APQP CHT-COP2-020-02

DISTRIBUTION OF THIS DOCUMENT TO PERSONS OTHER THAN COMPANY EMPLOYEES MUST BE AUTHORIZED BY THE GENERAL MANAGERDoc. No./Index CHT-COP2-020-02Process Responsible Project ManagerProcess Responsibilities and Interfaces Sales DepartmentEngineering Department, Production department, Quality department, Logistic departmentProcess - Input Customer NominationProject InformationScope Applied to new or changed product series whichrequires new processProcess - Output PPAP & qualified product & relative filesAim, Purpose and Characteristics (Kennzahlen) Let the project run smoothly according to customer requiremntField of Application Coroplast Harness Technology (Taicang) Co., Ltd.Terminology Protoype: Manually made sampleOTS: Off tooling sampleAP&PQP: Advanced product&process qualityplanningFMEA: Failure mode and effect analysisMSA : Measuring system analysisCMK: Machine capablity indicator Documents usedForms Feasibility study (CHT-COP2-020-F1)Project team appointment (CHT-COP2-020-F2)Project informationProject task (CHT-COP2-020-F4)Investment evaluation (CHT-COP2-020-F17)Project time schedule (CHT-COP2-020-F5)PFMEA (CHT-COP2-020-F6)Control plan (CHT-COP2-020-F8)Product Characteristic list (CHT-COP2-020-F9)Process Characteristic list (CHT-COP2-020-F10)Work instruction of preassembly (CHT-COP2-020-F13)Work instruction of assembly (CHT-COP2-020-F14)Inspection instruction sheet (CHT-COP2-020-F15)AP&PQP check list (CHT-COP2-020-F16)Cross-references ISO/TS16949 -2009DISTRIBUTION OF THIS DOCUMENT TO PERSONS OTHER THAN COMPANY EMPLOYEES MUST BE AUTHORIZED BY THE GENERAL MANAGER Attachments NOReleaseof the process by responsible Quality GM QualityDocument revisionIndex / Date of Creation / Date of Revision Reason 2011-06-08 UpatedDISTRIBUTION OF THIS DOCUMENT TO PERSONS OTHER THAN COMPANY EMPLOYEES MUST BE AUTHORIZED BY THE GENERAL MANAGERDISTRIBUTION OF THIS DOCUMENT TO PERSONS OTHER THAN COMPANY EMPLOYEES MUST BE AUTHORIZED BY THE GENERAL MANAGERDISTRIBUTION OF THIS DOCUMENT TO PERSONS OTHER THAN COMPANY EMPLOYEES MUST BE AUTHORIZED BY THE GENERAL MANAGERDISTRIBUTION OF THIS DOCUMENT TO PERSONS OTHER THAN COMPANY EMPLOYEES MUST BE AUTHORIZED BY THE GENERAL MANAGER1. Explanation for process1.1.1 Project authorizationAfter getting the agreement of quotation or nomination letter from customer and GeneralManager approved the project, the project can be launched.1.1.2 Project team definitionAfter General Manager approved the new project, General Manager appoints the ProjectLeader. The project leader comes from Project Engineer who is capable. Project Leadercan suggest the project team members and prepare “Project Team Members’Appointment (CHT-COP2-020-F2)”, and approved by General Manager.The project teamshould be involved Engineering, Quality, Purchasing, Sales, Production and Logisticpeople.1.1.3 Project target definitionProject Leader is responsible for preparing original “project task”(CHT-COP2-020-F4),and pass to review and approved by Gerneal Manager. Project task is including Quality,Buget, Cost, Production capacity, time schedule and so on.1.1.4 Project ScheduleProject Leader shall prepare “Project Schedule(CHT-COP2-020-F5) ”. It can be involvedthese phases from AP&PQP Manual according to customer requiremnt. It includesschedule, machine planning, personal planning, etc. See CHT-COP2-020-F5.1.1.5 Project Management ReviewProject team shall regularly (at least every two weeks) hold meeting to review project status and ask support from management. Review content should include following items:If phase target realized? what is the actual status?If all items have been determined with responsibility, action and timing plan?2.2 Porduct&Process Design and Development2.2.1 Drawing reviewMost of drawings come from customer and the