The scope of this procedure is to define the process from the sourcing decision to the successful introduction of a new or significantly modified production product by your organization to Dana (output from Quotation Processing), to the approval of the Part Submission Warrant (PSW).

Project Risk Assessment

The Regional Supplier Development personnel with a cross functional team, named the Launch Team, will review your organization’s profile data, any audits or self-assessments (from Supplier Approval Process), historical performance (for existing suppliers from the Supplier Performance Feedback Process), to determine the level of review required at each element of the APQP Status Report. 

The output of this process stage is the creation of the APQP Status Report sheets for all organizations in the program launch or change management request (items A-K on the APQP Status Sheet and item U – Review Type for each APQP Element)

Note:  At this stage of the process your organization has already been assessed and chosen through the supplier approval and quotation process.  This risk assessment is to determine the controls needed by the Launch Team in response to known areas of risk.  Where new areas of risk become evident throughout the APQP Process, changes to the controls will be made accordingly.
 

Identify Key Program Milestones

The Program Manager (or Change Manager for Change Management Requests) with the Buyer and Supplier Development personnel will determine the key milestones for the program and associated build level requirements (i.e. the material requirement dates and projected quantities) for your organization.

The output of this process stage is the completion of items L to P of the APQP Status Report (i.e. Build Level, Material Required Date, Quantity, and Number and type of Special Characteristics). 

NOTE:  Changes to the initial build schedule may be made during the course of the launch by the Launch Team.  The APQP Status Report shall be used to both record and communicate changes to the build and special characteristics and solicit responses from your organization.
 

Send Letter of Intent / Agreement / PO and APQP Document Package to Supplier

The Buyer is responsible for the communication of the supply agreement and APQP documentation to your organization.  The APQP Document Package is contained within the APQP Status Report excel file.   Blank copies of the forms can be found in the Supplier Document Center.

It is Dana’s expectation that your organization will review this information and develop their timeline for each element of the APQP Status Sheet (item X) and identify any issues prior to the Supplier Kick Off Meeting.

Issues that cannot be resolved prior to the Supplier Kick Off Meeting shall be noted on the APQP Status Sheet under the Sourcing Decision APQP element as Red Status with brief explanation in Remarks (item AA) or in Comments (item AB).

The output of this process stage is the delivery to your organization of the Sourcing Decision and APQP Documentation and the completion by your organization of the Supplier Timing Dates for the APQP Elements.

Supplier Kick Off Meeting

The Supplier Kick Off Meeting is held by the Program Manager (or Change Manager) and the Launch Team to clearly define to all organizations the critical path for the successful launch of the program.  A Launch Team member will be given the responsibility to record attendance and the minutes of the meeting. 

Attendance of at least one representative from your organization to (Dana Specific Supplier Requirements, 5.5.2.1 Customer Representative) is mandatory, with additional Supplier APQP Team members from your organization identified on the APQP Status Sheet welcome.

The output of this process stage is the Supplier Kick Off Meeting attendance record and minutes.
 

APQP Status Element Review and Deviation / Alert Requests

The Regional Supplier Development personnel will hold APQP Status Report meetings with your organization.  The purpose of this review is to clarify requirements with your organization and to verify progress toward launch targets.  Depending on the Review Type for the APQP elements under review, Dana may require additional supporting documentation (see Item U - Review Type, below).  The frequency of these reviews and updates are dependant on the risk factors identified, the review cycle established by Dana, and the current status.  Your organization is expected to hold internal launch meetings at a greater frequency to ensure flawless program launches.

Any issues that require changes from the stated requirements shall be approved through the Waiver / Deviation / Exception Process.  The purpose of this process is to clearly identify areas for improvement of the Supplier Development process and ensure that problems do not remain hidden.

This review may include a Process Series Review at the supplier’s location (see element 19 – Production Trial Run / Run at Rate).  This requirement may be waived if the supplier shows low risk factors and no yellow or red APQP elements, at the discretion of the Dana Launch Team.

Yellow or Red elements identified in prior reviews and their respective work plans and deliverable outputs will be reviewed by the team.  New Yellow or Red elements determined by the review require the identification of responsibility.  In cases where an engineering change is required, the Dana Product Group specific Supplier Engineering Change Management Process will be used. 

Where all items of the APQP Status Report are Green, the report is forwarded directly to the Program or Change Manager.

The output of this process is the updated APQP Status Report package, including Work Plans and any information from the Process Series Review, as appropriate.

Identify APQP Element(s) Affected

For issues that arise where engineering changes are not required, the Launch Team or your organization will identify the responsibility for the creation of the work plan.  The responsibility may lie with your organization or with Dana depending on the specific issue.
 

