Materi training APQP

38
Hendra Hendrasmara Industrial Battery Development Dept. 1 Advanced Product Quality Planning Cileungsi, 30 Sep 2014

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Pengenalan APQP

Transcript of Materi training APQP

Page 1: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.1

Advanced Product Quality Planning

Cileungsi, 30 Sep 2014

Page 2: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.2

APQP

• Memahami proses APQP

• Mengidentifikasi input dan output 5 phase APQP

• Memahami APQP sebagi methodology dalam

“new Product Development”

Page 3: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.3

30 Sep 2014 – by Hendra Hendrasmara

Page 4: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Advanced Product Quality Planning

APQP (Advanced Product Quality Planning)

adalah metode yang terstruktur mendefinisikan dan

menetapkan langkah-langkah yang dibutuhkan

untuk menjamin produk yang akan dihasilkan

memenuhi atau sesuai dengan keinginan

Customer.

4

Page 5: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Advanced Product Quality Planning

Apa itu Advanced ?

5

Control Plan

FMEA

SPC MSA

PPAP

Team Planning 5W 2H + Core Tools Implementation

Page 6: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Advanced Product Quality Planning

APQP dijelaskan dalam AIAG (Automotive Industry Action

Group) 810-358-3003.

Organisasi ini didirikan oleh visioner dari tiga produsen

otomotif Amerika Utara terbesar - Chrysler, Ford, dan

General Motors.

Keanggotaan AIAG telah berkembang dengan masuknya

perusahaan-perusahaan Jepang seperti Toyota, Honda dan

Nissan, dan part suppliers serta services providers mereka.

6

Page 7: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Advanced Product Quality Planning

7

Tujuan dari product quality planning adalah untuk

memfasilitasi komunikasi dengan semua orang

yang terlibat untuk memastikan bahwa langkah-

langkah yang diperlukan semua selesai tepat

waktu.

Perencanaan kualitas produk yang efektif

tergantung pada komitmen manajemen puncak

perusahaan untuk upaya yang diperlukan dalam

mencapai kepuasan pelanggan.

Page 8: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

APQP mengatur tahap-tahap perencanaan product (dan

proses manufaktur), mulai dari tahap konsep sampai

produksi massal.

Beberapa manfaat dari Product Quality Plan adalah:

• Mengatur Sumber Daya dalam upaya memenuhi

kepuasan Customer (persyaratan customer)

• Menghasilkan identifikasi awal terhadap kemungkinan

perubahan

• Menghindari adanya perubahan yang terlambat

• Menyediakan produk yang berkualitas tepat waktu dan

dengan cost yang serendah mungkin.

8

Advanced Product Quality Planning

Page 9: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

APQP dalam ISO/TS 16949

9

Phase Description Kalusul ISO/TS 16949

Phase 1 Plan define Program 7.3.1, 7.3.2, 7.3.2.1

Phase 2 Product Design and Development7.3.2.1, 7.3.2.3, 7.3.3, 7.3.3.1,

7.3.4, 7.3.4.1

Phase 3 Process Design and Development 7.3.2.2, 7.3.3.2, 8.2.3.1

Phase 4 Product and Process Validation 7.3.5, 7.3.6.3

Phase 5Feedback Assessment and

Corrective Action8.2.3.1

Page 10: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Tahap awal yang harus dibvangun oleh pemasok adalah

penetapan penanggung jawab untuk cross functional team.

Product Quality Planning yang efektif membutuhkan

keterlibatan seluruh perwakilan yang mencakup

engineering, manufacturing, material control, procurement,

quality, sales, pelayanan lapangan, serta subkontraktor dan

pelanggan yang terkait.

ORGANIZE THE TEAM

10

Dasar-dasar APQP

Page 11: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Hal ini penting untuk Product Quality Planning Team dalam

tahap awal perencanaan produk untuk mengidentifikasi

kebutuhan, harapan dan persyaratan pelanggan.

DEFINE THE SCOPE

11

Dasar-dasar APQP

• Pilih pemimpin tim proyek yang bertanggung jawab untuk mengawasi proses

perencanaan.

• Tentukan peran dan tanggung jawab masing-masing area yang diwakili.

• Mengidentifikasi pelanggan - internal dan eksternal.

• Tentukan kebutuhan pelanggan.

• Pilih ahli-ahli, individu, dan / atau subkontraktor yang harus ditambahkan ke tim.

