TRAINER FOLDER
for exercises related to APQP & PPAP by PSA:
PHASE 5:
RAMP UP
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EN J5 - End of development
E Product and process assessments. Parts deliveries at the requested level of quality and service.
N Correctives actions over. Lessons learned effective. End of development.
Date common Project.
Date prior to the start of PSA ramp-up
Thème Résultats attendus / Expected results
FD01 (PSA)
The final version of the Technical Specification (ST) is officialized taking into account all agreed
Technical specifications +
changes.
Requirements coverage matrix,
References and versions of the officialized ST are registered in APQP grid. (PSA)
including after sale
For Sofware: Final version of software coverage matrix is officialized taking into account all
requirements
agreed changes.
FD02 (PSA)
The final version of the supplier drawing is officialized taking into account all agreed changes
Product design file (supplier
(FETE or amendment FIPA) and all spare parts.
drawing)
References and versions of the officialized supplier drawing are registered in APQP grid.
FD03 (PSA)
List of Product Functional and
Technical Characteristics (CTF) The mass production PCP is officialized and released in PSA systems.
and Parts Inspection Standard It is registered in APQP grid. (PSA)
(PCP)
FD04 (SUP)
The Supplier Design Validation Plan and the PSA Integration & Validation Plan are completed. The
results are complying.
The results of Supplier Design Validation Plan are registered in APQP grid.
Design Validation Plan and
results
For Sofware - APQP-FD04-SW : Final version of software validation plan, taking into account
agreed changes(FETE, correction of defects) is availables in APQP grid.
Final tests from Supplier and PSA are finalized and results are accepted.
FD05 (SUP)
The action plans related to process FMEA are over. Risks are under control. If not, they are
Process FMEA monitored in the Control Plan.
The process FMEA can be consulted.
FD06 (SUP)
The long term process capabilities are met:
The capability targets (Cp, Cpk, TNC & mean deviation) specified in the PCP for Mass Production
are met at least on the two last production runs of a minimum of 30 parts each. The decision is
Toolings and production made in client-protection mode. (Refer to Quality Standard 01276_16_00027)
equipments, including supplier Nota1: In the PCP, the capability targets for each characteristic are either clearly mentioned or by
specific toolings (OSF) default specified with the use of standard values.
The process capability studies results are registered in APQP grid.
FD07 (SUP)
If requested, the Supplier Production Capacity Assessment (or self assessment) is completed and
Run at rate results are complying.
The assessment report is registered in APQP grid.
FD08 (SUP)
The results of the Process Control Plan Audit (PCPA) and the relevant action plans are complying.
Supplier process audit
The PCPA report and the action plans are registered in APQP grid.
FD09 (SUP)
The traceability system is in place with evidence of its efficiency, including tier 2 suppliers
Traceability components.
The final traceability statement is registered in APQP grid.
FD10 (SUP)
Specific packagings (including semi specific packagings) are available in proper quantities not to
Specific packaging
disturb mass production.
FD11 (PSA)
Part Submission Warrant Parts are consistently delivered on time, at the required quality and quantity level. There is no
(PSW) pending risk or defect.
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INSTRUCTION: you take part to the fifth gate / milestone review « END OF DEVELOPMENT».
You have to give a status on the maturity level on deliverables for the milestone 5 (GREEN, RED, GREY).
You have at your disposal 4 deliverables:
Ach
APQP - FD02: officialized drawings of suppliers ; FETEs signed
ievin
APQP - FD05: Process FMEA
g the
APQP - FD07: Production Capacity assessment atmile full rate
APQP - FD11: parts delivered on quality, on timeston
and on quantity / all defects solved
e5«
YOUR CONTRIBUTION :
END
Within groups, at paperboard, you have to analyse the 4 OF
supplied deliverables, then give a status.
DEV
YOUR DECISION : ELO
PME
Deliverable status (red, Why? Give NTthe explanation Required action (if necessary)
green,grey)
APQP - FD02 officialized
»
drawings of suppliers ;
FETEs signed
APQP - FD05 Process
FMEA
APQP - FD07 Production
Capacity assessment
APQP - FD11 parts
delivered on quality, on
time and on quantity /
all defects solved
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OFFICIALIZED DRAWINGS OF SUPPLIERS ; SIGNED FETEs
Since the acceptance of the PPAP at the end of phase 4, STELLANTIS and CORPALU have agreed on a
modification of a bore. STELLANTIS decided to formalize the change in the next wave of officialization by
end of year. CORPALU proposes to propose to validate Milestone 5.
PROCESS FMEA
The modification of the bore has been integrated into the Process FMEA : the action to improve the
process control (start-up checklist of a Manufacturing Order, modification of the control gauge) is ready to
be implemented in waiting for the agreement to officialize the modification by STELLANTIS.
PRODUCTION CAPACITY ASSESSMENT AT FULL RATE
CORPALU carried out the capacity assessment and entered the results in the APQP grid. Several deviations
are noted. CORPALU explains the action plan proposed to overcome the difficulties linked to the bottleneck
that constitutes heat treatment at the supplier THERMI25. CORPALU proposes to qualify a second heat
treatment supplier, not known to STELLANTIS.
PARTS DELIVERED ON QUALITY, ON TIME AND ON QUANTITY / ALL DEFECTS SOLVED
Since the start of production, three incidents were transmitted by quality department of STELLANTIS’s
plant on packaging issues:
interlayers were missing,
error on the label not consistent with the information received by EDI and included in the label,
gap in quantity between the label and the packaging unit.
STELLANTIS considers that the action plans have not sufficiently investigated the root causes. The curative
actions have prevented recurrence in the first two months of delivery. The effectiveness of corrective
action has still to be demonstrated by CORPALU. The CORPALU’s quality department has planned to get
more involved in solving logistic issues.
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