Changes to APQP Manual 1

st
to 2
nd
Edition
Page 1
st
Edition June, 1995 2
nd
Edition July 2008 Page
ii Acknowledgement removed Foreword to 2
nd
Edition amended iii
a!le "# $ontents updated v - vi
vi Product %uality Planning $ycle Product %uality Planning $ycle updated;
the term Study as !hanged "or Che!#
viii
1 &ntroduction
a) $he term produ!t ill %e used
throughout this manual and is meant as
either produ!t or servi!e& $he term supplier
ill also %e used throughout this manual and
is meant to apply to suppliers and
su%!ontra!tors
b) $his re"eren!e manual !ontains
guidelines that support the re'uirements
des!ri%ed in the Chrysler, Ford, and General
Motors Quality System Requirements
c) $he ords shall and must (
paragraph removed
&ntroduction
a) $he "olloing terms* used in
this edition are used to des!ri%e the
supply !hain& $he term organi+ation
re"ers to the unit to hi!h these guidelines
apply& $he term supplier repla!es the
term su%!ontra!tor that as used in the
,irst Edition
%) $his re"eren!e manual !ontains
guidelines that support the re'uirements
as des!ri%ed in -S./$S 10121 and
appli!a%le !ustomer-spe!i"i! re'uirements
1
3 Fundamentals "# Product %uality Planning
,irst step "or produ!t 'uality planning !hanged
$he term initial team as !hanged "or only
team
Fundamentals "# Product %uality
Planning
$he organi+ations "irst step in produ!t
'uality planning is to assign a pro!ess
oner "or the APQP pro4e!t& -n addition* a
!ross "un!tional team should %e esta%lished
to assure e""e!tive produ!t 'uality planning&
3
5 'ection & &ntroduction
$he paragraph All or# must %e done ith the
!ustomer in mind* providing %etter produ!ts and
servi!es than the !ompetition& $he early stage
as removed
$(a)ter & &ntroduction
$he paragraph $he goal o" any produ!t
program is meeting !ustomer needs hile
providing !ompetitive value& $he initial step
su%stitutes the paragraph removed
.utputs 6 Management Support
7parenthesis added)
1
8 1*1*1 +arket ,esearc(
$hings 9one :ight 7$9:) reports removed
1*1*1 +arket ,esearc(
;est pra!ti!es and <essons learned %ullets
ere added
1=
8 1*1*2 -istorical .arranty and %uality
&n#ormation
$hings 9one >rong 7$9>) reports removed
1*1*2 -istorical .arranty and %uality
&n#ormation
;est pra!ti!es and <essons learned %ullets
ere added
1=
8 1*1*/ eam E0)erience
$9:/$9> reports %ullet as removed
1*1*/ eam E0)erience
;est pra!ti!es and <essons learned %ullets
ere added
11
1= 1*1 2esign 3oals
$he term tentative was removed
1*1 2esign 3oals
$he senten!e $he ?oi!e o" the Customer
also in!ludes regulatory re'uirements su!h
as materials !omposition reporting and
polymeri! part mar#ing as added
12
Changes to APQP 2
@A
Edition* Buly 2==8 Page 1 o" 1=
Changes to APQP Manual 1
st
to 2
nd
Edition
Page 1
st
Edition June, 1995 2
nd
Edition July 2008 Page
1= 1*8 ,elia!ility and %uality 3oals
Senten!e .verall relia%ility goals should %e
eCpressed in terms o" pro%a%ility and
!on"iden!e limits& >as removed
Quality goals are targets %ased on !ontinual
improvement& Was removed
1*8 ,elia!ility and %uality 3oals
Quality goals should %e %ased on metri!s
su!h as parts per million* pro%lem levels* or
s!rap redu!tion& Amended last senten!e in
paragraph
12
1= 1*11 Preliminary 4isting o# ')ecial
Product and Process $(aracteristics
Senten!eD At this stage* the team should
