Concept Project Prototype Pilot

approval
90 days

Phase 0.0 Handover period

Project initiation

Phase 1.0
Plan and define project
Motherson.
Phase 2.0
Product design and development Proud to be
Phase 3.0
global
Process design and development

Phase 4.0
Product and process validation

Phase 5.0 Production

Feedback, assessment and corrective actions support

MR0 MR1 MR2 MR3 MR4 MR5

Standardised Development System (SDS) SMR stem

Project Management Handbook
Version 4.2
version 4.1

Disclosure or duplication without SMR's written consent is prohibited.

Agenda
Introduction
SDS Project management fundamentals
SDS processes
Key performance indicators
Flow charts
SDS support processes
Definitions and acronyms

2
SDS Introduction
SDS standardises a team approach to product development

SMR Development System

Quotation SDS
Management • SDS enables all functions to
support new product introduction
Sales
in a project team environment
• SDS is the structured utilisation
and coordination of cross
Development functional expertise to achieve:
• optimal performance
• quality
Production
• customer satisfaction
ramp up Production
• SDS defines
• intent
• processes
• responsibilities
Manufacturing

Modifications

• process flow
Purchasing
Controlling

Suppliers

• KPIs

Tooling
Quality
• forms
• templates
• guidelines
• inputs and outputs

Supporting SDS processes

3
Project team structure
The core project team is supported by a management team that also acts
as an escalation committee
Management

Head
Team

Engineering Head Head

SKAM Project Head Tooling
Director Purchasing Production
Management
Core team members

Project Manager

Design Manufacturing Tooling Quality

KAM Controlling Purchasing
Leader Engineer Engineer Engineer
Typical supporting
team members

Simulation Kaizen Styling Electronics Mould Test Plant

Logistics
Engineer Engineer Engineer Engineer Shop Engineer Engineer

4
Project team functions

Plans, organises and executes project activity. Manages resource to

Project Manager achieve project objectives. Ensures timing and costs are met. Initiates
timely corrective actions. Has highest authority within the team

Design Leader Responsible for product design

Initiates quotation. Key customer contact for negotiations, relations and

KAM
contract review. Sometimes called marketing officer

Cross functional team of managers and directors responsible for

Executive Team
management review and executive project support.

Responsible for cost monitoring. Ensures data is accurate and

Controlling
transparent. Supports project manager

Manages controls purchasing and suppliers. Key interface between

Purchasing Officer
suppliers and project team

Ensure customer expectations are met. Highlights lessons learned and

Quality Engineer
plays key role in developing production controls.

5
Project team functions

Key interface between production and SDS. Plans, sources, designs,

Manufacturing Engineer
specifies, verifies and implements manufacturing facilities and
(Production Engineer)
packaging. Can also be known as Production Engineer

Plant Engineer Maintains plant structure and services

Plans, sources, designs, specifies, verifies and implements injection

Tooling Engineer
moulding and other production tooling

Test Engineer Designs, procures, commissions test equipment. Provides feedback on

testing and design verification planning and reporting

Work Study Engineer

Measures, monitors and records direct operator work

Consulted on advanced lean manufacturing methodologies. Advises on

Kaizen Engineer
efficiency improvements

Facilitates component design and validation to agreed requirements,

Project Engineer timing and cost. Coordinates support processes at work level.
Can undertake Quality Engineering role.

6
SDS Objectives and benefits

SDS Objectives SDS Benefits

SDS provides standardised and value adding project SDS benefits are achieved through people and
management processes to ensure customer experts, key strategic suppliers, innovative R&D, “state
requirements and expectations are successfully of the art“ technologies
translated and delivered from agreed quote into a
quality product on time and within budget

By meeting Good application yields

• SMR, customer, supplier, government, regulatory, • Customer quality, service, product design and
safety, legal and international required standards launch system interface
• Customer scope, budget and timing expectations • Robust, optimised, safe product and process
• SMR cost objectives design, manufacturing and control
• ISO/TS 16949:2002 requirements • Reduced variation, waste and costs
• Improved yield

Customer satisfaction and retention Ensure all SMR operating operations are at
Sustained profitability International the same level with regards to
competitve advantage Project Management

7
Agenda

Introduction
SDS Project management fundamentals
SDS processes
Key performance indicators
Flow charts
SDS support processes
Definitions and acronyms

8
SDS behaviours

10 golden rules
1. SDS in mandatory.
2. Project Managers are key.
3. Management reviews are not delayed.
4. Phases end with sign off.
5. Project management is a disciplined team effort.
6. Satisfy the internal customers.
7. Team performance shall be transparent.
8. Be proactive.
9. Consider the impact on others.
10. Continually support project objectives.

9
SDS has 4 working levels

1 6 Phases and management reviews.

Mandatory for all SMR.
Management review forms shall be applied without deviation.

Core processes, responsibilities,

2 KPIs and outputs.
Mandatory for all SMR.

Forms.
Mandatory

3 for all SMR.

Shall be applied
without deviation.

Work instructions and templates.

Can be customised provided SDS intent, core
processes, responsibilities, KPIs and outputs are
aligned and achieved. SDS guidelines provide
support.

10
4
SDS customisation

Rules
• SDS Level 1 phases and level 2 core processes represent the minimum SDS requirement and shall be applied.
• SDS level 3 work instructions and templates may be customised. Refer SDS guidelines for process development
support.
• SDS level 4 forms shall be used without deviation.
• Additional value adding processes beyond minimum SDS requirements are allowed.
• Core SDS level 2 processes may be embedded in other organisational processes provided it can be clearly
demonstrated that SDS intent, responsibilities, KPIs and outputs are aligned and achieved.
• Finishing processes before schedule is allowed provided the work is effective.

Customer systems
• SDS is SMR policy and its application is mandatory.
• Where customers insist SMR shall apply their product development system (e.g APQP), SDS shall still be applied.
The minimum work necessary shall be undertaken to ensure both SDS and the customer system are satisfied.
• Under no circumstances shall SDS be abandoned or unfulfilled.

11
Management reviews and phase sign off
SDS has as phased approach.
Phases are signed off by management review

At management reviews an Executive Team reviews KPI performance.

A standard form is used and the entire project team contribute.
There are rules:
• Management reviews are not delayed
• If corrective actions are issued funding is frozen
• Corrective actions must be closed within 30 days

Possible corrective actions

30 Days Max

12
SDS has two KPI levels
KPIs performance is assessed during management reviews

Level 1 KPIs (operational)

• Measure overall project performance.
• Apply to all phases.
• Measured against baselines.
• Baselines are the agreed customer contract.
• Reported monthly and every management review:
• Milestones (customer committed timing)
• Costs
• Capital expenditure (CAPEX)
• Unit cost (Fast track)

Level 2 KPIs (phase specific)

• Phase and core process specific. eg: Phase 2,
DVP&R – deviations to specifications. KPI = 0
• Reported at management reviews and depend on phase

13
Project team meetings

RULES
1. Meetings occur at minimum weekly.
2. Attendance is mandatory for all core members and support members as required.
3. Team members shall be prepared beforehand with all relevant information and critical issues.
4. Project status is reported through the SDS “Project management meeting minutes and status report” and
corrective action planned (if required).
5. Project Manager has final say and uses SDS “Project management meeting minutes and status report”
format for recording and distributing actions. The format is mandatory but the medium can be customised.
6. Status is reported at component level directly against SDS processes ensuring SDS drives projects.
7. Refer SDS guideline G19 “Management review and phase sign off” for template.

14
Project manual and re-quote

Project Manual
• Every SDS project has a project manual.
• It defines project scope based on the agreed contract between SMR and the customer.
• It forms the benchmark for when re-quote is required from changed contract conditions.

Re-quote
• Customer changes during product development that significantly impact agreed project delivery and
profitability and are outside agreed contract conditions shall be re-quoted. Typical changes requiring re-
quote include:
• Specification and design concept changes
• Volume changes
• Additional CAPEX requirements

15
(Key) Characteristics
• Attributes having major impact on product performance and variation
• Directly related to customer satisfaction and SMR profitability
• Key symbol shows where characteristics appear and shall be perfectly aligned
Packaging
• Identified early and developed through SDS specification
DVP&R
• Excellent input is critical [2.4] [3.11mm]
• Fundamental to SDS success

0 1 2 3 4 Production
Tooling
Engineering specification PPAP
drawings [3.7] [4.9]
[2.11]
Manufacturing
facility
CAD model specification
and [3.2]
simulations
[2.5]
Preliminary Refined
Production PCP
characteristics DFMEA [2.1] PFMEA [3.1] Production PCP
characteristics [4.8]
[1.3] [4.8]
[0.3]

Preliminary Pre-launch Production

PCP system audit
PFMEA [3.3] [4.11]
[2.3]
Preliminary Internal
• Specifications and process flow Production Process run@rate
chart process flow instructions [4.10]
regulations
[1.4] chart and training
• Customer input [2.8] plan
• SMR cross functional Prototype [3.6] Customer
Measuring
input and lessons PCP systems run@rate
learned [2.9] analysis [4.12]
plan
[3.4]

16
Agenda

Introduction
SDS Project management fundamentals
SDS processes
Key performance indicators
Flow charts
SDS support processes
Definitions and acronyms

17
Level 1
SDS has 6 phases and management reviews

Concept Project Prototype Pilot SoP

approval
90 days

Phase 0.0 Handover period

Project initiation

Phase 1.0
Plan and define project

Phase 2.0
Product design and development

Phase 3.0
Process design and development

Phase 4.0
Product and process validation

Phase 5.0 Production

Feedback, assessment and corrective actions support

MR0 MR1 MR2 MR3 MR4 MR5

FEP sign off

SDS process

Management review

18
Level 1
Phase descriptions

Phase 0.0 This phase deals with quotation. New projects are approved based on
Project Initiation strategic alignment, technical feasibility and financial viability

Phase 1.0 This phase deals with defining the project and creating the execution
Plan and Define Project plan. Level 1 key performance indicator baselines are established

Phase 2.0 This phase deals with achieving and freezing robust product design.
Product Design and Development Early consideration is given to process design and production controls

Phase 3.0 This phase deals with achieving robust process design, production
Process Design and Development controls and supporting instructions and plans

Phase 4.0 This phase deals with establishing production readiness and validating
Product and Process Validation performance through tool tryouts, training builds and testing

Phase 5.0
This phase occurs after successful production launch. The project team
Feedback, Assessment and Corrective
continue to support production for 90 days
Actions

1
Phase 0.0 does not include Advanced Engineering or Frontloading

19
Level 2
Phase 0.0 Project initiation

Phase intent INITIATE VALUE ADDING PROJECTS

Plan and define Product design Process design Product and Feedback,
0 Project initiation 1 2 3 4 5 assessment and
project and development and development process validation corrective actions

Phase outcomes Goals

• SMR approval to proceed if the bid is successful. • Filter quotes. Efficiently and effectively initiate new projects.
• Ensure quotes are:
- Strategically aligned
- Technically feasible
- Financially viable
• Timely integration of advanced engineering technology, frontloading,
lessons learned and risk assessment.

Processes Responsibility Description

0.1RFQ registration KAM, BU Head (final decision) • Go/No-go decision: potential business opportunity is checked for
alignment with strategic plan.
0.2Quote initiation and team set up KAM • KAM establishes dedicated cross functional team and acts as project
manager. KAM organises meetings.
0.3Quote formulation • Go /No-go decision: technical feasibility is determined considering
KAM
frontloading, advanced engineering technology, lessons learned,
benchmarking, capacity, organisational capability, costs.
0.4 FEP and customer quote Controlling (FEP), KAM (quote) • FEP calculated. Customer specific quote prepared.
0.5 Quote handover KAM, BU Head (final decision) • Go/No-go decision (MR0): FEP is approved for customer handover.
MR0

20
Level 2
Phase 0.0 Project initiation
0
Project initiation

0.1 0.2 0.3 0.4

Quote initiation FEP & customer
RFQ registration Quote formulation
and team set up quote

SDS intent Strategically aligned quote. Cross functional teamwork. Technically feasible quote. Financially viable quote.
1.Receive and control customer 1.Raise SMR RFQ and 1.Study RFQ, develop and 1.Confirm customer and SMR
Activities
documents. allocate project code. control product/process/ funded investments.
tooling/packaging/logistics
2.Review and if necessary 2.Establish cross functional concepts according to the 2.Calculate and control FEP.
obtain additional information. project team and distribute SMR Production System
3.Estimate CAPEX limits.
information. (SPS) including:
3.Check alignment against • Assumptions 4.Develop pricing strategy.
strategic plan. Make Go/No- 3.Initiate ongoing team • BOM and product concept
go decision to proceed with meetings. • New Tooling Technology 5.Prepare quote in customer
quote. • Concept process and flow specific format.
• Preliminary characteristics
4.Inform customer of decision. • Project Jig Costs/Samples 6.Check quote against checklists.
• Initial make or buy
• Preferred suppliers. 7.Obtain approvals to submit FEP
• Capacity study to BU Head as required.
• Milestones
• Forecast deviations
• Risk assessment Go / No-go
Go / No-go
2.Determine project costs.
3.Determine spend profile and
project hours.
4.Assess technical feasibility
and make Go/No-go decision
to proceed - If not feasible
renegotiate with customer and
Outputs Go/No-go decision • SMR RFQ document propose feasible options • Controlled FEP document
• Customer specific quote document

• RFQ document (completed)

Guidelines • None • None
• Go/No-Go decision
• None
Responsible • BU Head (final decision) • KAM • Engineering Director • Controlling (FEP)
• KAM • KAM (quote)
• BU Head (final decision)
21
Level 2
Phase 0.0 Project initiation
– continuation –
30 days maximum
Management Phase 0
review 0 sign off

0.5
Quote handover

SDS intent Handover to customer.

Activities 1.Management review 0.
(BU Head approves FEP).
If not approved
renegotiate with customer.
2.Handover quote to customer.
3.Provide customer support after
handover.
4.Repeat phase 0 if contract
changes after FEP approval
(QCN).

Go / No-go

Outputs • Controlled customer

approved quote document
• (if bid successful).

Guidelines • None

Responsible • BU Head (final decision)

• KAM

22
Level 2
Phase 1.0 Plan and define project

Phase intent DEFINE PROJECT - CREATE EXECUTION PLAN - ESTABLISH BASELINES

Plan and define Product design Process design Product and Feedback,
0 Project initiation 1 2 3 4 5 assessment and
project and development and development process validation corrective actions

Phase outcomes Goals

• Project manual. • Translate approved RFQ into project manual.

• Level 1 KPI baselines: • Define project.
- Milestones (customer committed timing) • Create execution plan utilising cross functional input.
- Cost
• Ensure customer expectations are understood and will be achieved.
• Capital expenditure (CAPEX)
• Unit cost (Fast track) • Create project baselines for performance monitoring and re-quote.

Processes Responsibility Description

1.1Initiate project and create Project Manager • Cross functional team, meetings, minutes and status report are
project manual established. Approved RFQ is translated into a project manual.
KAM
1.2Define financial baseline • Baseline fast track and prelim. CAPEX created from approved RFQ
Design Leader
1.3Refine preliminary • Product and process concept is refined.
characteristics
Manufacturing Engineer
1.4Preliminary process flow chart • Requirements for tooling, manufacturing facilities, packing and
logistics are refined.
Tooling Engineer (tooling)
1.5Preliminary tooling and Manufacturing Engineer (facilities) • Potential suppliers are selected. Preliminary sourcing, implementation
manufacturing facilities plans
Project Manager and validation plans are initiated to support project objectives.
MR1
Project Manager
1.6 Corrective actions (if required) • Project Manager organises management review.
Executive Team
Phase sign off • Risk and roadblocks to project objectives are identified and removed.

• Phase ends and funds released to next phase.

