Apqp & Ppap -Taining Material
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1. IFB IFB APL APL 31/10/ 31/10/ 06 06 To Training on APQP & PPAP APQP & PPAP
Transcript of Apqp & Ppap -Taining Material
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IFB APLIFB APL 31/10/0631/10/06
To Training on
APQP & PPAPAPQP & PPAP
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APQP is the timing plan focusing on the project adherence with reference to the customer Schedules. It starts from the initial tool or part design till the Start of Production
“ IT IS BETTER TO SPEND A LITTLE EXTRA TIME DURING THE UPSTREAM PROCESS SO THAT THE DOWNSTREAM PROCESSES ARE FREE FROM ERRORS ”.
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THE ADVANCED PRODUCT QUALITY PLANNING (APQP) MODEL
WHAT IS APQP?
Advance Product Quality Planning is a structured & systematic method of defining and establishing the steps necessary to assure that a product satisfies the customer’s requirements.
The commitment from the Top Management is an essential requirement for the success of this process.
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The goals of Quality Planning are :
Effective communication with everyone involved.
On-time completion of all required steps
Minimal or no quality problems
Minimal product launch quality risks
Minimal cycle time to launch the product
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THE BENEFITS OF APQP
• Resources are directed toward customer satisfaction
• Required changes are identified early
• Changes close to or after product launch are avoided
• A quality product is provided on time at the lowest cost.
• An element of Continuous Improvement is built into the company.
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Plan and Define
Product Design and Development
Process Design and Development
Product and Process Validation
Feedback, Assessment and Corrective Action
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Manufacturing Only
ServiceSupplier Heat
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Define the Scope X X X
Plan and Define Section 1.0X
Product Design andDevelopment Section 2.0 X
Feasibility Section 2.13X X X
Process Design andDevelopment 3.0 X X X
Product and Process ValidationSection 4.0 X X X
Feedback, Assessment andCorrective Action-Section 5.0 X X X
Control Plan MethodologySection 6.0
X X X
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The product quality planning team’s first effort should be the development of a timing plan. This timing plan should list all tasks with responsibility and target dates. It is a good practice to follow the project management techniques like Gantt Chart, Critical Path Method, PERT etc. This plan can be regularly reviewed and updated as the planning evolves.
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• Determine customer needs
• Plan a quality program (which includes Scope, Time, Budget, etc.)
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Voice of the customer-market research-historical warranty and quality information-team experience
Business plan/marketing strategyProduct/process benchmark dataProduct/process assumptionsProduct reliabilityCustomer inputs
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OUTPUTS
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
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OBJECTIVESDevelop design features and characteristicCritically review engineering requirementsAssess potential manufacturing problems
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Design goals Reliability and quality goals Preliminary process flow chart Preliminary listing of special product and process characteristics Product assurance plan Management support Customer requirement ( special ch., identification, traceability,etc) Use of information targets for product quality, life, reliability, durability, maintainability,
timing and cost )
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OUTPUTS BY DESIGN RESPONSIBLE ACTIVITY
Design failure mode and effects analysis(DFMEA)Design for manufacturing and assemblyDesign verificationDesign reviewsPrototype build – control planEngineering drawings (including math data)Engineering specificationsMaterial specificationDrawing and specification changesProduct special characteristicsproduct error proofing as appropriateproduct definitiondiagnostic guidelines where applicable
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OUTPUTS BY PRODUCT QUALITY PLANNING TEAM
New equipment tooling and facilities requirementsSpecial product and process characteristicsGages/testing equipment requirementTeam feasibility commitment and management support
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OBJECTIVES
Develop a comprehensive and effective manufacturing system
Ensure that the manufacturing systems meets customer requirements.
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Design Output data Targets for productivity, process capability and cost customer requirements if any experience from previous developments Design failure mode and effect analysis (DFMEA) Design for manufacturibility and 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 Gages/testing equipment requirement Team feasibility commitment and management support
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Packaging standards specifications and drawings Product process quality system review Process flow chart Floor plan layout Process approval acceptance criteria Data for quality, reliability, maintainability and measurability Results of error proofing activities Methods of rapid detection and feedback of product/manufacturing
process non conformities Characteristics matrix Process failure mode and effects analysis (PFMEA) Pre-launch control plan Process instruction Measurement systems analysis plan Preliminary process capability study plan Packaging specification Management support
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Validate the manufacturing process & the productEnsure that customer’s expectations will be metIdentify additional concerns
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Packaging standardsProduct process quality system reviewProcess flow chartFloor plan layoutCharacteristics matrixProcess Failure Mode and Effects Analysis (PFMEA)Pre-launch control planProcess instructionMeasurement Systems Analysis PlanPreliminary process capability study planPackaging specificationManagement support
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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
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Obtain objective feedback for future planningTo plan the next phase of product development or modificationTo improve the system of planning (from lessons learnt)To identify opportunities for Improvement
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Production trial runMeasurement systems evaluationPreliminary process capability studyProduction part approvalProduction validation testingPackaging evaluationProduction control planQuality planning sign-off and management support
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OUTPUTS
Reduced variationCustomer satisfactionDelivery and service
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TEAM LEADER
Each program has a team leader, but a team leader may manage one or more programs. The team leader:
-is typically a senior Production or Quality Manager-interfaces with the customer-ensures that the Program Need Dates (PND) are met-is responsible for resources and organisation-is responsible until product launch-forms and manages one or more APQP Teams
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APQP TEAMS
Team CompositionTeam should be cross-functional; it is not composed of only people from the Quality Department. Typical members might come from:
-Engineering-Manufacturing-Material Control-Purchasing-Sales-Field Service-Subcontractors-Quality-Industrial Engineering-Maintenance-Customers(as appropriate)-Finance
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Team Responsibilities
Success of the Product Quality Planning Team is dependent upon the interest, commitment, support and direction of upper management. The APQP team:
- is the Product launch Steering Committee responsible for quality planning
- works with the programme manager establish PNDs- determines the extent of require APQP activities- determines initial risk assessments and feasibility requirements- demonstrates that all planning requirements have been met- ensures that concerns have been documented and scheduled for
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• Overall, through this process, the team initiates the building of a Culture of Simultaneous Engineering in the Organisation.
