafted
- [ ] MSA plan established
- [ ] Tooling/equipment ordered or available
- [ ] Packaging spec approved

---

### Phase 4: Product and Process Validation
**Purpose:** Validate manufacturing process

**Key Deliverables:**
| Deliverable | Description | Owner |
|-------------|-------------|-------|
| Significant Production Run | PPAP quantity produced | Production |
| MSA Results | Gage R&R complete | Quality |
| Preliminary Process Capability | Initial Cpk/Ppk studies | Quality |
| Production Part Approval | PPAP package complete | Quality |
| Production Validation Testing | Performance testing | Quality |
| Production Control Plan | Final control plan | Quality |
| Quality Planning Sign-Off | Team approval | Cross-functional |
| PSW | Part Submission Warrant | Quality |

**Gate 4 Criteria:**
- [ ] Significant production run complete
- [ ] MSA acceptable (<10% GR&R for CC, <30% for SC)
- [ ] Process capability acceptable (Ppk ≥1.67 for CC, ≥1.33 for SC)
- [ ] PPAP package complete per customer level
- [ ] Customer approval (PSW signed)
- [ ] Production control plan implemented
- [ ] Operators trained

---

### Phase 5: Feedback, Assessment and Corrective Action
**Purpose:** Continuous improvement during production

**Key Activities:**
| Activity | Description | Frequency |
|----------|-------------|-----------|
| Variation Reduction | Reduce process variability | Ongoing |
| Customer Satisfaction | Monitor complaints, returns | Monthly |
| Delivery Performance | OTD tracking | Weekly |
| Lessons Learned | Capture and share | Per program |
| Control Plan Updates | Based on experience | As needed |
| PFMEA Updates | Based on field issues | As needed |

**Ongoing Requirements:**
- [ ] Customer complaints tracked and resolved
- [ ] Process capability maintained
- [ ] Control plans current
- [ ] Lessons learned documented
- [ ] Continuous improvement projects active

---

## PPAP Submission Levels

| Level | Requirements | When Used |
|-------|--------------|-----------|
| **Level 1** | PSW only | Customer trusts supplier |
| **Level 2** | PSW with product samples and limited data | Reduced documentation |
| **Level 3** | PSW with product samples and complete data | **Default** |
| **Level 4** | PSW with complete data (no samples) | Customer-specific |
| **Level 5** | PSW with product samples and complete data at supplier site | Customer review on-site |

**MNMUK Default:** Level 3 unless customer specifies otherwise.

---

## PPAP 18 Elements

### Element Checklist

| # | Element | Level 1 | Level 2 | Level 3 | Level 4 | Level 5 | Owner |
|---|---------|---------|---------|---------|---------|---------|-------|
| 1 | Design Records | R | S | S | * | R | Engineering |
| 2 | Authorized Engineering Change Documents | R | S | S | * | R | Engineering |
| 3 | Customer Engineering Approval | R | R | S | * | R | Commercial |
| 4 | Design FMEA | R | R | S | * | R | Engineering |
| 5 | Process Flow Diagram | R | R | S | * | R | Mfg Eng |
| 6 | Process FMEA | R | R | S | * | R | Quality |
| 7 | Control Plan | R | R | S | * | R | Quality |
| 8 | Measurement System Analysis | R | R | S | * | R | Quality |
| 9 | Dimensional Results | R | S | S | * | R | Quality |
| 10 | Material, Performance Test Results | R | S | S | * | R | Quality |
| 11 | Initial Process Studies | R | R | S | * | R | Quality |
| 12 | Qualified Laboratory Documentation | R | S | S | * | R | Quality |
| 13 | Appearance Approval Report (AAR) | S | S | S | * | R | Quality |
| 14 | Sample Production Parts | R | S | S | R | R | Quality |
| 15 | Master Sample | R | R | S | * | R | Quality |
| 16 | Checking Aids | R | R | S | * | R | Quality |
| 17 | Customer-Specific Requirements | R | R | S | * | R | Quality |
| 18 | Part Submission Warrant (PSW) | S | S | S | S | S | Quality |

**Legend:** S = Submit to customer | R = Retain at supplier | * = Retain and submit on request

---

## Element Details

### Element 1: Design Records
- Released engineering drawings
- CAD data if applicable
- Current revision level
- All engineering specifications referenced

### Element 2: Authorized Engineering Change Docum