APQP PPT

Advanced Product Quality Planning (APQP) Based on the AIAG “Advanced Product Quality Planning and Control Plan” Reference Manual Presented By Dr. Cecelia Venuk November 2009

Objectives Understand the APQP Process
Identify the inputs / outputs of the 5 APQP phases
Understand APQP as a methodology for new product development


What is Quality Planning?

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The AIAG APQP Model What is APQP?








Advance Product Quality Planning is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer. The goal of product quality planning is to facilitate communication with everyone involved to assure that all required steps are completed on time. Effective product quality planning depends on a company’s top management commitment to the effort required in achieving customer satisfaction.

Why Product Quality Planning?














The bulk of cost of a product is committed at the early stages of a development cycle even though they are not expended until later. The cost of fixing a design and faulty decisions at later stages is exponentially greater than at an earlier stage. The opportunity costs of being late to market are very high, ex., lower market share, lower margins. Cross-functional teams typically provide a better quality solution to complex dynamic product development problems than single individuals. Early simultaneous involvement in product development by cross-functional teams using structured development process saves time and money over the product life cycle.

Fundamentals of Product Quality Planning










Organizing the team Define the scope Team-to-Team Communication Training Customer, supplier and subcontractor involvement Simultaneous \ Concurrent Engineering Control plans Concern Resolution Timing plan and chart

Product Quality Planning Chart Concept Program Initiation/Approval Approval

Prototype

Pilot

Launch

Planning

Planning

Product Design and Dev. Process Design and Development Product and Process Validation Production Feedback Assessment and Corrective Action Plan and Define Program

Product Design and Development

Process Design and Development

Product and Process Validation

Feedback Assessment and Corrective Action

1.0 Plan and Define Program Concept Program Initiation/Approval Approval

Planning

Plan and Define Program

Inputs Objectives Voice of the Customer  Determine customer needs. - Market Research  Define and plan a quality - Historical Warranty program. and Quality Information - Team Experience Business Plan/Marketing strategy Product/Process Benchmark Data Product Reliability Studies Customer Inputs Outputs Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flowchart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support

Breakout – Quality Planning Product Description: PPASS (Personal Portable Automotive Sound System) This is a new option for all mid to high price range vehicles that allows an individuals personal MP3 or IPOD system to be integrated with the sound system of suitably equipped automotive vehicles. This product is a universal MP3 / IPOD holder combined with a short-range wireless link that has already been developed by the automotive industry.

Breakout – Quality Planning PPASS Design Goals & Parameters • Dashboard will have a built-in wireless interface receiver that links with the any PPASS transmitter • Must integrate with a wireless transmitter with a dimension of .5” X 1.0” X .2” • Maximum holder dimension: 3” X 4.5” X 1.5” • Universal fixture for 98% of all types of players • Safely positioned in vehicle during vehicle operation, and is to be located within three (3) feet of the sound system. • Robust materials of construction (portable) with an expected lifetime of 3 years • Single neutral color – go will all interiors

2.0 Product Design and Development Program Approval

Prototype

Product Design and Dev.

Product Design and Development

Inputs The outputs of Section 1.0

Objectives  Develop design features and characteristics  Review engineering requirements  Assess potential manufacturing problems that could occur

Outputs Design Failure Mode and Effects Analysis (DFMEA) Design for Manufacturability and Assembly Design Verification Design Reviews Prototype build – Control plan Engineering Drawings Engineering Specifications Material Specifications Drawing and Specification Changes New Equipment, Tooling and Facilities Requirements Special Product and Process Characteristics Team Feasibility Commitment and Management Support

Breakout – Quality Planning Develop a design for the Personal Portable Automotive Sound System (PPASS) unit. Your team (4 to 6 people) has 20 minutes to: 1.

2.

3. 4.

Design a fixture to safely hold a MP3 / IPOD and a sound system interface. Identify any special customer characteristics or concerns Identify the material specifications Identify any special tooling and equipment

Inputs to Prototype Control Plan Pre-Launch

Production

Control Plan Number Reference Part Number/Latest Change Level

CONTROL PLAN SUMMARY

x

Prototype

Key Contact/Phone

Date (Orig.)

Part Name/Description

Supplier/Plant

Rev.

Date (Revised)

Core Team

Customer

PART/ PROCESS NUMBER

PROCESS NAME/ OPERATION DESCRIPTION

MACHINE, DEVICE, JIG,TOOLS, FOR MFG.

CHARACTERISTIC

PRODUCT

PROCESS

SPECIAL CHAR. CLASS

METHODS PRODUCT/PROCESS SPECIFICATION/ TOLERANCE LSL

#1

#1

#2

#3

#4 #5

TARGET

#6

EVALUATION/ MEASUREMENT TECHNIQUE

SIZE

SAMPLE FREQ.

CONTROL METHOD Error proofing

REACTION PLAN

CORRECTIVE ACTION

Other

USL

#7

#8

#9

Outputs & Expectations: 1 – Assure product meets specification 2 – Ensure attention to process/product characteristics 3 – Establish preliminary process/product characteristics 4 – Communicate to the customer

#10

3.0 Process Design and Development Prototype

Pilot

Process Design and Development

Process Design and Development

Objectives

Inputs  Develop comprehensive and The outputs of Section 2.0 effective manufacturing process  Ensure process capability to meet customer requirements Outputs Packaging Standards Product/Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis (PFMEA) Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Management Support

Breakout – Quality Planning Next Steps Continue with the process design and development. Your team (4 to 6 people) has 10 minutes to: 1. 2.

3.

Develop a process flow. Identify critical manufacturing parameters to measure and control Identify 3 potential failures with this product

Inputs to Pre-launch Control Plan x

Pre-Launch

Production

CONTROL PLAN SUMMARY

Prototype

Control Plan Number Reference

Key Contact/Phone

Date (Orig.)

