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1、APQPPPAP APQPA Perspective on 8-D and PFMEA and Control Plan During APQP and AfterwardsWhat 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 development activ
2、ities.APQP is an attempt to ensure communication both within a company and between a company and its customerMarketing&CommunicationsBenefits of APQPEnsures early planning takes place.Directs resources to the customer.Identifies required changes early in the process.Provides quality product on time
3、and at lowest cost.Enables cross-functional inputs and outputs.Addresses potential problems earlyMarketing&CommunicationsCustomer and Supplier InvolvementCustomer may initiate planning process.Supplier has the obligation to establish cross-functional team to manage process.Supplier should expect the
4、 same performance from their subcontractors.Marketing&CommunicationsDetermine Customer RequirementsPrintPurchase Request or Request for Quotation.Statement of Work(SOW)Customer visits and discussions.Product checklists.Marketing&CommunicationsTrainingCustomer needs and expectations.Working as a team
5、.Requirements of APQPFMEAAPQPPPAPMarketing&CommunicationsAPQP Five Phase ProcessPlanningProduct Design and DevelopmentProcess Design and DevelopmentProduct and Process ValidationProductionFeedback Assessment and Corrective ActionPilotLaunchConcept Initiation/ApprovalProgram ApprovalPrototypePlanning
6、Links Between the ToolsContract Review Program PlanDFMEATeam Feasibility CommitmentProduce Process Flow DiagramsConduct Process FMEADevelop Control PlanWork Instruction DevelopmentProduct and Process ValidationEnsure Continuous ImprovementPhase IPhase IIPhase IIPhase IIIPhase IIIPhase IIIPhase IIIPh
7、ase IVPhase VDetermine Customer Expectations and Plan for QualityIdentify Key Characteristics Determine Risk and FeasibilityAssociate Characteristics with Process Steps and Identify Key CharacteristicsExpose Sources of Variation and Finalize Key CharacteristicsDetermine Methods to Improve Process an
8、d Control VariationImplement Control Plan and Standardize the ProcessEnsure Customer Expectations are MetExercise Management OversightThe Target and The GoalMarketing&CommunicationsLink Between the DocumentsProcess Flow DiagramsUpdated after production trial run.Need to indicate special characterist
9、ics generated at each step.Completed Along with Control Plan(APQP Process).Generally contains same information as process traveler.Marketing&CommunicationsProcess Flow Diagram ExampleMarketing&CommunicationsAPQP Links to PFMEAProcess FMEAMust follow flow of the process flow diagram.Must include ALL
10、process special characteristics(as a minimum).Marketing&CommunicationsHow a PFMEA WorksWhere does the data for the PFMEA come from?What types of people are a part of the PFMEA team?What types of activities should we spend a lot of time on?PFMEAs/Control Plans and 8-Ds During APQPPFMEAs should be dri
11、ven by real data,including 8-Ds(internal and external),warranty and returned part analysisPFMEAs should be completed by process 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
12、 control plan in the processWhen there is a quality problem there is an opportunity to improve the control plan and the work instructionsAPQP Links to Control PlanControl PlansIncludes product and process special characteristics.Includes SPC requirements.Follows flow of process flow chart and PFMEA.