23
Level 2
Phase 1.0 Plan and define project
1
Plan and define project

1.1 1.2 1.3 1.4

Initiate project and
Define financial Refine preliminary Preliminary
create project
baseline characteristics process flow chart
manual

SDS intent Define project. Plan execution. Establish level 1 financial KPIs. Refine RFQ design concepts. Refine RFQ process flow.
Activities 1.Establish: 1.Establish and control 1.Study approved RFQ product 1.Study and refine approved
• Project team baseline fast track from and process concepts and RFQ product and process
• Weekly meetings approved RFQ. assumptions. concepts and assumptions.
• Master schedule 2.Raise and control 2.Utilise timely cross functional Utilise timely cross functional
• Project management meeting preliminary CAPEX. team and customer input to team input concurrent with
minutes and status report refine characteristics and other phase 1 processes
• IT document archive. 3.Create strategic
measurement methods according to the SMR
• Management review schedule. procurement plan.
concurrent with other phase 1 Production System (SPS):
2.Mutually understand approved RFQ 4.Refine “make or buy” •
processes according to the TAKT time
and translate into a controlled project estimation.
manual including: SMR Production System • Pull principle
• Approved RFQ/FEP references (SPS). Use checklists. • One piece flow
• Customer expectations 3.Develop preliminary gauge • Zero defects
• Specifications and regulations plan.
2.Create and control preliminary
• Deliverables 4.Develop samples build plan. process flow chart.
• Milestones 5.Incorporate plans into master
• Assumptions schedule.
• Concepts
• Preliminary characteristics
• Launch plan
• Risk assessment
Outputs • Controlled project manual • Controlled baseline fast track • Characteristics list document • Controlled preliminary process
document. document • Preliminary gauge plan flow chart document
• Master schedule document. • Controlled preliminary CAPEX document
• Project management meeting document • Sample build plan document
minutes and status report • Strategic procurement plan
document. document
Guidelines • G11 Project manual • G21 Define financial • G18 Key characteristics • G10 Process flow chart
• G19 Management review baseline • G16 Gauge R&R • G07 Manufacturing facility design
and phase sign off • KAM
Responsible • Project Manager • Purchasing • Design Leader • Manufacturing Engineer
24
Level 2
Phase 1.0 Plan and define project
– continuation –

Management 30 days maximum Phase 1

review 1 sign off

1.5 1.6
Preliminary tooling
Corrective actions
and manufacturing
(if required)
facilities plans

SDS intent Preliminary delivery plans. Keep project on course.

Activities 1.Study and refine approved RFQ 1.Continually identify risks and
product and process concepts, opportunities to project objectives and
CAPEX and assumptions KPIs. Initiate re-quote as required
according to the SMR Production when project scope changes.
System (SPS). Utilise timely cross 2.Plan actions and contingencies as
team functional Including suppliers. team.
2.Prepare preliminary specifications 3.Agree responsibilities and closure
and refine supplier RFQs (if dates.
required) concurrent with other
4.Detail and action through project
phase 1 processes.
management meeting minutes and
3.Create preliminary sourcing, status report.
implementation and verification
5.Maintain accurate Fast track.
plans supporting project objectives
and master schedule (launch plan).6.Monitor actions.
4.Incorporate plans into master 7.Close actions before management
schedule. review 1. Include key stakeholders.

Outputs • Preliminary tooling and • Zero issues at management

manufacturing facilities plan review 1
documents • Phase sign off document
• Supplier RFQ documents (SDS FORM MR1)
(if required)
Guidelines • G13 Tooling • G19 Management review
• G07 Manufacturing facility • G22 Corrective actions
design
Responsible • Tooling Engineer (tooling) • Project Manager
• Manufacturing Engineer
(facilities)
25
Level 2
Phase 2.0 Product design and development

Phase intent DELIVER ROBUST PRODUCT DESIGN

Feedback,
0 Project initiation 1 Plan and define 2 Product design 3 Process design 4 Product and 5 assessment and
project and development and development process validation corrective actions

Phase outcomes Goals

• Product design freeze. • Timely cross functional and concurrent input, design review and teamwork.
• Approval to finish process design. • Incorporate best practice and lessons learned with early risk assessment.
• Approval to place deposit on tooling and manufacturing facility. • Early consideration of process design and production controls.
• Generate and protect intellectual property.
• Zero defects.
• Simulations and prototype feedback and utilisation.

Processes Responsibility Description

2.1 DFMEA Design Leader • Product risks analysed and mitigated.

2.2 DFMA Manufacturing Engineer • Production needs for manufacture and assembly incorporated in design.
2.3 Preliminary PFMEA Manufacturing Engineer • Early process risk assessment undertaken.
2.4 DVP&R Design Leader • Design verification schedule created and design validation concluded.
2.5 CAD model & simulations Design Leader • Product design optimised and frozen by continual design review.
2.6 “Make or buy” evaluation Purchasing • Decision to make or buy concluded.
2.7 Supplier input, assessment and selection Purchasing • Capability & selection made
2.8 Production process flow chart Manufacturing Engineer • Production process flow specified.
2.9 Prototype PCP Quality/Project Engineer • Process controls initiated from flow chart , FMEAs and characteristics list.
2.10 Prototype construction and review Design Leader • Prototypes constructed and feedback utilised.
2.11 Engineering drawings Design Leader • Drawings released to suppliers, internal and external customers.
2.12 Database Project Engineer • Database created to enable production management.
MR2 Project Manager • Design frozen and Project Manager organises management review.
2.13 Corrective actions (if required) Project Manager • Risks and roadblocks to project objectives are identified and removed.
Phase sign off Executive Team • Phase ends and funds released to next phase.

26
Level 2
Phase 2.0 Product design and development
2
Product design and development

2.1 2.2 2.3 2.4

DVP& R
DFMEA DFMA Preliminary PFMEA
(design validation)

SDS intent Mitigate product risks. Meet production design needs. Mitigate process risks. Conclude design validation.
1.Confirm customer format and 1.Incorporate timely cross 1.Confirm customer format and 1.Confirm customer format.
Activities assessment criteria. functional team and external assessment criteria. 2.Develop and control verification
2.Undertake and control ongoing expert DFMA reviews into 2.Deploy characteristics from actions and test schedule for all
cross functional team product master schedule. DFMEA to PFMEA. phases required by Project manual
Coordinate with: [1.1] regulations and specifications.
risk assessment concurrent 3.Undertake and control
• CAD model and simulations 3.Select test facilities to support :
with other phase 2 processes. ongoing cross functional team
Incorporate: Preliminary [2.5]. • Master schedule
• Prototype construction [2.10]. process risk assessment • CAPEX
characteristics [1.3]. concurrent with other phase 2
2.Incorporate production needs • Customer approval
Coordinate with: processes. Coordinate with:
into product design. Optimise Coordinate with:
• Similar existing FMEAs manufacturing and assembly • Similar existing FMEAs • DFMEA [2.1]
• DVP&R [2.4] efficiency and capability. • Production process flow • CAD model and simulations
3.Determine and prioritise risk • Reduce assembly costs. chart [2.8] [2.5]
mitigation actions concurrent • Improve reliability • 2.9 Prototype PCP [2.9] • Prototype construction and
with other phase 2 processes. and quality. review [2.10]
4.Determine and prioritise risk
• Decrease equipment 4.Obtain approvals as required.
4.Action and close risk mitigation mitigation actions concurrent
actions through project and inventory. with other phase 2 processes. 5.Conclude design validation before
3.Determine and prioritise DFMA product design freeze including:
management meeting minutes 5.Action and close risk
actions concurrent with other • Regulations compliance
before product design freeze. mitigation actions into project
phase 2 processes. • Simulations
5.Obtain approvals as required. management meeting • Calculations
4.Action and close DFMA actions
minutes before product • Prototype testing
through project management
design freeze.
meeting minutes before product 6.Record and analyse results.
design freeze. 6.Obtain approvals as required. 7.Immediately feedback into other
phase 2 processes.
Outputs • Controlled DFMEA document. • Zero DFMA issues. • Controlled PFMEA document.
• Risk mitigation. • DFMA review records. • Risk mitigation • Controlled and approved
• Refined characteristics list • Refined characteristics list. DVP&R document.
document.
Guidelines • G17 FMEA • G01 DFMA • G17 FMEA • G14 DVP&R
Responsible • Design Leader • Manufacturing Engineer • Manufacturing Engineer • Design Leader
27
Level 2
Phase 2.0 Product design and development
– continuation –
Design review

2.5 2.6 2.7

“Make or buy” Supplier input, assessment
CAD model and simulations
evaluation and selection

SDS intent Optimise design. Conclude “make or buy” decisions. Understand and include suppliers.
Activities 1.Incorporate timely design reviews into master schedule. 1.Review: 1.Initiate RFQs with preferred suppliers from:
Coordinate with: • Project manual [1.1] Make or buy evaluation [2.6].
• DVP&R [2.4]
•FEP and CAPEX review. (assumptions) 2.Perform capability assessments according to
•Customer approvals • Define financial baseline [1.2] the SMR Supplier Development Manual.
2.Study approved RFQ concept and assumptions. (strategic procurement plan)
3.Develop and control CAD model concurrent to other phase 2 • FEP and CAPEX 3.Select suppliers. Specify and inform SMR
processes to meet project manual objectives. Generate and requirements and expectations.
2.Conclude make or buy
protect intellectual property. Incorporate: decisions. Coordinate with: 4.Develop suppliers according to SMR
Preliminary characteristics [1.3]. Supplier Development Manual.
• Supplier input, assessment
4.Conduct simulations eg: 5.Obtain timely supplier design review input.
Mould flow (rheology) FEA and modal analysis and selection [2.7]
• Production process flow chart Coordinate with:
Kinematics Dimensional variation
[2.8] • DVP&R [2.4]
5.Undertake structured design reviews using project team,
customers, external experts, suppliers, design manuals and • CAD model and simulations [2.5]
checklists as required. • Prototype construction and review [2.10]
6.Determine and prioritise design review actions incl Tolerance 3.Create preferred suppliers list.
Stack.. • Engineering drawings [2.11]
7.Action and close design review actions though project • FEP and CAPEX review.
management meeting minutes before product design freeze.
6.Action and close supplier design review
8.Freeze design before management review.
actions through project management meeting
9.Obtain approvals as required.
minutes before product design freeze.
Outputs • Simulation report documents. • “Make or buy” decision. • Approved supplier list document.
• Design review record documents. • Preferred suppliers list • Supplier assessment report
• Controlled product design freeze. document. documents.
• Supplier design input documents.
• Zero supplier design issues.
Guidelines • G02 Design review • None • None
Responsible • Design Leader • Purchasing Officer • Purchasing Officer

28
Level 2
Phase 2.0 Product design and development
– continuation –

Product
Design review design freeze

2.8 2.9 2.10

Prototype
Production process flow chart Prototype PCP construction and
review

SDS intent Specify process flow. Initiate production controls. Design feedback.
Activities 1.Study: 1.Study and incorporate: 1.Incorporate timely prototype
Preliminary process flow chart [1.4] and • Preliminary characteristics list construction into master
assumptions. Coordinate with: [1.3] schedule. Ensure prototypes
• Preliminary PFMEA [2.3] available for design review before
Coordinate with:
design freeze. Coordinate with:
• Prototype PCP [2.9] • Preliminary PFMEA [2.3] • Preliminary characteristics [1.3]
2.Utilise timely cross functional team input • Production process flow chart (sample build plan)
concurrent to other phase 2 processes to [2.8] • DVP&R [2.4]
refine manufacturing facility specification 2.Create and control prototype PCP • CAD model and simulations [2.5]
and concept according to the SMR concurrent to phase 2 processes
Production System (SPS): • Supplier input [2.7]
utilising cross functional input
• TAKT time • Engineering drawings [2.11]
according to the SMR Production
System (SPS). • FEP and CAPEX review.
• Pull principle
3.Refine gauging and measuring • Customer approvals.
• One piece flow
system needs. 2.Incorporate and close design
• Zero defects
4.Refine production training needs. review actions through project
3.Optimise, specify and control production management meeting minutes
process flow. 5.Obtain approvals as required. before product design freeze.
4.Initiate prototype PCP.

Outputs • Controlled production • Controlled prototype PCP • Prototype product.

process flow chart document.
document.

Guidelines • G10 Process flow chart • G04 Process control plan • G02 Design Review

Responsible • Manufacturing Engineer • Quality or Project Engineer • Design Leader

29
Level 2
Phase 2.0 Product design and development
– continuation –

30 days maximum
Management Phase 2
review 2 sign off

2.11 2.12 2.13

Engineering Corrective actions
Database
drawings (if required)

SDS intent Specify product. Initiate production management. Keep project on course.
Activities 1.Develop and control 2D 1.Input data into ERP system. 1.Continually identify risks and
drawings concurrent with other 2.Initiate production opportunities to project objectives
phase 2 processes. Protect management and capacity and KPIs. Initiate re-quote as
intellectual property. planning including: required when project scope
Incorporate: 1.3 Preliminary • BOM changes.
characteristics [1.3]. 2.Plan actions and contingencies as
Coordinate with: • Structure
team.
• CAD model and • Routing
3.Agree responsibilities and closure
simulations [2.5] • Volumes dates.
• Supplier input [2.7], • Timing 4.Detail and action through project
• Prototype PCP [2.9] • Approved suppliers management meeting minutes and
• Prototype construction • IMDS status report.
and review [2.10] 5.Maintain Fast track and database.
• Customer approvals 6.Monitor actions.
2.Refine RFQs, FEP and CAPEX 7.Close actions before management
(if required). review 2. Include key stakeholders.
3.Obtain approvals as required.

Outputs • Controlled and approved • Production management and • Zero issues at management
design freeze drawing capacity planning enabled. review 2
documents. • Phase sign off document
(SDS FORM MR2).
Guidelines • None • G05 Database • G19 Management review
• G22 Corrective actions
Responsible • Design Leader • Design Leader • Project Manager

30
Level 2
Phase 3.0 Process design and development

Phase intent DELIVER ROBUST PROCESS AND PRODUCTION CONTROLS

Plan and define Product design Process design Product and Feedback,
0 Project initiation 1 2 3 4 5 assessment and
project and development and development process validation corrective actions
Phase outcomes Goals
• Manufacturing facility purchased with deposit only.
Timely cross functional and concurrent input and teamwork.
• Tooling verified and ready for progress payment.
Safe, efficient and capable processes.
• Packaging and logistics purchased with deposit only.
100% first time through yield. Zero scrap or rework.
• Pre-launch PCP and support plans concluded.
Robust PCP, instructions and training plan.

Processes Responsibility Description

3.1PFMEA Manufacturing Engineer • Process risks analysed and mitigated.

3.2 Manufacturing facility design Manufacturing Engineer • Manufacturing facility specification frozen to enable purchase.
3.3 Pre-launch PCP Quality/Project Engineer • Production controls developed.
3.4 Measurement systems analysis plan Quality/Project Engineer • Measuring system sourcing, implementation and verification planned.
3.5 Production equipment safety Manuf./Tooling Engineers • Production processes made safe. Regulatory requirements met.
3.6 Process instructions and training plan Manufacturing Engineer • Process instructions developed and production training planned.
3.7 Tool design / FMEA Tooling Engineer • Tooling design frozen. Tooling ordered with deposit.
3.8 Verification of tool build Tooling Engineer • Tool construction verified ready for final payment
3.9 Verification of part dimensions Tooling Engineer • Part dimensions verified ready for final payment
3.10 Verification of tool functionality Tooling Engineer • Tool function verified ready for final payment
3.11 Packaging specification Manufacturing Engineer • Packing and logistics specification frozen.
MR3 Project Manager • Project Manager organises management review.
3.12 Corrective actions (if required) Project Manager
• Risks and roadblocks to project objectives are identified and removed.
Phase sign off • Phase ends and funds released to next phase.
Executive team

31
Level 2
Phase 3.0 Process design and development

• Manufacturing facility specification freeze

• Manufacturing facility ordered with deposit

3
Process design and development

3.1 3.2 3.3

PFMEA Manufacturing facility design Pre-launch PCP

SDS intent Mitigate process risk. Specify manufacturing facility. Progress production controls.
Activities 1.Develop and control Preliminary PFMEA 1.Fully develop manufacturing facility design. 1.Develop and control
[2.3] according to Production process flow Utilise timely cross functional team input Prototype PCP [2.9] according to
chart [2.8] and aligned with DFMEA [2.1] concurrent with other phase 3 processes. Meet Production process flow chart [2.8]
concurrent with other phase 3 outputs project manual objectives in accordance with utilising cross functional team input
utilising cross functional team input. SMR Production System (SPS). concurrent with other phase 3
Coordinate with: 2.Conclude (if required) Preliminary activities according to the SMR
manufacturing facility plan [1.5]: Production System (SPS). Include
• Similar existing FMEAs • Master schedule requirements from:
• Manufacturing facility design [3.2] • Approved supplier RFQs
• Manufacturing facility design [3.2]
• Pre-launch PCP [3.3] • FEP and CAPEX
• Training needs. • Tool design and FMEA [3.7]
• Tool design and FMEA [3.7]
3.Reconfirm training builds as per master schedule
2.Determine and prioritise risk mitigation
(launch plan) and DVP&R [2.4]. Coordinate with:
actions.
4.Secure floor space. • PFMEA [3.1]
3.Action and close risk mitigation actions 5.Freeze and control manufacturing facility
through project management meeting • Production equipment safety [3.5]
specification.
minutes before manufacturing facility 6.Obtain approvals as required. • Process instructions and training plan
specification and tooling design freeze. 7.Order manufacturing facility with deposit only. [3.6]
4.Obtain approvals as required. Hold final payment until after management 2.Determine training needs
review 3 and Training builds [4.4] complete. 3.Obtain approvals as required.

