apqp-bilingual rev 2 2010

8/6/2019 APQP-Bilingual Rev 2 2010

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Vision Technology International Limited

APQP

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APQP Reference Manual should be read, understood and

adhered to (as appropriate) by every supplier to the Big-3

, ()APQP


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APQPAPQP

Benefits

To direct resources to satisfy the client

To promote early identification of required changes

To avoid late changes

To provide a quality product on time at the lowest

costs

Organize team ()

Not only quality dept.

But also subcontractors and clients

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The first step: Form Cross Functional Team

Form the teamForm the team


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Select team leader

Define roles and responsibilities

Identify customer (internal and ext.)

Define customers req. (e.g. QFD) QFD

Select the disciplines, individuals ,and/or suppliers that mustbe added to the team, and those not required.,,;

Define the ScopeDefine the Scope

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Understand customer expectation, i.e. design, number oftests.,.

Assess the feasibility of proposed design, performancerequirements and manufacturing process

Identify costs, timing and any constraints

Determine assistance from customer

Identify documentation process or method


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The first order of CFT is: development of timing chart

:

Consideration: type of product, complexity and customer

expectation . Members should agree with.

Timing ChartTiming Chart

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Simultaneous EngineeringSimultaneous Engineering

Simultaneous Engineering:Cross functional Team strive for common goal

Replaces the sequential series of phases where results are

transmitted to the next area for execution

GOAL: Expedite the introduction of quality productssooner

:


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APQPAPQP

Concept

Initiation

/ Approval

Program

Approval

Prototype Pilot.

Launch

Product Design & Dev.

Planning

Process Design & Dev.

Product &Process Validation

Production

Feedback Assessment And Corrective Action

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Design Resp.Manufacturing

Resp.

Define the Scope X X

Plan and Define (sec. 1)

X

Product Design and Development (sec. 2)

X

Feasibility2.132.13 X X

Process Design and Development (sec. 3)

X X

Product and Process Validation (sec. 4)

X X

Feedback, Assessment and Corrective

Action (sec. 5)

X X


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Plan and Define ProgrammePlan and Define Programme1. 01. 0

Determine customer needs and expectations in order to plan

and define the quality system.

,

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Input

Voice of Customer

Customer Business plan/Marketing strategy/

Product/process benchmark data /

Product/process assumptions /

Product reliability studies

Customer input

Plan and Define ProgramPlan and Define Program

1.01.0


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1.11.1 VOCVOC

Source of info.:

- Market Reserach

- Warranty and Quality Info.

- Team Expererience


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1.11.1.1.1MARKET RESEARCHMARKET RESEARCH Customer interviews

Customer questionnaires and surveys

Market test and positioning report

New product quality and reliability

Competitive product quality studies

Best Practices

Lessons Learned

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1.1.21.1.2HISTORICAL WARRANTY AND QUALITYHISTORICAL WARRANTY AND QUALITY

INFORMATIONINFORMATION

Best Practices

Lessons Learned

Warranty reports

Capability indicators

Supplier plant internal quality reports


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1.1.21.1.2HISTORICAL WARRANTY ANDHISTORICAL WARRANTY AND

QUALITY INFORMATIONQUALITY INFORMATION

Problem resolution reports

Customer plant returns and rejections

Field return product analysis

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1.1.31.1.3 TEAM EXPERIENCETEAM EXPERIENCE

QFD projects

Media commentary and analysis: magazine and newspaper reports,:

Customer letters and suggestions

Best Practice

Lessons Learned

Dealer comments


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1.1.31.1.3 TEAM EXPERIENCETEAM EXPERIENCE Fleet Operators comments

Field service reports

Internal evaluations using surrogate customers

Road Trips

Management comments or direction

Problems and issues reported form internal customers

Government requirements and regulations

Contract review

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1.21.2 BUSINESSS PLAN/MARKETINGBUSINESSS PLAN/MARKETING

SYRATEGYSYRATEGY //

Customer business plan may place constraints (timing, cost,

investment, product positioning, research and development

(R&D) resources).

((R&D) )

The marketing strategy will define the target customer, the

key sales points, and key competitors.


