SGM-APQP-kic-off.ppt

1、SHANGHAI GM SUPPLIER QUALITY IMPROVEMENT PROCESS 上 海 GM 供 应 商 质 量 改 进 程 序,ADVANCED PRODUCT QUALITY PLANNING and CONTROL PLAN 产 品 质 量 先 期 策 划 和 控 制 计 划 Shanghai GM 上 海 GM Supplier Development/Quality 供 应 商 开 发/ 质 量,WHAT IS APQP? 什么是APQP？ It is a formal structured process - Allows the establishment of

2、 the necessary steps to assure a quality product which will meet the customers requirements. 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,Establish a quality plan which supports the development of products that meet customer requirements. 制 定一 个产 品质量 计划 来支持 产 品开发以满 足顾 客 要 求. Timely complet

3、ion of critical activities 按时 完 成 各 项 重 要 工 作 On time Production Part Approval 准 时 完 成 正式生 产 件 审 批 Ongoing conformance to specifications 自始至终达到 规范要 求 Continuous Improvement 不断改 善 产 品 质 量( 精 益 求 精),Purpose 目的,WHY APQP? 为什么需要 APQP?,Meet QS9000 requirements. 满足 QS9000 质量要求。 Increase customer satisfacti

4、on. 提高客户的满意程度。 Improve profit margin. 提高公司利润。 Increase success of company through a well-documented system for each project. 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。,WHY APQP? (Continue) 为什么需要APQP? (续前 ),Purpose 目的,Define the Scope 确定工 作范围 Plan and Define Program 计划与确定项 目 Product Design and Development 产 品 设 计

5、与 开发 Process Design and Development 工 艺 设 计 与 开发 Product and Process Validation 产 品 及 工 艺 认 证 Feedback, Assessment and Corrective Action 反 馈, 评 估 及 整改 措 施,Key Steps 关 键 步 骤,Process 程序,Set up a cross-functional project localization team 建立国产化项目横向协调小组 Select project team leader 选 出 项 目 小 组 负 责 人 Defin

6、e functional roles & responsibilities 确定职能 和 责 任 Identify internal and external customers 识别内 外 部客户 Define customer requirements 确定客户 要 求,Define the Scope 确定工作范围,Understand Customer Expectations 了 解客户期 望 Assess Feasibility of Proposed Design 评 估 所 提 出 设 计 之可 行 性 Identify Costs, Timing, and Constrain

7、ts 识别 所 需 费 用, 时 间 和制约 Determine Assistance Required from Customer 明确需要从客户处所得到的帮助 Identify Documentation Process/Method 确定文 件 记 录 之程 序 与方 法,Define the Scope 确定工作范围,(Continue 续前 ),Concept Initiation/Approval,Program Approval,PRODUCTDESIGN ANDDEVELOPMENT,PROCESS DESIGN ANDDEVELOPMENT,Prototype,Pilot,L

8、aunch,PLANNING,PRODUCT DESIGN AND DEV.,PROCESS DESIGN AND DEVELOPMENT,PRODUCT AND PROCESS VALIDATION,PLANNING,PRODUCTION,FEEDBACK ASSESSMENT AND CORRECTIVE ACTION,PLAN AND DEFINEPROGRAM,PRODUCT AND PROCESS VALIDATION,FEEDBACK ASSESSMENT AND CORRECTIVE ACTION,Product Quality Planning Timing Chart,概念

9、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,1.0 PLAN AND DEFINE PROGRAM,1.0 计 划 与 确 定 项 目,Product Reliability 产品可靠性,Key Words and Basic Concepts 关键词和基本概念,Study what data is available 研究现有的数据 Use data from frequ

10、ency of repair 使用维修频率的数据 What are the long term durability goals 长远的耐用性目标是什么,Product Assurance Plan 产品保证计划,Design requirements. 设计要求 Program requirements. 项目要求 Reliability goals.可靠性目标 Technology used.采用的技术 FMEA.失效模式及后果分析 Engineering requirements.工程要求,Key Words and Basic Concepts 关键词和基本概念,Based on: 基

