Doc. No.

QUALITY SYSTEM PROCEDURE Rev.No.

Date
Title : Advance Product Quality Planning
Page No.

Process Name :- Process for Advance Product Quality Planning.

Purpose :- To establish a system for carrying out advance product quality planning and development of control plans.

Scope :- It covers all New product and changes in New Product and existing product to be developed and manufactured by the company.
This procedure is applicable from development to till SOP ( Start of Production ) at Final customer end.
Process Owner :- Director - Sales & Marketing & QA - Head

Performance Criteria :-----

1. Time Overrun From Target Time
2. First Time ok at Customer Line Trial
3. New Product Development
4. ECN/PCN Change

Documents :-----

Sr. No. Document No. Document Name Indexing Special Protection Control Authority

----- ----- -------- ------ -------- --------

Records :-

Special
Sr. No. Document No. Record Name Retention Period Indexing Disposal Authority
Protection
Part Life + 5 Year for general parts &
1 Part Life + 11 year for Maru-A parts Product wise No Head - S & M

Part Life + 5 Year for general parts &

2 Part Life + 11 year for Maru-A parts Product wise No Head - S & M

Part Life + 5 Year for general parts &

3 Part Life + 11 year for Maru-A parts Product wise No Head - S & M

Part Life + 5 Year for general parts &

4 Part Life + 11 year for Maru-A parts Product wise No Head - S & M

Part Life + 5 Year for general parts &

5 Part Life + 11 year for Maru-A parts Product wise No Head - S & M

Part Life + 5 Year for general parts &

6 Part Life + 11 year for Maru-A parts Product wise No Head - S & M

Part Life + 5 Year for general parts &

7 Part Life + 11 year for Maru-A parts Product wise No Head - S & M

Prepared By Checked By Approved By

 Doc. No.
QUALITY SYSTEM PROCEDURE Rev
Date
Title : Advance Product Quality Planning Page No.
Sr. Reference /
Input Activity Output Resp. Checkpoint
No. Format
1st Phase( Plan & Define The Programme )

RFQ , Customer RFQ , Customer

Customer Dwg., Receive RFQ ( Request for Qutation to develop the Head - Sales &
parts )Part Drawing / Samples / ECN from approved drawing approved drawing RFQ Register
1 sample, ECN & Marketing / MD /
Customer Drawing, applicable Drawing, applicable ( )
RFQ QA / NPD
std., sample, ECN. std., sample, ECN.

Make Feasibility Report

Consider Man Power
Inform to Head - Sales &
Feasibility planning (New Feasibility Report
2 NO Feasibility Report Marketing /
Report joinee, Special ( )
Customer by Mail Project Incharge.
Is it Feasible Training Req. Etc.)
Or
YES Head - Sales & Consider all Feasibility Report
Telephonically
Marketing Parameters ( )

Inform To Customer by Mail / Letter Mail for Feasibility/ Head - Sales &
3 Viability Marketing

Head - Sales &

4 Send the Qutation to the Customer Quatation of Part Quatation on Letter Head
Marketing

Receving Of
LOI ( Letter Of Revevie the LOI ( letter of Intent ) / P.O ( Purchase Head - Sales &
5 Intent ) or P.O Order ) by Mail / Hard Copy LOI / P.O LOI / P.O from Customer
Marketing
( Purchase Order
)
Role &
Making of CFT Arrange Spec Meeting / Technical Review to
Making of CFT ( Cross Functional Team ) Nomination of CFT Head - Sales & Responsibility should CFT Formation
6
Team Team With Leader Marketing Clear of CFT ( )
Members
Clarify the requirements by
Sign - off Vendor
Information Sheet with
All Requirement
customer .( In case of Head - Sales &
signing off the Vendor Information Sheet / Spec Should Clear in Vendor Information Sheet
Specification there is no meeting for Marketing / / Spec. Review Meetin &
7 Vendor Information
Meeting Along Spec . Review with Project MOM
Sheet / Spec Review ( )
With Customer Review Sheet customer , Make the & Incharge / QA -
Sheet
mail to the customer Head
and Keep the same for
Carryout spec. meeting with customer to explain record

