Ford Full apqp.ppt

Advanced Product Quality PlanningAIAG APQP & Ctrl Plan Reference Guide, Page 5 • • • A structured method of defining the steps (process) necessary to assure that a product satisfies the customer The goal of APQP is to facilitate communication with everyone involved to ensure that all required steps are completed on time. Effective APQP depends upon top management commitment and support to assure that customer satisfaction is achieved 1 Advanced Product Quality Planning „Phase‟ Inputs & Outputs • Voice of the Customer – Market Research – Historical Warranty and Quality Information – Team Experience • Design Goals • Reliability and Quality Goals • Preliminary Bill of Material • Preliminary Process Flow Chart • Business Plan and Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • Service Phase 1 • Preliminary Listing of Special Product and Process Characteristics • Product Assurance Plan • Management Support Phase 2 • • • • • • • • • • • Packaging Standards Product / Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications • Design FMEA • DFM and DFA –Design for Manufacturability –Design for Assembly • Design Verification • Design Reviews • Prototype Build Control Plan • Engineering Drawings (including Math data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • Outputs by Design Responsible Activity • Outputs by Advanced Product Quality Planning Team • • • • Phase 3 • • New equipment, tooling and facilities requirements Special product and process characteristics Gage and testing equipment requirements Team feasibility commitment and management support Subcontractor build Supplier build Think Critical Paths 2 Advanced Product Quality Planning Inputs / Outputs - Phase 1 Phase 1 Inputs • Voice of the Customer ° Market Research ° Historical Warranty and Quality Information ° Team Experience Phase 1 Outputs (= Phase 2 Inputs) • Design Goals • Reliability and Quality Goals • Preliminary Bill of Material • Preliminary Process Flow Chart Phase 1 • Preliminary Listing of Special Product and Process Characteristics • Product Assurance Plan • Management Support • Business Plan and Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • Service 3 Advanced Product Quality Planning Phase 2 • • • Phase 1 Outputs (Phase 2 Inputs) Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support Phase 2 Outputs (Phase 3 Inputs) • Outputs by Design Responsible Activity • Outputs by Advanced Product Quality Planning Team • Design FMEA • DFM and DFA –Design for Manufacturability • • • • • • • Phase 2 • • –Design for Assembly Design Verification Design Reviews Prototype Build Control Plan Engineering Drawings (including Math data) Engineering Specifications Material Specifications Drawing and Specification Changes • • • New equipment. tooling and facilities requirements • Special product and process characteristics • Gage and testing equipment requirements • Team feasibility commitment and management support • Subcontractor build • Supplier build 4 Advanced Product Quality Planning .Inputs / Outputs . tooling and facilities requirements • Special product and process characteristics • Gage and testing equipment requirements • Team feasibility commitment and management support • Subcontractor build • Supplier build • Process Flow Chart • Floor Plan Layout • Characteristics Matrix • Process Failure Mode and Effects Analysis • Pre-Launch Control Plan • Process Instructions • Measurement Systems Analysis Plan • Preliminary Process Capability Study Plan • Packaging Specifications 5 Advanced Product Quality Planning .Inputs / Outputs .Phase 3 Phase 2 Outputs (Phase 3 Inputs) Phase 2 Design Activity Outputs • Design FMEA • DFM and DFA –Design for Manufacturability –Design for Assembly • Design Verification • Design Reviews • Prototype Build Control Plan • Engineering Drawings (including Math data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • Outputs by Design Responsible Activity • Outputs by Advanced Product Quality Planning Team Phase 2 APQP Team Outputs Phase 3 • Phase 3 Outputs • (Phase 4 Inputs) • Packaging Standards • Product / Process Quality System Review • New equipment. Phase 4 Phase 3 Outputs • Packaging Standards (Phase 4 Inputs) • Product / Process Quality System Review • Process Flow Chart • Floor Plan Layout • Characteristics Matrix • Process Failure Mode and Effects Analysis • Pre-Launch Control Plan • Process Instructions • Measurement Systems Analysis Plan • Preliminary Process Capability Study Plan • Packaging Specifications Phase 4 Outputs • Production Trial Run (Phase 5 Inputs) • Measurement Systems Evaluation • Preliminary Process Capability Study Phase 4 • Production Part Approval (PPAP) • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign-off 6 Advanced Product Quality Planning .Inputs / Outputs . Inputs / Outputs - Phase 5 Phase 4 Outputs • Production Trial Run (Phase 5 Inputs) • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval (PPAP) • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign-off Phase 5 Phase 5 Outputs • Reduced Variation • Customer Satisfaction • Delivery and Service 7 Advanced Product Quality Planning Voice of the Customer • External and Internal Customers • Stated, Real and Perceived Needs • Cultural Needs • Unintended Uses • Functional Needs vs. Technical Features 8 Advanced Product Quality Planning Market Research • • Customer interviews Customer questionnaires and surveys Marketing test and positioning reports Things Gone Right The following is a list of vehicle features. Please read the entire list and place an X next to those features of your new vehicle that you Particularly Like. Room & Comfort Fron t Roo m Fron t Sea t Co mfort En try & Exi t from Front Ca rgo Capa ci ty Ca rgo l oa di ng, unl oad in g Interior Appearance Se at Ap pea ra nce Instrumen t Pa nel Do or Pa nel s Ca rpe ti ng • • • • New product quality and reliability studies Competitive product quality studies “Things Gone Right” reports Exterior Appearance Fron t Vi ew Si de Vi ew Re ar Vi ew Pa int Mol di ng s Handling Ha ndl in g on Hi ghway Ha ndl in g in City, Parki ng Vi si bi l ity i n Rear Steeri ng Brakes Advanced Product Quality Planning 9 mi ssi ng Di rt in p ai nt internal quality Ru st. Mark a X in each box next to any item you have had trouble with. Ple ase describ e. o rn amen ts Other pai nt troub le s. • • • • • • Warranty reports Exterior Paint Capability Pa int mist o r so ra y ove r bo dy fin ish Ch ipp ed pa in t indicators Co lor di fferen ce be twe en bo dy pa nel s Scra tched p ai nt Un eve n col or on one b ody p ane l Sa gs. co rrosi on Bo dy pa int on mol di ng s.Historical Warranty and Quality Information • “Things gone Wrong” reports Things Gone Wrong Tell us about any troubles you have had with the vehicle. Pl ease descri be. reports Problem Steering & Handling resolution reports Steeri ng no isy Steeri ng requ ires h ig h or u neven effort Customer plant Co nstan t pu ll to on e si de returns and Ve hicl e vi brates at spe eds Be low 4 5 MPH Ab ove 4 5 MP H Steeri ng wh eel spo kes not correctl y posi ti on ed whe n fron t whe el s strei ght rejections Other steeri ng an d han dl in g p ro bl ems. Field return product analysis Advanced Product Quality Planning 10 . ru ns i n pai nt Supplier plant Pa int ot tap e stri pe s co min g off. key competitors • SWOT –Strengths –Weaknesses –Opportunities –Threats • Old vs. R&D resources • Strategy defines target customer. New –How deep and how far to go Advanced Product Quality Planning 11 .Business Plan . investment.Marketing Strategy • Framework for quality plan • May place constraints on timing. key sales points. cost. positioning. 1 • • • • Provides inputs to establish performance targets Must address key process(es) Must be measurable Methods for successful benchmarking: –Identify appropriate benchmark(s) –Find reason for gap between your status and benchmark –Develop a plan for closing gap. meeting or exceeding benchmark Advanced Product Quality Planning 12 .Process Benchmark Data • A requirement of QS 9000 para. 4.Product . Product .Process Assumptions • Assumptions –Features –Design –Process concepts –Technical innovations –Advanced materials –Reliability assessments –New technology • Document assumptions as part of project plan • Utilize as inputs to plan • Consider alternate paths in case assumptions do not play out Advanced Product Quality Planning 13 . Product Reliability Studies • Frequency of repairs or replacements within designated time period(s) –Repair or Throw-away? –LRU Level (Line Replaceability Unit) • Long range reliability and/or durability tests • Studies can be VERY costly and lengthy –EDCTP (Environmental Design Criteria Test Plan) Market Share Failures Durability MTBR = Mean Time Between Replacement Advanced Product Quality Planning MTBO = Mean Time Between Overhaul MTBF = Mean Time Between Failures 14 . Customer Inputs • Next users provide information about needs and expectations • Possibility of previous conducted reviews and studies • Used to develop measure of customer satisfaction Advanced Product Quality Planning 15 . Inter-Relationships Process Improvement Business Quality Objectives QFD QOS 8-D Problem Solving DOE Problem Prevention FTA RFTA SPC Tools Control Plan FMEA APQP Special / Critical Characteristics Customer Specified Special / Critical Characteristics 16 Advanced Product Quality Planning . Relationships Customer Requirements DFMEA PFMEA Control Plan PPAP Warrant Conceptual Structural Warrant Sample Product Condition Time Advanced Product Quality Planning 17 . Typical Automotive Trilogy Development APQP Timeline Process Flow Diagram (Includes ALL Processes) Process FMEA (On ALL Processes) Critical Characteristics & Failure Effects Issues CC Matrix Customer Requirements (drawing. Your company‟s internal design / process requirements Process Control Plan (Critical Processes from FMEA) Some Elements may be Included On Critical Characteristics & Characteristic Control Issues Design FMEA (On Intended Use) Advanced Product Quality Planning 18 . RFQ.). etc. Work Instruction Operation Number Advanced Product Quality Planning 19 . In some companies. these are not discrete documents.Document Links Process Flow Chart Operation Number Product/Process Characteristic Incoming Sources of Variation (Variation Class) PFMEA Operation Number Control Plan Operation Number Product/Process Characteristic Incoming Sources of Variation (Variation Class) Operation Number The APQP manual cites these links. The intent is to ensure discrete documents match. Document Critical Paths Define All Critical / Special Characteristics Process Flow Chart PFMEA DFMEA May or may not identify an input to the Process FMEA Provides input to control plan