Advanced Product Quality Planning – living document needs to be updated from time to time to improve efficiency.

1. Plan and Define 1.1. Voice of the customer 1.1.1. Market Research – Customer Interviews, questionnaires and surveys, Market test and positioning reports, new product quality and reliability studies, competitive product quality studies, best practices, lessons learned 1.1.2. Historical Warranty and Quality Information- best practices, lessons learned, warranty reports, capability indicators, supplier plant internal quality reports, problem resolution reports, customer plant returns and rejections, field return product analysis. 1.1.3. Team Experience - best practices, lessons learned, dealer comments, customer letters and suggestions, fleet operator’s comments, field service reports, internal evaluations using surrogate customers, road trips, management comments or direction, problems and issues reported from internal customers, government requirements and regulations, contract review, Media commentary and analysis, input from quality function deployment (QFD) projects. 1.1.3.1. Pre-contract review (team feasibility comments) 1.2. Business Plan and Marketing Strategy- The business plan may place constraints such as timing, cost, investment, product positioning, research and development on the team that affect the direction taken. The marketing strategy will define the target customer, the key sales points, and the key competitors. 1.3. Product/Process Benchmark Data- Identify the appropriate benchmark, understand reason for gap between current status and benchmark, develop a plan to close the gap, match the bench mark or exceed the benchmark. 1.4. Product Process Assumptions- there will be assumptions that the product has certain features, design or process concepts. These include technical innovations, advanced materials, reliability assessments, and new technology. 1.5. Product Reliability Studies- This type of data considers the frequency of repair or replacement of components within designated periods of time and the results of long term reliability/ durability tests. 1.6. Customer inputs- the next users can provide valuable information relating to their needs and expectations. If the new users of the product have already reviewed and researched on the product this can be used further used to develop agreed upon measures of customer satisfaction. 1.7. Design goals- these are a translation of the voice of the customer into measurable design objectives. The proper selection of the design goals assures that the voice of the customer is not lost in subsequent design activity. Voice of customer also includes regulatory requirements such as materials composition reporting and polymeric part marking. 1.8. Reliability and quality goals- based on customer wants and expectations (ex: no safety failures), program objectives (ex: competitor product reliability, warranty data, or frequency of repair over set time period), and reliability benchmarks. Quality goals should be based on metrics such as parts per million, problem levels or scrap reduction. 1.9. Preliminary Bill of material- established based on product/process assumptions and includes a potential supplier list. Appropriate design and manufacturing process must be selected. 1.10. Preliminary Process Flowchart- helps in defining the anticipated manufacturing process developed from the preliminary bill of material and product/process assumption. 1.11. Preliminary Identification of Special Product and Process Characteristics- identified by the customer with the knowledge of product and process. 1.12. Product Assurance Plan- translates design goals into design requirements. It should include the following:  Outlining of the program requirements  Identification of reliability, durability, and apportionment/allocation goals and/or requirements.  Assessment of new technology, complexity, materials, application, environment, packaging, service, and manufacturing requirements, or any other factor that may place the program at risk.  Use of FMEA  Development of preliminary engineering requirements.

Use data and experience to establish preliminary process parameters and packaging requirements 2. Material handling 2. function. 2. Communicate any concerns. Process adjustments 2. Engineering Drawings (Including math data). These characteristics should also be included in the control plan.7.2.13.need to be properly communicated and documented. tested. commitment and management Support-the team must be satisfied that the proposed design can be manufactured.13. Team feasibility.add these requirements to the timing chart 2. it also provides a mechanism to monitor progress.7. Packaging standards and Specifications. commitment and support from upper management.4.4.5. Ensure that particular attention has been given to special product and process characteristics 2. Dimensional tolerances 2. 2.9. Additional controls and/or procedural changes required to produce the product should be updated.3. Design Reviews. The team should assure that there is a process to determine that new equipment and tooling is capable and delivered on time. handling and storage requirements.2.8. 2.6.2. packaged.5. 2. and obtain customer approval as required. Design Verification. Performance Requirements 2.2. Special product and process characteristics 2.1.2.2. concept. Design for manufacturability and Assembly. Product/Process Quality System Review. Design. 2. manufacturability.2. 2. durability and appearance requirements need to be fulfilled by understanding the controlling specifications.Functional. Photo/Sample Record Process Design and Development 3.12. Number of components 2. New equipment. environmental.10. 2. Management support.5. Manufacturing and/or assembly process 2.1. assembled. and ease of assembly.13.2. and/or cost impact to the customer.3. deviations. Gage/Testing equipment requirements.5. Prototype build – Control Plan 2.It’s a simultaneous engineering process designed to optimize the relationship between design function.4. transit and unpacking. Ensure product integrity at point of use. Package should be compatible with all material handling equipment.effective method to avoid problems and misunderstandings. Engineering Specifications. tooling and facilities requirement.1.2. Dimensions to be evaluated to assure feasibility and compatibility with industry manufacturing and measuring standards. Post Contract Review 2. Material Specifications. 2.1.to be reviewed for special characteristics relating to physical properties. 2.5. documented and included in the .2. performance.6.13. 1.5. Assure that the product meets specification and report data as required 2.3. Drawings and specification changes.A disciplined analytical technique that assesses probability of failure as well as the effect of such failure. 3. It is living document continually updated as customer needs and expectations require. Product Design and Development 2.2.2.1.It verifies that the product design meets the customer requirements derived from activities described in section 1.Drawings should be reviewed to determine sufficient information is provided for dimensional layout of the individual parts.11. 2. 3.Customer packaging requirements. 2. Everything should be documented with all open issues that require resolution and should be presented to the management for their support.One of the key to success of APQP is the interest. report to management. and sensitivity to manufacturing variation. product performance and characteristics to remain unchanged during packaging.all these requirements need to be addressed by adding it to the timing chart. 2. For effective two way communication the team should assure that math data is compatible with the customer’s system. DFMEA – Design Failure Mode and Effect Analysis.2. and delivered in sufficient quantity on schedule at an acceptable cost to the customer.Product Quality planning team should review manufacturing sites quality management system.

