SECTION 2.3 – QUALITY ASSURANCE SCHEDULE (QAS) & TOOL
PROGRESS REPORT (TPR)
***** PRODUCTION PREPARATION *****
PURPOSE: To explain key points and submission procedure for the Quality
Assurance Schedule and Tool Progress Report.
EXPLANATION:
The goal of a Quality Assurance Schedule (QAS) is to provide a schedule of the
manufacturing and quality control activities necessary to assure the quality of parts
for Mass Production. This schedule must show the relationship of the supplier’s
production preparation activities to the REYES Supplier Parts Master Plan, and
should be prepared by a cross-functional team.
Suppliers are required to prepare a QAS for each Tier 1 part, as well as direct supply
sub-components. The schedule should span the time between the issuance of the
Production Drawing or RDDP by REYES Design and three months after SOP at
REYES. Similar parts, for example left hand and right hand, can be combined into
one schedule.
The Tool Progress Report (TPR) is a detailed schedule of tooling milestones. This
document allows REYES to track supplier tooling progress to schedule, as well as
determine the potential effect of part changes on tooling.
SUPPPLIER RESPONSIBILITY:
1) Quality Assurance Schedule:
The supplier must create and submit a QAS per the date indicated on the
REYES Supplier Parts Master Plan. The QAS should include, at a
minimum, the following:
A. Master Schedule at the top of the first page of the QAS.
Note: Include timing for parts to be received at REYES.
B. Supplier Trial and Sample Schedule indicating supplier
production trials and parts shipping schedule to meet trial
requirements.
Note: The supplier’s assembly trials must simulate the mass
production process and should include Mass Production level: (1)
team member(s), (2) material, (3) process flow-layout and
procedures, and (4) tool-dies, major equipment, fixtures and jigs.
Integrity of the process must be maintained through each trial
completion.
This section should also include:
Revision 1
March 2006
Reyes Automotive Group
San Antonio, TX
Section 2.3
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SECTION 2.3 – QUALITY ASSURANCE SCHEDULE (QAS) & TOOL
PROGRESS REPORT (TPR)
***** PRODUCTION PREPARATION *****
1) Build out/start up plan (if applicable); include timing for previous
model completion date, shut down period, inventory tracking,
and start-up for new model
2) Ship dates to REYES
3) Hiring and training of personnel
4) Part/component assembly trial
C. Component Build and Ship Schedules should show all major
components and indicate the location of the component build (i.e.
on-line, at tool builder, Japan, etc.).
Note: Sub-supplier control should include dates sources will be
selected, evaluated, and tried.
D. Production Level of the part’s components.
Note: The target for parts off production tooling and process is 1A,
at latest.
This section should include:
1)
2)
3)
4)
5)
RDDP or Mass Production Drawing Release date
Tooling – A general schedule
Equipment
Jigs
Checking fixtures
Note: The specifics for each new tool, jig, or checking fixture
should be detailed on individual Tool Progress Reports.
E. Timing for Evaluations that will be performed on the part or
component supplied to REYES. The detail of the required
evaluations should be specified on the Part Evaluation Plan. This
section should include:
1)
2)
3)
4)
5)
Material
Dimension
Appearance
Performance
Function
F. Plan for the internal Quality System Development at the supplier.
Examples of what to include are:
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March 2006
Reyes Automotive Group
San Antonio, TX
Section 2.3
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SECTION 2.3 – QUALITY ASSURANCE SCHEDULE (QAS) & TOOL
PROGRESS REPORT (TPR)
***** PRODUCTION PREPARATION *****
1)
2)
3)
4)
5)
6)
Standardized work
Maintenance logs
Receiving inspection checksheets
Daily check sheets
Procedures
Systems
G. SQM Requirements (Dates according to SQM / Supplier Parts
Master Plan):
1) Supplier Quality Assurance Contacts
2) QAS – Quality Assurance Schedule
3) TPR – Tool Progress Report
4) Part Evaluation Plan
5) Sample Data Sheets
6) Inspection Standard
7) C/F – Checking Fixture (if applicable)
8) Process FMEA
9) MQC/CP – Manufacturing Quality Chart / Control Plan
10) Material Certification
11) Engineering Change Instruction (ECI) Implementation
12) Color Match (if applicable)
13) Grain Approval (if applicable)
14) Provisional Approval
15) Final Approval
Note: The supplier shall indicate submission timing for the above
items on the QAS. If submission timing for any of the above
requirements, as indicated on the QAS, is after the due date
required by the Supplier Parts Master Plan, the supplier must
inform REYES Quality and outline the reasons for the delays.