based upon a risk analysis. Provides inputs to the Process FMEA and may provide inputs to the work instruction. Control Plan Work Instruction 20 Advanced Product Quality Planning . Hi gh 1 . M. Or Peop le Invol ve d: Ap pro va ls: Qua li ty Assuran ce Man age r Ope ra ti on s Mana ger Outsid e Supp li ers Affected : Mod el Ye ar/V ehi cl e(s): Sched ul ed Produ ctio n Rel eased : Qua li ty Assuran ce En gi neer Se nio r Ad vi so r En gin eer: Pa rt Numbe r: PFME A Date: Re v.Automotive Process FMEA Process Fai l ure Mo de An d Effects Ana lysi s Process: Pri ma ry Pro cess Re sp onsib il i ty: Other Di v. Lo w .10 De tectio n Pa rt Name Ope ra ti on Nu mb er SIR Co nta in er 1 De tectio n Occured Occured Se verity Se verity RPN Process Fun ctio n Ta ke TPP E Materi al He ld In Storage A re a Po ten ti al Fai l ure Mod e Wrong Ma teri al Po ten ti al Effe cts Of Fai lure Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Po ten ti al Cau se Of Fai lu re Insuffi ci en t Sup pl ie r Con trol Imprope r Han dl in g Mi si den ti fie d Materia l Cu rrent Con trol s Materi al Ce rti fi ca ti on Re qui re d With Each Sh ipme nt Re lea se V eri ficatio n Pe ri odi c Au di t Of Su ppl ie r Materi al Vi su al Inspectio n Re lea se V eri ficatio n Green "OK" T ag Cu stomer Notifi cati on Ch eck For Gree n "OK " Ta g A t Press Trace Card Ch eck L ist Trai ni ng Re comme nded Acti on s And Status Acti on s Ta ken RPN Re spo nsib le Acti vi ty 1 9 2 18 Out Of Sp ec Materi al Co nta min ated Materi al Materi al Co mp ositi on Ch ange 2 Move To Ap pro ve d Storage Un rel ea se d Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Frag mentatio n Su ppl ie r Process Con trol Ope n Boxes En gin eeri ng Ch ange Su ppl ie r Ch ang e Un trai ned L TO Un trai ned P erson nel 3 1 1 10 9 10 3 7 7 90 63 70 5 10 1 50 3 Ho ld In App ro ved Storage Until Ne eded Co nta min atio n Frag mentatio n Process Probl ems Ope n Con tai ne rs Ho use ke epi ng Area Mai nten ance Bo xes K ept In Se al ed Storage A re a Until Ne eded Bo xes L in ed Wi th Pl asti c Li ne r On Pal l ets Inside S to ra ge P. Faci li ty 1 10 3 30 Advanced Product Quality Planning 21 . Design Change Other Action When making a change to a document. Typically the engineering change system in a company and/or corrective action system ensures these occur.Effects of Changing the Process FMEA PFMEA Change in Detection Change in Occurrence Change in Severity And Or Control Plan Work Instruction A change in the severity of the effect of a potential problem can only be effected through a design change. it is important to consider the effects of that change on other documents. Advanced Product Quality Planning 22 . But this is not always the case. Review your company engineering change procedure / system and see if it does so. Advanced Product Quality Planning 23 .A Corrective Action System These are some typical ‘checks’ in the automotive world in response to a corrective action. A change to any one document typically drives an Engineering Change where the engineering change system is used to ensure that changes to any one document ensures appropriate changes to others. “Q” Body Intake manifold FMEA revised in response to an 8-D investigation I do NOT recommend product specific FMEAs unless you really cannot segregate your products into families for some reason. Brand spanking new Process FMEA developed.Product Specific FMEA Approach FMEA revised in response to an 8-D investigation Brand spanking new. FMEA revised in response to an 8-D investigation FMEA revised in response to an 8-D investigation Process FMEA Year 1 Year 2 Copy of process FMEA from a similar product Production Life Year 2002 . Advanced Product Quality Planning 24 . never before product.“Q” Body Intake manifold Process FMEA Year 1 Year 2003 . Registrar interpretation Q5 1/12 (AEC-A100): “. liquid chemicals and related materials must be addressed. and chemicals.” 25 Advanced Product Quality Planning ... gases. This is in contrast with a „process‟ flow where there is an individual Control Plan for each piece of equipment or a manufacturing „cell‟ (company definition). such as gasses.So in effect.Current Control Plans & FMEAs FAB or Other Manufacturing Entity „Receiving‟ Machine or Cell 1 Machine or Cell 2 Machine or Cell 3 „Pack & Ship‟ Internal or External Customer „Receiving‟ „Pack & Ship‟ Process FMEA covers an „equipment set‟ or „cost block‟ Recommended by the FMEA Team Device FMEA / Technology / Family Control Plan‟ = a flow of a „technology‟ or „device‟ Covers entire flow while product is under the control of the FAB including return of the product (if return is applicable) A Technology/Family Control Plan / Device FMEA follows an entire flow for a „technology‟ through a defined entity. A „Technology‟ consists of many similar devices. Received materials. „Receiving‟ in FAB FMEAs consists of what the FAB looks at when materials arrive... supplier's control plans will include wafers. families 26 Advanced Product Quality Planning .One Proposed Terminology FAB or Other Manufacturing Entity Process Control Plan / FMEA covers an „equipment set‟ (cell) or individual equipment „Receiving‟ „Pack & Ship‟ Machine or Cell 1 Machine or Cell 2 Machine or Cell 3 Technology Control Plan / FMEA .applies to devices. <----------------------- Corporate Level 3 ???? -------------------------> Receiving FAB 1 FAB 2 Assembly Final Pack Ship Control Plan & FMEA Responsibility = Materials? SQA? Ctrl Plan & FMEA Responsibility = FAB Ctrl Plan & FMEA Responsibility = FAB Ctrl Plan & FMEA Responsibility = ASSY Control Plan & FMEA White Space Issue Customer Warehouse Advanced Product Quality Planning 27 . the control plan. it is next to impossible in a course to „predict‟ how a company will react within their documentation to a change in any given document. page 100) methodology where the control plan is combined with the process FMEA. there is no process flow diagram per se to change. ° In speaking of differences in company documentation. there are companies which (for example) combine their control plan and their process flow diagram into one document. ° As we proceed through this presentation. Because of the possible permutations of how a document system is set up. The same is true of document changes. This said. keep in mind that where we discuss the changes in one document and its effects on another you will have to look at your company‟s documentation structure and determine equivalencies.Discrete Documents ° Early on I stressed that each APQP is unique both between companies and within a company. When the evaluation is made it may turn out that the „risk‟ number (the RPN) may be low and thus may not require a control. Because of the differences in how companies structure their documentation it is only possible in a course document such as this to address the effect of changing one document on another. On the previous page I discussed some of the expected effects of a change to the process FMEA. Another reason this is true is because every change to a process FMEA does not automatically require a change to. ° Another example is where a company uses the Ford Dynamic Control Plan (APQP and Control Plan manual. for example. 28 Advanced Product Quality Planning . Develop the Control Plan with Critical characteristics Process Control Plan Develop control mechanisms appropriate for Critical characteristics. Develop FMEA(s) Element for Every Process Give careful consideration to defining Control Plan stages: Prototype Pre-launch Production Use the appropriate RPN numbers and considerations of other appropriate information /data to determine Critical Characteristics.Automotive Documentation Development Process Flow Diagram Critical / Special Characteristics Develop Process Flow Listing Check for Customer Requirements. Process FMEA Enter Every „Major ‟ Process from Flow Listing into FMEA Form Give careful consideration to what you consider a „Major‟ process. 29 Advanced Product Quality Planning . Base Documentation • Critical Characteristics Matrix • Process Flow Diagram • Design FMEA • Process FMEA • Control Plan Advanced Product Quality Planning 30 . The Control Plan • • • A Control Plan is a written description of systems for parts and processes It is Process Dominated Three ‘Types’ or Phases –Prototype *A Design Output • Used During Prototype Build • Dimensional Measurements • Material and Performance Tests –Pre-Launch • Update After Prototype and Before Production –Production • Comprehensive • Process Controls • Test and Measurement Systems Used • Reaction Plan • Sampling Plans • SPC Requirements Advanced Product Quality Planning 31 . Example Control Plans • Example Control Plans included in the APQP Manual (starting on page 47): – Equipment • Set-Up Dominant Process • Machine Dominant Process • Fixture/Pallet Dominant Process • Tooling Dominant Process – People • Operator Dominant Process – Material • Material or Component Dominant Process – Methods • Preventive Maintenance Dominant Process – Environment • Climate Dominant Process Advanced Product Quality Planning 32 . AP PROV AL (S IGN / DAT E) NO. Process Engineering in one company is called Manufacturing Engineering in another company. Pro ce ss Fl o w Proc es s n am e Ma c hi ne De vic e J i g To o ls fo r Ma n ufac turi ng No . you derive the required information for each column. you might label departments or functional areas Engineering differently. Advanced Product Quality Planning 33 . in your company. Ch a ra cte ri s tic s Pro ce ss Pro du ct Pa ram eters Ch a ra cte ri s tic s Cl a ss Pro du ct/Pro ce ss Sp e ci fic ati o n Me tho ds Eva lu ati o n Me tho ds Sa mp l e Si ze/ Fre qu en c y An a lysi s Me tho ds RE ACTIONS IF OUT OF CONT ROL CONDIT IONS ARE ENCOUNT ERED Link to flow diagram & PFMEA Process Engineering PFMEA. In addition.Pre-La unch . Drawing Process Engineering Quality Engineering Process Engineering. your company may use multi-functional input where in this example a single source is identified. or you may assign responsibilities differently. Your task is to identify where. DAT E: CUST OMER E NG.Control Plan Data Sources Prototyp e . Quality Engineering Link to Drawing Characteristics Matrix Process Note that in your company.Produ cti on (ci rcle ) Co ntrol Pl an PA RT NAME: PRODUCT ENGINE ERING DE SIGNAT ED CONT ROL ITE M PRODUCER: SUPP LIER CODE: PL ANT: FIRST IS SUE D DATE : ( ) YES ( X ) NO RE VISION DA TE : CUST OMER SQA AP PROVA L (SIGN / DAT E) RE VIEW / AP PROV AL (S IGN / DAT E) PA RT NUMBE R: END ITE M AND CUST OMER: L ATE ST DRA WING/S PE C. Advanced Product Quality Planning 34 .Ford‟s Concept to Customer (CTC) Initiated in 1984. Technically obsolete. Troy I I I I I I I A A Advanced Product Quality Planning 35 . Test Equipment Select & Rate Suppliers Train Quality Personnel Supplier PSW Review & Sign-Off Set-Up & De-Bug Production and Inspection Equipment Preliminary Capability Studies For Production Processes Process Optimization (Design Of Experiments) Process Review (PFMEA Walk Through) Product Training Work Instructions (Manufacturing) Measurment and Test Equipment Verification Packaging Part Sample War rant A = Assistance I = Input R = Responsibility F = Sachs . Gages.A Simple APQP Sequence Responsibility Manufac turing Engineering Design Engineering Quality Ass uranc e Program Manager Purc hasing Produc tion Customer Materials Sales T R I R R R I R A R A I F I I I A R A R A A R A A R A A A F A A A I I I A F I A F A A A I I I A A I I I I I A A T A I I I I I I A I I I I I I I I I I A R R I I A I I I I A R R R R R R R A A I A A A A I I I I I I I A A A A A R A A A A I I I I I I F I R I R A A A A A R A R R A R A A R R A A A A A A A R T R I I I I Element A A A A I A I A A I A I Market Research Inf ormation Quality History Review Engineering Research Data Advanced Quality Planning Schedule Preliminary Product/Process Design Feasibility Analysis Design FMEA Process FMEA Prototype Build and Verification Signif icant Characteristics Final Product and Process Design Measurement and Test Equipment Needs & Costs Process Control Plan Process Flow Chart Audit and QA Work Instructions Order Production Tooling.Florence T = Sachs . 