APQP phase gate management and PPAP documentation for automotive product launches. Covers all 5 APQP phases, phase gate checklists, PPAP 18 elements, PSW generation, timing plans, and open issues tracking. USE WHEN user says 'APQP', 'PPAP', 'phase gate', 'product launch', 'PSW', 'PPAP elements', 'launch readiness', 'timing plan', or 'program management'. Integrates with PFMEA, ControlPlan, and MSA skills.
| Workflow | Trigger | File |
|---|---|---|
| PhaseGate | "phase gate review", "gate checklist" | Workflows/PhaseGate.md |
| PpapPackage | "PPAP elements", "PPAP submission" | Workflows/PpapPackage.md |
| TimingPlan | "timing plan", "launch schedule" | Workflows/TimingPlan.md |
| OpenIssues | "open issues", "issue tracker" | Workflows/OpenIssues.md |
Purpose: Determine customer needs and expectations
Key Deliverables:
| Deliverable | Description | Owner |
|---|---|---|
| Voice of Customer | Customer requirements documented | Commercial |
| Business Plan | Program justification, capacity, investment | GM |
| Product/Process Assumptions | Initial feasibility assessment | Engineering |
| Product Assurance Plan | Quality objectives, reliability goals | Quality |
| Preliminary BOM | Initial bill of materials | Engineering |
| Preliminary Process Flow | High-level manufacturing concept | Mfg Eng |
| Preliminary Special Characteristics | Initial CC/SC identification | Quality |
| Management Support | Resource commitment | GM |
Gate 1 Criteria:
Purpose: Develop design to near-final form
Key Deliverables:
| Deliverable | Description | Owner |
|---|---|---|
| DFMEA | Design Failure Mode Effects Analysis | Design Eng |
| Design for Manufacturability (DFM) | Manufacturing input to design | Mfg Eng |
| Design Verification Plan | DVP&R creation | Design Eng |
| Engineering Drawings | Released with GD&T | Design Eng |
| Engineering Specifications | Material, performance specs | Design Eng |
| Prototype Build | Sample parts for validation | Multiple |
| Prototype Control Plan | Inspection plan for prototypes | Quality |
| Special Characteristics (Updated) | CC/SC finalized | Quality |
Gate 2 Criteria:
Note: For contract manufacturing (MNMUK), Phase 2 is often customer-led. Focus on DFM feedback and prototype support.
Purpose: Develop manufacturing process
Key Deliverables:
| Deliverable | Description | Owner |
|---|---|---|
| Process Flow Diagram | All operations mapped | Mfg Eng |
| Floor Plan Layout | Equipment and flow layout | Mfg Eng |
| Characteristics Matrix | Link characteristics to operations | Quality |
| PFMEA | Process Failure Mode Effects Analysis | Quality/Mfg Eng |
| Pre-Launch Control Plan | Enhanced control for validation | Quality |
| Process Instructions | Operator work instructions | Mfg Eng |
| MSA Plan | Measurement system analysis plan | Quality |
| Preliminary Process Capability Plan | Cpk study plan | Quality |
| Packaging Standards | Pack spec developed | Logistics |
| Management Support (Updated) | Confirm resources | GM |
Gate 3 Criteria:
Purpose: Validate manufacturing process
Key Deliverables:
| Deliverable | Description | Owner |
|---|---|---|
| Significant Production Run | PPAP quantity produced | Production |
| MSA Results | Gage R&R complete | Quality |
| Preliminary Process Capability | Initial Cpk/Ppk studies | Quality |
| Production Part Approval | PPAP package complete | Quality |
| Production Validation Testing | Performance testing | Quality |
| Production Control Plan | Final control plan | Quality |
| Quality Planning Sign-Off | Team approval | Cross-functional |
| PSW | Part Submission Warrant | Quality |
Gate 4 Criteria:
Purpose: Continuous improvement during production
Key Activities:
| Activity | Description | Frequency |
|---|---|---|
| Variation Reduction | Reduce process variability | Ongoing |
| Customer Satisfaction | Monitor complaints, returns | Monthly |
| Delivery Performance | OTD tracking | Weekly |
| Lessons Learned | Capture and share | Per program |
| Control Plan Updates | Based on experience | As needed |
| PFMEA Updates | Based on field issues | As needed |
Ongoing Requirements:
| Level | Requirements | When Used |
|---|---|---|
| Level 1 | PSW only | Customer trusts supplier |
| Level 2 | PSW with product samples and limited data | Reduced documentation |
| Level 3 | PSW with product samples and complete data | Default |
| Level 4 | PSW with complete data (no samples) | Customer-specific |
| Level 5 | PSW with product samples and complete data at supplier site | Customer review on-site |
MNMUK Default: Level 3 unless customer specifies otherwise.
