D_020_4_03_EN_RevE

Form: APQP Workbook - Rev D

CoverSupplier APQP WorkbookSupplier Name:Supplier Location:Supplier Code:Part Number:Part Name:Revision Level:Component Priority Level:Lead Customer/Program:Report Date:

&LDate: 16 Jan 2008Revision: DDoc No: D_020_4_03Page &P of &N&C&A

&RProcess Owner / Department:R. Spariosu / Supplier DevelopmentApproved by:R. Blanchette / Global Director, SDE

5 PhasesSupplier APQP: Five Phases

&LDate: 16 Jan 2008Revision: DDoc No.: D_020_4_03Page &P of &N&C&A

&RProcess Owner/Department:R. Spariosu / Supplier DevelopmentApproved by:R. Blanchette / Global Director, SDE

Table of ContentsSupplier APQP: Table of ContentsCoverShows the 5 APQP Phases and the activities that occur within them.Table of ContentsLists all of the forms and examples included in this workbook.IntroductionDisplays a pictorial representation of APQP elements tracked in the Progress Report in relationship to TRW's launch profile.Blank Time LineSuppliers are required to create a Master Time Line for the launch of the awarded component(s). It is expected that a Gantt chart is used as the format. For those suppliers who do not have software available to meet this requirement, a blank time line is provided for their use.Key Metrics ReportKey Metrics contain those elements that contribute to a successful launch. This form allows for five reviews. The minimum requirement is to use it at APQP-5. The APQP-5 report is generated at the time product is manufactured for the PPAP submission. The additional columns would either be used at the discretion of the SDE or based on circumstances that require additional reviews.Key Metrics GraphVisually displays and compares the results of the Key Metrics reports generated during APQP-4 and/or APQP-5.Key Metrics DefinitionsOperational definitions for the twelve key metrics. Explains the metric and its method of calculation.Progress ReportReporting form for suppliers to track progress on all APQP deliverables.Other APQP ToolsEmbedded copies of the Component Design Review, Product Characterisitics Matrix, and Launch Readiness Audit.Supply Chain MapForm for showing multi-tier suppy chain relationships involved in providing the component/assembly to TRW. The information documented here will also be used in the creation of the Product Characteristics Matrix.Supply Chain Map ExampleAn example of how a Supply Chain Map may appear for a typical metal component.Product Characteristics Matrix - Tier IIThe PCM is used initially to define and determine appropriate controls for special characteristics, other process critical features and customer touch points. This tab is used to define the process at TRW's direct supplier. Throughout the APQP phase of launch this form is used as the Pre-Launch Control Plan and also forms the basis for Safe Launch Planning.Product Characteristics Matrix - Sub-SupplierThe use of this tab is identical to the functionality define above, with the exception that this is used to document the remaining supply chain's, below the Tier II supplier, impact on the critical features.In Cell Check (Blank)This form is used document inspection results for those characteristics and features identified on the Product Characteristics Matrix during the Safe Launch Plan implementation period.In Cell Check (Example)An example of the In Cell Check.SLP - Weekly QOS ReportFormat to be used for a weekly summary of the inspection results from the Safe Launch Plan.Open IssuesThe action plan format used to document open issues, their actions and resolution throughout the APQP process. This combines several different action plans generated by different, individual tools into a single document.ContactsLists the individuals involved in the component(s) launch, for both TRW and the supplier, and their respective contact information. This tab is optional and may be used as needed.


&RProcess Owner/Department:R. Sparisou / Supplier DevelopmentApproved by:R. Spariosu / Global Director, SDE

IntroductionSupplier APQP: Five Phase Time LineThe TRW Automotive Supplier Advanced Product Quality Planning (APQP) process consists of 5 Phases. Essential to this process are 12 Key Supplier Metrics (KSM). These metrics are established in the initial phase and then updated and reviewed during each of the following phases. The time line below illustrates the relationship between the 5 Phases, their deliverables and the Global Development & Product Introduction Management process.