2 Quality System – 4.9 Process Control – 4.QS 9000 • APQP Involves: – 4.10 Receiving (Incoming) – 4. Packaging and Delivery – 4.4 Design Control – 4.15 Handling.11 Inspection.14 Corrective Action – 4.1 Management Responsibility – 4.12 Inspection and Test Status – 4.13 Control of Nonconforming Product – 4.19 Servicing – 4.20 Statistical Techniques 36 Advanced Product Quality Planning . Storage.16 Quality Records – 4.3 Contract Review – 4. Measuring and Test Equipment – 4.5 Document and Data Control – 4.18 Training – 4. Enter Every „Major ‟ Process from Flow Listing into FMEA Form Give careful consideration to what you consider a „Major‟ process. 37 Advanced Product Quality Planning . Develop FMEA(s) Element for Every Process Use the appropriate RPN numbers and considerations of other appropriate information /data to determine Critical Characteristics.Automotive Documentation Development Develop Process Flow Listing Check for Customer Requirements. Give careful consideration to defining Control Plan stages: Prototype Pre-launch Production Develop the Control Plan with Critical characteristics Develop control mechanisms appropriate for Critical characteristics. APQP Design & Process Controls • Design Reviews • Design Verification • Design Validation • Process Validation • Design FMEA • Process FMEA • Prototype Validation Advanced Product Quality Planning 38 . Product Quality Planning Responsibility Matrix APQP Phases Define the Scope Plan and Def ine (Section 1.0) Product Design and Development (Section 2.0) Feasibility (Section 2.13) Process Design & Development (Section 3.0) Product and Process Validation (Section 4.0) Feedback, Assessment and Corrective Action (Section 5.0) Control Plan Methodology (Section 6.0) Design X X X X X X X X Manuf acturing X Service Supplier X X X X X X X X X X X AIAG APQP & Ctrl Plan Reference Guide, Page 2 Advanced Product Quality Planning 39 Product Quality Planning Checklists • Design FMEA • • • • • • • Design Information New Equipment, Tooling and Test Equipment Product/Process Quality Flow Plan Process Flow Chart Process FMEA Control Plan Check Lists for these line items are in the AIAG‟s APQP & Control Plan reference manual contained as a group - Appendix A starting on page 63. Use them! 40 Advanced Product Quality Planning Benefits of APQP • Ensures 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-functional inputs and outputs • Addresses potential problems early in –Design –Manufacturing Advanced Product Quality Planning 41 Progressive Fundamentals • KEY** Organize a Cross-Functional TEAM • • • • • Define the scope Team-to-team communications Training Simultaneous (concurrent) engineering Control Plan Phases –Prototype –Pre-Launch –Production • Concern resolution –Includes analytical techniques 42 Advanced Product Quality Planning . Teams Small Teams! Big Teams! Communication! 43 Advanced Product Quality Planning . Training •Customer Needs and Expectations •Working as a Team •Group process skills •Development skills •Requirements of APQP •FMEA •APQP •PPAP Advanced Product Quality Planning 44 . & Management Advanced Business Selected Staff.Recommended Statistical Courses Basic Business Office. Quality Engineers& QA Manager & Product Engineering *Your APQP Team should attend as many classes as time will allow 45 Advanced Product Quality Planning . & Management Statistical Process Control Production Floor. Production Staff & Management. All of Quality & Engineering Design of Experiments Specific Production Staff. All of Quality & Engineering Measurement System Analysis Production Staff & Management. Staff. Page 5 Advanced Product Quality Planning 46 .Product Quality Planning Timing Chart AIAG APQP & Ctrl Plan Reference Guide. Timing Plan Contents • Identify individual tasks • Track resources by task • Establishes dependencies between tasks • Determine critical path • Track specific tasks or groups of tasks • Status reports Advanced Product Quality Planning 47 . You should have (at least) an index of the project plan with the location and owner (responsibility) of each element clearly identified. Each item does not. have to reside in ‘one book’. How to measure Definitions and specifications Market analysis Feasibility • • • • Time Resources Plant space Etc.Project Plan Elements º º º º º º º Mission Scope Objectives Requirements • Consider this a ‘laundry list’ for an index. º º º º Timeline Control system Team Cost Estimate Advanced Product Quality Planning 48 . however. • Requirements .Technical.Goal.What will and will not be included consideration to available technology) (with • Objectives . key sales points. performance. key competitors. profit. customer and approach • Scope . start (delivery) target date.Deliverables • Definition and specification . etc. quality. length of run.Project Plan Definitions I • Mission .Criteria it must meet • Market analysis .Expected annual production volume. target price (Japan). Advanced Product Quality Planning 49 . etc. responsibility.Degree to which current tooling and equipment can be used • Timeline .Major milestones and detail task schedule • Control system .Project Plan Definitions II • Preliminary Feasibility .Who.Answers questions such as: –How will progress be measured? –Who will receive reports? –How are changes handled? –What limits are there on authority. Advanced Product Quality Planning 50 . and accountability? • Team . from where and who is the team leader? –Beware of Turf Wars! • Cost estimate .Estimate with assumptions. Often „all‟ information is not available. Cu rrent Cap abi l ity Ti mel in e Co ntrol System Te am Defin iti on Ti tle Pa rt # Cu stomer Da te Specific Prel im. Cost Estimate Project vs D&D (Design & Development) Advanced Product Quality Planning 51 .Project Plan Summary Sheet Broad Proj ect # Mod el /Ye ar Proj ect Missio n Proj ect Sco pe Proj ect Obj ecti ve s Co ntractura l Re qui rements Produ ct Defin iti on & Spe c. pages 81 thru 85 Advanced Product Quality Planning 52 .Chrysler & Ford) Dimensional (Dynamic) Control Plan (DCP) Mistake Proofing (Poka-Yoke) Process Flow Charting Quality Function Deployment (QFD) System Failure Mode & Effects Analysis (SFMEA) See AIAG’s APQP & Control Plan reference manual appendix B.Analytical Techniques • • • • • • • • • • • • • Assembly Build Variation Analysis Benchmarking Cause & Effect Diagram Characteristics Matrix Critical Path Method Design of Experiments (DOE) Design for Manufacturability & Assembly (DFM & DFA) Design Verification Plan & Report (DVP&R . Critical Characteristics Matrix Advanced Product Quality Planning 53 Characteristics I •CHARACTERISTIC: A distinguishing feature, dimension or property of a process or its output (product) on which variable or attribute data can be collected. (P39 APQP) •CHARACTERISTIC, CRITICAL, CHRYSLER DEFINITION: Characteristics applicable to a component, material, assembly, or vehicle assembly operation which are designated by Chrysler Corporation Engineering as being critical to part function and having particular quality, reliability and/or durability significance. These include characteristics identified by the shield, pentagon, and diamond. (49 PPAP) •CHARACTERISTIC, CRITICAL (INVERTED DELTA), FORD DEFINITION: Those product requirements (dimensions, performance tests) or process parameters that can affect compliance with government regulations or safe vehicle/product function, and which require specific supplier, assembly, shipping, or monitoring and included on Control Plans. (P49 PPAP) •CHARACTERISTIC, CRITICAL, GM DEFINITION: See Key Product Characteristic. (P49 PPAP) •CHARACTERISTIC, KEY CONTROL (KCCs): Those process parameters for which variation must be controlled around a target value to ensure that a significant characteristic is maintained at its target value. KCCs require ongoing monitoring per an approved Control Plan and should be considered as candidates for process improvement. (P49 PPAP) •CHARACTERISTIC, KEY PRODUCT (KPC): Those product features that affect subsequent operations, product function, or customer satisfaction. KPCs are established by the customer engineer, quality representative, and supplier personnel from a review of the Design and Process FMEA‟s and must be included in the Control Plan. Any KPCs included in customer -released engineering requirements are provided as a starting point and do not affect the supplier‟s responsibility to review all aspects of the de sign, manufacturing process, and customer application and to determine additional KPCs. (P49 PPAP) 54 Characteristics II • CHARACTERISTIC, PROCESS: Core team identified process variables (input variables) that have a cause and effect relationship with the identified Product Characteristic(s) which can only be measured at the time of occurrence. (6.3 #20 APQP) •CHARACTERISTIC, PRODUCT: Features or properties of a part, component or assembly that are described on drawings or other primary engineering information. (6.3 #19 APQP) •CHARACTERISTIC, PRODUCT, CRITICAL (D), CHRYSLER DEFINITION: A defect which is critical to part function and having particular quality, reliability, and durability significance. (QS-9000) •CHARACTERISTIC, PRODUCT, MAJOR, CHRYSLER DEFINITION: A defect not critical to function, but which could materially reduce the