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viewrelpiartPaAPQP4Wind ManualAdvanced Product Quality Planning Manual for the Wind IndustryVERSION 1.2 - AUGUST 2019

APQP4WindLysbrohøjen 248600 SilkeborgDenmarkviewMail: contact@apqp4wind.orgWebsite: www.apqp4wind.orgLinkedIn: APQP4WindText and data:Manual and Toolbox developed by the APQP4Wind Working Group and Board of DirectorsPhoto credit, front page:GE Renewable EnergyMcLean’s Mountain Wind Farm, CanadaPhotographer: John HryniukCopyright:APQP4Wind, all rights reservedreLayout and print:Digitalprint - EgetryklpVersion:Advanced Product Quality Planning Manual for the Wind IndustryVersion 1.2 - August 2019Ivan MikkelseniaContributors:Bureau Veritas CertificationDNV GL Bent WeibelKaren VejbyrtGE Renewable EnergyJessica Groff BarrKevin CreaganPaKK Wind SolutionsClaus Lindberg OlesenKarolina Zielinska Kim Schmidt PetersenLM Wind Power Abhay WaghmareFlemming Skov IversenSiemens Gamesa Renewable EnergyDev Anand PrakashHenning HeckerHenrik HjortkjaerLee ButcherVestas Wind SystemsArun John SelvaHenning Bach JokumsenVinayan EP

Introduction to APQP4WindAt the beginning of 2014, Wind Denmark (formerly known as the Danish Wind IndustryAssociation) started a network group consisting of Suppliers with an interest in qualityassurance. To strengthen the network, wind turbine manufacturers and utility companieswere invited to participate on equal footing with the Suppliers.viewIn February 2014, the first meeting in Wind Denmark’s Quality Assurance (QA) networktook place. This marked the very beginning of quality assurance cooperation between windturbine manufacturers, utility companies and Suppliers within the Danish windindustry, and subsequently the idea of APQP4Wind was born.With facilitation from Wind Denmark and support from the Danish Industry Foundation,Siemens Gamesa Renewable Energy and Vestas Wind Systems shared leadership of theAPQP4Wind project running from 2015 to 2018 in cooperation with KK Wind Solutions andLM Wind Power.In August 2018, APQP4Wind was established as an independent organization with globalreach and a board of directors representing GE Renewable Energy, KK Wind Solutions,LM Wind Power, Siemens Gamesa Renewable Energy, Vestas Wind Systems, and WindDenmark.The purpose of APQP4WindreAPQP4Wind is a common quality assurance methodology for the global wind industry.The background for the APQP4Wind Manual is the continuous quality improvement that isneeded to reduce risk, lower the costs of poor quality and keep pace with the ongoing trendtowards decreases in the Levelized Cost of Energy within the wind industry.lpAdvance Product Quality Planning (APQP) is a well-known concept within the automotiveindustry and has been the backbone for maturing quality performance at Customers andSuppliers for decades. In the context of APQP4Wind, the concept of APQP in this Manual isadapted to the business areas and special conditions differentiating wind fromautomotive.rtiaThe APQP4Wind Manual aims to make the process of product quality assurance demandsas well as Production Part Approval Process (PPAP) as clear as possible. The Manual is madeto fit the entire wind industry and set a common standard and best practice for how to planand execute quality assurance in the entire supply chain, from manufacturers to Suppliers ofcomponents.The standards made available in this Manual are made to substitute company-specificprocedures and set aligned methods and procedures for all Suppliers and Sub Suppliers toreduce time to market and increase efficiency within the global wind industry.PaThe APQP4Wind Manual has been subjected to multiple reviews involving subject matterexperts from the APQP4Wind Working Group, Board of Directors, members of WindDenmark’s QA network and a certifying body.All future activities, documents and references can be found at:www.apqp4wind.orgThe APQP4Wind Manual will refer several times to the Toolbox consisting of a Workbookand Analysis 1

Table of ContentsIntroduction5Supply Chain Pyramid5Product Quality Planning Cycle6Responsibility Matrix7APQP4Wind Framework8APQP4Wind Process Flow8Phase Input & Output91.1.Voice of Customer1.2. Design Goals1.3.Product & Process Benchmark Data1.5.Historical Data & Quality Information111.6.Sub Supplier Screening111.7.APQP Kick Off1.8.Product Quality Planning Teamre112.1.Engineering Design Review (EDR)1212121313142.3. Team Feasibility Commitment (TFC)142.4. DFMEA (Design Failure Mode & Effect Analysis)152.5. Special Characteristics152.6. Design for Manufacturability, Assembly, Transport & Service162.7. Design Verification Plan (DVP)162.8. New Equipment, Tooling, Gauge/Test & Facilities Requirement162.9. Preliminary BOM & BOM Management172.10. Sub Supplier Assessments172.11. Engineering Change Management (ECM)17rtialp2.2. Drawing & Specification ReviewPhase 3. Product Requirement FulfillmentPa111.4. Product & Process AssumptionsPhase 2. Product Design & DevelopmentAPQP4Wind10111.9. Product Quality Plan (PQP)210viewPhase 1. Plan, Define & Scope Quality Program3.1.Design Verification Report (DVR)18183.2. Tool Design & Approval183.3. Sub Supplier Product Quality Plan193.4. Customer Engineering Approval193.5. Prototype Control Plan193.6. Prototype Builds19

