User Guide#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End
Date123456789101112131415X25%N/ADeliverable RYG
RatingIP50%Location: / Site:Status (%):25% - Action Identified 50%
- Owner Identified75% - Action in Progress 100% - Action
Closed75%RRed: Some questions have a negative answer and no
recovery plan is in place or the plans identified will have an
impact in program timing. Support is required. When an item is
highlighted Red an assessment on the impact to the WP timing needs
to be provided.Reviewed by:100%YYellow: Some questions have a
negative answer but a recovery plan is in place which will prevent
impact on timingReviewed with:GGreen: All questions have a positive
answer (Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 User Guide
The questions are used to evaluate the quality of the
deliverable attached to the element. Typical aspects of the
deliverable to be evaluated through the questions are:1.
Quality/availability of the inputs needed to build the deliverable
2. Cross-functional approach to answer the deliverables3. Quality
/conformity to a standard if any or to best practices 4. control of
the outcome of the deliverable (e.g. action plan)
Input evidence of the answer to the question (e.g.: document
reference) here. If an "X" is in the preceding N column (column D)
then describe the issue here including root cause in order to
identify proper actions .Actions identified based on the root cause
described in the Evidence column when the RYG column is Red or
Yellow.These are typical action management milestones . The due
date should be aligned with the closure date of the deliverable as
planned in the APQP timing. In cases where the due date is not
aligned with APQP timing, the RYG status is most likely Red .Date
of revision for the provided status and personnel involvedY* - Put
an "X" if complete and is OK or "IP" if in-progress as planned.N -
Put an "X" if it is Not OK .N/A - Put an "X" if you have agreed
with your customer that this question is Not Applicable.RYG - Put
an "R" here if the answer to the question is not acceptable and
there is no recovery plan. Put a "Y" here if there are problems
with the question but is recoverable with an action plan inplace.
Put a "G" if it is on track or satisfactorily complete. When you
put an "R" or "Y" you will need to complete the "Actions Required"
and subsequent columns.
3.01 Process Flow Chart#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was the
manufacturing process flow chart created by a cross functional team
including Manufacturing Engineering, Production and Quality
(incluging others as applicable)?2Is enough information available
to create the process flow chart?All input data to the
manufacturing flow chart are avaiblable such as: preliminary design
drawings, preliminary bill of material, process
specificatioin/requirements, Preliminary Key Characteristics and
Critical Items, material/ components introduction points..3Is the
manufacturing flow chart specific to the product?4Does the
manufacturing flow chart include manufacturing, inspection and test
phases for subassemblies and finished product?The manufacturing
process flow chart is not limited to final assembly, it combines
final assembly and construction of all the subasseblies required to
make the product.5Does the manufacturing flow chart include
subcontracted activities?The manufacturing process flow requirement
is cascaded to them.6Does the manufacturing flow chart include
critical process steps (e.g.: long lead time equipement, processes
requiring operators to be certified by external parties)7Is the
manufacturing flow chart identifying quality metrics (process steps
scraps %, rework %, First Pass Yield %, Non Destructive Testing FPY
%, Cp and Cpk, R1, OEE,)?8Does the process flow chart include Key
Characteristics and their monitoring? 9Does the process flow chart
include means (machine, equipment) & tools used? In so far as
they are identified.10Does the manufacturing flow chart include
standard Operating Instruction needed and available at each process
step?11Is the process flow chart kept up-to-date and configuration
managed?12Have any additional risks including mitigation plans been
identified that may affect this
deliverable?131415X25%N/ADeliverable RYG RatingIP50%Location: /
Site:75%RRed: Some questions have a negative answer and no recovery
plan is in place or the plans identified will have an impact in
program timing. Support is required. When an item is highlighted
Red an assessment on the impact to the WP timing needs to be
provided.Reviewed by:Status (%):25% - Action Identified 50% - Owner
Identified100%YYellow: Some questions have a negative answer but a
recovery plan is in place which will prevent impact on
timingReviewed with:75% - Action in Progress 100% - Action
ClosedGGreen: All questions have a positive answer (Y) and are
ongoing normal program developmentDate :
&"Arial,Bold"&20 3.01 Process Flow Chart
3.02 Floor Plan Layout#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was the
Floor plan layout created by a cross functional team including
Process Engineering, Production Manager, Quality, Facilities
Management, Maintenace and Health, Safety & Environment
Representatives?2Have all the necessary inputs been taken into
account and they are frozen at the right stage (e.g., Build Process