expected performance of a product, unfavorably affect customer satisfaction, or reduce production efficiency. (QS-9000) •CHARACTERISTIC, PRODUCT, MINOR, CHRYSLER DEFINITION: A defect, not classified as critical or major, which reflects a deterioration from established standards. (QS-9000) •CHARACTERISTIC, PRODUCT, SAFETY/EMISSION/NOISE (S), CHRYSLER DEFINITION: A defect which will affect compliance with Chrysler Corporation and Government Vehicle Safety/Emission/Noise requirements. (QS-9000) •CHARACTERISTIC, SAFETY, CHRYSLER DEFINITION “Shield <S>: Specifications of a component, material, assembly or vehicle assembly operation which require special manufacturing control to assure compliance with Chrysler Corporation and government vehicle safety requirements. (QS-9000) 55 and tooling aid procedures where ongoing process control is not automatically mandated.Characteristics III • CHARACTERISTIC. CHRYSLER DEFINITION “Diamond” <D>: Specifications of a component. (P104 APQP) •CHARACTERISTIC. (P50 PPAP) •CHARACTERISTIC. (Appendix C QS-9000) & 56 (Appendix C APQP) . or theft prevention requirements. capability. (QS-9000) •CHARACTERISTIC. reliability and durability significance. SPECIAL: Product and process characteristics designated by the customer. CHRYSLER DEFINITION “Pentagon” <P>: Limited to highlighting Critical characteristics on (Production) part drawings. including governmental regulatory and safety. noise. SPECIAL. (Appendix C QS-9000) & (Appendix C APQP) •CHARACTERISTIC. (QS-9000) •CHARACTERISTIC. and control for the life of the part. CHRYSLER DEFINITION “Diamond” <D>: Specific critical characteristics that are process driven (controlled) and therefore require SPC to measure process stability. emissions. CHRYSLER DEFINITION: Special characteristics selected by the supplier through knowledge of the product and process. material. SAFETY. SIGNIFICANT. SPECIAL. CHRYSLER DEFINITION “Shield” <S>: Engineering designated specifications or product requirements applicable to component material. (Appendix C QS9000) & (Appendix C APQP) •CHARACTERISTIC. CHRYSLER DEFINITION: Specifications which require special manufacturing control to assure compliance with Chrysler or government vehicle safety requirements. and/or selected by the supplier through knowledge of the product and process. tools and fixture. assembly or vehicle assembly operation which are designated by Chrysler as being critical to function and having particular quality. SPECIAL. assembly operation(s) which require special manufacturing control to assure compliance with governmental vehicle safety. SPECIAL. radio frequency interference. . occupant protection. (Appendix C QS-9000) •CHARACTERISTIC. or the ability to process or build the product. braking. Tests) or process parameters which can affect compliance with government regulations or safe Vehicle/Product Function and which require specific producer. noise.SC” <None>: Those product. FORD DEFINITION “Significant/Characteristic . emissions. . function.). assembly.Characteristics IV • CHARACTERISTIC.). process. (Appendix C APQP) •CHARACTERISTIC. radio frequency interference. . . etc. etc. steering control. shipping or monitoring actions and inclusion on the Control Plan. GM DEFINITION “Safety/Compliance” <S>: Product characteristic for which reasonably anticipated variation could significantly affect customer the product‟s safety or its compliance with government regulations (such as: f lammability. FORD DEFINITION “Significant Characteristic . GM DEFINITION “Safety/Compliance” <S/C>: Product characteristic for which reasonably anticipated variation could significantly affect customer the product‟s safety or its compliance with government regulations (such as: flammability. SPECIAL. . SPECIAL. mounting or appearance. SPECIAL. Specifications. GM DEFINITION “Fit/Function” <F/F>: Product characteristic for which reasonably anticipated variation is likely to significantly affect customer satisfaction with a product (other than S/C) such as its fits. . SPECIAL. SPECIAL. and test requirements that are important to customer satisfaction and for which quality planning actions shall be included in the Control Plan. emissions. (Appendix C QS-9000) •CHARACTERISTIC. (Appendix C APQP) 57 .S/C” <None>: Characteristics that are important to the customer and that must be included on the Control Plan. (Appendix C QS-9000) & (Appendix C APQP) •CHARACTERISTIC. occupant protection. braking. etc. noise. FORD DEFINITION “Critical Characteristic” <Inverted Delta>: Those product requirements (Dimensions. steering control. . SPECIAL. . etc. (Appendix C QS-9000) & (Appendix C APQP) •CHARACTERISTIC. SIGNIFICANT): A process characteristic for which variation must be controlled to some target value to ensure that variation in a special product characteristic is maintained to its target value during manufacturing and assembly. SPECIAL. PROCESS (e. KEY. (QS-9000) •CONTROL ITEM PART. (P57 FMEA) •CHARACTERISTIC. or is likely to significantly affect customer satisfaction with a product. (6. and initial product parts. GM DEFINITION “Standard” <None>: Product characteristic for which reasonably anticipated variation is unlikely to significantly affect a product‟s safety. (QS -9000) 58 . developmental parts.3 #19 APQP) •CHARACTERISTIC. compliance with governmental regulations. (Appendix C QS-9000) & (Appendix C APQP) •CHARACTERISTIC. (P55 FMEA) •CHARACTERISTIC. SIGNIFICANT): A product characteristic for which reasonably anticipated variation could significantly affect a product‟s safety or compliance with governmental standards or regulations. CRITICAL.g. CRITICAL. SPECIAL. MAJOR. SPECIAL. CHRYSLER DEFINITION “Pentagon” <P>: Critical tooling symbol used to identify special characteristics of fixtures. MAJOR. gages. KEY.Characteristics V • CHARACTERISTIC. TOOLING. FORD DEFINITION: Product drawings/specifications containing Critical Characteristics.. PRODUCT (e. fit/function. SPECIAL.g. PRODUCT: Core team compilation of important product characteristics from all sources. Ford Design and Quality Engineering approval is required for changes to Control Item FMEA‟s and Control Plans.. All Special Characteristics must be listed on the Control Plan. SPECIAL. The documents provided have been used as a basis for analyzing the ability to meet all specified requirements. Changes recommended (See attached) Design revision required to produce product within specif ied requirements Feasible Feasible Not Feasible Team Member/Title/Date Team Member/Title/Date Team Member/Title/Date Team Member/Title/Date 59 Advanced Product Quality Planning This form is on course disk .Phase 1 Project Review Project # Model/Y ear Title Part # Customer Date Our advanced quality planning team has considered the f ollow ing questions in Phase 1 of our APQP process. 3. goals. 12. 11. f actors that may place the program at risk. 2. All 'NO' answ ers are supported w ith attached comments identif ying our concerns and/or proposed changes to enable us to meet specif ied requirements. 5. No Checklist Item Has historical data and experience concerning customer needs been considered? Has full consideration been given to the overall business plan and marketing strategy? Have product/process benchmark data been considered? Have the product/process assumptions been identif ied and challanged? Have product reliability studies been conducted? Have there ben appropriate customer inputs into the process? Do the design goals reflect the data generated? Do the quality and reliability goals ref lect appropriate standards? Is the preliminary bill of materials suff iciently thorough? Does the preliminary process flow chart relate to the primary BOM and product/process assumptions? Are all special product and process characteristics lited? Does the produxct assurance plan include and outline of program requirements. 8. 7. FMEA. and preliminary enginering standards requirements? Product can be produced as specif ied w ith no revisions. 10. Yes 1. 4. 6. 9. Phase 1 Responsibility Matrix Management Maintenance Engineering Purchasing Production Laboratory Quality Sales Phase 1: Plan and Define Program Materials Output Design Goals Reliability and Quality Goals Preliminary BOM Preliminary process flow chart Preliminary list of special product and process characteristics. Product assurance plan Management Support Advanced Product Quality Planning This form is on course disk 60 MIS HR . APQP Phase 2: Product Design and Development Advanced Product Quality Planning 61 . Phase 2 Outputs • Outputs by Design Responsible Activity • Outputs by Advanced Product Quality Planning Team Advanced Product Quality Planning 62 . Outputs by Design Responsible Activity • Design FMEA • DFM and DFA –Design for Manufacturability –Design for Assembly • • • • • • • Design Verification Design Reviews Prototype Build .Control Plan Engineering Drawings (including Math data) Engineering Specifications Material Specifications Drawing and Specification Changes Advanced Product Quality Planning 63 . Additional Outputs by Design Responsible Activity • Updated special characteristics list • Prototype parts build –Make .Buy decisions –Parts inspection –Assembly of prototype(s) • Preferably manufacturing. not model shop –Inspection layout –Prototype validation testing • Redesign as required and design review • Update DFMEA (and System Level FMEA if appropriate) • Feasibility report Advanced Product Quality Planning 64 . FMEAs Advanced Product Quality Planning 65 . you MUST (should) have customer DFMEA • Check list (AIAG APQP Manual Appendix A-1) Advanced Product Quality Planning 66 .DFMEA • Disciplined analytical tool –Assess probability of failure –Effect of failure • Must be continually updated • Causes changes and/or additions to previously selected special product and/or process characteristics • If you do not have design control. PFMEA Example Process Fai l ure Mo de An d Effects Ana lysi s Process: Pri ma ry Pro cess Re sp onsib il i ty: Other Di v.Hi gh 1 . M. Or Peop le Invol ve d: Ap pro va ls: Qua li ty Assuran ce Man age r Ope ra ti on s Mana ger Outsid e Supp li ers Affected : Mod el Ye ar/V ehi cl e(s): Sched ul ed Produ ctio n Rel eased : Qua li ty Assuran ce En gi neer Se nio r Ad vi so r En gin eer: Pa rt Numbe r: PFME A Date: Re v. Lo w .10 De tectio n Pa rt Name Ope ra ti on Nu mb er SIR Co nta in er 1 De tectio n Occured Occured Se verity Se verity RPN Process Fun ctio n Ta ke TPP E Materi al He ld In Storage A re a Po ten ti al Fai l ure Mod e Wrong Ma teri al Po ten ti al Effe cts Of Fai lure Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Po ten ti al Cau se Of Fai lu re Insuffi ci en t Sup pl ie r Con trol Imprope r Han dl in g Mi si den ti fie d Materia