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1.31.3 PRODUCT/PROCESS BENCHMARK DATAPRODUCT/PROCESS BENCHMARK DATA

//

Establishing product/process performance targets. /

Successful benchmarking is:

:

Identify the appropriate benchmarks

Understand the reason for the gap

Develop a plan to close the gap

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1.41.4 PRODCUT/PROCESS ASSUMPTIONSPRODCUT/PROCESS ASSUMPTIONS

// Assumptions that the product has certain features, design, or

process concepts include:

, :

Technical innovations

Advanced materials

Reliability assessments

New technology


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1.51.5 PRODUCT RELIABILITY STUDIESPRODUCT RELIABILITY STUDIES

Data considers frequency of repair or replacement of

components.

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1.61.6 CUSTOMER INPUTSCUSTOMER INPUTS

Next users of the product can provide valuable informationrelating to their needs and expectations.

In addition, the next product users may have alreadyconducted some or all of the aforementioned reviews andstudies.

,


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Output

Design goals

Reliability and quality goals

Preliminary bill of material

Preliminary process flow chart

Preliminary listing of special product & process characters

Product assurance plan Management Support

Plan and Define ProgramPlan and Define Program1.01.0

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1.71.7 DESIGN GOALSDESIGN GOALS

Translation of the Voice of the Customer into tentative andmeasurable design objectives.

The Voice of the Customer also includes regulatoryrequirements such as materials composition reporting andpolymeric part marking.

,


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1.81.8 RELIABILITY AND QUALITY GOALSRELIABILITY AND QUALITY GOALS

Reliability goals - established based on customer wants andexpectations and reliability benchmarks.

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1.81.8 RELIABILITY AND QUALITY GOALSRELIABILITY AND QUALITY GOALS

Quality goals targets based on continual improvement.Examples:. :

parts per million(PPM)/

defect levels

scrap reduction


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1.91.9 PRELIMINARY BILL OF MATERIALPRELIMINARY BILL OF MATERIAL

Based on product/process assumptions and include early

subcontractor list.

/

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1.101.10 PRELIMINARY PROCESS FLOW CHARTPRELIMINARY PROCESS FLOW CHART

Development from the preliminary bill of material andproduct/process assumptions.

/


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1.111.11 Special product & process charactersSpecial product & process characters

Listing developed from: :

Product assumption

Reliability goals

Identification of SC from anticipated manufacturing process

Similar part FMEAs

FMEAs

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:

(

)

(S/C)

(

)SPC

()

/-

SC

-

(

)

(

)

(

)/

/

-CC


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11.12.12 PRODUCT ASSURANCE PLANPRODUCT ASSURANCE PLAN

Translates design goals into design requirement Outlining of program requirement

Identification of reliability

Assessment of new technology, materials, environment, packaging,

manufacturing requirements, other factor that may place the program atrisk.

Use of Failure Mode Analysis

Development of preliminary engineering standards requirements

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1.131.13 MANAGEMENT SUPPORTMANAGEMENT SUPPORT

Management should be updated management at theconclusion of product quality planning phase to

Reinforce their commitment and support

program timing and planning for resources and staffing


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Concept

Initiation

/ Approval

Program

Approval

Prototype Pilot.

Launch


Planning



Production


2.02.0Product Design & DevelopmentProduct Design & Development

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To assure a comprehensive and critical review of engineering

requirements and other related technical information to assure

that voice of customer can be met.



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Output

Design Dept.

DFMEA

Design for manufacturing & assembly

Design verification

Design Review

Prototype build

Eng. drawings, spec. & material spec.

Drawing & spec. changes


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Output

Quality Planning Team

New equipment, tooling and facilities requirements

Special product and process characteristics

Gage/testing equipment requirements /

Team feasibility commitment & management support



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A disciplined analytical technique that assesses theprobability of failure as well as the effect of such failure.

Refer to Potential Failure Mode and Effect Analysisreference manual

The Design FMEA Checking in Appendix A-1FMEAA-1

2.12.1 DESIGN FAILURE MODE ANDDESIGN FAILURE MODE ANDEFFECTS ANALYSIS (DFMEA)EFFECTS ANALYSIS (DFMEA)

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A Simultaneous Engineering process designed to optimize

the relationship between design function, manufacturability,

and ease of assembly.

2.22.2 DESIGN FORDESIGN FOR

MANUGFACTURABILITY ANDMANUGFACTURABILITY AND

ASSEMBLYASSEMBLY


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Item should be considered by the Product Quality PlanningTeam:: Design, concept, function, and sensitivity to manufacturing

variation

Manufacturing and/or assembly process/

Dimensional tolerances

Performance requirements

Number of components

Process adjustments

Material handling

2.22.2 DESIGN FORDESIGN FORMANUGFACTURABILITY ANDMANUGFACTURABILITY AND

ASSEMBLYASSEMBLY

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Verifies that the product design meets the customer

requirements

2.32.3 DESIGN VERIFICATIONDESIGN VERIFICATION


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Regularly scheduled meetings led to prevent problems and

misunderstandings.

