aad_APQP-PPAP

1、APQPPPAP 1APQPA Perspective on 8-D and PFMEA and Control Plan During APQP and Afterwards2What is APQP?APQP is a defined process for a product development system for Ford, Daimler- Chrysler, GM and their suppliers. APQP is an attempt to provide a common path and synchronization of product development

2、 activities.APQP is an attempt to ensure communication both within a company and between a company and its customerMarketing & CommunicationsBenefits of APQPEnsures early planning takes place.Directs resources to the customer.Identifies required changes early in the process.Provides quality product

3、on time and at lowest cost.Enables cross-functional inputs and outputs.Addresses potential problems earlyMarketing & CommunicationsCustomer and Supplier InvolvementCustomer may initiate planning process.Supplier has the obligation to establish cross-functional team to manage process.Supplier should

4、expect the same performance from their subcontractors.Marketing & CommunicationsDetermine Customer RequirementsPrintPurchase Request or Request for Quotation.Statement of Work (SOW)Customer visits and discussions.Product checklists.Marketing & CommunicationsTrainingCustomer needs and expectations.Wo

5、rking as a team.Requirements of APQPFMEAAPQPPPAPMarketing & CommunicationsAPQP Five Phase ProcessPlanningProduct Design and DevelopmentProcess Design and DevelopmentProduct and Process ValidationProductionFeedback Assessment and Corrective ActionPilotLaunchConcept Initiation/ApprovalProgram Approval

6、PrototypePlanningLinks Between the ToolsContract Review Program PlanDFMEATeam Feasibility CommitmentProduce Process Flow DiagramsConduct Process FMEADevelop Control PlanWork Instruction DevelopmentProduct and Process ValidationEnsure Continuous ImprovementPhase IPhase IIPhase IIPhase IIIPhase IIIPha

7、se IIIPhase IIIPhase IVPhase VDetermine Customer Expectations and Plan for QualityIdentify Key Characteristics Determine Risk and FeasibilityAssociate Characteristics with Process Steps and Identify Key CharacteristicsExpose Sources of Variation and Finalize Key CharacteristicsDetermine Methods to I

8、mprove Process and Control VariationImplement Control Plan and Standardize the ProcessEnsure Customer Expectations are MetExercise Management OversightThe Target and The GoalMarketing & CommunicationsLink Between the DocumentsProcess Flow DiagramsUpdated after production trial run.Need to indicate s

9、pecial characteristics generated at each step. Completed Along with Control Plan (APQP Process).Generally contains same information as process traveler.Marketing & CommunicationsProcess Flow Diagram ExampleMarketing & CommunicationsAPQP Links to PFMEAProcess FMEAMust follow flow of the process flow

10、diagram.Must include ALL process special characteristics (as a minimum).Marketing & CommunicationsHow a PFMEA WorksWhere does the data for the PFMEA come from?What types of people are a part of the PFMEA team?What types of activities should we spend a lot of time on?PFMEAs/Control Plans and 8-Ds Dur

11、ing APQPPFMEAs should be driven by real data, including 8-Ds (internal and external), warranty and returned part analysisPFMEAs should be completed by process experts and should be a driver of the control plans and work instructionsWork instructions (Post control log, process parameter logs, prevent

12、ive maintenance, etc.) implement the control plan in the processWhen there is a quality problem there is an opportunity to improve the control plan and the work instructionsAPQP Links to Control PlanControl PlansIncludes product and process special characteristics.Includes SPC requirements.Follows f

13、low of process flow chart and PFMEA.May require customer approval.Marketing & CommunicationsTypes of Control PlansPrototype build control plan(s) Pre-launch control planProduction control planMarketing & CommunicationsPrototype Build Control PlanA description of the dimensional measurements.Material

14、 testsFunctional tests that will occur during prototype build.Marketing & CommunicationsPre-launch Control PlanDescription of dimensional measurements, materials, and functional tests.Adds additional product and process controls.Purpose is to contain potential nonconformities utilizing:More frequent

15、 inspections and/or tests.More in-process and finsl inspection and/or check points.Statistical evaluations.Increased audits.Marketing & CommunicationsProduction Control PlanUp-date pre-launch control plan.Add:Sampling plansControl methodSPC, inspection, attribute data and mistake proofing.Reaction p

16、lanNonconformances clearly identified, quarantined and disposition made.Requires customer approval unless otherwise specified.Marketing & CommunicationsControl Plan UseInitial: To document and communicate initial process control.Next: Guidance in controlling processes and to ensure product quality.L