Definition , Value Stream Mapping Analysis, Inbound / Outbound
Logistics Flow, H&S and environmental rules, Plant Lay Out Blue
Print and plan, existing facility utilities )?3Have Material Flow,
Storage and Buffer areas been considered when defining the plant
(facility) lay out?4Have People Flow (e.g., spaghetti charts) been
considered when defining the lay out?5Is the floor layout optimized
to remove waste (overproduction, movement, inventory, waiting,
overprocessing, defects and transportation) from the process?6Have
health, safety, ergonomic, environmental and facility requirements
been validated in the proposed lay out?7Is the plant (facility) lay
out implementation plan and its readiness in line with program
schedule?8Have Capital expenditure targets been considered by the
lay out? Has Capital Expenditure been approved?9Is the floor plan
layout up-to-date and managed in configuration? Is it consistent
with the latest process flow chart?10Have any additional risks
including mitigation plans been identified that may affect this
deliverable?1112131415X25%N/ADeliverable RYG RatingIP50%Location: /
Site:Status (%):25% - Action Identified 50% - Owner Identified75% -
Action in Progress 100% - Action Closed75%RRed: Some questions have
a negative answer and no recovery plan is in place or the plans
identified will have an impact in program timing. Support is
required. When an item is highlighted Red an assessment on the
impact to the WP timing needs to be provided.Reviewed
by:100%YYellow: Some questions have a negative answer but a
recovery plan is in place which will prevent impact on
timingReviewed with:GGreen: All questions have a positive answer
(Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.02 Floor plan Layout
3.03 Prod Prep Planning#QuestionY*NN/ARAGEvidencesActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was this
activity undertaken by a cross functional team including
Manufacturing Engineering, Quality, Production, Maintenance, Human
Resources and Procurement (for outsourced equipment)?Capacity2Do
you have established, demonstrated capacity?Did you use OEE as the
basis for your calculation?3Did you undertake your evaluation
considering different volume scenarios (including retrofit and
spares)?This should consider internal and supplier capacity.4Did
you consider the volume profile over 1, 3 and 5 year timescales
considering demand from all of your customers?This should consider
internal and supplier capacity.5Did you evaluate an increase based
on a surge in customer demand (eg +20% in 3 months)?This should
consider internal and supplier capacity.Production Preparation
Plan6Is the list of equipment requirements complete and does it
cover all aspects of the manufacturing process as described in the
process flow chart?7Have you confirmed the capacity for all
existing equipment?8Have you confirmed the theoretical capacity for
new equipment with the equipment supplier(s)?9Are specifications
released and available for procurement? Are specifications
complete, relevant and with the correct level of detail to allow
procurement to commence?10Are all applicable customer, industry and
regulatory standards taken account of in the preparation
plan?11Does the plan cover outsourced parts?12Does the plan cover
in house manufacturing preparation?13Does the plan cover human
resources (headcount)?14Does the plan cover the tasks required in
order to validate that the process is qualified?15Is the overall
implementation plan validated and accepted by the customer?16Is the
implementation schedule in line with programme needs?17Is there a
defined reporting mechanism to track progress against the plan with
an agreed escalation process for delays?The reporting method and
frequency has been agreed with the customer.18Have any additional
risks including mitigation plans been identified that may affect
this deliverable?X25%N/ADeliverable RYG RatingIP50%Location: /
Site:Status (%):25% - Action Identified 50% - Owner Identified75% -
Action in Progress 100% - Action Closed75%RRed: Some questions have
a negative answer and no recovery plan is in place or the plans
identified will have an impact in program timing. Support is
required. When an item is highlighted Red an assessment on the
impact to the WP timing needs to be provided.Reviewed
by:100%YYellow: Some questions have a negative answer but a
recovery plan is in place which will prevent impact on
timingReviewed with:GGreen: All questions have a positive answer
(Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.03 Production Preparation
Planning
3.04 Oper Staff & TrainPlan#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was the
operator staffing and training plan created by a cross functional
team including Production, Quality and Human Resources?2Did you
evaluate the new skill requirements against the existing skills
matrix?3Did you use the capacity evaluation of manpower
requirements to determine the level of human resources which you
require?4Do you have a timing plan in place for the recruitment of
suffient operators which is in line with program timing
requirements?5Do you have a timing plan in place for the training
of sufficient operators to an appropriate level in line with
program timing requirements?6Have you identified and secured the
appropiate resources to train/certify the operators in line with