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OBJECTIVES
Determine customer needsPlan a quality programme
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INPUTS
VOICE OF THE CUSTOMER
Market Research
Obtain market research data to reflect the needs expectations of the customer through
Customer interviewsCustomer questionnaires and surveysNew Product quality and reliability studiesCompetitive product quality studiesThings Gone Right (TGR) reportsFocus Group discussions
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Historical Warranty and Quality Information
Asses customer and wants and the potential for their recurrence
Things Gone Wrong (TGW) reportsWarranty reportsCapability indicatorsSupplier plant internal quality reportsProblem resolution reportsCustomer plant returns and rejectionField return product analysisProduct Sampling & Audit Reports
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Team Experience
Various reports of the organization’s personnel Formal feedback from the customer’s visits tot the plant Past track records similar product’s performance
consolidated during the various reviews meetings Collective experience of the team
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BUSINESS PLAN / MARKETING STRATERGY
The Business Plan Marketing Strategy are the basis of the Product Quality plan
The Business Plan may define the direction the team will take regard to:
-Timing-Cost-Investment-Product positioning-Research and development (R&D)-Target objectives for obsolescence
The Marketing Strategy will define:-Target customer-Key sales points-Key competitors
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PRODUCT / PROCESS BENCHMARK DATA
Benchmarking helps to establish performance targets
Identify appropriate benchmarksIdentify comparative companies to collaborate for benchmarkingCollect data and summarizeIdentify the gap between current status and the benchmark, and take one of the following actions:
- Close the gap- Match the benchmark- Exceed the benchmark
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PRODUCT AND PROCESS ASSUMPTIONS
Product and process assumptions presume the product has certain features, design or process concepts.
Technical innovationsAdvanced materialsReliability assessmentsNew technology
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PRODUCT RELIABILITY
Product Reliability studies compare frequency of repair/replacement of components and the results of long-term reliability /durability tests.
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CUSTOMER INPUTS
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DESIGN GOALS
Design goals are tentative and are measurable objectives based on :
Product assumptionsFunctional performanceDimensionsWeightMaterialsAesthetic
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RELIABILITY AND QUALITY CONTROL
Reliability and quality goals must include the following targets:
Things Gone Wrong (TGW) targetsThings Gone Right (TGR) targetsUseful Life Reliability targetsWarranty targetsIncoming Quality targetsProcess Quality Targets
Note: The above targets must address systems, sub-systems, Components & parts levelP
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PRELIMINARY BILL OF MATERIAL
The team should establish a Preliminary bill of material based onProduct process assumptions
Include an early subcontractor listSelect appropriate design and manufacturing processA preliminary make Vs buy analysis
PRELIMINARY PROCESS FLOW CHART
The manufacturing process should be described using a Preliminary Process Flow Chart, developed from :
Preliminary bill of materialProduct/Process assumptions
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PRELIMINARY LISTING OF SPECIAL PRODUCT AND PROCESS CHARCTERISTICS
A Preliminary List of Special Product and Process Characteristics should be developed based on analysis of inputs including but not limited to :
Product assumptions based on customer needs and expectationsIdentification of reliability goals / requirementsIdentification of special process characteristics from manufacturing processSimilar part FMEAsEarlier experienceP
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PRODUCT ASSURANCE PLAN
The Product Assurance Plan translates design goals into design requirements.
Outlining of program requirements Identification of reliability, durability, and apportionment/
allocation goals and/or requirements Assessment of new technology, complexity, skill, materials,
application, environment, packaging, service, and manufacturing requirements, or any other factor that my place the program at risk.
Development of Failure Mode Analysis (FMA) Development of preliminary engineering standards
requirements
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MANAGEMENTS SUPPORT
The understanding, acceptance, and commitment of the Top Management formally provided to the team. This includes the assessment of funds, manpower and their deployment at the appropriate time.
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RISK ASSESSMENT
APQP Requirements
- APQP Scope
If program is considered low risk or only minor changes are required, supplier may skip some elements, such as:
- Existing control plans may be used - Packaging evaluations may not required
Team must conduct a risk assessment as soon as possible to determine if all elements in the APQP process must be completed.
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- Customer Inputs
Customer may require all APQP elements to be completed
Customer must agree to all deviations from the APQP process
If it is agreed that an element is not required, supplier should formally record this status
- Subcontractor APQP Status
The supplier performs risk assessment of potential subcontractors as initial step in evaluating subcontractor APQP status
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The Status reporting should cover the following hierarchy:
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Vehicle Review
Feature of the Status Report
Give an overview of plan vs achievement Identify critical success factors Identify potential threats to fulfillment of objectives Determine any resources to be provided to expedite the progress Facilitates communication to all concerned Facilitates the next process to be ready for their side of the activity Provides a reference for tracking for future use Provide assurance that all activities are considered in advance Provide a basis for approving change to the timing, content, scope, etc.
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OBJECTIVES
Develop design features and characteristicsCritically review engineering requirementsAssess potential manufacturing problems
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Design goalsReliability and quality goalsPreliminary bill of materialPreliminary process flow chartPreliminary listing of special product and process characteristicsProduct assurance planManagement support
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OUTPUTS BY DESIGN RESPONSIBLE ACTIVITY
DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA)
OBJECTIVES
A Design FMEA is an analytical technique utilized by a Design Responsible Engineer/Team to ensure that potential failure modes and associated causes/mechanisms have been considered and addressed. The Design FMEA supports the design process in reducing risk of failures by :
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- Aiding in design requirements and design alternatives- Aiding in initial design for manufacturing and assembly
requirements- Ensuring that potential failure modes and their effects have been
considered in the design/development process- Exposing design deficiencies- Providing additional information which will be useful in planning thorough and efficient design test and development processes- Ensuring Design controls are effective in highlighting potential
threats- Detecting potential failure modes, and listing and ranking them according to their effect on customer- Providing an open issue format for recommending and tracking
risk actions- Providing future reference for analysing concerns, evaluating
design changes, and developing advanced designs.
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• The Design FMEA should not relay on the process controls to overcome the potential design weaknesses but should take into account the limitations of the manufacturing process.
