APQP_for_Avalon_Suppliers

APQP Process 前期产品质量策划过程,Engine Business Global Purchasing 发动机业务全球采购,Definitions 定义,APQP - Advanced Product Quality Planning APQP -前期产品质量策划 VPI - Value Package Introduction VPI-价值包引进 Cummins new product introduction process 康明斯新产品引进过程 Cross functional approach 跨功能方式 VPI SQI Lead Quality Engineer responsible for information flow between EBGP SQI and program teams VPI SQI Lead-负责发动机事业部全球采购的供应商质量工程师和项小组之间信息交流的质量工程师。 Source Release - Process used for quality approval prior to PPAP 货源发放-在生产件批准程序（PPAP）之前用于质量批准的过程。,Definitions定义,PCC Production Capability Certification PCC-生产产能认证 Cummins run at rate process 康明斯认证生产速率过程 DQR Drawing Quality Review DQR-图纸质量审评 Cummins process to cross functionally review drawings for any discrepancies 如有差异，康明斯跨功能对图纸进行评审的过程。 MQV Manufacturing Quality Verification MQV-制造质量证明 Cummins process to drive elimination of defects 按照康明斯流程推动消除缺陷。 CES Cummins Engineering Standards CES-康明斯工程标准 CES #10012 governs source approval testing CES #10012 管理货源批准测试,APQP vs. PPAP,APQP: A project management tool 前期产品质量策划: 一种项目管理工具 Methodical process used to introduce new products & processes 用于引进新产品和新过程的条理清晰的过程 Cross functional 跨功能 Used from concept to launch 使用在从概念到发放的过程中 PPAP: The proof a supplier is capable of making quality parts at production rates 生产件批准程序：供应商有能力按生产效率生产出优质零件的证明 Pulls together key APQP information 收集关键APQP信息 Documents the production process 用文件记录生产过程,How they fit at Cummins 它们是如何适合康明斯的,VPI (Value Package Introduction) VPI（价值包引进） Overall system used by Cummins 康明斯使用的整体系统 APQP 前期产品质量策划 Process to communicate & manage Cummins VPI requirements to suppliers in a standard language 用“标准”语言与供应商沟通和管理康明斯价值包引进要求的过程 Not Cummins specific 非仅限于康明斯 PPAP 生产件批准程序 Process to verify that requirements were completed satisfactorily. 证明已经圆满完成要求的过程,Benefits of APQP 前期产品质量策划的裨益,Communicates requirements to suppliers 与供应商对需求进行沟通 Identifies changes early in the process 在过程初期识别变化 Provides quality product 提供优质产品 on time and at lowest cost 按时且成本最低 Enables cross-functional inputs and outputs 实现跨功能的输入和输出 Addresses potential problems early 尽早处理潜在问题 Design 设计 Manufacturing 制造 Reduces miscommunication 减少错误传达 Ensures successful program launches 确保项目成功启动,PPAP Expectations for Avalon 对Avalon项目生产件批准程序的期望,PPAPs completed six months prior to production 必须在量产前六个月完成PPAP SOP 7/1/08 - PPAP 1/1/08 PPAPs require full production rate capability PCC must be documented PPAP要求完全生产率产能必须用文件记录PCC Initial annual capacity of 72K 第一年产能要求72K PPAPs completed in Chinese & English 用中英文完成PPAP,Avalon VPI APQP Avalon项目VPI的产品前期质量策划,Suppliers are expected to utilize APQP 期望供应商使用前期产品质量策划 Should be part of normal work flow 应为正常工作流程的一部分 Cummins/BFCEC SQIE involvement is required 要求康明斯/北京福田康明斯发动机有限公司供应商质量改进工程师的参与 Frequency and type of audit will depend on risk 审核的频率和类型根据风险程度而定 Contact your SQIE if you have any questions 如有疑问，联系您的供应商质量改进工程师,APQP - Key Strategies 前期产品质量策划-关键策略,Get involved early 尽早参与 Dont wait for the PPAP request 不要等发出PPAP的要求后再开始 Communicate issues to SQIEs 与供应商质量改进工程师就出现的问题进行沟通 Can provide help 可以提供帮助 Programs want no surprises 项目中不希望发生意外事件 Communicate often 经常沟通 Engineering 工程 Purchasing 采购 Between China/EU/UK/US 中国与欧洲/英国/美国之间的沟通,APQP - Key Strategies 前期产品质量策划-关键策略,Request drawing quality reviews and design review participation 要求参与到图纸质量评审和设计评审当中来 Drive design for manufacturability and assembly 提高设计的可制造性和可装配性 Document all requirements 用文件记录所有的要求 Open issues log critical 记录所有未决事宜 Follow up on everything 