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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 customerBenefits 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 lowest cost.Enabl
3、es cross-functional inputs and outputs.Addresses potential problems earlyCustomer 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 their subcontractors.Dete
4、rmine Customer RequirementsPrintPurchase Request or Request for Quotation.Statement of Work(SOW)Customer visits and discussions.Product checklists.TrainingCustomer needs and expectations.Working as a team.Requirements of APQPFMEAAPQPPPAPAPQP Five Phase ProcessPlanningProduct Design and DevelopmentPr
5、ocess Design and DevelopmentProduct and Process ValidationProductionFeedback Assessment and Corrective ActionPilotLaunchConcept Initiation/ApprovalProgram ApprovalPrototypePlanningLinks Between the ToolsContract Review Program PlanDFMEATeam Feasibility CommitmentProduce Process Flow DiagramsConduct
6、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 Key Characteristics Determine Risk and Feasibi
7、lityAssociate 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 Customer Expectations are MetExercise Manage
8、ment OversightThe Target and The GoalLink Between the DocumentsProcess Flow DiagramsUpdated after production trial run.Need to indicate special characteristics generated at each step.Completed Along with Control Plan(APQP Process).Generally contains same information as process traveler.Process Flow
9、Diagram ExampleAPQP Links to PFMEAProcess FMEAMust follow flow of the process flow diagram.Must include ALL process special characteristics(as a minimum).How 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
10、spend a lot of time on?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 process experts and should be a driver of the control plans and work instructionsWork instructio
11、ns(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 instructionsAPQP Links to Control PlanControl PlansIncludes product and process special cha
12、racteristics.Includes SPC requirements.Follows flow of process flow chart and PFMEA.May require customer approval.Types of Control PlansPrototype build control plan(s)Pre-launch control planProduction control planPrototype Build Control PlanA description of the dimensional measurements.Material test
13、sFunctional tests that will occur during prototype build.Pre-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
14、-process and finsl inspection and/or check points.Statistical evaluations.Increased audits.Production Control PlanUp-date pre-launch control plan.Add:Sampling plansControl methodSPC,inspection,attribute data and mistake proofing.Reaction planNonconformances clearly identified,quarantined and disposi
15、tion made.Requires customer approval unless otherwise specified.Control 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 control and measurement systems used.M
16、ultiple 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.Part Submission StatusNever ship production parts before receiving customer approval.Supplier must ensure that future pr
17、oduction continues to meet customer requirements.No production parts can be shipped until approval is received.Automotive Documentation DevelopmentDevelop Process Flow ListingCheck for Customer RequirementsEnter Every “Major”Process from Flow Listing into FMEA Form Give careful consideration to what
18、 you consider a“Major”processDevelop FMEA Element for Every ProcessUse the appropriate RPN numbers and considerations of other appropriate information/data to determine Critical characteristicsDevelop the Control Plan with Critical CharacteristicsDevelop control mechanisms appropriate for Critical c
19、haracteristics.Give careful consideration to defining Control Plan stagesPrototype Pre-launch ProductionProvides Proof of CapabilityMade up of Documents from APQP PPAP PurposeEnsure that customer design record and specification requirements are understood.Ensure that the process has the potential fo
20、r producing product meeting those requirementsPPAP ScopeProduction parts-generally 300 pieces.Includes internal and external sources for information.Submission required prior to first production shipment.Base DocumentationCritical characteristics matrix.Process flow diagram.Design FMEA(supplied by c
21、ustomer).Process FMEA.Control plan.GeneralSupplier 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 requirement
22、sComply with customer developed material specifications and/or approved source list.GeneralSuppliers 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 pl
23、us one calendar year.Elements 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 studiesParts
24、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 requirementsRequired documentation is avail
25、able for proper submission level.Signs warrant and provided date,title and telephone number.Part 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.Fo
26、r parts less than 0.100 kilogram,weigh 10 parts together and report the average weight.Master 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 datePreliminary P
27、rocess 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 1.67 requires action plan unless otherwise specified.Production Trial RunProduction tooling,equipment,environment,faciliti
28、es and cycle time.Process Instructions and control plans.Minimum quantity set by the customer.Generally 300 parts.Production Trial Run Product Used ForPreliminary process capability studies.MSA(if not completed earlier)Final Feasibility.Process review.Production Validation Testing.PPAPPackaging eval
29、uationFirst time capabilityQuality planning sign-offMeasurement System 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.Packaging EvaluationPackaging must conform to specifications de
30、veloped by customer or supplier.Assess protection of product.Customer specified packaging must be evaluated by team.Pilot or production trial run parts usually used in evaluation.Floor Plan LayoutDetermine acceptability of inspection and test points.Control chart locationsVisual aidesInterim repair
31、stationsNonconforming material storageKeyed to material flow and control planReview 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 reviewOb
32、tain management commitment to assist in open issuesQuality 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
33、:We use voting 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 PME
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