This conversation will discuss common problems / challenges for using spreadsheets for the APQP business process and will also include advice on how to get your project funded. It will include a review of a database application that was designed by volunteers that have been using spreadsheets for over 10 years. Their requirement included "Better than spreadsheets, but not too complicated, our we will go back to spreadsheets!"

1. APQP for Wind Energy 2.0
Moving from spreadsheets to a database
Presented By:
John M. Cachat
jmc@peproso.comSep 10, 2020
1@ Copyright 2020 John M. CachatSep 10, 2020

2. Housekeeping
Phones are
muted
Use the question
block for
questions
Copy of
presentation can
be downloaded
during this event
Certificate of
Attendance
Provided
2@ Copyright 2020 John M. CachatSep 10, 2020

3. Why Bother?
Build a knowledge base from PPAP and dramatically
shorten time and improve results to minimize risk
• PPAP Creation Time – Reduce 60%
• PPAP Reporting / Submission time – Reduce 90%
• PPAP Effectiveness – Improve 80%
3@ Copyright 2020 John M. CachatSep 10, 2020

4. Intended Audience
• You already know about PPAP
• You have experience trying to do PPAP with email and
spreadsheets OR another big system that is annoying,
cumbersome, and you want to go back to spreadsheets
• You may, or may not, require Supplier PPAP, but if you do,
that is even more cumbersome
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5. Without understanding
what your people need,
how the process works,
the software will fail.
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6. “If it is too complicated, I am going back to spreadsheets.”
“I am not trying to have the software do my job.
I want it to make my job easier.”
“Don’t automatically do anything. Let me decide.”
Voice of the Customer (VOC)
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PPAP referenced in Annual Reports

8. Frustrations…
• Our customers tell us to use this form…
• Just fill out the spreadsheet and send it in…
• Didn’t we already buy software that does this?
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9. 85% use
spreadsheets
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10. Spreadsheets and manual
10
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11. Easier to use and flexible
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12. Challenges
• Is this an ERP, PLM, or
QMS issue?
• We make parts, we do
not design them
• Better than
spreadsheets, but not
complex?
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15. Why isn't my PLM effective
"We spent over 5 years and $5M trying
to get three different PLM apps
launched for PPAP and they all failed. It
wasn't until I heard this presentation
that I understood why."
Very rigid, on purpose
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User Roles are very, very different
• Designing Systems
•Requires highly engineering tools
•Focus is on potential design
related failures and their causes.
• Making Parts
• Over 80% use spreadsheets
• Focuses is on potential process
failures and their causes.
Very rigid versus very flexible

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Software DFMEA to PFMEA? No!
design related failures
process failures

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People DFMEA to PFMEA? Yes!

19. Project Management (80/20)
vs.
Document Authoring (20/80)
Missed a Deadline- Bummer
Product Recall - $$$$
DFMEA, Process Flow, PFMEA, Control Plan, Gage Study, etc.)
Think about this….
19@ Copyright 2020 John M. CachatSep 10, 2020

20. Simply uploading spreadsheets is a risk
One industry certification oversight body
reported 400 major and 6,000 minor audit
findings on control plans
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21. Supplier Portals and Project
Management Software
Simply
uploading
spreadsheets
is a risk!
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Better than spreadsheets, but not complex?

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Like spreadsheets, but better
Spell Checking
Column Sorting
Row Filtering
Smart Search's

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Like spreadsheets, but better
Sort and Filter Columns

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Like spreadsheets, but better
Pin Columns
The pin columns feature allows a user to temporarily freeze a
specific column(s) in place while freely scrolling through the rest of
the form. This feature is like the “freeze panes” option available in
spreadsheet applications and is available when viewing and editing
forms in CTS.

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Like spreadsheets, but better
Hide Columns
The hide column feature allows a user to temporarily hide
columns for the purpose of bringing relevant information
into view to reference during data entry, reducing the need
to scroll back and forth across the form.

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Like spreadsheets, but better
CTS View – Single View across all Forms

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Like spreadsheets, but better
Freeze Versions
Provides you with the
ability to store a
snapshot of Forms
documents for
archiving purposes
(CTS View, Process
Flow, PFMEA, Control
Plan, and DFMEA).

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Like spreadsheets, but better
FMEA Action Items
Brings the right side of the FMEA to life!

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Like spreadsheets, but better
Form Configurator

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Like spreadsheets, but better
Email Notifications

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33. Workflow needed?
What it actually is
What you think it is
What it should be
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Workflow needed - No

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Stuff assigned to me…

36. Who Needs to Manage the Risk?
• Legal – protect the company
• Marketing – protect the brand
• Finance – pay me now or pay me later
• Engineering – provide the data
• Purchasing – define the supplier expectations
• Operations – provide input and performance data
• Quality – compliance and continuous improvement
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37. Supplier PPAP Process Flow
• Purchase Order Drives PPAP Request –
Part Number / Revision Level Driven
• Engineering Provides Part Data – with
Product Characteristics & DFMEA
• Supplier Completes PPAP process and
submits paperwork / forms
• Supplier Document Review (full, partial, re-
submit)
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38. Reporting and Analytics capability
• What are the Top 10 issues I need to know about?
• Are the actions on the top 10 issues adequate?
• Are we getting better? Worse?
• What do I have to work on, by Due dates?
• Average RPN (Pareto / or Top 10) by
• Product / Process
• Operation
• Failure Mode
• Cause
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39. Recommended Solution
• Database Driven
• Improved security
• Reporting and Analytics capability
not possible with spreadsheets
• Do not charge the suppliers!
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Detailed Screen Shots and Private
Webinars Available

41. Now Available
APQP / PPAP Solution for part manufacturers
• Cloud based or on premise
• Single Instance, Multi-tenant
• Corporate View across all Plants and Suppliers
• Integration with ERP, PLM, QMS
• Microsoft Technology Stack
• Source Code if needed
41@ Copyright 2020 John M. CachatSep 10, 2020

42. @ Copyright 2020 John M. Cachat 42Sep 10, 2020
If you want to schedule a private web meeting
with your executive team,
email jmc@peproso.com

43. APQP for Wind Energy 2.0
Moving from spreadsheets to a database
Presented By:
John M. Cachat
jmc@peproso.comSep 10, 2020
43@ Copyright 2020 John M. CachatSep 10, 2020

44. About Us
John Cachat
jmc@peproso.com
Contact
Proven expertise in business
information systems
Services
Assess Current Status
Develop Short- and Long-Term Plans
Develop Specific Solutions
Assist in ROI Analysis
44@ Copyright 2020 John M. CachatSep 10, 2020

45. About John M. Cachat
• Driving Business Performance
– Helping companies align their business and technology
– Focus on people, process, and then the technology
– Subject matter expert on business process management
– On-going research into next generation of technology for enterprise systems
• 30+ years experience in enterprise systems
– USAF Research Project (1985)
– Founder of enterprise quality software company (1988)
– Chair of ASQ technical committee on computerizing quality (1992)
• Trusted advisor to global organizations, government agencies, and
professional groups
http://www.linkedin.com/in/johncachat
45@ Copyright 2020 John M. CachatSep 10, 2020