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1、APQPIntroduction講師：顏光華講師：顏光華 蔡建河蔡建河 2003-08-13151/21/2022TV Rheinland Taiwan Ltd. 2003 TV Rheinland Taiwan Ltd. All rights reserved.先期產品品質規劃與管制計劃先期產品品質規劃與管制計劃(APQP)APQPA (Advanced) 先期的先期的P (Product) 產品產品Q (Quality) 品質品質P (Planning) 規劃規劃CPC (Control) 管制管制P (Plan) 規劃規劃 APQP的淵源的淵源APQP的前身是福特汽車的的前身是福特汽車的
2、AQP(AdvancedQuality Planning)編輯編輯APQP & CP (Control Plan管制計劃管制計劃)的時候，的時候，為了調合三大汽車廠及卡車廠本身的為了調合三大汽車廠及卡車廠本身的APQP需求需求，以福特的，以福特的Mr. Mike Mazur為主的團隊，參考各為主的團隊，參考各廠之特色，撰寫了廠之特色，撰寫了APQP and Control Plan (先期先期產品品質規劃與管制計劃產品品質規劃與管制計劃)先期產品品質規劃和管制計劃效益先期產品品質規劃和管制計劃效益u降低顧客與供應商在產品品質規劃方面之複雜降低顧客與供應商在產品品質規劃方面之複雜性性u做為供應商
3、與分包商在產品品質規劃需求上容做為供應商與分包商在產品品質規劃需求上容易溝通之方法易溝通之方法u滿足顧客之資源指引滿足顧客之資源指引u推動早期明定變更之要求推動早期明定變更之要求u避免晚期變更避免晚期變更u準時提供低成本之合格產品準時提供低成本之合格產品What is the AIAGs APQP Reference Manual? APQP手冊的目的手冊的目的 It Is General Information 泛用資訊 It Does Not Address Specific Manufacturer Information or Requirements 非強制要求 It is NOT
4、Auditable 非稽核用 It Does NOT Address Any Specific Industry or Manufacturer 不限產業Basics Do NOT try to write a procedure just like the APQP reference manual. 不要 100% copy 該手冊 Look at what YOU are doing and relate it to the APQP process described by the reference manual. 查核貴公司活動與手冊規定的關聯性 Be ready to expla
5、in Equivalencies - Where and How and What your system does which fulfills APQP timeline elements.解釋貴公司做法與手冊規定的一致性The Target & Goal目標目標產品品質規劃時序圖產品品質規劃時序圖原型試作原型試作量試量試概念啟始概念啟始認可認可規劃規劃計畫計畫認可認可產品研發產品研發製程發展製程發展製程研發製程研發/驗證驗證產品研發產品研發/驗證驗證計畫計畫/定義定義研發守案研發守案生產生產生產階段生產階段/迴饋矯正迴饋矯正產品產品 / 製程製程驗收驗收產品產品/製程驗收製程驗收生產計畫
6、生產計畫迴饋與矯正迴饋與矯正量產量產QS 9000APQP Involves: QS 條文與條文與APQP的關聯性的關聯性 4.1 Management Responsibility 4.2 Quality System 4.3 Contract Review 4.4 Design Control 4.5 Document and Data Control 4.6 Purchasing 4.9 Process Control 4.10 InspectionQS 9000APQP Involves: 4.11 Inspection, Measuring and Test Equipment 4.