This workbook consists of 10 forms in support of this process. Suppliers are expected to use this process regardless of the priority ranking assigned components/materials requiring submission of a PPAP package.New Product Launch Profile (GDPIM Phases)APQP PHASEOUTPUT2: Quote Requests, Early Sourcing4: Finalize Sourcing5: Supplier Kick-Off5: Supplier Tool, Equipment, Gauge Design6: Supplier Process Realization6: Supplier PPAP7: TRW Customer PPAP8: Start of Production1.Supplier Kick-Off1.1Design FMEA1.2Preliminary Capacity Study reviewed1.3Manufacturing Feasibility reviewed1.4Component Design Review1.5Key Supplier Metrics initiated1.6Supplier Project timing plan1.7Open Issues Action Plan created2.Equipment & Tool Design2.1Sub contractor PPAP approval2.2Product Characteristic Matrix initiated2.3Process flow chart2.4PFMEA2.5Control Plan2.6Appearance Approval Process (when applicable)2.7Key Supplier Metrics reviewed3.Product/Production Realization3.1Measurement/ Testing equipment3.2Tooling3.3Capital equipment3.4Training3.5Process instructions3.6Quality System and Plan review3.7Packaging3.8Launch Readiness Audit3.9Key Supplier Metrics reviewed4.Pre-PPAP4.1ELV/IMDS4.2Safe Launch Plan finalized4.3Supplier Ramp Plan4.4Plant Readiness Review4.5Launch Readiness Audit4.6Key Supplier Metrics reviewed5.Product/Process Validation & Launch5.1PPAP5.2Launch Readiness Audit5.3Run at Rate5.4Key Supplier Metrics reviewed5.5OK to Launch Sign-Off



Blank Time LineSupplier APQP: Blank Time LineAPQP PHASEOUTPUTYear 1Year 2020406081012141618202224262830323436384042444648505202040608101214161820222426283032343638404244464850521.Supplier Kick-Off1.1Design FMEA1.2Preliminary Capacity Study reviewed1.3Manufacturing Feasibility reviewed1.4Component Design Review1.5Key Supplier Metrics initiated1.6Supplier Project timing plan1.7Open Issues Action Plan created2.Equipment & Tool Design2.1Sub contractor PPAP approval2.2Product Characteristic Matrix initiated2.3Process flow chart2.4PFMEA2.5Control Plan2.6Key Supplier Metrics reviewed3.Product/Production Realization3.1Measurement/ Testing equipment3.2Tooling3.3Capital equipment3.4Training3.5Process instructions3.6Packaging3.7Key Supplier Metrics reviewed4.Pre-PPAP4.1ELV/IMDS4.2Safe Launch Plan finalized4.3Supplier Ramp Plan4.4Plant Readiness Review4.5Launch Readiness Audit4.6Appearance Approval Process (when applicable)4.7Key Supplier Metrics reviewed5.Product/ Process Validation & Launch5.1PPAP5.2Launch Readiness Audit5.3Run at Rate5.4Key Supplier Metrics reviewed5.5OK to Launch Sign-Off6.Other Requirements6.16.26.36.46.56.66.7KEY:XPlanned startOPlanned completion+Actual start>Actual end



APQP Element GraphsSupplier APQP: Key Metrics Elements GraphSupplier Name:0Supplier Location:0Supplier Code:0Part Number:0Part Name:0Revision Level:0Component Priority Level:0Lead Customer/Program:0Report Date:31-Dec-1899CLICK ON THE BUTTON TO UPDATE THE "KEY METRICS STATUS" GRAPH:GoalActualGoal31-Dec-9931-Dec-9931-Dec-9931-Dec-9931-Dec-99APQP Readiness0.0%0.0%0.0%0.0%0.0%Instructions0.0%0.0%0.0%0.0%0.0%FTC0.0%0.0%0.0%0.0%0.0%Process Efficiency0.0%0.0%0.0%0.0%0.0%Capability0.0%0.0%0.0%0.0%0.0%Testing0.0%0.0%0.0%0.0%0.0%% Process Complete0.0%0.0%0.0%0.0%0.0%LRA0.0%0.0%0.0%0.0%0.0%Sub-Tier PPAP0.0%0.0%0.0%0.0%0.0%PPAP Completion0.0%0.0%0.0%0.0%0.0%Ramp Plan0.0%0.0%0.0%0.0%0.0%GSQM 2200.0%0.0%0.0%0.0%0.0%10973131-Dec-9931-Dec-9931-Dec-9931-Dec-9931-Dec-99Red00000Yellow00000Green1212121212PRIMARY INDICATORSBaseline60 DayMfg0.0%0.0%PPAP0.0%0.0%DLN0.0%0.0%