APQP - Product
Prepare detailed deviations(if
APQP Matrix as per Category .
any) Development Time Plan
Product Development
Prepare APQP - Product Development Time Plan in Time Plan ( )
Product Project Review Meeting
Product Develoment Plan sheet from Prototype to APQP plan to be
development Project Leader ( )
8 approval of SOP. review at specified
Plan sheet & Its CFT APQP Matrix
freq. ( )
Review Review the Project on Weekly Basis By CFT Head &
Fortnightly Basis of Top Management

Training about APQP / FMEA / Cp & Cpk / PPAP to the Training Need
Cocerrn person who will handle the APQP or Project QA Head , NPD Head
8.a Identification
& HR
Development & Training of Testing Equipment ( )

Phase -II
( Poduct Design & Development )

9 MAKE PROCESS FLOW DIAGRAM ( PFD )

10 Make Process Bill of Material ( BOM ) Bill of Material Head -Tool Room Approved Source Bill of Material

Past Problem
Past Problem Past Problem History
11 Past Problem history study Head -Tool Room last 1year data History Sheet
History Sheet
( )

Component
12
Make component Drawing, if Required Component Drawing NPD
Drawing

Drawing Review All Requirement to

13 Drawing Review Head -Tool Room
Component drawing Review Record be Cleared

Head -Tool
14 PFD Review Review of Process Flow Chart PFD Review Record As per Requirement
Room/QA

List Of Critical
Special Identified Critical As per Dwg. / Spec. Parameters
15
Identification of Special Characterstics Head -Tool Room
Characterstics Parameters Review Discussion ( )

PPE work
Instrucction &
Regulatory Evaluation of Regulatory /Statuory requirement, NPD
16 Declaration on
Requirement Environment , Health & Safety. Company Letter
Head
 Phase-III
(Process Design & Development)

Prepration of Prepare Process Failure Mode and Effect Analysis As per AIAG - 4
17 PFMEA QA
PFMEA (FMEA) Guidelines

Development As Per Development Tool Development Time

18 Set Development Targets with Responsibility APQP Matrix Head -Tool Room Plan (
Targets Time Plan )

19 Control Plan Prepare Control Plan Proto type Control Plan Head -Tool Room

Start Tool manufacturing as per Development As per tool design. Tool Colour coding
Preparation Tool
20 Targets Tools Head -Tool Room Identification on tool (
Manufacturing
as per define colour )

Special
Identification of New Resources Requirement List of new resource Head -Tool
21 Equipment
(Man, Machine, requirement Room/QA
requirement Material ,Measuring Equipments etc.)

Approved Supplier
Sourcing of Identification & Approval of supplier for Raw Material As per supplier
22 Approved Supplier Purchase Head List
RM/BOP / BOP Parts. selection criteria.
( )

Trial of Samples will

continue till OK
samples. Defect Monitioring
Do Sample Trial Run along with CFT & submitt the OK Refer IP ( Initial Part Sheet during
23 Samples Trial Sample to Customer along with Inspection Report . Sample Parts Head -Tool Room
) Procedure Identify Development
the gaps / Problem ( )
during sample
preperation

Follow-up Results From Customer During Product Gap Register TGR

Development Action On Customer / TGW
24 Follow Up Customer Feedback Head -Tool Room
Feedback (
)

Review with customer & Update past Problem Past Defect History
Customer
25 history Sheet & control plan etc. Documents Review Head -Tool Room sheet
Feedback
( )
 Phase - IV
( Product & Process Varification)

Head -Tool Refer WI of Lay Out Layout Plan WI

26 Prepare Layout Plan ( If Required ) Layout plan
Room/NPD Plan ( )

BOP Parts Component Procurement (RM & BOP) Head - Sales &
27 Approved Source
Requirement Marketing

List Of Critical Prepare SPC Plan SPC Plan

28 SPC Plan Head QA
Diamension ( )

Process Control
29
Prepare Operator Process Instruction/ SOP/ Process Control Sheet Head -Tool Room Sheet
Process Sheets & Trainings ( )

Packing Standard
30 Logistic Study & Packaging finalization. Packing Standard
( )