• Memahami harapan pelanggan, yaitu, desain, sistem pengujian.

• Menilai kelayakan desain yang diusulkan, persyaratan kinerja dan proses manufaktur.

• Mengidentifikasi biaya, waktu, dan kendala yang harus diperhatikan.

• Tentukan bantuan yang diperlukan dari pelanggan.

• Mengidentifikasi proses dokumentasi atau metode.

Page 12: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Product Quality Planning Team harus membangun jalur

komunikasi dengan tim pelanggan dan tim pemasok lainnya.

Ini mungkin termasuk pertemuan rutin dengan tim lain.

Tingkat kontak tim-to-tim tergantung pada sejumlah isu yang

membutuhkan kesepakatan.

Team-to-Team

12

Dasar-dasar APQP

Page 13: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Keberhasilan Product Quality Plan tergantung pada program

pelatihan yang efektif untuk mengkomunikasikan semua

persyaratan dan pengembangan keahlian untuk memenuhi

kebutuhan dan harapan pelanggan.

Training

13

Dasar-dasar APQP

Page 14: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Pelanggan utama dapat memulai proses perencanaan

kualitas dengan pemasok. Namun, pemasok memiliki

kewajiban untuk membentuk tim lintas fungsional untuk

mengelola proses Product Quality Planning.

Pemasok harus mengharapkan kinerja yang sama dari

subkontraktor mereka.

Customer and Organization Involved

14

Dasar-dasar APQP

Page 15: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Simultaneous Engineering adalah proses di mana cross

functional team berusaha untuk mencapai tujuan bersama.

Tujuannya adalah untuk mempercepat pengenalan produk-

produk berkualitas lebih cepat. Product Quality Planning

team menjamin bahwa area lain / tim lain merencanakan

dan melaksanakan kegiatan yang mendukung tujuan

bersama.

Simultaneous Engineering

15

Dasar-dasar APQP

Page 16: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Control Plans adalah deskripsi yang tertulis untuk

mengendalikan part dan proses.

Terbagi dalam 3 phase :

• Prototype

Penjelasan mengenai pengukuran dimensi dan material, test performance yang akan

terjadi selama pembuatan Prototype.

• Pre-launch

Penjelasan mengenai pengukuran dimensi dan material, test performance yang akan

terjadi setelah Prototype dan sebelum mass Production.

• Production

Sebuah dokumentasi lengkap dari karakteristik produk / proses, kontrol proses, tes, dan

sistem pengukuran yang akan terjadi selama produksi massal.

Control Plans

16

Dasar-dasar APQP

Page 17: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.

Permasalahan-permasalahan yang terjadi selama proses

perencanaan harus didokumentasikan dalam matrik

penanggungjawab dan target waktu. Meminta rekomendasi

dari ahli sangat disarankan untuk masalah yang sulit.

Concern Resolution

17

Dasar-dasar APQP

Page 18: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.18

Dasar-dasar APQP

Product Quality Timing Plan

Plans Relative to the Timing Chart

Suksesnya sebuah program bergantung kepada kepuasan

pelanggan terutama waktu dan cost.

Tim perencana harus memastikan product qulity planning

bisa disesuaikan dengan harapan pelanggan

Keberhasilan program apapun tergantung pada pemenuhan

kebutuhan dan harapan pelanggan pada waktu yang tepat

dengan biaya yang sesuai.

Page 19: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.19

PLAN AND

DEFINE

PROGRAM

PRODUCT

DESIGN AND

DEVELOPMENT

VERIFICATION

PROCESS

DESIGN AND

DEVELOPMENT

VERIFICATION

PRODUCT

AND PROCESS

VALIDATION

FEEDBACK

ASSESSMENT AND

CORRECTIVE ACTION

PRODUCT QUALITY PLANNING TIMING CHART

ConceptInitiation/Approval

ProgramApproval Prototype

PLANNINGPLANNING

PRODUCT DESIGN AND DEV.