Outputs • Controlled PFMEA document. • Controlled and approved • Controlled pre-launch PCP
• Risk mitigation. manufacturing facility specification document.
document freeze.
Guidelines • G17 FMEA • G07 Manufacturing facility design • G04 Process control plan
Responsibility • Manufacturing Engineer • Manufacturing Engineer • Quality or Project Engineer

32
Level 2
Phase 3.0 Process design and development
– continuation –

3.4 3.5 3.6

Measurement systems Process instructions
Production equipment safety
analysis plan and training plan

SDS intent Ensure validation and availability. Make production safe. Train production to execute PCP.
Activities 1.Plan measurement systems 1.Incorporate timely safety hazard and 1.Create and control process
sourcing, verification and ergonomic reviews into master schedule instructions required by:
implementation required by Pre- covering: Production process flow chart [2.8] • Project manual [1.1] (launch
launch PCP [3.3] to support master and Prototype PCP [2.9]. plan)
schedule (launch plan) and CAPEX. 2. Coordinate with:
• Pre-launch PCP [3.3]:
Coordinate with Process instructions • Project Manual (launch plan) [1.1].
and training plan [3.6]. Include: • Manufacturing facility design [3.2] • Process instructions
• Pre-launch PCP [3.3] • Calibration, breakdown and
•Sourcing
• Process instructions and training plan [3.6] maintenance procedures
•Certification • Tool design and tool FMEA [3.7] • Technical manuals
•Instructions • Packaging specification [3.11]
• Test methods
•Training 3.Use external experts as required.
•Calibration 4.Determine and prioritise hazard elimination and 2.Prepare training plan to support
ergonomic optimisation actions. project objectives according to the
•R&R SMR Production System (SPS).
5.Action and close through project management
•Registration 3.Incorporate plan into master
meeting minutes before manufacturing facility
•Approval specification, tooling design, packaging and schedule.
2.Incorporate plan into master logistics freezes. 4.Secure production resource
schedule. 6.Obtain and control regulatory and other 5.Create and maintain skills matrix.
approvals as required.

Outputs • Measurement systems • Hazards eliminated and • Controlled process

analysis plan document. ergonomics optimised. instruction documents.
• Review record documents. • Training plan document.
• G08 MSA plan • Controlled regulatory approval • Skills matrix document.
• Quality or Project Engineer documents.

Guidelines • G23 Production equipment safety • G03 Training builds

Responsibility • Manufacturing Engineer • Manufacturing Engineer

33
Level 2
Phase 3.0 Process design and development
– continuation –
• Tooling design freeze
• Tooling ordered with deposit

3.7 3.8 3.9

Verification of tool Verification of part
Tool design and FMEA
build dimensions

SDS intent Specify tooling. Verify tool construction. Verify part dimensions.
Activities 1.Fully develop tooling design using timely supplier 1.Check tooling construction 1.Check part meets
and other cross functional team input concurrent meets specification and specification and is
with other phase 3 processes. Meet project checklists. Coordinate with: functional.
manual objectives in accordance with SMR • Verification of part dimensions Coordinate with:
production system (SPS).
[3.9]
2.Utilise FMEA, tooling standards & checklists as
required. • Verification of tool functionality• Verification of tool build [3.8]
[3.10] • Verification of tool
3.Conclude (if required) Preliminary tooling
plan [1.5]: 2.Make timely corrections functionality [3.10]
• Master schedule (if required) to continually 2.Make timely corrections
• Approved supplier RFQs support master schedule (if required) to continually
• FEP and CAPEX (launch plan), database and support master schedule
• Training needs. CAPEX. (launch plan), database
4.Reconfirm tool tryouts required by master 3.Validate changes and hold final and CAPEX.
schedule (launch plan) and DVP&R [2.4]. payment until after 3.Validate changes and hold
5.Freeze and control tooling specification. management review 3 and tool final payment until after
6.Obtain approvals as required. tryouts complete. management review 3 and
7.Create tooling records. tool tryouts complete.
4.Document tool history.
8.Order tooling with deposit only. Hold final 4.Document tool history.
payment until after management review 3 and
Tool tryouts [4.3] complete.

Outputs • Controlled and approved • Supplier certification • Supplier certification

tooling specification documents. documents.
document freeze • Tool modification record • Tool modification record
• Tooling records. documents. documents.

Guidelines • G13 Tooling • G13 Tooling • G13 Tooling

Responsibility • Tooling Engineer • Tooling Engineer • Tooling Engineer

34
Level 2
Phase 3.0 Process design and development
– continuation –
Tooling verified Management Phase 3
ready for progress payment review 3 sign off

30 days maximum
3.10 3.11 3.12
Verification of tool Corrective actions
Packaging specification
functionality (if required)

SDS intent Verify tool functionality. Specify packaging and logistics. Keep project on course.
Activities 1.Check tooling meets 1.Study approved RFQ product and 1.Continually identify risks and
specification and checklists. process concepts and assumptions. opportunities to project objectives and
Check tooling is safe and 2.Utilise timely cross functional team KPIs. Initiate re-quote as required
functional. input to fully develop, freeze and when project scope changes.
Coordinate with: control packaging and logistics 2.Plan actions and contingencies as
specification concurrent with other
• Verification of tool build [3.8] team.
phase 3 processes in accordance to
• Verification of part SMR Production system (SPS). 3.Agree responsibilities and closure
dimensions [3.9] 3.Conclude sourcing, implementation dates.
2.Make timely corrections and verification plan and training 4.Detail and action through project
(if required) to continually needs. Coordinate with management meeting minutes and
Manufacturing facility design [3.2], status report.
support master schedule
master schedule (launch plan) and
(launch plan), database DVP&R [2.4]. 5.Maintain Fast track and database.
and CAPEX. 6.Monitor actions.
4.Incorporate plan into master
3.Validate changes and hold schedule. 7.Close actions before management
final payment until after 5.Obtain approvals as required. review 3. Include key stakeholders.
management review 3 and 6.Order packaging and logistics with
tool tryouts complete. deposit only. Hold final payment
4.Document tool history. until after management review 3 and
Training builds [4.4] complete.

Outputs • Supplier certification • Controlled and approved • Zero issues at management review 3.
documents. packaging and logistics • Phase sign off document
• Tool modification record specification document (SDS FORM MR3).
documents. freeze.
Guidelines • G13 Tooling • G24 Packaging and logistics • G19 Management Review
• G22 Corrective Actions
Responsibility • Tooling Engineer • Manufacturing Engineer • Project Manager
35
Level 2
Phase 4.0 Product and Process Validation

Phase intent VERIFY PRODUCT, PROCESS AND PRODUCTION CONTROLS

Plan and define Product design Process design Product and Feedback,
0 Project initiation 1 2 3 4 5 assessment and
project and development and development process validation corrective actions
4.0 Outcomes Goals

• Full production approval. • Fully develop processes and train production.

• Full payment for tooling, manufacturing facility and packaging. • Implement production PCP.
• Approve materials, components and product.
• Approve process by simulated production build.
• Make production fully responsible and independent.

Processes Responsibility Description

4.1 Gauge R&R Quality/Project Engineer • Reliable measurements ensured.

4.2 Gauge certification and registration •
Quality/Project Engineer Gauges approved and released to production.
4.3 Tool try out • Parts and tooling verified
4.4 Training builds Tooling Engineer
4.5 Tool life deviation (if required) Manufacturing Engineer • Production trained and processes developed.
4.6 Production tool approval Design Leader • Non critical dimensions concessed for life.
4.7 DVP&R conclusion • Tooling approved and released to production.
4.8 Production PCP Tooling Engineer
4.9 PPAP Design Leader • Product verification testing concluded and approved.
4.10 Internal run@rate • Production controls fully implemented.
4.11 Production system audit Quality/Project Engineer
4.12 Customer run@rate Quality/Proj Eng/Purch
• Product,materials,components approved for
MR4 • Production simulated internally to assess production readiness.
Manufacturing Engineer
4.13 Corrective actions (if required) • PCP implementation audited.
Quality/Project Engineer
Phase sign off • Processes approved by customer.
Manufacturing Engineer
• Project Manager organises management review.
Project Manager
• Risks and roadblocks to project objectives are identified and removed.
Project Manager
• Phase ends and project team support production for 90 days.
Executive Team

36
Level 2
Phase 4.0 Product and process validation
Final tooling
payment made

4
Product and process validation

4.1 4.2 4.3

Gauge certification and
Gauge R&R Tool tryout
registration

SDS intent Ensure reliable measurements. Release gauges to production. Verify tool and parts.
Activities 1.Source gauges required by Measurement 1.Certify gauges required by 1.Progress payment and implement
systems analysis plan [3.4]. Measurement systems analysis tooling. Hold final payment until after tool tryouts
2.Certify and calibrate gauges required by plan [3.4]. complete.
Gauge certification and registration [4.2]. 2.Create controlled gauge 2.Undertake tool tryouts according to master
3.Develop instructions required by: records. schedule and database. Continually
• Measurement systems analysis plan [3.4] 3.Create calibration schedule. support launch plan.
• Production PCP [4.8] (if required) 4.Register gauges required by 3.Implement corrections and improvement actions
Measurement systems analysis (if required). Coordinate with:
4.Execute R&R studies required by • DVP&R [2.4]
plan [3.4].
Measurement systems analysis plan [3.4].
5.Obtain approvals required by • Measurement systems analysis plan [3.4]
5.Generate and analyse report. • Process instructions and training plan [3.6]
Measurement systems analysis
6. Make timely corrections and validate plan [3.4] and release to • Training builds [4.4]
changes (if required). Continually support production. • Production PCP [4.8]
master schedule (launch plan) and prepare • PPAP [4.9]
for Gauge registration [4.2].
4.Close actions through project management
meeting minutes. Freeze and control master
settings before Internal run@rate [4.10]

Outputs • Acceptable R&R. • Gauges released to production. • Controlled and frozen master
• R&R report documents. • Controlled gauge record settings documents.
documents. • Tool tryout report documents.

• G15 Gauge certification • G13 Tooling

Guidelines • G16 Gauge R&R
and registration

Responsibility • Quality or Project Engineer • Quality or Project Engineer • Tooling Engineer

37
Level 2
Phase 4.0 Product and process validation
– continuation –
Final manufacturing
Facility payment made

4.4 4.5 4.6

Tool life deviation Production
Training builds tool approval
(if required)

SDS intent Concess non critical dimensions.

Train and develop production. Release tools to production.
Activities 1.Determine deviations to specification. 1.Obtain production approval
1. Progress payment and implement Incorporate assumptions from: Verification for tooling before PPAP [4.9].
manufacturing facility. Hold final of part dimensions [3.9] Use checklists as required.
payment. until after training builds 2.Determine if deviations critical.
complete. 2.Handover tooling records.
3.Determine where corrections or tool life
2. Undertake training builds according to deviations required and feasible. Consider
master schedule and database. impact on replacement and capacity tooling.
Continually support launch
4.Determine and prioritise corrective actions.
plan.
5.Action and close corrective actions through
3. Implement corrections and improvement
project management meeting minutes before
actions (if required). Coordinate with:
PPAP [4.9]. Coordinate with:
• DVP&R [2.4]
• DVP&R [2.4]
• Measurement systems analysis
plan [3.4] • Measurement systems analysis plan
[3.4]
• Process instructions and training
• Process instructions and training [3.6]
plan [3.6]
• Tool tryouts [4.3] • Tool tryouts [4.3]
• Production PCP [4.8] • Training builds [4.4]
• PPAP [4.9] • Production PCP [4.8]
4. Close actions through project 6.Obtain approvals as required for tool life
management meeting minutes before deviations.
Internal run@rate [4.10]. 7.Record and control tool life deviations.

• Fully developed processes. • Controlled tool life deviation • Production approval

Outputs documents.
• Production fully trained. documents (if required).

Guidelines • G03 Training builds • G13 Tooling • G13 Tooling

Responsibility • Manufacturing Engineer • Design Leader • Tooling Engineer

38
Level 2
Phase 4.0 Product and process validation
– continuation –
4.7 4.8 4.9 4.10
DVP&R conclusion Internal
Production PCP PPAP
(product validation) run@rate

Conclude product validation. Specify production controls. Approve parts for production. Simulate production.
1.Immediately analyse results and 1.Develop and control Pre-launch PCP
feedback to project team. [3.3] utilising cross functional team 1.Obtain internal and supplier 1.Ensure run@rate readiness
SDS intent input concurrent with other phase 4 PPAP approvals according before customer PPAP. Use
2.Determine if design changes or
activities according to the SMR to master schedule before checklists.
Activities deviations required.
Production System (SPS). Include Internal run@rate 4.10: 2.Undertake internal run@rate
3.For design changes (if required) repeat
lessons learned from: • Materials. according to master
and record phase 2 processes. Action
and close though project management • Measurement systems analysis • Supplied components schedule.
meeting minutes before PPAP [4.9]. [3.4] and assemblies. 3.Generate and analyse report.
Coordinate with: • Manufactured 4.Determine if process flow
• Process instructions and
• DFMEA [2.1] components and changes or other corrective
training [3.6]
• Engineering drawings [2.11] • Tool tryouts [4.3] assemblies. actions required.
• Measurement systems analysis 2.Prepare customer PPAP 5.For process flow changes
• Training builds [4.4]
[3.4] documents. repeat phase 3 processes.
• DVP&R conclusion [4.7]
• Process instructions and training 3.Execute PPAP with external Action and close though
[3.6] • PPAP [4.9] project management meeting
customer according to
• Tool tryouts [4.3] 2.Determine corrective actions (if master schedule and minutes before Customer
• Training builds [4.4] required) and close before Production customer specific run@rate [4.12].
• Tool life deviation [4.5] (if required) system audit [4.11] and customer requirements. 6.Close all other actions before
PPAP. Coordinate with: 4.Obtain and control Customer run@rate [4.12].
• Production PCP [4.8]
• Tool tryouts [4.3] customer approval(s) before
4.For deviations (if required) liaise with
• Training builds [4.4] SoP.
customers, gain and record approvals
before PPAP [4.9]. • PPAP [4.9] 5.Release tooling to
5.Conclude product validation before PPAP 3.Obtain approvals as required production.
[4.9].