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PROGRAM MANAGEMENT RESPONSIBILY
Program Management Responsibility is to ensure that :- A design responsible cross-functional team develops the DFMEA- The DFMEA is prepared using a customer approved manual- Campaigns, recalls, user plant concerns, similar part DFMEAs, things gone wrong,
and warranty data are addressed during DFMEA development- Every component design function is included in the DFMEA- Failure modes are described in physical, technical and measurable terms- Effects of failure address the effect on each part, next higher assembly system,
vehicle, customer wants, and government regulations- Corrective actions, responsibilities, and completion dates are addressing high
severity numbers and high risk priority numbers.- Risk priority numbers are revised to quantify the impact of corrective actions.- Potential special product characteristics are considered in the FMEA- Potential causes of failure are identified for all failure modes.
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Design for Manufacturibility and Assembly is a simultaneous engineering Process design to optimise the relationship between design function,manufacturibility and ease of assembly.
Customer needs and expectations will determine the extent of the APQP. Team involvement in this activity.
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DESIGN VERIFICATION
OBJECTIVETo ensure that the Design Output meets the Design Input requirementsTo develop a Design Verification Plan
DESIGN VERIFICATION PLANThe Design Verification Plan is a single document containing both the TestPlan and the Test report
The Test Plan itemizes all tests necessary to assure that functional and reliability criteria and target requirements are met and specifies :
- Test responsibility- Test quantities- Timing requirement- Acceptance Criteria
The Test Report provides test results and progress made toward design targets specified by the Test Plan
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USES
The Design Verification Plan is a working document to aid engineering Personnel in :
Development of thoroughly planned tests needed to assure that the Component or system meets all engineering requirements
Ensuring that product reliability meets customer-driven objectives
Indicating situations where customer timing requires an accelerated test Plan
Summarizing functional, durability, and reliability testing requirements in one document
Providing easily prepared test status and progress reports for Design Reviews
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PROGRAM MANAGEMENT RESPONSIBILITY
Program Management Responsibility is to ensure that : A cross-functional team is formed for the completion of the design verification
plan. Specified tests, methods, equipment, acceptance criteria, samples sizes, design
level, and timing are clearly documented in the design verification plan Tests include variation within tolerance on product characteristics selected by the
team The design verification plan includes testing environmental aging, dimensional
wear and material fatigue The plan includes testing the useful life of the product The plan includes testing the effects of the external environment (climate road
surface conditions, etc.,) The plan includes testing the effects of the internal environment created
neighboring subsystems The plan includes testing of the physical interfaces between components or
systems The plan includes testing that detect a failure using variables data. Note: A failure is significant – partial, degraded, intermittent, or total product failure. The team agrees on the definitions of failure and success The plan includes documentation and reaction processes when product failure
distribution design and reliability goals are not met.
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DESIGN REVIEWS
OBJECTIVES
Design Reviews are regularly scheduled meetings led by engineering and are intended to prevent problems and misunderstandings and to monitor the progress of design activities and report to management.Design Reviews are more than engineering inspection; they are evaluations of :
Design/functional requirement considerations Formal reliability and confidence goals Component / subsystem / system duty cycles Computer simulation and bench test results DFMEAs Review for the Design for Manufacturibility and Assembly effort Design of Experiments (DOE) and assembly build variation results Test failures Design Verification progress Safety Concerns
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PROGRAM MANAGEMENT RESPONSIBILITY
Program Management Responsibility is to ensure that :
Design feasibility concerns are resolved in time Issues brought up in the Design Verification Plan and Sign off
Report are addressed Issues brought up in the APQP Status Report are addressed Issues regarding reliability, quality, cost, Safety and timing are
Identified
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PROTOTYPE BUILD – CONTROL PLAN
OBJECTIVES
Prototype Control Plan describes the controls to be ensured during the Prototype build stage. These could include the dimensional measurements, materials and functional tests that will occur during prototype build
The Prototype Control Plan evolves into the Production Control Plan It is used to measure the preliminary capability of “potential” special
characteristics identified during the Design FMEA process It supplies information to the manufacturing / assembly about the type of
controls expected Specific requirements and supporting data such as P.I.P.C.% (Percent
indicates that are process capable) and P.I.S.T (percent of inspection points that satisfy tolerance) may be required to support prototype vehicle evaluations.
Prototypes should be manufactured using production equipment when possible.
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PROGRAM MANAGEMENT RESPONSIBILITY
Program Management Responsibility is to ensure that :
- A cross – functional team is used to complete the Prototype-Build Control Plan
- The team reviews all product characteristics, identifies prototype requirements, and obtains Design Engineering approval
- Potential special characteristics are clearly identified on the Control Plan
- Inspection plans are developed for all material and engineering specifications
- Gages and test equipment used for the prototype are identified on the Prototype Control Plan
- Gages and test equipment must be accurate, discriminate, repeatable and reproducible
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- The control plan includes documented measurement procedures, techniques and datums
- The reaction plan clearly states that all nonconformance and repairs require customer authorization
- The customer has the opportunity to approve Prototype Control Plan
- Prototype processes that are different from production are identified on the Prototype Control Plan
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ENGINEERING DRAWINGS SPECIFICATIONS MATERIALSPECIFICATIONS AND DRAWINGS 7 SPECIFICATION
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OBJECTIVES
Drawings and specifications cover all engineering drawings, CAD Data, Material specifications, and engineering specifications
Customer designs do not preclude the planning team’s responsibility to review engineering drawings
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- Engineering drawings may include drawings special (governmental regulatory and safety) characteristics that must be shown on the control plan
- When customer engineering drawings are nonexistent, supplier drawings should be reviewed by the planning team to determine which characteristics affect fit, function, durability and / or governmental regulatory safety requirements.
- Drawings should be reviewed to determine if there is sufficient information for a dimensional layout of the individual parts
- Control or datum surfaces / locators should be clearly identified so that appropriate functional gages and equipment can be designed for ongoing
controls.- Dimensions should be evaluated to assure feasibility and compatibility with
industry manufacturing and measuring standards.- Team should assure that math data is compatible with customer’s system
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SPECIAL PRODUCT AND PROCESS CHARACTERISTICS
The Product Quality Planning Team should review the preliminary
special product and process characteristics list and reach a consensus during development and design.