17、ast A living document reflecting current methods of control and measurement systems used.Marketing & CommunicationsMultiple Molds, Tools, Dies and PatternsComplete dimensional layer required from one part from each cavity as a minimum.Supplier must identify specific cavity for each part submitted.Ma

18、rketing & CommunicationsPart Submission StatusNever ship production parts before receiving customer approval.Supplier must ensure that future production continues to meet customer requirements.No production parts can be shipped until approval is received.Marketing & CommunicationsAutomotive Document

19、ation DevelopmentDevelop Process Flow ListingCheck for Customer RequirementsEnter Every “Major Process from Flow Listing into FMEA Form Give careful consideration to what you consider a “Major processDevelop FMEA Element for Every ProcessUse the appropriate RPN numbers and considerations of other ap

20、propriate information / data to determine Critical characteristicsDevelop the Control Plan with Critical CharacteristicsDevelop control mechanisms appropriate for Critical characteristics.Give careful consideration to defining Control Plan stagesPrototype Pre-launch ProductionMarketing & Communicati

21、onsMarketing & CommunicationsProvides Proof of CapabilityMade up of Documents from APQP Marketing & CommunicationsPPAP PurposeEnsure that customer design record and specification requirements are understood.Ensure that the process has the potential for producing product meeting those requirementsMar

22、keting & CommunicationsPPAP ScopeProduction parts - generally 300 pieces.Includes internal and external sources for information.Submission required prior to first production shipment.Marketing & Communications Base DocumentationCritical characteristics matrix.Process flow diagram.Design FMEA (suppli

23、ed by customer).Process FMEA.Control plan.Marketing & CommunicationsGeneralSupplier is responsible for meeting all applicable specifications.Do not submit parts and documentation results if they are outside specification.Take corrective action to meet all design record requirements.Contact customer

24、if unable to meet all requirementsComply with customer developed material specifications and/or approved source list.Marketing & CommunicationsGeneralSuppliers are required to complete and maintain copies of all documentation identified in “requirements for approval regardless of submission level.Re

25、cords of PPAP are to be retained for the life of the part plus one calendar year.Marketing & CommunicationsElements of a PPAPPart submission warrantSubcontractor warrantsDesign record (customer/design documentation)Sample/Master sample (Master sample retained by supplier)Dimensional analysisTest dat

26、aFlow diagramControl planPFMEAMeasurement Systems Analysis (GR&R)Capability studiesMarketing & CommunicationsParts Submission WarrantUpon satisfactory completion of all required measurements and tests, enter all required information on the warrant.A separate is required for each part number.Responsi

27、ble supplier official verifiesMeasurements and tests conform to customer requirementsRequired documentation is available for proper submission level.Signs warrant and provided date, title and telephone number.Marketing & CommunicationsMarketing & CommunicationsPart WeightDetermine part weight withou

28、t packaging or shipping material.Report weight in kilograms to three decimal places.Weight determinationWeigh 10 parts randomly selected and report the average weight.For parts less than 0.100 kilogram, weigh 10 parts together and report the average weight.Marketing & CommunicationsMaster SampleReta

29、in same as PPAP, orUntil new master sample is produced for the purpose of a customer approval.Identify master sample by:Part numberDrawing level or revision levelCustomer approval dateMarketing & CommunicationsPreliminary Process Capability StudiesCharacteristics identified in the control plan.Usual

30、ly 100 pieces minimum.May be 30 if run is less.Ppk 1.67 is acceptable unless otherwise specified.Ppk 1.67 requires action plan unless otherwise specified.Marketing & CommunicationsProduction Trial RunProduction tooling, equipment, environment, facilities and cycle time.Process Instructions and contr

31、ol plans.Minimum quantity set by the customer.Generally 300 parts.Marketing & CommunicationsProduction Trial Run Product Used ForPreliminary process capability studies.MSA (if not completed earlier)Final Feasibility.Process review.Production Validation Testing.PPAPPackaging evaluationFirst time capa

32、bilityQuality planning sign-offMarketing & CommunicationsMeasurement System Analysis (MSA)Complete studies as defined in the MSA plan.Minimum are those identified in the control plan.Subjected to evaluation prior to or during production trial.Marketing & CommunicationsPackaging EvaluationPackaging must conform to specifications developed by customer or supplier.Assess protection of product.Customer specified packaging must be evaluated by team.Pilot or production trial run parts usually used in evaluation.Marketing & CommunicationsFloor Plan LayoutDetermine acceptability of inspection