How do you approach the "Safe Launch" Process

bkirch

Involved In Discussions
#1
Could anyone share how they approach what i have heard called a Safe Launch process? In our company, the safe launch process happens when we are in the pre-PPAP phase on new work. So, each time we sample the new work for development, we have data that we gather or test that we conduct which we call a safe launch phase. For us we have three safe launch phases, the third phase happens at PPAP. The first two occur before PPAP. Is this a approach common, or does more of this type of activity happen after PPAP? Also, does anyone have an example of a record or questions that is used for the safe launch activity?
 
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lk2012

#3
Hi,
the Safe Launch is usually triggered by a certain number of problems occurring during the pre-production (prototype) phase.
There's a really good material on this published by the German OEM's, have a look online for QMS training on Safe Launch / APQP from the likes of Continental or BOSCH.
hope this helps a bit
Lil
 

reunalla

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#4
Hi,
I have a similar question.
Based on my previous experience all of my previous workplaces called "safe launch" an offline extra check. Everything online was "in process check" or "end of line check". The content difference was that safe launch had selected points in the product which needed to be rechecked with somebody out of the line with the same method or completely different method. (e.g SPC online - 100% measurement offline)

Now one of the responsible managers in my current workplace says that "safe launch" can be an online check with extra experienced workers, doing the same check which is already sold to the customer that we will do until the end of the production (in Control Plan without mentioning that it is safe launch for 90 days after SOP)

I found no reference in any standards and requirement yet what is the real approach on safe launch.

Also other debate I have: what is the meaning of a "safe launch plan"? My opinion is that SLP is a document which clarifies who, how, and how long will do the safe launch and what is the exit criteria. I as a internal auditor do not want to accept a CP as SLP with no wording in it which says something is "safe launch", no exit criteria.

Any opinion/advice?

Thanks
 

Ron Rompen

Trusted Information Resource
#5
When I read 'safe launch' I immediately think of the GM GP12 requirement - basically it is increased inspection (either frequency OR sample size, usually both) for a period of time after PPAP submission and approval, to ensure that the process is as stable as everyone presumed it is. Characteristics should be selected to reflect as broad a scope of the manufacturing process as possible; however this doesn't mean you have to reinspect EVERYTHING. Work with your SQA/SQE and find out what they expect for this.
 

optomist1

A Sea of Statistics
Trusted Information Resource
#6
Well said......depending on the circumstances leading up to invoking "safe launch" measures, the requirements can be pretty onerous, i.e. a third party selected by the OEM (usually supplier pays), can be deployed at the point of manufacture to effectively "watch every step" of assembly, test, final checks, use of witness marks on parts to confirm step completion, leak check etc., at least for the first 90 days post launch date....as stated your SQE and Release Engineer usually discuss and prescribe what is required....some OEMs document these measures via a Quality Inspection Standard or similar documents....
 

optomist1

A Sea of Statistics
Trusted Information Resource
#7
Folks, brain cramp a few days ago, pls see below corrected term below bolded Blue


Well said......depending on the circumstances leading up to invoking "safe launch" measures, the requirements can be pretty onerous, i.e. a third party selected by the OEM (usually supplier pays), can be deployed at the point of manufacture to effectively "watch every step" of assembly, test, final checks, use of witness marks on parts to confirm step completion, leak check etc., at least for the first 90 days post launch date....as stated your SQE and Release Engineer usually discuss and prescribe what is required....some OEMs document these measures via a Part Inspection Standard (PIS) or similar documents....
 

bobdoering

Stop X-bar/R Madness!!
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#8
Best thing to do is list your critical characteristics and any characteristics you have ever had a customer complaint on. Set up a reasonable time period, such as 6 weeks. Do a final inspection gaging of those characteristics (even if it is go/no go because you are looking for good/bad not control). As you reach 6 weeks of no occurrences of each characteristic, use that data to stop that check. Do it by line item, not wait until all checks are clean. Once you have shown no occurrences on the last check, safe launch is complete.

Not too hard. Protects the customer, and therefore protects you.
 

optomist1

A Sea of Statistics
Trusted Information Resource
#10
to put a little finer point on this discussion, based upon my experience very similar scenarios:
SLP, often contains customer specific requirements, based upon each OEM, triggered by the previously described events, or if in the opinion of the OEM/SQE, the supplier's process although "PPAP'd", still possess an unacceptable degree of risk, such as a "new" process/operation, one that is relatively new to the point of manufacture....one of the SLP goals is to prevent, what some OEMs call Product Related Issues (PRIs) during manufacture, these usually lead to vehicles being temporarily being quarantined pending resolution of the PRI. PRIs are undesirable, as they usually have supplier charges/damages associated with the event
 
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