Pre launch Control

Proto Type Prelaunch Control Plan
31 Prelaunch Control Plan Head QA Plan
Contol Plan
( )

Head -Tool
32 Make MSA / Gauge R&R Plan MSA Plan MSA Plan
Room

As per Prelaunch
33 Production Trial Run (Pillot Lot) Initial Lot Head -Tool Room
Control Plan

Process validation
Prepare process
34
Process / Product Validation Prosses validation data Head -Tool Room sheet
Validation
( )

Capability Study
SPC Plan Process Capability Evaluation (Cp &Cpk Stuudy) Capability Result Head QA
35 ( )

NPD
MSA / Gauge R & R
MSA / Gauge MSA/ Gauge R&R
36
MSA / Gauge R & R Study Study
R& R Plan Result
( )

Submit the PPAP Lot to customer as per AIAG As per AIAG - 4

PPAP
37
PPAP Manual - 4 of PHASE - 3 or as per PPAP Documents Head QA Manuals
Documents List
Customer Requirement Requirements

38 Prepared PPAP Head - Sales &

Documents PPAP Documents approval from customer Ref . The IP ( Initial
Customer Approval Marketing / QA -
Part ) Procedure
Head / NPD Head
Phase -V
(Feedback and Corretive Action)

NPD / TOOL
Customer As per customer Defect History Sheet
39
Feedback Analysis / Corrective Action ROOM / QA -
Feedback Feedback during Development
HEAD
( )

APQP Sign - Off APQP Sign off from customer and get Signed Signed PSW from Customer Signed
40 Head QA
from Customer PSW ( Part Submission Warrant ) from Customer Customer PSW

Pre Launch Pre Launch Control Pre Launch Cp for

41 Prepare Pre Launch Control Plan Head QA
Control Plan Plan Start Of IPC

As per Customer
Prepare Mass
Start of Initial Production Control ( IPC ) NPD Head / QA Schedule. Mass Production
42 Production Plan Production Plan
Head Pre Launch Control Plan
( IPC )
Plan Will Be Used

Handover to After Completion of IPC ( Initial Production Handover sheet of

Plan ) Handover the Project with Detailed docs. to NPD Head / QA Refer IPC . Handover Check
43 Production Docs. To Relvant
Cocern Area with duly Signature of Both Parties. Head Procedure Sheet of Docs.
Deptt. Deptts.

Prepared By Checked By Approved By

 ADVANCE PRODUCT QUALITY PLANNING- & RESP. MATRIX

Part
CATEGORY FOR APQP Name LEGEND
A New Product / Part / New Technology E Process Sequence/ Layout change Part No. Activity to be done.

B Design change of Existing Part F Process Equipment change Category Blank Activity not required.

C Material Change G Relocation of plant Prime Resp. Deptt.

Process Parameter Change ( Current / Voltge / Time / Temp / Pressure

D H Supplier change Supporting Deptt.
etc.

CATEGORY Responsible Department

S.NO. Description Remarks

Tool
A B C D E F G H MKT NPD QA PROD PUR HR
Room

1
Receipt of Enquiry along with specification / Drawing/
Reference sample etc.

2 Pre Feasibility Study

3 Clarification from customer for incomplete information

4 Technical Feasibility & Risk Assessment.

Phase 1 ( Plan
and Define The
Programm e)
5 Cost Estimation (Quotation submission to customer).

6 Receipt of LOI from Customer

7 Preparation of CFT

Preparation of APQP Matrix / Timing Chart with

8 Review Frequancy of CFT Leader and Top
Management

8.a
Traninig Of APQP / FMEA / MSA / SPC & Spl
Measuring Tools

9 Process Flow Chart (Prototype)

10 Bill of Material (BOM if any)

11 Past Problem History Study

2nd Phase
12 Component Drawing (if reqd)
( Product design
and Development
)
13 Component Drawing Review

14 Review of process Flow chart

15 Identification of Special Characteristics

16
Evaluation of Regulatory/ Statutory requirement,
Enviroment, Health & Safety.

17 Process FMEA

18 Development Targets

19 Control Plan (prototype)

20 Tool Manufacturing

21
Identification of New Resources Requirement (Man,
3rd Phase Mtl., Machine, Measuring eq etc)
( Process design
and Development
)
22
Sourcing of Raw Material/BOPs (Identification &
Approval of Suppliers)