13、May require customer approval.Marketing&CommunicationsTypes of Control PlansPrototype build control plan(s)Pre-launch control planProduction control planMarketing&CommunicationsPrototype Build Control PlanA description of the dimensional measurements.Material testsFunctional tests that will occur du
14、ring prototype build.Marketing&CommunicationsPre-launch Control PlanDescription of dimensional measurements,materials,and functional tests.Adds additional product and process controls.Purpose is to contain potential nonconformities utilizing:More frequent inspections and/or tests.More in-process and
15、 finsl inspection and/or check points.Statistical evaluations.Increased audits.Marketing&CommunicationsProduction Control PlanUp-date pre-launch control plan.Add:Sampling plansControl methodSPC,inspection,attribute data and mistake proofing.Reaction planNonconformances clearly identified,quarantined
16、 and disposition made.Requires customer approval unless otherwise specified.Marketing&CommunicationsControl Plan UseInitial:To document and communicate initial process control.Next:Guidance in controlling processes and to ensure product quality.Last A living document reflecting current methods of co
17、ntrol and measurement systems used.Marketing&CommunicationsMultiple Molds,Tools,Dies and PatternsComplete dimensional layer required from one part from each cavity as a minimum.Supplier must identify specific cavity for each part submitted.Marketing&CommunicationsPart Submission StatusNever ship pro
18、duction 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.Marketing&CommunicationsAutomotive Documentation DevelopmentDevelop Process Flow ListingCheck for Custome
19、r 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 to determine Critical characteristic
20、sDevelop the Control Plan with Critical CharacteristicsDevelop control mechanisms appropriate for Critical characteristics.Give careful consideration to defining Control Plan stagesPrototype Pre-launch ProductionMarketing&CommunicationsMarketing&CommunicationsProvides Proof of CapabilityMade up of D
21、ocuments from APQP Marketing&CommunicationsPPAP PurposeEnsure that customer design record and specification requirements are understood.Ensure that the process has the potential for producing product meeting those requirementsMarketing&CommunicationsPPAP ScopeProduction parts-generally 300 pieces.In
22、cludes internal and external sources for information.Submission required prior to first production shipment.Marketing&Communications Base DocumentationCritical characteristics matrix.Process flow diagram.Design FMEA(supplied by customer).Process FMEA.Control plan.Marketing&CommunicationsGeneralSuppl
23、ier is responsible for meeting all applicable specifications.Do not submit parts 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 specif
24、ications and/or approved source list.Marketing&CommunicationsGeneralSuppliers are required to complete 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.Ma
25、rketing&CommunicationsElements of a PPAPPart submission warrantSubcontractor warrantsDesign record(customer/design documentation)Sample/Master sample(Master sample retained by supplier)Dimensional analysisTest dataFlow diagramControl planPFMEAMeasurement Systems Analysis(GR&R)Capability studiesMarke
26、ting&CommunicationsParts Submission WarrantUpon satisfactory completion of all required measurements and tests,enter all required information on the warrant.A separate is required for each part number.Responsible supplier official verifiesMeasurements and tests conform to customer requirementsRequir
27、ed documentation is available for proper submission level.Signs warrant and provided date,title and telephone number.Marketing&CommunicationsMarketing&CommunicationsPart WeightDetermine part weight without packaging or shipping material.Report weight in kilograms to three decimal places.Weight deter
28、minationWeigh 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.Marketing&CommunicationsMaster SampleRetain same as PPAP,orUntil new master sample is produced for the purpose of a customer approval.Identi
29、fy master sample by:Part numberDrawing level or revision levelCustomer approval dateMarketing&CommunicationsPreliminary Process Capability StudiesCharacteristics identified in the control plan.Usually 100 pieces minimum.May be 30 if run is less.Ppk 1.67 is acceptable unless otherwise specified.Ppk 1
30、.67 requires action plan unless otherwise specified.Marketing&CommunicationsProduction Trial RunProduction tooling,equipment,environment,facilities and cycle time.Process Instructions and control plans.Minimum quantity set by the customer.Generally 300 parts.Marketing&CommunicationsProduction Trial
31、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-offMarketing&CommunicationsMeasurement System Analysis(MSA)Complete studies as def
32、ined in the MSA plan.Minimum are those identified in the control plan.Subjected to evaluation prior to or during production trial.Marketing&CommunicationsPackaging EvaluationPackaging must conform to specifications developed by customer or supplier.Assess protection of product.Customer specified pac
33、kaging must be evaluated by team.Pilot or production trial run parts usually used in evaluation.Marketing&CommunicationsFloor Plan LayoutDetermine acceptability of inspection and test points.Control chart locationsVisual aidesInterim repair stationsNonconforming material storageKeyed to material flo
34、w and control planMarketing&CommunicationsReview 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 assis
35、t in open issuesMarketing&CommunicationsQuality ProblemsyesnonoyesnoyesnoyesCause unknownUse PFMEANote:When a customer problem occurs,follow customer prescribed methodologyWhen to use 8-DWhen the cause is unknownWhen you need to get input from several partiesWhen customers dictate useNote:We use vot
36、ing techniques,X to Y variable testing,and IS/IS Not to determine the root cause.However,you still may not know what the root cause is?Update the PFMEA&Control PlansProcess FlowPFMEAControl PlanWork InstructionScrap,Rework DataWarranty&Assembly Plant DataAfter the 8-D is completed,the PMEA and the c
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