11、于,2.0 PRODUCTION DESIGN AND DEVELOPMENT,2.0 产 品 设 计 与 开 发,Design FMEA Design for Manufacturability and Assembly Design Verification Design Reviews Prototype Build Engineering Drawings Material Specifications Drawing and Specification Changes,2.0 PRODUCTION DESIGN AND DEVELOPMENT,OUTPUTS,By Design Re

12、sponsible Activity,By APQP Team,New Equipment, Tooling and Facilities Requirements Special Product and Process Characteristics Prototype Control Plan Gages/Testing Equipment Requirements. Team Feasibility Commitment & management Support,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

13、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,Team Feasibility Commitment 项目可行性承诺书,Customer: _ Part Name:_ Part Number: _ Feasibility Considerations: Our Product quality planning team has considered the following questions, not intended to be all-inclus

14、ive in performing a feasibility evaluation. The drawings and /or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All “no” answers are supported with attached with comments identifying our concerns and /or proposed changes to enable us t

15、o meet the specified requirements.,Conclusion,Feasible Product can be produced as specified with no revisions. Feasible Changes recommended (see attached). Not Feasible Design revision required to produce product within the specified requirements. _ _ Team member/Title/ Date Team Member/ Title/ Date

16、,Sign-off,Key words and Basic Concepts,Key Words and Basic Concepts 关键词和基本概念,Feasibility commitment 可行性承诺,Can it be manufactured?Can it be assembled? 是否能制造?是否能装配? Can it be tested?Can it be delivered at specified volume? 是否能测试 ?是否能按指定的数量发运? Will it satisfy the customer requirements? 是否使客户满意? Is the

17、cost accepted to the customer? 是否成本能为客户接收?,Management support. 管理层支持,Key Words and Basic Concepts 关键词和基本概念,Prototype Build - Control Plan 样件制造-控制计划,Assure that the product or service meets specification and report data as required. 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. Ensure that particular attention has been

18、 given to special product and process characteristics. 保证对产品和工艺特性予以足够的重视. Use data and experience to establish preliminary process parameters and packaging requirements. 利用已有的数据和经验设定初步工艺参数和包装要求. Communicate any concerns, deviations, and/or cost impact to the customer 与客户就任何建议, 偏差和/或成本进行交流.,Control P

19、lan should be prepared by APQP team 控制计划应由APQP小组完成,Control Plans 控制计划,Prototype Control Plan - A description of the dimensional measurement, material and performance tests that will occur during Prototype build. 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-launch Control Plan - A description of the dimens

20、ional measurement, material and performance tests that will occur after Prototype and before full production. 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. Production Control Plan -Comprehensive documentation of product/ process characteristic, process control,testing, and measurement system that will

21、occur during mass production. 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.,2.0 PRODUCTION DESIGN AND DEVELOPMENT,Example of Control Plan,2.0 产品设 计 与 开 发,控 制 计 划,Special Product/Process Characteristic 特殊产品/工艺特性,The customer requirements.客户要求 Reliability goals可靠性目标 Special processes.特殊生产工艺 Simil

22、ar product FMEAs类似产品的FMEA,Key Words and Basic Concepts 关键词和基本概念,Characteristics normally designed by the customer as significant. 产品的特征通常由客户作为重点标明,Based on: 基于:,Design FMEA Example,2.0 PRODUCTION DESIGN AND DEVELOPMENT,System Subsystem Component Design Responsibility,Model Year(s)/Vehicle(s) 199x/li

23、on 4dr/Wagon Key Date,Core Team,FMEA Number Page of Prepared By FMEA Date (Orig.),Item Function,Potential Effect(s) of Failure,Potential Failure Mode,S E V.,C l a s s,Potential Cause(s) of Mechanism(s) of Failure,O c c u r,Current Design Control,D e t e c t,R. P. N.,Recommended Action,Responsibility