7、12 Inspection and Test Status 4.13 Control of Nonconforming Product 4.14 Corrective Action 4.15 Handling, Storage, Packaging and Delivery 4.16 Quality Records 4.18 Training 4.19 Servicing 4.20 Statistical TechniquesEach APQP is Unique 每一APQP都是獨一無二的 Because of product and program differences 產品及計劃不同
8、Timing and sequence are dependent upon customer needs and expectations 依客戶需求及期望展開時間及順序 Product complexity 產品複雜性 Stamping 沖壓 Sub-assembly 組立 New 新產品 Modification 設變Progressive Fundamentals 成功的基礎 KEY* Organize a Cross-Functional TEAM 組成跨功能小組 Define the scope 定義範圍 Team-to-team communications 組對組溝通 Trai
9、ning 訓練 Simultaneous (concurrent) engineering 同步工程 Control Plan Phases 控制計劃階段 Prototype, Pre-Launch, Production Concern resolution 解決問題 Includes analytical techniques 分析的技術Team Organization Cross-functional 跨功能小組 Engineering (Typically the leader), Quality Assurance, Purchasing, Manufacturing Engine
10、ering, Material Control, Sales/Marketing Etc. Participation appropriate for phase being conducted 依階段有不同參加人員 Resources - Team defines Needs小組定義需求 *Should* involve customer or subcontractor participation (not always feasible) 客戶或供應商的參與Define Scope Select team members and functions 選擇組員及功能 Define role
11、s and responsibilities 定義權責 Identify external customer needs, expectations and requirements 鑑別外部客戶需求 Identify internal customer needs, expectations and requirements 鑑別內部客戶需求 Complete preliminary feasibility study 完成初期可行性評估 Identify costs, timing and constraints 鑑別成本, 時間及限制 Identify documentation pro
12、cess and method鑑別文件及方法 Develop program plan (if project is a go) 發展開發計劃Team-to-Team Communication Manage using the APQP process 使用APQP過程管理 Understanding of How We Work As A Team了解如何以小組方式運作 Should have a Focus Person & Distributed Minutes 應有核心人員及分發紀錄 Customer teams, Internal teams, Subcontractors tea
13、ms Subcontractors should be encouraged to embrace APQP and QS 9000 分包商應被鼓勵使用APQP, QS-9000Training Customer needs and expectations客戶需求 Working as a Team以小組方式運作 Development skills 開發技巧 Requirements of APQP FMEA PPAP SPCRecommended Statistical Courses 建議的統計課程建議的統計課程Basic Business 基本業務 Advanced Business
14、 進階業務 Office, Staff, & Management Selected Staff, & ManagementStatistical Process Control MSA Design of Experiment 統計製程管制 量測系統分析 實驗計劃法Production Floor, Production Staff & Management, All of Quality & Engineering u*Your APQP Team should attend as many classes as time will allow Production Staff & Man
15、agement, All of Quality & EngineeringSpecific Production Staff, Quality & Engineering, QA manager, product engineerCustomer and Supplier Involvement客戶及廠商的參與客戶及廠商的參與 Customer may initiate the planning process 由客戶啟動計劃過程 Supplier has the obligation to establish cross-functional team to manage process 廠
16、商有義務建立跨功能小組來管理過程 Supplier should expect the same performance from their subcontractors 廠商應要求其供應商有相同表現Simultaneous (Concurrent) Engineering 同步工程 Requires cross-functional team participation需要跨功能小組參與 Replaces prior system of sequential phases 取代過去順序式的做法 Expedite new product introduction 加速新產品導入 APQP t
17、eam ensures that other functions and teams plan and execute activities support common goals 確保其他小組計劃並執行支援活動Customer Requirements 客戶要求客戶要求 Ways to Determine Customer Requirements 來源 Print 圖面 Purchase Request or Request for Quotation 採購單 QFD - Quality Function Deployment 品質機能展開 Service Engineers 售服工程師