your plan?7Do you have an agreed reporting schedule in place which
tracks progress on recruitment and training?Does this report status
to the customer if required?8Is the recruitment progressing to
plan?Recruitment is complete for the current phase of the
program.9Is the training progressing to plan?Training and cross
training is complete for the current phase of the
program.101112131415X25%N/ADeliverable RYG Rating25%50%Location: /
Site:Status (%):25% - Action Identified 50% - Owner Identified75% -
Action in Progress 100% - Action Closed75%RRed: Some questions have
a negative answer and no recovery plan is in place or the plans
identified will have an impact in program timing. Support is
required. When an item is highlighted Red an assessment on the
impact to the WP timing needs to be provided.Reviewed
by:100%YYellow: Some questions have a negative answer but a
recovery plan is in place which will prevent impact on
timingReviewed with:GGreen: All questions have a positive answer
(Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.04 Operator Staffing and Training
Plan
3.05 PFMEA#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was the
PFMEA flow chart created by a cross functional team including
Design Engineering, Manufacturing Engineering, Production and
Quality (incluging production control & supply chain if
applicable)?2Was one of the team members trained in FMEA
methodology?3Was the Process Flow used as the basis of the PFMEA
exercise?All subcontracted activities have been considered.4Did the
activity consider similar parts and PFMEAs as part of the
activity?5Were historical non-conformance and warranty issues
reviewed and included in the scope of the activity?6Is the PFMEA
documented and recorded on a suitable template? Is the document
date and configuration controlled?7Have all potential failure modes
been properly evaluated considering Severity, Occurence and
Detection for the initial RPN calculation?8Has the scoring been
consistent using a methodology based on industry guidance for
ranking rules?9Have Process Key Characteristics / Critical Items /
Product Key Characteristics been considered and highlighted in the
PFMEA analysis in order to assure them and ultimately minimize the
variation where applicable?10Do all failure modes with high RPNs
have an action, action owner, and a due date?Action plan is
progressing to plan at date of review.11Is PFMEA Analysis up to
date reflecting the latest information on product performance (ie,
Shopfloor feedback, Continuous Improvement process or operations,
Functionnal evolution, Non conformities etc.)?12Have RPNs been
reassessed only following the implementation of identified actions
and evaluation of the effectiveness of the action?13Has action been
taken to ensure that defects are not passed on to the next process
step?14Have any additional risks including mitigation plans been
identified that may affect this deliverable?X25%N/ADeliverable RYG
RatingIP50%Location: / Site:Status (%):25% - Action Identified 50%
- Owner Identified75% - Action in Progress 100% - Action
Closed75%RRed: Some questions have a negative answer and no
recovery plan is in place or the plans identified will have an
impact in program timing. Support is required. When an item is
highlighted Red an assessment on the impact to the WP timing needs
to be provided.Reviewed by:100%YYellow: Some questions have a
negative answer but a recovery plan is in place which will prevent
impact on timingReviewed with:GGreen: All questions have a positive
answer (Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.05 Process Failure Mode and Effects
Analysis (PFMEA)
3.06 Process KCs#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was the
activity undertaken by a cross functional team including
Manufacturing Engineering, Quality and Operations?2Has the team
considered the Product Key Characteristics in this activity?3Has
the team considered the PFMEA in this activity?4Has the team
considered lessons learned from previous projects in this
activity?5Is there agreement between all functions on the final
list of Process Key Characteristics?6Have any additional risks
including mitigation plans been identified that may affect this
deliverable?789101112131415X25%N/ADeliverable RYG
RatingIP50%Location: / Site:Status (%):25% - Action Identified 50%
- Owner Identified75% - Action in Progress 100% - Action
Closed75%RRed: Some questions have a negative answer and no
recovery plan is in place or the plans identified will have an
impact in program timing. Support is required. When an item is
highlighted Red an assessment on the impact to the WP timing needs
to be provided.Reviewed by:100%YYellow: Some questions have a
negative answer but a recovery plan is in place which will prevent
impact on timingReviewed with:GGreen: All questions have a positive
answer (Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.06 Process Key Characteristics
3.07 Pre Launch Control Plan#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was the
control plan created by a cross functional team including
Manufacturing Engineering, Quality, Design Engineering and
Operations, Supply Chain and Maintenance (as required)?2Are all the
high risk failure modes identified in the PFMEA addressed in the
Control Plan?3Is the control plan consistent with customer