2.42.4 DESIGN REVIEWSDESIGN REVIEWS

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A description of the dimensional measurements and material

and functional tests that will occur during prototype build.

Control Plan Checklist is provided in both Appendix A-8

A-8

2.52.5 PROTOTYPE BUILDPROTOTYPE BUILD CONTROLCONTROL

PLANPLAN


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Engineering drawings from customer may include special

(government regulatory and safety) characteristics that must

be shown on the control plan.

()

Drawings should be reviewed by planning team to determine

which characteristics affect fit, function, durability and/or

governmental regulatory safety requirements.

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2.62.6 ENGINEERING DRAWINGSENGINEERING DRAWINGS

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Should determine which characteristics affect functional,

durability, and appearance requirements.

2.72.7 ENGINEERING SPECIFICATIONSENGINEERING SPECIFICATIONS


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Should be reviewed for Special Characteristics

2.8 MATERIAL SPECIFICATIONS2.8 MATERIAL SPECIFICATIONS

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Ensure that the changes are promptly communicated and

properly documented

2.92.9 DRAWING AND SPECIFICATIONDRAWING AND SPECIFICATION

CHANGESCHANGES


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New equipment and facilities requirements may come from::

The DFMEADFMEA

Product Assurance

Design Reviews

2.102.10 NEW EQUIPMENT, TOOLING ANDNEW EQUIPMENT, TOOLING AND

FACILITIES REQUIREMENTSFACILITIES REQUIREMENTS

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Team should address these requirements by adding the items

to the Timing Chart

Team should ensure that the new equipment and tooling iscapable and delivered on time

New Equipment, Tooling and Test Equipment Checklist inAppendix A-3A-3

2.102.10 NEW EQUIPMENT, TOOLING ANDNEW EQUIPMENT, TOOLING AND

FACILITIES REQUIREMENTSFACILITIES REQUIREMENTS


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The organizations product quality team should build on this

listing and reaching consensus through the evaluation of the

technical information.

,

2.112.11 SPECIAL PRODUCT AND PROCESSSPECIAL PRODUCT AND PROCESS

CHARACTERISTICSCHARACTERISTICS

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Gages/testing equipment requirements may also be

identified.

/

Add these requirement to the Timing Chart

2.122.12 GAGES/TESTING EQUIPMENTGAGES/TESTING EQUIPMENT

REQUIREMENTSREQUIREMENTS

//


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The Product Quality Planning Team must assess the

feasibility of the proposes design.

Customer design ownership does not preclude the

organizations obligation

2.132.13 TEAM FEASIBILITY COMMITMENTTEAM FEASIBILITY COMMITMENT

AND MANAGEMENT SUPPORTAND MANAGEMENT SUPPORT

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Team must be satisfied that the proposed design can

manufactured assembled

tested

packaged

delivered in sufficient quantity

at an acceptable cost to the customer on schedule




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The Design Information Checklist in Appendix A-2 allowsthe team to review its effortsA-2

Team Feasibility commitment form shown in Appendix E

E



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3.03.0Process Design & DevelopmentProcess Design & Development

Concept

Initiation

/ Approval

Program

Approval

Prototype Pilot.

Launch


Planning



Production



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Develop a manufacturing system and its related control plans

to assure that customer requirements, needs and expectations

are met.

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Output

Package standards

Product/process quality system review/

Process flow chart

Floor plan layout

Characteristics Matrix

Process FMEA



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Output

Pre-launch control plan

Process instructions

Measurement system analysis plan

Preliminary process capability study plan

Packaging specifications

Management support


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Flow Manufacturing

Coating

Machining

Welding

Pressing

Our integrated line is

balanced to meet

customer demand.

Our people are flexible,

and WIP is down due

to single piece flow.

Now that we do quick

changeovers, we can

run every part every day.


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Quality

Error ProofingTwo-point Inspection

CONTROL

WARNING

Jig

The light goeson if themachine fails.

jamming

pin

The part wongo on unlessit orientedproperly

I checked it,but let me knowif there are anyproblems.