跟进所有事宜 Document evidence 文件证明 Evidence books 证明资料手册 Utilize APQP checklists and manuals 使用APQP检查清单和手册,Source Release 货源发放,Source Release Overview 货源发放概览,Supplier certifies parts are to print 供应商确保零件满足图纸要求 Documents exceptions and deviations 用文件记录例外情况和偏差 All non-conformances must be approved by design engineer 所有不合格情况必须经过设计工程师批准 Source Release approves quantity of parts, or preliminary process 货源发放批准的是一定数量的零件或初步工艺 SQIE retains data 供应商质量改进工程师保留数据 A copy of the signed Record of Conformance is kept with APQP evidence book 将一份签好字的合格记录和APQP证明文件信息保存在一起,Source Release Package Content 货源发放整套文件的内容,Full layout on three pieces 三件的全尺寸报告 Must include everything on the drawing 必须包括图纸上的所有内容 Check that supplier has correct drawing and standards 检查供应商是否使用正确的图纸和标准 100% inspection or acceptable Cpk - Ppk demonstrated for majors and criticals 100%检验或有可接收的Cpk值-主要和关键尺寸/特性的Ppk Quality engineering judgment call to accept anything less than 100% inspection. 对于没有100%进行检验的项目需要质量工程师的评判方可接收。 Signed Record of Conformance 签字认可的符合性报告,Source Release Expectations for Beta 1 货源发放对Beta 1的期望,Send documentation to SQIE for approval. 提供文件给供应商质量改进工程师进行批准。 Which SQIE depends on country of origin. 根据原产国来确定是哪个供应商质量改进工程师。 SQIE reviews and signs ROC 供应商质量改进工程师进行审核以及签署符合性报告。 Any discrepancies must be approved by engineering. 如有任何偏差需要得到工程师的批准。 Send copy of Signed ROC and documentation with the parts (to UK or to DFM Logistics). 提交零件同时付一份签字的符合性文件（给英国或东风物流公司） Parts received without signed ROC will be held for inspection at Darlington. 收到零件时如果没有签署的符合性报告，则零件需要由Darlington进行检验。,Record of Conformance 符合性报告,APQP 28 elements 前期产品质量策划过程28要素,Purchase Agreement 采购协议,Delays in tooling starts could impact key process or gauging components 开模延迟会影响关键过程或零部件的测试 Get involved and mitigate risk 积极参与与降低风险 Often agreements for key processes can be reached in advance of the full agreement 关键过程的协议通常可以在完整协议之前达成 Ensure the quoted capacity is documented 确保用文件记录所报出的产能 Will be used as the target in the PCC process 将在PCC过程中作为目标使用 Copy in evidence book 保存备份在证明资料中,1. Purchase Agreement采购协议,Complete with Cummins PO or letter of intent/ agreement. 收到康明斯订单 或意向书/协议 则完成此过程。,Is there a purchasing agreement in place? Is one needed for this supplier? Reference PUR-02-04-14 采购协议到位了吗？ 需要给供应商一份吗？ 参见PUR-02-04-14,Letter of intent will be issued to Avalon suppliers. The LOI will include volumes and PPAP need dates. The LOI will satisfy this element. 对于Avalon项目，会出意向书给供应商。意向书中会包含产品的量及需要完成PPAP的日期。收到意向书即为拥有此要素。,Manufacturing Process Layout 制造过程全记录,Used to document what was used when 当出现以下情况时通常要对制造过程进行记录 Many parts are implemented in phases 很多零件分阶段执行 Some parts will move to China after Beta 一些Beta阶段过后要转到中国的零件 Information that could be used in working quality issues 这些信息可以用于处理质量问题 Containment, process start dates, etc. 遏制、过程启动日期等,Manufacturing Process Layout 制造过程全记录,Tooling and process changes documented over time. 按照时间进度对模具和过程的变更进行文件记录,Can be divided into any type of appropriate sections, Prototype Early Production - Production, Alpha Beta, etc. 可以按照任何适当的类别进行分类，快速成型样品-先期生产-量产-Alpha-Beta阶段等,Key components only. Should follow high level process flow. 仅关键零件。应当按照高水平的工艺流程。,Design Responsibility 设计职责,Design responsibility must be: 设计职责是必须要： Clearly defined 定义清晰 Agreed within the team 在团队中达成一致 Documented through ownership of tech profile, DVP &R, ID type codes (IMS), etc. 设计职责必须通过技术文件的所有者、DVP &R, ID 类型编码等进行记录 Design related activities, if any required by the supplier, should be communicated and agreed through the RFQ process. 