24、 & Target Completion Action,Action Results,Actions Taken,S e v,O c c,D e t,R. P. N.,Front Door L.H. H8HX-0000-A Ingress to and Energy from Vehicle Occupant protection from weather noise, and side impact Support anchorage for door hardware including mirror,hinge latch and window regulator,Corroded in

25、terior lower door panels,Deteriorated life of door leading to: Unsatisfactory appearance due to through paint over time Impaired function of interior door hardware,7,Upper edge of protective wax application specified for inner door panels is too low,Insufficient wax thickness specified,Inappropriate

26、 wax formulation specified,Entrapped air prevents wax from entering corner/edge access,6 4 2 5,Vehicle general durability test vah T- 118. T - 109. T - 301,Vehicle general durability testing - as above,Physical and Chem Lab test - Report No. 1265,Design aid investigation with non - functional spray

27、head,7 294 7 196 2 28 8 280,Add Laboratory accelerated corrosion testing,Add laboratory accelerated corrosion testing,Conduct Design of Experiments on wax thickness,None,Add team evaluation using product spray equip. and specified wax,A Tage-Body Engrg 8X 09 30,Combine with test for wax upper edge v

28、erification,A Tate Body Engrg 9X 01 15,Body Engrg & Assy Ops 8X 11 15,Based on test results( Test No) 1481) upper edge spec raised 125mm,Test results(Test No. 1481) show specified thickness is adequate. DOE show 25% variation in specified thickness is acceptable,7 2 2 28 7 2 2 28 7 1 3 21,x,T. Fende

29、r-Car Product Dev. Children-Manufacturing, Ford-Assy Ops ( Dalton, Fraser, Henley Assembly Plants,Body Engineering,9X 03 01 ER,1234,1,1,A. Tate -X6412 -Body Engr,8X 03 22,3.0 Process Design and Development,3.0 生产工艺设计与开发,Characteristic Matrix特性矩阵,Shows the relationship between process parameters and

30、the operations. 显示工艺参数和操作之间的关系 The more relationship there is the more important the characteristic. 关系越多, 特性就越重要,Key Words and Basic Concepts 关键词和基本概念,Example: 例如,3.0 Process Design and Development,Process Responsibility,Model Year(s)/Vehicle(s) Key Date,Core Team,FMEA Number Page of Prepared By FM

31、EA Date (Orig.),Process Function Requirements,Potential Effect(s) of Failure,Potential Failure Mode,S E V.,C l a s s,Potential Cause(s) of Mechanism(s) of Failure,O c c u r,Current Process Control,D e t e c t,R. P. N.,Recommended Action,Responsibility & Target Completion Action,Action Results,Action

32、s Taken,S e v,O c c,D e t,R. P. N.,Manual application of wax in side door To cover inner door, lower surfaces at minimum wax thickness to retard corrosion,Insufficient wax coverage over specified surface,Deteriorated life of door leading to: Unsatisfactory appearance due to through paint over time I

33、mpaired function of interior door hardware,7,Manually inserted spray head not inserted far enough,Visual check each hour- 1/shift for film thickness (depth meter) and coverage,Add positive depth stop to sprayer,MFG Engrg 9X 10 15,Stop added, sprayer checked on line,Example of Process FMEA,8,5,280,7

34、2 5 70,Automate sprayer,MFG Engrg 9X 12 15,Rejected due to complexity of diffe- rent doors on same line,Spray heads clogged - Viscosity too high - Temperature too low - Pressure too low,5,Test spray pattern at start-up and after idle periods, and preventative maintenance program to clean heads,Item,

35、4.0 Product and Process Validation,4.0 产品和工艺的认证,4.0 Product and Process Validation,Example of Process Capability Study,SPEC.,MAXIMUM,MINIMUM,92054422,DECOR PANEL ASSEMBLY,5.40 mm,5.00 mm,SAMPLE QUANTITY,3D COORDINATE M/C,UNIT OF MEASURE,GAUGE,REMARK,DATE,MEASURED BY,APPROVED BY,21. AUG 1996,J. K. KI