APQP Element Graphs

RedYellowGreenKey Metrics Status

Key Metrics Report

APQP ReadinessCapabilityLRAGSQM 220Primary Indicators

Key Metrics Definitions

0-Jan-000-Jan-000-Jan-000-Jan-000-Jan-00Key Metric Values at Review

Progress ReportSupplier APQP: Key Supplier Metrics ReportSupplier Name:0Supplier Location:0Supplier Code:0Part Number:0Part Name:0Revision Level:0Component Priority Level:0Lead Customer/Program:0Report Date:31-Dec-1899Primary Indicator:GoalResultsProduction Preparation Influencing FactorsTargetKEY MEASUREABLESMANUFACTURABILITY1. APQP ReadinessNumber of 'Progress Report' elements with Green statusTotal number of elements from'Progress Report'0.0%0.0%0.0%0.0%0.0%2. Process InstructionsTotal number of instructions completedTotal number of instructions needed.0.0%0.0%0.0%0.0%0.0%3. First Time CapabilityResults from Run at Rate, line 25Ideal % of good parts0.0%0.0%0.0%0.0%0.0%4. Process EfficiencyOverall Utilization percentage.Maximum allowable utilization0.0%0.0%0.0%0.0%0.0%5. Process CapabilityNumber of capable designated characteristics featuresTotal number of designated characteristics features0.0%0.0%0.0%0.0%0.0%6. Test AchievementNumber of tests passed% of total tests0.0%0.0%0.0%0.0%0.0%PPAP7. Process Implementation - % CompletedHigh volulme process or Interim Process with ConcessionProduction volumes provided off production intent process50.0%0.0%0.0%0.0%0.0%8. Launch Readiness AuditScore achieved during eventGoal is 100%.0.0%0.0%0.0%0.0%0.0%9. Sub-Component PPAP ApprovalsNumber of sub-components and materials PPAP approvedTotal number of purchased sub-components/materials0.0%0.0%0.0%0.0%0.0%10. PPAP Package CompletionNumber of PPAP required documents completedNumber of PPAP required documents required0.0%0.0%0.0%0.0%0.0%DLN11. Supplier Ramp PlanState of completed supplier ramp planRamp planned completed and shipping to releases50.0%0.0%0.0%0.0%0.0%12. GSQM 220 DeploymentEnter completed stage of PCM (see comments)Complete Stage 5 by SOP50.0%0.0%0.0%0.0%0.0%SUPPLIER SIGN-OFF (MANAGER LEVEL)FunctionProject LeaderPurch/SalesProduction ControlQualityEngineeringDesignManufacturingName (print)SignatureTRW SIGN-0FFTRW Internal Use onlySDEName (print)SignatureCommodity Mgr/BuyerName (print)SignatureSQAName (print)Signature

UPDATE "KEY METRICS STATUS"&LDate: 16 Jan 2008Revision: DDoc No.: D_020_4_03Page &P of &N&C&A

&RProcess Owner/Department:R. Spariosu / Supplier DevelopmentApproved by:R. Blanchette / Global Director, SDENumber of good parts made divided by the total number of parts made. Enter percentage as a decimal.Enter the number "1." This represents 100% good parts in the trial run.The number of designated characteristics, at the time of the review, that have a Ppk > 1.67.The total number of features with designated characteristics on the drawing.Enter the appropriate stage of process implementation in regard to manufacturing for serial production.1. Prototype process implemented; No deviation or concession released detailing situation; No documented containment plan.2. Interim process implemented, with partial production intent process in place; No detailed deviation or concession released; No documented containment plan.3. Prototype or partially implement process; Released deviation or concession detailing plan, controls and timing; No documented containment plan for non-comformances to drawing/specifications.4. Prototype, partially implement process,or fully implemented production intent process implemented; Released deviation or concession detailing plan, controls and timing; Documented containment plan for non-comformances to drawing/specifications.5. Production intent process fully implemented; No drawing/specification non-conformances requiring deviation, or concession, and containment required.Enter the number 5, which represents the proper state of process implementation (5. Production intent process fully implemented; No drawing/specification non-conformances requiring deviation, or concession, and containment required).Enter the number corresponding to the completed stage from the list below.1. Has not received any production releases from using plant(s).2. Is receiving production releases from the using plant(s), but no production schedule or plan documented to meet those volumes or has ramp plan, is receiving plant releases, but not shipping to ramp plan and/or releases.3. Has not received production releases from plant(s), but has created a preliminary planned based on quoted volumes and program timing.4. Is receiving production releases and has created a plan, but production schedule does not reflect the plan.5. Is receiving production releases, has created a ramp plan and this plan is reflected in the production schedule.Enter the number 5, which corresponds to the final stage for developing a ramp plan. (Is receiving production releases, has created a ramp plan and this plan is reflected in the production schedule.)The final score of the Launch Readiness Audit conducted during APQP Phases 3 and 5.The Launch Readiness minimum score is 90%. 100% is used in the calculation to reflect the actual score achieved.The number of material and performance specification tests passed. A failure of a single sample in any test series represents a failure of that test.Determined by dividing the total number of required tests in the materials and performance specifications into the number of tests passed.Current number of purchased sub-components and materials PPAP approved.The total number of purchased sub-components and materials requiring PPAP approval.The number of PPAP submission package required documents requested by TRW that are complete and ready to be compiled into the package.The total number of requested PPAP submission package documents. This may include in addition to the AIAG standard requirements Warrant Letters for each sub-component/material, the PCM, etc.The number of elements from the APQP Progress report showing 'GREEN' status.The total number of elements found on the APQP Progress Report.Take the Overall Utilization % from the Run at Rate form and enter it.85% is the preferred acceptable utilization %, but 100% is allowed since CPV is 15% above FPV.. Any number greater than 100% requires a approved Run at Rate Expection form or a documented plan to add capacity to reduce the utilization % below 100.GSQM 220 deployment is based on the completion status of the PCM. These stages are:1. TRW supplier has completed the form, less SLP.2. TRW's supplier has completed their sub-supplier form, less SLP.3. Supplier section completed, including SLP.4. Sub-supplier section completed, including SLP.5. Characteristic Review signed off on both tabs.6. Complete sign-off on both tabs for "Safe Launch Exit Approval."Stage 5 is the sign-off of the Product Characteristic Review approvals. Enter '5' for components when the PPAP for manufacturing process will be submitted before SOP, or within 30 days after SOP.