Phase 4. Process Design & Development4.1.20Preliminary Process Flow Chart & Floor Plan204.2. PFMEA (Process Failure Mode & Effect Analysis)214.3. MSA Plan (Measurement System Analysis)214.4. Preliminary Process Capability Study Plan224.5. Packaging & Transport Specifications22Phase 5. Process Requirement FulfillmentProcess Flow Chart & Floor Plan5.2.Production Tool Builds5.3.0-Series Control Plan5.4.Work Instructions5.5.Preliminary Process Capability Study5.6.Sub Supplier PPAP Completion232424Phase 6. Product & Process Validation0-Series Production6.2.Performance Test Report & Certification6.3.Material Test Report & Certification242425252526266.5.Appearance Approval Report266.6.MSA Report (Measurement System Analysis)266.7.Product Validation Testing266.8.Form, Fit & Function (FFF)276.9.lpre6.1.6.4. Dimensional Report23view5.1.23Serial Production Control Plan276.10. Packaging & Transport EvaluationiaPhase 7. Product & Process Approval2728PPAP Documentation (Production Part Approval Process)287.2.Master Samples287.3.PPAP Submission & PSW (Part Submission Warrant)29Part7.1.APQP4Wind3

APQP4Wind – Glossary & Abbreviation29APQP4Wind – Appendix List1Special Characteristics32Appendix2Failure Mode & Effect Analysis (FMEA)34Appendix3Process Capability Studies42Appendix4Measurement System Analysis (MSA)44Appendix5Production Part Approval Process (PPAP)48PartialpreviewAppendix4APQP4Wind

IntroductionThe purpose of this document is to communicate to Suppliers and Sub Suppliersa common Advanced Product Quality Planning (APQP) Manual developed by theAPQP4Wind Organization. The Manual provides the information and requirements todevelop a product quality plan that should enable development and production of productor service that will fulfill wind turbine manufacturers’ requirements.The main objective of the approach outlined in this Manual is to: Reduce the risk of defects and the costs of quality when introducing new designsviewand components, thereby bringing down the costs of energy. Reduce complexity. Improve alignment of Product Quality Planning (PQP) in the wind industry value chain.Provide an effective medium to easily communicate product qualityrequirements to Suppliers and Sub Suppliers.Avoid problem/failure repetition.The key benefits for the wind industry of using the approach described in this Manual are: and increase efficiency.Support profitable growth.re Preventive approach to quality. Shift from quality control to quality assurance. Enable maturing of the Supplier base globally. Support standardization and simplification of processes to reduce time to marketrtialpThe purpose of this Manual is to provide guidance to Suppliers on the quality requirementsand enable organizations to develop appropriate communication forms. This Manualsupports the quality requirements in the wind power industry by providing recommendedformats and templates such as the Product Quality Plan (PQP). Supplier shall comply withCustomer specific quality requirements specified in addition to this Manual.Environmental, Health and Safety (EHS) requirements are not in scope of this Manual,however, the Supplier shall comply with the legal or Customer specific requirements withrespect to EHS shall be complied.The term “product” used throughout this Manual should be interpreted as the system, subsystem, component or service provided.PaSupply Chain PyramidWind PowerCustomerOriginalEquipment ManufacturerTier 1 SupplierDefinitions: “Wind Power Customer”: Client and/or End-User of OriginalEquipment Manufacturer’s product. “Original Equipment Manufacturer”: Wind turbinemanufacturer also called “OEM”. “Tier 1 Supplier”: Direct Suppliers to the Original EquipmentManufacturer. “Tier 2 Supplier”: Supplier to Tier 1 Suppliers. Suppliers alsocalled sub-tier Supplier to “OEM”.Tier 2 SupplierThe above illustration depicts the supply chain structure applicable to this Manual.APQP4Wind5

The scope of this Manual with respect to the Supply Chain Pyramid is further clarified bythe Customer-Supplier relationship model below. The Customer-Supplier levels may extendbeyond Level 3. The requirements in this Manual shall be applicable to all levels exceptLevel 1 of the model. Hereafter, the words 'Customer' and 'Supplier' are used based on thebelow model.CustomerOriginalEquipmentManufacturerTier 1(Supplier)OriginalEquipmentManufacturerLevel 1viewWind PowerCustomerSupplierTier 1(Supplier)Level 2Tier 2(Sub Supplier)Level 3Product Quality Planning CyclereThe Product Quality Planning Cycle is shown below as a graphical illustration of theAPQP4Wind Quality Program. The various phases are sequenced to represent plannedtiming and follow a typical Plan-Do-Check-Act (PDCA) cycle.lpThe purpose of the Product Quality Planning Cycle is: To set a clear path for planning, implementing and verifying the productconformance to requirements through quality assurance activities. To enable Suppliers and Sub Suppliers to deliver products with the required qualityand quantity, right the first time and on time.iaProduct& ProcessApprovalPlan, Define& Scope QualityProgramActrtPlanCheckPaProduct & uctDesign &DevelopmentThe Product Quality Planning Cycleemphasizes a cross functional approachbetween the Customer and Supplier,thereby improving communication andcollaboration in the entire product sDesign &DevelopmentReference:WorkbookSheet: ProductQuality PlanAs an outcome of product quality planning, the Supplier shall have a Product Quality Planwhich contains a list of quality deliverables that are outcomes of various quality assuranceactivities that the Supplier executes.The level of activities in the Product Quality Plan may vary, based on the product beingdeveloped.6APQP4Wind