The output of this process step is the identification of the element(s) affected by issues requiring detailed work plans, and the responsibility for each issue and element.

Create Work Plan

The creation of an effective work plan is reported with the APQP Status Report on the Work Plan tab.  The work plan shall be reviewed, by your organization, at a frequency commensurate with the magnitude of the risks to the critical path of the program.  Work Plans are a summary of the key activities required to re-establish the critical path of the program, and shall reference supporting materials, as required by Supplier Development or the Program Manager.

The output of this process step is the completion of the work plans for each issue and element that is not at green status with any supporting materials available upon request of the Launch Team.

Work Plan Approval and Escalation

If any items on a work plan are found not to be feasible or effective by the Launch Team and/or the Program Manager, the program will be escalated to highlight needs for additional resources or alternative business relationships to execute the launch plan.  Your organization is responsible for providing any additional information referenced in the work plan.

The output of this process step is the approval or rejection of the Work Plan by the Launch Team and/or the materials needed to escalate the issue.

Program Management Review

At the intervals defined by the Program Manager, program launch information including all respective Supplier APQP information shall be reviewed.  This process is owned by Program Management.  Your organization’s Supplier APQP information must be updated at a minimum, at a frequency to support Dana Program Management reviews.  Your organization’s representative will be notified of any action items assigned to your organization by Supplier Development.

The output of this process step is the Dana Program Management Meeting and any associated action plans for your organization.

PPAP and Supplier Launch Criteria

If all Supplier Launch criteria have been met, your organization will have completed the APQP process with the submission of a PPAP documentation package at the requested level of submission and the appropriate approvals have been obtained.  By default, a level 3 PPAP is required (Dana Specific Supplier Requirements 7.3.6.3)  Supplier Development is responsible for approving any change from the default PPAP submission level.

If a PPAP is found to be deficient, Supplier Development will change the status of element 22: Production Part Approval (PSW) to red or yellow.  Red status indicates a rejection based on a documented failure to meet a specified requirement or incomplete submission after PSW was due.  Yellow status can only be used where your organization has submitted PSW under a Waiver / Deviation / Exception.  The APQP Status Report must reference the Waiver / Deviation / Exception report and work plan for full PSW submission.

Where launch criteria have not yet been met, the APQP Status will continue to be reviewed at intervals sufficient to support the overall review cycle of the Program or as needed in response to alerts and deviations.

System Improvement

On of the goals of the APQP process is to improve itself over time.  The effectiveness of the APQP process is measured on its ability to meet the goal of flawless launches.  The efficiency of the APQP process (i.e. the effective use of resources) to flawlessly launch a new product will be improved through suggestions and findings of its participants.  At any stage in the program your organization may submit improvement ideas through the Supplier Ideas System. 

APQP Status Report

The purpose of APQP is to ensure that both your organization and Dana increase the value of our partnership through the effective introduction and change management of products and lean processes. 

It is the goal of Dana to clearly define the expectations before, during and after the launch of a new production part, for our suppliers to develop deliverable targets to delight our customers and markets.  Where expectations are unclear, the suppliers are encouraged to communicate specific process and content improvement with Dana. 

APQP Status Report Items

A. Supplier

Your organization’s name for the manufacturing facility.

B. Location

Your organization’s city, state/province/region and country for the manufacturing facility.

C. Supplier Code

Your organization’s DUNS number.

D. Risk Assessment

Identify if your organization is providing product from a new site, using new technology (to the supplier), or a new process by checking the appropriate box.  The other risk category may be derived from risk factors identified by a Supplier Systems Assessment for from risks identified at reviews of the APQP Status Reports.

E. Program

Program name.  Where appropriate, identify Dana’s customer’s program name.

F. Model Year

The effective model year of the products’ introduction.

G. Lead Part No.

Dana’s part number for the first part of a part family covered by this APQP Status Report.  Include additional part numbers in the comment section (28) covered by your organization for the specified program.

H. Part Name

Dana’s part name for the lead part number.  Include additional part names by part number in the comment section (28).

I. Notice Level

Enter the notice level of the part being reviewed (if applicable).

J. User Plant(s)

List of the Dana facilities using the part number(s).

K. Team Members

At a minimum the your organization’s Customer Representative to Dana (TS-16949:2002 5.5.2.1), and Dana’s Buyer, Supplier Development representative, and the Program Manager shall be listed as team members with contact phone numbers.