The consensus should be documented on the Control Plan- The supplier can use any form that accomplishments
the same documentation requirements The customer may have unique approval requirements
Note : Refer to Chrysler, Ford and General Motors Quality System Requirements Section II
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OR
MA
NU
FA
CT
UR
AB
ILIT
Y A
ND
A
SS
EM
BL
Y
60.
IFB APLIFB APL 31/10/0631/10/06
PROGRAM MANAGEMENT RESPONSIBILITY
Program Management Responsibility ensures that :
The customer has been given Program Need Dates Drawings and specifications include engineering specifications
tests and Product Validation Test requirements, and are documented in time for the Pre-Launch Control Plan development
Major feasibility are resolved prior to the Production Trial Run The supplier’s or subcontractor’s material has been approved.
DE
SIG
N F
OR
MA
NU
FA
CT
UR
AB
ILIT
Y A
ND
A
SS
EM
BL
Y
61.
IFB APLIFB APL 31/10/0631/10/06
OUTPUTS BY PRODUCT QUALITY PLANNING TEAM
NEW EQUIPMENT TOOLING. GAGES/TESTING AND FACILITIES REQUIREMENTS
OBECTIVES
To ensure the facilities, tools and gages requirements are identified, procured, and proven-out in time to meet program need dates. The DFMEA activity considerations and / or Design Reviews may identify new equipment and facilities requirements.
Product APQP should add these items to the Timing Chart Team should ensure that the new equipment, gages and
tooling is capable and can be delivered on time. Facilities progress should be monitored to assure completion
before Planned production tryout.
DE
SIG
N F
OR
MA
NU
FA
CT
UR
AB
ILIT
Y A
ND
A
SS
EM
BL
Y
62.
IFB APLIFB APL 31/10/0631/10/06
PROGRAM MANAGEMENT RESPONSIBILITY
Program Management Responsibility is to ensure that :
The product quality timing plan includes facilities, permits, planning,approval, drawing and utilities.
Funding approval is complete Tooling, equipment, and gages have been sourced with
statistical requirements. Acceptance criteria has been agreed upon Tooling and equipment comply with TE-9000 requirements (as
appropriate) There is a trial run at the machine builder’s location to qualify
equipment, Tooling and gages. Corrective Actions for all gages and tooling that do not meet
customer Requirements must be completed prior to the production trial run.
DE
SIG
N F
OR
MA
NU
FA
CT
UR
AB
ILIT
Y A
ND
A
SS
EM
BL
Y
63.
IFB APLIFB APL 31/10/0631/10/06S
PE
CIA
L P
RO
DU
CT
& P
RO
CE
SS
C
HA
RA
CT
ER
IST
IC OBJECTIVES
To identify the Special Product & Process CharacteristicsTo ensure that they are adequately reviewed through FMEA and addressed in Control PlansTheir Designation is consistent with the supplier’s system and Customer’sExpectations
PROGRAM MANAGEMENT RESPONSIBILITY
The product Quality planning team ensures the timely identification & review of these characteristics
The relevant documents where they have to be identified are reviewed Their designation symbols are consistent with the supplier’s system There is an assessment of potential risks with these characteristics and
corrective actions are initiated in advance through Statistical Studies, Mistake proofing, etc.
64.
IFB APLIFB APL 31/10/0631/10/06T
EA
M F
EA
SIB
ILIT
Y C
OM
MIT
ME
NT
&
MA
NA
GE
ME
NT
SU
PP
OR
T OBJECTIVES
The Advanced Product Quality Planning Team must assess the feasibility of manufacturing the proposed design.
Customer design ownership does not preclude the supplier’s obligation to assess design feasibility
The team must be satisfied that proposed design is fir for its intended use and meets customer expectations, including:
- Time schedules- Testing requirements- Packaging requirements- Delivery requirements- Cost objectives- Quality Objectives
Suppliers must also assess risk and determine which of their subcontractor must do a feasibility assessment. Suppliers that affect special characteristics must do a feasibility assessment.
65.
IFB APLIFB APL 31/10/0631/10/06
PROGRAM MANAGEMENT RESPONSIBILITY
Program Management Responsibility ensures that :
The team agrees that the proposed design is suitable for its intended use and can be manufactured, assembled, tested, packaged, and delivered in sufficient quantity and acceptable cost and quality on schedule
Suppliers have completed risk assessment and determined which suppliers will do a feasibility assessment
The team provides a feasibility document to the customer
TE
AM
FE
AS
IBIL
ITY
CO
MM
ITM
EN
T &
M
AN
AG
EM
EN
T S
UP
PO
RT
66.
IFB APLIFB APL 31/10/0631/10/06P
RO
CE
SS
DE
SIG
N &
DE
VE
LO
PM
EN
T
OBJECTIVESDevelop design features and characteristicCritically review engineering requirementsAssess potential manufacturing problems
INPUTS
Design goals Reliability and quality goals Preliminary process flow chart Preliminary listing of special product and process characteristics Product assurance plan Management support Customer requirement ( special ch., identification, traceability,etc) Use of information targets for product quality, life, reliability, durability, maintainability,
timing and cost )
67.
IFB APLIFB APL 31/10/0631/10/06
OUTPUTS
PACKAGING STANDARDS
This is applicable if the customer has any packaging standards to be incorporated.If not, the design of packaging should ensure product integrity at the point of use.
PR
OC
ES
S D
ES
IGN
& D
EV
EL
OP
ME
NT
68.
IFB APLIFB APL 31/10/0631/10/06P
RO
DU
CT
& P
RO
CE
SS
QU
AL
ITY
S
YS
TE
M R
EV
IEW
OBJECTIVES
To ensure that the existing Quality System can meet the requirements of the new product
To identify the system modification, additions to be done for meeting the Quality Assurance requirements
PROGRAM MANAGEMENT RESPONSIBILITY
To ensure that the team activity considers this element and it is timed The responsibility for review of the system is defined The review considers all aspects of the Quality System (Ref: ISO
9000/QS 9000) The identification of new/modified documents, resources, training, etc.
are completed on time and action initiated for their completion
69.
