Restoring APQP Discipline at a Tier-1 Supplier

INDUSTRY: Automotive Manufacturing

SERVICES: Process Alignment and Management Support.

Situation.

A large electric vehicle OEM contacted Seraph regarding a Tier One supplier. The supplier was not properly following APQP (Advanced Product Quality Planning) best practices and was inconsistent in documentation on shipments. This raised concern on whether they were following other standard quality protocols. The OEM was also concerned about an over-burdened project management team, resulting in poor communication and confusion.

Actions.

• The goal was to present a more efficient way for the supplier to resolve PPAP issues (Production Part Approval Process), lead their teams more effectively, and manage projects.
• There were 22 parts to undergo annual validation of PPAPs, 13 from the USA and 9 from China.
• The Seraph team analyzed CMM data(Coordinate Measuring Machine), Control Plans, FMEAs (Failure Modes & Effects Analysis), and PSWs (Part Submission Warrant) and physically audited the OEM parts.

Results.

• The Seraph team created new program management concepts, including suggestions for immediate and strategic wins.
• We created current and future state mapping to solve the top issues.
• In spite of resistance from the local team, Seraph successfully reviewed 13 of the OEM’s parts for CMM, Control Plan, and FMEA.
• We provided a list of open issues as part of the handover process.
• If all open issues are addressed, the supplier would achieve:
  • Improved customer communications.
  • A more robust NPI (New Product Information) process.
  • Improved Serial Project Teams, established to provide clarity on roles and responsibility.
  • Improve ECR (Engineering Change Request) processes.
  • More efficient RFI (Request for Information) processes.