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Advanced Product Quality Planning (APQP)
Based on the AIAG “Advanced Product
Quality Planning and Control Plan”
Reference Manual
Presented By Dr. Cecelia Venuk
November 2009
Objectives
� Understand the APQP Process
� Identify the inputs / outputs of the 5 APQP phases the 5 APQP phases
� Understand APQP as a methodology for new product development
What is Quality Planning?
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The AIAG APQP Model
What is APQP?
� Advance Product Quality Planning is a structured method of defining and establishing the steps necessary to assure that a product satisfies the necessary to assure that a product satisfies the customer.
� The goal of product quality planning is to facilitate communication with everyone involved to assure that all required steps are completed on time.
� Effective product quality planning depends on a company’s top management commitment to the effort required in achieving customer satisfaction.
Why Product Quality Planning?� The bulk of cost of a product is committed at the early stages
of a development cycle even though they are not expended until later.
� The cost of fixing a design and faulty decisions at later stages is exponentially greater than at an earlier stage.The cost of fixing a design and faulty decisions at later stages is exponentially greater than at an earlier stage.
� The opportunity costs of being late to market are very high, ex., lower market share, lower margins.
� Cross-functional teams typically provide a better quality solution to complex dynamic product development problems than single individuals.
� Early simultaneous involvement in product development by cross-functional teams using structured development process saves time and money over the product life cycle.
Fundamentals of Product
Quality Planning
� Organizing the team � Define the scope � Team-to-Team Communication
Training � Training � Customer, supplier and subcontractor
involvement� Simultaneous \ Concurrent Engineering� Control plans � Concern Resolution � Timing plan and chart
Product Quality Planning Chart
ConceptConceptInitiation/ApprovalInitiation/Approval
ProgramProgramApprovalApproval PrototypePrototype PilotPilot LaunchLaunch
Planning Planning
Product Design and Dev.
Process Design and Development
Product and Process Validation
Production
Feedback Assessment and Corrective Action
Plan andPlan andDefineDefine
ProgramProgram
ProductProductDesign andDesign and
DevelopmentDevelopment
ProductProductand Processand Process
ValidationValidation
ProcessProcessDesign andDesign and
DevelopmentDevelopment
FeedbackFeedbackAssessment andAssessment andCorrective ActionCorrective Action
1.0 Plan and Define Program
ConceptConcept
Initiation/ApprovalInitiation/ApprovalProgramProgram
ApprovalApproval
Planning
Inputs
Voice of the Customer
- Market Research
- Historical Warranty
and Quality Information
- Team Experience
Business Plan/Marketing strategy
Objectives� Determine customer needs.
� Define and plan a quality
program.
Plan andPlan and
DefineDefine
ProgramProgram
Business Plan/Marketing strategy
Product/Process Benchmark Data
Product Reliability Studies
Customer Inputs
Outputs
Design Goals
Reliability and Quality Goals
Preliminary Bill of Material
Preliminary Process Flowchart
Preliminary Listing of Special Product and Process Characteristics
Product Assurance Plan
Management Support
Breakout – Quality Planning
Product Description: PPASS
(Personal Portable Automotive Sound System)
This is a new option for all mid to high price range vehicles
that allows an individuals personal MP3 or IPOD system to that allows an individuals personal MP3 or IPOD system to
be integrated with the sound system of suitably equipped
automotive vehicles. This product is a universal MP3 / IPOD
holder combined with a short-range wireless link that has
already been developed by the automotive industry.
Breakout – Quality Planning
PPASS Design Goals & Parameters
• Dashboard will have a built-in wireless interface receiver
that links with the any PPASS transmitter
• Must integrate with a wireless transmitter with a • Must integrate with a wireless transmitter with a
dimension of .5” X 1.0” X .2”
• Maximum holder dimension: 3” X 4.5” X 1.5”
• Universal fixture for 98% of all types of players
• Safely positioned in vehicle during vehicle operation, and
is to be located within three (3) feet of the sound system.
• Robust materials of construction (portable) with an
expected lifetime of 3 years
• Single neutral color – go will all interiors
ProgramProgramApprovalApproval PrototypePrototype
Product Design and Dev.
