SGM-APQP-kic-off.ppt

SHANGHAIGMSUPPLIERQUALITYIMPROVEMENTPROCESS上海GM供应商质量改进程序 ADVANCEDPRODUCTQUALITYPLANNINGandCONTROLPLAN产品质量先期策划和控制计划ShanghaiGM上海GMSupplierDevelopment Quality供应商开发 质量 WHATISAPQP 什么是APQP Itisaformalstructuredprocess Allowstheestablishmentofthenecessarystepstoassureaqualityproductwhichwillmeetthecustomer srequirements 它是一个正规而有序的方法 确立并建立必要的步骤来确保产品满足客户的要求 Introduction简介 Establishaqualityplanwhichsupportsthedevelopmentofproductsthatmeetcustomerrequirements 制定一个产品质量计划来支持产品开发以满足顾客要求 Timelycompletionofcriticalactivities按时完成各项重要工作OntimeProductionPartApproval准时完成正式生产件审批Ongoingconformancetospecifications自始至终达到规范要求ContinuousImprovement不断改善产品质量 精益求精 Purpose目的 WHYAPQP 为什么需要APQP MeetQS9000requirements 满足QS9000质量要求 Increasecustomersatisfaction 提高客户的满意程度 Improveprofitmargin 提高公司利润 Increasesuccessofcompanythroughawell documentedsystemforeachproject 建立一套完善的适用于每个项目的质量体系从而使公司走向成功 WHYAPQP Continue 为什么需要APQP 续前 Purpose目的 DefinetheScope确定工作范围PlanandDefineProgram计划与确定项目ProductDesignandDevelopment产品设计与开发ProcessDesignandDevelopment工艺设计与开发ProductandProcessValidation产品及工艺认证Feedback AssessmentandCorrectiveAction反馈 评估及整改措施 KeySteps关键步骤 Process程序 Setupacross functionalprojectlocalizationteam建立国产化项目横向协调小组Selectprojectteamleader选出项目小组负责人Definefunctionalroles responsibilities确定职能和责任Identifyinternalandexternalcustomers识别内外部客户Definecustomerrequirements确定客户要求 DefinetheScope确定工作范围 UnderstandCustomerExpectations了解客户期望AssessFeasibilityofProposedDesign评估所提出设计之可行性IdentifyCosts Timing andConstraints识别所需费用 时间和制约DetermineAssistanceRequiredfromCustomer明确需要从客户处所得到的帮助IdentifyDocumentationProcess Method确定文件记录之程序与方法 DefinetheScope确定工作范围 Continue续前 ConceptInitiation Approval ProgramApproval PRODUCTDESIGNANDDEVELOPMENT PROCESSDESIGNANDDEVELOPMENT Prototype Pilot Launch PLANNING PRODUCTDESIGNANDDEV PROCESSDESIGNANDDEVELOPMENT PRODUCTANDPROCESSVALIDATION PLANNING PRODUCTION FEEDBACKASSESSMENTANDCORRECTIVEACTION PLANANDDEFINEPROGRAM PRODUCTANDPROCESSVALIDATION FEEDBACKASSESSMENTANDCORRECTIVEACTION ProductQualityPlanningTimingChart 概念形成 审批 项目审批 产品设计与开发 工艺设计与开发 手工样件 小批量 投产 策划 产品设计与开发 工艺设计与开发 产品及工艺认证 策划 生产 反馈 评估及整改措施 计划与确定项目 产品及工艺认证 反馈 评估及整改措施 产品质量策划时间表 1 0PLANANDDEFINEPROGRAM 1 0计划与确定项目 ProductReliability产品可靠性 KeyWordsandBasicConcepts关键词和基本概念 Studywhatdataisavailable研究现有的数据Usedatafromfrequencyofrepair使用维修频率的数据Whatarethelongtermdurabilitygoals长远的耐用性目标是什么 ProductAssurancePlan产品保证计划 Designrequirements 设计要求Programrequirements 项目要求Reliabilitygoals 可靠性目标Technologyused 采用的技术FMEA 失效模式及后果分析Engineeringrequirements 工程要求 KeyWordsandBasicConcepts关键词和基本概念 Basedon 基于 2 0PRODUCTIONDESIGNANDDEVELOPMENT 2 0产品设计与开发 DesignFMEADesignforManufacturabilityandAssemblyDesignVerificationDesignReviewsPrototypeBuildEngineeringDrawingsMaterialSpecificationsDrawingandSpecificationChanges 2 0PRODUCTIONDESIGNANDDEVELOPMENT OUTPUTS ByDesignResponsibleActivity