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? ? ? ? ? ? ? . . Effective product quality planning depends on a company’s top management commitment to the effort required in achieving customer satisfaction.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. ex.. lower margins. . The cost of fixing a design and faulty decisions at later stages is exponentially greater than at an earlier stage. Early simultaneous involvement in product development by cross-functional teams using structured development process saves time and money over the product life cycle. The opportunity costs of being late to market are very high. Cross-functional teams typically provide a better quality solution to complex dynamic product development problems than single individuals.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. lower market share. supplier and subcontractor involvement Simultaneous \ Concurrent Engineering Control plans Concern Resolution Timing plan and chart .Fundamentals of Product Quality Planning Organizing the team Define the scope Team-to-Team Communication Training Customer. Product Quality Planning Chart Concept Program Initiation/Approval Approval 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 Prototype Pilot Launch Planning . 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 Plan and Define Program .0 Plan and Define Program Concept Program Initiation/Approval Approval Planning Inputs Objectives Voice of the Customer Determine customer needs. .Historical Warranty program.Market Research Define and plan a quality . and Quality Information .1. . 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 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. 2” • Maximum holder dimension: 3” X 4. • Robust materials of construction (portable) with an expected lifetime of 3 years • Single neutral color – go will all interiors . and is to be located within three (3) feet of the sound system.5” • Universal fixture for 98% of all types of players • Safely positioned in vehicle during vehicle operation.0” X .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 1.5” X 1. 0 Product Design and Development Program Approval Prototype Inputs The outputs of Section 1. Product Design and Development 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 .2.0 Objectives Develop design features and characteristics Review engineering requirements Assess potential manufacturing problems that could occur Product Design and Dev. Identify any special customer characteristics or concerns Identify the material specifications Identify any special tooling and equipment . Design a fixture to safely hold a MP3 / IPOD and a sound system interface. 2. Your team (4 to 6 people) has 20 minutes to: 1. 3. 4.Breakout – Quality Planning Develop a design for the Personal Portable Automotive Sound System (PPASS) unit. CONTROL METHOD Error proofing Other REACTION PLAN CORRECTIVE ACTION SIZE #1 #1 #2 #3 #4 #5 #6 #7 #8 #9 #10 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 . DEVICE. CLASS METHODS PRODUCT/PROCESS SPECIFICATION/ TOLERANCE LSL TARGET USL EVALUATION/ MEASUREMENT TECHNIQUE SAMPLE FREQ. CHARACTERISTIC PRODUCT PROCESS SPECIAL CHAR.Inputs to Prototype Control Plan Pre-Launch Production Control Plan Number Reference Part Number/Latest Change Level x Prototype CONTROL PLAN SUMMARY Date (Orig.) Supplier/Plant Core Team Rev. JIG. FOR MFG.TOOLS. Date (Revised) Key Contact/Phone Part Name/Description Customer PART/ PROCESS NUMBER PROCESS NAME/ OPERATION DESCRIPTION MACHINE. 0 Objectives Develop comprehensive and effective manufacturing process Ensure process capability to meet customer requirements Process Design and Development Process Design and Development 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 .0 Process Design and Development Prototype Pilot Inputs The outputs of Section 2.3. 3. Identify critical manufacturing parameters to measure and control Identify 3 potential failures with this product .Breakout – Quality Planning Next Steps Continue with the process design and development. Develop a process flow. Your team (4 to 6 people) has 10 minutes to: 1. 