Volvo Apqp
-
Upload
amolpagdal -
Category
Documents
-
view
467 -
download
4
Transcript of Volvo Apqp
-
8/20/2019 Volvo Apqp
1/30
AdvancedProductQuality
Planning
Volvo 3P
APQP
APQP
Information for suppliers
-
8/20/2019 Volvo Apqp
2/30
APQP information for suppliers
2
Volvo 3P APQP
APQP
Contents
1 - What is APQP and its benefits ?
2 - When to start and how to share APQP planning and status with Volvo ?
3 - Where to find APQP information / templates ?
4 - What are the Volvo APQP specifics ?
5 - Conclusion: what to keep in mind
-
8/20/2019 Volvo Apqp
3/30
1 - What is APQP and its benefits?
-
8/20/2019 Volvo Apqp
4/30
APQP information for suppliers
4
Volvo 3P APQP APQP
APQP Definition and Objective accordingto AIAG
• Definition
”APQP is a guideline designed to produce a product quality plan
which will support the development of a product or service that
will satisfy the customer”
• Objective
”To facilitate communication with everyone involved to assure
that all required steps are completed on time”.
-
8/20/2019 Volvo Apqp
5/30
APQP information for suppliers
5
Volvo 3P APQP APQP
Advanced Product Quality Planning
is supplier’s planningin compliance with AIAG reference manual
It is a VOLVO
requirement (incl.
RTS, PAA, PHR) as
specified in SQAM
Pre-requisite: supplier is trained to APQP
according to AIAG reference and its own
development process is in compliance with it
-
8/20/2019 Volvo Apqp
6/30
APQP information for suppliers
6
Volvo 3P APQP APQP
What does APQP mean for Volvo?
• Supplier APQP team is responsible for performing the APQP and report toVolvo team during the APQP review meetings, using the APQP reviewcheck-list
• A very detailed supplier timing chart synchronised with Volvo project milestones
• A very detailed APQP check-list review aiming to identify and manage risks
• A management by project phases (not by activity as it was done in the past)
• A regular Volvo-supplier APQP follow-up meeting with formal reviews prior toVOLVO releases
• Additional 3 Volvo specific best practices (RTS, PAA, PHR)
→
A robust way of working cross-functionally between Volvo and supplier aiming todeliver a project at contracted QDCF
-
8/20/2019 Volvo Apqp
7/30
APQP information for suppliers
7
Volvo 3P APQP APQP
APQP is supplier's planning that integrates VOLVO
inputs, constraints and deliverables and is synchronizedwith VOLVO project milestones
Examples of Volvo inputs:
• Technical requirements
• Time plan: part release dates, PPAP date, SP date…
• Prototype requirements
• Verification and validations performed by Volvo
….
APQP simplifiedprocess flow
-
8/20/2019 Volvo Apqp
8/30
APQP information for suppliers
8
Volvo 3P APQP APQP
Volvo Objective for APQP
Have suppliers develop a relevant
plan for new part launch
Plan for
activities
Volvo - supplier interactions
Deliver to the plan
Successful activities on time !
-
8/20/2019 Volvo Apqp
9/30
APQP information for suppliers
9
Volvo 3P APQP APQP
Benefits of APQP• Secures supplier project management is in place
• Ensures early planning takes place
• Establishes pro-active communication on both
Volvo and supplier side
• Identifies required changes early in the process in
order to mitigate risks and to reduce need for late
design and process changes
• Provides quality product on time and at lower cost
• Improves PPAP approved on time
• Reduces PPM levels at SOP
• Reduces field failures
Stronger & earlier supplier’s involvement in Projects
0
100
Supplier involvement
Room for Manoeuvre
IG VG CSG DG FDCG IG PPG EG
DeploymentConcept
Study
Detailed
Dvlpt
Final
Dvlpt
Industriali-
zationPre-study
CG FG LG RG
QDCF
CSG
DG FDCG IG PPG EG
DeploymentConcept
StudyDetailed
DvlptFinalDvlpt
IndustrializationPre-study
CG FG LG RG
Industrial launchCosts
Time
IG VG
Advanced Qual ity in Projects
-
8/20/2019 Volvo Apqp
10/30
2 - When to start and how to share APQPplanning and status with Volvo ?
-
8/20/2019 Volvo Apqp
11/30
APQP information for suppliers
11
Volvo 3P APQP APQP
Suppliers should provide the first APQP planning
with their answer to the Request for Quotation
10.4 Advanced Product Quality
Planning
(…)
The supplier is requested to build its
Plan of Product Realization according to
the AIAG APQP Manual.