PROCESS DESIGN AND DEVELOPMENT

PRODUCT AND PROCESS VALIDATION

PRODUCTION

FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

Pilot Launch

Pro

ble

m

Time

Page 20: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.20

PLAN AND

DEFINE

PROGRAM

ConceptInitiation / Approval

ProgramApproval

PLANNING

1.0 PLAN AND DEFINE PROGRAM

INPUTS 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

Tujuan :

Menentukan kebutuhan pelanggan

Menentukan dan merencanakan

Program quality

• Voice of the Customer

• Market Research

• Historical Warranty and Quality Information

• Team Experience

• Business Plan/Marketing Strategy

• Product/Process Benchmark Data

• Product/Process Assumptions

• Product Reliability Studies

• Customer Inputs

Page 21: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.21

PRODUCT

DESIGN AND

DEVELOPMENT

VERIFICATION

ProgramApproval Prototype

PRODUCT DESIGN AND DEV.

2.0 PRODUCT DESIGN AND DEVELOPMENT

INPUTS OUTPUTS

• Design Failure Mode and Effects

Analysis (DFMEA)

• Design for Manufacturability 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

Requirements

• Team Feasibility Commitment and

Management Support

• 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

Tujuan :

Develop design features and characteristic

Review engineering requirement

Menilai masalah manufactur yang mungkin terjadi

Page 22: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.22

PROCESS

DESIGN AND

DEVELOPMENT

VERIFICATION

Prototype

PROCESS DESIGN AND DEVELOPMENT

Pilot

3.0 PROCESS DESIGN AND DEVELOPMENT

INPUTS OUTPUTS

• Packaging Standards

• Product/Process Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics Matrix

• Process Failure Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control Plan

• Process Instructions

• Measurement Systems Analysis

Plan

• Preliminary Process Capability

Study Plan

• Packaging Specifications

• Management Support

• Design Failure Mode

and Effects Analysis

(DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

Tujuan :

Mengembangkan proses manufactur

yang komprehensif dan efektif

Pastikan kapabilitas proses untuk

memenuhi kebutuhan pelanggan

Page 23: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.23

PRODUCT

AND PROCESS

VALIDATION

Prototype

PRODUCT AND PROCESS VALIDATION

Pilot Launch

4.0 PRODUCT AND PROCESS VALIDATION

Tujuan :

Validasi produk

Validasi control plan

Pastikan produk sesuai kebutuhan pelanggan

Identifikasi masalah

INPUTS OUTPUTS

• Production Trial Run

• Measurement Systems

Evaluation

• Preliminary Process

Capability Study

• Production Part

Approval

• Production Validation

Testing

• Packaging Evaluation

• Production Control

Plan

• Quality Planning Sign-

Off and Management

Support

• Packaging Standards

• Product/Process Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics Matrix

• Process Failure Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control Plan

• Process Instructions

• Measurement Systems Analysis

Plan

• Preliminary Process Capability

Study Plan

• Packaging Specifications

• Management Support

Page 24: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.24

PLANNING

PRODUCTION

FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

Pilot Launch

5.0 FEEDBACK ASSESMENT AND CORRECTIVE ACTION

FEEDBACK

ASSESSMENT AND

CORRECTIVE ACTION

• 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

• Reduced Variation

• Customer Satisfaction

• Delivery and Service

INPUTS OUTPUTS

Tujuan :

Mengevaluasi semua variasi (data variabel dan data attribut)

Mengevaluasi efektivitas Product quality planning

Penggunaan Control Plan dan Corrective action

Page 25: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.25

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 26: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.26

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 27: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.27

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer Inputs

INP

UT

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 28: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.28

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

INP

UT

OU

TP

UT

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 29: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.29

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

• Design Failure

Mode and Effects

Analysis (DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

INP

UT

INP

UT

OU

TP

UT

OU

TP

UT

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 30: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.30

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

• Design Failure

Mode and Effects

Analysis (DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

• Packaging

Standards

• Product/Process

Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics

Matrix

• Process Failure

Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control

Plan

• Process Instructions

• Measurement

Systems Analysis

Plan

• Preliminary

Process Capability

Study Plan

• Packaging

Specifications

• Management

Support

INP

UT

INP

UT

INP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 31: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.31

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

• Design Failure

Mode and Effects

Analysis (DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

• Packaging

Standards

• Product/Process

Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics

Matrix

• Process Failure

Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control

Plan

• Process Instructions

• Measurement

Systems Analysis

Plan

• Preliminary

Process Capability

Study Plan

• Packaging

Specifications

• Management

Support

• 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

INP

UT

INP

UT

INP

UT

INP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 32: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.32