23 Sample Trial Run

24
Follow-up results from customer during product
development

25
Review with customer & Update Past Defect History
& Control Plan etc.

26 Layout plan

27 Component procurement (RM & BOP)

28 SPC Plan

29
Operator Process Instruction / SOP / Process Sheets &
Trainings

30 Logistic Study & Packaging finallization.

31 Pre Launch Control Plan

32 MSA / Gauge R&R Plan

4th Phase Production Trial Run ( Pilot Lot ) - 300 Parts --- Initial
( Product and 33
Process
Product Lot
Verification )
34 Process / Product validation

35 Process Capability Evaluation (Cp Cpk Study)

36 MSA / Gauge R&R Study

PPAP Lot Submission with to customer as per AIAG

37 PPAP MANUAL of PHASE - 3 or as per Customer
Requirement

38 Customer Approval

39 Feedback Analysis / Corrective Action .

40 Sign off - PSW

5th Phase
( Feedback )
42
Mass Production Plan ( Initial Production Control ) -
3month / 5Lot / 5000 Nos. Whichever Later.

43
Handover to Production Deptt. With Production
Control Plan and Another Relavant Douments
Prepared Verified Approve
Rev. No. Description Date Signature
by: by: d by:
 Format No:---

New Product Development Timing Plan Revision No:--

Effective Date :--

Category as per APQP Matrix Details of Changes : Deptt. Name Signature

CFT (PROJECT) TEAM

Part Name

Part Number Signature of Top Management

Customer

Review Freq. of CFT Leader) Signature Project Leader

Review Freq. Of Top
Management )
Sample Submission Date
Month - Month - Month - Month - Month - Month - Month -
SOP ( PPAP ) Date

Week No.-1 Week No.-2 Week No.-3 Week No.-4 Week No.-5 Week No.-6 Week No.-7 CFT -
CFT - Head Top Mgt CFT - Head Top Mgt CFT - Head Top Mgt
S.No. Description Resp. Person Deptt. Status Review Review Review Review Review Review
Head
Review
Time Plan To Customer

Phase - 1 ( Plan & Define Program )

Receipt of Enquiry along with specification / Drawing/ Plan

1
Reference sample etc. Actual
Plan
2 Pre Feasibility Study
Actual
Plan
3 Clarification from customer for incomplete information
Actual
Plan
4 Technical Feasibility & Risk Assessment.
Actual
Plan
5 Cost Estimation (Quotation submission to customer).
Actual
Plan
6 Receipt of LOI from Customer
Actual
Plan
7 Preparation of CFT
Actual
Preparation of Timing Chart / APQP Matrix with Review Plan
8
Freq. of Top Management & CFT Leader Actual
Traninig Of APQP / FMEA / MSA / SPC & Spl Measuring Plan
8.a
Tools Actual
Phase - II ( Product Design & Development )
Plan
9 Process Flow Chart (Prototype)
Actual
Plan
10 Bill of Material (BOM if any)
Actual
Plan
11 Past Problem History Study
Actual
Plan
12 Component Drawing (if reqd)
Actual
Plan
13 Component Drawing Review
Actual
Plan
14 Review of process Flow chart
Actual
Plan
15 Identification of Special Characteristics
Actual

Evaluation of Regulatory/ Statutory requirement, Enviroment, Plan

16
Health & Safety. Actual
 Format No:---

New Product Development Timing Plan Revision No:--

Effective Date :--

Category as per APQP Matrix Details of Changes : Deptt. Name Signature

CFT (PROJECT) TEAM

Part Name

Part Number Signature of Top Management

Customer

Review Freq. of CFT Leader) Signature Project Leader

Review Freq. Of Top
Management )
Sample Submission Date
Month - Month - Month - Month - Month - Month - Month -
SOP ( PPAP ) Date