如果供应商对产品的设计有任何要求，应当在报价过程中针对这些与设计相关的项目进行交流并达成一致意见。 The preferred method to document design responsibility is component ID codes such as 15-1 (something permanent and systemic). 首选的记录设计职责的方法是采用零部件ID编码，如：15-1（持久且具有系统性的信息）。,3. Design Responsibility设计职责,Typical ID Codes 典型的ID代码,4. DVP & R 设计验证计划及报告,Design Validation Planning and Report 设计验证计划及报告 Used when the supplier has design control or is performing design related activities 当供应商控制设计或执行与设计相关的活动时使用 Developed and agreed within the team 在团队内开发并协商一致 Feasibility agreed to with the supplier (best if prior to final quote) 就可行性问题与供应商协商一致（最好能在确定最终报价之前完成） Design inputs (tech profile) must be clearly defined, documented, and understood 必须清楚定义、记录和理解设计输入（技术文件）,DVP & R 设计验证计划及报告,Special consideration must be made for the risks associated with a supplier that does not have any experience with the new and/or unique products, processes, and engineering tasks that are being developed. 对正在开发的新的和/或独特产品、过程和工程任务没有经验的供应商，必须特别考虑其相关风险性。 A Cummins expert review of all new and unique product/processes and related engineering tasks must be completed to ensure adequacy 康明斯的专家必须完成所有新产品/过程、独特产品/过程和相关工程任务的评审，以确保有足够的能力。,DVP & R设计验证计划及报告,Reference to Tech Profile 参见技术文件,Requirements clear And very specific 要求清晰且详细,Responsibilities clearly defined. CTC versus supplier and engineers name. 清楚定义职责则，CTC与供应商和工程师的姓名,DVP & R Example 设计验证计划及报告的示例,Design FMEA 设计潜在失效模式与后果分析,Suppliers should request to review if Cummins responsibility 如果是康明斯负责设计，供应商应提出要求来回顾设计的FMEA。 Suppliers should complete if suppliers responsibility 如果是供应商负责设计，供应商应完成设计的FMEA。,Design Review 设计评审,Suppliers should participate if Cummins responsibility 如果是康明斯负责评审，供应商应参与 Suppliers must participate if suppliers responsibility 如果是供应商负责评审，供应商必须参与 Design review notes should be kept in Evidence Book 设计评审的记录应保存在证明文件记录中,Prototype Control Plans 样品控制计划,Difficult to complete at prototype suppliers 在样品供应商处难以完成 Should be automatic at production suppliers 在产品供应商处应自动化 Good opportunity to experiment with requirements and processes 试验要求与过程的好机会 Source release is required for all prototype parts used in VPI builds 用于VPI装机上的所有样品零件都要求货源发放,Drawings and Specifications 图纸和规范,Drawing control is very difficult 图纸控制非常困难 Ensure preliminary drawings are identified 确保初步的图纸有进行标识 SQIE and Supplier DQR participation is critical 供应商质量改进工程师供应商图纸质量回顾的参与很重要 DQRs also serve as technical reviews DQRs还承担技术评审的工作 DQRs also serve as feasibility reviews DQRs还承担可行性评审的工作 Make sure suppliers have all appropriate CES 确保所有的供应商都有适当的CES,Drawings and Specifications 图纸和规范,Supplier graphics are becoming more prevalent. 供应商图表越来越普遍 The goal of the Supplier Graphics process is to: 供应商图表过程的目的是： Eliminate the confusion caused when Cummins and the supplier are using their own internally created specifications for the same item. 当康明斯与供应商针对同一个项目使用各自内部创建的规范时，消除所引起的混淆。 Reduce duplication of work already performed by the supplier and utilize the suppliers expertise in specifying their own products 对于供应商已经做的工作可以减少重复，并且利用供应商的专业技能来规范他们的产品。