headquarters, sometimes it will be madeby CHT according to customer’s sample a s well as specification, in this case, thedrawing has to be approved by customer.Project team shall review following itemsCustomer requirementDrawing status (from customer or headquarters)Special Product CharacteristicsProduct Specification from customerSimiliar product experienceAfter reviewing, project team define preliminary product characteristic chart.DISTRIBUTION OF THIS DOCUMENT TO PERSONS OTHER THAN COMPANY EMPLOYEES MUST BE AUTHORIZED BY THE GENERAL MANAGER2.2.2 Drawing analysis and process evaluation2.2.2.1Project team call meeting according to:Product Drawing AnalysisSpecification from customerProduct CharacteristicDesign information from customerThe previous experienceSimilar product experienceto discuss and prepare the preliminary：Flow ChartWorking InstructionInspection Working InstructionPFMEA(If required)Control Plan(If required)2.2.3. Investment evaluationAfter drawing and process analysis, process engineer provides the spec of process.Equipment engineer needs to prepare the investment plan and leads the equipmentspurchasing & verification, all the equipments for this project to be indicated, andindicates which equipments will be ordered, then submit to GM for approval. The detail,please refert to “CHT-COP2-020-F17”.2.2.4. Equipments and toolings releaseEquipment engineer leads to check and accept new equipments & toolings & fixture related to equipment. Process engineer leads to check and accept independenttoolings & fixture. Engineering (if needed) and quality teams will attend and givesupport.2.2.5. Prototyping MakingIn order to verify harness design or process design or required by Customer, CHTmakes some prototypes that can be made by manual tools, or through some existedprodution facilities. The related documents maybe not complete.Process Engineer hasto instruct sample maker how to manufacture samples and follow sample makingprocess. The detail, please refer to “CHT-EN-WI-001 Sample Making Process”After prototype is confirmed by Customer or project team, project team has to updatedrawings, BOM, as well as relevant production process and work instruction.DISTRIBUTION OF THIS DOCUMENT TO PERSONS OTHER THAN COMPANY EMPLOYEES MUST BE AUTHORIZED BY THE GENERAL MANAGER2.2.6 Sample marking (OTS,BMG)Sample marking refer to “sample process CHT-EN-WI-001”.2.2.7. Process FMEAAccording to customer requirement and the similiar product experience, the project team should define the product characteristic (CHT-COP2-020-F9) and processcharacteristic(CHT-COP2-020-F10).These characteristics shold be considered in theFlow Chart (CHT-COP2-020-F7), Process FMEA (CHT-COP2-020-F6) and Control Plan(CHT-COP2-020-F8) and meet each other by project team. The Characterstic classdefinition, please refer to CHT-EN-WI-002.For corrective action in P-FMEA, first of all we should focus on high security (S>7) andthose several items of high RPN (>100).2.2.8. Packaging SpecificationIf customer has provied some related documents or requirement of packing, project team should follow itIf not, project team should prepare the packing conception and send it to cusomter to approve2.2.9. Logistic planLogistic plan comprises internal logistic plan such as:Warehouse conceptProduction logistic and alsoTransport logistic planCustomer stockingFIFO2.3 Process Setup and Implementation2.3.1 LayoutProcess engineer is reponsible for the layout.2.3.2 MSAQuality engineer should check and verify the GR&R studying and gauge verification.2.3.3 Product checking and testingDISTRIBUTION OF THIS DOCUMENT TO PERSONS OTHER THAN COMPANY EMPLOYEES MUST BE AUTHORIZED BY THE GENERAL MANAGER Dimension checking and performance testing according to Pre-launch Control Plan,Product validation requirement and drawing.。