Part Number/Latest Change Level

Part Name/Description

Supplier/Plant

Rev.

Date (Revised)

Core Team

Customer

PART/ PROCESS NUMBER

PROCESS NAME/ OPERATION DESCRIPTION

MACHINE, DEVICE, JIG,TOOLS, FOR MFG.

CHARACTERISTIC

PRODUCT

PROCESS

SPECIAL CHAR. CLASS

METHODS PRODUCT/PROCESS SPECIFICATION/ TOLERANCE LSL

#1

#1

#2

#3

#4 #5

TARGET

#6

EVALUATION/ MEASUREMENT TECHNIQUE

SIZE

SAMPLE FREQ.

CONTROL METHOD Error proofing

REACTION PLAN

CORRECTIVE ACTION

Other

USL

#7

#8

Outputs & Expectations: 1 – Communication for process control 2 – Input to pre-launch control plan 3 – Product quality & customer satisfaction 4 – Identified opportunities for improvement

#9

#10

4.0 Product and Process Validation Prototype

Pilot

Objectives

Launch

Inputs The outputs of Section 3.0

Product and Process Validation

Product and Process Validation

   

Validate the product Validate the manufacturing process Validate the control plan Ensure product meets customer requirements  Identify concerns

Outputs Production Trial Run Measurement Systems Evaluation Preliminary Process Capability Study Production Part Approval Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off and Management Support

5.0 Feedback, Assessment and Corrective Action Pilot

Launch

Inputs The outputs of Section 5.0

Planning

Production Feedback Assessment and Corrective Action

Feedback Assessment and Corrective Action

Objectives  Evaluate all variation (variable and attribute data)  Evaluate effectiveness of product quality planning  Use control plan and corrective action

Outputs Reduced Variation Customer Satisfaction Delivery and Service

Summary: The AIAG APQP Model What is APQP?













APQP is a process, not just an event Integration of quality tools with management functions Status Reporting and Program Management Multi-disciplinary team approach to quality planning Satisfies requirement of TS, with linkage to several ISO/TS 16949:2002 elements Tool for continuous improvement

Summary: The 5 Phases of APQP 1.Plan and Define the Program 2.Product Design and Development 3.Process Design and Development 4.Product and Process Validation 5.Feedback, Assessment and Corrective Action

1. 2. 3. 4. 5.

APQP Acronyms







APQP – Advance Product Quality Planning D/P-FMEA – Design/Process Failure Mode Effect Analysis DVP&R – Design Verification Plan & Report AIAG – Automotive Industry Action Group TS 16949 – (Sector-specific) Technical Specification (for automotive industry) MSA – Measurement Systems Analysis I/M/T – Inspection/Measurement/Test

Questions

Related Information

New Product Development and Launch Process New Process Development

Concept Initiation/Approval

APQP

Project Start

Program Approval

Ramp to Volume

First Silicon

Production

Planning

Planning Product Design and Development Process Design and Development and Validation Product and Application Validation

Production

Applicable ISO/TS 16949 Requirements Design & Dev. Planning 7.3 (Product) ISO/TS 16949:2002

APQP and ISO/TS 16949:2002

Feedback Assessment and Corrective Action

Production & Service Provision 7.5 Monitoring & Measurement of Processes 8.2.3.1

Design & Dev. Planning 7.3 (Process) 7.1 Planning of Product Realization 7.2 CustomerRelated Processes

Monitoring & Measurement of Product 8.2.4 

Production Part Approval - 7.3.6.3

Feedback Assessment - 8 Continual Improvement - 8.5

Retention/Submission Requirements Table I.4.1 – AIAG PPAP Reference Guide 3 ed. All listed items may not necessarily apply to every customer part from every supplier, Consult design record and customer to determine which items or records apply Submission Level Requirement 1.

AIAG PPAP: Contents and Submission levels Note: the PPAP form and descriptions of each requirement is from the AIAG reference manual for PPAP, Third Edition

Design/Development Records

Level 1

Level 2

Level 3

Level 4

Level 5

R

S

S

•

R

-for proprietary components/details

R

R

R

•

R

-for all other components/details

R

S

S

•

R

2.

Engineering Change Documents, if any

R

S

S

•

R

3.

TI Engineering Final Approval

R

R

S

•

R

4.

Design FMEA (or Risk Assessment)

R

R

S

•

R

5.

Process Flow Diagrams

R

R

S

•

R

6.

Process FMEA (or Risk Assessment)

R

R

S

•

R

7.

Dimensional Results

R

S

S

•

R

8.

Material, Performance Test Results

R

S

S

•

R

9.

Initial Process Study

R

R

S

•

R

10.

Measurement System Analysis Studies

R

R

S

•

R

11.

Qualified Laboratory Documentation

R

S

S

•

R

12.

Control Plan

R

R

S

•

R

13.

Part submission Warrant (PSW)

S

S

S

S

R

14.

S

S

S

•

R

R

R

R

•

R

16.

Appearance Approval Report, (AAR) if applicable Bulk Material Requirements Checklist (for bulk material PPAP only) Sample Product

R

S

S

•

R

17.

Master Sample (See I.2.2.17)

R

R

R

•

R

18.

Checking Aids

R

R

R

•

R

19.

Records of Compliance With Customer-Specific Requirements

R

R

S

•

R

15.

S = The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items at appropriate locations, including manufacturing. R = The supplier shall retain at appropriate locations, including manufacturing, and make readily available to the customer representative upon request. • = The supplier shall retain at appropriate locations, and submit to customer upon request.

Training/Graphics/APQP/R-S Requirement Table.doc