• Concluded DVP&R document. • Controlled and approved • Controlled internal approval • Run@rate report document.
Outputs
production PCP document. documents.
• Controlled customer approval
documents.
Guidelines • G14 DVP&R • G04 Process control plan • G9 PPAP • G12 Run@Rate

Responsibility • Design Leader • Quality or Project Engineer • Purchasing/Quality/Project • Manufacturing Engineer

Engineer
39
Level 2
Phase 4.0 Product and process validation
– continuation –

Management 30 days maximum

Phase 4
Review 4 sign off

4.11 4.12 4.13

Customer run@rate Corrective actions
Production system audit
(if required)

SDS intent Check PCP implementation. Approve process for production. Keep project on course.
Activities 1.Continually identify risks and opportunities to
1.Audit Production PCP [4.8] 1.Ensure run@rate readiness before
project objectives and KPIs. Initiate re-quote
implementation before Customer customer review. Use checklists.
as required when project scope changes.
run@rate [4.12]. Include full 2.Undertake customer run@rate according
manufacturing process from 2.Plan actions and contingencies as team.
to master schedule.
incoming to outgoing goods. 3.Agree responsibilities and closure dates.
3.Generate report.
2.Generate and analyse report. 4.Detail and action through project management
4.Submit report to customer according to
3.Determine and prioritise corrective meeting minutes and status report.
customer specific requirements.
actions (if required). 5.Maintain Fast track and database.
5.Obtain customer approval(s) before SoP.
4.Action and close though project 6.Monitor actions.
6.Release manufacturing facility to
management meeting minutes before 7.Close actions before management review 4.
production.
Customer run@rate [4.12]. Include key stakeholders.

Outputs • Audit report document. • Controlled customer approved • Zero issues at management
run@rate document. review 4.
• Phase sign off document
(SDS FORM MR4).

Guidelines • G12 Run@rate • G12 Run@Rate • G19 Management Review

• G22 Corrective Actions

Responsible • Project Manager

40 • Quality or Project Engineer • Manufacturing Engineer

Level 2
Phase 5.0 Feedback, assessment and corrective actions

Phase intent HANDOVER TO PRODUCTION - END SDS.

Plan and define Product design Process design Product and Feedback,
0 Project initiation 1 2 3 4 5 assessment and
project and development and development process validation corrective actions

Phase outcomes Goals

• Project signed off. • Monitor and refine processes.
• Project team disbanded. • Check long term capability.
• Record and disseminate lessons learned.
• Agree on residual risk and capability.
• Redeploy project team.

Processes Responsibility Description

5.1 Capability, lessons learned Project Manager • Lessons learned and post SDS improvement opportunities identified
and improvement opportunities for final report. Long term capability checked.

5.2 Transfer responsibility to Project Manager

• Processes monitored and refined.
production

• Normal production responsibilities assumed. Project team supports.

MR5 Project Manager
• Project Manager submits final report.
• Project team and production agree on residual risk and capability.
Project sign off Executive Team
.
• Project ends and Project Team disbands.
5.3 Production support Production

• Improvement opportunities identified in final report implemented.

41
Level 2
Phase 5.0 Feedback, assessment and corrective actions

90 days production Project

SoP sign off
Management
review 5

5
Feedback, assessment and corrective actions

5.1 Capability, lessons 5.2 5.3

learned and Transfer responsibility to
Production support
improvement production
opportunities
SDS intent Capture and share experience. Make production independent. Continual post SDS improvement.
Activities 1.Capture lessons learned. 1.Assume normal production 1.Commence charging customer
2.Identify post SDS improvement responsibilities (production). for customer requested
opportunities. 2.Monitor and refine processes for 90 days modifications.
3.Confirm long term capability. (Project Team). 2.Implement improvement
3.Agree on residual risk and capability opportunities identified in final
4.Create final report.
between production and project team. report.
5.Disseminate:
4.Archive project documentation. 3.Provide ongoing customer
• Lessons learned. and production support.
• Improvement opportunities. 5.Organises management review and
Continue to protect customer
submit final report.
property.
6.End SDS and disband project team.

Outputs • Final report document • Management review • Continual improvement

(SDS FORM MR5). • Project sign off document • PCO report documents.
(SDS FORM MR5). • Engineering change
documents.
• PPAP documents.

Guidelines • G06 Lessons learned and • G20 Transfer responsibility to • None

improvement opportunities production

Responsibility • Project Manager • Project Manager (Management review) • Production

• Executive Team (Project sign off)

42
Agenda

Introduction
SDS Project management fundamentals
SDS processes
Key performance indicators
Flow charts
SDS support processes
Definitions and acronyms

43
Phase 1 KPIs
Project initiation

Process KPI Target Comment

Completion and control. Completed and controlled.

1.1 Project
Deviations to Zero deviations at Deviations include timing and cost
manual
approved quote management review 1
Completion and control. Completed and controlled.
1.2 Financial
Deviations to a Zero deviations Deviations include unit cost and capital expenditure
baseline
approved quote. management review 1
Completed.
Completion Zero issues at
1.3 Refine management review 1
preliminary
characteristics Forecast deviations to No new deviations
customer requirements. since those approved in
phase 0
1.4 Preliminary Completed and controlled.
process flow Completion and control Zero issues at
chart management review 1
Completed.
Completion Zero issues at
management review 1
1.5 Preliminary
tooling and Tooling feasibility and No deterioration in feasibility.
manufacturing CAPEX forecast. No CAPEX increase.
facilities plans
Manufacturing facility
No deterioration in feasibility.
feasibility and CAPEX
No CAPEX increase.
forecast.

1.6 Corrective Phase sign off must occur within 30 days of

actions Outstanding actions Zero
management review 1

44
Phase 2 KPIs
Product design and development

Process KPI Target Comment

Registration and control Registered and controlled

2.1 DFMEA
Residual risk Phase sign off constitutes residual risk acceptance.
Acceptable to customers
at product design freeze If required obtain written customer approvals.

Unresolved issues at
2.2 DFMA product design Zero
freeze

Registration and control Registered and controlled

2.3 Preliminary
PFMEA
Residual risk Phase sign off constitutes residual risk acceptance.
Acceptable to customers
at product design freeze If required obtain written customer approvals.

Approved Includes external customer, Design Leader, test

Approval
as required facilities and Test Engineers as required
2.4 DVP&R
Deviation to agreed
specifications and Zero
regulations

45
Phase 2 KPIs
Product design and development
– continuation –

Process KPI Target Comment

Design frozen
Design freeze and control For all components.
and controlled

Formal design reviews 2 minimum

SMR patents lodged*. None

Intellectual property infringed. * If possible
2.5 CAD model No confidentiality breached.
and simulations
Unresolved issues at
Zero
product design freeze

Tooling feasibility and No deterioration in feasibility.

CAPEX forecast. No CAPEX increase.

Manufacturing facility
No deterioration in feasibility.
feasibility and CAPEX
No CAPEX increase.
forecast.
Completed.
2.6 Make or buy Completion Zero issues
evaluations
at management review 2

Supplier status Approved Commencement of APQP Documents

2.7 Supplier input,

assessment and Supplier design input Documented Formal design freeze approval from each supplier
selection
Unresolved supplier
issues at product design Zero
freeze

46
Phase 2 KPIs
Product design and development
– continuation –

Process KPI Target Comment

2.8 Production
Registration and control Registered and controlled
process flow chart

2.9 Prototype PCP Registration and control Registered and controlled

Minimum one prototype

Availability constructed before product
2.10 Prototype design freeze
construction and
review Unresolved issues at
Zero
product design freeze.

Design frozen
Design freeze and control For all components
and controlled
2.11 Engineering
drawings
Approved Includes external customer, internal approval and
Approval
as required suppliers as required

Initiated.
2.12 Database Inititation Zero issues
at management review 2

2.13 Corrective Phase sign off must occur within 30 days of

actions Outstanding actions Zero
management review 2

47
Phase 3 KPIs
Process design and development

Process KPI Target Comment

Registration and control Registered and controlled

3.1 PFMEA
Residual risk Phase sign off constitutes residual risk acceptance.
Acceptable to customers
at process design freeze If required obtain written customer approvals.
Specification frozen and
3.2 Manufacturing Specification freeze controlled. Zero issues
facility design and control at
management review 3
3.3 Pre-launch Registration and control Registered and controlled
PCP

3.4 Measurement Availability. Incorporated into master

systems analysis schedule.
plan Deviation to PCP Zero deviations to PCP

3.5 Production Unresolved issues at

Zero
equipment safety process design freeze

48
Phase 3 KPIs
Process design and development
– continuation –

Process KPI Target Comment

Availability. Incorporated into master

Deviation to pre-launch schedule. Zero deviations to
PCP and launch plan PCP and launch plan
3.6 Process Outstanding process Must enable production training including tool
instructions and instructions at Zero tryouts, training builds and production support
training plan management review 3 services. May be developed in phase 4.

Registration and control Registered and controlled

Specification frozen and

3.7 Tool design Specification freeze
controlled. Zero issues at
and tool FMEA and control
management review 3

3.8 Verification of Deviation

Zero
tool build to specification

3.9 Verification of Critical deviations Non critical deviations may have tool life deviations
Zero
part dimensions to specification applied subject to approval.

3.10 Verification of Deviation

Zero
tool functionality to specification

Specification frozen and

3.11 Packaging Specification freeze
controlled. Zero issues at
specification and control
management review 3

3.12 Corrective Phase sign off must occur within 30 days of

actions Outstanding actions Zero
management review 3

49
Phase 4 KPIs
Product and process validation

Process KPI Target Comment

4.1 Gauge R&R R&R Acceptable

4.2 Gauge
Certification and
certification and Certified and registered
registration
registration

No unplanned tool tryouts.

Planned tool tryouts
No missed tool tryouts
4.3 Tool tryouts
Unresolved issues at
Zero
management review 4

No unplanned training builds.

Planned training builds.
No missed training builds.
Planned training.
No outstanding training
4.4 Training builds
Unresolved issues at
Zero
management review 4

Deviation
Zero
to specification
4.5 Tool life
deviations
Unresolved issues at
Zero
management review 4

4.6 Production
Approval Production approved
tool approval

50
Phase 4 KPIs
Product and process validation
– continuation –

Process KPI Target Comment

Deviation
Zero
to specification
4.7 DVP&R
conclusion
Ensure Homologation Approval documentation is
Outstanding validation Zero
available

4.8 Production Registered and controlled

Registration and control
PCP

Includes materials, supplied parts, components and

Zero
4.9 PPAP Approvals assemblies. Includes internal and external
outstanding approvals
approval.

Zero Includes cycle time, capacity planning and planned

Deviations to database
(cost increasing deviations) down time.

Management review 4 sign off depends on whether

‘First time through‘ yield 106 PPM residual capability is acceptable to internal and
external customers
Management review 4 sign off depends on whether
4.10 Internal
Rework Zero PPM residual capability is acceptable to internal and
run@rate
external customers
Management review 4 sign off depends on whether
Scrap Zero PPM residual capability is acceptable to internal and
external customers

Unresolved issues at
Zero
management review 4

51
Phase 4 KPIs
Product and process validation
– continuation –

Process KPI Target Comment

Zero deviations or other
4.11 Production Deviation issues at
system audit to production PCP management
review 4

4.12 Customer Approval Customer approved

run@rate

4.13 Corrective Phase sign off must occur withing 30 days of

Outstanding actions Zero
actions management review 4

52
Phase 5 KPIs
Feedback, assessment and corrective action

Process KPI Target Comment

No worse than
Capability
4.12 Customer run@rate
5.1 Capability,
lessons learned 3 minimum (things gone right)
Lessons learned
and improvement 3 minimum (things gone wrong)
opportunities

Improvement opportunities 5 minimum

Production and the project team shall agree on the

Unresolved issues Zero residual risk and capability before management
5.2 Transfer review 5
responsibilty to
production
Project sign off Signed off

53
Agenda

Introduction
SDS Project management fundamentals
SDS processes
Key performance indicators
Flow charts
SDS support processes
Definitions and acronyms

54
SDS
Level 1

Input: Phase 0

BU Head
SKAM
Customer* RFQ Project initiation

MR0 (FEP sign off)

*Customer may be SMR

Phase 1

Direct
Eng

Team
Exec
Plan and define
project
MR1

Phase 2
Direct
Eng

Team
Exec
Product design
and development
MR2

Phase 3
Direct
Eng

Team
Exec
Process design
and development
MR3
Management review
Phase 4
Direct
Eng

Team
Exec

Product and process

validation
Process customer and
MR4
person who approves
work
Process facilitator Phase 5 Output:
MR5
Direct
Eng

Team
Exec

Feedback, Saleable and profitable product in

assessment and full production
corrective action

55
Phase 0
Project initiation

Input: 0.1

SKAM
KAM
Customer* RFQ RFQ registration

*Customer may be SMR

BU Head Decision:
Strategically
aligned?

0.2

SKAM
KAM
Quote initiation
and team set up Outputs:
• FEP document
• Customer specific quote
document
0.3
Direct
Eng

KAM
Quote formulation

SKAM
0.5

KAM
Quote handover
Engineering Decision:
Director Technically
feasible?

0.4
g
Controllin

Process customer and

SKAM

Decision: BU Head
person who approves FEP
Financially
work process facilitator and customer quote viable?
Main
and person who does
work
Person with final authority

56
Phase 0 Project initiation
0.1 RFQ Registration

Start phase 0

Inputs:
• Customer RFQ 0.1.1

SKAM
KAM
• Strategic plan Receive customer
documents

0.1.2

SKAM
KAM
Review and check
details

Decision: N
Details
complete?
Y
0.1.3
Output:
Head
BU
KAM

Check alignment
against strategic Go / No-go decision
plan

Process customer and N 0.1.4

SKAM
KAM

person who approves Decision: Inform customer of End

work Continue
Process facilitator and decision
quotation?
person who does work
Y
0.2 Quote initiation
and team set up

57
Phase 0 Project initiation
0.2 Quote initiation and team set up

Input: 0.2.1

SKAM
KAM
Customer RFQ Raise SMR RFQ and
allocate project code

0.2.2

SKAM
Establish project team

KAM
and distribute
information

0.2.3

SKAM
KAM
Initiate ongoing team Output: 0.3 Quote
meetings SMR RFQ document formulation

Process customer and

person who approves
work
Process facilitator and
person who does work

58
Phase 0 Project initiation
0.3 Quote formulation

Input: 0.3.1

Team

KAM
SMR RFQ Develop product and
(includes customer information) process concepts

0.3.2

Team

KAM
Determine project
costs

Process customer and

0.3.3
person who approves Team Determine spend

KAM
work
Process facilitator and profile and project
person who does work hours

Additional activities
0.3.4

Director
Eng
Team

• Check legal requirements. Output:

Assess technical
Go / No-go decision
• Secure intellectual property and feasibility
manufacturing innovation protection.
• Perform patent check.
• Designate production site.
• Propose possible project team. 0.3.3
N

SKAM
Renegotiate with 0.1

KAM
Decision:
• Complete checklist of deliverables Continue customer. Propose RFQ registration
ready for project initiation. quotation? feasible options
• Comply with SMR production system Y
[SPS]
0.4 FEP and customer
specific quote

59
Phase 0 Project initiation
0.4 FEP and customer quote

Input: 0.4.1

g
Controllin
KAM
RFQ document (completed) Confirm customer and
SMR funded
investments

g
Controllin
0.4.2

KAM
Calculate FEP

g
Controllin
0.4.3

KAM
Estimate CAPEX limits

0.4.4

SKAM
KAM

Process customer and Develop pricing

person who approves strategy
work
Process facilitator and
person who does work 0.4.5

SKAM
KAM

Prepare quote in
Additional activities customer specific
• Issue possible deviations and additional format.
input as QCN together with customer RFQ.
0.4.6
SKAM
• Ensure deviations from original quote are
KAM

Check quote against

clearly stated.
checklists
• Consider presentation meeting at customer
site.
0.4.7 Outputs: 0.5 Quote
• Hold follow up meeting to review strategy
SKAM

handover
KAM

Obtain approvals to • Controlled FEP document

and delivery effectiveness submit FEP to • Customer specific quote
BU Head document
60
Phase 0 Project initiation
0.5 Quote handover

Inputs: MR0

BU Head
0.5.1 Output:

SKAM
• FEP
Management review 0. Go / No-go decision
• Customer specific quote
BU Head reviews FEP

0.5.3

SKAM
Decision: N

KAM
Submit to Renegotiate with
customer customer
?
Y

Phase 0 sign off

0.5.2 0.5.3

SKAM
SKAM

KAM
KAM

Handover quote to Customer support after

customer handover

Process customer and

person who approves
work End phase 0
Back to 0.1
Process facilitator and 0.1

SKAM
RFQ registration if
KAM

person who does work RFQ registration

quote changes after
handover

61
Phase 1
Plan and define project

Proj Mgr
1.1

Direct
Eng
Initiate project and
create project manual

Proj Mgr
1.2

KAM
Define financial
baseline

Inputs: Key outputs:

Proj Mgr
1.3

Leader
Des
• Approved customer RFQ •Project manual
Refine preliminary
• Approved FEP •Zero issues at management
characteristics
review 1

1.4

Proj Mgr
Eng
Manuf

Preliminary
process flow chart

1.5

Proj Mgr
Eng
Tool/Man

Preliminary tooling
and manufacturing
facilities plans

Process customer and Concurrent processes

person who approves
work process facilitator
Main
and person who does
work

62
Phase 1 Plan and define project
1.1 Initiate project and create project manual

Start phase 1

Customer N
End
approval
received?
Y

1.1.1
Inputs:

Engineering Director
Establish:
• Controlled and approved
Project Manager • project team
customer RFQ • weekly meetings
• Controlled and approved
• master schedule
FEP • project management meeting minutes and status report
• IT document archive
• management review schedule incorporated into master
schedule

1.1.2
Mutually understand approved RFQ and translate into
controlled project manual including:

Engineering Director
• Approved RFQ/FEP references
Project Manager

• Customer expectations
• Specifications and regulations Outputs:
• Deliverables • Controlled project manual
• Milestones document
Process customer and • Assumptions • Master schedule document
person who approves • Concepts • Project management
work • Preliminary characteristics meeting minutes and status
Process facilitator and
person who does work • Launch plan report document
• Risk assessment • IT document archive

Concurrent with other phase 1 processes

63
Phase 1 Plan and define project
1.2 Define financial baseline

Inputs: 1.2.1

Proj Mgr
Establish and control

KAM
• Controlled and approved customer RFQ
baseline Fast track
• Controlled and approved FEP
from approved RFQ

Proj Mgr
1.2.2

KAM
Raise preliminary
CAPEX

g
Purchasin

Proj Mgr
1.2.3
Create strategic
procurement plan

Outputs:
g
Purchasin

Proj Mgr
1.2.4 • Controlled Baseline Fast track document
Refine “make or buy” • Controlled preliminary CAPEX document
estimation • Strategic procurement plan document

Concurrent with other phase 1 processes

Process customer and

person who approves
work
Process facilitator and
person who does work

64
Phase 1 Plan and define project
1.3 Refine preliminary characteristics

Inputs:
1.3.1

Des Leader
• Controlled and approved customer

Proj Mgr
RFQ Study approved RFQ
• Controlled and approved FEP concepts and
• SMR production system [SPS] assumptions

1.3.2

Proj Mgr
Leader
Des
Refine characteristics
using team input

Des Leader
1.3.3

Proj Mgr
Develop preliminary
gauge plan

1.3.4

Proj Mgr
Leader
Des

Develop samples build

plan

Outputs:
1.3.5
Proj Mgr

Director
Eng
• Characteristics list document
Incorporate plans into • Preliminary gauge plan
master schedule
Process customer and document
person who approves • Sample build plan document
work
Process facilitator and
person who does work Concurrent with other phase 1 processes

65
Phase 1 Plan and define project
1.4 Preliminary process flow chart

Inputs:
• Controlled and approved customer 1.4.1

Manufacturing Engineer
RFQ Study and refine approved RFQ
• Controlled and approved FEP

Project Manager
process, concepts and assumptions.
• SMR production system [SPS] Utilise team input and develop
according to SMR Production
System:
• TAKT time
• Pull principle
• One piece flow
Manufacturing Engineer • Zero defects

Project Manager
1.4.2 Output:
Develop and control preliminary Controlled preliminary process
process flow flow chart document

Process customer and

person who approves
work
Process facilitator and
person who does work

Concurrent with other phase 1 processes

66
Phase 1 Plan and define project
1.5 Preliminary tooling and manufacturing facilities plans

Inputs:
• Controlled and approved customer RFQ 1.5.1

Eng
Man/Tool

Proj Mgr
• Controlled and approved FEP Study approved RFQ
• SMR production system [SPS] concepts and
assumptions

1.5.2

Eng
Man/Tool

Proj Mgr
Prepare preliminary
specifications and refine
supplier RFQs
(if required)

1.5.3
Eng
Man/Tool

Proj Mgr
Create preliminary
sourcing, implementation
and verification plans

Eng Director
1.5.4
Proj Mgr

Outputs:
Incorporate plans into • Preliminary tooling and manufacturing
master schedule facilities plans documents
Process customer and • Supplier RFQ documents (if required)
person who approves
work
Process facilitator and
person who does work Concurrent with other phase 1 processes

67
Phase 1 Plan and define project
Management review 1 and phase sign off
Management review 1

Input: MR1
SDS FORM MR1

Project manager

Proj Mgr

Director
Eng
organises team
presentation

Executive team
e Team
Executiv

Output:

Head
BU
reviews project Phases sign off status (SDS FORM MR1)
performance
Executive Team

Freeze funding.
BU Head

Failed Decision: Successful End phase 1.

Re plan project at Phase Release funds to phase 2
Phase 2
Executive direction sign off?
30 days
maximum
Executive team
e Team
Executiv

Delayed

Head
BU
issues corrective
actions

Process customer and

person who approves Project team
e Team
Executiv
Proj Mgr

work closes actions End phase 1. Phase 2

Process facilitator and Release funds to phase 2
person who does work within 30 days

68
Phase 1 Plan and define project
1.6 Corrective actions (if required)

Proj Mgr
Inputs: 1.6.1

Director
Eng
• Controlled and approved Identify risks and
customer RFQ opportunities
• Controlled and approved FEP

Proj Team

Proj Mgr
1.6.2
Plan actions and
contingencies

1.6.3
Proj Team

Proj Mgr
Agree
responsibilities and
closure dates

1.6.4
Proj Mgr

Director
Eng
Detail and action in
project management
meeting minutes
Output:
Zero issues at management review 1
Proj Mgr

Director
Eng

1.6.5
Maintain Fast Track
Process customer and Management review 1
person who approves
work
Process facilitator and 1.6.7 MR1
Proj Mgr

Proj Mgr
Director
Eng

Director
Eng
person who does work 1.6.6 Close actions before
Monitor actions management
review 1

69
Phase 2
Product design and development

Proj Mgr
Leader
Des
2.1
DFMEA 2.7 Process customer and

ng
Purchasi

Proj Mgr
Supplier input, person who approves
assessment and work process facilitator
Main

nProj Mgr
Productio
selection
Eng
Manuf
2.2 and person who does
DFMA work

Proj Mgr
2.8

Eng
Manuf
Production process
flow chart

Proj Mgr
Key inputs: 2.3
Eng
Manuf

• Project Preliminary
manual PFMEA

Proj Mgr
Eng
Qual/Proj
• SMR 2.9
production Prototype PCP
Proj Mgr Key outputs:
system [SPS]
Leader
Des

2.4 • Product design freeze

DVP&R • Zero issues at management review

Proj Mgr
2.10 2
Leader
Des Prototype construction
and review
2.5
Proj Mgr
Leader
Des

CAD Model
and simulations

Proj Mgr
Leader
Des

2.11
Engineering Drawings
ng
Purchasi

Proj Mgr

2.6
“Make or buy“ decision

Proj Mgr
Leader
Des

2.12
Database

Concurrent processes

70
Phase 2 Product design and development
2.1 DFMEA

Inputs:
• Preliminary characteristics [1.3] 2.1.1

Leader
Design

KAM
• Controlled project manual Confirm customer format
• SMR production system [SPS] and assessment criteria
• Other concurrent phase 2 process
outputs
• Similar existing FMEAs
2.1.2

Project Mgr
Leader
Design
Ongoing concurrent
team product risk
assessment

Project Mgr
2.1.3
Leader
Design
Determine and prioritise
risk mitigation actions

2.1.4

Project Mgr
Leader
Design

Close risk mitigation

actions before product
design freeze

Process customer and

Project Mgr
person who approves 2.1.5 Outputs:
Leader
Design

work Obtain approvals as • Controlled DFMEA document

Process facilitator and • Residual risk acceptable to
required
person who does work
customers at product design
freeze
Coordinated with:
• DVP&R [2.4]
• Other concurrent phase 2 processes

71
Phase 2 Product design and development
2.2 DFMA

Inputs:
• Controlled project manual 2.2.1

Engineer
Manuf

Manager
Project
• SMR production system [SPS] Incorporate coordinated
• Other concurrent phase 2 DFMA reviews into master
process outputs schedule

2.2.2

Production
Engineer
Manuf
Incorporate production
needs into product design

Engineer 2.2.3
Manuf

Manager
Project
Determine and prioritise
DFMA actions

2.2.4 Outputs:
Engineer
Manuf

Manager
Project
Close DFMA actions • Zero DFMA issues
before product design • DFMA review record
freeze documents

Process customer and

Coordinated with:
person who approves
• CAD model and simulations [2.5]
work
Process facilitator and • Prototype construction [2.10]
person who does work • Other concurrent phase 2 processes

72
Phase 2 Product design and development
2.3 Preliminary PFMEA
Inputs:

Manuf Eng
• Controlled DFMEA [2.1] 2.3.1

KAM
• Controlled project manual Confirm customer format
• SMR production system [SPS] and assessment criteria
• Other concurrent phase 2
process outputs
• Similar existing FMEAs

Des Leader
Manuf Eng
2.3.2
Deploy characteristics
from DFMEA to PFMEA

Outputs:

Project Mgr
2.3.3
Leader
Design
• Controlled preliminary PFMEA
Ongoing concurrent team
document
process risk assessment • Residual risk acceptable to
customers at product design
freeze

Project Mgr
2.3.4
Leader
Design

Determine and prioritise

risk mitigation actions

2.3.5

Project Mgr

Project Mgr
2.3.6
Leader
Design

Close risk mitigation

Leader
Design
Process customer and Obtain approvals as
actions before product
person who approves required
design freeze
work
Process facilitator and
person who does work Coordinated with:
• Production process flow chart [2.8]
• Prototype PCP [2.9]
• Other concurrent phase 2 processes

73
Phase 2 Product design and development
2.4 DVP&R (design validation)
Inputs:
• Controlled project manual (launch 2.4.1

Leader
Design

KAM
plan, specifications and regulations) Confirm
[1.1] customer format
• Controlled CAPEX
• Master schedule
• Other concurrent phase 2 process
2.4.2

Project Mgr
outputs

Leader
Design
Develop verification
actions and schedule Output:
for all phases Controlled and approved
DVP&R document with
validated design

Project Mgr
2.4.3
Leader
Design
Select and coordinate
test facilities

2.4.7

Project Team
Project Mgr

Project Mgr
2.4.4
Leader
Design

Leader
Design
Immediately feedback
Obtain approvals
into other
as required
phase 2 processes

2.4.5

Project Team
Project Mgr

Project Mgr
2.4.6
Leader
Design

Conclude and control

Leader
Design
Process customer and Record and analyse
design validation before
person who approves results
product design freeze
work
Process facilitator and
person who does work
Concurrent with other phase 2 processes. Coordinated with:
• DFMEA [2.1]
• CAD model and simulations [2.5]
• Prototype construction and review [2.10]

74
Phase 2 Product design and development
2.5 CAD Model and simulations

Inputs: 2.5.1 Outputs:

Project Mgr
• Preliminary characteristics [1.3] • Controlled product design freeze

Leader
Design
Incorporate
• Controlled project manual • Design review record documents
design reviews into
concepts and specifications [1.1] • Simulation report documents
master schedule
• Controlled Fast track
• Controlled CAPEX
• Master schedule Coordinated

Project Team
2.5.2 with:

Project Mgr
Project Mgr
• SMR production system [SPS] 2.5.9

Leader
Design
Study • DVP&R [2.4]
• Design manuals Obtain approvals
approved RFQ concept • Other
• Checklists as required
and assumptions concurrent
• Other concurrent phase 2
phase 2
process outputs
processes

Project Mgr

Project Mgr
2.5.3
Leader
Design

Leader
Design
2.5.8
Develop and control CAD
Freeze design
model

2.5.7

Project Mgr

Project Mgr
Leader
Design

Leader
Design
2.5.4 Close design review
Conduct simulations actions before product
design freeze
Project Mgr

Project Mgr
Process customer and 2.5.5 2.5.5
Leader
Design

Leader
Design
person who approves Undertake structured Determine and prioritise
work design reviews design review actions
Process facilitator and
person who does work

75
Phase 2 Product design and development
2.6 “Make or buy” evaluation

Inputs:
• Strategic procurement plan [1.2] 2.6.1

Purchasing

Proj Mgr
• Controlled project manual Review project manual
• Controlled FEP assumptions and
• Controlled CAPEX strategic procurement
• Other concurrent phase 2 plan
processes

Purchasing
2.6.2

Proj Mgr
Conclude
make or buy decisions

Purchasing

Outputs:

Proj Mgr
2.6.3
Create • Make or buy decisions
preferred suppliers list • Preferred suppliers list
document

Process customer and

person who approves
Coordinated with:
work
Process facilitator and • Supplier input, assessment and selection [2.7]
person who does work • Production process flow chart [2.8]
• Other concurrent phase 2 processes

76
Phase 2 Product design and development
2.7 Supplier input, assessment and selection
Inputs:

Project Mgr
Purchasing
• Preferred suppliers list [2.6] 2.7.1
• Controlled project manual Initiate RFQs
• Controlled CAPEX with preferred suppliers
• Master schedule
• Other concurrent phase 2
process outputs

Project Mgr
Purchasing
2.7.2
Supplier
capability assessment

2.7.3 Outputs:

Purchasing

Project Mgr
Select suppliers. • Approved suppliers list document
Specify SMR • Supplier assessment report documents
requirements • Supplier design input documents
• Zero supplier design issues
Purchasing

Project Mgr
2.7.4
Develop suppliers

2.7.6

Project Mgr
Purchasing
Close supplier design

Project Mgr
Purchasing

2.7.5 input actions before

Process customer and Obtain supplier design product design freeze
person who approves input
work Coordinated with:
Process facilitator and • DVP&R [2.4]
person who does work • CAD model and simulations [2.5]
• Make or buy evaluation [2.6]
• Prototype construction [2.10]
• Engineering drawings [2.11]
• Other concurrent phase 2 processes
77
Phase 2 Product design and development
2.8 Production process flow chart

Inputs: 2.8.1

Manuf Eng

Mgr
Project
• Controlled preliminary process flow Study preliminary
chart [1.4] process flow and
• Controlled project manual assumptions
• SMR production system [SPS]
• Other concurrent phase 2 process 2.8.2

Project Mgr
Manuf Eng
outputs Refine manufacturing
facility specification and
concept

2.8.3
Manuf Eng

Mgr
Project
Optimise, specify and
control production
process flow
Manuf Eng

Output:

Mgr
Project
2.8.4
Controlled production process flow chart
Initiate prototype PCP
document

Process customer and

person who approves Coordinated with:
work • Preliminary PFMEA [2.3]
Process facilitator and • Make or buy evaluation [2.8]
person who does work • Prototype PCP [2.9]
• Other concurrent phase 2 processes

78
Phase 2 Product design and development
2.9 Prototype PCP

Inputs:
• Preliminary characteristics list and
gauge plan [1.3]

Manager
Project
Team
Project
• Controlled preliminary PFMEA [2.3] 2.9.1
• Controlled production process flow Study inputs
chart [2.8]
• Controlled project manual
• SMR production system [SPS]
2.9.2

Engineer
Qual/Proj

Manager
Project
• Other concurrent phase 2 process
Create and control
outputs
prototype PCP

2.9.3
Engineer
Qual/Proj

Manager
Project
Refine measuring
systems and gauging
needs

2.9.4
Engineer
Qual/Proj

Manager
Project
Refine production
training needs

2.9.5 Output:
Engineer
Qual/Proj

Manager
Project

Process customer and Obtain approvals Controlled prototype PCP document

person who approves as required
work
Process facilitator and
person who does work
Coordinated with:
• Preliminary PFMEA [2.3]
• Production process flow chart [2.8]
• Other concurrent phase 2 processes

