APQP Checklist (Process Design and Development)

• Project Name

• Company

• Location
  Address

• Project Manager

• Conducted on

  Date

Process Design and Development

• Have Process FMEA’s been updated from Design phase activities?

  Yes

  No

• Have Key Process Characteristics been finalized?

  Yes

  No

• Are Actions followed up and are Process FMEAs updated to reflect actions taken?

  Yes

  No

• Have Mistake Proofing requirements been updated for high-risk operations?

  Yes

  No

• Are Supplier Product Development Plans and supporting documentation available and reviewed?

  Yes

  No

• Are Special Characteristic Matrixes utilized?

  Yes

  No

• Do matrixes identify Special Characteristic to Manufacturing Process operation relationships?

  Yes

  No

• Are Pre-Launch Control Plans utilized and included specific additional actions/reactions, linkage to key Design and Process FMEAs and Process Flow charts, statistical evaluation of the process, reaction plans if problems are encountered in builds and Quality Assurance vs. Quality Control Methodology?

  Yes

  No

• Are Product Level Predictive Indicators established and includes First Time Capability (FTC) vs Product Quality Assessments and FTC vs Warranty?

  Yes

  No

• Have Tooling, Equipment, Gage, Fixture, and Test Equipment requirements been finalized and included comparison to key process characteristics and comparison to Control Plan to identify any new requirements?

  Yes

  No

• Have Process Capability Estimates been finalized for each process characteristic?

  Yes

  No

• Are reaction plan developed for each characteristic that does not meet capability targets?

  Yes

  No

• Are Component Packaging and Shipping Design and Test Plans available and include packaging and shipping instruction, Shipping and Part identification label, Lab and Shipping Test requirements for expendable packaging and/or returnable containers, returnable container management program.

  Yes

  No

• Have Operator Process Instructions been finalized and do they reflect FMEAs, Control Plan(s), Engineering requirements, Process Flow Chart, Floor Plan Layout, Characteristic Matrix, etc.?

  Yes

  No

• Is Operator Training performed and are training plans available?

  Yes

  No

• Are Pilot Builds conducted and include components from Hard Tooled processes and reviews that components meet design intent for Process Capability?

  Yes

  No

• Is System and/or Component Production Validation Testing conducted and includes test results that include descriptive statistics, capability statistics and dentification of any test Failures on Design and Process FMEAs?

  Yes

  No

• Are Supplier Process Sign-offs performed and include a procedure for Process Sign-offs offs and a systematic and sequential review of the manufacturing process at quoted peak daily line rate, including manpower, facilities, equipment, material, methods, procedures, etc.?

  Yes

  No

• Are Potential Process Failure Modes identified with the use of Process FMEAs at the product level, system, and component level designs?

  Yes

  No

• Are high-risk failure modes identified by station and are lists available?

  Yes

  No

• Are Measurement Systems Analysis plans developed and do they include the responsibility for gage linearity, accuracy, repeatability, reproducibility, correlation for duplicate gages and measuring devices on manufacturing calibration systems?

  Yes

  No

Completion

• Additional Recommendations

• Name & Signature of Project Manager

  Sign
APQP Personnel

• Name & Signature

  Sign

• Designation & Department