(…)
The supplier is requested to submit with
its proposal … a preliminary APQP
plan …
Request For Quotation
-
8/20/2019 Volvo Apqp
12/30
APQP information for suppliers
12
Volvo 3P APQP APQP
How to match with Volvo GDP? Development supplier
SQE coordinatescompletion of
VOLVO APQP
activities with the
Project Team
Supplier performs APQP activities under
its responsibility
Supplier
Product
Design
Supplier
Process
Design
Supplier
Process
Development
SupplierProduct &
Process
Validation
APQP
KICK-OFF
review
APQP
PRODUCT DESIGN
review
APQP
PROCESS DEVELOPMENT
review
APQP
LAUNCH
review
APQP
INDUSTRIALIZATION
review
Concept Study Detailed development Final development Industrialization
DG FDCG IG PPG RG
A
Release
B
Release
C
Release
P
Release
Supplier
selected
PPAP
Approved
Volvo
PPAP
amendment
VOLVO Project team performs
APQP activities under its
responsibility and consult Supplier
APQP deliverables
Volvo
PPAP
order
-
8/20/2019 Volvo Apqp
13/30
APQP information for suppliers
13
Volvo 3P APQP APQP
How to match with Volvo GDP ? Production supplier
SQE coordinatescompletion of
VOLVO APQP
activities with the
Project Team
Supplier performs APQP activities under
its responsibility
Supplier
Process
Design
Supplier
Process
Development
SupplierProduct &
Process
Validation
Supplier
selected
APQP
KICK-OFF
review
APQP
PROCESS DEVELOPMENT
review
APQP
LAUNCH
review
APQP
INDUSTRIALIZATION
review
Concept Study Detailed development Final development Industrialization
DG FDCG IG PPG RG
A
Release
B
Release
C
Release
P
Release
PPAP
Approved
Volvo
PPAP
amendment
VOLVO Project team performs
APQP activities under its
responsibility and consult Supplier
APQP deliverables
Volvo
PPAP
order
-
8/20/2019 Volvo Apqp
14/30
APQP information for suppliers
14
Volvo 3P APQP APQP
APQP planning: bad example
Updated:
2012
Jan Feb Mar Apr May J un Jul Aug Sep Oct Nov Dec Jan Febr Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Febr Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Projekt milestones
V3P APQP
Product Milesones
Process Checkpoints
Verification PPAP
P-drawing
MRD Blanks 10w28
MRD 10w36
Production 10w38
PSW 10w42
Allocatition request
Hub equipm Mfg
Personell BC
Logistic system Updating communication system
Material Handling
2011
Ref.V3P APQP
Plan Issue 1 date 10/8-09
2009
Project Plan
2010
03/11/09
P#3
10w2409w38
P#2
11w48
P#4
SoP
11w35
Packa in
10w47
PS
10w43
SPR
10w34
1 ST
10w25
IR
09w38
PDR
09w26
KO
09w26
P#0
Manufacturing & InstallOrders
09w40
10w34
Legend:
KO = APQP Kick-off
PDR = Product Design Review
PDR = Process Design ReviewIR = Industrialization Review
1 ST = 1:st part from Serial
SPR = Significant Production Run
LR = Launch Review
Training
LR
11w27
RFQDesi n
P
Significant prod. Run
10w42
-
8/20/2019 Volvo Apqp
15/30
-
8/20/2019 Volvo Apqp
16/30
APQP information for suppliers
16
Volvo 3P APQP APQP
APQP review: the way to share APQP withVolvo
OBJECTIVES
•Detects any deviation,
assesses the risks and
assigns actions
•Gives visibility of the
progress to Volvo andsupplier teams
•Escalate the roadblocks
to project management /
line organization for
decision or action
DEFINITION
A formal meeting where Volvo
reviews supplier's APQP plan.
Volvo and supplier check that
the project at component level
is on track with respect to
deadlines and results.