18、 Verbal Communications 口頭溝通 Development Engineers 開發工程師 Product Check List 查檢表Base Documentation 文件文件 Critical Characteristics Matrix 特性矩陣 Process Flow Diagram 流程圖 Design FMEA Process FMEA Control PlanChicken or Egg 先有雞先有蛋先有雞先有蛋? Which is First? Second? Third? Control Plan? Process Flow Diagram? Des
19、ign FMEA? Process FMEA? Process Documentation (Work Instructions)? Why Does it Matter? 為何重要 Typical Automotive Trilogy Development 開發三部曲開發三部曲The Links 連接連接 Each Flow Chart element with historical issue must have a matching FMEA element. As a trilogy, remember - the links must all match. 流程, 歷史事件及FME
20、A的連接/三部曲 The trilogy documents must precisely link to your process documentation (work instructions or however your company addresses this issue)三部曲文件與製程文件的連接The Control Plan 管制計劃管制計劃A Control Plan is a written description of systems for parts and processes 是一文件化的描述零件及過程系統Process Dominated 過程導向Proto
21、type 原形 *A Design Output 是一設計輸出Used During Prototype Build, Dimensional Measurements, Material and Performance Tests 於原形階段使用, 包括尺寸確認, 材質及功能測試Pre-Launch 量試Update After Prototype and Before Production 於原形階段之後量產之前使用Production 量產Comprehensive, Process Controls, Test and Measurement Systems Used, Reactio
22、n Plan, Sampling Plans, SPC Requirements 包括完整的製程管制, 測試及量測系統, 應變計劃, 抽樣計劃, SPCQS9000:1998 - FMEAs 4.2.3 - Quality Planning 4.2.3.5 Process Failure Mode and Effects Analysis (Process FMEAs)Process FMEAs shall consider all special characteristics. Efforts shall be taken to improve the process to achieve
23、 defect prevention rather than defect detection. Certain customers have FMEA review and approval requirements that shall be met prior to production part approval (see customer specific pages). Refer to the Potential Failure Mode and Effects Analysis reference manual. 所有特殊特性都要包括, 預防勝於偵測QS9000:1998 -
24、Control Plans 4.2.3 - Quality Planning 4.2.3.7 The Control PlanSuppliers shall develop Control Plans at the system, subsystem, component and/or material level, as appropriate for the product supplied. 包括系統,子系統, 零件及材料The Control Plan requirement encompasses processes producing bulk material (e.g., st
25、eel, plastic resin, paint) as well as those producing parts.包括散裝材料及生產零件The output of the advanced quality planning process, beyond the development of robust processes, is a Control Plan. Control Plans may be based on existing plans (for mature products and capable processes). New plans are required
26、when products or processes differ significantly from those in current production. APQP的輸出是管制計劃, 可基於現有計劃, 當產品或過程有明顯差異時, 應有新計劃QS9000:1998 - Control Plans 4.2.3 - Quality Planning4.2.3.7 The Control Plan (continued)The Control Plan shall cover three distinct phases as appropriate: 應包括三階段Prototype 原形- a
27、 description of the dimensional measurements and material and performance tests that will occur during Prototype build. Supplier shall have prototype control plans when required. 當有客戶要求時 Prototype CP 要有Pre-launch量試 - a description of the dimensional measurements and material and performance tests th
28、at will occur after Prototype and before full Production. Production 量產- a comprehensive documentation of product/process characteristics, process controls, tests, and measurement systems that will occur during mass production.QS9000:1998 - Quality Planning Suppliers shall establish cross-functional