IFB APLIFB APL 31/10/0631/10/06P
RO
CE
SS
FL
OW
CH
AR
T
OBJECTIVES
To ensure that all operations of a manufacturing flow have been graphically shown to show the direct and alternate paths of production
Customer requirements, in the form of product characteristics, are mapped to the affected operations.
Sources of variation and process characteristics are considered at each operation
A comprehensive Process Flow Chart provides the foundation for the development of an effective Process FMEA and Control Plan.
70.
IFB APLIFB APL 31/10/0631/10/06
SOURCES
Customer Prints In-Process Prints Plant Layout Problems reports and Logs System and / or Design FMEA Process FMEA from a similar product or process
Note: The Process flowchart and the appropriate updates to the Floor Plan shall be completed at this level. Other documents that will be partially or fully completed at the same time as the Process Flowchart include the following :
Floor Plan Characteristics Matrix (optional) List of Special Product and Process Characteristics Process flow In-process prints
EXERCISE 6 :
PR
OC
ES
S F
LO
W C
HA
RT
71.
IFB APLIFB APL 31/10/0631/10/06F
LO
OR
PL
AN
LA
YO
UT
OBJECTIVES
The Floor plan should be developed and reviewed to determine the acceptability of inspection points, control chart location, applicability of visual aids, interim repair stations and storage areas to contain defective material.
It can be also used for evaluating the ergonomics factors, requirements for Reduced material travel, etc
72.
IFB APLIFB APL 31/10/0631/10/06C
HA
RA
CT
ER
IST
IC M
AT
RIX Characteristics Matrix :
Displays the relationship between product/process characteristics and the operations of the process
Identified the impacts operations have on characteristics Identifies the impacts that characteristics have on each other Provides criteria for assessing importance levels of
characteristics Indicates where common tooling is used.
73.
IFB APLIFB APL 31/10/0631/10/06
THE BASIC STEPS IN CONSTRUCTING THE CHARACTEISTICS MATRIX
List all the characteristics in order on the top row of the matrix List all the operations in order by OP# on the left column of the matrix Place a relationship symbols in interior cells in the Matrix RELATIONSHIP
SYMBOLS
Using the following symbols indicates the relationships between operations and characteristics
* Indicates a characteristic is cut or changedC Indicates a characteristic is used for clampingL Indicates a characteristic is used for location in a subsequent OperationA Affects a subsequent operation or other characteristicT Indicates relationships within an operation, such as common tools or tool headM Characteristic is automatically monitored
CH
AR
AC
TE
RIS
TIC
MA
TR
IX
74.
IFB APLIFB APL 31/10/0631/10/06P
FM
EA PROCESS FAILURE MODE AND EFFECTS ANALYSIS (PFMEA)
OBJECTIVESThe primary objective of the Process Failure Mode Effects Analysis (PFMEA) is to reduce manufacturing risk by :
Aiding in the analysis of new manufacturing and assembly processes Assuring that potential manufacturing and / or assembly process failure modes
and effects are considered. Identifying process deficiencies and provide for the development of controls to
resolve the problems by : - Eliminating or reducing the frequency of unacceptable products - Increasing the detection of unacceptable products
Identifying critical characteristics and significant characteristics contributing to the development of a complete manufacturing control plan
Establishing priorities for process improvement activities Providing automatic process design documentation to guide the development
of future manufacturing and assembly processes.
75.
IFB APLIFB APL 31/10/0631/10/06
Note : Output from the PFMEA is used as a basis for :
Control Plan developmentPreliminary Process Capability Study Plan developmentFinalisation of special product and process characteristicsDevelopment of Process and monitoring instructionsP
FM
EA
76.
IFB APLIFB APL 31/10/0631/10/06
SOURCES
The data or reference documents that should be utilised by the cross-functional team to help develop the PFMEA include :
Process FMEA AIAG Reference ManualCharacteristics MatrixWarranty informationCustomer Complaints and Returns DataCorrective or Preventive ActionsProcess Flow ChartSystem and / or Design FMEAPFMEA for similar products or processesInternal Quality Reports
PF
ME
A
77.
IFB APLIFB APL 31/10/0631/10/06
PROGRAM MANAGEMENT RESPONSIBILITY
The Team Leader and APQP team should manage the construction of the processFMEA and assess the finished document to ensure that the following expectationsare met :
The PFMA is developed on or before the Program Need Date A cross functional team has been formed to assist in the development of the
PFMEA Appropriate data have been identified that shall be used by the team to develop
the PFMA. Some forms of data for a similar product or process might include:- Warranty information- TGW data- Corrective or preventive actions- A list of current error proofing techniques used for similar processes- Higher assembly of component processes- FMEAs from similar product- Other data that would help assist the group better understand and assess the process
PF
ME
A
78.
IFB APLIFB APL 31/10/0631/10/06
The appropriate PFMEA is chosen Failure modes are quantifiable The effects on all customers are considered Causes are identified that point to process deficiencies Risk has been assessed and reduced to acceptable levelsP
FM
EA
79.
IFB APLIFB APL 31/10/0631/10/06P
RE
-LA
UN
CH
CO
NT
RO
L P
LA
N
OBJECTIVES
To ensure that a written plan for controlling all parts and process after prototype and before full production is documented.
The plan should include :
- All operations listed on the Process Flow Chart.- The machine jig or tooling- Product and process characteristics- Designation of special characteristics- Specifications or tolerances- Gaging or evaluation techniques- Sample sizes and frequency- Control methods- Reaction instruction at each stage of production
80.
IFB APLIFB APL 31/10/0631/10/06
The Pre-launch Control Plan will be similar to the Production Control Plan but should include greater sampling for certain characteristics to reflect the initial capability studies (Ppk) and audits to validate that the process is robust.
A full layout inspection will normally be performed at this stage and then yearly or as specified by the customer.
Note : The Pre-Launch Control Plan is used as input for finalizing:- Measurement System Analysis Plans- Operator Process and Monitoring Instructions- Reaction Plan- Preliminary Process Capability Study Plan
PR
E-L
AU
NC
H C
ON
TR
OL
PL
AN
81.
