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Fundamentals of
APQP and CP
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Fundamentals of Product Quality Planning
Product Quality Planning: Structured method of defining and established the steps Assuring customer satisfaction
The GOAL of Product Quality Planning: Facilitate Communication with everyone involved to assure
that all required are completed on time.
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Organize the Team
Step -1: Assign a process owner for the APQP Project.
Step -2 : Establishing the Cross Functional Team (CFT)
The team should include representatives from multiple functions such as Engineering Manufacturing Material control Purchasing Quality Human resources Sales Field service Suppliers and Customers.
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Define the Scope – APQP & CP
Select a project team leader Define the roles and responsibilities of each area
represented Identify the customers – internal and external Define customer requirements Select the disciplines, individuals, and/or suppliers that
must be added to the team, and those not required. Understand customer expectations, i.e., design, number of
tests.
Conti…
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Define the Scope – APQP & CP
Assess the feasibility of the proposed design, performance requirements and manufacturing process.
Identify costs, timing, and constraints that must be considered.
Determine assistance required from the customer. Identify documentation process or method.
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Team–to-Team
The organization’s Product
Quality Planning team must
establish lines of communication
with other customer and
organization teams.
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Customer and Organization Involvement
Organization must expect the same performance from
their suppliers.
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Product Quality Planning Cycle
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Product Quality Planning Cycle
PDCA
Plan Technology and Concept Development
Do Product / Process Development and Prototype Verification
Check Confirmation Product and Validation Process
Act Continual Improvement
Steps:
1. Plan and Define
2. Product Design and Development
3. Process Design and Development
4. Product and Process Validation
5. Feedback Assessment and Corrective Action
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Simultaneous Engineering
Simultaneous Engineering is a process where Cross Functional
Teams (CFTs) strive for a common goal.
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Control Plans
Control plans are written descriptions of the systems for
controlling parts and processes.
Phases of Control Plans
Prototype
Pre-launch
Production
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Concern Resolution
Disciplined problem-solving methods are recommended in
difficult situations.
Analytical techniques should be used as appropriate.
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Product Quality Timing Plan
Timing Elements:
Type of product,
Complexity of product, and
Customer expectations.
All CFT members should agree with each event, action, and timing.
Each event must have a START and COMPLETION date with actual point of progress.
Product Quality Timing Plan
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APQP and CP
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APQP and CP
Team ExperienceThe Team may use any source of any information as appropriate, including :
1. Input from higher system level or past QFD projects.
2. Media commentary and analysis (magazine and newspaper reports, etc.)
3. Customer letters and suggestions.
4. TGR or TGW reports.
5. Dealer comments.
6. Fleet Operator’s comments.
7. Field service reports.
8. Internal evaluations using surrogate customers.
9. Road trips.
10. Management comments or direction.
11. Problems and issues reported from internal customers.
12. Government requirements and regulations.
13. Contract review.
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Plans Relative to the Timing Chart
The success of any program depends on
meeting customer needs and expectations
in a timely manner
at a cost that represents value.
APQP Team (CFT) is responsible for assuring
that timing meets or exceeds the customer
timing plan.
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Continual improvement
Recurring activity to increase the ability to fulfill requirements.
Continual Improvement
Depicting product quality planning as a
cycle illustrates the never ending pursuits of
continual improvement that can only be
achieved by taking the experience in one
program and applying that acquired
knowledge to the next program.
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Continual Improvement - DMAIC
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Continual Improvement – Deming Cycle
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Continual Improvement
Reduction of Process and Product Variation
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Any Questions?
APQP and CP