ADVANCED PRODUCT QUALITY PLANNING (APQP) ANDCONTROLPLAN Reference Manual Issued June 1994, Second Printing February 1995 (new cover only) Copyright1994, 1995 Chrysler Corporation, Ford Motor Company, and General Motors Corporation FOREWORD This Reference Manual and Reporting Format were developed by the Advanced Product Quality Planning (APQP) and the Control Plan teams that were sanctioned by Chrysler, Ford, General Motors Supplier Quality Requirements Task Force. The Task Force charter is to standardize the reference manuals, procedures, reporting formats, and technical nomenclature used by Chrysler, Ford, and General Motors in their respective supplier quality systems. Accordingly, this manual and format, approved and endorsed by Chrysler, Ford and General Motors, should be used by suppliers implementing APQP techniques into their design/manufacturing processes. In the past, Chrysler, Ford, and General Motors each had their own guidelines and formats for ensuring supplier APQP compliance. Differences between these guidelines and formats resulted in additional demands on supplier resources. To improve upon this situation, Chrysler, Ford and General Motors agreed to develop and distribute this Manual. The work group responsible for this Manual was led by Mike Mazur of Ford Motor Company. This manual provides general guidelines for preparing plans and checklists for ensuring that Advanced Product Quality Planning is in actuality carried out at the supplier. It does not give specific instructions on how to arrive at each APQP or Control Plan entry, a task best left to each component review team. While these guidelines are intended to cover all situations normally occurring either in the early planning, design phase, or process analysis, there will be questions that arise. These questions should be directed to your customer's Supplier Quality activity. If you are uncertain as to how to contact the appropriate activity, contact your buyer in your customer's Purchasing office. The Task Force gratefully acknowledges: the leadership and commitment of Vice Presidents Thomas T. Stallkamp at Chrysler, Norman F. Ehlers at Ford, and G. Richard Wagoner, Jr. of General Motors; the assistance of the AIAG in the development, production, and distribution of this manual; and the guidance of Task Force Principals Russell Jacobs (Chrysler), Radley Smith (Ford), and Dan Reid (General Motors). This procedure is copyrighted by Chrysler, Ford and General Motors, all rights reserved, 1994. Additional copies can be ordered from AIAG 810-358-3003. Suppliers of the Automotive Industry have permission to copy any forms and/or checklists. June 1994 ACKNOWLEDGEMENT This document, which includes a reference manual and reporting format, represents the consensus of the members of the Advanced Product Quality Planning and Control Plan teams sanctioned by the Chrysler, Ford, General Motors Supplier Quality Requirements Task Force. Team members, whose names appear below, wish to acknowledge the many contributions made by individuals from within their respective organizations, individuals without whose support and assistance this document would not have been possible. Advanced Product Ouality Planning Team Members Chrysler General Motors Robert Roush Michael A. Mazur R. Dan Reid Andy Kucharski Roderick A. Munro David L. Kraush Suppliers Paul Anglin ITT Automotive Brenda Dusek Harvard Industries Charles R. Dykstra Inverness Casting Donald Geis Federal Mogul Corporation Al Walton United Technologies Control Plan Team Members Frederick N. Baz Ford Brenda Dusek Harvard Industries Rebecca French General Motors Gary Hoyt Chrysler Mary Ann Raymond Robert Bosch Corporation Additional Assistance Bea Anderson Chrysler ii Table of Contents TABLE OF CONTENTS Page No. Introduction 1 Product Quality Planning Responsibility Matrix 2 Fundamentals of Product Quality Planning 3 Product Quality Planning Timing Chart 5 1.0 Plan and Define Program 6 1.1 Voice of the Customer 7 1.1.1