IFB APLIFB APL 31/10/0631/10/06
SOURCES
The data or inputs that will be used to develop the Pre-launch Control Plan may include some or all of the following. This data will be reviewed By the cross-functional team during their meetings.
Advance Product Quality Planning and Control Plan AIAG Reference Manual Customer Prints Inspection Plans and Sampling Frequency Work Instructions for similar parts or processes List of special characteristics List of Machines, tools, Jigs or Fixtures List of Gaging with data showing calibration, discrimination, accuracy,
repeatability and reproducibility Performance Testing Requirements Design Reviews Optimisation Data (e.g., QFD, DOE, etc.,) Process Flow Chart System and / or Design FMEA Process FMEA
PR
E-L
AU
NC
H C
ON
TR
OL
PL
AN
82.
IFB APLIFB APL 31/10/0631/10/06
PROGRAM MANAGEMENT RESPONSIBILITY
The Team Leader and APQP Team should manage the construction of the Production Control Plan and assess the finished document to ensure that the following expectations are met :
A cross-functional team to assist in the development of the Control Plan
All operations and special characteristics are included on the Control Plan
Recommended actions from the PFMEA are incorporated in the Control Plan
Sampling plans are included as defined by customer requirements Sampling Plans for Ppk studies for Special Characteristics are
included on the Control Plan Work Instructions for setup, operation, testing, inspection, SPC and
reaction are indicated on the Control Plan The Production Control Plan identifies all qualified measurement and
test equipment
PR
E-L
AU
NC
H C
ON
TR
OL
PL
AN
83.
IFB APLIFB APL 31/10/0631/10/06
The customer is given the opportunity to approve the Control Plan Tests and measurements for PPAP approval are included on the
Control Plan Instructions are defined for all material and engineering specifications Only rational sampling plans are used. Control methods are defined to produce only acceptable product output Control methods should focus on :
- meeting all customer requirements- process control rather than product control- prevention rather than detection- targeting nominal rather than specification limits- error proofing rather than inspection- managing the control method
PR
E-L
AU
NC
H C
ON
TR
OL
PL
AN
84.
IFB APLIFB APL 31/10/0631/10/06
Process data have been used to confirm cause and effect relationships between product and process characteristics. The PFMEA should be a primary tool for exposing process deficiencies and potential product/ process relationships.
The Production Control Plan and PFMEA are consistent in defining current process controls
PR
E-L
AU
NC
H C
ON
TR
OL
PL
AN
85.
IFB APLIFB APL 31/10/0631/10/06P
RO
CE
SS
IN
ST
RU
CT
ION
S
OBJECTIVES
To ensure that documented instructions are available at all operations where the absence of such instructions could adversely affect quality. Instructions shall include specific information that describes in a step-by-step fashion ‘how to’ perform an activity.
Instructions provide all the required information to perform a job and shall be referenced by an operator for a number of different circumstances required on-the-job Work Instructions shall be referenced by the Control Plan.
86.
IFB APLIFB APL 31/10/0631/10/06
OPERATING INSTRUCTIONS
• After ensuring setup, follow Quality Check Sheet Instructions• Follow Process Parameter Log Instructions• Change tool as indicated on Control Plan• Follow SPC Instruction as noted on control plan and quality check sheet• Master Gages per frequency indicated on control plan
REACTION INSTRUCTIONS
If Non-Conforming material is detected.
• Stop Process• Isolate Non-conforming Material. Place in proper Quarantine Area• Correct Problem• Inform Supervisor if problem persists
Note all out of control conditions on control chart (only for charted Characteristics)
PR
OC
ES
S I
NS
TR
UC
TIO
NS
87.
IFB APLIFB APL 31/10/0631/10/06M
EA
SU
RE
ME
NT
SY
ST
EM
E
VA
LU
AT
ION
PL
AN
OBJECTIVES
A plan must exist for the evaluation of measurement devices and methods specified in the Control Plan to ensure gage linearity, accuracy, repeatability, reproducibility, and correlation (for duplicate gages)
88.
IFB APLIFB APL 31/10/0631/10/06P
RE
LIM
INA
RY
PR
OC
ES
S
CA
PA
BIL
ITY
ST
UD
Y P
LA
N
OBJECTIVES
To ensure that there is a plan for conducting the Process Capability Study for characteristics identified as Special Characteristics. This plan should include the methodology to be adopted, the responsibility, the timing etc.
Appropriate training needs have to be identified and the measurement systems to be used are covered under Measurement Systems Analysis plan.
89.
IFB APLIFB APL 31/10/0631/10/06P
AC
KA
GIN
G E
VA
LU
AT
ION OBJECTIVES
To ensure that individual product packaging (including interior partitions) is designed and developed.
PROGRAM MANAGEMENT RESPONSIBILITY
Manage and assess packaging design and evaluation to ensure meeting theFollowing expectations:
Packaging requirements will be agreed upon by the supplier and the customer
The packaging design must assure that the product performance and characteristics will remain unchanged during packing, shipping and unpacking
Packaging evaluations must test the packaging under the expected conditions of transport and material handling. (Customer-specified packaging does not preclude Advance Product Quality Planning Team involvement in evaluating the packaging method.)
90.
IFB APLIFB APL 31/10/0631/10/06P
RO
DU
CT
& P
RO
CE
SS
VA
LID
AT
ION OBJECTIVES
Validate the manufacturing process Ensure that customer expectations will be met Identify additional concerns
INPUTS 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 instruction Measurement Systems Analysis Plan Preliminary process capability study plan Packaging specification Management support
91.
IFB APLIFB APL 31/10/0631/10/06P
RO
DU
CT
ION
TR
IAL
RU
N
OBJECTIVES
To ensure the effectiveness of the manufacturing process, using production Tooling, equipment, environment (including production operators), facilities and cycle times.
PROGRAM MANAGEMENT RESPONSIBILITY
Manage and assess the production trial run to ensure meeting the following expectations :
The pre-launch control plan is followed during the production trial run.
The trial run must be used to confirm or add linkages between product and process characteristics.Note : Linkages should be captured in the PFMEA.
Corrective design and process actions must be established for concerns
identified during the trial run.