H. Management Status Reviews must be conducted to encompass
each of the above listed items. These should show on the QAS as
periodic milestones, which allow for adequate “target vs. actual”
reviews of process, tooling, countermeasure activities, etc.
2. Tool Progress Report (TPR):
A. A Tool Progress Report must be prepared for each new die,
jig/equipment, and checking fixture, as well as for tooling to be
modified for model year changes.
Revision 1
March 2006
Reyes Automotive Group
San Antonio, TX
Section 2.3
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SECTION 2.3 – QUALITY ASSURANCE SCHEDULE (QAS) & TOOL
PROGRESS REPORT (TPR)
***** PRODUCTION PREPARATION *****
Note: If additional tooling is added after Provisional Approval has
been issued, see Process Change Request requirements.
B. List all major steps from design to trial on each Tool Progress
Report.
C. Write in target date at the end of each bar on the Tool Progress
Report.
Note: Dates should coincide with those found on the QAS.
D. Write in Tool Completion Date in the assigned space.
3. All related departments within the supplier, must approve the QAS and
TPR before submission. In addition, the supplier’s top management is
responsible for monitoring this plan to achieve milestones as scheduled.
4. The supplier must submit a QAS with the TPR attached to both REYES
Quality and the appropriate REYES Purchasing contact per the date
indicated on the Supplier Parts Master Plan.
5. REYES Quality and Purchasing will review and confirm the supplier’s
activity to the Master Schedule. Request for any adjustments will be
negotiated between the supplier and REYES Quality.
6. The supplier must review the QAS and TPR status periodically.
A. If all schedules meet the plan indicate “No change to schedule” on
the QAS/TPR Status Report and submit a copy to both REYES
Quality and Purchasing by the 5th of each month.
Note: These updates will discontinue at SOP.
B. If there are any changes to dates or content on the original QAS or
TPR they must be listed on the QAS/TPR Status Report. A copy of
both the status report and the revised QAS/TPR must be submitted
to both REYES Quality and Purchasing by the 5th of each month.
Periodically, REYES may require the supplier to re-submit an
update of the QAS and TPR. If requested, these updates must be
submitted by the requested date.
Revision 1
March 2006
Reyes Automotive Group
San Antonio, TX
Section 2.3
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SECTION 2.3 – QUALITY ASSURANCE SCHEDULE (QAS) & TOOL
PROGRESS REPORT (TPR)
***** PRODUCTION PREPARATION *****
QAS/TPR SUBMISSION PROCEDURE
INITIAL DRAFT
SUPPLIER
REYES QUALITY
 Draft QAS/TPR
 Review within the supplier
 Submit for review to REYES
Quality and appropriate
Purchasing contact per QA
Project Plan
REVISIONS
File: Original
(one copy)
(one copy)
 Review draft
 Negotiate revisions
with supplier
 Review draft
 Provide feedback to
REYES Quality
File
File
 Revise QAS/TPR
 Review internally
 Note revisions on QAS/TPR
Status Report & attach
QAS/TPR
 Submit to REYES Quality &
Purchasing by 5th of each
month
REYES PURCH.
(one copy)
(one copy)
 Review revisions
 Negotiate changes
with supplier
File
 Review revisions
 Provide feedback to
REYES Quality
File
File: Original
Revision 1
March 2006
Reyes Automotive Group
San Antonio, TX
Section 2.3
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SECTION 2.3 – QUALITY ASSURANCE SCHEDULE (QAS) & TOOL
PROGRESS REPORT (TPR)
UPDATES
***** PRODUCTION PREPARATION *****
 Update the progress regularly
for both the QAS & TPR. If
no change to any schedule,
submit only the QAS/TPR
Status Report to REYES
Quality and Purchasing by
the 5th of each month.
File: Original
Revision 1
March 2006
(one copy)
(one copy)
Review
File
Reyes Automotive Group
San Antonio, TX
Review
File
Section 2.3
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