Week No.-1 Week No.-2 Week No.-3 Week No.-4 Week No.-5 Week No.-6 Week No.-7 CFT -
CFT - Head Top Mgt CFT - Head Top Mgt CFT - Head Top Mgt
S.No. Description Resp. Person Deptt. Status Review Review Review Review Review Review
Head
Review
Time Plan To Customer
Phase - III ( Process Design & Development )
Plan
17 Process FMEA
Actual
Plan
18 Development Targets
Actual
Plan
19 Controlplan ( Prototype )
Actual
Plan
20 Tool Manufacturing
Actual

Identification of New Resources Requirement (Man, Mtl., Plan

21
Machine, Measuring eq etc) Actual

Sourcing of Raw Material/BOPs (Identification & Approval of Plan

22
Suppliers) Actual
Plan
23 Sample Trial Run & Submission of OK Samples
Actual
Plan
24 Follow-up results from customer during product development
Actual

Review with customer & Update Past Defect History & Plan
25
Control Plan etc. Actual
Plan
26 Layout plan
Actual
 Format No:---

New Product Development Timing Plan Revision No:--

Effective Date :--

Category as per APQP Matrix Details of Changes : Deptt. Name Signature

CFT (PROJECT) TEAM

Part Name

Part Number Signature of Top Management

Customer

Review Freq. of CFT Leader) Signature Project Leader

Review Freq. Of Top
Management )
Sample Submission Date
Month - Month - Month - Month - Month - Month - Month -
SOP ( PPAP ) Date

Week No.-1 Week No.-2 Week No.-3 Week No.-4 Week No.-5 Week No.-6 Week No.-7 CFT -
CFT - Head Top Mgt CFT - Head Top Mgt CFT - Head Top Mgt
S.No. Description Resp. Person Deptt. Status Review Review Review Review Review Review
Head
Review
Time Plan To Customer

Phase - IV ( Product & Process Validation )

Plan
27 Component procurement (RM & BOP)
Actual
Plan
28 SPC Plan
Actual
Operator Process Instruction / SOP / Process Sheets & Plan
29
Trainings Actual
Plan
30 Logistic Study & Packaging finallization.
Actual
Plan
31 Pre Launch Control Plan
Actual
Plan
32 MSA / Gauge R&R Plan
Actual
Plan
33 Production Trial Run (Pilot Lot)
Actual
Plan
34 Process / Product validation
Actual
Plan
35 Process Capability Evaluation (Cp Cpk Study)
Actual
Plan
36 MSA / Gauge R&R Study
Actual

Plan
37
PPAP Lot Submission with to customer as per AIAG PPAP
Manual of PHASE - 3 or as per Customer Requirement Actual

Plan
38 Customer Approval
Actual
Plan
39 Feedback Analysis & Corrective Action
Actual
Phase - V ( Feedback Assessment & Corrective action )

Plan
40 Sign off PSW
Actual
Plan
41 Pre Launch Control Plan
Actual
Plan
42 Start OF Initial Production Control
Actual
Plan
43 Handover to Production Deptt.
Actual

CFT Leader

Signature Of Reviewer
Top Management ( Director / V.P / Plant Head /
M.D)

Review Status :- OK on Track Delay can be achieved Off track action required .
Legends Plan Actual
Activity
completed
Signature

If any activities is postpnd / prepond & delay write comments If any activities is postponed / preponed & delay write comments If any activities is postponed / preponed & delay write comments Project complete Dt.
S.No
Detail of activity / reason for delay / rescheduling etc. Signature S.No. Detail of activity / reason for delay / rescheduling etc. Signature S.No. Detail of activity / reason for delay / rescheduling etc. Signature
.

PREPARED BY ISSUED BY APPROVED BY ( )

 Doc. No

Issued Date

Request For Quatation ( RFQ Register ) Rev No.