l Cu rrent Con trol s Materi al Ce rti fi ca ti on Re qui re d With Each Sh ipme nt Re lea se V eri ficatio n Pe ri odi c Au di t Of Su ppl ie r Materi al Vi su al Inspectio n Re lea se V eri ficatio n Green "OK" T ag Cu stomer Notifi cati on Ch eck For Gree n "OK " Ta g A t Press Trace Card Ch eck L ist Trai ni ng Re comme nded Acti on s And Status Acti on s Ta ken RPN Re spo nsib le Acti vi ty 1 9 2 18 Out Of Sp ec Materi al Co nta min ated Materi al Materi al Co mp ositi on Ch ange 2 Move To Ap pro ve d Storage Un rel ea se d Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Frag mentatio n Su ppl ie r Process Con trol Ope n Boxes En gin eeri ng Ch ange Su ppl ie r Ch ang e Un trai ned L TO Un trai ned P erson nel 3 1 1 10 9 10 3 7 7 90 63 70 5 10 1 50 3 Ho ld In App ro ved Storage Until Ne eded Co nta min atio n Frag mentatio n Process Probl ems Ope n Con tai ne rs Ho use ke epi ng Area Mai nten ance Bo xes K ept In Se al ed Storage A re a Until Ne eded Bo xes L in ed Wi th Pl asti c Li ne r On Pal l ets Inside S to ra ge P. Faci li ty 1 10 3 30 67 Advanced Product Quality Planning . • Design. concept. function and sensitivity (tolerancing) to manufacturing variation Manufacturing and/or assembly process Dimensional tolerances Performance requirements Number of components (complexity) Process adjustments Material handling DFM and DFA • • • • • • Advanced Product Quality Planning 68 . Design Verification • Inspection methods • Testing methods • Ensure that all design outputs meet design input requirements –Alternate calculations –CAD/math data –Review design stage documents before release Advanced Product Quality Planning 69 . Design Reviews .Evaluations • Design/functional requirement(s) and considerations • • • • • • Formal reliability and confidence goals Component/subsystem/system duty cycles Computer simulation and bench test results DFMEA(s) Review of the DFM and DFA Design of experiments (DOE) and assembly build variation results • Test failures • Design verification progress • Max/Min builds Advanced Product Quality Planning 70 . Ford & Chrysler) • Product/process validation of components Advanced Product Quality Planning 71 .Design Review Tracking • Track verification progress using a design verification plan and report (DVP&R . Early Process Flow Diagram Advanced Product Quality Planning 72 . 1 2.2 2.1 2.2 2.0 8.1 2.2 2.0 Key Control Characteristic Material Certification Tag 2 2.2 2.0 7.0 Key Product Characteristic Material Specs Item # 1.0 9.2 2.Process Flow Diagram Example Process Flow Diagram Part Numbe r: Part De scription: Prep ared By: Date : 4/5/93 Rev.2 2.0 Tearstrip In Cove r 2.Flash Free Cover Filled Out Free Of Foreign Material 3 Visually Inspect Cover 6.1 2.1 2.0 Flange Th ickness In Cover 5.0 73 Advanced Product Quality Planning . : C Approved By: QA Manager Operations Manager Senior Advisor QA Engineer Fabrication Step 1 Inspect Store Move Operation Description Move "OK" Vinyl Material From Storage Area and Load Into Press.2 2.0 Pressure Control Protrusions Height Pressure Control Protrusions Filled Out Cover .1 2.0 Hole Diameter In Co ver 4.2 Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Machine Se tup 3.1 2. Auto Injection Mold Cover In Tool # Item # 1. Control Plan Methodology • Aids in the manufacturing of products according to customer requirements • Provide structured approaches • Contain a written summary of the system used in minimizing process and product variation • Forms provided in the AIAG handbook are examples of how to document • Alternate formats can be used if they contain necessary information • Must be maintained and used throughout the product life cycle 74 Advanced Product Quality Planning . Control Plan Use • Initial: 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 Advanced Product Quality Planning 75 . DFMEA. Statistical Data • Use A-8 Control Plan checklist in APQP manual to evaluate Advanced Product Quality Planning 76 .Control Plan • Ensure Control Plan is aligned to. Process Flow. PFMEA • Control Methods appropriate to variation type(s) • Incorporates Lessons Learned. and correlates with. several prototype builds may be necessary and may require updates to the control plan Advanced Product Quality Planning 77 .Prototype Build Control Plan • A description of the dimensional measurements • Material tests –Functional tests that will occur during prototype build –Depending upon product complexity. Part Name/Description Supplier/Plant Supplier Code Key Contact / Phone Core Team Supplier/Plant Apoproval/Date Other Approval/date (If Req'd) Characteristics Part/ Process Number Process Name/ Operation Description Machine. Jig.) Date (Rev.) Customer Engineering Approval/Date Customer Quality Approval/Date Other Approval/date (If Req'd) Methods No./ Latest Change No. Class Product/ Process Spec/ Tolerance Evaluation Measurement Technique Date (Orig.Standard Control Plan Example Control Plan Number Part No. Product Process Size Frequency Control Method Reaction Plan Advanced Product Quality Planning This form is on course disk 78 . Device. Special Char. Tools f or Mf g. Ford‟s Dimensional Control Plan (DCP) Advanced Product Quality Planning 79 . / La st R&R % Gage Process % Pro ce ss Cp k or Dev Process % Pro ce ss Cp k or Dev Type Of Freq .13 5mm [7] Au to Inj ecti on Mol d Co ver In TL# [1] [2] [3] [4] [5] [6] [7] [1] [2] [3] [4] [5] [6] [7] 2.60 9 Advanced Product Quality Planning This form is on course disk 80 .68 5mm .0.60 mm . X bar and Start Of R Cha rts Ea ch Run An d E ach SQC Sh ift Da tab ase [17] [18] Ope ra to r Process Se t-Up Au dit Gag e Metho d Instructi on an d (Proce d. Ea ch Box 3.Control Plan Example (GM) Process Control P la n Su ppl ie r Na me: Su ppl ie r Re p.0 Ho le Di ame te r (Cover) 4. # ) Freq uen cy Green "OK" Re lea se .+/.0 Ch eck Every Ve ndor Bo x Ce rt(s).: Ti tle: Ke y Pro duct Co ntro l Cha ra cteristics Su ppl ie r Co de: Te lep hon e: Da te: 4/5/93 Gag e Study Pa rt Numbe r: Pa rt Descrip ti on : En gin eeri ng Ch ange L ette r: Process Pl an Effe ctive Date: 4/5/93 Process Capa bi li ty Process Perfo rma nce Co ntrol s (Short T erm Ca pab il i ty) (Lon g Term Capab il i ty) [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] Ite m Ke y Pro duct Ke y Control Ope ra ti on Gag e Attr.+/. Of Ch ara cteri stic/ Ch ara cteri stics De scri ptio n Ope ra ti on Va ri abl e Da te R&R Ca pabi l ity Ca pabi l ity From Pe rform. Sp ec Da te Ta rge t/No m.0.0.60 7 2.2 3.1 2. Metho d 1.11 mm 2-7 = 0. Da te Ta rge t/No m.41 mm . Pe rform From Co ntrol Inspect.+/.0 Vi nyl Materia l Sp ec Te ar Strip (Cover) 1 = 0.25 mm To ol Se tu p Machi ne Se tup Au to Inj ecti on Mol d Cover TL # [1] [2] [3] [4] [5] [6] [1] [2] [3] [4] [5] [6] Ve ri fy To Sp ec Sh eet X bar and 5 Pi eces R Cha rts Every 6 Mon th s SQC Da tab ase 3. Prototype Build • Make -buy decisions • Part inspections • Assemble prototypes • Perform layout inspection • Validation testing (Who will do testing?) • Redesign as required • Update DFMEA and SFMEA if required Advanced Product Quality Planning 81 . durability.Customer or Supplier Engineering Drawings (including math data) • Review for special and/or critical characteristics • Review controlling drawings when engineering drawings are nonexistent • Review drawings for: –Dimensions for form. fit. function. government S&R –Control or datum surfaces/locators for function gages and equipment –Feasibility/compatibility with industry standards • Compatibility of math data with two-way communications (Written waivers acceptable) Advanced Product Quality Planning 82 . Customer or Supplier Engineering Specifications • Review and understand controlling specifications • Identify functional. determined by supplier and included in control plan Advanced Product Quality Planning 83 . durability and appearance requirements • Should define: –Sample size –Frequency –Acceptance criteria • Otherwise. Material Specifications • Review Material Specifications for Special Characteristics –Physical properties –Performance –Environmental –Handling –Storage • Include in Control Plan Advanced Product Quality Planning 84 . 5 „Document and Data Control‟ applies (requires a Change Control system) Advanced Product Quality Planning 85 .Drawing and Specifications Changes • Change control requirement applies • Ensure proper communication • QS 9000 Element 4. tooling and facilities requirements • Special product and process characteristics • Gage and testing equipment requirements • Team feasibility commitment and management support • Subcontractor build • Supplier build Advanced Product Quality Planning 86 .APQP Team Outputs • New equipment. Tooling and Facilities Requirements • Preliminary identification of new equipment. tooling and facilities • Address these items on the timing chart • Address capability requirements • Establish delivery times • Complete check list in AIAG APQP & Control Plan reference manual Appendix A-3 Advanced Product Quality Planning 87 .New Equipment. pre-launch and production • Listing should be a team consensus Advanced Product Quality Planning 88 .Special Product and Process Characteristics List • Upgrade preliminary list started in Phase 1 from information gathered through review and development of design features – Additional sources • • • • DFMEA SFMEA if applicable PFMEA Previous history These may overlap • Must be on control plans for prototype. Gage and Testing Equipment Requirements • Preliminary identification of inspection. test and measurement equipment • Requirements on timing chart –Complete in time to conduct measurement systems analysis –Equipment builder –Pilot build –Production trial run Advanced Product Quality Planning 89 . including: –Design feasibility –Can be manufactured. Commitment and Management Support • Team feasibility commitment • Complete program review check list. • Management Support –Report project status to management –Recommend continue or drop project depending on feasibility –Cover open issues and concerns –Management support as required Advanced Product Quality Planning 90 . tested and packaged –Can be delivered in the right quantities on schedule at acceptable cost –Review design information check list in AIAG APQP Reference manual Appendix A-2 as part of feasibility inputs • Open issues that require resolution with assigned responsibility and timing. assembled.Team Feasibility. if appropriate • Sample quantity required • Check that it is according to: –Work instructions –Control plan • Where to be produced Advanced Product Quality Planning 91 .Subcontractor Pilot Build • Supplier participated. Supplier Pilot Sample Build • Parts availability • Tooling and equipment availability • Measurement equipment availability Advanced Product Quality Planning 92 . Tooling. Facilities Requirements Special Product & Process Characteristics Prototype Control Plan Gages / Testing Equipment Requirements Team Feasibility Committment Management Support Subcontractor Built Supplier Build This form is on course disk Advanced Product Quality Planning 93 MIS HR .Phase 2 Responsibility Matrix Management Maintenance Engineering Purchasing Production Laboratory Quality Sales Phase 2: Product Design and Development Materials Output DFMEA DFM / DFA Design Verification Design Reviews Prototype Build Engineering Drawings (inc. math data) Engineering Specifications Material Specifications Drawing / Specification Changes New Equipment. etc. 8a 8b No Checklist Item Is the product adequately def ined (applic ation requiremetns . 