29、 teams to develop Control Plans . 應建立跨功能小組以發展管制計劃 Develop FMEA 發展FMEA Establish Actions to reduce RPN 提出行動以降低RPN Develop CC&SC 發展CC&SCSemiconductor Supplement 半導體補充件半導體補充件 Quality Planning - 4.2.3.S During the advanced quality planning processes, the supplier shall include all processes from the inc
30、oming material through shipping and warehousing 從進料到出貨及倉儲都要包括 Failure Mode and Effects Analysis and Control Plan documents shall include these processes. FMEA/ CP 要考慮/包括所有製程? The Intent:The supplier shall *consider* all processes. But - does it mean that all process shall be included in the FMEA and
31、 Control Plan?包括所有製程? APQP Manual : 1995 6.2 Overview “A control plan is a written description of the system for controlling parts and processes” “In effect, the Control Plan describes the actions that are required at each phase of the process including receiving, in-process, out-going, and periodic
32、 requirements to assure that all process outputs will be in a state of control” 描述個階段所需的各項管制以確保期為管制狀態Concern Resolution 問題的解決問題的解決 Design or Process concerns 設計或過程問題 Responsibility matrix 職責 Disciplined problem solving methods 解決問題的手法 Use analytical techniques (*as appropriate)(See AIAGs APQP & Cont
33、rol Plan reference manual page 4 and appendix B, page 81) 如因果圖, 特性矩陣圖, 標竿法, 裝配變異分析Timing Plan日程計劃日程計劃 Depends upon Product complexity, Customer expectations 考慮產品複雜性及客戶要求 Team plan for Training, Event and Action 訓練, 事件及行動 Framework for tracking 追蹤的機制 Basis for status reporting 狀況回報 Prepare a timing c
34、hart using available project or similar software 使用軟體製作時間表Do NOT Under Estimate the Importance of Timing!Timing Plan Contents日程計劃的內容日程計劃的內容 Identify individual tasks 鑑別個別任務 Track resources by task 依任務追蹤資源 Establishes dependencies between tasks 鑑別任務關聯性 Determine critical path 決定關鍵路徑 Track specific ta
35、sks or groups of tasks 追蹤任務 Status reports 狀況報告Project Plan Definitions 專案計劃的定義 Mission - Goal, customer and approach 任務, 目標, 客戶及方法 Scope - What will and will not be included (with consideration to available technology) 範圍-要包含哪些, 可用的技術 Objectives - Technical, profit, performance, quality, 目標要包含哪些 Re
36、quirements Deliverables 要求-可交貨 Definition and specification - Criteria it must meet 定義及規範- 一定要符合條件 Market analysis - Expected annual production volume, start (delivery) target date, target price, key sales points, key competitors, etc.市場分析-年產量,交貨時間, 目標價, 主要賣點, 主要競爭者Project Plan Definitions (continue
37、d)專案計劃的定義(續)Preliminary Feasibility - Degree to which current tooling and equipment can be used初期可行性評估, 哪些模治具及設備可用Timeline - Major milestones and detail task schedule時間表-里程碑及細部專案計劃的時程Control system - Answers questions such as:管制系統How will progress be measured? Who will receive reports? How are chang
38、es handled? What limits are there on authority, responsibility, and accountability?如何衡量進度?誰應收到報告?如何處理變更?權責界線為何?Cost estimate - Estimate with assumptions. Often all information is not available.成本預估, 假設法, 通常什麼資訊都沒有Analytical Techniques 分析技術Assembly Build Variation Analysis組裝造成的變異分析Benchmarking標竿比較Cau
39、se & Effect Diagram魚骨圖Characteristics Matrix特性矩陣Critical Path Method關鍵路徑法Design of Experiments (DOE)實驗計劃法Design for Manufacturability & Assembly (DFM & DFA)製造性及裝配設計Design Verification Plan & Report (DVP&R - Chrysler & Ford)設計驗證計劃及報告Dimensional (Dynamic) Control Plan (DCP)動態管制計劃Mistake Proofing (Poka