2.0 Product Design and Development
Inputs
The outputs of Section 1.0
Objectives� Develop design features and
characteristics
� Review engineering requirements
� Assess potential manufacturing
problems that could occurProduct Design and Dev.
ProductProductDesign andDesign and
DevelopmentDevelopment
Outputs
Design Failure Mode and Effects Analysis (DFMEA)
Design for Manufacturability and Assembly
Design Verification
Design Reviews
Prototype build – Control plan
Engineering Drawings
Engineering Specifications
Material Specifications
Drawing and Specification Changes
New Equipment, Tooling and Facilities Requirements
Special Product and Process Characteristics
Team Feasibility Commitment and Management Support
Breakout – Quality Planning
Develop a design for the Personal Portable Automotive Sound System (PPASS) unit. Your team (4 to 6 people) has 20 minutes to:has 20 minutes to:
1. Design a fixture to safely hold a MP3 / IPOD and a sound system interface.
2. Identify any special customer characteristics or concerns
3. Identify the material specifications4. Identify any special tooling and equipment
Inputs to Prototype Control PlanCONTROL PLAN SUMMARY
Control Plan Number Reference Key Contact/Phone Date (Orig.) Rev. Date (Revised)
Part Number/Latest Change Level Part Name/Description Supplier/Plant Core Team
Customer
MACHINE,
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ REACTION
CHARACTERISTIC METHODS
CONTROLSAMPLE
PrototypePre-Launch Production
CORRECTIVE
x
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ REACTION
NUMBER DESCRIPTION FOR MFG. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. PLAN
TOLERANCE TECHNIQUE Error proofing Other
METHOD
CORRECTIVE
ACTION
LSL TARGET USL
#2#1#1 #6 #5#4#3 #7 #8 #9 #10
Outputs & Expectations:1 – Assure product meets specification
2 – Ensure attention to process/product characteristics
3 – Establish preliminary process/product characteristics
4 – Communicate to the customer
PilotPilotPrototypePrototype
3.0 Process Design and Development
Inputs
The outputs of Section 2.0
Objectives� Develop comprehensive and
effective manufacturing process
� Ensure process capability to
meet customer requirements
Process Design and Development
ProcessProcessDesign andDesign and
DevelopmentDevelopment
Outputs
Packaging Standards
Product/Process Quality System Review
Process Flow Chart
Floor Plan Layout
Characteristics Matrix
Process Failure Mode and Effects Analysis (PFMEA)
Pre-Launch Control Plan
Process Instructions
Measurement Systems Analysis Plan
Preliminary Process Capability Study Plan
Packaging Specifications
Management Support
Breakout – Quality PlanningNext Steps
Continue with the process design and development. Your team (4 to 6 people) has 10 minutes to:
1. Develop a process flow.2. Identify critical manufacturing parameters to
measure and control3. Identify 3 potential failures with this product
Inputs to Pre-launch Control PlanCONTROL PLAN SUMMARY
Control Plan Number Reference Key Contact/Phone Date (Orig.) Rev. Date (Revised)
Part Number/Latest Change Level Part Name/Description Supplier/Plant Core Team
Customer
MACHINE,
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ REACTION
CHARACTERISTIC METHODS
CONTROLSAMPLE
PrototypePre-Launch Production
CORRECTIVE
x
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ REACTION
NUMBER DESCRIPTION FOR MFG. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. PLAN
TOLERANCE TECHNIQUE Error proofing Other
METHOD
CORRECTIVE
ACTION
LSL TARGET USL
#2#1#1 #6 #5#4#3 #7 #8 #9 #10
Outputs & Expectations:1 – Communication for process control
2 – Input to pre-launch control plan
3 – Product quality & customer satisfaction
4 – Identified opportunities for improvement
PrototypePrototype PilotPilot LaunchLaunch
4.0 Product and Process Validation
Inputs
The outputs of
Section 3.0
Objectives� Validate the product
� Validate the manufacturing process
� Validate the control plan
� Ensure product meets customer
requirements
Product and Process Validation
ProductProductand Processand Process
ValidationValidation
Outputs
Production Trial Run
Measurement Systems Evaluation
Preliminary Process Capability Study
Production Part Approval
Production Validation Testing
Packaging Evaluation
Production Control Plan
Quality Planning Sign-Off and Management Support
requirements
� Identify concerns
5.0 Feedback, Assessment
and Corrective ActionPilotPilot LaunchLaunch
Planning
Inputs
The outputs of Section 5.0Objectives
� Evaluate all variation (variable
and attribute data)
� Evaluate effectiveness of product
quality planning
� Use control plan and corrective
Production
Feedback Assessment and Corrective Action
FeedbackFeedbackAssessment andAssessment andCorrective ActionCorrective Action
Outputs
Reduced Variation
Customer Satisfaction
Delivery and Service
� Use control plan and corrective
action
Summary:
The AIAG APQP Model
What is APQP?
