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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

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Advanced Product Quality Planning

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Page 1: Apqp ppt

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

Page 2: Apqp ppt

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

Page 3: Apqp ppt

What is Quality Planning?

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Page 4: Apqp ppt

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.

Page 5: Apqp ppt

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.

Page 6: Apqp ppt

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

Page 7: Apqp ppt

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

Page 8: Apqp ppt

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

Page 9: Apqp ppt

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.

Page 10: Apqp ppt

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

Page 11: Apqp ppt

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

Page 12: Apqp ppt

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

Page 13: Apqp ppt

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

Page 14: Apqp ppt

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

Page 15: Apqp ppt

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

Page 16: Apqp ppt

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

Page 17: Apqp ppt

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

Page 18: Apqp ppt

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

Page 19: Apqp ppt

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

Page 20: Apqp ppt

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.

Page 21: Apqp ppt

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

Page 22: Apqp ppt

Questions

Page 23: Apqp ppt

Related Information

Page 24: Apqp ppt

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

Page 25: Apqp ppt

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