Il check it outbefore I do thenext operation.

Material Movement

Make what we need when we need it

Pull System

KIT

ADDRESS

0017-0010-002R

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3.13.1 PACKAGING STANDARDSPACKAGING STANDARDSANDAND

SPECIFICATIONSSPECIFICATIONS

Packaging design should ensure product integrity at point

of use.


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3.23.2 PRODUCT/PROCESS QUALITYPRODUCT/PROCESS QUALITY

SYSTEM REVIEWSYSTEM REVIEW /

Team should review the manufacturing site(s) Qualitymanagement system

Any additional controls and/or procedural changes requiredto produced the product should be updated, documented andincluded in the manufacturing control plan.

/

Checklist provided in Appendix A-4 A-4

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3.33.3 PROCESS FLOW CHARTPROCESS FLOW CHART

Process flow used to analyze sources of variations ofmachines, material, methods, and manpower

The flow chart assists the organizations product qualityplanning team to focus on process when conducting thePFMEA and DFMEAPFMEADFMEA,.

The Process Flow Chart Checklist in Appendix A-6 can beusedA-6


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3.43.4 FLOOR PLAN LAYOUTFLOOR PLAN LAYOUT

The floor plan should be developed and reviewed todetermine Acceptability of inspection points

Control chart location Applicability of visual aids Interim repair stations Storage areas to contain defective material

Floor Plan Checklist in Appendix A-5 can be used.A-5

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-optimize the material travel, handling and

value-added use of the floor space,

-facilitate the synchronous flow of materials

through the process


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3.53.5 CHARACTERISTICS MATRIXCHARACTERISTICS MATRIX

A recommended analytical technique for displaying the

relationship between process parameters and manufacturing

stations.

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3.63.6 PROCESS FAILUTE MODE ANDPROCESS FAILUTE MODE AND

EFFECTS ANALYSISEFFECTS ANALYSIS

A PFMEA should be conducted during product quality

planning and before beginning production.

PFMEA The process FMEA Checklist in Appendix A-7 can be used.

A-7FMEA


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3.73.7 PREPRE--LAUNCH CONTROL PLANLAUNCH CONTROL PLAN

A description of the dimensional measurements and material

and functional tests that will occur after prototype and before

full production.

Control Plan Checklist in Appendix A-8 can be used.

A-8

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3.83.8 PROCESS INSTRUCTIONSPROCESS INSTRUCTIONS

Instructions should be developed from the following sources::

FMEAs

Control plan(s)

Engineering drawings, performance specifications,material specifications, visual standards and industrystandards


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3.83.8 PROCESS INSTRUCTIONSPROCESS INSTRUCTIONS

Process flow chart

Floor plan layout

Characteristics matrix

Packaging standards

Process parameters

Organization expertise and knowledge of the processes

and products

Handling requirements

Operators of the Process

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3.93.9 MEASUREMENT SYSTEMSMEASUREMENT SYSTEMS

ANALYSIS PLANANALYSIS PLAN

A plan to accomplish the required measurement systems

analysis is developed.


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3.103.10 PRELIMINARY PROCESSPRELIMINARY PROCESSCAPABILITY STUDY PLANCAPABILITY STUDY PLAN

The characteristics identified in the control plan will serve

as the basis for the preliminary process capability study

plan.

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3.113.11 MANAGEMENT SUPPORTMANAGEMENT SUPPORT

The organizations product quality team should update

management at the conclusion of product quality planning

phase to

Reinforce their commitment and support


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4.04.0Product and Process validationProduct and Process validation

/

.


Planning



Production


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To validate control plan and flow chart are being followed and

the products meet customer requirements



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Output

Significant production run

Measurement system evaluation

Preliminary process capability study

Production part approval

Production validation testing

Packaging evaluation Production control plan

Quality planning sign-off and management support


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Using production tooling, equipment, production

environment, facility, production gage and production

rate. (Refer to the Chrysler, Ford, and General Motors

Production Part Approval Process (PPAP) manual or the

appropriate customer-specific requirements for additional

details )

(PPAP

)

4.14.1 SIGNIFICANTSIGNIFICANTPRODUCTION RUNPRODUCTION RUN


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Output of the significant production run (product) is usedfor:():

Preliminary process capability study

Measurement systems evaluation

Production rate demonstration

Process review

Production validation testing


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Production part approval

Packaging evaluation

First time capability (FTC)

(FTC)

Quality planning sign-off



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Sample production parts

Master sample (as required)

()

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Measurement devices and methods should be subjected to

measurement system evaluation during or prior to the

significant production run. ,

4.24.2 MEASUREMENT SYSTEMMEASUREMENT SYSTEM

EVALUATIONEVALUATION


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Should be performed on characteristics identified in

the control plan.