requirements?4Are the different Control plan versions and their
applicability tracked?Control plan version has to be aligned with
the part configuration.Track evolution is including the reason of
change for each control5Does the Control Plan cover all issues
identified during the development process?6Are all Product and
Process Key Characteristics (and Critical Items) included and
highlighted in the control plan?7Are the methods (inspection gate,
SPC chart,...) used to record results referenced in the control
plan ?8In case of out-of-tolerances, is the Reaction Plan (Out of
Control Action Plan (OCAP)) available at the work station and
referenced into the control plan?9Are all specifications required
by the control plan (tolerances, measurement specification, test
frequency and sample size, control method, reaction plan)
implemented on the shop floor?10Are all active Control Plan items
cascaded to the shop floor documentation and performed?11Are key
characteristics identified by the customer cascaded down to
subsupplier control plans?12Is the control plan regularly updated
(in accordance with customer requirements) and reflects the current
manufacturing activities (Feedback loop, root causes analysis and
process control improvement)? 13Have any additional risks including
mitigation plans been identified that may affect this
deliverable?14X25%N/ADeliverable RYG RatingIP50%Location: /
Site:Status (%):25% - Action Identified 50% - Owner Identified75% -
Action in Progress 100% - Action Closed75%RRed: Some questions have
a negative answer and no recovery plan is in place or the plans
identified will have an impact in program timing. Support is
required. When an item is highlighted Red an assessment on the
impact to the WP timing needs to be provided.Reviewed
by:100%YYellow: Some questions have a negative answer but a
recovery plan is in place which will prevent impact on
timingReviewed with:GGreen: All questions have a positive answer
(Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.07 Pre Launch Control Plan
3.08 MSA Plan#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was the
MSA Plan created by a cross functional team including Manufacturing
Engineering, Production and Quality (Plus design engineering as
required)?2Has the pre-launch control plan been released and
references method/control device information needed for MSA
activity?3Has the list of measurement systems to be validated been
created using:> Criticality of the measurements (as a minimum
anything linked to a key characteristic)> Past experience of
using the measurement system and evidence of its capabilityand been
approved by the cross functional team?4Is there an MSA leader
assigned to each of the MSA activities to be performed?5Are the
objectives of each test to be done clear and communicated to all
involved parties (i.e. affected operation, MSA Leader, measurement
experts)?6Is the accuracy of the control device acceptable for the
measurement system application?7Is there a calibration plan and
protocol for the measurement devices to be used in the gage R&R
nd in line with the applicable standards and methods?8For each
measurement system has a gage R&R target value been defined?9Is
the MSA Plan communicated and agreed by all interested parties
(i.e. management in the operation affected, Metrology Management
)?10Have the training needs to perform the measurement identified
and planned ?11Have any additional risks including mitigation plans
been identified that may affect this
deliverable?12131415X25%N/ADeliverable RYG Rating25%50%Location: /
Site:Status (%):25% - Action Identified 50% - Owner Identified75% -
Action in Progress 100% - Action Closed75%RRed: Some questions have
a negative answer and no recovery plan is in place or the plans
identified will have an impact in program timing. Support is
required. When an item is highlighted Red an assessment on the
impact to the WP timing needs to be provided.Reviewed
by:100%YYellow: Some questions have a negative answer but a
recovery plan is in place which will prevent impact on
timingReviewed with:GGreen: All questions have a positive answer
(Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.08 Measurement System Analysis (MSA)
Plan
3.09 Mfg Process Doc#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was the
manufacturing documentation created by a cross functional team
including Manufacturing Engineering, Production, Quality and
Facilities Maintenance (including other functions as required)?2Is
there a completed Manufacturing and Inspection File related to the
product including all relevant information: Configuration
controlled drawing, Traveller Sheet, Routings, Bill Of Material,
Work instructions, manufacturing and test/inspection tools?3Are all
relevant technical and test specifications to be applied to the
product defined in the manufacturing and inspection file?4Are all
documents needed for production (manufacture, installation,
storage, handling, part list, acceptance test sheet, control
report, delivery procedures,...) listed and released?5Are work
instructions defined? Work instructions provide operators with a
detailed description to produce in a standardized serial production
condition.6Is all material needed listed for all Workstations?7Has
all documentation been reviewed and understood by the operators?