assure that a preliminary list o" spe!ial
produ!t and pro!ess !hara!teristi!s resulting
"rom the analysis o" the inputs pertaining to
!ustomer needs and eCpe!tations is
developed& Was removed
$he paragraphD $his listing !ould %e
developed "rom %ut is not limited to the
"olloingD Was substituted
1*11 Preliminary &denti#ication o# ')ecial
Product and Process $(aracteristics
ECamples o" input to identi"i!ation o" spe!ial
!hara!teristi!s in!ludeD substitutes previous
pararaph
13
11 1*12 Product Assurance Plan
$he senten!eD $he amount o" e""ort devoted
to the Produ!t Assuran!e Plan %y the Produ!t
Quality Planning $eam depends on the
!ustomer needs* eCpe!tations and
re'uirements& Was removed
;ulletD Aevelopment o" ,ailure Mode
Analysis 7,MA) 7re"eren!ed in AppendiC E)
was clari!ied
$he "inal senten!eD $he Produ!t
Assuran!e( was removed
1*12 Product Assurance Plan
,irst paragraph addsD and is %ased on
!ustomer needs and eCpe!tations
$he Produ!t Assuran!e Plan !an %e
developed in any "ormat understood %y the
organi+ation and should in!lude was re"
written
;ulletD Fse o" ,ailure Mode and E""e!ts
Analysis 7,MEA) clari!ies the previous
requirement
13
11 1*1/ +anagement 'u))ort 1*1/ +anagement 'u))ort
Senten!eD Parti!ipation %y management in
produ!t 'uality planning meetings is vital to
ensuring the su!!ess o" the program& Was
relocated
A "un!tional goal&& as !hanged intoD A
primary goal(
(* in!luding program timing an planning "or
resour!es and sta""ing to support re'uired
!apa!ity& Was added
12
13-12 "ut)uts !y 2esign ,es)onsi!le Acti5ity
-eading modi#ied
"ut)uts !y Product %uality Planning eam
-eading modi#ied
2esign "ut)uts
AP%P "ut)uts
15-18
12 2esign Failure +ode and E##ects Analysis
62F+EA7
2esign Failure +ode and E##ects Analysis
62F+EA7
Entire paragraph as reritten
18
Changes to APQP 2
@A
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Changes to APQP Manual 1
st
to 2
nd
Edition
Page 1
st
Edition June, 1995 2
nd
Edition July 2008 Page
12 2esign #or +anu#actura!ility and
Assem!ly
,inal paragraph su%stituted
2esign #or +anu#actura!ility and
Assem!ly
,inal paragraph su%stitution
11
1G 2*8 2esign ,e5iews 2*8 2esign ,e5iews
AddedD (* and o%tain !ustomer approval as
re'uired& $o "irst paragraph
11
10 2*5 Prototy)e 9uild $ontrol Plan
All prototypes that are the ( senten!e as
modi"ied
2*5 Prototy)e 9uild $ontrol Plan
-t is the organi+ationHs produ!t 'uality
planning teamHs responsi%ility to revie
prototypes "or the "olloingD modi!ies the
previous pararaph
2=
15 2*10 :ew E;ui)ment, ooling and
Facilities ,e;uirements
2*10 :ew E;ui)ment, ooling and
Facilities ,e;uirements
( to surpass planned as !hanged into
prior to
21
15 2*11 ')ecial Product and Process
$(aracteristics
(* resulting "rom understanding the ?oi!e o"
the Customer was removed
( during the revie and development o"
design "eatures through the evaluation (*
AppendiC C !ontains a ta%le des!ri%ing the
sym%ols Chrysler* ,ord and 9eneral Motors
use to denote Spe!ial Chara!teristi!s& was
removed
(* as re'uired* to support the Prototype*
Pre-laun!h* and Produ!tion Control Plans&
Was removed
2*11 ')ecial Product and Process
$(aracteristics
-n the stage o" ( !hanged "or -n the Plan
and Ae"ine Program Stage 7Chapter 1)
Senten!eD $he organi+ation should re"er to
the appropriate !ustomer-spe!i"i!
