ALLISON TRANSMISSION, INC.
APQP Kick-off Checklist
The purpose of this meeting is to develop a common understanding concerning the total requirements of the part/material by ensuring proper communication and buy-in occurs between our companies. This form encompasses questions from the AIAG Advanced Product Quality Planning and Allison Transmission, Inc. (ATI) Supplier Quality Manual AT-1927. Its intent is to ensure advanced product quality planning activities occur at the appropriate time and establish customer requirements for part qualification, part availability, quality, packaging, scheduling, terms & conditions, unit cost information, and tooling information.
This document should be completed and provided to the Commodity Manager & SQE prior to the meeting date.
DATE: / PROJECT/PROGRAM:COMM. MGR.: / SUPPLIER NAME:
/ MANUFACTURING LOCATION:
ASQE
/ DUNS #:PROD. ENGR.:
/ SUPPLIER CONTACTS:- ACCT MGR:
- QUALITY REP:PART NO: / PART DESCRIPTION:
CHANGE LEVEL:
SECTION 1. CUSTOMER REQUIREMENTS
1. Does the supplier understand all the applications and intended end uses of the parts/materials for all customers?
Yes / No / If Yes, Explain:2. Does the supplier have the latest information about program timing (example: Drawing release, Prototype – series, Matching, LRIPs, SOP)?
Yes / No / Explain:Review Program Milestones with supplier.
Key Project Milestones / Dates / Key Project Milestones / Dates3. Does the supplier have and understand the latest TS16949 Manual & AIAG Manuals (FMEA, SPC, Measurement Systems Analysis, PPAP and the Advanced Product Quality Planning (APQP) and Control Plan Manual)?
Yes / No / Explain:4. Has the supplier provided all information listed in the Required Quality Information letter AT-1927-4 as outlined in the RFQ package?
Yes / No / Explain:5. Does the supplier have and understand all the requirements listed in the Supplier Quality Manual AT-1927?
Yes / No / Explain:6. Does Supplier understand and agree to AT-1700 ATI Packaging & Identifications Requirements?
Yes / No / Explain:7. Has the AT-1703 Container Assumption Form been provided and returned to the Commodity Manager?
Yes / No / Explain:8. Are returnable containers required?
Yes / No / Explain:9. Are there any packaging issues to be resolved?
Yes / No / Explain:10. Does supplier have electronic communications capability and required systems testing complete
for scheduling and shipping?
Yes / No / Explain:SECTION 2. Product Design / Development
11. Does the supplier have and understand ALL of the latest drawings and specifications (TES, TIS, etc.) ?
Yes / No / Explain plans to obtain:12. Has an Advanced Development Validation (ADV) plan been provided, if specified in the requirements?
Yes / No / Specify planned date:13. If communication link for math data exchange is needed have appropriate contacts been taken?
Yes / No / Explain:14. If ATI is design responsible, has a Design-FMEA review been completed between supplier and the ATI Engineer?
Yes / No / Specify planned date:15. If Supplier is design responsible, has a Design-FMEA been completed? Are actions in place to reduce high RPNs? Has a review with the ATI engineer been completed?
Yes / No / Specify planned dates:16. If supplier is responsible for system, has a system FMEA been completed and been reviewed?
Yes / No / Specify planned dates:17. Have special characteristics (reference Supplier Quality Manual AT-1927) been identified and included in drawings and specifications? Is the supplier aware of the special characteristics? Is the supplier’s intended process able to meet the capability requirements of the special characteristics?
Yes / No / Explain:18. Are controls for special characteristics clearly identified?
Yes / No / Explain:19. Does the supplier understand the critical nature of dimensions that interface with the customer’s application of their mating parts?
Yes / No / List all known interfaces:If no explain the process to control special characteristics
20. Are there any Pre-Prototype/Prototype requirements?
Yes / No / List them in the space below:MRD Type & Date / Quantity / Supplier Promised Date / Comments
21. Does the supplier understand the requirements of GP-11 procedure?
Yes / No / Explain:22. Will the appropriate control plan be developed for use during each build phase?
Yes / No / Explain:23. Per the Supplier Quality Manual AT-1927, what amount of design and or test is required by supplier?
SECTION 3. PROCESS DESIGN/DEVELOPMENT
Key activities from the Supplier Quality Manual and Timing Chart (Ref. AT-1927 & AT-1927-2).