,Facilities, Equipment and Tools 设施、设备和工具,Time phase plan critical 时间阶段计划 Include quality / PPAP steps 包括质量/PPAP步骤 List all equipment 列出所有的设备 Can use Gantt chart 可以使用干特图 Sound the alarm at any delay 对任何延迟进行提醒,Facilities, Equipment and Tools 设施、设备和工具,Typically documented via a Gantt chart 典型的方法是用甘特图进行记录 Other similar methods acceptable 其他类似的方法也是可接受的,Gauging and Test Equipment 量具和检测设备,Best to include in equipment plan 最好包含在设备计划中 Same strategy applies 同样的策略这里也适用,Preliminary Compatibility Matrix 初步兼容性矩阵,Similar to feasibility agreement 与可行性协议相似 translates into Cummins language 翻译成康明斯语言 standard form available (QSP1.04 appendix 8.7) 康明斯提供标准格式(QSP1.04 附录 8.7),Preliminary Compatibility Matrix 初步兼容性矩阵,Completed by supplier 由供应商完成 use engineering judgments 使用工程判断 use information from prototypes 使用样品制造过程中得到的一些信息 Focus on majors 集中主要精力在主要项目上 consider all features 考虑所有的特性 Copy in evidence book 在证明资料文件中保留备份,Preliminary Compatibility Matrix 初步兼容性矩阵,Utilize form In QSP 1-04 使用QSP 1-04的表格,List all concerns if any 如果有任何担心，逐一列出,Action is Similar to Team Feasibility Commitment 行动事项与小组 可行性承诺中 的类似。,Clear commitment that the drawing requirements will be met. 清楚的承诺满足图纸 要求。,Signed by the appropriate person 有适当人员的签字,Sub Contract APQP 分包商的APQP,Drive same steps at all levels 在所有级别推行相同的步骤 We wont assume Tier I can manage Tier II 我们不会假定一级分包商会管理二级分包商 We will review Tier II documentation with Tier I 我们会与一级分包商一道评估二级分包商的文件 May do joint review at Tier II or Tier I 可以在二级分包商或一级分包商处进行联合评审 Critical for some Tier II suppliers 对于一些二级供应商很关键 Foundries 铸造厂,Team Feasibility Agreement 团队可行性协议,Standard AIAG form 使用汽车行业协会组织的标准格式 Suppliers can use their own version 供应商也可以使用自己的版本 Copy in evidence book 在证明文件中保留备份,Team Feasibility Agreement 团队可行性协议,No Exceptions Noted! 不许有例外情况,Standard AIAG Form 标准AIAG格式,Look for appropriate team participation. 寻找适当的团队参加,Logistics / EDI Capability 物流/电子数据交换产能,Usually nothing needed for current suppliers 现有供应商通常不需要任何东西 Can only facilitate logistics and EDI for new suppliers 只为新供应商提供物流和EDI Refer to this Website for EDI details and E-Commerce team contacts: 欲知EDI详情和电子商务团队联系方式，请参见以下网站 Evidence with memos 邮件证明资料,Logistics / EDI Capability 物流/电子数据交换产能 Beta 1 (30 engines) Beta 1 30台发动机,Current Cummins suppliers will receive EDI orders 现有康明斯供应商会收到EDI订单。 Locations other than production source may receive EDI orders! 非生产厂之外的地点也可能收到EDI订单！ New China suppliers will receive EDI orders via DFM Logistics in China 中国地区新的供应商会通过东风进出口公司收到EDI订单。 Parts will ship to Darlington UK 零件将发运到英国的Darlington Parts must be ready for use June 1 在6月1日前必须有零件可以使用 No ROC could delay build 没有ROC可能会延迟装机 Evidence with memos 邮件证明资料,Packaging Specifications 包装规范,Obtain approval from plant packaging engineer 供应商应从工厂包装工程师处获得批准 Complete form in packaging standard 完成包装标准中的表格 Keep memos and completed form in evidence book 将邮件和完成的表格一同存档备份 Refer to iSCM website document library for the worldwide packaging standard 参考iSCM网站上文件库中的全球包装标准 Or ask you SQIE for a copy 或者向你的供应商质量改进工程师索要一份,Manufacturing Process Flow Charts 制造工艺流程图,Industry Standard 行业标准 Any changes to approved process flow must have customer approval 对于已经批准的流程图若有任何变更必须或者客户的批准,Process FMEA 过程失效模式与后果分析,Industry standard 行业标准 Identify all major features 标识所有主要特性 Use historical data, experience from prototype builds 使用样品制造过程中的历史数据和经验 Cover all steps and features 包含所有的步骤和特性 Follow up on high RPN actions 对于RPN值高的项目所要采取的行动进行跟进 Issue log 问题记录 Use and modify this document to make improvement 使用并修改此文件来进行改进 Use for MQV 用于制造质量验证过程中,Manufacturing Quality Verification 制造质量验证,Cummins developed tool 康明斯开发的模具 Drives elimination of key defects 驱动消除关键缺陷 Customer touch points critical 客户触摸点尤其关键 Need to failsafe 需要故障保护 Should begin before tooling starts 必须在工装开始前启动 May change design, tooling, gauging or processes 可以变更设计、工装、量具或过程 Training package available 可获得整套培训的资料,Manufacturing Quality Verification 制造质量验证,Critical issues 关键问题,Design the defect out of the part or process 设计零件/过程如何没有缺陷,Fail safe Fail safe Fail safe 故障保护 Redundancy Redundancy 冗余,Measurement System Evaluation 测量系统评估,Industry standard 行业标准 Required for gauges used to measure major characteristics and part specific gauges (no history) 对于用来测量主要特性和零件的专用检具（无历史）需要进行测量系统的评估 Review generic R and R for all others 对于所有其他量具评估其通用的可重复性和可再现性 Consider attribute study for visual inspections. 