5. 3. 6a 6b 6c 7. 8.33? Product c an be produc ed as specif ied w ith no rev is ions. 4. 2. Changes recommended (See attached) Design revision required to produce product within specif ied requirements Feasible Feasible Not Feasible Team Member/Title/Date Team Member/Title/Date Team Member/Title/Date Team Member/Title/Date This form is on course disk Advanced Product Quality Planning 94 . All 'NO' answ ers are supported w ith attac hed comments identif ying our concerns and/or propos ed changes to enable us to meet specif ied requirements . The documents provided hav e been used as a basis for analy zing the ability to meet all specified requirements. Yes 1.) to enable f eas ibility evaluation? Can engineering perf ormance s pec if ications be met as w ritten? Can produc t be manuf actured to toleranc es specified on the draw ing? Can produc t be manuf actured w ith Cpks whic h meet requirements ? Is there adequate capac ity to produce product? Can the produc t be manuf actured w ithout incurring any unus ual: Costs f or tooling? Costs f or capital equipment? Alturnate manufacturing methods? Is Statis tical Proc ess Control required on the produc t? Where Statistic al Proces s Control is us ed on s imilar produc t? Are the proces ses in control and stable? Are Cpks greater than 1. 6.Phase 2 Project Review Projec t # Model/Y ear Title Part # Customer Date Our adv anc ed quality planning team has considered the f ollow ing questions in Phase 2 of our APQP process. APQP Phase 3: Process Design and Development Advanced Product Quality Planning 95 . Phase 3 Outputs • Packaging Standards • • • • Product / Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix • Process Failure Mode and Effects Analysis • Pre-Launch Control Plan • Process Instructions • Measurement Systems Analysis Plan • Preliminary Process Capability Study Plan • Packaging Specifications Advanced Product Quality Planning 96 . Typical Design Responsibility Outputs • DFMCA • DFM/DFA • DV • Design Reviews • Prototype Build • Engineering Drawings • Engineering Specifications • Material Specifications • Drawing and Specification Changes Advanced Product Quality Planning 97 . Typical APQP Team Outputs • New Equipment • Facilities • Etc. Advanced Product Quality Planning 98 . tooling and equipment – Delivery of gages in time for MSA plan – Delivery of equipment • Must consider approval at equipment subcontractor. inhouse installation. tooling and equipment – Order gages. equipment and facilities list – Update process flow chart – Update PFMEA – Quote in-house gages.Process Design and Development Outputs • Packaging standards • Product and process quality system review • Process flow chart • Floor plan layout • Characteristics matrix • PFMEA • Pre-launch control plan • Process instructions • Measurement systems analysis plan • Preliminary process capability study plan (Typically 100 Parts) • Additional Outputs – Update tooling. debugging and process potential studies (runoff) • Management support – Subcontractor pilot build – Supplier pilot build Advanced Product Quality– Planning Salable 99 units? . Packaging Standards • From customer • Developed during prototype or prelaunch runs Advanced Product Quality Planning 100 . Product and Process Quality System Review • Team must review existing quality systems manual to ensure that changes resulting from APQP (if any) are reflected • Must comply with QS 9000 • Changes must be reflected in control plan • Reference AIAG APQP Reference manual Appendix A-4 check list Advanced Product Quality Planning 101 . Process Flow Chart • Update process flow chart (Example in AIAG APQP Reference manual Appendix A-6) • Describes current or proposed process flow • Used to analyze sources of variation • Helps analyze total process • Needed for process FMEA. characteristics matrix and control plan • Reference AIAG APQP Reference manual Appendix A-6 check list Advanced Product Quality Planning 102 . 2 Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Tool Setup Machine Se tup Machine Se tup 3.0 Pressure Control Protrusions Height Pressure Control Protrusions Filled Out Cover . Auto Injection Mold Cover In Tool # Item # 1.2 2.0 Hole Diameter In Co ver 4. : C Approved By: QA Manager Operations Manager Senior Advisor QA Engineer Fabrication Step 1 Inspect Store Move Operation Description Move "OK" Vinyl Material From Storage Area and Load Into Press.0 Key Product Characteristic Material Specs Item # 1.1 2.2 2.0 Key Control Characteristic Material Certification Tag 2 2.0 8.Process Flow Diagram Example Process Flow Diagram Part Numbe r: Part De scription: Prep ared By: Date : 4/5/93 Rev.1 2.2 2.0 7.1 2.1 2.2 2.0 Flange Th ickness In Cover 5.0 103 Advanced Product Quality Planning .2 2.Flash Free Cover Filled Out Free Of Foreign Material 3 Visually Inspect Cover 6.2 2.1 2.1 2.0 Tearstrip In Cove r 2.2 2.0 9.1 2. Floor Plan Layout • • • • Determine acceptability of inspection and test points Control chart location(s) Visual aides Interim repair stations (rework) • Nonconforming material storage • Keyed to material flow and control plan • Reference AIAG APQP Reference manual Appendix A-5 Advanced Product Quality Planning 104 Characteristics Matrix • Displays relationship between: –Process parameter –Manufacturing stations • Reference AIAG APQP Reference manual Appendix B, page 82 Advanced Product Quality Planning 105 Process FMEA • To the extent possible, potential failure modes have been considered and addressed • May be started after design FMEA in Phase 2 • Needs to be updated regularly • Must be done prior to committing new tools and equipment • Living document • Typically started too late! • Reference AIAG APQP Reference manual Appendix A-7 Advanced Product Quality Planning 106 Automotive Process FMEA Process Fai l ure Mo de An d Effects Ana lysi s Process: Pri ma ry Pro cess Re sp onsib il i ty: Other Di v. Faci li ty 1 10 3 30 Advanced Product Quality Planning 107 .10 De tectio n Pa rt Name Ope ra ti on Nu mb er SIR Co nta in er 1 De tectio n Occured Occured Se verity Se verity RPN Process Fun ctio n Ta ke TPP E Materi al He ld In Storage A re a Po ten ti al Fai l ure Mod e Wrong Ma teri al Po ten ti al Effe cts Of Fai lure Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Po ten ti al Cau se Of Fai lu re Insuffi ci en t Sup pl ie r Con trol Imprope r Han dl in g Mi si den ti fie d Materia l Cu rrent Con trol s Materi al Ce rti fi ca ti on Re qui re d With Each Sh ipme nt Re lea se V eri ficatio n Pe ri odi c Au di t Of Su ppl ie r Materi al Vi su al Inspectio n Re lea se V eri ficatio n Green "OK" T ag Cu stomer Notifi cati on Ch eck For Gree n "OK " Ta g A t Press Trace Card Ch eck L ist Trai ni ng Re comme nded Acti on s And Status Acti on s Ta ken RPN Re spo nsib le Acti vi ty 1 9 2 18 Out Of Sp ec Materi al Co nta min ated Materi al Materi al Co mp ositi on Ch ange 2 Move To Ap pro ve d Storage Un rel ea se d Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Frag mented Co ntai ner Un pre di ctabl e De pl oyme nt Frag mentatio n Su ppl ie r Process Con trol Ope n Boxes En gin eeri ng Ch ange Su ppl ie r Ch ang e Un trai ned L TO Un trai ned P erson nel 3 1 1 10 9 10 3 7 7 90 63 70 5 10 1 50 3 Ho ld In App ro ved Storage Until Ne eded Co nta min atio n Frag mentatio n Process Probl ems Ope n Con tai ne rs Ho use ke epi ng Area Mai nten ance Bo xes K ept In Se al ed Storage A re a Until Ne eded Bo xes L in ed Wi th Pl asti c Li ne r On Pal l ets Inside S to ra ge P. M. Lo w . Or Peop le Invol ve d: Ap pro va ls: Qua li ty Assuran ce Man age r Ope ra ti on s Mana ger Outsid e Supp li ers Affected : Mod el Ye ar/V ehi cl e(s): Sched ul ed Produ ctio n Rel eased : Qua li ty Assuran ce En gi neer Se nio r Ad vi so r En gin eer: Pa rt Numbe r: PFME A Date: Re v.Hi gh 1 . Pre-launch Control Plan • Description of dimensional measurements. materials and functional tests • Adds additional product and/or process controls • Purpose is to contain potential nonconformities utilizing: –More frequent inspections and/or tests –More in-process and final inspection and/or check points –Statistical evaluations –Increased audits –Reference AIAG APQP Reference manual Appendix A-8 check list Advanced Product Quality Planning 108 . Automotive Control Plan Control Plan Number Part No. Jig. Class Product/ Process Spec/ Tolerance Evaluation Measurement Technique Date (Orig. Product Process Size Frequency Control Method Reaction Plan Advanced Product Quality Planning 109 . Tools f or Mf g.) Date (Rev.) Customer Engineering Approval/Date Customer Quality Approval/Date Other Approval/date (If Req'd) Methods No./ Latest Change No. Special Char. Device. Part Name/Description Supplier/Plant Supplier Code Key Contact / Phone Core Team Supplier/Plant Apoproval/Date Other Approval/date (If Req'd) Characteristics Part/ Process Number Process Name/ Operation Description Machine. tools and facility lists • • • • • • • Updated process flow chart. PFMEA and control plan Quotes for in-house tooling. equipment and gages Selection of potential new subcontractors Quote and delivery of gages in time for MSA plan Equipment build and runoffs Generation of a subcontractor pilot build Generation of a supplier pilot build Advanced Product Quality Planning 110 .Additional Phase 3 Outputs • Updated equipment. Updated Tool. Equipment and Facilities Lists • Information from PFMEA and other sources • Address on timing chart • Address capability requirements • Reference AIAG APQP Reference manual Appendix A-3 check list Advanced Product Quality Planning 111 . Quoting In-House Tooling. Equipment and Gages • Delivery timing for pilot build or production trial run • Include capability requirements • Include trial run/runoff/prove-out requirements • Gage delivery for MSA plan and runoff • Reference AIAG APQP Reference manual Appendix A-3 Advanced Product Quality Planning 112 . tracking and follow-up for subcontracted work • Provide technical resources