ATTENDEES
Expected attendees :
•SQE
•Development (SIPD
leader, design engineer…)
•Buyer
… Manufacturing, Logistic,
Geometry, Laboratory…
•Supplier team (project
leader, engineering, quality,sales, manufacturing,
methods…)
-
8/20/2019 Volvo Apqp
17/30
APQP information for suppliers
17
Volvo 3P APQP APQP
APQP reviews - Who Does What
SQE
Design
engineer
Buyer
Organizes the APQP reviews for
Key Components
Makes sure that all PROCESSdesign, verifications & validations
activities are integrated/completed :
timing and results
Ensures that the overall supplier
APQP plan is complete and
matches project milestones
Participates in APQP reviews for Key Components
Ensures that all PRODUCT design , verifications & validations activities are integrated/completed: timing and results
Participates in APQP reviews for
key components
Ensures APQP activities underhis responsibility are
integrated/completed:
timing and results
Supplier
project team
updates its
APQP plan and
evaluate the
project status:
Timing &Results
-
8/20/2019 Volvo Apqp
18/30
APQP information for suppliers
18
Volvo 3P APQP APQP
APQP review reporting file
• APQP review reporting file is owned by the supplier
and totally shared with Volvo
• Contains
– contact directory
– co-signed time-plan – 1 check-list of questions per review
– 1 cover page for the summary. Project status and risks
-
8/20/2019 Volvo Apqp
19/30
APQP information for suppliers
19
Volvo 3P APQP APQP
APQP review reporting file instruction
-
8/20/2019 Volvo Apqp
20/30
-
8/20/2019 Volvo Apqp
21/30
-
8/20/2019 Volvo Apqp
22/30
3 – Where to find APQP informationand Volvo templates / guidelines
-
8/20/2019 Volvo Apqp
23/30
APQP information for suppliers
23
Volvo 3P APQP APQP
Information, guidelines and templates• APQP manual from AIAG
http://www.aiag.org
• APQP in Volvo supplier portal
– APQP guideline for suppliers
– APQP review file – Generic APQP time plan
– APQP responsibility matrix
• Supplier Quality Assurance Manual
-
8/20/2019 Volvo Apqp
24/30
4 - What are Volvo APQP specifics
(best practices)
-
8/20/2019 Volvo Apqp
25/30
APQP information for suppliers
25
Volvo 3P APQP APQP
RTS - Review of Technical Specification
OBJECTIVES
•Make sure the supplier
understands early
enough all the technical
specifications of the
components to be supplied
to Volvo
•Supplier agrees on the
feasibility of these
specifications.
DEFINITION
A documented review of
technical specifications.
“Technical specifications”,
includes all the documentation
needed to specify and verify a
product (part version report orPVR, drawings, digital models,
technical requirements or TR,
standards, etc).
ATTENDEES
Expected attendees :
•Design engineer
•SQE
•Buyer
•Supplier team
-
8/20/2019 Volvo Apqp
26/30
APQP information for suppliers
26
Volvo 3P APQP APQP
PAA - Product Application Agreement
OBJECTIVES
•The PAA ensures the
supplier agrees (by written
approval) that the product
he has designed will be
compatible with
environment constraintswhen installed and used in
all of the application
environments defined by
Volvo.
DEFINITION
The Product Application
Agreement (PAA) is a signed
agreement between Volvo and
a supplier.
ATTENDEES
Expected attendees :
•Design engineer
•Supplier team
•Buyer
Temperature
Vibration
Humidity
Electromagneticcompatibility
Proximity of
other parts
And more...
-
8/20/2019 Volvo Apqp
27/30
APQP information for suppliers
27
Volvo 3P APQP APQP
PHR - Part Handling Review
OBJECTIVES
•The PHR ensures the
supplier agrees (by written
approval) on the
INDUSTRIAL
ENVIRONMENT &
PROCESS with which thepart he delivers is
assembled on
Trucks/Powertrain units.
DEFINITION
The Part Handling Review
(PHR) is a signed agreement
between Volvo and a supplier.
Physical visits to all VOLVO
plant areas shall be conducted
for PHR
ATTENDEES
Expected attendees :
•Volvo Manufacturing team
•Supplier team
•SQE
•Buyer
Parts
Delivery
(Inbound
logistic)
Truck /
Powertrain unit
delivery area
Storage
Assembly processTests
Tooling
And more...Handling Cleanliness
Rework
-
8/20/2019 Volvo Apqp
28/30
5 – Conclusion: what to keep in mind
-
8/20/2019 Volvo Apqp
29/30
APQP information for suppliers
29
Volvo 3P APQP APQP
APQP – What to keep in mind ?• APQP is owned by supplier and reported to Volvo,
using the APQP review file
• APQP plan takes into account the VOLVO constraints• Supplier provides his first APQP plan with the answer to the Request
for Quotation
• It is reviewed at least at each APQP review meeting
• APQP should contain enough details to be understandable
• Critical path and risk areas should be identified
• The plan must drive actions
• There will be problem: they must be fixed or escalated
-
8/20/2019 Volvo Apqp
30/30
APQP information for suppliers
30
Volvo 3P APQP APQP
Glossary• APQP: Advanced Product Quality Planning
• DFMEA: Design – Failure Mode and Effect Analysis
• DVP&R: Design Validation Plan and Report
• GDP: Global Development Process
• GPS: Global Purchasing System
• MSA: Measurement System Analysis
• PAA: Product Application Agreement
• PFMEA: Process – Failure Mode and Effect Analysis• PHR: Part Handling review
• PPAP: Production Part Approval Process
• QDCF: Quality Delivery Cost Features
• RFQ: Request For Quotation
• RTS Review of Technical Specification
• SQE: Supplier Quality Engineer