Product and Process Validation 4. The purpose of the pre-launch control plan is to contain potential non-conformities during or prior to initial production runs. 3.4.7. The flow chart helps assist the PQPT to focus on the process when conducting the PFMEA and designing the control plan. Floor Plant layout. feeds. operators. the responsibility to ensure gage linearity.3. value-added use of floor space and should facilitate the synchronous flow of materials thru the process. This should include the additional product/process controls to be implemented until the production process is validated. Process Flowchart. repeatability. 3.must be conducted using the production tooling. The output of this is used for:  Preliminary process capability study  Measurement system analysis  Production rate demonstration  Process review  Production validation testing  Production Part Approval Process (PPAP)  Packaging evaluation  First time capability  Quality planning sign off  Sample production parts  Master Sample (as required) 4. [Control items. inspection points.this should provide sufficient understanding and detail for all personnel who have direct responsibility for the operation of the processes. environment.the specified monitoring and measuring devices and methods should be used to check the control plan identified characteristics to engineering specification and to be subjected to measurement system evaluation during or prior to the significant production run. Measurement systems analysis.Analytic technique for displaying relationship between process parameters and manufacturing stations. facility. 3. 3. and staffing to meet the required capacity and resolve any open issues. Set-up parameters should be included such as machine speeds. team expertise.6. providing resources.3. Process Instructions. The customer usually sets the minimum quantity for a significant production run. Helps in analyzing total process instead of individual steps in the process.provides evidence that all customer engineering design record and specification requirements are properly understood by the organization and that the .9. and tooling and should be accessible by operators and supervisors.8.11. equipment.4.10. Process Failure Mode and Effects analysis (PFMEA). reproducibility and correlation for duplicate gages. Significant Production Run. applicability of visual aids.4. and storage area to contain non confirming material] 3.critical to keep upper management informed to gain assistance in confirmation of planning. handling.this plan should include at a minimum a laboratory scope appropriate for the required measurements and tests. Preliminary Process Capability Study Plan3. Pre-Launch Control Plan-are a description of the dimensional measurements and material functional tests that will occur after prototype and before full production. To improve pre launch control plan the following can be done:  More frequent inspection  More in-process and final check points  Enhanced audits  Identification of error-proofing devices 3. and previous experience. It is an opportunity for the PQPT to improve the existing quality system based on customer input. 4. interim repair stations. Preliminary Process Capability Study-the study provides an assessment of the readiness of the process for production.2. 3. accuracy. gages and rate.The floor plan should be developed in such a manner to optimize the material travel. 3. Management support. 4.5.Schematic representation of current or proposed process flow. Production Part Approval. manufacturing control plan. Characteristics Matrix. control chart locations. cycle times.It is a disciplined review of a new or revised process problems for a new or revised product program. Measurements Systems Analysis Plan.1.

equipment and personnel. Production Control Plan-it is a written description of the systems for controlling production parts and processes.this portfolio is beneficial for capturing.control charts and other statistical techniques should be used as tools to identify process variation. Reduced Variation.1. inventory. Quality planning Sign off and Management Support.the PQPT team should perform a review at the manufacturing location(s) and co-ordinate a formal sign-off. and anticipated improvement for customer review. 4. 4. 5. 5. Packaging Evaluation.6.5.8.3. It is a logical extension of the pre-launch control plan. The organization and the customer become partners in making the changes necessary to correct any deficiencies and to improve customer satisfaction. Customerspecified packaging does not prelude the organization’s PQPT involvement in evaluating the effectiveness of the packaging.All test shipments and test methods must assess the protection of the product from normal transportation damage and adverse environmental factors. Improved Delivery Service. 4.7.detailed planning activities and demonstrated process capability of a product or service are important components to customer satisfaction. The product quality sign-off indicates to the management that the appropriate APQP activities have been completed. The experience gained in this stage provides the customer and organization with the necessary knowledge to reduce process.2.5.4. and quality costs and to provide the right component or system for the next product. Assessment and Corrective Action 5. manufacturing process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. timing.refers to engineering tests that validate that products made from production tools and process meet customer engineering standards including appearance requirements. Analysis and corrective actions should be used to reduce variation. Feedback. Methods for this can be the following:  Review of things gone wrong/ things gone right  Data from warranty and other performance metrics  Corrective action plans  “Read-across” with similar processes and products  DFMEA and PFMEA studies . Production Validation Testing. Proposals should be developed including costs.helps in solving problems and continual improvement.all PFMEA recommendations have been addressed. Continual improvement requires attention not only to special causes of variation but understanding common causes seeking ways to reduce these sources of variation. retaining and applying knowledge. 4. Improved Customer Satisfaction.  Monitoring and measuring devices  Demonstration of required capacity. It is a living document and should be updated to reflect the addition or deletion of controls based on experience gained by producing parts. When problems occur it is essential for the customer and the organization to form a partnership to correct the problem and satisfy the end-user customer. The reduction or elimination of a common cause may provide the additional benefit of lower costs. Effective use of lessons learned/ best practices. Using production processes. 5. The sign-off occurs prior to first product shipment and includes a review of the following:  Process flowcharts should exist and are being followed  Control plans exist and are available and followed at all times  Process instructions.

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