Stage 6 is the SLP Exit approval, on the PCM, and cannot be completed until after SOP. Enter '6' for situations where the process validation needs to include SLP sign-off.The total number of set-up, manufacturing and inspection instructions completed, and released, at the time of the review.The total number of set-up, manufacturing and inspection instructions needed.Enter either "APQP-3"; Date of Review; or Review name, i.e., 30-day, 60-day, etc.Enter either "APQP-5"; Date of Review; or Review name, i.e., 30-day, 60-day, etc.Enter either Date of Review or Review name, i.e., 30-day, 60-day, etc.Enter Date of Review or Review name, i.e., 30-day, 60-day, etc.Enter Date of Review or Review name, i.e., 30-day, 60-day, etc.

Other APQP ToolsAPQP: Key Supplier Metrics Operational DefinitionsThis section defines the Key Supplier Metrics that will be tracked throughout the five APAP Phases. Reviews will be held toward the end of each of the five phases. Review of these metrics, in the Phase 5, will take place before the final full PPAP approMetricDefinitionGoalResultsAPQP ReadinessData is derived from the 'APQP Progress Report'. This metric tracks the percentage of GREEN elements compared to the total number of elements being tracked.Enter the number of GREEN elements at the time of the report.Enter the total number of elements being tracked. There are 33 elements on the APQP Progress Report. For suppliers where the DFMEA does not apply subtract 1. For suppliers who are not providing an Appearance item, subtract 1.Process InstructionsTotal number of set-up, manufacturing and inspection instructions needed.Enter number of completed process instructions at the time of the review.Enter total number of process instructions needed for serial production.First time CapabilityPercentage of good parts to the total number of parts produced during the Run at Rate.

Form No.: D_020_4_12Enter, as a decimal number, the ratio of total parts produced to good parts from the trial run.Enter the number '1,' which represents the production of 100% good, or usable, parts.Process EfficiencyThis is the percentage that the process is utilized.The Overall Utilization % from the Run at Rate form.Maximum allowable utilized capacity is 100% when the standard shift pattern and CPV are used.Process CapabilityThe number of designated characteristics with a Ppk > 1.67.Enter the number of characteristics, with a Ppk > 1.67, at the time of the review.Enter the total number of designated characteristics on the drawing.Test AchievementTotal number of performance and materials tests that need to be conducted to meet the specifications shown on the drawing. This number is a combination of the number of unique tests multiplied by the number of samples required for the test.This is the total number of samples that passed all of the required testing at the time of the review.The should represent the total number of individual tests required times the number of samples, for each test, that is required.Process Implementation - % CompletedThis metric assesses the level of implementation of the full production intent process. Processes that are not fully implemented at the Start-of-Production require a deviation, or concession, to allow shipment. This document needs to clearly define the state of the process implementation, provide a time line for completing the implementation, list any non-conformities to the drawing and/or specifications, and a containment plan to keep those non-conformances from reaching TRW.Enter the appropriate stage of process implementation in regard to manufacturing for serial production.1. Prototype process is implemented; No released deviation of concession; No containment plan.2. Intermim process implemented, with partial production intent process; No released deviation or concession; No containment plan.3. Prototype or partially implemented process; Released deviation or concession; No containment plan.4. Partial or fully implemented process; Released deviation or concession; Containment plan implemented.5. Fully implemented process; No deviation or concession required5. Fully implemented process; No deviation or concession required.Launch Readiness AuditA comprehesive audit tool's score, which assesses a process's state of preparation to meet serial production requirements.

