Post on 06-Feb-2018
APQP - Advanced Product Quality Planning
A sophisticated way for Value Management to add Value
to Products and to create Wealth for Companies
by Dipl. rer. oec. Axel Peter Ried
CEO of Ried Management Methods International Technical Consultants
Headquarters Hamburg, Germany
presented at the
CSVA 2011 Conference Toronto, Ontario
November 14-16, 2011
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
APQP - Advanced Product Quality Planning
an organized and well structured sophisticated process
to define and develop products and services
meeting all requirements
and being presented to the Market exactly on time
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Value Management and APQP
make it a great deal easier to
plan
monitor
implement
very complex projects.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
APQP and QS 9000
all suppliers of systems, sub-systems and parts
of the Automotive Industry must apply the APQP
processes in conjunction with Value Management
and Simultaneous Engineering.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
India‘s growing Automotive Industry
and all its national suppliers
will more and more be asked
to implement VM and APQP.
Well applied
this will guarantee the wealth of the Indian Industry.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Value Management and APQPare the Key Instruments of all important OEMs
(Original Equipment Manufacturers)
Daimler Chrysler
Ford
General Motors
Volkswagen
Audi
BMW
All of them are Key Customers
of Ried Management Methods.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Time to Market (TTM)
to reduce TTM for cars down from 5 to 3 years
very sophisticated Management Tools had to be
designed.
VM and APQP were identified to be the best tools to
add value
and create wealth.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
QS 9000 and VDA Strategy
VM and APQP are an integrated part of the
QS 9000 and the VDA Strategy
and will be also systematically applied
for all present and future suppliers out of India.
Each supplier must be certified in these tools.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
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M1 PhaseM1
PhaseD1
PhaseD1
PhaseD2
PhaseD2
PhaseP1
PhaseP1
PhaseP2
PhaseP2
PhaseP3
PhaseP3
Phase
StopGate 1
StopStopGate 1Gate 1
StopGate 2
StopStopGateGate 2 2
StopGate 3
StopStopGate 3Gate 3
StopStopStop StopStopStop
Project StartProject Start
APQP - Advanced Product Quality Planning
Product Product DesignDesign
ProcessProcess Design Design
Product and ProcessProduct and Process ValidationValidation
ProductionProduction
A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Value Management and the APQP Process
Define the Development Phases for new products
including the targets to
simplify the choice of projects
make sure, that sophisticated products will be implemented on time
improve the communicationof the company‘s departmentsguarantee a well controlled overall processstructure by very disciplined activities
identify and eliminate or reduce risks
use the resources very target orientedand the best way possible.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Value Management and APQP
is being always applied in
Project Teams
and Product Teams.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
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Division Division ManagerManager
SalesSales KeyKey Account Account Managers Managers
ProjectProjectTeamTeam
ProductProductTeamTeam
PurchasingPurchasingEngineeringEngineering
IndustrialIndustrialEngineeringEngineering
APQP Division APQP Division OrganizationOrganization
A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
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Manager of DivisionVE Project
Teams
Manager of DivisionVE Project
Teams
VE Project ManagerTeam 2
VE Project ManagerTeam 2
Key Account Manager
Key Account Manager
VE Project ManagerTeam 1
VE Project ManagerTeam 1
PurchasingEngineer
PurchasingEngineer
Project EngineerIndustrial
Engineering
Project EngineerIndustrial
Engineering
Project Engineer
Design + Engineering
Project Engineer
Design + Engineering
Quality EngineerQuality
Engineer
VE Project ManagerTeam 3
VE Project ManagerTeam 3
APQP - Project Management Organization
A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
The VM - APQP Phases
Phase M1
This Phase checks
the total market chance
and if the project is in accordance
It includes main activities like:
estimation and evaluation of the potentialson the basis of client‘s information, market analysisand other research studies
evaluation of project chances
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
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C lie n t:P ro je c t:A p p lic a tio n :D a te :
E va lu a tio n R e s u lt < 1 5 0 p o in ts – n o fu rth e r a c tiv it ie s≥ 1 5 0 p o in ts – p o s s ib ly in te re s tin g
T h e p ro je c t is v e ryre c o m m e n d a b le .
> 1 8 0 p o in ts - re co m m e n d a b le> 2 1 0 p o in ts – ve ry re c o m m e n d a b le
E v a lu a tio nC rite r ia
W e ig h in gF a c to r
R a n k in g T o ta lV a lu e
C lie n t B o n u sIm p le m e n ta tio n P ro b a b ility
A -P ro je c tP ro d u c t S a le s P e r io d (y e a rs )U n its p e r ye a rS a le s /ye a r a fte r S O PC o m p e titio n S itu a tio n
T a rg e t a c h ie ve m e n ta n d c h a n c e s (T )
S a le s k n o w h o wE n g in e e rin g k n o w h o wM a n u fa c tu r in g kn o w h o wE n g in e e rin g In v e s t,o f w h ic h c lie n t p a y s fo r %M a n u fa c tu r in g a n d Q C -In ve s tA va ila b ility o f R e s o u rc e s
A d v a n ta g e s a n d R is k s (A )T o ta l T + A
S p e c ify re a so n s ,if p ro je c t w ill b e d e n ie d
E v a lu a tio n o f P ro je c t C h a n c e s – M 1 P h a s e
A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Phase D 1 Feasibility Study
to check the implementation chances to meet all targets (functions, quality, cost, profit etc.)
to identify and eliminate risks
to intensively check the customer ‘sDuty Book requirements
to fully understand the client‘s application ideas
to finally determine the Duty Bookin close cooperation with the client
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
The Duty Book describes
cost targets
technical functions and requirements
schedule requirements
quality requirements
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Documentation
first application of FMEA (Failure Mode Effect Analysis)
application of QFD - Quality Function Deployment
first definition of possible suppliers
benchmarking with competitor products
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Design Verification
The Design Verification makes sure that the Design performs the
requirements and functions of the Duty Book.