Rev. Date

Page No

Date of
Contact No. Of Submission Of Date of Receipt Of Submission Date Receipt Date Of Date of Pilot Lot
S.No. Date Customer Name Address Part Description Dwg. No. Feasible / Not Feasible Submission Of APQP Sign Off Sign Head Engg. Sign. MD
Customer Quatation Date Purchse Order Of Samples Sample Approval Approval
Pilot Lot

Prepared By Issued By Approved By

 Doc No:-

Bill Of Material Rev No:-

Date :-

Date:----

Contact Person'S ISO / TS

Contact Person ISO / TS ISO / TS
S. NO. Material Spec Supplier Name Supplier Address Mobile No. & Next Audit Approved
Name Certified Audit Done
E - Mail Address Due Date
1

2
3

10

11

12

13

14

15

16

17

18

19

20

Prepared By Approved By Issued By

 Format No :---HOU/MKT/F/04
Issued date:--- 15.05.2020
PRE-FEASIBILITY STUDY Revision No:--- 00
Revision Date :--- ….
Page No:--- 1 OF 1
CUSTOMER : NAPINO DATE : 30.06.21

PART NAME : HOUSING BOTTOM PART NO : A3C0927750000

FEASIBILITY CONSIDERATIONS

All "no" answers are to be supported with comments

S.No YES NO COMMENTS

1 Is product descrption adequate for feasibility evaluation? YES

Does your unit is capable to meet Product Performance

2 YES
Specifications ?

3 Can product be manufactured to tolerance specified on drawing ? YES

Can product be manufactured with Cpk's that meet

4 YES
requirements ?

5 Is there adequate capacity to produce product ? YES

6 Does the manufacturing of this product will require additional: YES

• Is any new machine required NO

• Is any new equpment / insrument required NO

• Capital tooling ? YES

• Alternative manufacturing methods ? NO

7 Is statistical process control required on product ? YES

Is statistical process control presently used on similar products ?

8 YES
If yes

• Are the processes in control and stable ? YES

• Are Cpk's greater than 1.33 ? YES

9 Avalibility of Adequate Man Power

New Joinee NO

Existing YES

Conclusion :---

Feasible ( Product Can Be Produced as Specified with no

1 YES
Revisions. )

Partial Feasibal ( Change Recommended ( See Attached

2
Sheet )

Not Feasible ( design revision Required to produce Product

3
with in Specified requirements.

Sign - off (CFT members) :----

S.No Name Of Team Memebre Designation Signature

1 Mr.Akshay Gupta CEO

2 Mr.Pradeep Tomar PLANT HEAD

3 Mr. Arvind Kumar Tool Room Head

4 Mr.Himanshu PRODUCTION HEAD

5 Mr.Sunil Sharma NPD AM

6 Mr. RP singh NPD /QA HEAD

 Format No :---HOU/MKT/F/04
Issued date:--- 15.05.2020
PRE-FEASIBILITY STUDY Revision No:--- 00
Revision Date :--- ….
Page No:--- 1 OF 1
CUSTOMER : NAPINO DATE : 18.08.2022

PART NAME : HOUSING BOTTOM PART NO : A3C1050220000

FEASIBILITY CONSIDERATIONS

All "no" answers are to be supported with comments

S.No YES NO COMMENTS

1 Is product descrption adequate for feasibility evaluation? YES

Does your unit is capable to meet Product Performance

2 YES
Specifications ?

3 Can product be manufactured to tolerance specified on drawing ? YES

Can product be manufactured with Cpk's that meet

4 YES
requirements ?

5 Is there adequate capacity to produce product ? YES

6 Does the manufacturing of this product will require additional: YES

• Is any new machine required NO

• Is any new equpment / insrument required NO

• Capital tooling ? YES

• Alternative manufacturing methods ? NO

7 Is statistical process control required on product ? YES

Is statistical process control presently used on similar products ?

8 YES
If yes

• Are the processes in control and stable ? YES

• Are Cpk's greater than 1.33 ? YES

9 Avalibility of Adequate Man Power

New Joinee NO

Existing YES

Conclusion :---

Feasible ( Product Can Be Produced as Specified with no

1 YES
Revisions. )

Partial Feasibal ( Change Recommended ( See Attached

2
Sheet )

Not Feasible ( design revision Required to produce Product

3
with in Specified requirements.

Sign - off (CFT members) :----

S.No Name Of Team Memebre Designation Signature

1 Mr.Akshay Gupta CEO

2 Mr.Pradeep Tomar PLANT HEAD

3 Mr. Arvind Kumar Tool Room Head

4 Mr.Himanshu PRODUCTION HEAD

5 Mr.Sunil Sharma NPD AM

6 Mr. RP singh NPD /QA HEAD