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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 mon path and synchronization of product development activiti
2、es.APQP is an attempt to ensure munication both within a pany and between a pany 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.Enables cross-fun
3、ctional 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.Determine Custom
4、er RequirementsPrintPurchase Request or Request for Quotation.Statement of Work SOWCustomer visits and discussions.Product checklists.TrainingCustomer needs and expectations.Working as a team.Requirements of APQPFMEAAPQPPPAPAPQP Five Phase ProcessPlanningProduct Design and DevelopmentProcess Design
5、and DevelopmentProduct and Process ValidationProductionFeedback Assessment and Corrective ActionPilotLaunchConcept Initiation/ApprovalProgram ApprovalPrototypePlanningLinks Between the ToolsContract Review Program PlanDFMEATeam Feasibility mitmentProduce Process Flow DiagramsConduct Process FMEADeve
6、lop 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 FeasibilityAssociate Ch
7、aracteristics 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 Management OversightTh
8、e Target and The GoalLink Between the DocumentsProcess Flow DiagramsUpdated after production trial run.Need to indicate special characteristics generated at each step.pleted Along with Control Plan APQP Process.Generally contains same information as process traveler.Process Flow Diagram ExampleAPQP
9、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 e from?What types of people are a part of the PFMEA team?What types of activities should we spend a lot of time on?P
10、FMEAs/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 pleted by process experts and should be a driver of the control plans and work instructionsWork instructions Post control log,process
11、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 characteristics.Includes SPC req
12、uirements.Follows flow of process flow chart and PFMEA.May require customer approval.Types of Control PlansPrototype build control plans Pre-launch control planProduction control planPrototype Build Control PlanA description of the dimensional measurements.Material testsFunctional tests that will oc
13、cur 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-process and finsl inspection
14、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 disposition made.Requires customer ap
15、proval unless otherwise specified.Control Plan UseInitial:To document and municate 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.Multiple Molds,Tools,Dies and Patt
16、erns plete 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 production continues to meet customer
17、 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 you consider a“Major processDevelo
18、p 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 characteristics.Give careful conside
19、ration 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 for producing product meeting those r
20、equirementsPPAP 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 customer.Process FMEA.Control plan.G
21、eneralSupplier 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 requirements ply with customer developed materi
22、al specifications and/or approved source list.GeneralSuppliers are required to plete 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.Elements of a PPAPPa
23、rt submission warrantSubcontractor warrantsDesign record customer/design documentationSample/Master sample Master sample retained by supplierDimensional analysisTest dataFlow diagramControl planPFMEAMeasurement Systems Analysis GR&RCapability studiesParts Submission WarrantUpon satisfactory pletion
24、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 available for proper submission level.Signs warrant
25、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.For parts less than 0.100 kilogram,weigh 10 parts
26、 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 Process Capability StudiesCharacteristics identi
27、fied 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,facilities and cycle time.Process Instructions and cont
28、rol plans.Minimum quantity set by the customer.Generally 300 parts.Production Trial Run Product Used ForPreliminary process capability studies.MSA if not pleted earlierFinal Feasibility.Process review.Production Validation Testing.PPAPPackaging evaluationFirst time capabilityQuality planning sign-of
29、fMeasurement System Analysis MSA plete 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 developed by customer or supplier.Assess protection of p
30、roduct.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 stationsNonconforming material storageKeyed to materia
31、l 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 reviewObtain management mitment to assist in open issuesQualit
32、y 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 voting techniques,X to Y variable testing,and IS/
33、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 pleted,the PMEA and the control plan should be revised and updated as appl
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