for tool and gage design.Selecting Potential New Subcontractors • Responsible for planning. fabrication and full dimensional inspection Advanced Product Quality Planning 113 . if appropriate • Build sample quantity required –Machine trial runs –Pilot run(s) • In accordance with appropriate work instructions • In accordance with control plan • Production tooling and equipment. if possible Advanced Product Quality Planning 114 .Subcontractor Pilot Sample Build • Supplier participation. if specified • have process instructions in place • Have control plan in place • Provide required quantity • Complete MSA • Generate required documentation as planned Advanced Product Quality Planning 115 .Supplier Pilot Build • Provide for customer participation. Project Review III • Include in control plan • Manufacturing location‟s quality system manual should be reviewed • Procedures and control plans to be updated to reflect changes • Last chance to eliminate problems before ramp-up Advanced Product Quality Planning 116 . Phase 3 Responsibility Matrix Management Maintenance Engineering Purchasing Production Laboratory Quality Sales Phase 3: Process Design & Development Materials Output Packaging Standards Product/Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix PFMEA Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Management Support This form is on course disk Advanced Product Quality Planning 117 MIS HR . and bef ore full produc tion. Changes recommended (See attached) Design revision required to produce product w ithin specified requirements Team Member/Title/Date Team Member/Title/Date This form is on course disk Feasible Feasible Not Feasible Team Member/Title/Date Team Member/Title/Date 118 Advanced Product Quality Planning . interim repair stations. reproducability. repeatrability. 10. material. 4. and storage area to contain def ec tive materials? Is a char acter istics matr ix appropriate and has one been constructed? Does the process FMEA c heck list indicate any problems and is there a s ystem f or periodic review of the PFMEA? Does the control plan check list indicate that all dimensional requirements. 6.Phase 3 Project Review Projec t # Model/Y ear Title Part # Customer Date Our advanced qu al ity pl an ni ng team has con si dered the fol l owi ng qu esti ons in Ph ase 3 of our APQP process. including robots? Product c an be produced as specified with no revisions. transit. applic ability of visual aids. are included? Are clear proces s instruc tions in appropriate detail and are they c ros s-ref erenc ed to all appropriate s ources ? Does the meas urement sy stems analysis plan inc lude responsibility to ensure gage linearity. 7. and f unctional tes ts that w ill occ ur af ter the prototype. control chart locations . 2. Th e documen ts provi de d have been u se d as a ba si s for a nal yzin g the ab il i ty to meet al l specifi ed requi remen ts. and correlation for duplic ate gages? Has the preliminary proc ess capability study plan been c ompleted? Do the packaging specif ic ations resulting f rom the packaging design as sure that produc t perf ormanc e and characteristic s will remain unchanged during packing. and will it have c ompatability w ith all material handling equipment. Checklist Item Does pac kaging des ign ens ure produc t integrity at point of use and meet cus tomer specs ? Is the produc t proc ess quality c hecklis t completed f or the sy stem review ? Does the process flow chart indicate any problems w ith the proces s? Does the floor plan c hecklis t indic ate any problems w ith the aceptability of inspection points . Al l 'NO' answe rs a re supp orte d wi th attached co mments i den ti fyi ng ou r co nce rn s an d/or prop osed ch ang es to ena bl e us to meet specifi ed re qui remen ts. unpacking. 8. 9. 11. 3. Yes 1. No 5. ac curacy . APQP Phase 4: Product and Process Validation Advanced Product Quality Planning 119 . Phase 4 Outputs • Production trial run • Measurement system evaluation (complete) • Preliminary process capability study • Production part approval • Production validation testing • Packaging evaluation • Production control plan • Quality planning sign-off and management support Advanced Product Quality Planning 120 . Process Instructions • Work instructions for operating personnel • Sources: † † † † † † † † † † † † † † † † † FMEAs Control plans Engineering drawings and specifications Material specifications Visual standards Industry standards Process flow chart Floor plan layout Characteristic matrix Packaging standards Process parameters Producer expertise Handling requirements Operators of process Accessible operators Include set-up parameters Reference QS 9000 Element 4.9 „Process Control‟ 121 Advanced Product Quality Planning . Measurement Systems 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 Advanced Product Quality Planning 122 . Bias. evaluate total variation –>30% unacceptable. and Linearity • Gage R & R acceptance guidelines –< 10% acceptable –10-30% may be acceptable.MSA Studies • Measurement uncertainty determined –Gage R&R. measuring system needs improvement • Verify study performed correctly Advanced Product Quality Planning 123 . Stability. What others can you think of? 124 .Measurement Systems Analysis Plan Ensures Gage:  Linearity  Accuracy  Repeatability  Reproducibility  Correlation for duplicate gages  Gages may be needed prior to gage sign-off at subcontractor plant or any in-house pilot runs Material Sample Collection Sample Preparation Parallax Reproducibility Inspector Training Practice Methods Test Method Workmanship Samples Ergonomics Standards Measurement Discrimination Bias Repeatability Calibration Lighting Humidity Vibration Temperature Linearity Instrument Environment These are some of the variables in a measurement system. Measurement Precision Indicates Poor Precision Advanced Product Quality Planning 125 . Measurement Bias & Repeatability Precise Accurate Imprecise Inaccurate Bias You can correct for Bias You can NOT correct for Imprecision 126 . Preliminary Process Capability Study Plan • Must include characteristics identified in control plan • Few characteristics for simple component • Many characteristics for complex product with many parts • Reference AIAG Fundamental SPC Reference Manual Advanced Product Quality Planning 127 . Packaging Evaluation • Packaging must conform to specifications developed 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 Advanced Product Quality Planning 128 . Packaging Specifications • • • • • For individual products Customer packaging Generic standards where appropriate Must ensure delivery quality Compatible with all material handling equipment used Advanced Product Quality Planning 129 . PPAP Sub-Set APQP Launch Binders PPAP Submission • The End Product of APQP! Advanced Product Quality Planning 130 . Advanced Product Quality Planning 131 . • Test results and records from APQP are submitted with Part Submission Warrant. operators. etc • Parts from production run are analyzed.Production Part Approval Process PPAP • Production parts are manufactured at the production site using production tooling. equipment. gaging. Purpose of PPAP •For the supplier to demonstrate: ° All design records and specification. Advanced Product Quality Planning 132 . ° The process has the capability to produce product that meets requirements. ° Requirements are properly understood. Production Part Approval Process (PPAP) • • Production Part Approval Process Parts produced at production site using: –Production tooling –Production gages –Process –Operators –Environment –Process settings • • • • • Feeds Speeds Cycle times Pressures Temperatures • • • • • Intent is to validate (prove) that products made using production equipment meet engineering requirements If submission level is not known. contact customer Default level is 3 Customer approval is required prior to quantity production Reference AIAG Production Part Approval Process reference manual Advanced Product Quality Planning 133 . Advanced Product Quality Planning 134 . PPAP Scope • Production parts .generally 300 „pieces‟ • Service subcontractors .fulfill requirements • Bulk material • Includes internal and external sources for information • Submission required prior to first production shipment • PPAP Manual Section I.3 “Customer Notification and Submission Requirements” (starting on page 11) for guidance Advanced Product Quality Planning 135 . Application AIAG PPAP Manual Defines When PPAP Submission is Required ° New part Something Changed ° Correction to discrepancy in previous submission ° Design or process change ° Change in source of subcontracted materials or services ° Transfer or rearrangement of tooling & equipment Advanced Product Quality Planning 136 . Methodology • Buyer enters PPAP submission date on purchase order.xls electronic submission (Delphi) Advanced Product Quality Planning 137 . • Notify supplier and manufacturing of status. • Approver determines submission level. • Supplier submits PPAP –PPAPALL. –Level 5 at supplier site • Approver determine part submission status. –Default level 3 –Default level 4 for raw material • Approver evaluates PPAP package. as required • Sample Parts • Print/Design Record • Engineering Change Documents • Check fixtures/aids • Process Flow Diagram • PFMEA • Control Plan • Early Production Containment Plan (Pre-Launch Control Plan) • Process capability studies • Gage Measurement System Analysis • Lab Accreditation & scope • Restricted & Reportable Materials form • Interim Worksheet.Supplier Data Received • Warrant • DFMEA • Appearance Approval Report (AAR). if required 138 Advanced Product Quality Planning . Flow Chart • Linkage of Product Characteristics from DFMEA to Operational Steps. • Use A-6 Process Flow Chart checklist in APQP manual to evaluate. Advanced Product Quality Planning 139 . • Operation numbers consistent with PFMEA. Control Plan. • Ensure identification of inspection and rework. Operator Instructions. Risk. Design Intent Issues • Confirm Manufacturing Process Capability Considered • Focus on Critical Characteristics • Lessons Learned Incorporated • Use A-1 Design FMEA Checklist in APQP Manual to Evaluate Advanced Product Quality Planning 140 .DFMEA • Assess Feasibility. Operator Instructions.PFMEA • Linkage with DFMEA. Process Flow. effectiveness assessed and RPN recalculated • Use A-7 Process FMEA checklist in APQP manual Advanced Product Quality Planning 141 . implemented. Control Plan. etc • Degree to which high RPN‟s are addressed with preventive strategies • Action Plans assigned. Additional controls included for proper duration or quantity.Pre-Launch Control Plan • Early Production Containment Requirements –1. –2. • Short