36、M,C. W. KIM,100PCS,mm,G R&R : PC=29.7%,GROUP NO,SAMPLES,X1,X2,X3,X4,X5,5.23 5.23 5.25 5.23 5.24 5.25 5.25 5.27 5.24 5.23 5.22 5.23 5.25 5.24 5.26 5.22 5.23 5.26 5.22 5.25,5.22 5.24 5.23 5.27 5.23 5.23 5.23 5.24 5.21 5.24 5.26 5.26 5.23 5.27 5.24 5.27 5.24 5.27 5.23 5.24,5.24 5.25 5.25 5.28 5.23 5.26

37、 5.28 5.23 5.23 5.26 5.23 5.28 5.24 5.26 5.22 5.26 5.24 5.25 5.23 5.21,5.26 5.23 5.21 5.26 5.23 5.23 5.24 5.23 5.24 5.27 5.21 5.25 5.28 5.28 5.29 5.28 5.22 5.26 5.22 5.27,5.22 5.26 5.24 5.22 5.25 5.25 5.22 5.24 5.26 5.23 5.24 5.23 5.25 5.23 5.30 5.24 5.24 5.22 5.23 5.26,26.20 26.21 26.18 26.26 26.22

38、 26.22 26.22 26.21 26.18 26.23 26.16 26.27 26.23 26.34 26.21 26.27 26.17 26.26 26.13 23.23,5.240 5.242 5.236 5.252 5.244 5.244 5.242 5.236 5.246 5.232,0.04 0.03 0.06 0.04 0.03 0.03 0.06 0.04 0.05 0.04 0.05 0.05 0.05 0.08 0.06 0.02 0.05 0.01 0.03 0.06,5.232,5.252,5.246,5.268,5.242,5.252,5.234,5.252,5

39、.226,5.246,R,CHART,CHART,R,5.271,5.244,5.217,0.097,0.046,CHART,CL =,UCL =,LUL =,R CHART,CL = R = 0.064 UCL= D4R = 0.097 = R/d2 = 0.00198 CP = T/6 = 3.37 CPk = ( 1 - k ) CP = 2.63,= 5.244,= 5.271,+ A2R,- A2R,= 5.217,Prototype,Pre-Launch,Production,Control Plan Number,Part Number/Latest Change Level,S

40、upplier /Plant,Part Name/Description,Supplier Code,Part/ Process Number,Process Name/ Operation Description,Machine, Jig, Device, Tools For Mfg,Key Contact/Phone,Core Team,Supplier/Plant Approval/Date,Other Approval/Date ( If req抎),Date(Orig.),Date(Orig.),Customer Engineering Approval/Date( If requi

41、red),Customer Quality Approval/Date( If required),Other Approval( If required),Reaction Plan,Control Method,Sample,Method,Size,Freq.,Evaluation Measurement Technique,Product/Process Specification/Tolerance,Special Char. Class,Characteristics,No.,Product,Process,4.0 Product and Process Validation,Exa

42、mple of Production Control Plan,x,12345M,52321231/D,Engineer Block,ABC Company/Plant # 2,123H,A.B. Casting 813-123-4567,See Attached List,9-9 - 92,2-20 - 93,3,Machine Surface 揂,Rotary machine,Holding fixture #4,Holding fixture # 10,51,52,53,Depth of cut,Perpendicular cut,Holding casting in fixture f

43、or proper orientation,*,*,2 +/-0.25,+/-,1,=,Fixture free from debris,Depth gage,Gage 050,Visual inspection,5,1 PC,1 PC,per hr per fixture,every 4 hrs,After each cycle,X - R Chart,X-MR Chart,Air blow- off,Quarantine adjust and reset,Quarantine adjust and reset,Readjust air blow- off,5.0 Feedback, Assessment and Corrective Action,5.0 反馈, 评估及整改措施,Variable Gage Study Short method,Gage Study Long Method,Relationship between QS9000 and APQP,Quality Planning 质量策划 4.2.3,PPAP 正式生产件审批 II.1,APQP,QS9000,*,A C T,P L A N,D O,S T U D Y,Continual Improvement,Techn