The operator is trained to the work instructions and training
records are kept.8Is the configuration management process
formalized and the associated requirements properly cascaded into
the Manufacturing and Inspection folder? Content of folder is
consistent with the latest process and product definition.9Has
there been regular assessments to verify the update of the
Manufacturing and Inspection File and its implementation (SOIs) in
production?101112X25%N/ADeliverable RYG RatingIP50%Location: /
Site:Status (%):25% - Action Identified 50% - Owner Identified75% -
Action in Progress 100% - Action Closed75%RRed: Some questions have
a negative answer and no recovery plan is in place or the plans
identified will have an impact in program timing. Support is
required. When an item is highlighted Red an assessment on the
impact to the WP timing needs to be provided.Reviewed
by:100%YYellow: Some questions have a negative answer but a
recovery plan is in place which will prevent impact on
timingReviewed with:GGreen: All questions have a positive answer
(Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.09 Manufacturing Process
Documentation
3.10 Supply Chain Risk#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Was the
activity undertaken a cross functional team including Procurement,
Quality, Production control & planning (including finance if
applicable)?2Is there a supply chain map specific to the product
and does it reflect the current Supply Chain process (including sub
assemblies and procured parts)?3Does the supply chain map identify
major Suppliers (single source, critical suppliers,...)?4Does the
supply chain map identify bottlenecks from the capacity
analysis?5Does the supply chain map consider stocking policy and
stock locations?6Does the supply chain map capture Supply Chain
Indicators such as On Time Delivery, Rejection Rate? 7Is the supply
shain map up-to-date and reflect the current condition? Is there a
"future state" map defined to address concerns identified (eg extra
capacity, sole source, long leadtime etc)?8Has the supply chain
risk register considered the impact of supplier failure to our
business?Consider how long production would stop before a new
supplier could be introduced. Estimate the cost to evaluate an
alternative source (tooling, testing, Customer approvals etc).
Consider the technical complexity of product any emergency
stock.9Has the supply chain risk register considered the risk of
financial, quality, delivery, geo-political problems at
suppliers?10Have the risks been evaluated and prioritised?11Is
there a clear mitigation plan in place for all major risks?Action,
owner and due date clearly defined.12Have any additional risks
including mitigation plans been identified that may affect this
deliverable?131415X25%N/ADeliverable RYG RatingIP50%Location: /
Site:Status (%):25% - Action Identified 50% - Owner Identified75% -
Action in Progress 100% - Action Closed75%RRed: Some questions have
a negative answer and no recovery plan is in place or the plans
identified will have an impact in program timing. Support is
required. When an item is highlighted Red an assessment on the
impact to the WP timing needs to be provided.Reviewed
by:100%YYellow: Some questions have a negative answer but a
recovery plan is in place which will prevent impact on
timingReviewed with:GGreen: All questions have a positive answer
(Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.10 Supply Chain Risk Management
3.11 Prod Readiness Review#QuestionY*NN/ARYGEvidenceActions
RequiredResponsibleOpen DateDue DateStatus%Actual End Date1Has the
Production Readiness Review been supported by a multifunctional
team involving Operations, Supply Chain, Quality, Manufacturing
Engineering, Design Engineering, Customer Support and chaired by
the Program Leader, in charge of this product? 2Are all component
products qualified (materials, parts, constituent assy, equipment)
and available at the correct design configuration?Internal and
outsourced suppliers.3Is the production process and equipment in
place and ready for use?Processes are qualified to the appropriate
specifications.Where applicable TRL (technology readiness level)
and MRL (manufacturing readiness level) have been achieved in line
with program requirements.4Is the product definition finished and
released? All concessions are closed. All forecast modifications
have been implemented.Design Verification & Validation is
complete.5Does the current production condition reflect the latest
design & engineering documentation?6Is the production
manufacturing documentation in place and reflects the current
product and process definition?7Are sufficient operators trained
and in place?8Are ERP and information systems configured to the
latest product and process definitions?9Is the capacity ramp up
plan in place and sufficient to meet projected customer demand?In
house and suppliers.10Have Operations, Quality and Procurement
confirmed that the production process is ready to enter into serial
production phase?11Has management confirmed that they are satisfied
that the production process is ready to enter serial production
phase?12Is all material needed available at all Workstations?13Have
any additional risks including mitigation plans been identified
that may affect this deliverable?X25%N/ADeliverable RYG
RatingIP50%Location: / Site:Status (%):25% - Action Identified 50%
- Owner Identified75% - Action in Progress 100% - Action
Closed75%RRed: Some questions have a negative answer and no
recovery plan is in place or the plans identified will have an
impact in program timing. Support is required. When an item is
highlighted Red an assessment on the impact to the WP timing needs
to be provided.Reviewed by:100%YYellow: Some questions have a
negative answer but a recovery plan is in place which will prevent
impact on timingReviewed with:GGreen: All questions have a positive
answer (Y) and are ongoing normal program developmentDate :
&"Arial,Bold"&20 3.11 Production Readiness Review