Form No.: D_020_4_09The score achieved on the Launch Readiness Audit. Enter data as a decimal number.The minimum goal for full release for production is 90%. Goal is 100% and entered as "1".Sub-Component PPAP ApprovalsNumber PPAPs approved for the purchased sub-components and materials that makes up the final shipped component/material, and that do not have any deviations, waivers, and/or concessions granted by any tier below TRW.The number of approved sub-component and material PPAPs at the time of the report.The number of approved sub-component and materials making up the shipped component/material.PPAP Package CompletionNumber of PPAP submission package elements completed compared to required number.The number of elements (or documents) completed for the PPAP package at the time of the review.The total number of required elements, or documents, required to be submitted.Supplier Ramp PlanThis element evaluates a supplier's ability to meet ramp-up timing and volumes.Enter the number corresponding to the completed stage from the list below. 1. Has not received any production releases from using plant(s). 2. Is receiving production releases from the using plant(s), but no production schedule or plan documented to meet those volumes or has ramp plan, is receiving plant releases, but is not shipping to plan and/or releases. 3. Has not received production releases from plant(s), but has created a preliminary planned based on quoted volumes and program timing. 4. Is receiving production releases and has created a plan, but production schedule does not reflect the plan. 5. Is receiving production releases, has created a ramp plan and this plan is reflected in the production schedule.Enter the goal, Level 5-Is receiving production releases, has created a ramp plan and this plan is reflected in the production schedule.GSQM 220 DeploymentThis element provides status of the completion of the safe launch plan, on the PCM (D_020_4_20).Enter number of completed stage at time of review.Enter the number '5' representing the completion of the PCM, less the exit from the Safe Launch Plan. This applies to situations where the PPAP will be submitted in a span of time from before SOP to 30 days after SOP.

Enter the number '6' for situations where the SLP exit is required for closing APQP.


&RProcess Owner/Department:R. Sparisou / Supplier DevelopmentApproved by:R. Blanchette / Global Director, SDE

Supply Chain Map - FormSupplier APQP: Progress Report - Status OverviewSupplier Name:0Supplier Location:0Supplier Code:0Part Number:0Part Name:0Revision Level:0Component Priority Level:0Lead Customer/Program:0Report Date:31-Dec-1899PROGRAM MILESTONESEventDateEventDateNeededCommittedCompletedNeededCommittedCompletedDesign FreezeFirst Off-ToolFirst Off-ProcessTRW PV BuildPPAP submissionStart of ProductionPHASE/ELEMENT STATUS OVERVIEWAPQP PhaseElementDatePercent CompleteStatusIssues / Recovery Plan / ActionsNeededCommittedComplete2040608010011.1Design FMEAG1.2Preliminary Capacity Study reviewedY1.3Manufacturing Feasibility reviewedR1.4Component Design ReviewN/A1.5Key Supplier Metrics initiated1.6Supplier Project timing plan1.7Open Issues Action Plan created22.1Subcontractor PPAP approval2.2Product Characteristic Matrix initiated2.3Process flow chart2.4PFMEA2.5Control Plan2.6Key Supplier Metrics reviewed33.1Measurement/ Testing equipment3.2Tooling3.3Capital equipment3.4Training3.5Process instructions3.6Packaging3.7Launch Readiness Audit3.8Key Supplier Metrics reviewed44.1ELV/IMDS4.2Safe Launch Plan finalized4.3Supplier Ramp Plan4.4Plant Readiness Review4.5Launch Readiness Audit4.6Appearance Approval Process (when applicable)4.7Key Supplier Metrics reviewed55.1PPAP5.2Launch Readiness Audit5.3Run at Rate5.4Key Supplier Metrics reviewed5.5OK to Launch Sign-Off


&RProcess Owner/Department:R. Spariosu / Supplier DevelopmentApproved by:R. Blanchette / Global Director, SDEEnter "N/A" for any event that is not part of the launch time line.

For blank rows enter key events defined by the component commodity or customer process.Date from Program Timing Plan that an event should take place.Date that TRW or the Supplier committed to meeting the deliverable.Actual date the action/event takes place.Date from Program Timing Plan that an event should take place.Date that TRW or the Supplier committed to meeting the deliverable.Actual date the action/event takes place.Enter key events as defined by the component commodity or customer program deliverables.

