APQP产品先期质量策划(英文版)

APQPPPAP,APQP,APerspectiveon8-DandPFMEAandControlPlanDuringAPQPandAfterwards,WhatisAPQP?,APQPisadefinedprocessforaproductdevelopmentsystemforFord,Daimler-Chrysler,GMandtheirsuppliers.APQPisanattempttoprovideacommonpathandsynchronizationofproductdevelopmentactivities.APQPisanattempttoensurecommunicationbothwithinacompanyandbetweenacompanyanditscustomer,BenefitsofAPQP,Ensuresearlyplanningtakesplace.Directsresourcestothecustomer.Identifiesrequiredchangesearlyintheprocess.Providesqualityproductontimeandatlowestcost.Enablescross-functionalinputsandoutputs.Addressespotentialproblemsearly,CustomerandSupplierInvolvement,Customermayinitiateplanningprocess.Supplierhastheobligationtoestablishcross-functionalteamtomanageprocess.Suppliershouldexpectthesameperformancefromtheirsubcontractors.,DetermineCustomerRequirements,PrintPurchaseRequestorRequestforQuotation.StatementofWork(SOW)Customervisitsanddiscussions.Productchecklists.,Training,Customerneedsandexpectations.Workingasateam.RequirementsofAPQPFMEAAPQPPPAP,APQPFivePhaseProcess,Planning,ProductDesignandDevelopment,ProcessDesignandDevelopment,ProductandProcessValidation,Production,FeedbackAssessmentandCorrectiveAction,Pilot,Launch,ConceptInitiation/Approval,ProgramApproval,Prototype,Planning,LinksBetweentheTools,ContractReviewProgramPlan,DFMEA,TeamFeasibilityCommitment,ProduceProcessFlowDiagrams,ConductProcessFMEA,DevelopControlPlan,WorkInstructionDevelopment,ProductandProcessValidation,EnsureContinuousImprovement,PhaseI,PhaseII,PhaseII,PhaseIII,PhaseIII,PhaseIII,PhaseIII,PhaseIV,PhaseV,DetermineCustomerExpectationsandPlanforQuality,IdentifyKeyCharacteristics,DetermineRiskandFeasibility,AssociateCharacteristicswithProcessStepsandIdentifyKeyCharacteristics,ExposeSourcesofVariationandFinalizeKeyCharacteristics,DetermineMethodstoImproveProcessandControlVariation,ImplementControlPlanandStandardizetheProcess,EnsureCustomerExpectationsareMet,ExerciseManagementOversight,TheTargetandTheGoal,LinkBetweentheDocuments,ProcessFlowDiagrams,Updatedafterproductiontrialrun.Needtoindicatespecialcharacteristicsgeneratedateachstep.CompletedAlongwithControlPlan(APQPProcess).Generallycontainssameinformationasprocesstraveler.,ProcessFlowDiagramExample,APQPLinkstoPFMEA,ProcessFMEA,Mustfollowflowoftheprocessflowdiagram.MustincludeALLprocessspecialcharacteristics(asaminimum).,HowaPFMEAWorks,WheredoesthedataforthePFMEAcomefrom?WhattypesofpeopleareapartofthePFMEAteam?Whattypesofactivitiesshouldwespendalotoftimeon?,PFMEAs/ControlPlansand8-DsDuringAPQP,PFMEAsshouldbedrivenbyrealdata,including8-Ds(internalandexternal),warrantyandreturnedpartanalysisPFMEAsshouldbecompletedbyprocessexpertsandshouldbeadriverofthecontrolplansandworkinstructionsWorkinstructions(Postcontrollog,processparameterlogs,preventivemaintenance,etc.)implementthecontrolplanintheprocessWhenthereisaqualityproblemthereisanopportunitytoimprovethecontrolplanandtheworkinstructions,APQPLinkstoControlPlan,ControlPlans,Includesproductandprocessspecialcharacteristics.IncludesSPCrequirements.FollowsflowofprocessflowchartandPFMEA.Mayrequirecustomerapproval.,TypesofControlPlans,Prototypebuildcontrolplan(s)Pre-launchcontrolplanProductioncontrolplan,PrototypeBuildControlPlan,Adescriptionofthedimensionalmeasurements.MaterialtestsFunctionalteststhatwilloccurduringprototypebuild.,Pre-launchControlPlan,Descriptionofdimensionalmeasurements,materials,andfunctionaltests.Addsadditionalproductandprocesscontrols.Purposeistocontainpotentialnonconformitiesutilizing:Morefrequentinspectionsand/ortests.Morein-processandfinslinspectionand/orcheckpoints.Statisticalevaluations.Increasedaudits.,ProductionControlPlan,Up-datepre-launchcontrolplan.Add:SamplingplansControlmethodSPC,inspection,attributedataandmistakeproofing.ReactionplanNonconformancesclearlyidentified,quarantinedanddispositionmade.Requirescustomerapprovalunlessotherwisespecified.,ControlPlanUse,Initial:Todocumentandcommunicateinitialprocesscontrol.Next:Guidanceincontrollingprocessesandtoensureproductquality.LastAlivingdocumentreflectingcurrentmethodsofcontrolandmeasurementsystemsused.,MultipleMolds,Tools,DiesandPatterns,Completedimensionallayerrequiredfromonepartfromeachcavityasaminimum.Suppliermustidentifyspecificcavityforeachpartsubmitted.,PartSubmissionStatus,Nevershipproductionpartsbeforereceivingcustomerapproval.Suppliermustensurethatfutureproductioncontinuestomeetcustomerrequirements.Noproductionpartscanbeshippeduntilapprovalisreceived.,AutomotiveDocumentationDevelopment,DevelopProcessFlowListing,CheckforCustomerRequirements,EnterEvery“Major”ProcessfromFlowListingintoFMEAForm,Givecarefulconsiderationtowhatyouconsidera“Major”process,DevelopFMEAElementforEveryProcess,UsetheappropriateRPNnumbersandconsiderationsofotherappropriateinformation/datatodetermineCriticalcharacteristics,DeveloptheControlPlanwithCriticalCharacteristics,DevelopcontrolmechanismsappropriateforCriticalcharacteristics.,GivecarefulconsiderationtodefiningControlPlanstages,PrototypePre-launchProduction,ProvidesProofofCapabilityMadeupofDocumentsfromAPQP,PPAPPurpose,Ensurethatcustomerdesignrecordandspecificationrequirementsareunderstood.Ensurethattheprocesshasthepotentialforproducingproductmeetingthoserequirements,PPAPScope,Productionparts-generally300pieces.Includesinternalandexternalsourcesforinformation.Submissionrequiredpriortofirstproductionshipment.,BaseDocumentation,Criticalcharacteristicsmatrix.Processflowdiagram.DesignFMEA(suppliedbycustomer).ProcessFMEA.Controlplan.,General,Supplierisresponsibleformeetingallapplicablespecifications.Donotsubmitpartsanddocumentationresultsiftheyareoutsidespecification.Takecorrectiveactiontomeetalldesignrecordrequirements.ContactcustomerifunabletomeetallrequirementsComplywithcustomerdevelopedmaterialspecificationsand/orapprovedsourcelist.,General,Suppliersarerequiredtocompleteandmaintaincopiesofalldocumentationidentifiedin“requirementsforapproval”regardlessofsubmissionlevel.RecordsofPPAParetoberetainedforthelifeofthepartplusonecalendaryear.,ElementsofaPPAP,PartsubmissionwarrantSubcontractorwarrantsDesignrecord(customer/designdocumentation)Sample/Mastersample(Mastersampleretainedbysupplier)DimensionalanalysisTestdataFlowdiagramControlplanPFMEAMeasurementSystemsAnalysis(GR&R)Capabilitystudies,PartsSubmissionWarrant,Uponsatisfactorycompletionofallrequiredmeasurementsandtests,enterallrequiredinformationonthewarrant.Aseparateisrequiredforeachpartnumber.ResponsiblesupplierofficialverifiesMeasurementsandtestsconformtocustomerrequirementsRequireddocumentationisavailableforpropersubmissionlevel.Signswarrantandprovideddate,titleandtelephonenumber.,PartWeight,Determinepartweightwithoutpackagingorshippingmaterial.Reportweightinkilogramstothreedecimalplaces.WeightdeterminationWeigh10partsrandomlyselectedandreporttheaverageweight.Forpartslessthan0.100kilogram,weigh10partstogetherandreporttheaverageweight.,MasterSample,RetainsameasPPAP,orUntilnewmastersampleisproducedforthepurposeofacustomerapproval.Identifymastersampleby:PartnumberDrawinglevelorrevisionlevelCustomerapprovaldate,PreliminaryProcessCapabilityStudies,Characteristicsidentifiedinthecontrolplan.Usually100piecesminimum.Maybe30ifrunisless.Ppk1.67isacceptableunlessotherwisespecified.Ppk1.67requiresactionplanunlessotherwisespecified.,ProductionTrialRun,Productiontooling,equipment,environment,facilitiesandcycletime.ProcessInstructionsandcontrolplans.Minimumquantitysetbythecustomer.Generally300parts.,ProductionTrialRunProductUsedFor,Preliminaryprocesscapabilitystudies.MSA(ifnotcompletedearlier)FinalFeasibility.Processreview.ProductionValidationTesting.PPAPPackagingevaluationFirsttimecapabilityQualityplanningsign-off,MeasurementSystemAnalysis(MSA),CompletestudiesasdefinedintheMSAplan.Minimumarethoseidentifiedinthecontrolplan.Subjectedtoevaluationpriortoorduringproductiontrial.,PackagingEvaluation,Packagingmustconformtospecificationsdevelopedbycustomerorsupplier.Assessprotectionofproduct.Customerspecifiedpackagingmustbeevaluatedbyteam.Pilotorproductiontrialrunpartsusuallyusedinevaluation.,FloorP