79
Phase 2 Product design and development
2.10 Prototype construction and review

Inputs:
• Preliminary characteristics and

Project Manager
sample build plan [1.3]

Design Leader
2.10.1
• Controlled preliminary process flow Incorporate
chart [1.4] prototype construction
• Controlled project manual into master schedule
• Controlled Fast track
• Master schedule
• Other concurrent phase 2 process
outputs

Project Manager
Design Leader
2.10.2
Close Output:
design review actions Prototype product
before product design
freeze

Coordinated with:
• CAD model and simulations and design review [2.5]
• Supplier input [2.7]
• Prototype PCP [2.9]
Process customer and • Engineering drawings [2.11]
person who approves • Other concurrent phase 2 processes
work
Process facilitator and
person who does work

80
Phase 2 Product design and development
2.11 Engineering drawings

Inputs:
• Preliminary characteristics [1.3]

Project Manager
• Controlled project manual

Design Leader
• Master schedule 2.11.1
• Other concurrent phase 2 process Develop and control
outputs 2D drawings

Project Manager
Design Leader
2.11.2
Refine RFQs, FEP,
CAPEX (if required)

Project Manager
Design Leader

2.11.2 Output:
Obtain approvals Controlled and approved design freeze
as required drawing documents
Process customer and
person who approves
work
Process facilitator and Coordinated with:
person who does work • CAD model and simulations [2.5]
• Supplier input [2.7]
• Prototype PCP [2.9]
• Prototype construction and review [2.10]
• Other concurrent phase 2 processes

81
Phase 2 Product design and development
2.12 Database

Inputs:
• Approved suppliers [2.7]

Project Manager
Design Leader
• Controlled project manual 2.11.1
• Controlled Fast track Input data
• Controlled FEP into ERP system
• Master schedule
• Other concurrent phase 2
process outputs

Project Manager
2.11.2
Production
Initiate production Output:
management and Production management and
capacity planning capacity planning enabled

Concurrent with other phase 2 processes

Process customer and

person who approves
work
Process facilitator and
person who does work

82
Phase 2 Product design and development
Management review 2 and phase sign off
Management review 2

Input: MR2
SDS FORM MR2

Project manager

Proj Mgr

Director
Eng
organises team
presentation

Executive team
e Team
Executiv

Output:

Head
BU
reviews project Phases sign off status (SDS FORM MR2)
performance
Executive Team

Freeze funding.
BU Head

Failed Decision: Successful End phase 2.

Re plan project at Phase Release funds to phase 3
Phase 3
Executive direction sign off?
30 days
maximum
Executive team
e Team
Executiv

Delayed

Head
BU
issues corrective
actions
Process customer and
person who approves
work Project team
e Team
Executiv
Proj Mgr

Process facilitator and End phase 2.

closes actions Phase 3
person who does work Release funds to phase 3
within 30 days

83
Phase 2 Product design and development
2.13 Corrective actions (if required)

Inputs:

Proj Mgr
2.13.1

Director
Eng
• Controlled project
Identify risks and
manual opportunities
• Controlled Fast track
• Controlled CAPEX
• Master schedule

Proj Team

Proj Mgr
• KPIs 2.13.2
Plan actions and
contingencies

2.13.3
Proj Team

Proj Mgr
Agree
responsibilities and
closure dates

2.13.4
Proj Mgr

Director
Eng
Detail and action in
project management
meeting minutes
Output:
Zero issues at management review 2
Proj Mgr

2.13.5
Director
Eng

Maintain Fast Track

and database
Process customer and Management review 2
person who approves
work
Process facilitator and 2.13.7 MR2
Proj Mgr

Proj Mgr
Director
Eng

Director
Eng
person who does work 2.13.6 Close actions before
Monitor actions management
review 1

84
Phase 3
Process design and development

Proj Mgr
Eng
Manuf
3.1
PFMEA
Process customer and

Proj Mgr
Eng
Tooling
3.7 person who approves
Tool design and FMEA work process facilitator
Main

Proj Mgr
3.2
Eng
Manuf

and person who does

Manufacturing
work
facility design

Proj Mgr
3.8

Eng
Tooling
Verification of
tool build

Proj Mgr
Eng
Qual/Proj

Key inputs: 3.3

• Product Pre-launch PCP Key outputs:
design freeze 3.9 • Tooling ordered with deposit and

Proj Mgr
Eng
Tooling
• SMR Verification of validated
production part dimensions • Manufacturing facility specification
3.4
Proj Mgr
Eng
Qual/Proj

system [SPS] freeze

Measurement systems • Packaging and logistics specification
analysis plan

Proj Mgr
Eng
3.10 freeze
Tooling
Verification of • Pre launch PCP and support plans
tool functionality • Zero issues at management review 4
Manuf Eng

nProj Mgr
Productio

3.5
Production equipment
safety
Manuf Eng

Proj Mgr
3.11
Packaging
specification
Proj Mgr

3.6
Eng
Manuf

Process instructions
and training plan

Concurrent processes

85
Phase 3 Process design and development
3.1 PFMEA

Inputs:

Project Manager
Engineer
Manufacturing
• Controlled DFMEA [2.1]
• Controlled preliminary PFMEA [2.3] 3.1.1
• Controlled production process flow Develop:
chart [2.8] Preliminary PFMEA [2.3]
• Other concurrent phase 3 process
outputs
• Similar existing FMEAs

Project Manager
Engineer
Manufacturing
3.1.2
Determine and prioritise risk
mitigation actions

Project Manager
Engineer
Manufacturing

Process customer and 3.1.3

person who approves Close risk mitigation actions before
work process design freeze
Process facilitator and
person who does work

Coordinated with: Outputs:

Project Manager
Engineer
Manufacturing

• Manufacturing facility design [3.2] • Controlled PFMEA document

• Pre-launch PCP [3.3] 3.1.4 • Residual risk acceptable to
• Tool design and FMEA [3.7] Obtain approvals as required customers at process design
• Other concurrent phase 3 processes freeze

86
Phase 3 Process design and development
3.2 Manufacturing facility design
Inputs:
• Preliminary manufacturing facility 3.2.1

Proj Mgr
Eng
Manuf
Fully develop
plan [1.5]
• Controlled product design freeze manufacturing
facility design
[2.5]
• Controlled production
process flow chart [2.8] 3.2.2
• Controlled prototype PCP [2.9] Conclude:

Manuf Eng

Proj Mgr
• Controlled project manual (launch Preliminary
plan) [1.1] manufacturing
• Controlled Fast track facility plan [1.5]
• Controlled CAPEX (if required)
• Master schedule
• SMR production system [SPS]
• Manufacturing facility standards 3.2.3

Proj Mgr
Eng
Manuf

• Checklists Reconfirm
• Other concurrent phase 3 process training builds
outputs
Output:
Controlled and approved manufacturing facility

Proj Mgr
specification document freeze
Eng
Manuf

3.2.4
Process customer and Secure floor space
person who approves
work
Process facilitator and
person who does work 3.2.5
Proj Mgr
Eng
Manuf

Coordinated with: Freeze and control

manufacturing 3.2.7

Engineering Director
• PFMEA [3.1]
facility specification Order manufacturing
• Production equipment safety [3.5]
Proj Mgr facility with deposit
• Process instructions and training
only. Hold final
plan [3.6]
3.2.6 payment until after
Proj Mgr

• Tool design and FMEA [3.7]

Eng
Manuf

Obtain approvals management review 3

• Packaging specification [3.11]
as required and phase 4 training
• Other concurrent phase 3 process
builds complete
outputs

87
Phase 3 Process design and development
3.3 Pre-launch PCP

Inputs:
• Controlled product design freeze
[2.5]

Quality or Project Eng

• Controlled production
process flow chart [2.8] 3.3.1

Proj Mgr
• Controlled prototype PCP [2.9] Develop and control
• Controlled project manual Prototype PCP [2.9]
• SMR production system [SPS]
• Other concurrent phase 3 process
outputs

Quality or Project Eng

3.3.2

Proj Mgr
Process customer and
Determine
person who approves
training needs
work
Process facilitator and
person who does work

Coordinated with:
Quality or Project Eng

• PFMEA [3.1]
• Manufacturing facility design [3.2]
• Production equipment safety [3.5] 3.3.3 Proj Mgr Output:
• Process instructions and training Obtain approvals Controlled pre-launch PCP document
plan [3.6] as required
• Tool design and FMEA [3.7]
• Other concurrent phase 3 process
outputs

88
Phase 3 Process design and development
3.4 Measurement systems analysis plan

Inputs:

Quality or Project Eng

• Controlled project manual (launch

Project Manager
plan) [1.1] 3.4.1
• Preliminary gauging plan [1.3] Plan
• Controlled prototype PCP [2.9] measurement systems
• Controlled CAPEX sourcing, verification and
• Master schedule implementation
• SMR production system [SPS]
• Other concurrent phase 3 process
outputs

Engineering Director
Project Manager

3.4.2 Output:
Incorporate plan Measurement systems analysis plan
into master schedule document

Coordinated with:
Process customer and • Pre-launch PCP [3.3]
person who approves • Process instructions and training
work plan [3.6]
Process facilitator and
• Other concurrent phase 3 process
person who does work
outputs

89
Phase 3 Process design and development
3.5 Production equipment safety

Inputs: 3.5.1
Incorporate

Manuf Eng
• Controlled product design freeze

Proj Mgr
[2.5] safety hazard and
• Controlled production ergonomic reviews
process flow chart [2.8] into master
• Controlled prototype PCP [2.9] schedule
• Controlled project manual (launch
plan and regulations) [1.1]
• Controlled Fast track 3.5.2

Manuf Eng

Proj Mgr
• Controlled CAPEX Use
• Master schedule external experts
• SMR production system [SPS] as required
• Other concurrent phase 3 process Outputs:
• Hazards eliminated and ergonomics optimised
outputs
• Review record documents
3.5.3 • Controlled regulatory approval documents
Determine and
Manuf Eng

Proj Mgr
prioritise hazard
elimination and
ergonomic
optimisation actions

3.5.4 Coordinated with:

Close 3.5.5 • Manufacturing facility design
Manuf Eng
Production
Manuf Eng

[3.2]

Proj Mgr
hazard elimination Obtain and control
and ergonomic regulatory and other • Pre-launch PCP [3.3]
optimisation actions approvals • Process instructions and
Process customer and as required training plan [3.6]
before process
person who approves • Tool design and FMEA [3.7]
design freeze
work • Packaging specification [3.11]
Process facilitator and
person who does work • Other concurrent phase 3
process outputs

90
Phase 3 Process design and development
3.6 Process instructions and training plan

Inputs:

Manuf Eng
• Controlled product design freeze

Proj Mgr
3.6.1
[2.5] Create and control
• Controlled production process instructions
process flow chart [2.8]
• Controlled prototype PCP [2.9]
• Controlled project manual (launch
plan) [1.1]
• Master schedule

Manuf Eng

Proj Mgr
• SMR production system [SPS] 3.6.2
• Other concurrent phase 3 process Prepare training plan
outputs
Outputs:
• Controlled process instruction
documents
• Training plan document

Eng Director
• Skills matrix document
Proj Mgr

3.6.3
Incorporate plan into
master schedule

Coordinated with:
• Manufacturing facility design
Eng Director

Manuf Eng
3.6.4

Proj Mgr
3.6.5
Proj Mgr

Secure [3.2]
Create and maintain • Pre-launch PCP [3.3]
production resource skill matrix • Tool design and FMEA [3.7]
Process customer and
• Packaging specification [3.11]
person who approves
• Other concurrent phase 3
work
Process facilitator and process outputs
person who does work

91
Phase 3 Process design and development
3.7 Tool design and FMEA

Inputs: 3.10 Verification of tool functionality

Tool Eng
3.7.1

Proj Mgr
• Preliminary tooling plan [1.5]
Fully develop 3.9 Verification of tool part dimensions
• Controlled product design freeze
tooling design
[2.5]
• Controlled production
process flow chart [2.8] 3.8 Verification of tool build

Tool Eng

Proj Mgr
• Controlled prototype PCP [2.9]
• Controlled project manual (launch 3.7.2
plan) [1.1] Utilise FMEA, tooling
• Controlled Fast track standards, checklists
• Controlled CAPEX as required
• Master schedule 3.7.3 Outputs:
• Controlled and approved tooling
Tooling Eng
• SMR production system [SPS] Conclude:

Proj Mgr
• Tooling standards Preliminary specification document freeze
• Tooling record documents
• Checklists tooling plan [1.5]
• Other concurrent phase 3 process (if
outputs required)

3.7.4
Tool Eng

Proj Mgr
Reconfirm 3.7.8

Engineering Director
tool tryouts Order tooling with
deposit only.

Proj Mgr
Process customer and
Hold final
person who approves
payment until after
work 3.7.5
Process facilitator and management review 3
Tool Eng

Proj Mgr

person who does work Freeze and control

and phase 4 tool
tooling
tryouts complete
Coordinated with: specification
• Production equipment safety [3.5]
• Process instructions and training
Tool Eng

Tool Eng

3.7.6
Proj Mgr

plan [3.6] 3.7.7

Proj Mgr
• Other concurrent phase 3 process Obtain approvals Create
outputs as required tooling records

92
Phase 3 Process design and development
3.8 Verification of tool build

Inputs:
• Controlled project manual (launch

Tooling Eng

Project Mgr
3.8.1
plan) [1.1] Check construction
• Controlled database [2.12] meets specification
• Controlled tooling specification and checklists
[3.7]
• SMR production system [SPS]
• Master schedule
• Controlled CAPEX

Tooling Eng

Project Mgr
3.8.2
Make corrections
(if required)

Coordinated with:
3.8.3
• Project manual (launch plan) [1.1]

Eng Director
Project Mgr

Validate changes.
• Verification of part dimensions [3.9]
Hold final payment
• Verification of tool functionality [3.10]
until after
• Other concurrent phase 3 processes
management review
3 and tool tryouts

Process customer and

person who approves Outputs:
Tooling Eng

Project Mgr

work 3.8.4 • Supplier certification documents

Process facilitator and Document tool • Tool modification record documents
person who does work history

93
Phase 3 Process design and development
3.9 Verification of part dimensions

Inputs:
• Controlled project manual (launch

Tooling Eng

Project Mgr
3.9.1
plan) [1.1] Check part meets
• Controlled database [2.12] specification
• Controlled tooling specification and is functional
[3.7]
• SMR production system [SPS]
• Master schedule
• Controlled CAPEX

Tooling Eng

Project Mgr
3.9.2
Make corrections
(if required)

Coordinated with:
3.9.3
• Project manual (launch plan) [1.1]

Eng Director
Project Mgr

Validate changes.
• Verification of tool build [3.8]
Hold final payment
• Verification of tool functionality [3.10]
until after
• Other concurrent phase 3 processes
management review
3 and tool tryouts

Process customer and

person who approves Outputs:
Tooling Eng

Project Mgr

work 3.9.4 • Supplier certification documents

Process facilitator and Document tool • Tool modification record documents
person who does work history

94
Phase 3 Process design and development
3.10 Verification of tool functionality

Inputs: 3.10.1
• Controlled project manual (launch

Tooling Eng

Project Mgr
Check tool meets
plan) [1.1] specification and
• Controlled database [2.12] checklists.
• Controlled tooling specification Check tool is
[3.7] safe and
• SMR production system [SPS] functional
• Master schedule
• Controlled CAPEX

Tooling Eng

Project Mgr
3.10.2
Make corrections
(if required)

Coordinated with:
3.10.3
• Project manual (launch plan) [1.1]

Eng Director
Project Mgr

Validate changes.
• Verification of tool build [3.8]
Hold final payment
• Verification of part dimensions [3.9]
until after
• Other concurrent phase 3 processes
management review
3 and tool tryouts

Process customer and

person who approves Outputs:
Tooling Eng

Project Mgr

work 3.10.4 • Supplier certification documents

Process facilitator and Document tool • Tool modification record documents
person who does work history

95
Phase 3 Process design and development
3.11 Packaging specification

Coordinated with:
Inputs: • DVP&R [2.4]
• Preliminary manufacturing facility

Project Team
• PFMEA [3.1]

Project Mgr
plan [1.5] 3.11.1
Study • Production equipment safety [3.5]
• Controlled product design freeze
approved RFQ • Process instructions and training
[2.5]
concept and assumptions plan [3.6]
• Controlled production
• Other concurrent phase 3 process
process flow chart [2.8]
outputs
• Controlled prototype PCP [2.9]
• Controlled project manual (launch
plan, concept and assumptions)
Output:

Project Mgr
[1.1] 3.11.2

Manuf Eng
• Controlled Fast track Fully develop, freeze and Controlled and approved packaging
• Controlled CAPEX control packaging and specification document freeze
• Master schedule logistics specification
• SMR production system [SPS]
• Other concurrent phase 3 process
outputs 3.11.6
Order packaging and

Project Mgr
3.11.3

Manuf Eng
logistics with deposit only.