24. Does the supplier understand ALL items listed on the APQP Project Plan?
Yes / No / Explain:25. Has the supplier provided a APQP Timing Chart for these parts?
Yes / No / Explain:26. ATI APQP requires periodic reviews. Specify your planned reporting frequency: _
27. Have the following preliminary documents been completed?
Process Flow Chart If No:
Yes / No / Specify completion date:Process FMEA
Yes / No / Specify completion dateControl Plan
Yes / No / Specify completion dateIf Yes, upon completion of this checklist, review in detail these documents.
28. Has error proofing been considered during PFMEA creation and included in quoted price?
Yes / No If No, explain plans to achieve quality requirements29. Is any new equipment, tooling, gages, special fixtures or test equipment needed to produce this part?
Yes / No / Comment30. Allison Transmission minimum required acceptance criteria for the PPAP initial study for special characteristics is established in the Supplier Quality Manual AT-1927.
Are any print, material specifications or process control plan changes needed to meet these requirements?
31. Has the supplier confirmed their responsibility for management of all tiered suppliers & verified they will conduct AQPQ, PPAP and R@R of these sub-tiers?
SECTION 4.0 PPAP (Production Part Approval Process)
32. Lead-time for tooling: ______starting when (provide specific date or event): ______
33. After tool completion, first parts off tools, lead-time for PPAP submission: ______
34. Is additional lead time required after PPAP approval to meet the contracted LCR/MCR?
Yes / No / Explain:35. Does the supplier understand the requirements for Full PPAP?
Yes / No / Explain:36. Does the supplier know where to obtain the required forms for PPAP?
Yes / No / Explain:37. Define the number of samples to be submitted along with PPAP documentation.
Total # of Samples: ______
Samples per Cavity: ______
Total # of Cavities: ______
38. Is a production trial run required?
Yes / No / Explain:39. Will validation parts (if applicable) be produced from 100% production tools?
Yes / No / Explain:40. GP-12 Early Production Containment – In effect from PPAP approval through the period specified in GP-12.
Does the supplier understand the GP-12 requirements in the Supplier Quality Manual AT-1927?
Yes / No / Explain:Run @ Rate & Capacity Related
41. Fill in the following capacity information:
A. What is the daily contracted capacity? ______
B. Daily Max Capacity Rate (MCR) ______
C. Number of tool sets required for LCR ______
D. Number of machines/lines/cells required for LCR ______
E. Capacity per tool set ______
F. Net capacity per day ______
G. Number of work hours per day ______
H. Number of shifts per day ______
I. Number of days per week ______
J. Maximum sustainable tooling capacity ______
1) Hours per day ______
2) Days per week ______
42. Will LCR be met in 5 days, in 20hr/day
Yes / No / Explain:43. Run @ Rate (Reference Supplier Quality Manual AT-1927) – Normally 8 Weeks Prior to SOP
Does the supplier understand the requirements for Run @ Rate?
Yes / No / Explain:44. Does the supplier understand the procedures that apply when problems occur at a ATI plant?
(Fast Response, Corrective Actions as described in Supplier Quality Manual, Controlled Shipping level 1 & 2, New Business
Hold)
Yes / No / Explain:SECTION 5.0 – SUPPLIER QUALITY PERFORMANCE
45. What is supplier’s PPM rating to ATI & overall? ______
46. Does supplier have any parts currently in controlled shipping environment?
Yes / No / Explain:47. Does supplier have any open quality notifications?
Yes / No / Explain:SECTION 6.0 COMMERCIAL INFORMATION
48. Did supplier provide cost breakdown data sheet using form AT-1804?
Yes / No49. Are there any exceptions to the Supplier Quality Manual requirements?
Yes / No / Explain:50. Is tooling cost finalized?
Yes / No / Explain:51. Did supplier provide cost breakdown data sheet using form AT-1810?
Yes / No52. Does ATI own tooling?
Yes / No53. TIER II SUPPLIERS – Note the following information:
Supplier Name / Duns # / LocationSECTION 7 - OTHER ISSUES
54. Does the supplier understand they must complete a “Declaration of Conformance / Restricted and Reportable Substances for Parts” form (GMW 3059) prior to completion of PPAP?
Yes / No / Explain:Date:
ATI Attendees: / Supplier Attendees:
Advanced Supplier Quality Engineer (ASQE) / Quality Manager
Product Engineer / Program Manager
Commodity Manager / Manufacturing Engineer
Other
/ Quality Engineer1
18-Dec-2015