re'uirements "or additional details on the use
o" spe!ial produ!t and pro!ess
!hara!teristi!s was added
,inal senten!e as added
21-22
15 2*1/ eam Feasi!ility $ommitment and
+anagement 'u))ort
2*1/ eam Feasi!ility $ommitment and
+anagement 'u))ort
AppendiC E* no is AppendiC A
22
11 "ut)uts "ut)uts
Pa!#aging Standards no is
Pa!#aging Standards I Spe!i"i!ations
Pre-laun!h Control Plan no is
Pre-laun!h Control Plan 7in!luding Error-
Proo"ing Aevi!es)
2G
2= /*1 Packaging 'tandards /*1 Packaging 'tandards <
')eci#ications
Previous se!tion 3&11 as merged into this
se!tion
20
2= /*2 Product=Process %uality 'ystem
,e5iew
/*2 Product=Process %uality 'ystem
,e5iew
(* to assist in its evaluation as modi"ied to
readD to veri"y !ompleteness
20
Changes to APQP 2
@A
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st
to 2
nd
Edition
Page 1
st
Edition June, 1995 2
nd
Edition July 2008 Page
2= /*/ Process Flow $(art /*/ Process Flow $(art
(* to assist in its evaluation as modi"ied to
readD to veri"y !ompleteness
20
2= /*8 Floor Plan 4ayout /*8 Floor Plan 4ayout
$he term de"e!tive as su%stituted
"or non-!on"orming
(* to assist in its evaluation as
modi"ied to readD to veri"y !ompleteness
$he "inal senten!e o" the paragraph
as addedD $he "loor plan layout should
%e developed( ma#ing a dire!t re"eren!e
to $S 10121 re'uirements under !lause
0&3&1
25
21 /*> Process Failure +ode and E##ects
Analysis 6PF+EA7
A P,MEA is a living do!ument&& was
removed
/*> Process Failure +ode and E##ects
Analysis 6PF+EA7
(* to assist in its evaluation as
modi"ied to readD to veri"y !ompleteness
25
21 /*1 Pre?4aunc( $ontrol Plan /*1 Pre?4aunc( $ontrol Plan
ECamples areD !hanged "or
ECamples o" enhan!ements in the pre-
laun!h !ontrol plan areD
:o%ust added to Statisti!al
evaluations
(* to assist in its evaluation as
modi"ied to readD to veri"y !ompleteness
25
22 /*8 Process &nstructions /*8 Process &nstructions
(understanda%le pro!ess
instru!tions provide su""i!ient detail "or all
operating( was chaned to (pro!ess
instru!tions provide su""i!ient
understanding and detail "or all(
Pa!#aging standards was chaned
"or Pa!#aging standards I spe!i"i!ations
Produ!er eCpertise was chaned "or
.rgani+ation eCpertise
,inal senten!e modi"ied to in!lude
!ustomer-spe!i"i! re'uirements
28
22 /*9 +easurement 'ystems Analysis Plan /*9 +easurement 'ystems Analysis Plan
in!luding !he!#ing aids was added
a la%oratory s!ope appropriate "or
the re'uired measurements and tests*
was added
28
22 /*12 +anagement 'u))ort
$he purpose o" this revie is to in"orm upper
management o" program status and gain their
!ommitment to assist in resolution o" any
/*11 +anagement 'u))ort
:epla!ement teCtD $his revie is !riti!al to
#eeping upper management in"ormed as ell
as gaining assistan!e to assist in resolution o"
21
Changes to APQP 2
@A
Edition* Buly 2==8 Page 2 o" 1=
Changes to APQP Manual 1
st
to 2
nd
Edition
open issues was replaced any open issues& Management support
in!ludes the !on"irmation o" the planning(
Page 1
st
Edition June, 1995 2
nd
Edition July 2008 Page
2G "ut)uts 6!ecome in)uts #or 'ection 5*07 "ut)uts 6!ecome in)uts #or $(a)ter 57
Produ!tion $rial :un was chaned !or
Signi"i!ant Produ!tion :un
33
20 8*1 Production rial ,un
,inal "easi%ility %ullet was removed
8*1 'igni#icant Production ,un
$he term !y!le time was chaned
!or produ!tion gages and produ!tion rate
:e"eren!e to the PPAP manual and
Customer-spe!i"i! re'uirements was
added
Produ!tion rate demonstration %ullet
was added
Sample produ!tion parts %ullet was
added
Master sample 7as re'uired) %ullet
was added
32
20 8*2 +easurement 'ystems E5aluation 8*2 +easurement 'ystems Analysis
$he spe!i"ied monitoring and
measuring devi!es substituted $he
spe!i"ied measurement devices
:e"eren!e to !ustomer-spe!i"i!
re'uirements was added
32-3G
20 8*8 Production Part A))ro5al 8*8 Production Part A))ro5al
Entire paragraph as reritten
3G
20 8*5 Production @alidation esting 8*5 Production @alidation esting
(in!luding appearan!e re'uirements was
added
3G
25 8*1 Production $ontrol Plan
:e"eren!e to the use o" ,ord Aynami!