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

• Design Failure

Mode and Effects

Analysis (DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

• Packaging

Standards

• Product/Process

Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics

Matrix

• Process Failure

Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control

Plan

• Process Instructions

• Measurement

Systems Analysis

Plan

• Preliminary

Process Capability

Study Plan

• Packaging

Specifications

• Management

Support

• 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

• Reduced Variation

• Customer

Satisfaction

• Delivery and

Service

INP

UT

INP

UT

INP

UT

INP

UT

INP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 33: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.33

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

• Design Failure

Mode and Effects

Analysis (DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

• Packaging

Standards

• Product/Process

Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics

Matrix

• Process Failure

Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control

Plan

• Process Instructions

• Measurement

Systems Analysis

Plan

• Preliminary

Process Capability

Study Plan

• Packaging

Specifications

• Management

Supportc

• 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

• Reduced Variation

• Customer

Satisfaction

• Delivery and

Service

INP

UT

INP

UT

INP

UT

INP

UT

INP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

FMEA

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 34: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.34

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

• Design Failure

Mode and Effects

Analysis (DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

• Packaging

Standards

• Product/Process

Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics

Matrix

• Process Failure

Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control

Plan

• Process Instructions

• Measurement

Systems Analysis

Plan

• Preliminary

Process Capability

Study Plan

• Packaging

Specifications

• Management

Support

• 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

• Reduced Variation

• Customer

Satisfaction

• Delivery and

Service

INP

UT

INP

UT

INP

UT

INP

UT

INP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

FMEA

APQP

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 35: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.35

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

• Design Failure

Mode and Effects

Analysis (DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

• Packaging

Standards

• Product/Process

Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics

Matrix

• Process Failure

Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control

Plan

• Process Instructions

• Measurement

Systems Analysis

Plan

• Preliminary

Process Capability

Study Plan

• Packaging

Specifications

• Management

Support

• 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

• Reduced Variation

• Customer

Satisfaction

• Delivery and

Service

INP

UT

INP

UT

INP

UT

INP

UT

INP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

FMEA

APQPSPC

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 36: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.36

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

• Design Failure

Mode and Effects

Analysis (DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

• Packaging

Standards

• Product/Process

Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics

Matrix

• Process Failure

Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control

Plan

• Process Instructions

• Measurement

Systems Analysis

Plan

• Preliminary

Process Capability

Study Plan

• Packaging

Specifications

• Management

Support

• 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

• Reduced Variation

• Customer

Satisfaction

• Delivery and

Service

INP

UT

INP

UT

INP

UT

INP

UT

INP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

FMEA

APQP

MSA

SPC

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 37: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.37

• Organize the

Team

• Define the Scope

• Establish Team-to-

Team

Communication

• Provide Core

Tools Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan Format

• Decide on

Concern Resolution

• Develop Product

Quality Timing Plan

• Voice of the

Customer

• Business

Plan/Marketing

Strategy

• Product/Process

Benchmark Data

• Product/Process

Assumptions

• Product Reliability

Studies

• Customer 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

• Design Failure

Mode and Effects

Analysis (DFMEA)

• Design for

Manufacturability 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

Requirements

• Team Feasibility

Commitment and

Management Support

• Packaging

Standards

• Product/Process

Quality System

Review

• Process Flow Chart

• Floor Plan Layout

• Characteristics

Matrix

• Process Failure

Mode and Effects

Analysis (PFMEA)

• Pre-Launch Control

Plan

• Process Instructions

• Measurement

Systems Analysis

Plan

• Preliminary

Process Capability

Study Plan

• Packaging

Specifications

• Management

Support

• 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

• Reduced Variation

• Customer

Satisfaction

• Delivery and

Service

INP

UT

INP

UT

INP

UT

INP

UT

INP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

OU

TP

UT

FMEA

APQP

MSA

SPC

PPAP

APQP PROCESS FLOW

Prepare for

APQP

Plan and Define

Program

Product Design

and

Development

Product and

Process

Validation

Process Design

and

Development

Feedback,

Assessment and

Corrective Action

Page 38: Materi training APQP

Hendra Hendrasmara – Industrial Battery Development Dept.38

ANALYTICAL TECHNIQUES

1. Assembly Build Variation Analysis

2. Benchmarking

3. Cause and Effect Diagram

4. Characteristics Matrix

5. Critical Path Method

6. Design of Experioments (DoE)

7. Design for Manufacturability and Assembly

8. Design Verification Plan and Report (DVP&R)

9. Mistake Proofing / ErrorProofing

10. Process Flow Charting

11. Quality Function Deployment (QFD)