apqpppap（apqpppap 命令行）

APQP/PPAP - Advanced Product Quality Planning & Production Part Approval

When to Activate This Skill

• "What APQP phase are we in?"
• "Create a phase gate checklist"
• "What PPAP elements are required?"
• "Generate a PSW for [part]"
• "Create a timing plan for [program]"
• "Track open issues for [launch]"
• "What's needed for PPAP Level [X]?"
• "Run readiness review"

Workflow Routing

APQP Five Phases

Phase 1: Plan and Define Program

Purpose: Determine customer needs and expectations

Key Deliverables:

Gate 1 Criteria:

• Customer requirements documented and reviewed
• Feasibility assessment complete
• Resource plan approved
• Risk assessment performed
• Timing plan established

Phase 2: Product Design and Development

Purpose: Develop design to near-final form

Key Deliverables:

Gate 2 Criteria:

• DFMEA complete (RPN addressed)
• Design reviews completed
• Drawings released
• Prototypes built and validated
• Design verification results acceptable
• Special characteristics agreed with customer

Note: For contract manufacturing (MNMUK), Phase 2 is often customer-led. Focus on DFM feedback and prototype support.

Phase 3: Process Design and Development

Purpose: Develop manufacturing process

Key Deliverables:

Gate 3 Criteria:

• Process flow complete and approved
• PFMEA complete (high RPNs addressed)
• Pre-launch control plan approved
• Work instructions drafted
• MSA plan established
• Tooling/equipment ordered or available
• Packaging spec approved

Phase 4: Product and Process Validation

Purpose: Validate manufacturing process

Key Deliverables:

Gate 4 Criteria:

• Significant production run complete
• MSA acceptable (<10% GR&R for CC, <30% for SC)
• Process capability acceptable (Ppk ≥1.67 for CC, ≥1.33 for SC)
• PPAP package complete per customer level
• Customer approval (PSW signed)
• Production control plan implemented
• Operators trained

Phase 5: Feedback, Assessment and Corrective Action

Purpose: Continuous improvement during production

Key Activities:

Ongoing Requirements:

• Customer complaints tracked and resolved
• Process capability maintained
• Control plans current
• Lessons learned documented
• Continuous improvement projects active

PPAP Submission Levels

MNMUK Default: Level 3 unless customer specifies otherwise.

PPAP 18 Elements

Element Checklist

Legend: S = Submit to customer | R = Retain at supplier | * = Retain and submit on request

Element Details

Element 1: Design Records

• Released engineering drawings
• CAD data if applicable
• Current revision level
• All engineering specifications referenced

Element 2: Authorized Engineering Change Documents

• ECNs (Engineering Change Notices)
• Deviations approved by customer
• Temporary deviations with expiry dates

Element 3: Customer Engineering Approval

• Evidence of customer approval for design
• Typically for proprietary designs
• Not required if customer-owned design

Element 4: Design FMEA (DFMEA)

• Covers design failure modes
• Often customer responsibility for contract manufacturing
• MNMUK may not have access if design is proprietary

Element 5: Process Flow Diagram

• All operations including rework/inspection
• Material flow indicated
• Must match Control Plan operations

Element 6: Process FMEA (PFMEA)

• All process failure modes
• Current controls documented
• RPN/AP action items closed
• Special characteristics identified
• Reference: Load Pfmea skill

Element 7: Control Plan

• Matches PFMEA and process flow
• All special characteristics controlled
• Appropriate sample sizes and frequencies
• Reaction plans defined
• Reference: Load Controlplan skill

Element 8: Measurement System Analysis (MSA)

• Gage R&R for all variable gages
• Attribute agreement for attribute checks
• Acceptance: <10% for CC, <30% for SC
• Reference: Load Msa skill

Element 9: Dimensional Results

• All drawing dimensions measured
• Sample size typically n=3-5 parts
• Include layout inspection report
• Mark CC/SC results

Element 10: Material, Performance Test Results

• Material certifications
• Performance test results (DVP&R)
• Third-party test reports if required
• Traceability to material lots

Element 11: Initial Process Studies

• Capability studies (Ppk/Cpk)
• Minimum 30 parts, 300 readings for SPC
• Acceptance: Ppk ≥1.67 (CC), ≥1.33 (SC)
• Reference: Load Spc skill

Element 12: Qualified Laboratory Documentation

• Scope of lab accreditation
• ISO/IEC 17025 scope if applicable
• Third-party lab certifications

Element 13: Appearance Approval Report (AAR)

• Required for appearance items only
• Color, grain, texture approval
• Customer-signed AAR form

Element 14: Sample Production Parts

• Parts from significant production run
• Quantity per customer requirement (typically 3-10)
• Representative of normal production

Element 15: Master Sample

• Retained production sample
• Same as submitted samples
• Stored per retention requirements

Element 16: Checking Aids

• Custom gages, fixtures, templates
• Calibrated and identified
• Match Control Plan references

Element 17: Customer-Specific Requirements

• OEM-specific PPAP requirements
• May include additional forms/checklists
• Check customer portal/manual

Element 18: Part Submission Warrant (PSW)

• Summary of PPAP submission
• Weight, material declaration
• Customer-specific markings
• Authorized signatures

PSW Generation Guide

Required Information

# Part Submission Warrant

## Part Information
| Field | Value |
|-------|-------|
| Part Number | [Customer P/N] |
| Part Name | [Description] |
| Drawing Number | [Dwg #] |
| Drawing Rev | [Rev Level] |
| Customer | [Customer Name] |
| Buyer/Code | [Buyer Name/Code] |