Term Capability • Long Term Capability on similar process Advanced Product Quality Planning 142 . PFMEA and statistical data used to determine what additional controls necessary. inspection. attribute data and mistake-proofing –Reaction plan • Nonconformances clearly identified.Production Control Plan • Update pre-launch control plan (living document) • Add: –Sampling plans –Control method –SPC. B and G Advanced Product Quality Planning 143 . quarantined and disposition made • Requires customer approval unless otherwise specified • Reference AIAG APQP Reference manual Appendix A-8. Production Validation Testing • Engineering tests validate products manufactured with: –Production tools –Production processes –Production operators • Performed under end-use operating conditions • Multiple validations for multiple intended uses • Reference QS 9000 Element 4.4.8 Advanced Product Quality Planning 144 . facilities and cycle time • Process instructions and control plans • Minimum quantity set by customer (Can be increased by team) • Generally 300 parts Advanced Product Quality Planning 145 . equipment. environment.Production Trial Run • Production tooling. Production Trial Run Product Used For: • Preliminary process capability studies • • • • • • • • • MSA (if not completed earlier) Final feasibility Process review Production validation testing PPAP Packaging evaluation First time capability Quality planning sign-off Design changes (if required) 146 Advanced Product Quality Planning . which shows the calculations for Cpk as well as Ppk. and Pr) are used to measure the performance of a system to meet customer needs. Cpk In 1991. they have slightly different uses. Estimated sigma and the related capability indices (Cp. So which value is best to report. Advanced Product Quality Planning 147 . Use it when you want to measure a system's actual process performance. the ASQC/AIAG Task Force published the "Fundamental Statistical Process Control" reference manual.Ppk vs. Actual or calculated sigma (sigma of the individuals) and the related indices (Pp. These should be used to eliminate confusion about calculating Cpk. and Cr) are used to measure the potential capability of a system to meet customer needs. Use it when you want to analyze a system's aptitude to perform. Cpk. Cpk or Ppk? Although they show similar information. Ppk. Preliminary Process Capability Studies • Characteristics identified in the control plan • Usually 100 pieces minimum • May be 30 if run is less • Ppk ≥ 1.0 at spec limit –+-3 sigma = 1.67 is acceptable unless otherwise specified • Ppk ≤ 1.67 –Allows „flop‟ within spec limit 148 Advanced Product Quality Planning .67 requires action plan unless otherwise specified • Reference AIAG Fundamental SPC Reference Manual –1. fi/~leo/ Advanced Product Quality Planning 149 .sci.com Courtesy of The Red Road http://www.Process Analysis Animation Elsmar. fi/~leo/ Advanced Product Quality Planning 150 .Histogram Animation Elsmar.com Courtesy of The Red Road http://www.sci. com Courtesy of The Red Road http://www.Process Capability Animation Elsmar.sci.fi/~leo/ Advanced Product Quality Planning 151 . fi/~leo/ Advanced Product Quality Planning 152 .com Courtesy of The Red Road http://www.sci.Process Capability Animation Elsmar. 67 Interpretation Conclusion Process probably Current control plan meets customer sufficient requirements 1.33 Process will not meet customer requirements 100% inpection is needed until Cpk>1.33 requirements achieved Ppk<1.33<Ppk<1.67 Process may not Additional controls meet customer needed until Cpk>1.33 achieved 153 Advanced Product Quality Planning .Process Capability Studies Capability Ppk > 1. • Rejected –Corrected submission required before production quantities may be shipped.Part Submission Status Possibilities • Full Production Approval • Interim Approval –Authorize shipment to Delphi without Full Production Approval –Corrective Action Plan is required. Advanced Product Quality Planning 154 . Interim Part Classes – A Parts from production tooling and meet specs. • D Parts do not meet specs. parts meet specs. B–Parts from production tooling and require rework to meet specs. 155 Advanced Product Quality Planning . not all PPAP requirements have been met. • C Parts not from production tooling. • E Parts do not meet specs and vehicles with class E parts require retrofit to make them saleable. Review and Sign-Off • Process instructions in place and followed • Flow charts in place and followed • GR&R plans exist and are followed • Publish final feasibility report • Obtain formal sigh-off • Schedule and conduct management review • Obtain management commitment to assist in open issues Advanced Product Quality Planning 156 . 7. Al l 'NO' answe rs a re supp orte d wi th attached co mments i den ti fyi ng ou r co nce rn s an d/or prop osed ch ang es to ena bl e us to meet specifi ed re qui remen ts. Th e documen ts provi de d have been u se d as a ba si s for a nal yzin g the ab il i ty to meet al l specifi ed requi remen ts. 5. No Checklist Item Has the production trial run been conducted and does it indicate the need f or any change? Does the evaluation of the measurement systems indicate any need to modif y the control plan characteristics? Does the preliminary process capability study indicate any potential problems? Has the production part been approved? Has the production validation testing indicated any problems? Has the evaluation of the packaging of test shipments. 6. w here feasible. 2. Changes recommended (See attached) Design revision required to produce product w ithin specified requirements Team Member/Title/Date Team Member/Title/Date Feasible Feasible Not Feasible Team Member/Title/Date Team Member/Title/Date Advanced Product Quality Planning This form is on course disk 157 . 3.Phase 4 Project Review Project # Model/Y ear Title Part # Customer Date Our advanced qu al ity pl an ni ng team has con si dered the fol l owi ng qu esti ons in Ph ase 4 of our APQP process. and test methods indicated any dif ficulty? Has the control plan methodology check list indicated any problems w ith that document? Product can be produced as specified with no revisions. Yes 1. 4. Phase 4 Responsibility Matrix Management Maintenance Engineering Purchasing Production Laboratory Quality Phase 4: Product and Process Validation Materials Sales Output 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 Management Support Advanced Product Quality Planning This form is on course disk 158 MIS HR . Assessment and Corrective Action • The results of continuing production are evaluated for common or special causes of variation during this phase to ensure that the products satisfy customer satisfaction requirements • The effectiveness of the quality process should be evaluated during this process step –Includes continual improvement efforts –Includes delivery and service performance Advanced Product Quality Planning 159 .APQP Phase 5: Feedback. Continuing Production Continuing Production Continuing Production Determining Ongoing Capability Develop Delivery & Service Measurement Plan Measure Customer Satisfaction Cpk > or = 1.33 Develop & Implement Corrective Action Plan Measure Delivery & Service Develop QOS Measurement Attend Customer QOS Meeting As Required Continuous Improvement Plan & Feedback Ford’s Interpretation 160 Advanced Product Quality Planning . Phase 5 Outputs • Reduced variation • Customer satisfaction • Delivery and service Advanced Product Quality Planning 161 . negotiate or change design Advanced Product Quality Planning 162 .Reducing Variation • Identify process variation • take corrective action to reduce variation • Develop proposal for customer review • Gain customer decision to implement. 6 Advanced Product Quality Planning 163 .1.Customer Satisfaction • Product or service must perform in customer‟s environment • Supplier must participate • Supplier and customer must be partners • Reference QS 9000 Element 4. Customer Satisfaction Metrics • Warranty • Customer rating • Labour claims • Concerns reports • Nonconforming material reports • Corrective actions • On time delivery • Tech calls • Returns • PPM • Response time • On-site representative • Market share • Cost control (total cost) 164 Advanced Product Quality Planning . 15 Advanced Product Quality Planning 165 .Delivery and Service • Continues the supplier .customer partnership in problem solving and continuous improvement • Replacement parts and services are important • Leads to possible price reduction from: –Inventory cost reduction –Process cost reduction –Cost of quality reduction –Reference QS 9000 Element 4. Asse ssme nt and Cor re ctiv e Ac tion Materials 166 Sales Output Reduced Variation Customer Satisfaction Delivery and Service This form is on course disk Advanced Product Quality Planning MIS HR .Phase 5 Responsibility Matrix Management Maintenance Engineering Purchasing Laboratory Production Quality Phase 5: Fe e dback. Th e documen ts provi de d have been u se d as a ba si s for a nal yzin g the ab il i ty to meet al l specifi ed requi remen ts. Yes 1. Changes recommended (See attached) Design revision required to produce product w ithin specified requirements Team Member/Title/Date Team Member/Title/Date Feasible Feasible Not Feasible Team Member/Title/Date Team Member/Title/Date This form is on course disk Advanced Product Quality Planning 167 . 3. No Checklist Item Has a system f or reducing f uture variation been developed and is it in place? Is there a system f or ensuring continuing customer satisfaction? Is there a process in place f or monitoring delivery and service so that it continues to met customer needs? Product can be produced as specified with no revisions.Phase 5 Project Review Project # Model/Y ear Title Part # Customer Date Our advanced qu al ity pl an ni ng team has con si dered the fol l owi ng qu esti ons in Ph ase 5 of our APQP process. Al l 'NO' answe rs a re supp orte d wi th attached co mments i den ti fyi ng ou r co nce rn s an d/or prop osed ch ang es to ena bl e us to meet specifi ed re qui remen ts. 2. Summary • AIAG PPAP Manual Defines Requirements • APQP Product and Process Validation • Supplier submits PPAP to proper level • PPAP package evaluated and status determined • Supplier and customer manufacturing site notified of PPAP approval status Advanced Product Quality Planning 168 . Check Lists • • • • • A-1 Design FMEA Check List A-2 Design Information Checklist A-3 New Equipment.APQP Manual Appendix A . Tooling and Test Equipment Checklist A-4 Product / Process Quality Checklist A-5 Floor Plan Check List • • • A-6 Process Flow Chart Checklist A-7 Process FMEA Checklist A-8 Control Plan Checklist Advanced Product Quality Planning 169 .