Control Plan 7ACP) was removed
8*1 Production $ontrol Plan
7Approval o" the pro!uring organi+ation7s) may
%e re'uired) was chaned !or 7Approval o" the
authori+ed !ustomer representative may %e
re'uired)
3G
25 8*8 %uality Planning 'ign?"## and
+anagement 'u))ort
8*8 %uality Planning 'ign?"## and
+anagement 'u))ort
Entire paragraph as reritten
3G-30
21 'ection 5*0 &ntroduction
-t is the o%ligation o" all suppliers to meet
!ustomer re'uirements on all !hara!teristi!s&
Spe!ial Chara!teristi!s must meet the indi!es
spe!i"ied %y the !ustomer was removed
$(a)ter 5 &ntroduction
.rgani+ations that "ully implement
an e""e!tive APQP pro!ess ill %e in a
%etter position to meet !ustomer
re'uirements in!luding any spe!ial
!hara!teristi!s spe!i"ied %y the !ustomer
was added
"ut)uts 6 E""e!tive use o" <essons
<earned / ;est Pra!ti!es %ullet was added
31
21 5*1 ,educed @ariation 5*1 ,educed @ariation 31
Changes to APQP 2
@A
Edition* Buly 2==8 Page G o" 1=
Changes to APQP Manual 1
st
to 2
nd
Edition
Se!ond paragraph as !ompletely reritten
Changes to APQP 2
@A
Edition* Buly 2==8 Page 0 o" 1=
Changes to APQP Manual 1
st
to 2
nd
Edition
Page 1
st
Edition June, 1995 2
nd
Edition July 2008 Page
3= 5*2 $ustomer 'atis#action 5*2 &m)ro5ed $ustomer 'atis#action
Se!tion as entirely reritten* eC!ept "or the
last paragraph&
2=
3= 5*/ 2eli5ery and 'er5ice
,ailure to !orre!t a pro%lem the "irst time
alays damages the supplierHs reputation and
!ustomer partnership& -t is important that %oth
supplier and !ustomer listen to the ?oi!e o"
the Customer was removed
5*/ &m)ro5ed 2eli5ery and 'er5ice
( alays merit the same
!onsideration ( was !hanged !or must
also meet re'uirements (
$he goal is "irst time 'uality&
Eoever* here pro%lems or de"i!ien!ies
o!!ur in the "ield it is essential that the
organi+ation and !ustomer "orm an
e""e!tive partnership to !orre!t the pro%lem
and satis"y the end-user !ustomer was
added
2=
5*8 E##ecti5e Ase o# 4essons 4earned =
9est Practices
Paragraph as added
2=
32 'ection >*1 a!le o# $ontents
:emoved
33 >*2 "5er5iew $(a)ter > &ntroduction
-n the se!ond paragraphD Araings and
visual standards replaced s#et!hes
23
35 >*/ $ontrol Plan $olumn 2escri)tions >*1 $ontrol Plan $olumn 2escri)tions
Fse o" ne ta%ular design
25
35 >7 'u))lier $ode >7 'u))lier $ode
Pro!uring .rgani+ation chaned "or
Customer
25
35 97 'u))lier = Plant A))ro5al = 2ate 97 "rganiBation = Plant A))ro5al = 2ate
:e"eren!e to !ustomer-spe!i"i! re'uirement
added
25
31 127 $ustomer Engineering A))ro5al = 2ate 127 $ustomer Engineering A))ro5al = 2ate
:e"eren!e to !ustomer-spe!i"i! re'uirement
added
21
31 1/7 $ustomer %uality A))ro5al = 2ate 1/7 $ustomer %uality A))ro5al = 2ate
:e"eren!e to !ustomer-spe!i"i! re'uirement
added
21
31 187 :um!er 187 :um!er
s#et!hes 7!omputer generated or otherise)
replaced by draings or other visual
standards
21
21 217 ')ecial $(aracteristics
$his !hara!teristi!s are variously termed*
!riti!al* #ey* sa"ety* or signi"i!ant& AppendiC C
provides a !ross re"eren!e to these sym%ols
217 ')ecial $(aracteristics
:e"eren!e to the use o" !ustomer-spe!i"i!