## Supplier Information
| Field | Value |
|-------|-------|
| Supplier Name | Multimatic Niche Manufacturing UK |
| Supplier Code | [Customer-assigned code] |
| Address | [MNMUK Address] |
| Contact | [Quality Manager] |
| Phone/Email | [Contact details] |

## Submission Details
| Field | Value |
|-------|-------|
| PPAP Level | [1-5] |
| Submission Reason | [Initial, Change, Re-submission] |
| Engineering Change Level | [ECN #] |
| Purchase Order | [PO #] |

## Weight Declaration
| Measured | Specified | Difference |
|----------|-----------|------------|
| [Actual kg] | [Nominal kg] | [± kg] |

## Material Information
| Field | Value |
|-------|-------|
| Material | [Material spec] |
| Supplier | [Material supplier] |
| IMDS/MDS ID | [If required] |

## Special Characteristics
| Char | Drawing Ref | Result |
|------|-------------|--------|
| CC | [Zone/Ref] | PASS/FAIL |
| SC | [Zone/Ref] | PASS/FAIL |

## Submission Checklist
- [ ] All required elements per submission level included
- [ ] Capability requirements met
- [ ] No open issues or deviations
- [ ] Customer-specific requirements addressed

## Disposition (Customer Use)
[ ] Approved
[ ] Interim Approval (expiry: _______)
[ ] Rejected (reason: _______)

## Authorization
| Role | Signature | Date |
|------|-----------|------|
| Quality Manager | __________ | ________ |
| Customer Rep | __________ | ________ |

Timing Plan Elements

Standard Milestones

MNMUK Program Phases

Open Issues Management

Issue Categories

Issue Status

Issue Tracking Format

## Open Issues Log

| # | Issue | Category | Owner | Target | Status | Notes |
|---|-------|----------|-------|--------|--------|-------|
| 1 | [Description] | [Cat] | [Name] | [Date] | [Status] | [Notes] |

Phase Gate Review Meeting

Agenda Format

1. Program Status (5 min)

- Timeline status (Green/Yellow/Red) - Budget status - Customer communication

1. Deliverable Review (20 min)

- Checklist walkthrough - Evidence of completion - Identify gaps

1. Risk Review (10 min)

- Open issues summary - Top 3 risks - Mitigation status

1. Gate Decision (5 min)

- Pass / Conditional Pass / Fail - Actions if conditional - Next gate schedule

Gate Decision Criteria

IATF 16949 Alignment

APQP/PPAP is a core requirement of IATF 16949 (Clause 8.3 - Design and Development).

MNMUK IATF 16949 Context

Certification Target: November 2027 Current Status: ISO 9001 Certified, upgrading to IATF 16949

Reference Documentation:

• Compliance Plan: ~/projects/work/docs/compliance/IATF16949_Compliance_Plan.md
• Quality Manual: ~/projects/work/docs/work-instructions/QM-001_Quality_Manual.md

IATF Requirements Addressed by This Skill

Capability Requirements (per QM-001)

PMO Governance

APQP programs at MNMUK are managed through the Programme Management Office (PMO):

• Monthly IATF Steering Committee reviews program status
• Phase gate reviews align with IATF documentation requirements
• Lessons learned feed into quality system continuous improvement

Integration with Related Skills

PFMEA

PFMEA is PPAP Element 6:

• Required for all PPAP levels
• Must be complete before Gate 3
• High RPN items must be addressed

Load: read ~/.claude/skills/Pfmea/SKILL.md

Control Plan

Control Plan is PPAP Element 7:

• Pre-launch for Gate 3
• Production for Gate 4
• Must align with PFMEA

Load: read ~/.claude/skills/Controlplan/SKILL.md

MSA

MSA is PPAP Element 8:

• Plan at Gate 3
• Results at Gate 4
• All gages must pass

Load: read ~/.claude/skills/Msa/SKILL.md

SPC

Initial process studies are PPAP Element 11:

• Capability studies at Gate 4
• Cpk/Ppk targets must be met

Load: read ~/.claude/skills/Spc/SKILL.md

Internal Audit

APQP program audit requirements:

• Phase gate reviews documented
• PPAP records auditable
• Process effectiveness verified

Load: read ~/.claude/skills/Internalaudit/SKILL.md

Examples

Example 1: Check PPAP readiness

User: "What PPAP elements do I need for Level 3?"
→ Lists all 18 elements with Submit/Retain status
→ Highlights elements to submit
→ Notes MNMUK-specific considerations

Example 2: Run phase gate review

User: "Run Gate 3 checklist for the XYZ project"
→ Loads PhaseGate workflow
→ Walks through Phase 3 deliverables
→ Identifies gaps and assigns actions

Example 3: Generate PSW

User: "Create a PSW for part 12345"
→ Collects required information
→ Generates PSW document
→ Includes all declarations and checklists

Example 4: Track program timing

User: "What's the timeline for our new damper launch?"
→ Loads TimingPlan workflow
→ Creates milestone schedule
→ Identifies critical path items

Supplementary Resources

For detailed guidance: read ~/.claude/skills/Apqpppap/CLAUDE.md

For templates: ls ~/.claude/skills/Apqpppap/templates/

For phase gate checklists: read ~/.claude/skills/Apqpppap/reference/gate-checklists.md

For PPAP element forms: read ~/.claude/skills/Apqpppap/reference/ppap-forms.md