Professional Documents
Culture Documents
Core
Tools
Ken Coll
248-209-4455
kencoll@ameritech.net
ASQ Automotive Division
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APQP
Advanced Product Quality
Planning
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APQP
What is it?
Management of product development
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PROGRAM
APPROVAL
PROTOTYPE
PILOT
LAUNCH
PLANNING
PLANNING
Planning
INPUTS
|
Planning
OUTPUTS
Product
Design &
Dev. INPUTS
|
Product
Design &
Dev.
OUTPUTS
Process Design
&
Dev. INPUTS
|
Process Design
&
Dev. OUTPUTS
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Product &
Process
Validation
INPUTS
|
Product &
Process
Validation
OUTPUTS
Feedback,
Assessment &
Corrective Action
INPUTS
|
Feedback,
Assessment &
Corrective Action
OUTPUTS
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Concept Initiation/Approval
Inputs:
Voice of the Customer
Market Research (Including OEM Vehicle Timing and
Volume Expectations
Historical Warranty and Quality Information
Team Experience
Business Plan/Marketing Strategy
Product/Process Benchmark Data
Product/Process Assumptions
Product Reliability Studies
Customer Inputs
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Concept Initiation/Approval
Outputs:
Design Goals
Reliability and Quality Goals
Preliminary Bill of Materials
Preliminary Process Flow Chart
Preliminary Listing of Special Product and Process
Characteristics
Product Assurance Plan
Management Support
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Program Approval
Design Outputs:
APQP Outputs:
Design Verification
Design Reviews
Prototype Build -- Control Plan
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Prototype
Outputs:
Packaging Standards and Specifications
Product/Process Quality System Review
Process Flow Chart
Floor Plan Layout
Process Failure Mode and Effects Analysis (PFMEA)
Characteristics Matrix
Pre-Launch Control Plan
Process Instructions
Measurement System Analysis Plan
Management Support
Preliminary Process Capability Study Plan
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Pilot
Outputs:
Significant Production 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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Launch
Outputs:
Reduced Variation
Improved Customer Satisfaction
Improved Delivery and Service
Effective Use of Lessons Learned/Best Practice
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Pitfalls
APQP treated as a Quality Department Responsibility
APQP a separate process, not integrated into product
development
Key stakeholders brought in late (quality, production,
suppliers)
Milestones and deliverables ignored
No top management involvement/support
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FMEA
Failure Mode and Effects
Analysis
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FMEA
What is it?
A risk analysis of a part or process
Why do we use it?
To find and fix a problem before
something breaks or someone gets hurt
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Types of FMEAs
Design FMEA
Process FMEA
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Types of FMEAs
Others:
System FMEA
Concept FMEA
Environmental FMEA
Machinery FMEA
Software FMEA
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FMEA Process
Subsystem
Function
Requirements
Potential
Failure
Mode
Potential
Effect(s) of
Failure
S
e
v
What are
the Effects?
C
Potential
O
l
Cause(s)/
c
a Mechanism(s) c
s
of Failure
u
s
r
Current
Controls
Prevention
Detection
D
e
t
e
c
R. Recommended Responsibility
P.
Action(s)
& Target
N.
Completion Date
Action Results
Actions
S O D
Taken
e c e
v c t
What can be
done?
How bad
is it?
Design
Changes
Process
Changes
Special
Controls
What can go
wrong?
What are
the
Cause(s)?
Changes to
Standards,
Procedures, or
guides
How
often
does it
happen?
No function
Partial / Over
/Degraded
Function
Intermittent
Function
How good is
this method at
detecting it?
Unintended
Function
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R.
P.
N.
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Pitfalls
FMEA started late in the development process (just in time
for PPAP!)
FMEA never updated after release
FMEA not updated from nonconformity corrective actions
Right side (action area) is blank
RPN thresholds
FMEA written by one person
FMEA treated as a Quality Department Responsibility
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Control Plan
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Control Plan
What is it?
A summary of controls used to make sure my
customer gets good product
Why do we use it?
To make sure controls are used and stay in
place
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Control Plan
CONTROL PLAN
Prototype
Control Plan Number
Pre-Launch
Production
Key Contact/Phone
Date (Orig.)