40、-Yoke)防呆Process Flow Charting流程圖Quality Function Deployment (QFD)品質機能展開System Failure Mode & Effects Analysis (SFMEA) See AIAGs APQP & Control Plan reference manual appendix B, pages 81 thru 85 I II III IV V 計計劃劃及及定定義義 產產品品設設計計及及開開發發 製製程程設設計計及及開開發發 產產品品及及製製程程查查證證 回回饋饋評評估估及及矯矯正正 1.1 顧客聲音 1.7 設計目標 2.1
41、 DFMEA 3.1 包裝標準 4.1 量試 5.1 減少變異 1.1.1 市場調查 1.8 品質可靠度及品質 目標 2.2 製造性及組立之設計 3.2 產品/製程品質制度檢討 4.2 量測系統分析評估 5.2 顧客滿意 1.1.2 歷來之保固及品質資料 1.9 初期材料清單 2.3 設計驗證 3.3 製程流程圖 4.3 初期製程能力PPK 研究 5.3 交貨及服務 1.1.3 小組經驗 1.10 初期製程流程圖 2.4 設計審查 3.4 平面圖配置 4.4 PPAP 1.2 經營計劃 1.11 初期特殊材料及 製程特性表 2.5 原型建立及管制計劃 3.5 特性矩陣 4.5 生產驗收測試 1
42、.3 產品/製程之標竿資料 1.12 產品保證計劃 2.6 工程圖及數學數據 3.6 PFMEA 4.6 包裝評估 1.4 產品/製程假設 1.13 管理階層之支持 2.7 工程規格 3.7 量試管制計劃 4.7 量產管制計劃 1.5 產品可靠度研究 2.8 材料規格 3.8 製程說明書 4.8 品質規劃簽署及管理階層之支持 1.6 顧客輸入 2.9 圖面及規格變更 3.9 量測系統分析計劃 2.10 新裝備, 模具 及設備要求 3.10 初期製程能力研究計劃 2.11 特殊產品/製程特性 3.11 包裝規格 先期產品品質規劃先期產品品質規劃(APQP)階段區分階段區分INPUTS/OUTPU
43、TSINPUTS/OUTPUTSAPQP Phase 1: Plan and Define Program/ input定義及計劃,輸入Voice of the Customer 客戶的聲音 Market research市調 Historical warranty and quality information過去保固及品質資料 Team experience小組的經驗 Complaints抱怨 Recommendations建議 Data and/or other information其他數據Voice of the Customer 客戶的聲音內外部客戶可陳述的真實的, 可感受到的需求
44、文化上的需求功能需求vs 技術特性u顧客洽訪顧客洽訪u顧客問卷和調查顧客問卷和調查u銷售試驗及市場定位報告銷售試驗及市場定位報告u新產品品質與可靠度研究新產品品質與可靠度研究u競爭性產品品質研究競爭性產品品質研究u產品改善報告產品改善報告市場調查市場調查u產品失效報告產品失效報告u保固作業報告保固作業報告u製程能力指標製程能力指標u廠內品質報告廠內品質報告u品質問題解決報告品質問題解決報告u從中心廠退貨或拒收從中心廠退貨或拒收u市場退回分析市場退回分析以往保固與品質資訊以往保固與品質資訊u來自於較高層次來自於較高層次(組裝組裝)的資訊的資訊u媒體的評論和分析；如雜誌、報紙媒體的評論和分析；如雜
45、誌、報紙u顧客文字及建議顧客文字及建議u問題的發生與解決報告問題的發生與解決報告u零售商的建議零售商的建議u車隊人員的建議車隊人員的建議u對使用代用品顧客之評估對使用代用品顧客之評估u路試路試u管理階層建議和指示管理階層建議和指示u內部顧客問題反應內部顧客問題反應u政府要求及法則政府要求及法則u合約審查合約審查研發小組的經驗研發小組的經驗u顧客經營計畫及行銷策略為產品品質計畫顧客經營計畫及行銷策略為產品品質計畫的構架的構架u顧客事業計畫之限制項目（如下）；會影顧客事業計畫之限制項目（如下）；會影響研發方向響研發方向時效、成本、資金、產品定位、研發資時效、成本、資金、產品定位、研發資源源u顧客行
46、銷策略會定義：顧客行銷策略會定義：目標顧客目標顧客主要賣點主要賣點主要競爭者主要競爭者經營經營計畫計畫 / 行銷策略行銷策略Product - Process Benchmark Data 產品/製程之標竿資料 A requirement of QS 9000 para. 4.1QS 9000 的要求Provides inputs to establish performance targets提供輸入以建立性能指標Must address key process(es)必須指出主要製程Must be measurable必須可量測Methods for successful benchmar
47、king: Identify appropriate benchmark(s), Find reason for gap between your status and benchmark, Develop a plan for closing gap, meeting or exceeding, benchmark鑑別標竿, 找出真因, 建立改正計劃, 符合標竿或超出之Product - Process Assumptions 產品/製程假設 Assumptions: Features, Design, Process concepts, Technical innovations, Adv
48、anced materials, Reliability assessments, New technology假設: 特性設計製程概念, 技術創新, 先進材料, 可靠度查核, 新技術 Document assumptions as part of project plan紀錄假設使成為計劃的一部分 Consider alternate paths in case assumptions do not play out當假設不能執行考慮替代方案時Product Reliability Studies產品可靠度研究 Frequency of repairs or replacements wit
49、hin designated time period(s)在預計的時間修理或更換的頻率 Repair or Throw-away?修理或丟棄 Long range reliability and/or durability tests長時間可靠度研究或耐久測試 Studies can be VERY costly and lengthy研究可能是非常貴而且耗時 MTBR = Mean Time Between Replacement MTBO = Mean Time Between Overhaul MTBF = Mean Time Between FailuresCustomer Input
50、s顧客輸入 Next users provide information about needs and expectations下一使用者提供需求及期望的訊息 Possibility of previous conducted reviews and studies先前審查及研究結果輸入的可能性 Used to develop measure of customer satisfaction使用先前資訊已發展衡量客戶滿意的方法APQP Phase 1:Plan and Define Program/ output定義及計劃,輸出設計目設計目標標 轉化顧客的聲音轉化顧客的聲音, 需要及期望，成