ByAPQPTeam NewEquipment ToolingandFacilitiesRequirementsSpecialProductandProcessCharacteristicsPrototypeControlPlanGages TestingEquipmentRequirements TeamFeasibilityCommitment managementSupport 输出 设计FMEA设计的制造 装配可行性设计验证设计评审手工样件制造工程图纸材料要求规范图纸与规范的变更 产品质量先期策划工作小组 设计工作小组 新设备 工装及厂房要求产品及工艺特性手工样件控制计划量具 试验设备要求项目可行性书面承诺及管理层支持 2 0产品设计与开发 TeamFeasibilityCommitment项目可行性承诺书 Customer PartName PartNumber FeasibilityConsiderations OurProductqualityplanningteamhasconsideredthefollowingquestions notintendedtobeall inclusiveinperformingafeasibilityevaluation Thedrawingsand orspecificationsprovidedhavebeenusedasabasisforanalyzingtheabilitytomeetallspecifiedrequirements All no answersaresupportedwithattachedwithcommentsidentifyingourconcernsand orproposedchangestoenableustomeetthespecifiedrequirements Conclusion FeasibleProductcanbeproducedasspecifiedwithnorevisions FeasibleChangesrecommended seeattached NotFeasibleDesignrevisionrequiredtoproduceproductwithinthespecifiedrequirements Teammember Title DateTeamMember Title Date Sign off KeywordsandBasicConcepts KeyWordsandBasicConcepts关键词和基本概念 Feasibilitycommitment可行性承诺 Canitbemanufactured Canitbeassembled 是否能制造 是否能装配 Canitbetested Canitbedeliveredatspecifiedvolume 是否能测试 是否能按指定的数量发运 Willitsatisfythecustomerrequirements 是否使客户满意 Isthecostacceptedtothecustomer 是否成本能为客户接收 Managementsupport 管理层支持 KeyWordsandBasicConcepts关键词和基本概念 PrototypeBuild ControlPlan样件制造 控制计划 Assurethattheproductorservicemeetsspecificationandreportdataasrequired 确保产品和服务能满足所要求的规范并根据要求提供数据 Ensurethatparticularattentionhasbeengiventospecialproductandprocesscharacteristics 保证对产品和工艺特性予以足够的重视 Usedataandexperiencetoestablishpreliminaryprocessparametersandpackagingrequirements 利用已有的数据和经验设定初步工艺参数和包装要求 Communicateanyconcerns deviations and orcostimpacttothecustomer与客户就任何建议 偏差和 或成本进行交流 ControlPlanshouldbepreparedbyAPQPteam控制计划应由APQP小组完成 ControlPlans控制计划 PrototypeControlPlan Adescriptionofthedimensionalmeasurement materialandperformanceteststhatwilloccurduringPrototypebuild 样件控制计划 在样件制造过程中对产品的尺寸 材料和性能试验的描述 Pre launchControlPlan Adescriptionofthedimensionalmeasurement materialandperformanceteststhatwilloccurafterPrototypeandbeforefullproduction 试生产控制计划 在样件之后正式批量生产之前 对产品的尺寸 材料和性能试验的描述 ProductionControlPlan Comprehensivedocumentationofproduct processcharacteristic processcontrol testing andmeasurementsystemthatwilloccurduringmassproduction 正式生产控制计划 在批量生产过程中 对产品工艺特性 过程控制 测试和计量系统制定的综合性文件 2 0PRODUCTIONDESIGNANDDEVELOPMENT ExampleofControlPlan 2 0产品设计与开发 控制计划 SpecialProduct ProcessCharacteristic特殊产品 工艺特性 Thecustomerrequirements 客户要求Reliabilitygoals可靠性目标Specialprocesses 特殊生产工艺SimilarproductFMEAs类似产品的FMEA KeyWordsandBasicConcepts关键词和基本概念 Characteristicsnormallydesignedbythecustomerassignificant 产品的特征通常由客户作为重点标明 Basedon 基于 DesignFMEAExample 2 0PRODUCTIONDESIGNANDDEVELOPMENT SystemSubsystemComponentDesignResponsibility ModelYear