Supplier Chain Map - ExampleSupplier APQP: Other ToolsCOMPONENT DESIGN REVIEWCLICK HEREPRODUCT CHARACTERISTICS MATRIXCLICK HERELAUNCH READINESS AUDITCLICK HEREPPAP CHECKLISTCLICK HERE


&RProcess Owner/Department:R. Sparisou / Supplier DevelopmentApproved by:R. Blanchette / Global Director, SDE

PCMSupplier APQP: Supply Chain MapSupplier:0Part Number:0Date:Revision:Tier VTier IVTier IIITier IITRW receiving OperationOEM CustomerTier



SLPSupplier APQP: Supply Chain Map - ExampleTIER 4SUPPLIERTIER 3SUPPLIERTIER 2SUPPLIERKojak Heat TreatBenton Harbor, MIHarden & DrawFine Fasteners, Inc.Benton Harbor, MIM8x20 Weld Stud59039813ACold FormingAnaconda SteelErie, PAC1038 RodSteel MillWhite & JonesJackson, MIC1038 RodWire Draw, Anneal3rd Party WarehouseCUSTOMERTRW MesaMesa, AZOEM Z910TIER 1 SUPPLIERSaf-StoreMesa, AZWarehouse ServicesAAA Heat TreatFrederick, MDHarden & DrawPrecision FormingAmarrillo, TXAirbag Reaction Can49019804AStamping body, end caps, bracketsABC Nut Co.Summit, NJM8x15 Staking Nut59039812CCold FormingPacific SteelLos Angeles, CAC1024 RodSteel MillB&C ProcessingGeorgetown, PAC1024 RodWire Draw, AnnealTRW AlfdorfAlfdorf, GermanyOEM Z910Dynamic Chemical SuppliesTulsa, OKCoating materials, solventsZephyr CoatingsAustin, TXE-Coat


&RProcess Owner:R. Spariosu / Supplier DevelopmentApproved by:R. Blanchette / Global Director, SDE

SLP - QOSSupplier APQP: Product Characteristic MatrixPart Name:Supplier Name:PCM Revision Date:Part Number/ Revision:Location:Project/ Program:TRW Using Plant(s):#Product Design InputsSupplier Process Control InformationSafe Launch Plan (SLP)Product CharacteristicLevel/ClassDFMEASeverityPFMEASeverityPFMEAOccurancePFMEADetectionRPNControl Method(s)Gauge R&RSample Size / FrequencyControl MethodSample Size / Frequency0000000000000000000000000000000000Safe Launch Plan duration is for 90 days after start of production unless otherwise specified.Other:SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.SLP data must be sent to TRW (check one):Safe Launch Plan must remain in effect until TRW approves SLP exit.All production material sent to TRW during the SLP time period must be subjected to the agreed Safe Launch Plan. This includes material produced during PPAP.PCM APPROVALSNamePosition/ TitleSignatureDateCommentsTRWA SDETRWA Plant SQASupplier Representative

&LDate: 29 April 2008Revision: BDoc No: D.020.4.20Page &P of &N&CD_020_4_20-&A

&RProcess Owner/Department:R. Blanchette / Supplier DevelopmentApproved by: / VP PurchasingDesignated characteristic as defined by TRW drawings & specifications. Also include characteristics considered important by TRW Engineering, Operations, or the supplier.

High FMEA severity characteristcs critical to- function- assembly- suppliers process- customer touch points

Also include characteristics with a history of issues (high occurance ranking on PFMEA) .

Enter specification/ limitslevel/ class of characteristic:

- as identified on TRW drawings/ specification- as identified by supplier- customer touch point (CTP)PFMEA severity for failure mode with the highest RPN associated with this characteristic.PFMEA occurance for failure mode with the highest RPN associated with this characteristic.PFMEA detection ranking for failure mode with the highest RPN associated with this characteristic.Enter the control method. Examples: Visual inspection, attribute gage, variable gage, poke yoke...

List all controls if multiple controls are in place.Risk Priority NumberEnter the control method. Examples: Visual inspection, attribute gage, variable gage, poke yoke...

List all controls if multiple controls are in place. Include additional safe-launch controls.DFMEA severity as defined by TRW engineering (or related to defined level of characteristic)For variable gage enter % Tolerance from the GR&R analysis. For attribute gage enter "pass" or "fail" from GR&R study. Enter "N/A" if GR&R is not applicable to control method.Sample size and inspection frequency for each control.Sample size and inspection frequency for each control.Hide Empty RowsShow All Rows

