QsutraQMS

Programme · PRG-2247

Brake Caliper Housing

TOYOTETSU INDIA AUTO PARTS (P) LTD · Part BRK-2247-A · PPAP Level 3 · Programme Manager view

Launch

2025-09-15

0 days to go

Status

AMBER

Days to Launch

0

Gates Signed

2/5

G3 in review

Open Actions

2 open

3 overdue

High Risks

2

APQP Stage-Gate Progress

2/5 gates signed
Currently in Phase 3 · Gate G3 in review

Phase 1 · Planning

100% · 10/10

G1

Phase 2 · Product Design

100% · 10/10

G2

Phase 3 · Process Design

68% · 7/10

G3

Phase 4 · Validation

0% · 0/10

G4

Phase 5 · Launch

0% · 0/10

G5

Stage-gate governance: A phase cannot exit until every mandatory deliverable is complete, RPN-critical actions are closed, and the gate is signed by the named approver. Gates lock the snapshot — nothing edits backwards.

Phase Completion Trend

Open Actions

Complete Floor Plan & Process Layout drawing

Suresh Kumar · Due 2025-06-30 · Phase 3OVERDUE

HIGH

Submit Packaging Specification to customer for approval

Suresh Kumar · Due 2025-06-20 · Phase 3OVERDUE

MEDIUM

Finalise Supplier PPAP requirements for 3 sub-suppliers

Priya Nair · Due 2025-06-25 · Phase 3

HIGH

Close PFMEA RPN item: Porosity in casting (RPN 108)

Suresh Kumar · Due 2025-06-15 · Phase 3OVERDUE

HIGH

Confirm MSA gauge availability for Phase 4 studies

Priya Nair · Due 2025-07-05 · Phase 4

MEDIUM

Stage-Gate Governance

No phase exit without sign-off

  1. G1 · Planning Gate

    Signed 2025-01-20

    Approver: Vikram Desai (Plant Manager)

    • · Programme Plan approved
    • · Feasibility committed
    • · Team & RACI signed

  2. G2 · Product Design Gate

    Signed 2025-03-05

    Approver: Vikram Desai (Plant Manager)

    • · DFMEA closed (RPN ≤ threshold)
    • · Design records approved
    • · Drawings released

  3. G3 · Process Design Gate

    In Review

    Approver: Vikram Desai (Plant Manager) + Customer Witness

    • · PFMEA + Control Plan approved
    • · Tooling qualified
    • · Process flow signed

  4. G4 · Validation Gate

    Locked

    Approver: Priya Nair (Quality Manager) + Customer

    • · MSA + Cpk targets met
    • · Run@Rate passed
    • · PPAP submitted

  5. G5 · Launch Gate

    Locked

    Approver: Rajesh Iyer (Programme Manager) + Plant Manager

    • · Customer PPAP approved
    • · Lessons learned filed
    • · Safe-launch closed

Hard rule: a phase cannot start until the prior gate is signed. Override requires Plant Manager + Programme Manager dual approval — every override is logged and visible to leadership.

Programme Milestones

  1. Phase 1 Gate Approved

    Phase 1 · 2025-01-20

    Complete

  2. DFMEA Approved

    Phase 2 · 2025-02-10

    Complete

  3. Phase 2 Gate Approved

    Phase 2 · 2025-03-05

    Complete

  4. PFMEA Approved

    Phase 3 · 2025-04-25

    Complete

  5. Control Plan Approved

    Phase 3 · 2025-05-10

    Complete

  6. Phase 3 Gate Target

    Phase 3 · 2025-07-05

    At Risk

  7. Trial Run Completion

    Phase 4 · 2025-07-20

    Not Started

  8. PPAP Submission to Customer

    Phase 4 · 2025-08-10

    Not Started

  9. PPAP Customer Approval

    Phase 4 · 2025-08-25

    Not Started

  10. SOP Mass Production

    Phase 5 · 2025-09-15

    Not Started
Risk Register
ProgrammeHIGH

Phase 3 gate delay risk — 3 deliverables overdue

Mitigation: Daily standup initiated; PM escalation to Plant Manager

Open
DesignHIGH

Porosity defect in casting — RPN 108 still open

Mitigation: Vacuum casting trial scheduled for 10 Jun

Open
SupplierMEDIUM

Sub-supplier PPAP for seals not yet initiated

Mitigation: Supplier visit scheduled 30 Jun

Open
ResourceMEDIUM

CMM availability conflict with another programme in Jul

Mitigation: Booking confirmed for Jul 18–22 slot

Mitigated