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1、APQPPPAP 精品资料网APQPA Perspective on 8-D and PFMEA and Control Plan During APQP and Afterwards 精品资料网What is APQP?APQP is a defined process for a product development system for Ford,Daimler-Chrysler,GM and their suppliers.APQP is an attempt to provide a common path and synchronization of product develo
2、pment activities.APQP is an attempt to ensure communication both within a company and between a company and its customer 精品资料网Benefits of APQPEnsures early planning takes place.Directs resources to the customer.Identifies required changes early in the process.Provides quality product on time and at
3、lowest cost.Enables cross-functional inputs and outputs.Addresses potential problems early 精品资料网Customer and Supplier InvolvementCustomer may initiate planning process.Supplier has the obligation to establish cross-functional team to manage process.Supplier should expect the same performance from th
4、eir subcontractors.精品资料网Determine Customer RequirementsPrintPurchase Request or Request for Quotation.Statement of Work(SOW)Customer visits and discussions.Product checklists.精品资料网TrainingCustomer needs and expectations.Working as a team.Requirements of APQPFMEAAPQPPPAP 精品资料网APQP Five Phase ProcessP
5、lanningProduct Design and DevelopmentProcess Design and DevelopmentProduct and Process ValidationProductionFeedback Assessment and Corrective ActionPilotLaunchConcept Initiation/ApprovalProgram ApprovalPrototypePlanning 精品资料网Links Between the ToolsContract Review Program PlanDFMEATeam Feasibility Co
6、mmitmentProduce Process Flow DiagramsConduct Process FMEADevelop Control PlanWork Instruction DevelopmentProduct and Process ValidationEnsure Continuous ImprovementPhase IPhase IIPhase IIPhase IIIPhase IIIPhase IIIPhase IIIPhase IVPhase VDetermine Customer Expectations and Plan for QualityIdentify K
7、ey Characteristics Determine Risk and FeasibilityAssociate Characteristics with Process Steps and Identify Key CharacteristicsExpose Sources of Variation and Finalize Key CharacteristicsDetermine Methods to Improve Process and Control VariationImplement Control Plan and Standardize the ProcessEnsure
8、 Customer Expectations are MetExercise Management Oversight 精品资料网The Target and The Goal 精品资料网Link Between the Documents 精品资料网Process Flow DiagramsUpdated after production trial run.Need to indicate special characteristics generated at each step.Completed Along with Control Plan(APQP Process).Genera
9、lly contains same information as process traveler.精品资料网Process Flow Diagram Example 精品资料网APQP Links to PFMEA 精品资料网Process FMEAMust follow flow of the process flow diagram.Must include ALL process special characteristics(as a minimum).精品资料网How a PFMEA WorksWhere does the data for the PFMEA come from?
10、What types of people are a part of the PFMEA team?What types of activities should we spend a lot of time on?精品资料网PFMEAs/Control Plans and 8-Ds During APQPPFMEAs should be driven by real data,including 8-Ds(internal and external),warranty and returned part analysisPFMEAs should be completed by proces
11、s experts and should be a driver of the control plans and work instructionsWork instructions(Post control log,process parameter logs,preventive maintenance,etc.)implement the control plan in the processWhen there is a quality problem there is an opportunity to improve the control plan and the work i
12、nstructions 精品资料网APQP Links to Control Plan 精品资料网Control PlansIncludes product and process special characteristics.Includes SPC requirements.Follows flow of process flow chart and PFMEA.May require customer approval.精品资料网Types of Control PlansPrototype build control plan(s)Pre-launch control planPro
13、duction control plan 精品资料网Prototype Build Control PlanA description of the dimensional measurements.Material testsFunctional tests that will occur during prototype build.精品资料网Pre-launch Control PlanDescription of dimensional measurements,materials,and functional tests.Adds additional product and pro
14、cess controls.Purpose is to contain potential nonconformities utilizing:More frequent inspections and/or tests.More in-process and finsl inspection and/or check points.Statistical evaluations.Increased audits.精品资料网Production Control PlanUp-date pre-launch control plan.Add:Sampling plansControl metho
15、dSPC,inspection,attribute data and mistake proofing.Reaction planNonconformances clearly identified,quarantined and disposition made.Requires customer approval unless otherwise specified.精品资料网Control Plan UseInitial:To document and communicate initial process control.Next:Guidance in controlling pro
16、cesses and to ensure product quality.Last A living document reflecting current methods of control and measurement systems used.精品资料网Multiple Molds,Tools,Dies and PatternsComplete dimensional layer required from one part from each cavity as a minimum.Supplier must identify specific cavity for each pa
17、rt submitted.精品资料网Part Submission StatusNever ship production parts before receiving customer approval.Supplier must ensure that future production continues to meet customer requirements.No production parts can be shipped until approval is received.精品资料网Automotive Documentation DevelopmentDevelop Pr