PCM Sub-SupplierSupplier APQP: Safe Launch Plan Data and Exit ApprovalPart Name:0Supplier Name:0PCM Revision Date:31-Dec-99Part Number/ Revision:0Location:0Project/ Program:0TRW Using Plant(s):0#Product Design InputsSafe Launch Plan (SLP)Cpk from PPAPDate:Date:Date:Date:Date:Date:Product CharacteristicLevel/ClassControl MethodSample Size / FrequencyQuantity InspectedQuantity RejectedPpkQuantity InspectedQuantity RejectedPpkQuantity InspectedQuantity RejectedPpkQuantity InspectedQuantity RejectedPpkQuantity InspectedQuantity RejectedPpkQuantity InspectedQuantity RejectedPpkAdditional columns are hidden. Unhide them as needed.00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000Safe Launch Plan duration is for 90 days after start of production unless otherwise specified.Other:0Enter accumulated production data where specified in this form. Use of the SLP Weekly QOS Form will be directed by TRW as necessary.Submit data to the TRW Plant per the agreed frequency on the Product Characteristic Matrix unless instructed otherwise by TRW.SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.To exit SLP: Sign and submit this form with all data. Acceptablilty of SLP exit request will be determined by TRW SQA.SAFE LAUNCH PLAN EXIT APPROVALSNamePosition/ TitleSignatureDateCommentsSupplier RepresentativeTRWA Plant SQA

&LDate: 25 Apr 2008Revision: BDoc No: D.020.4.20Page &P of &N&CD_020_4_20-&A&RProcess Owner/Department:R. Blanchette / Supplier DevelopmentApproved by: / VP PurchasingHide Empty RowsShow All RowsShould include all process data in a cumulative long term capability calculationInitial short term Capability study from PPAP

In Cell CheckSafe Launch Plan: QOS ReportTotalWEEK0Incidents0QTY0PPM0000000000000000Fault No.Failure ModeTotalActionTimingW14W15W16W17W18W19W20W21W22W23W24W25W26W27W28W29000000000000000000000

&LDate: 01 Aug 2005Revision: CDoc No: D_020_4_05Page &P of &N&CD_020_4_20-&A

&RProcess Owner/Department:K. Gillis / Supplier DevelopmentApproved by:E. Carpenter / VP Purchasing

In Cell Check

IncidentPareto Failures By Process

In Cell (Example)

&APage &PIncidentsPPMIncidentPPMTouch Point Incident & PPM Monitoring

Open IssuesSupplier APQP: Product Characteristic MatrixPart Name:Supplier Name:PCM Revision Date:Part Number/ Revision:Location:Project/ Program:TRW Using Plant(s):#Product Design InputsSupplier Process Control InformationSafe Launch Plan (SLP)Product CharacteristicLevel/ClassDFMEASeverityPFMEASeverityPFMEAOccurancePFMEADetectionRPNControl Method(s)Gauge R&RSample Size / FrequencyControl MethodSample Size / Frequency0000000000000000000000000000000000Safe Launch Plan duration is for 90 days after start of production unless otherwise specified.Other:SLP Exit Criteria: Zero internal or external defects detected during SLP. The SLP period restarts upon detection of a defect.SLP data must be sent to TRW (check one):Safe Launch Plan must remain in effect until TRW approves SLP exit.All production material sent to TRW during the SLP time period must be subjected to the agreed Safe Launch Plan. This includes material produced during PPAP.PCM APPROVALSNamePosition/ TitleSignatureDateCommentsTRWA SDETRWA Plant SQASupplier Representative

&LDate: 29 April 2008Revision: BDoc No: D.020.4.20Page &P of &N&CD_020_4_20-&A

&RProcess Owner/Department:R. Blanchette / Supplier DevelopmentApproved by: / VP PurchasingDesignated characteristic as defined by TRW drawings & specifications. Also include characteristics considered important by TRW Engineering, Operations, or the supplier.

High FMEA severity characteristcs critical to- function- assembly- suppliers process- customer touch points

Also include characteristics with a history of issues (high occurance ranking on PFMEA) .

Enter specification/ limitslevel/ class of characteristic:

- as identified on TRW drawings/ specification- as identified by supplier- customer touch point (CTP)PFMEA severity for failure mode with the highest RPN associated with this characteristic.PFMEA occurance for failure mode with the highest RPN associated with this characteristic.PFMEA detection ranking for failure mode with the highest RPN associated with this characteristic.Enter the control method. Examples: Visual inspection, attribute gage, variable gage, poke yoke...

List all controls if multiple controls are in place.Risk Priority NumberEnter the control method. Examples: Visual inspection, attribute gage, variable gage, poke yoke...