L. Build Level

Build Levels are specific to Dana’s Customer applications.  For guidance, the build levels associated with several distinct phases should be represented: prototype (soft-tooled), low volume production trails (soft or hard tooled) and high volume production trials (hard tooled).

M. Material Requirement Date

Dana’s material requirement dates for your organization to supply pre-production build levels, production part approval builds, and conduct capacity and capability trials.

N. Quantity

The number of components required to support the build levels.

O. No. SCs

Number of Significant Characteristics.  NOTE: Significant Characteristics may be identified by Dana or by your organization.

P. No CC’s

Number of Critical Characteristics.  NOTE: Critical characteristics may be identified by Dana or by your organization.

Q. PIST (%)

Percentage of Inspection points which Satisfy Tolerance.  This is the defects (out-of tolerance conditions) which exist per opportunity (inspection point) expressed as a percentage.  Action thresholds will be established by the Buyer and Supplier Development representative for each build level of the program.  The out-of-tolerance condition can be solved through changes in the design specification of the product (Engineering Change Request) or through corrective action / tool modifications (Supplier Corrective Action Request).

R. PIPC (%)

Percentage of Indices (Cpk / Ppk) that a Production Capable.  This is the number of significant or critical characteristics on the drawings or specifications that achieve production process capability (Ppk of 1.67 or greater) over the total number of significant or critical characteristics (15 and 16 above) expressed as a percentage.  The Supplier must be able to provide objective evidence of the capability, upon request.

S. APQP Elements

This is a listing of the core APQP elements required to successfully launch a product into Dana’s production environment.

T. GYR Status

Red: Target dates and/or deliverables are at risk.  A recovery work plan is not available and/or implemented, or the work plan does not achieve program targets

Yellow: Target dates and/or deliverables are at risk.  A resourced recovery work plan has been developed to achieve program targets, and has been approved by the appropriate Launch Team member

Green: Target dates and/or deliverables not at risk.  APQP activities expected to meet results given current resources.

Yellow and Red items require the creation of a work plan that meets the objectives of the program.  Work plans require specific issue to be resolved actions, responsibilities, commitment dates, and deliverable output of the action.  The Work Plan template can be found in the APQP Documentation Package.

U. Review Type

In reaction to risks associated with the program, the type of review will be specified by Dana’s Program Management for each element of the APQP Status report.  The types of review are:

A)    On-site review of focus element at your organzition

B)    Your organization’s presentation in person at Dana location with supporting documentation for APQP focus element

C)    Your organization’s presentation via conference call for APQP focus element

D)    Your organization submits APQP Status sheet and supporting documentation to APQP Team for the APQP focus element

E)    Your organization submits only the APQP Status Report to the Launch Team

V. Focus Element Rating

The Focus Element Rating is determined by completing the chick-list associated with specific focus elements.  Note:  The number of focus elements using check-lists and the focus element checklists themselves will be updated by Launch Teams as expectations and expertise in the use of the system improve over time.  Ensure that the Supplier is issued the latest revision of the checklist available on the Supplier Document Center.

W.  Program Need Date

The Program Need Dates for each focus element are established by Dana at the beginning of the program to support achieving Dana’s commitments to its customers and shows the date by which the focus element must be completed to retain the integrity of the critical path of the program.  The Program Need Date sheet may be used to develop the initial timeline for the program as a guideline.  

After the initial launch meeting with your organization, these dates shall only be modified by the Dana to ensure that any impact on the critical path of the program is understood and controlled. 

X. Supplier Timing Date

The Supplier Timing Date is the commitment date established by your organization in support of Dana’s critical path.  The Supplier Timing Date is determined by your organization’s internal APQP process and resources.  Any Supplier Timing Dates that exceed the program needs shall be addressed with a work plan action item.

Y. Closed Date

The Closed Date is the day the focus element was determined completed by the Launch Team members.  The Program Manager has final determination of the closure of APQP focus elements.

Z. Champion Initials

A representative from your organization or Dana Launch Team member shall be identified by their initials to lead each APQP focus element.  It is the responsibility of the Champion to ensure that the focus element information is correct, to collect, provide and store supporting documentation for the Team and lead focus element actions indicated on the work plan.

AA. Remarks or Assistance Required

APQP is a process to ensure the success of both your organization’s and Dana’s strategic plans. As such, the remarks or assistance required column is for use by your organization to identify potential areas of risk to the APQP team to allow the risk to be reduced or eliminated through a coordinated and collaborative effort between organizational and functional units. 

AB. Comments

Any additional comments may be added in this section.  If additional space is required beyond what is provided, attach additional worksheets or files as required (for electronic submissions).

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