s Vehicle s 199x lion4dr WagonKeyDate CoreTeam FMEANumberPageofPreparedByFMEADate Orig ItemFunction PotentialEffect s ofFailure PotentialFailureMode SEV Class PotentialCause s ofMechanism s ofFailure Occur CurrentDesignControl Detect R P N RecommendedAction Responsibility TargetCompletionAction ActionResults ActionsTaken Sev Occ Det R P N FrontDoorL H H8HX 0000 AIngresstoandEnergyfromVehicleOccupantprotectionfromweathernoise andsideimpactSupportanchoragefordoorhardwareincludingmirror hingelatchandwindowregulator Corrodedinteriorlowerdoorpanels Deterioratedlifeofdoorleadingto UnsatisfactoryappearanceduetothroughpaintovertimeImpairedfunctionofinteriordoorhardware 7 Upperedgeofprotectivewaxapplicationspecifiedforinnerdoorpanelsistoolow Insufficientwaxthicknessspecified Inappropriatewaxformulationspecified Entrappedairpreventswaxfromenteringcorner edgeaccess 6425 VehiclegeneraldurabilitytestvahT 118 T 109 T 301 Vehiclegeneraldurabilitytesting asabove PhysicalandChemLabtest ReportNo 1265 Designaidinvestigationwithnon functionalsprayhead 729471962288280 AddLaboratoryacceleratedcorrosiontesting Addlaboratoryacceleratedcorrosiontesting ConductDesignofExperimentsonwaxthickness None Addteamevaluationusingproductsprayequip andspecifiedwax ATage BodyEngrg8X0930 Combinewithtestforwaxupperedgeverification ATateBodyEngrg9X0115 BodyEngrg AssyOps8X1115 Basedontestresults TestNo 1481 upperedgespecraised125mm Testresults TestNo 1481 showspecifiedthicknessisadequate DOEshow25 variationinspecifiedthicknessisacceptable 722287222871321 x T Fender CarProductDev Children Manufacturing Ford AssyOps Dalton Fraser HenleyAssemblyPlants BodyEngineering 9X0301ER 1234 1 1 A Tate X6412 BodyEngr 8X0322 3 0ProcessDesignandDevelopment 3 0生产工艺设计与开发 CharacteristicMatrix特性矩阵 Showstherelationshipbetweenprocessparametersandtheoperations 显示工艺参数和操作之间的关系Themorerelationshipthereisthemoreimportantthecharacteristic 关系越多 特性就越重要 KeyWordsandBasicConcepts关键词和基本概念 Example 例如 3 0ProcessDesignandDevelopment ProcessResponsibility ModelYear s Vehicle s KeyDate CoreTeam FMEANumberPageofPreparedByFMEADate Orig ProcessFunctionRequirements PotentialEffect s ofFailure PotentialFailureMode SEV Class PotentialCause s ofMechanism s ofFailure Occur CurrentProcessControl Detect R P N RecommendedAction Responsibility TargetCompletionAction ActionResults ActionsTaken Sev Occ Det R P N ManualapplicationofwaxinsidedoorTocoverinnerdoor lowersurfacesatminimumwaxthicknesstoretardcorrosion Insufficientwaxcoverageoverspecifiedsurface Deterioratedlifeofdoorleadingto UnsatisfactoryappearanceduetothroughpaintovertimeImpairedfunctionofinteriordoorhardware 7 Manuallyinsertedsprayheadnotinsertedfarenough Visualcheckeachhour 1 shiftforfilmthickness depthmeter andcoverage Addpositivedepthstoptosprayer MFGEngrg9X1015 Stopadded sprayercheckedonline ExampleofProcessFMEA 8 5 280 