re'uirements as added
G1
Changes to APQP 2
@A
Edition* Buly 2==8 Page 5 o" 1=
Changes to APQP Manual 1
st
to 2
nd
Edition
and des!riptive terms was removed
Page 1
st
Edition June, 1995 2
nd
Edition July 2008 Page
23 2/7 E5aluation = +easurement ec(ni;ue
Se!ond part o" the paragraph as repla!ed
2/7 E5aluation = +easurement ec(ni;ue
Se!ond part o" the paragraph as added
G3
23 257 $ontrol +et(od
that eCists as repla!ed
:e"er to the eCamples "or ho
typi!al pro!esses are !ontrolled was
relocated !urther down on the pararaph
257 $ontrol +et(od
,irst senten!e addedD $his is one o"
the !riti!al elements to an e""e!tive !ontrol
plan&
( that eCists was replaced %y (
and the ris#s identi"ied during 'uality
planning 7e&g& ,MEA)
G3
20 >*8 Process Analysis
,igure 1 and !orresponding "ootnote as
removed
>*2 Process Analysis G0
25 'u))lement A 'u))lement A
$erm Automo%ile chaned !or Automotive
G5
G3 'u))lement F
Core team mem%er removed* only J& Bones
GGG-3=G= as le"t
'u))lement F 03
G5 'u))lement J $ontrol Plan $(ecklist 'u))lement J $ontrol Plan $(ecklist
Che!#list updated on 'uestions @o&
1* 2* 2&
Questions 11 I 12 added
05
03-51 A))endi0 $(ecklists A))endi0 $(ecklists
Column @/A as added
:evision level as added
9eneral revision o" the !ontent
removing and adding di""erent 'uestions
52-85
81 A))endi0 9 Analytical ec(ni;ues
? $ause and E##ect 2iagram ?
A))endi0 9 Analytical ec(ni;ues
$ause and E##ect 2iagram
,igure 1 as added 7relo!ated "rom page 20
in the ,irst Edition)
1=
83 A))endi0 9 Analytical ec(ni;ues
? Aimensional Control Plan 7ACP) 6
:emoved
? Aynami! Control Plan 7ACP) - :emoved
A))endi0 9 Analytical ec(ni;ues 12
83 A))endi0 9 Analytical ec(ni;ues
+istake Proo#ing 6Poka?Coke7
A))endi0 9 Analytical ec(ni;ues
+istake Proo#ing = Error Proo#ing
Entire paragraph has %een reritten
12
8G A))endi0 9 Analytical ec(ni;ues
'ystem Failure +ode and E##ects Analysis
6'F+EA7
:emoved
85 A))endi0 $ ')ecial $(aracteristics A))endi0 $ ,e#erence +aterial 10
Changes to APQP 2
@A
Edition* Buly 2==8 Page 8 o" 1=
Changes to APQP Manual 1
st
to 2
nd
Edition
:emoved :e"eren!e to A-A9 manuals as added
Changes to APQP 2
@A
Edition* Buly 2==8 Page 1 o" 1=
Changes to APQP Manual 1
st
to 2
nd
Edition
Page 1
st
Edition June, 1995 2
nd
Edition July 2008 Page
81 A))endi0 2 ,e#erence +aterials
:epla!ed %y @e AppendiC C
A))endi0 2 eam Feasi!ility
$ommitment
,ormat has %een updated
18
11 A))endi0 E eam Feasi!ility
$ommitment
:epla!ed %y @e AppendiC A
A))endi0 E Product %uality Planning
'ummary and A))ro5als
,ormat has %een updated
1==
1G A))endi0 3 FordDs Powertrain 2ynamic
$ontrol Planning
:emoved
1=3 A))endi0 - 3lossary A))endi0 F 3lossary
Fpdated "or %etter !ompati%ility ith -S./$S
10121 and !urrent industry pra!ti!es
1=3
1=5 A))endi0 & Acronyms
:emoved
1=1 A))endi0 J 9i!liogra)(y
:emoved
111 A))endi0 E &nde0 A))endi0 3 &nde0
Fpdated indeC ta%le
1=G
113 A))endi0 4 Forms
:emoved
Changes to APQP 2
@A
Edition* Buly 2==8 Page 1= o" 1=