Refer to the Production Part Approval Process

reference manual

4.34.3 PRELIMINARY PROCESSPRELIMINARY PROCESS

CAPABILITY STUDYCAPABILITY STUDY

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4.44.4 PRODUCTION PART APPROVALPRODUCTION PART APPROVAL

All customer engineering design record and specificationrequirements are properly understood by the organization

The manufacturing process has the potential to produceproduct consistently meeting these requirements during andactual production run at the quoted production rate.

Refer to Production Part Approval Process reference manual.


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Refers to engineering tests that validate that products made

from production tools and processes meet engineering

standards.

4.54.5 PRODUCTION VALIDATIONPRODUCTION VALIDATION

TESTINGTESTING

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Assess the protection of the product from normal

transportation damage and adverse environmental factors.

4.64.6 PACKAGING EVALUATIONPACKAGING EVALUATION


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A written description of the system for controlling parts and

processes.

Appendix A-8 present Control Plan Methodology and a

checklist to verify completeness.A-8

4.74.7 PRODUDTION CONTROL PLANPRODUDTION CONTROL PLAN

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Team performs its review at the manufacturing location(s)

and coordinates a formal sign-off.

The sign-off occurs prior to first product shipment and

includes a review of the following:

:

4.84.8 QUALITY PLANNING SIGNQUALITY PLANNING SIGN--OFF ANDOFF AND

MANAGEMENT SUPPORTMANAGEMENT SUPPORT


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4.84.8 QUALITY PLANNING SIGNQUALITY PLANNING SIGN--OFFOFF


Process flow chart

Control plan

Process instruction

Monitoring and measuring devices

Demonstration of required capacity

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Upon the completion of the sign-off, a review with

management should be scheduled to inform

management of the program status and gain theirsupport with any open issues.

The Product Quality Planning Summary and Sign-off

report shown in Appendix F is an example.

F

4.84.8 QUALITY PLANNING SIGNQUALITY PLANNING SIGN--OFF ANDOFF AND

MANAGEMENT SUPPORTMANAGEMENT SUPPORT


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5.05.0Feedback, Assessment & Corrective ActionFeedback, Assessment & Corrective Action

/

.


Planning



Production


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Evaluate the effectiveness of APQP process, reduce variation

and enhance customer satisfaction by employing statistical

technique



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Output

Reduced Variation

Customer Satisfaction

Delivery and Service

Effective use of Lessons Learned/Best Practice

/

Employee Environment & Involvement

BusinessObjectives Scrap

J a n. Ap r. J u l. De c.

Uptime

Goal

OnTime Delivery

Goal

Goal

Employee InformationCenter

J a n. Ap r. J u l. De c.J a n. Ap r. J u l. De c.

Our improvementTeams efforts have

helped us meetour goals.


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5.15.1 REDUCED VARIATIONREDUCED VARIATION

Statistical techniques should be used as tools to identify process

variation Analysis and corrective actions should be used to

reduce variation.


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5.25.2 CUSTOMER SATISFACTIONCUSTOMER SATISFACTION

The product or service must perform in the customer

environment.

The organization and customer must be partners in making the

changes necessary to correct deficiencies to improve customer

satisfaction.

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5.35.3 DELIVERY AND SERVICEDELIVERY AND SERVICE

Experience gained provides the customer and organization with

the necessary knowledge to reduce process, inventory, and

quality costs and to provide the right component or system for

the next product.


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5.4 EFFECTIVE USE OF LESSONS

LEARNED/BEST PRACTICES

/

A lessons Learned or Best Practices portfolio is beneficialfor capturing, retaining and applying knowledge,

Input to Lessons Learned and Best Practices can beobtained through a variety of methods including:

Review of Things Gone Rights/Things Gone Wrong(TGR/TGW)

Data from warranty and other performance metrics

Corrective action plans Red-across with similar products and processes

DFMEA and PFMEA

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5.4 EFFECTIVE USE OF LESSONS

LEARNED/BEST PRACTICES

/

/

:(TGR/ TGW)

DFMEA & PFMEA


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