� APQP is a process, not just an event
� Integration of quality tools with � Integration of quality tools with management functions
� Status Reporting and Program Management
� Multi-disciplinary team approach to quality planning
� Satisfies requirement of TS, with linkage to several ISO/TS 16949:2002 elements
� Tool for continuous improvement
Summary:
The 5 Phases of APQP
1.Plan and Define the Program
2.Product Design and Development
1.
2.3.Process Design and Development
4.Product and Process Validation
5.Feedback, Assessment and
Corrective Action
2.
3.
4.
5.
APQP Acronyms
� APQP – Advance Product Quality Planning
� D/P-FMEA – Design/Process Failure Mode Effect AnalysisEffect Analysis
� DVP&R – Design Verification Plan & Report
� AIAG – Automotive Industry Action Group
� TS 16949 – (Sector-specific) Technical Specification (for automotive industry)
� MSA – Measurement Systems AnalysisI/M/T – Inspection/Measurement/Test
Questions
Related Information
APQP and
Planning
Product Design and Development
Process Design and Development and Validation
Product and Application Validation
Production
Feedback Assessment and Corrective Action
ConceptInitiation/Approval
Planning
ProductionFirst SiliconRamp toVolume
ProgramApproval
New Product Development and Launch Process
AP
QP
ProjectStart
New ProcessDevelopment
APQP and ISO/TS 16949:2002
Applicable ISO/TS 16949 Requirements
Design & Dev. Planning 7.3 (Process)
Design & Dev. Planning 7.3 (Product)
7.1 Planning ofProduct Realization
7.2 Customer-Related Processes
Production & Service Provision 7.5
Monitoring & Measurement ofProcesses 8.2.3.1
���� Production Part Approval - 7.3.6.3
ISO
/TS
169
49:2
002
Feedback Assessment - 8
Continual Improvement - 8.5
Monitoring & Measurement of Product8.2.4
Retention/Submission Requirements Table I.4.1 – AIAG PPAP Reference Guide 3 ed.
All listed items may not necessarily apply to every customer part from every supplier,
Consult design record and customer to determine which items or records apply
Submission Level
Requirement Level 1 Level 2 Level 3 Level 4 Level 5
1. Design/Development Records R S S • R
-for proprietary components/details R R R • R
-for all other components/details R S S • R
2. Engineering Change Documents, if any R S S • R
3. TI Engineering Final Approval R R S • R
4. Design FMEA (or Risk Assessment) R R S • R
5. Process Flow Diagrams R R S • R
6. Process FMEA (or Risk Assessment) R R S • R
7. Dimensional Results R S S • R
8. Material, Performance Test Results
R S S • R
AIAG PPAP:
Contents
and
9. Initial Process Study R R S • R
10. Measurement System Analysis Studies R R S • R
11. Qualified Laboratory Documentation R S S • R
12. Control Plan R R S • R
13. Part submission Warrant (PSW) S S S S R
14. Appearance Approval Report, (AAR)
if applicable S S S • R
15. Bulk Material Requirements Checklist
(for bulk material PPAP only) R R R • R
16. Sample Product R S S • R
17. Master Sample (See I.2.2.17) R R R • R
18. Checking Aids R R R • R
19. Records of Compliance
With Customer-Specific Requirements R R S • R
S = The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items
at appropriate locations, including manufacturing.
R = The supplier shall retain at appropriate locations, including manufacturing, and make readily available to the customer
representative upon request.
• = The supplier shall retain at appropriate locations, and submit to customer upon request.
Training/Graphics/APQP/R-S Requirement Table.doc
and
Submission
levelsNote: the PPAP form and
descriptions of each requirement
is from the AIAG reference
manual for PPAP, Third Edition