List all controls if multiple controls are in place. Include additional safe-launch controls.DFMEA severity as defined by TRW engineering (or related to defined level of characteristic)For variable gage enter % Tolerance from the GR&R analysis. For attribute gage enter "pass" or "fail" from GR&R study. Enter "N/A" if GR&R is not applicable to control method.Sample size and inspection frequency for each control.Sample size and inspection frequency for each control.Hide Empty RowsShow All Rows

ContactsSafe Launch Plan: In Cell Check100% IN CELL KEY FEATURES VERIFICATIONAND CUSTOMER TOUCH POINTSFEATURES TO BE QUALIFIEDPart DescriptionOperator Name:___________ Work Cell:_________

Quantity Inspected:____________Date:______________Verification MethodPassFail1234567891011**Threaded nut hole positionChecking Jig012**Abutment hole positionChecking Jig013**Abutment hole diameterPlug Gauge014**Nut thread checkThread gauge315**Nut weld torqueBrakeaway torque516**Abutment and locating plate gapFeeler Gauge617**Dust ring gap to backplate checkFeeler Gauge718**Cable guide gapSnap gauge1119**Locating abutment plate smooth surfaceVisual1020**No Cracks on backplate (visual boundary sample)Visual221**NO paint scratch and or contamination, blistering, runsVisual522**23**24Part NumberCOMMENTS :The Items Qualified Are To Be Marked With "YELLOW" Paint.Supervisor Signature : Date :



Safe Launch Plan: In Cell Check ExampleTRW AutomotiveSpecial Work InstructionCustomer /Project:OPERATIONOP25 SAFE LAUNCH PRODUCTIONFEATURES TO BE QUALIFIEDPart DescriptionBrake Assy LHBrake Assy RHOperator Name:___________ Work Cell:_________

Quantity Inspected:____________Date:______________Verification MethodPassFail1**Lining identification codeVisual2**Mass weight and rivet presenceVisual3**Date code on shoeVisual4**PKB rivet crimped washerVisual5**Pkb lever hookGap Gauge6**Wheel cylinder screw torqueAir Torque/markPart Number1454400214544001COMMENTS :The Items Qualified Are To Be Marked With "YELLOW" Paint.Supervisor Signature : Date :


&RProcess Owner/Department:R. Spariosu / Supplier DevelopmentApproved by:R. Blanchette / Global Director, SDESave lunch checking item Station15Part No.issueStationDocument No.RevIssue dateSheet 1/1Part/ Process Description :145-44001/145-44002ADVICS / IMV02315461523 April'04Example

Supplier APQP: Open Issues - Corrective Action PlanopenOpenclosedOverdueSupplier Name:0Component Manufacturing Location:0Supplier Code:0ClosedTRW Part Numbe(s):Issued by:Customer Name:Customer Platform:TRW Product:Status:Launch ActivityDateLaunch ActivityDateLaunch ActivityDateAction plan reviewAction plan reviewSupplier VisitSupplier VisitDate scheduledDate actualDate scheduledDate actualAPQP gateway reviewAPQP gateway reviewDesign ReviewDesign ReviewRun @ Rate auditRun @ Rate auditLRR auditLRR auditP&P auditP&P auditSafe launch planSafe launch planotherSupplierOtherItem NumberSource of IssueSource Ref NumberConcern / Problem / Open Issue DescriptionActionDatesStatusResponsibilityOpenedDueClosedDistribution:


&RProcess Owner/Department:R. Spariosu / Supplier DevelopmentApproved by:R. Blanchette / Global Director, SDEFill in when a supplier has multiple manufacturing locationsEnter multiple part numbers when a family of components are being launched.Name of individual who originally fills out and publishes this form.Maintains history of launch activities between TRW and Supplier. Selections are from a drop down menu.Date that the Launch Activity took place.Show Open - actions not completed and/or verified effectiveClosed -actions completed and verified effectiveAction Plan item number. Assigned sequentially as new items are added.Indicates the source of the issue. If the option is not available in the drop down menu, leave blank.Enter the APQP Element number, Design Review question number, etc.Driver Air Bag, Anti-lock Brakes, Seat Belt Retractor, etc.

Part NumberTRW APQP: Contacts- APQP TEAMReport Date / RevisionContact InformationContact InformationFunctionFunctionSupplierTRW Purchasing Commodity MgrNameNameDept.Dept.Tel.Tel.Fax.Fax.E-mailE-mailAdress/LocationAdress/LocationTRW Purchasing Product Line MgrNameNameDept.Dept.Tel.Tel.Fax.Fax.E-mailE-mailAdress/LocationAdress/LocationTRW Supplier Development EngineeringNameNameDept.Dept.Tel.Tel.Fax.Fax.E-mailE-mailAdress/LocationAdress/LocationTRW EngineeringNameNameDept.Dept.Tel.Tel.Fax.Fax.E-mailE-mailAdress/LocationAdress/LocationTRW Receiving Plant Logisitic & PackagingNameNameDept.Dept.Tel.Tel.Fax.Fax.E-mailE-mailAdress/LocationAdress/LocationTRW Receiving Plant QualityNameNameDept.Dept.Tel.Tel.Fax.Fax.E-mailE-mailAdress/LocationAdress/LocationProject managementNameNameDept.Dept.Tel.Tel.Fax.Fax.E-mailE-mailAdress/LocationAdress/Location



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