Project Mgr
Manuf Eng

Conclude sourcing,
Hold final payment until
verification and
after management review 3
implementation plan
and phase 4 training builds
and training needs
complete

Process customer and

Eng Director
Project Mgr

Project Mgr
Manuf Eng
person who approves 3.11.4 3.11.5
work Incorporate plan Obtain approvals
Process facilitator and
into master schedule as required
person who does work

96
Phase 3 Process design and development
Management review 3 and phase sign off
Management review 3

Input: MR3
SDS FORM MR3

Project manager

Proj Mgr

Director
Eng
organises team
presentation

Executive team
e Team
Executiv

Output:

Head
BU
reviews project Phases sign off status (SDS FORM MR3)
performance
Executive Team

Freeze funding.
BU Head

Failed Decision: Successful End phase 3.

Re plan project at Phase Release funds to phase 4
Phase 4
Executive direction sign off?
30 days
maximum
Executive team
e Team
Executiv

Delayed

Head
BU
issues corrective
actions
Process customer and
person who approves
Project team
e Team
Executiv
Proj Mgr

work End phase 3.

Process facilitator and closes actions Phase 4
person who does work Release funds to phase 4
within 30 days

97
Phase 3 Process design and development
3.12 Corrective actions (if required)
Inputs:

Proj Mgr
3.12.1

Director
Eng
• Controlled project
Identify risks and
manual opportunities
• Controlled Fast track
• Controlled CAPEX
• Master schedule

Proj Team

Proj Mgr
• KPIs 3.12.2
Plan actions and
contingencies

Proj Team 2.12.3

Proj Mgr
Agree
responsibilities and
closure dates

3.12.4
Proj Mgr

Director
Eng
Detail and action in
project management
meeting minutes
Output:
Zero issues at management review 3
3.12.5
Proj Mgr

Director
Eng

Maintain Fast Track

and database
Process customer and Management review 3
person who approves
work
Process facilitator and 3.12.7 MR3
Proj Mgr

Proj Mgr
Director
Eng

Director
Eng
person who does work 3.12.6 Close actions before
Monitor actions management
review 1

98
Phase 4
Product and process validation

Proj Mgr
Eng
Qual/Proj
4.1
Gauge R&R
Process customer and

Proj Mgr
Leader
Des
4.7 person who approves
DVP&R conclusion work
Main process facilitator

Proj Mgr
4.2
Eng
Qual/Proj

and person who does

Gauge certification
work
and registration

Proj Mgr
Eng
Qual/Proj
4.8
Key inputs: Production PCP
Key outputs:

Proj Mgr
• Tooling
Eng
Tooling

4.3 • Approved product and process

• Manufacturing • Production fully trained and independent
Tool tryout
facility

Qua/Pro/Pur
• Implemented production PCP

KAM
Design /
• Pre-launch 4.9 • Zero issues at management review 5
PCP and PPAP
Manuf Eng

Proj Mgr
support plans
4.4
• Launch plan
Training builds Manuf Eng

Proj Mgr
4.10
Internal run@rate
4.5
Proj Mgr
Leader
Des

Tool life deviation

(if required)

Proj Mgr
4.11
Eng
Qual/Proj

Production
system audit
n
Productio

4.6
Eng
Tooling

Production

Manuf Eng
tool approval
4.12

KAM
Customer run@rate

Concurrent processes

99
Phase 4 Product and process validation
4.1 Gauge R&R
Inputs:

Eng
Qual/Proj

Proj Mgr
• Controlled pre-launch PCP 4.1.1
[3.3] Source gauges
• Measurement systems
analysis plan [3.4]
• Controlled process
instructions and training

Eng
Qual/Proj

Proj Mgr
4.1.2
plan [3.6] Certify and calibrate
• Controlled CAPEX
• Master schedule Eng
Qual/Proj

Proj Mgr
4.1.3
Develop instructions

4.1.4
Eng
Qual/Proj

Proj Mgr
Execute R&R
studies
4.2 Gauge certification and registration

4.1.5
Eng
Qual/Proj

Proj Mgr

Generate and
analyse reports
Process customer and
person who approves
work 4.1.6 Outputs:
Process facilitator and
Eng
Qual/Proj

Proj Mgr

person who does work Make corrections • Acceptable R&R

and validate • R&R report documents
(if required)

100
Phase 4 Product and process validation
4.2 Gauge certification and registration

Inputs:

Eng
Qual/Proj

Proj Mgr
• Controlled pre-launch PCP 4.2.1
[3.3] Certify gauges
• Measurement systems
analysis plan [3.4]
• Master schedule 4.2.2

Eng
Qual/Proj

Proj Mgr
Create and control
unique
records

4.2.3
Eng
Qual/Proj

Proj Mgr
Create
calibration schedule
Eng
Qual/Proj

Proj Mgr
4.2.4
Register gauges

Outputs:
4.2.5
Eng
Qual/Proj

Proj Mgr

• Gauges released to production

Obtain approvals
• Controlled gauge record
as required
Process customer and documents
person who approves
work
Process facilitator and
person who does work

101
Phase 4 Product and process validation
4.3 Tool tryout
Inputs: 4.3.1
• Controlled project manual (launch Progress payment

Tooling Eng

Project Mgr
plan) [1.1] and implement
• Controlled DVP&R [2.4] tooling. Hold final
• Controlled database [2.12] payment until after
• Measurement systems analysis tool tryouts
plan [3.4] complete
• Controlled process instructions
and training plan [3.6]
• Master schedule
4.3.2
• Checklists
Tooling Eng

Project Mgr
Undertake
• Other concurrent phase 4 outputs
tool tryouts
according to
master schedule

Coordinated with:
• DVP&R [2.4]
4.3.3
• Training builds [4.4]
Tooling Eng

Project Mgr
Implement
• Production PCP [4.8]
improvements
• PPAP [4.9]
actions and
• Other concurrent phase 4 processes
corrections
(if required)

Process customer and 4.3.4

person who approves Outputs:
Tooling Eng

Project Mgr

Close actions and

work • Controlled and frozen master setting
Process facilitator and freeze master
settings before: documents
person who does work • Tool tryout report documents
Internal run@rate
• Completed skills matrix document (tooling)
[4.10]

102
Phase 4 Product and process validation
4.4 Training builds
4.4.1
Inputs:
• Controlled project manual (launch Progress payment

Eng Director
Project Mgr
and implement
plan) [1.1]
• Controlled DVP&R [2.4] manufacturing
• Controlled production process facility. Hold final
payment until after
flow chart [2.8]
• Controlled database [2.12] training builds
• Controlled pre-launch PCP [3.3] complete.
• Measurement systems analysis
plan [3.4]
4.4.2
• Controlled process instructions
Manuf Eng

Project Mgr
Undertake
and training plan [3.6]
training builds
• Master schedule
according to
• Checklists
master schedule
• Other concurrent phase 4 outputs

4.4.3 Concurrent with other phase 4 processes.

Coordinated with:
Manuf Eng

Project Mgr
Implement
improvements • DVP&R [2.4]
actions and • Tool tryouts [4.3]
corrections • Production PCP [4.8]
(if required) • PPAP [4.9]

Process customer and

person who approves
Manuf Eng

4.4.4
Project Mgr

Outputs:
work Close actions
Process facilitator and • Fully developed processes
person who does work before: Internal • Completed skill matrix document
run@rate [4.10] (manufacturing)

103
Phase 4 Product and process validation
4.5 Tool life deviation (if required)
Inputs:
4.5.1

Proj Mgr
• Controlled DVP&R [2.4]

Leader
Des
Determine
• Controlled CAD model and Corrections coordinated with:
deviations to
simulations [2.5] • DVP&R [2.4]
specification
• Controlled Engineering drawings • Tool tryouts [4.3]
[2.11] • Training builds [4.4]
• Controlled pre-launch PCP [3.3] 4.5.2 • Other concurrent phase 4 processes

Proj Mgr
Leader
Des
• Measuring systems analysis [3.4] Determine
• Controlled Process training and if deviations Deviations aligned with:
instructions [3.6] critical • DVP&R [2.4]
• Verification of part dimensions • CAD model and simulations [2.5]
[3.7] 4.5.3 • Engineering drawings [2.11]

Proj Mgr
• Master schedule
Leader
Des

Determine • Process instructions and training [3.6]

• Other concurrent phase 4 outputs where corrections or • Tooling specification [3.7]
tool life deviations • Gauge certification and registration [4.2]
required • Production PCP [4.8]
• PPAP [4.9]
4.5.4

Proj Mgr
Leader
Des

Determine and
prioritise corrective
actions Output:
Controlled tool life deviation documents
(if required)
4.5.5
Proj Mgr
Leader
Des

Action and close

corrective actions
Process customer and before: PPAP [4.9]
person who approves
work
Process facilitator and
4.5.6
Proj Mgr

4.5.7

Proj Mgr
Leader
Des

Leader
Des

person who does work

Obtain approvals as Record and control
required tool life deviations

104
Phase 4 Product and process validation
4.6 Production tool approval

Tooling Eng
Inputs: 4.6.1

Production
• Controlled tooling specification Obtain production
[3.7] approval before:
• Checklists as required PPAP [4.9]

Tooling Eng

Production
4.6.2 Output:
Handover Production approval documents
tooling records

Process customer and

person who approves
work
Process facilitator and
person who does work

105
Phase 4 Product and process validation
4.7 DVP&R conclusion (product validation)

Inputs:
• Controlled DVP&R [2.4] Process customer and
• Controlled engineering drawings person who approves
[2.11] work
• Controlled production PCP [4.8] 4.7.1 Process facilitator and

Proj Team

Proj Mgr
person who does work

Leader
Des
• Controlled project manual (launch Immediately analyse
plan and specifications) [1.1] results and feedback to
• Controlled CAPEX project team
• Master schedule
• Other concurrent phase 4 outputs 4.7.2

Proj Mgr
Leader
Des
Determine Coordinated with:
if design changes or • DFMEA [2.1]
deviations required • Engineering drawings [2.11]
• Measurement systems analysis [3.4]
Project Manager

PHASE 2
Eng Director

4.7.3 • Process instructions and training

Repeat and record

Director
Eng
[3.6]
Mgr
Project

For design changes

phase 2 processes as • Tool tryout [4.3]
(if required) repeat
required. Close actions • Training builds [4.4]
phase 2
before: PPAP [4.9] • Tool life deviation (if required) [4.5]
• Production PCP [4.8]
4.7.4 • PPAP [4.9]
For deviations
Des Leader

• Other concurrent phase 4 processes

(if required) liaise with

KAM
customers. Gain and
record approvals
before: PPAP [4.9]

4.7.5 Output:
Proj Mgr
Leader
Des

Conclude product Controlled and concluded DVP&R document

validation before: PPAP with validated product
[4.9]

106
Phase 4 Product and process validation
4.8 Production PCP

Inputs:
• Controlled production
process flow chart [2.8]

Quality or Project Eng

Project Manager
• Controlled pre-launch PCP [3.3]
• Controlled project manual 4.8.1
• SMR production system [SPS] Develop and control:
• Other concurrent phase 4 process Pre-launch PCP [3.3]
outputs

Quality or Project Eng

4.8.2

Project Manager
Process customer and Determine
person who approves corrective actions
work (if required) and close
Process facilitator and
person who does work before: Production system
audit [4.11]

Coordinated with:
• PFMEA [3.1]
• Process instructions and training [3.6]
Quality or Project Eng

• Tool design and FMEA [3.7]

• Gauge certification and registration [4.2] Project Manager
4.8.3 Output:
• PPAP [4.9]
Obtain approvals Controlled production PCP document
• Run@rates [4.10 and 4.12]
as required
• Production system audit [4.11]
• Other concurrent phase 4 process outputs

107
Phase 4 Product and process validation
4.9 PPAP
Inputs:

Qual/Proj/Purch
• Customer specific PPAP document

Des Leader
4.9.1
templates Coordinated with:
• Material certification Obtain
internal and supplier PPAP • DFMEA [2.1]
• Controlled DFMEA [2.1] • Engineering drawings [2.11]
• Controlled production process flow approvals
• PFMEA [3.1]
chart [2.8] • Measurement systems analysis [3.4]
• Controlled engineering drawings [2.11] • Process instructions and training
• Controlled PFMEA [3.1] [3.6]
• Verification of part dimensions [3.9] • Gauge R&R [4.1]

Qual/Proj Eng

Project Mgr
• Controlled packaging specification 4.9.2 • Tool tryout [4.3]
• Gauge R&R [4.1] Prepare • Training builds [4.4]
• Controlled tool life deviations (if external customer • Tool life deviation (if required) [4.5]
required) [4.5] PPAP documents • DVP&R conclusion [4.7]
• Controlled and concluded DVP&R [4.7] • Production PCP [4.8]
• Controlled production PCP [4.8] • Run@rates [4.10 and 4.12]
• Run@rates [4.10 and 4.12] • Other concurrent phase 4 processes
• Sample product
• Controlled Project manual
Qual/Proj Eng

Project Mgr
• Master schedule 4.9.3 Outputs:
• Other requirements nominated by Execute • Controlled internal approval documents
customer. Note: in some PPAP with • Controlled external customer approval
circumstances above inputs may not external customer documents
be required.
Qual/Proj Eng

Production
Proj Mgr
Process customer and 4.9.4 KAM 4.9.5
person who approves Obtain and control Release
work customer approvals tooling to production
Process facilitator and
person who does work

108
Phase 4 Product and process validation
4.10 Internal run@rate
Inputs:
• Controlled production process flow
chart [2.8]
4.10.1

Manuf Eng
• Controlled database [2.12]

Proj Mgr
• Controlled process instructions [3.6] Ensure readiness. Coordinated with:
• Training builds (skills matrix) [4.4] Use • PFMEA [3.1]
• Production tool approval [4.6] checklists • Measurement systems analysis [3.4]
• Controlled production PCP [4.8] • Process instructions and training
• Controlled internal PPAP approval [3.6]

Manuf Eng
4.10.2 • Production PCP [4.8]

Proj Mgr
[4.9]
• Controlled project manual (launch Undertake • PPAP [4.9]
run@rate • Production system audit [4.11]
plan) [1.1]
• Checklists • Other concurrent phase 4 processes
• Other concurrent phase 4 outputs Manuf Eng
4.10.3

Proj Mgr
Output:
Generate and analyse
Process customer and Run@rate report document
report
person who approves
work
Process facilitator and
person who does work 4.10.4
Determine
Manuf Eng

4.10.6

Manuf Eng
Proj Mgr

Proj Mgr
if process Close other corrective
changes or actions before: Customer
other corrective actions run@rate [4.12]
required
PHASE 3
Project Mgr

Repeat and record

Eng Director

4.10.5
Director
Eng
Mgr
Project

phase 3 processes as For process changes

required. Close actions (if required)
before: Customer repeat phase 3
run@rate [4.12]

109
Phase 4 Product and process validation
4.11 Production system audit
Inputs:
• Controlled production process flow

Qual/Proj Eng
chart [2.8]

Project Mgr
4.11.1
• Controlled process instructions [3.6] Audit:
• Controlled production PCP [4.8] Production PCP
• Master schedule [4.8]
• Checklists
• Other concurrent phase 4 outputs