92.
IFB APLIFB APL 31/10/0631/10/06
OUTPUT
Production Part Approval Preliminary Process capability Study Measurement Systems Evaluation Final Feasibility Process Review (feedback to process flow and Process
FMEA, input to Production Control Plan) Production Validation Testing Packaging Evaluation First Time Capability (FTC) Quality Planning sign-off
PR
OD
UC
TIO
N T
RIA
L R
UN
93.
IFB APLIFB APL 31/10/0631/10/06M
EA
SU
RE
ME
NT
SY
ST
EM
E
VA
LU
AT
ION
The study should be done as per the Plan defined in Process Design & Development. This study should address all the Measurement Systems listed in the Control plan and the measurement systems used for SPC.
94.
IFB APLIFB APL 31/10/0631/10/06P
RE
LIM
INA
RY
PR
OC
ES
S
CA
PA
BIL
ITY
ST
UD
Y
OBJECTIVES
To ensure the determination of an acceptable level of process capability for all characteristics designated by the customer or supplier as Special Characteristics, prior to part submission.
To provide a statistical assessment of the readiness of the process for production prior to program launch to determine if the production process is likely to produce product that will meet the customer’s requirements.
95.
IFB APLIFB APL 31/10/0631/10/06
PROGRAM MANAGEMENT RESPONSIBILITY
Manage and assess the Preliminary Process Capability Study to ensure meeting the following expectations :
All special characteristics must be studied and have Pp and Ppk >1.67.
Statistical and analytical techniques used to determine capability must be acceptable to the customer.
Preliminary capability studies must be performed as documented in the pre-launch control plan
Preliminary capability studies must be completed and the customer given the opportunity for review prior to Production Part Approval.
PR
EL
IMIN
AR
Y P
RO
CE
SS
C
AP
AB
ILIT
Y S
TU
DY
96.
IFB APLIFB APL 31/10/0631/10/06P
RO
DU
CT
ION
PA
RT
AP
PR
OV
AL
P
RO
CE
SS
PRODUCTION PART APPROVAL PROCESS (PPAP)
OBJECTIVES
To ensure there is documented verification that all customer the supplier meets engineering design requirements and the process has the potential to produce to these requirements during an actual production run.
To validate that the products made from the production tools and processes meet the engineering requirements.
To ensure that all the requirements mentioned in PPAP manual are adhered to.
97.
IFB APLIFB APL 31/10/0631/10/06P
RO
DU
CT
ION
VA
LID
AT
ION
T
ES
TIN
G OBJECTIVES
To ensure that products made from production tools and processes meet engineering standards
PROGRAM MANAGEMENT RESPONSIBILITY
Manage and assess production validation testing to ensure meeting the following expectations:
Parts for testing must be selected from the production trial run per the sample sizes and frequencies outlined in the pre-launch control plan
All customer specified dimensional, material, functional and reliability tests must be completed prior to production part approval
For tests not completed prior to production part approval, appropriate action plans and customer approvals are required.
98.
IFB APLIFB APL 31/10/0631/10/06P
AC
KA
GIN
G E
VA
LU
AT
ION
OBJECTIVES
To ensure that the packaging material meets both the specification requirements and the performance requirements.
The packaging material in full packaged condition is tested in conditions that resemble the conditions of use and / or tested in actual user conditions.
The program should allow appropriate timing for completion of this activity.
Feedback received from this stage should be used for modifying the packaging specifications.
99.
IFB APLIFB APL 31/10/0631/10/06P
RO
DU
CT
ION
CO
NT
RO
L P
LA
N
OBJECTIVES
To ensure that a comprehensive plan for controlling all parts and processes before full production is documented.
The plan includes all operations listed on the Process Flow Chart, including :
- The machine jig or tooling- Special product and process characteristics- Designation of special characteristics- Specification or tolerances- Gaging or evaluation techniques- Sample sizes and frequency- Control method and reaction instructions at each stage of
production.
100.
IFB APLIFB APL 31/10/0631/10/06
SOURCES
The data or inputs that will be used to develop the Pre-launch Control Plan may include some or all of the following. This data will be reviewed by the cross-functional during their meetings.Advanced Product Quality Planning and Control Plan AIAG Reference ManualCustomer PrintsIn-process PrintsCustomer and Internal SpecificationsInspection Plans and Sampling FrequencyWork Instructions for similar parts or processesList of Special CharacteristicsList of Machines, tools, Jigs or FixturesList of Gaging with data showing calibration, discrimination, accuracy, repeatability and reproducibilityPerformance Testing RequirementsDesign ReviewsOptimisation Data (e.g, QFD, DOE etc.,)Process Flow ChartSystem and / or Design FMEAProcess FMEAP
RO
DU
CT
ION
CO
NT
RO
L P
LA
N
101.
IFB APLIFB APL 31/10/0631/10/06
PROGRAM MANAGEMENT RESPONSIBILITY
The Team Leader and APQP Team should manage the construction of the Production Control Plan and assess the finished document to ensure that the following expectations are met :
A cross-functional team to assist in the development of the Control Plan All operations and special characteristics are included on the Control Plan Recommended actions from the PFMEA are incorporated in the Control Plan Sampling plans are included as defined by customer requirements Sampling Plans for Ppk studies for Special Characteristics are included on the
Control Plan Work Instructions for setup, operation, testing, inspection, SPC and Reaction are
indicated in the Control Plan The Production Control Plan identifies all qualified measurement and test
equipment The customer is given the opportunity to approve the Control Plan Tests and measurements for PPAP approval are included on the Control Plan Instructions are defined for all material and engineering specifications Only rational sampling plans are usedP
RO
DU
CT
ION
CO
NT
RO
L P
LA
N
102.
IFB APLIFB APL 31/10/0631/10/06
Control methods are defined to produce only acceptable product output Control methods should focus on :
- meeting all customer requirements- process control rather than product control- prevention rather than detection- targeting nominal rather than specification limits- error proofing rather than inspection- managing the control method
Process data have been used to confirm cause and effect relationships between product and process characteristics. The PFMEA should be a primary tool for exposing deficiencies and potential product/ process relationships.