| # | Element | Level 1 | Level 2 | Level 3 | Level 4 | Level 5 | Owner |
|---|---|---|---|---|---|---|---|
| 1 | Design Records | R | S | S | * | R | Engineering |
| 2 | Authorized Engineering Change Documents | R | S | S | * | R | Engineering |
| 3 | Customer Engineering Approval | R | R | S | * | R | Commercial |
| 4 | Design FMEA | R | R | S | * | R | Engineering |
| 5 | Process Flow Diagram | R | R | S | * | R | Mfg Eng |
| 6 | Process FMEA | R | R | S | * | R | Quality |
| 7 | Control Plan | R | R | S | * | R | Quality |
| 8 | Measurement System Analysis | R | R | S | * | R | Quality |
| 9 | Dimensional Results | R | S | S | * | R | Quality |
| 10 | Material, Performance Test Results | R | S | S | * | R | Quality |
| 11 | Initial Process Studies | R | R | S | * | R | Quality |
| 12 | Qualified Laboratory Documentation | R | S | S | * | R | Quality |
| 13 | Appearance Approval Report (AAR) | S | S | S | * | R | Quality |
| 14 | Sample Production Parts | R | S | S | R | R | Quality |
| 15 | Master Sample | R | R | S | * | R | Quality |
| 16 | Checking Aids | R | R | S | * | R | Quality |
| 17 | Customer-Specific Requirements | R | R | S | * | R | Quality |
| 18 | Part Submission Warrant (PSW) | S | S | S | S | S | Quality |
Legend: S = Submit to customer | R = Retain at supplier | * = Retain and submit on request
# 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 | __________ | ________ |
| Milestone | APQP Phase | Typical Timing |
|---|---|---|
| Program Kick-Off | 1 | T-24 weeks |
| Design Release | 2 | T-18 weeks |
| Tooling Order | 2 | T-16 weeks |
| Process Design Complete | 3 | T-12 weeks |
| Tooling Receive | 3 | T-10 weeks |
| First Article | 3 | T-8 weeks |
| PPAP Run | 4 | T-6 weeks |
| PPAP Submission | 4 | T-4 weeks |
| Customer Approval | 4 | T-2 weeks |
| SOP (Start of Production) | 5 | T-0 |
| Phase | Duration | Key Activities |
|---|---|---|
| Quotation | 1-2 weeks | RFQ response, feasibility |
| Award | 1 week | PO receipt, kick-off |
| Planning | 2-3 weeks | APQP plan, team formation |
| Development | 4-8 weeks | Process design, tooling |
| Validation | 2-4 weeks | PPAP run, capability |
| Approval | 1-2 weeks | PPAP submission, PSW |
| Launch | 1-2 weeks | Production ramp-up |
| Category | Description | Example |
|---|---|---|
| Design | Drawing/specification issues | GD&T clarification needed |
| Process | Manufacturing capability | Cpk below target |
| Tooling | Equipment/fixture issues | Tool modification required |
| Quality | Inspection/testing gaps | MSA fail, need new gage |
| Supply | Material/supplier issues | Long lead material |
| Commercial | Contract/pricing issues | Scope change |
| Status | Definition | Action |
|---|---|---|
| Open | Issue identified, not resolved | Assign owner, target date |
| In Progress | Work underway | Track to completion |
| Pending | Waiting on external input | Follow up required |
| Closed | Issue resolved | Document resolution |
| Escalated | Risk to timing/quality | Management attention |
## Open Issues Log
| # | Issue | Category | Owner | Target | Status | Notes |
|---|-------|----------|-------|--------|--------|-------|
| 1 | [Description] | [Cat] | [Name] | [Date] | [Status] | [Notes] |
Program Status (5 min)
Deliverable Review (20 min)
Risk Review (10 min)
Gate Decision (5 min)
| Decision | Criteria | Action |
|---|---|---|
| Pass | All deliverables complete, no critical issues | Proceed to next phase |
| Conditional Pass | Minor items open, clear path to close | Proceed with tracking |
| Fail | Critical items incomplete, significant risk | Hold, develop recovery plan |
APQP/PPAP is a core requirement of IATF 16949 (Clause 8.3 - Design and Development).
Certification Target: November 2027 Current Status: ISO 9001 Certified, upgrading to IATF 16949
Reference Documentation:
~/projects/work/docs/compliance/IATF16949_Compliance_Plan.md~/projects/work/docs/work-instructions/QM-001_Quality_Manual.md| IATF Clause | Requirement | APQP/PPAP Coverage |
|---|---|---|
| 8.3.2.1 | Design and development planning (APQP) | Full 5-phase APQP |
| 8.3.3.1 | Product design inputs | Phase 1 & 2 deliverables |
| 8.3.3.2 | Manufacturing process design inputs | Phase 3 deliverables |
| 8.3.4.1 | Design outputs (DFMEA, Control Plan) | Phase 2-4 outputs |
| 8.3.5.2 | Manufacturing process validation | Phase 4 validation |
| 8.3.6.1 | Design and development changes | Re-submission triggers |
| 9.1.1.1 | Process capability monitoring | PPAP Element 11 |
| Characteristic | Ppk Minimum | Notes |
|---|---|---|
| Critical (CC) | ≥1.67 | Safety/regulatory impact |
| Significant (SC) | ≥1.33 | Fit/function impact |
| Standard | ≥1.00 | All other characteristics |
APQP programs at MNMUK are managed through the Programme Management Office (PMO):
PFMEA is PPAP Element 6:
Load: read ~/.claude/skills/Pfmea/SKILL.md
Control Plan is PPAP Element 7:
Load: read ~/.claude/skills/Controlplan/SKILL.md
MSA is PPAP Element 8:
Load: read ~/.claude/skills/Msa/SKILL.md
Initial process studies are PPAP Element 11:
Load: read ~/.claude/skills/Spc/SKILL.md
APQP program audit requirements:
Load: read ~/.claude/skills/Internalaudit/SKILL.md
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
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