Qual/Proj Eng

Project Mgr
4.11.2
Generate and
Qual/Proj Eng analyse report

4.11.3

Project Mgr
Determine and Coordinated with:
prioritise corrective • Run@rates [4.10 and 4.12]
actions • Other concurrent phase 4 processes
(if required)

Process customer and

Qual/Proj Eng

person who approves

Project Mgr

4.11.4 Output:
work Close actions
Process facilitator and Audit report document
person who does work before: Customer
run@rate [4.12]

110
Phase 4 Product and process validation
4.12 Customer run@rate
Inputs:
• Customer
• Controlled production process flow
4.12.1

Manuf Eng
chart [2.8]

Proj Mgr
• Controlled database [2.12] Ensure readiness.
• Controlled process instructions [3.6] Use
• Training builds (skills matrix) [4.4] checklists
• Production tool approval [4.6]
• Controlled production PCP [4.8] Coordinated with:

Manuf Eng
4.12.2

Proj Mgr
• Controlled Internal PPAP approval • PPAP [4.9]
Undertake
[4.9] • Other concurrent phase 4 processes
• Product system audit [4.11] run@rate
• Controlled project manual (launch
plan) [1.1] Manuf Eng
• Checklists

Proj Mgr
4.12.3 Output:
• Other concurrent phase 4 outputs
Generate report Controlled customer approval document

4.12.4
Manuf Eng

Submit report to

Production
4.12.6

Proj Eng
KAM
customer according to Release manufacturing
customer specific facility to production
requirements

Process customer and

Manuf Eng

person who approves 4.12.5

KAM

work Obtain approvals

Process facilitator and before SoP
person who does work

111
Phase 4 Product and process validation
Management review 4 and phase sign off
Management review 4

Input: MR4
SDS FORM MR4

Project manager

Proj Mgr

Director
Eng
organises team
presentation

Executive team
e Team
Executiv

Output:

Head
BU
reviews project Phases sign off status (SDS FORM MR4)
performance
Executive Team

Freeze funding.
BU Head

Failed Decision: Successful

Re plan project at End phase 4 SoP
Phase
Executive direction (Phase 5)
sign off?
30 days
maximum
Executive team
e Team
Executiv

Delayed

Head
BU
issues corrective
actions
Process customer and
person who approves
work Project team
e Team
Executiv
Proj Mgr

Process facilitator and

closes actions End phase 4 SoP
person who does work
within 30 days (Phase 5)

112
Phase 4 Product and process validation
4.13 Corrective actions (if required)
Inputs:

Proj Mgr
4.13.1

Director
Eng
• Controlled project
Identify risks and
manual opportunities
• Controlled Fast track
• Controlled CAPEX
• Master schedule

Proj Team

Proj Mgr
• KPIs 4.13.2
Plan actions and
contingencies

Proj Team 4.13.3

Proj Mgr
Agree
responsibilities and
closure dates

4.13.4
Proj Mgr

Director
Eng
Detail and action in
project management
meeting minutes
Output:
Zero issues at Management review 4
4.13.5
Proj Mgr

Director
Eng

Maintain Fast Track

and database
Process customer and Management review 4
person who approves
work
Process facilitator and 4.13.7 MR4
Proj Mgr

Proj Mgr
Director
Eng

Director
Eng
person who does work 4.13.6 Close actions before
Monitor actions management
review 1

113
Phase 5
Feedback, assessment and corrective action

Proj Team 5.1

Proj Mgr
Capability, lessons learned
and improvement
opportunities
Key input:
Output:
Production
Final report (SDS FORM MR5)
monitoring
for 90 days
Proj Team

Proj Mgr
5.2
Transfer responsibility
to production

END SDS
Concurrent processes

Head Production
Mark/Purch/Eng
Process customer and
person who approves
5.3
work
Process facilitator and Production support
person who does work

114
Phase 5 Feedback, assessment and corrective action
5.1 Capability, lessons learned and improvement
opportunities

Proj Team
Input:

Proj Mgr
5.1.1
SDS FORM MR5 Capture
lessons learned

5.1.2
Identify
Proj Team

Proj Mgr
post SDS
improvement
opportunities
Manuf Eng

5.1.3

Proj Mgr
Output:
Confirm long term Final report (SDS FORM MR5)
capability

Process customer and

Executive Team

person who approves 5.1.5

Team
Executive

BU Head
5.1.4
Proj Mgr

work Disseminate lessons

Process facilitator and Create learned and
person who does work final report improvement
opportunities

115
Phase 5 Feedback, assessment and corrective action
5.2 Transfer responsibility to production
Inputs:
• Production process
flow chart [2.8] 5.2.1
END SDS

Production

Production
Head
• Database [2.12] Assume
• Process instructions and normal production
training [3.6] responsibilities
• Gauge certification and
registration [4.2]
• Tool life deviations (if required)
[4.5] Output:
• Production tool approval [4.6] Project sign off document (SDS FORM MR5)
Project Team 5.2.2

Production
Head
• Production PCP [4.8]
Monitor and refine
• PPAP [4.9]
processes
• SMR production system (SPS)
for 90 days
Eng Director

5.2.3 5.2.6
Production
Head

Team
Executive

BU Head
Agree End SDS.
residual risk and Disband project
capability team

Process customer and

5.2.5
Project Team

person who approves 5.2.4

Team
Executive
Manager
Project
Manager
Project

work Organise
Process facilitator and Archive
management
person who does work project
review.
documentation
Submit final report

116
Phase 5 Feedback, assessment and corrective action
5.3 Production support
Inputs:
• Controlled production process
flow chart [2.8]
• Controlled database [2.12] 5.3.1

SKAM
KAM
• Controlled process training and Commence
instructions [3.6] charging customer for customer
• Gauge certification and requested modifications
registration [4.2]
• Production tool approval [4.6]
• Controlled production PCP [4.8]
• Controlled PPAP [4.9]
• Final report [5.1]
• SMR production system (SPS)

Head Production
Production 5.3.2
Implement
improvement opportunities
identified in final report
Marketing/Prod/Eng

Head Production
5.3.3 Outputs:
Process customer and Provide • Continual improvement
person who approves ongoing customer and • PCO report documents
work production support and continue • Controlled engineering change
Process facilitator and
person who does work to protect customer property. documents
• Controlled PPAP documents

117
Agenda

Introduction
SDS Project management fundamentals
SDS processes
Key performance indicators
Flow charts
SDS support processes
Definitions and acronyms

118
Design support processes
SDS is supported by a number of processes

Manufacturing

Modifications

Purchasing
Controlling

Suppliers

Tooling
Quality
Supporting processes

119
Project controlling
Project controlling assures the project is completed
within the approved budget
Controlling process
Phase 0
0 0 0 0 0  Determines total project cost
. . . . .
1 2 3 4 5  Manages cost
 Estimates resource cost
Phase 1  Develops financial baseline
1 1 1 1 1 1
. . . . . .  Monitors against baseline and controls cost
1 2 3 4 5 6

Phase 2

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

Phase 3

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12

Phase 4
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13

Phase 5
5 5 5
. . . Essential input
1 2 3
Involvement

120
Manufacturing
Manufacturing is integral to SDS
Manufacturing process
Phase 0  Fundamental to all phases
0 0 0 0 0
. . . . .  Key product design input
1 2 3 4 5
 Integrated into production

Phase 1
 Development
1 1 1 1 1 1
. . . . . .
 Planning
1 2 3 4 5 6  Training

Phase 2

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

Phase 3

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12

Phase 4
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13

Phase 5
5 5 5
. . . Essential input
1 2 3
Involvement

121
Change management
Assures project scope and document changes are
managed and recorded
Change management process
 Defines and controls what is and what is not
Phase 0 included in project
0 0 0 0 0
. . . . .  Structures changes and makes them visible
1 2 3 4 5
 Gives formal authorisation and record

Phase 1
 Control level and mechanism must be
1 1 1 1 1 1 appropriate to document under control
. . . . . .
1 2 3 4 5 6

Phase 2

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

Phase 3

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12

Phase 4
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13

Phase 5
5 5 5
. . . Fully controlled according to appropriate control
1 2 3
Controlled within team

122
Purchasing / Supplier integration
Purchasing and supplier integration ensures suppliers
contribute and are involved in SDS
Supplier integration process

Phase 0
 Supplier performance is essential to SMR
0 0 0 0 0 profitability and reputation
. . . . .
1 2 3 4 5
 Supplier contribute essential design input
S
 Supplier development and relationship building is
Phase 1 required for long term viability
1 1 1 1 1 1
. . . . . .
1 2 3 4 5 6
S S S S S S

Phase 2

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13
S S S S S S S S S S S S

Phase 3

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12
S S S S S S S S S S S S

Phase 4
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13
S S S S S S S S S

Phase 5
5 5 5 Essential input
. . .
1 2 3 Purchasing involvement
S S
SDirect supplier input
123
Quality (or Project Engineer)
Quality assures customer expectations are met
Quality process
Phase 0 • Planning and actions to satisfy customers
0 0 0 0 0
. . . . . • Determine quality policies and objectives
1 2 3 4 5 • Assure compliance to specifications, regulations
and PPAP
Phase 1 • Ensure product is saleable
1 1 1 1 1 1
. . . . . . • Ensure measuring capability
1 2 3 4 5 6
• Highlight lessons learned
Phase 2

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

Phase 3

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12

Phase 4
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13

Phase 5
5 5 5
. . . Essential input
1 2 3
Involvement

124
Tooling
Tooling is integral to SDS
Tooling process
Phase 0 Planning, design, specification and implementation
0 0 0 0 0
. . . . . of tooling including:
1 2 3 4 5 injection moulding tooling

assembly tooling

packaging tooling
Phase 1
1 1 1 1 1 1 supplied component tooling
. . . . . .
1 2 3 4 5 6

Phase 2

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

Phase 3

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12

Phase 4
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13

Phase 5 Essential input

5 5 5
. . . tooling involvement
1 2 3

125
Agenda

Introduction
SDS Project management fundamentals
SDS processes
Key performance indicators
Flow charts
SDS support processes
Definitions and acronyms

126
Definitions

Approvals are written acceptance by customers that they are satisfied to receive process outputs. Approvals may be granted by internal and
external customers.

Assumptions are key decisions that significantly affect project outcomes.

CAPEX is the project capital expenditure budget.

Characteristics are attributes having major impact on product performance and variation. They are directly related to customer satisfaction and
SMR profitability.

Checklists contain lessons learned, best practice, regulatory and specification checks.

Control is a change management process assuring changes are managed and documented. Control level must be appropriate to document under
control.

Controlled means documents are fully controlled according to control applied. Control level must be appropriate to document under control.

Customers are the receivers and approvers of process outputs. Customers

Customer requirements include all things expected by the customer throughout the program life.

Design freeze is the optimal and final design after which changes are not allowed. Design freeze is a critical project milestone and changes after
tooling is made have severe consequences. Changes after design freeze (if required) are corrective actions and shall come under change
management control.

Design review is a structured review to a set agenda before design freeze. Design reviews are mandatory and are undertaken by the project team
(internal) and external experts as required.

Design validation is concluded before product design freeze to ensure a design is optimal, functional and capable.

Fast Track is product cost tracking. It records actual product cost against quoted and shows deviations, risks and opportunities.

FEP is a financial evaluation package and determines profitability for the program life. It compares revenue against expenditure based on quoted
costs and volumes.

127
Definitions
– continuation –

Launch plan details the production ramp up strategy with training builds supporting customer committed timing.

Manufacturing facility includes all equipment identified on the process flow chart excluding tooling. For example an injection moulding tool is the
responsibility of the Tooling Engineer but the Manufacturing Engineer is responsible for robots and conveyors for removing parts from the injection
moulding tool.

Master schedule is the project master timing chart controlled by the Project Manager.

Order with deposit means purchasing major capital expenditure according to a frozen specification and an approved supplier quote by spending
the minimum amount to enable manufacture and delivery. Full payment is withheld until the purchase is fully functional and approved. Payment may
be progressed according to the stage of development and approval.
Production support services are those functions required to support expected production including, maintenance, calibration, and technical
support.
Production support (for 90 days) means the project team are available to production as required. Production are responsible for supporting
external customers but It is expected the project team liaise and or visit production daily and continue to refine processes.
Product validation is undertaken on final product to demonstrate compliance with specifications.
Project management meeting minutes and status report are updated weekly by the project manager for assigning and tracking daily project
activities. Activities are broken down to component level under SDS core process categories and have an assigned responsibility and close out
date. The weekly project meeting is the forum for planning minutes.
Prototype PCP includes intended production requirements and may include temporary processes r validating prototypes.

Residual risk and capability is the long term and agreed risk and capability accepted by customers.

Run@rate is a simulated production run to test production fitness.

Specification freeze is the optimal and final design after which changes are not allowed. Specification freeze is a major contract milestone and
definition and changes made after are corrective actions and shall come under change management control

Tooling FMEA is only undertaken for unique design. If tooling is well understood and from a generic design then a checklist of best practice and
lessons learned can serve as a generic tooling FMEA.

Tool life deviations are non critical and not feasible to correct. Subject to approvals they may be concessed for tooling life.

128
Acronyms

Cpk Capability Index ERP Enterprise Resource Planning (information system)

Ppk Performance Index ES Engineering Specification
AD Actual Data / Math Surface within +/- 0.5mm ESOW Engineering Statement of Work
AIAG Automotive Industry Action Group FD Final Data / Math Surface OK for Tool Construction
APQP Advanced Product Quality Planning and Control Plan FEA Finite Element Analysis
BoM Bill Of Materials FEP Financial Evaluation Package
BU Business Unit FMEA Potential Failure Mode and Effects Analysis
C&PS Customer and Production Support GA General Assemblies
CA(R) Corrective Action (Report) SKAM Global Key Account Manager
CAD Computer Aided Design HIC High Impact (incl. Special) Characteristics
CAE Computer Aided Engineering IMDS International Material Data System
CAPEX Capital Expenditure Authorisation IRR Internal Rate of Return
CA(R) Corrective Action (Report) ISIR Initial Sample Inspection Report
CC Critical Characteristics JIS Job Instruction Sheet
CFT Cross Functional Team JIT Just In Time
CIP Continual Improvement Process KAM Key Account Manager
CRT Component Review Team KPI Key Performance Indicator
DFMA Design for Manufacturability and Assembly MPS Master Production Schedule
DFMEA Design Failure Mode and Effects Analysis MR Management Review
DFSS Design For Six Sigma MSA Measurement Systems Analysis
DoE Design of Experiments NPI New Product Introduction
DVP Design Verification Plan NPV Net Present Value
DVP&R Design Verification Plan and Report OEE Office of Energy Efficiency
DWI Departmental Work Instruction OEE Availability x Performance x Quality

129
Acronyms
– continuation –

OEM Original Equipment Manufacturer SC Significant Characteristics

OHS Occupational Health and Safety SDS SMR Development System
PER Project Expenditure Request SLA Stereolythography (3D Layering)
PCCR Pre Check Customer Request SoP Start of production
PCN Product (or Process) Change Notice SOR Statement of Requirements
PCO Project Cost Objectives SOW Statement of Work
PCP Prototype / Pre-Launch / Production Control Plan SPC Statistical Process Control
PDM Product Data Management SPC Special Product Characteristics
PFMEA Process Failure Mode and Effects Analysis SPR Significant Production Run
PLM Product Lifecycle Management STA Supplier Technical Assistance
PM Project Manager / Project Management SVP Start of Volume Production
PMI Project Management Institute SMR SMR Vision Systems
PMT Project Management Team SWI Standard Work Instruction
PPAP Production Part Approval Process TA Target Agreement
PPM (Reject) Parts Per Million TAKT Total available cycle time
PSW Part Submission Warrant TGR/TGW Things Gone Right/Things Gone Wrong
PV Product Validation / Verification TPM Total Productive Maintenance
QCN Quoted Change Notification VA/VE Value Analysis/Value Engineering
QFD Quality Function Deployment VMI Vendor Managed Inventory
R&D Research and Development WIP Work In Progress
R&R (Gauge) Repeatability and Reproducibility
RFQ Request For Quotation
ROAM Return on Assets Managed

130
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131