The Production Control Plan and PFMEA are consistent in defining current process controls
PR
OD
UC
TIO
N C
ON
TR
OL
PL
AN
103.
IFB APLIFB APL 31/10/0631/10/06Q
UA
LIT
Y P
LA
NN
ING
SIG
N-O
FF
&
MA
NA
GE
ME
NT
SU
PP
OR
T
OBJECTIVES
The APQP team should review all the activities have been successfully completed and make a formal sign-off. Management support is necessary prior to the quality planning sign-off.
104.
IFB APLIFB APL 31/10/0631/10/06C
ON
TIN
UO
US
IM
PR
OV
EM
EN
T
FEEDBACK, ASSESSMENT & CORRECTIVE ACTIONS
OBJECTIVES
Obtain objective feedback for future planning To plan the next phase of product development or
modification To improve the system of planning (from lessons learnt) To identify opportunities for Improvement
105.
IFB APLIFB APL 31/10/0631/10/06
INPUTS
Production trial runMeasurement systems evaluationPreliminary process capability studyProduction part approvalProduction validation testingPackaging evaluationProduction control planQuality planning sign-off and management support
CO
NT
INU
OU
S I
MP
RO
VE
ME
NT
106.
IFB APLIFB APL 31/10/0631/10/06
OUTPUTS
REDUCED VARIATION
Control charts and other statistical techniques should be used as tools to identify process variation. Analysis and corrective actions should be used to reduce variation. Continual improvement required attention not only to the special causes of variation but understanding common causes and seeking ways to reduce these sources of variation. Proposals should be developed including costs, timing, and anticipated improvement for customer review. Often the reduction or elimination of a common cause results in lower costs. Suppliers should not be reluctant to prepare proposals based on value analysis, reduction of variation, etc., The decision to implement, negotiate, or progress to the next product design level is the customer’s prerogative.CO
NT
INU
OU
S I
MP
RO
VE
ME
NT
107.
IFB APLIFB APL 31/10/0631/10/06
CUSTOMER SATISFACTION
Detailed planning activities and demonstrated process capability of a product or service do not always guarantee customer satisfaction. The product or service must perform in the customer environment. The product usage stage required supplier participation. It is in this stage where the most can be learned by both the supplier and customer. The effectiveness of the Product Quality Planning efforts can be evaluated in this stage. The supplier and customer must be partners in making the changes necessary to correct deficiencies to achieve customer satisfaction.
CO
NT
INU
OU
S I
MP
RO
VE
ME
NT
108.
IFB APLIFB APL 31/10/0631/10/06
DELIVERY AND SERVICE
The delivery and service stage of quality planning continues the supplier/customer partnership in solving problems and continual improvement. The customer’s replacement and service operations always merit the same consideration in quality, cost and delivery. Failure to correct a problem the first time always damages the supplier’s reputation and customer partnership. It is important that both and supplier and customer listen to the Voice of the Customer. The experience gained in this provides the customer and supplier with the necessary knowledge to recommend price reductions achieved by reducing process, inventory, and quality costs to provide the right component or system for the next product.
CO
NT
INU
OU
S I
MP
RO
VE
ME
NT
109.
IFB APLIFB APL 31/10/0631/10/06
PPAPProduction part approval process 3rd Edition 1999Production part approval process 4th Edition 2006
110.
IFB APLIFB APL 31/10/0631/10/06
What is the purpose of PPAP?
To list all the activities in the form of process flow chart, review the failure modes and analyze the effects in terms of risk management.The top management involves on freezing the control mechanism.It also gives the transparency and confidence to the customer on the defined as well as the agreed procedures
111.
IFB APLIFB APL 31/10/0631/10/06
What is the purpose of PPAP?
To review the system of manufacturing the part or product and identifying the gaps with reference to the systems requirements.Less launching problems.No ambiguity during the running of the part on a long term basis.Approval on not only the part but the means of doing also.
112.
IFB APLIFB APL 31/10/0631/10/06
When To Submit PPAP:
A new part or material or Colour Correction of DiscrepancyProduct modified by an engineering change
113.
IFB APLIFB APL 31/10/0631/10/06
Significant Production Run:
A This can be run from one hour to eight hours of production with the specific production quantity to total minimum of 300 consecutive parts, unless otherwise specified by authorised customer representative.Significant production shall be conducted at the production site at the production rate using the production tooling, gauging, processes, materials and operators.
114.
IFB APLIFB APL 31/10/0631/10/06Retention / Submission Requirements
Sl No Requirements Level 1 Level 2Level
3Level
4Level 5
1 Design record R S S * R
2 Engineering Change Documents If any R S S * R
3 Customer Engineering Approval If Required R R S * R
4 Design FMEA R R S * R
5 Process Flow Diagram R R S * R
6 Process FMEA R R S * R
7 Control Plan R R S * R
8 Measurement System Analysis Studies R R S * R
9 Dimensional Results R S S * R
10 Material, Performance Test results R S S * R
11 Initial Process Studies R R S * R
12 Qualified Laboratory Documentation R S S * R
13 Appearance Approval Report S S S * R
14 Sample Product R S S * R
15 Master Sample R R R * R
16 Checking Aids R R R * R
17Records Of Compliance With Customer Specific requirements
R R S * R
18 Parts Submission Warrant S S S S R
115.
IFB APLIFB APL 31/10/0631/10/06
Approval Status
Approved – Indicates that the part or material including all sub assemblies meet customer requirements. Organisation is therefore authorised to ship production quantities of the product, subject to releases from the customer scheduling activity.Interim Approval – Permits shipment of material for production requirements on a limited time or piece quantity basis. Interim Approval only be granted when the organisation has clearly defined the non-compliances preventing approval and prepared an action plan agreed upon by the customer. PPAP re-submission is required to obtain a status of “Approved”.
116.
IFB APLIFB APL 31/10/0631/10/06
Approval Status
Rejected – The PPAP submission does not meet customer requirements, based on the production lot from which it was taken and accompanying documentation. In such cases the submission process, as appropriate, shall be corrected to meet customer requirements. The submission shall be approved before production quantities may be shipped.
117.
IFB APLIFB APL 31/10/0631/10/06