72570 Automatesprayer MFGEngrg9X1215 Rejectedduetocomplexityofdiffe rentdoorsonsameline Sprayheadsclogged Viscositytoohigh Temperaturetoolow Pressuretoolow 5 Testspraypatternatstart upandafteridleperiods andpreventativemaintenanceprogramtocleanheads Item 4 0ProductandProcessValidation 4 0产品和工艺的认证 4 0ProductandProcessValidation ExampleofProcessCapabilityStudy SPEC MAXIMUM MINIMUM 92054422 DECORPANELASSEMBLY 5 40mm 5 00mm SAMPLEQUANTITY 3DCOORDINATEM C UNITOFMEASURE GAUGE REMARK DATE MEASUREDBY APPROVEDBY 21 AUG1996 J K KIM C W KIM 100PCS mm GR R PC 29 7 GROUPNO SAMPLES X1 X2 X3 X4 X5 5 235 235 255 235 245 255 255 275 245 235 225 235 255 245 265 225 235 265 225 25 5 225 245 235 275 235 235 235 245 215 245 265 265 235 275 245 275 245 275 235 24 5 245 255 255 285 235 265 285 235 235 265 235 285 245 265 225 265 245 255 235 21 5 265 235 215 265 235 235 245 235 245 275 215 255 285 285 295 285 225 265 225 27 5 225 265 245 225 255 255 225 245 265 235 245 235 255 235 305 245 245 225 235 26 26 2026 2126 1826 2626 2226 2226 2226 2126 1826 2326 1626 2726 2326 3426 2126 2726 1726 2626 1323 23 5 2405 2425 2365 2525 2445 2445 2425 2365 2465 232 0 040 030 060 040 030 030 060 040 050 040 050 050 050 080 060 020 050 010 030 06 5 232 5 252 5 246 5 268 5 242 5 252 5 234 5 252 5 226 5 246 R CHART CHART R 5 271 5 244 5 217 0 097 0 046 CHART CL UCL LUL RCHART CL R 0 064UCL D4R 0 097 R d2 0 00198CP T 6 3 37CPk 1 k CP 2 63 5 244 5 271 A2R A2R 5 217 Prototype Pre Launch Production ControlPlanNumber PartNumber LatestChangeLevel Supplier Plant PartName Description SupplierCode Part ProcessNumber ProcessName OperationDescription Machine Jig Device ToolsForMfg KeyContact Phone CoreTeam Supplier PlantApproval Date OtherApproval Date Ifreq抎 Date Orig Date Orig CustomerEngineeringApproval Date Ifrequired CustomerQualityApproval Date Ifrequired OtherApproval Ifrequired ReactionPlan ControlMethod Sample Method Size Freq EvaluationMeasurementTechnique Product ProcessSpecification Tolerance SpecialChar Class Characteristics No Product Process 4 0ProductandProcessValidation ExampleofProductionControlPlan x 12345M 52321231 D EngineerBlock ABCCompany Plant 2 123H A B Casting813 123 4567 SeeAttachedList 9 9 92 2 20 93 3 MachineSurface揂 Rotarymachine Holdingfixture 4 Holdingfixture 10 51 52 53 Depthofcut Perpendicularcut Holdingcastinginfixtureforproperorientation 2 0 25 1 Fixturefreefromdebris Depthgage Gage050 Visualinspection 5 1PC 1PC perhrperfixture every4hrs Aftereachcycle X RChart X MRChart Airblow off Quarantineadjustandreset Quarantineadjustandreset Readjustairblow off 5 0Feedback AssessmentandCorrectiveAction 5 0反馈 评估及整改措施 VariableGageStudyShortmethod GageStudyLongMethod RelationshipbetweenQS9000andAPQP QualityPlanning质量策划4 2 3 PPAP正式生产件审批II 1 APQP QS9000 ACT PLAN DO STUDY ContinualImprovement Technology ConceptDevelopment Pr