The following activities have to be completed:
comparison of the new design with similar already existing Design (if available) to assure that all lessons learned areapplied the right way.
check of alternative solutions
preparation of alternative calculations
check of Design Documents
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
D1 Feasibility Check
The VE-Project Team must come to a consensus that
the chosen Design Concept will definitely meet the
customer‘s requirements:
functions
quality
cost
technical aspects
Mile Stone Plan and its key dates
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
D1 - Review
At the end of the APQP - D1 – Phase
the Team will prepare a D1-Review
to finally confirm that the next APQP Phase can be started.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
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ProductEngineerDesign
ProductEngineerDesign
ProductionExperts
Manufacturingand Assembly
ProductionExperts
Manufacturingand Assembly
LeaderProduct Team
LeaderProduct Team
MaterialsManagementEngineering
MaterialsManagementEngineering
Product EngineerIndustrial
Engineering
Product EngineerIndustrial
Engineering
APQP - Product Team Organization
Phase D2-Product Development
During this phase all Engineering Activitiesfor the new product will be completed:
A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Manufacturing and Assembly Processes
will be designed in a way that these guarantee a
permanent high quality levelwithin the SPC and PPM Targets
Well structured test programs
are a most important part of the Design Validation.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Client Confirmation and Design Freeze
The successful Design Validation is the basis of the
Design Confirmation by the client
and the Design Freeze
From now on any changes will definitely cause
heavy consequences (schedule, cost etc.).
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Duty Book and Specification Review
Supplier and client will review the Duty Book and the
specification which will be binding from now on - and will
have to be performed completely.
Quality = = Client RequirementsProduct Performance
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11
A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Design Review
Step 1 Planning, definition of the Review Teamand preparation of a Review Plan
Step 2 Development of Review Check-Lists
Step 3 Preparation of necessary documents and procedures
Step 4 Implementation, i.e. identification of problems, development of solutions and documentation
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Project Mile Stone Plan
describes all activities for the different Project Phases.
An excellent tool is the MS-Project software.
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No. of Activity Activity No. of Days Month/ Year
Jan01 02 03 04
Feb05 06 07 08
March
A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Special Product and Process Criteria
Each product developed by a VE-Team
must meet all specific client criteria,
such as for example:
safety relevant items
delicate manufacturing processes
which may causesafety, cost, function and schedule consequences
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Control Plan
The Control Plan makes sure that
prototypes
first samples
pre series-
and series products
will be checked systematically and consequently.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
The Control Plan describes
what to check
how to check
how much to check
by whom to check
where to check
by which mean to check
the checking criteria
and which measures have to be takenin case of variances
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
DFMA - Design for Manufacturability and Assembly
Target = to optimize the product in regard to function
and quality performance
sensitivity of design, concept and functionto manufacturing variances
production and assembly processes
requirements of specification parametersand drawing tolerances
number of parts and components
process control possibilities
material-flow and -handling
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Design Validation
The Design Validation must be performed
to guarantee that the product really performs
all requirements of the client.
The final validation will be done for the final product.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
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FMEA – Failure Mode Effect Analysis
FMEA wil be applied systematically during the
D2 – Product Development Phase
to avoid any defects in the future.
FMEA asks three main questions about:
1. Probalbility that the defect happens
2. Effects for the client and the product
application
3. Probablility of the detection before the product
will be shipped to the client
A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
D2-Review
At the end of the
D2-Phase Product Development
a final review will be prepared
to guarantee that all D2-Phase activities
were fully achieved.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
P1-Phase - Process Design
During this Phase the VE Project Teams complete the Product and Process Design.
On this basis a final calculation of:
parts
manufacturing cost
manufacturing tools/machines and processes
control equipment
will be prepared.
Also all drawings of parts and componen will be finally checked and confirmed.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
P1 - Feasibility Check
The members of the Team must also reach a consensus that all criteria of the developed product will be achieved:
Quality
Cost
Technique
Schedule
On this basis the product production will be finally confirmed and
started.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
P1 - Review
The results of the P1 - Phase
will be checked and confirmed
by a P1 - Review by the VE Project Team.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
P2 - Phase - Product and Process Validation
The P2 - Phase makes sure
that all conditions are completed to manufacture the new product:
in the required number of units
in the required quality
at the lowest possible cost
at the right time to meet the delivery time schedule
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
P2 - Review and Start of Pre-Series Production
In order to start the Pre-Series Production,
the P3 - Phase Review must be completed.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
P3 - Phase - Series Production
On the basis of the confirmed results
of the Pre-Series Production and the client‘s confirmation
the Series Production P3 will be started.
A specific check-list
„Confirmation of Series Production“
will be completed to document that all processes are fully in operating function and that the products being manufactured and assembled are achieving all requirements and targets.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Customer full satisfaction
The customer now is fully satisfied
as he gets his products in the desired quality
and always on time.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
Special Product and Process Criteria
The consequent application of the APQP procedures
in Value Management and VE-Teams guarantees
value added products
and the basis to create wealth for companies.
because companies applying the APQP proceduresare becoming and staying a remarkable and calculable partner
for customers from around the world.
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A Ried Management Presentation at the CSVA 2011 Conference Toronto, Ontario, Nov. 14-16, 2011
Ried Management MethodsThe way of success... - you should know
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Good Luck!