Date (Rev.)
Core Team
Part Name/Description
Supplier/Plant Approval/Date
Supplier/Plant
Supplier Code
MACHINE,
PART/ PROCESS NAME/ DEVICE,
PROCESS OPERATION
JIG,TOOLS,
NUMBER DESCRIPTION
FOR MFG.
CHARACTERISTICS
NO.
METHODS
SPECIAL
CHAR. PRODUCT/PROCESS EVALUATION/
SAMPLE
PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE
FREQ.
TOLERANCE
TECHNIQUE
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CONTROL
METHOD
REACTION
PLAN
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c) Process control
process parameters,
part number(s),
d) Methods
part name/description,
error-proofing,
key contact,
control method.
b) Product control
corrective action.
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Control Plan
Pitfalls
Control plan and PFMEA not aligned
Control plan and operator instructions not aligned
Control plan out of date
Control plan not updated from nonconformity corrective
actions
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PPAP
Production Part Approval
Process
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PPAP
What is it?
Requirements for approval of production parts.
Why do we use it?
To make sure that I understand all my customer
requirements, and that I can meet them under
actual production conditions.
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PPAP
1
Design Records
Design FMEA
Process FMEA
Control Plan
Dimensional Results
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12
13
14
15
Master Samples
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Checking Aids
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18
11
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Pitfalls
PPAP is treated as a separate process, rather than integrated
into product development
Incomplete PPAP
Assuming that submission levels are whats required, rather
than whats submitted
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SPC
Statistical Process
Control
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SPC
What is it?
A collection of statistical methods, especially
control charts, used to analyze and control a
process
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Variation
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Mean = Average or
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Standard Deviation =
Variance =
or s
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Normal Distribution
68.25%
95.46%
99.73%
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Statistical Control
Variation
In- Control
Out-of-Control
(Common Cause)
(Special Cause)
Acceptable
Case 1
Case 3
Unacceptable
Case 2
Case 4
(Capability)
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Overall Variation
Within
Subgroup
Variation
Overall
Variation
Within
Subgroup
Variation
Overall
Within
if stable
Performance
Capability
If centered
Ppk
Cpk
Pp
Cp
Kenneth J Kortge
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Acceptable
May Be Acceptable
May require an improvement plan
Not Acceptable
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2 Types of Data
Variable
Attribute
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Variables Charts
Typical:
Chart
Type
X-Bar & R
Median
Primary
Usage
Routine monitoring of
manufacturing
processes
Usually used as a
monitoring tool for
product or processes
What Is
Charted
Sample
Subgroup
Size
Usually 3 to 6
Should be an odd
number: 3, 5, 7, etc.
One
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Attribute Charts
Typical:
Chart Type
P Chart
nP Chart
C Chart
U Chart
Primary
Usage
Used for
analyzing
proportion or
percent
nonconforming
or defective parts
Used for
analyzing the
number
nonconforming
or defective
parts
Used for
analyzing
nonconformities
or defects
Used for
analyzing
nonconformities
per unit
What is
Charted
Plots the
proportion or
percent of the
nonconforming
units
Plots the
number of
nonconforming
items
Plots the
average number
of
nonconformities
in each sample
Sample
Subgroup
Size
Variable
Fixed
Fixed
Variable
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X & R Chart
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LCLX
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Pitfalls
Ignoring out of control conditions
Comparing control limits to spec limits
Making process adjustments without understanding the
source of the special cause variation
Putting SPC charts on everything
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MSA
Measurement Systems
Analysis
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MSA
What is it?
A collection of statistical methods used to assess
how much I can trust the information from a
gauge
Why do we use it?
Since all my information about a part/process
comes from gauges, I need to know when the
gauge information is dependable, and do
something when its not
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Typical:
10 Parts
3 Appraisers
3 Trials
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GRR / R&R
2
GRR =
2
Reproducibility
2
+
Repeatability
% Total Variation vs. % Tolerance
Number of Distinct Categories (NDC)
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Appraiser A
Repeatability
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Reproducibility
Appraiser
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Actual
Total
Process
Measurement
Think of a
right triangle
Measurement
Variation
Process Variation
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Total
Process
Measurement
Measurement
Variation
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QUESTIONS
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