2. FOR MFG.) Supplier/Plant Core Team Rev. CHARACTERISTIC PRODUCT PROCESS SPECIAL CHAR. CLASS METHODS PRODUCT/PROCESS SPECIFICATION/ TOLERANCE LSL TARGET USL EVALUATION/ MEASUREMENT TECHNIQUE SAMPLE FREQ. Date (Revised) Key Contact/Phone Part Name/Description Customer PART/ PROCESS NUMBER PROCESS NAME/ OPERATION DESCRIPTION MACHINE.TOOLS.Inputs to Pre-launch Control Plan Control Plan Number Reference Part Number/Latest Change Level x Pre-Launch Production Prototype CONTROL PLAN SUMMARY Date (Orig. JIG. DEVICE. CONTROL METHOD Error proofing Other REACTION PLAN CORRECTIVE ACTION SIZE #1 #1 #2 #3 #4 #5 #6 #7 #8 #9 #10 Outputs & Expectations: 1 – Communication for process control 2 – Input to pre-launch control plan 3 – Product quality & customer satisfaction 4 – Identified opportunities for improvement . 4.0 Product and Process Validation Prototype Pilot Launch Objectives Inputs The outputs of Section 3.0 Validate the product Validate the manufacturing process Validate the control plan Ensure product meets customer requirements Identify concerns Product and Process Validation Product and Process Validation 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 Objectives Evaluate all variation (variable and attribute data) Evaluate effectiveness of product quality planning Use control plan and corrective action Planning Production Feedback Assessment and Corrective Action Outputs Reduced Variation Customer Satisfaction Delivery and Service Feedback Assessment and Corrective Action . 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.Summary: The AIAG APQP Model What is APQP? APQP is a process. with linkage to several ISO/TS 16949:2002 elements Tool for continuous improvement . Assessment and Corrective Action 1.Process Design and Development 4. 2.Product Design and Development 3.Summary: The 5 Phases of APQP 1. 5. 3.Product and Process Validation 5. 4. .Plan and Define the Program 2.Feedback. 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 . 8.2.1 Monitoring & Measurement of Product 8.3.2.3 (Product) Design & Dev.3 Feedback Assessment .3 (Process) 7. Planning 7.1 Planning of Product Realization 7.8 Continual Improvement .5 Monitoring & Measurement of Processes 8.New Product Development and Launch Process New Process Development Concept Initiation/Approval Project Start APQP Program Approval First Silicon Ramp to Volume Production Planning Product Design and Development Process Design and Development and Validation Product and Application Validation Planning Production ISO/TS 16949:2002 APQP and ISO/TS 16949:2002 Feedback Assessment and Corrective Action Applicable ISO/TS 16949 Requirements Design & Dev. Planning 7.7.6.2 CustomerRelated Processes Production & Service Provision 7.4 Production Part Approval .5 .3. Retention/Submission Requirements Table I. 5. 16. 12.17) Checking Aids Records of Compliance With Customer-Specific Requirements S = The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items at appropriate locations. Design/Development Records -for proprietary components/details Level 1 R R R R R R R R R R R R R R S S R R R R R Level 2 S R S S R R R R S S R R S R S S R S R R R Level 3 S R S S S S S S S S S S S S S S R S R R S Level 4 • • • • • • • • • • • • • • S • • • • • • Level 5 R R R R R R R R R R R R R R R R R R R R R 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 -for all other components/details 2. and make readily available to the customer representative upon request. 11. Performance Test Results Initial Process Study Measurement System Analysis Studies Qualified Laboratory Documentation Control Plan Part submission Warrant (PSW) Appearance Approval Report. if any TI Engineering Final Approval Design FMEA (or Risk Assessment) Process Flow Diagrams Process FMEA (or Risk Assessment) Dimensional Results Material. including manufacturing. 13.doc . (AAR) if applicable Bulk Material Requirements Checklist (for bulk material PPAP only) Sample Product Master Sample (See I. R = The supplier shall retain at appropriate locations. • = The supplier shall retain at appropriate locations. 18. Engineering Change Documents. 17. 3. 7. Consult design record and customer to determine which items or records apply Submission Level Requirement 1. 9. 14. Training/Graphics/APQP/R-S Requirement Table.1 – AIAG PPAP Reference Guide 3 ed. including manufacturing.2. 10.4. All listed items may not necessarily apply to every customer part from every supplier. 6. 4.2. 8. 19. and submit to customer upon request. 15.