18、ocess Flow ListingCheck for Customer RequirementsEnter Every “Major”Process from Flow Listing into FMEA Form Give careful consideration to what you consider a“Major”processDevelop FMEA Element for Every ProcessUse the appropriate RPN numbers and considerations of other appropriate information/data t
19、o determine Critical characteristicsDevelop the Control Plan with Critical CharacteristicsDevelop control mechanisms appropriate for Critical characteristics.Give careful consideration to defining Control Plan stagesPrototype Pre-launch Production 精品资料网 精品资料网Provides Proof of CapabilityMade up of Do
20、cuments from APQP 精品资料网PPAP PurposeEnsure that customer design record and specification requirements are understood.Ensure that the process has the potential for producing product meeting those requirements 精品资料网PPAP ScopeProduction parts-generally 300 pieces.Includes internal and external sources f
21、or information.Submission required prior to first production shipment.精品资料网 Base DocumentationCritical characteristics matrix.Process flow diagram.Design FMEA(supplied by customer).Process FMEA.Control plan.精品资料网GeneralSupplier is responsible for meeting all applicable specifications.Do not submit p
22、arts and documentation results if they are outside specification.Take corrective action to meet all design record requirements.Contact customer if unable to meet all requirementsComply with customer developed material specifications and/or approved source list.精品资料网GeneralSuppliers are required to c
23、omplete and maintain copies of all documentation identified in“requirements for approval”regardless of submission level.Records of PPAP are to be retained for the life of the part plus one calendar year.精品资料网Elements of a PPAPPart submission warrantSubcontractor warrantsDesign record(customer/design
24、 documentation)Sample/Master sample(Master sample retained by supplier)Dimensional analysisTest dataFlow diagramControl planPFMEAMeasurement Systems Analysis(GR&R)Capability studies 精品资料网Parts Submission WarrantUpon satisfactory completion of all required measurements and tests,enter all required in
25、formation on the warrant.A separate is required for each part number.Responsible supplier official verifiesMeasurements and tests conform to customer requirementsRequired documentation is available for proper submission level.Signs warrant and provided date,title and telephone number.精品资料网 精品资料网Part
26、 WeightDetermine part weight without packaging or shipping material.Report weight in kilograms to three decimal places.Weight determinationWeigh 10 parts randomly selected and report the average weight.For parts less than 0.100 kilogram,weigh 10 parts together and report the average weight.精品资料网Mast
27、er SampleRetain same as PPAP,orUntil new master sample is produced for the purpose of a customer approval.Identify master sample by:Part numberDrawing level or revision levelCustomer approval date 精品资料网Preliminary Process Capability StudiesCharacteristics identified in the control plan.Usually 100 p
28、ieces minimum.May be 30 if run is less.Ppk 1.67 is acceptable unless otherwise specified.Ppk 1.67 requires action plan unless otherwise specified.精品资料网Production Trial RunProduction tooling,equipment,environment,facilities and cycle time.Process Instructions and control plans.Minimum quantity set by
29、 the customer.Generally 300 parts.精品资料网Production Trial Run Product Used ForPreliminary process capability studies.MSA(if not completed earlier)Final Feasibility.Process review.Production Validation Testing.PPAPPackaging evaluationFirst time capabilityQuality planning sign-off 精品资料网Measurement Syste
30、m Analysis(MSA)Complete studies as defined in the MSA plan.Minimum are those identified in the control plan.Subjected to evaluation prior to or during production trial.精品资料网Packaging EvaluationPackaging must conform to specifications developed by customer or supplier.Assess protection of product.Cus
31、tomer specified packaging must be evaluated by team.Pilot or production trial run parts usually used in evaluation.精品资料网Floor Plan LayoutDetermine acceptability of inspection and test points.Control chart locationsVisual aidesInterim repair stationsNonconforming material storageKeyed to material flo
32、w and control plan 精品资料网Review and Sign-OffProcess instructions in place and followed!Flow charts in place and followed!GR&R plans exist and are followedPublish final feasibility reportObtain formal sign-offSchedule and conduct management reviewObtain management commitment to assist in open issues 精
33、品资料网Quality Problemsyesnonoyesnoyesnoyes 精品资料网Cause unknownUse PFMEANote:When a customer problem occurs,follow customer prescribed methodology 精品资料网When to use 8-DWhen the cause is unknownWhen you need to get input from several partiesWhen customers dictate useNote:We use voting techniques,X to Y va
34、riable testing,and IS/IS Not to determine the root cause.However,you still may not know what the root cause is?精品资料网Update the PFMEA&Control PlansProcess FlowPFMEAControl PlanWork InstructionScrap,Rework DataWarranty&Assembly Plant DataAfter the 8-D is completed,the PMEA and the control plan should
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