对于目测检验项目要考虑其属性研究,Pre-Launch Control Plans 试生产控制计划,Industry Standard 行业标准 Typically used for trial run 典型用于试生产 Should be production control plan with provisions for capability studies 应为量产的控制计划，并要进行能力研究,Operator Process Instructions 过程作业指导书,Must have adequate set up instructions 必须要有充分的作业指导 Key to long term capability 对于长期能力是关键 Digital photos are good tool 数码照片可以作为很好的工具来使用 Include gages 包括量具,Production Trial Run 生产试运行,This is not the time to debug 这个阶段已经不是调试的时候了 All debugging should already be done 所有的调试工作都应该已经完成 Root out issues only found at production 这个时候只应该发现量产中会出现的问题 Follow PCC process 跟进PCC过程 Enforce trial run quantity in QS 执行QS中要求的试运行数量 Document with PCC form 存档PCC表 Suppliers processes may be acceptable 供应商过程可能是可接受的 “ build review” or “run at rate” “装机的评估”或“生产效率”,Production Compatibility Matrix 生产兼容性矩阵,Enforce Cpk guidelines in QS 执行QS中的Cpk指导要求 Study size 研究批量的大小 Can be multiple lots for low volume 对于低产量的产品可以进行多批次研究 Acceptable Cpk criteria 可接受的Cpk标准 Demonstrate stability 证明稳定性 Evidence with capability summary 产能总结的证明资料 Can use QSP 1.04 appendix 8.6 可以使用QSP1.04附录8.6,Production Compatibility Matrix 生产兼容性矩阵,Capability requirements from PPAP manual PPAP手册中的能力要求,Production Compatibility Matrix 生产兼容性矩阵,Used as a capability summary 用作能力总结 Equivalent forms can be used 也可以使用同等表格,PPAPs can not be approved with undefined or inadequate capability. 对于未定义的项目以及未显示充分能力的项目PPAP不能得到批准。,Ensure all major and critical characteristics have adequate capability defined 确保所有主要和关键特性 都已经显示了足够的能力,Class III, IV, and V issues should drive containment, 100% inspection, or a stop to the program. Reference appropriate procedures for actions required. 对于三、四和五类问题需要驱动遏制措施、100%检验或者停止项目。参考对于所要求的措施的适当程序。,Production Compatibility Matrix 生产兼容性矩阵,V.,IV.,Engineer approval for drawing release.,III.,.,II.,I.,Production Control Plans 量产控制计划,Industry standard 行业标准 Ensure appropriate SPC is in place and documented for majors and criticals 确保对主要和关键特性有进行适当的SPC统计并有文件记录 Should support on demand Cpk status inquiries 应该对Cpk状态查询的需要提供支持 Must support PUR 02-04-07-01 必须支持PUR 02-04-07-01,Production Control Plans 量产控制计划,Major characteristic is monitored with individual and moving range chart,Production Source Approval 量产货源批准,Cummins identifies critical components by CES #10012 康明斯通过CES#10012来标识出关键零件 Identified by noun name 通过名字来标识 Related to safety or emissions 与安全或排放相关 Source approval is given for location, materials, process and design 对地点、材料、过程和设计给出货源批准 No change without prior approval by Cummins Engineer 在康明斯工程师批准之前不允许有变更 Source approval code is required 要求有货源批准代码 PPAP cannot be approved until source approval testing is completed. 在货源批准测试完成之前不能对PPAP给予批准。,Production Source Approval 量产货源批准,Dan J Kraszeski 05/24/2004 12:47 PM To: John Ferguson/Ind/CumminsCummins Subject: Re: Pin Status by Part Number John, Please consider this memo Engineering approval of Chaparral Steel as an alternate steel source for Midrange piston pins produced by supplier x. Adequate source approval tests have been completed to close the project. Dan,Asking appr