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    22 views115 pages

    Aiag Apqp 2th Edition PDF

    Uploaded by

    Carlos Nunes

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    © All Rights Reserved
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    Advanced Product Quality Planning and Control! Plan Falah Old Second Edition ADVANCED PRODUCT QUALITY PLANNING (APQP) AND CONTROL PLAN Reference Manual Second Edition ued June 1994, Second Printing February 1995 (new Coenen a, 38 Chrysler Corporation, Ford Motor Com ISBNO7eN eOSee Tae al Motors Corporation FOREWORD Second Edi Efizetive November 1,200, APQP and Control Plan Second Edition replaces APQP and Control Plan First Edition unless otherwise specified by your cusiomer. APOP and Control Plan Second Edition includes: ‘+ incorporation of the customer focused process approach + updated terminology and concepts consistent with ISO/TS 16949 and other Chrysler, Ford and General Motors core tool manuals © appropriate references to customer specifics provided without the full text This manus! continues to provide general guidelines for ensuring that Advanced Product Quality Planning is implemented in accordance with ths requirements of the customer. It does not give specific instructions on bow toarrive at each APQP orContmol Planentry, a task best left to each organization While these guide lines are intended to cover most situations normally occurring either in the carly planning, design phase, or process analysis, there will be questions that arise. These questions shauld be directed to your authorized customer representative, The Supplicr Quality Requirements Task Force gratefully acknowledges the contributions of the following indi viduals and their respective companies that participated in the revision process Bryan Book, Chrysler LLC, Chair Russ Hopkins, Ford Motor Company’ William Fisk, General Motors Corporation Robert Minkler, Delphi Corporation Craig Williams, Eatan Corporation This document is copyrighted by Chrysler LLC, Ford and General Motors, all rights reserved, 2008, ‘Additional eopies can be ordered from AIAG. arg. Organizations purchasing APQP Secand Edition have permission to copy any forms andlor checklists contained hewin July 2008 TABLE OF CONTENTS FOREWORD. : : STABLE OR OONWENTS csi isooctane IxTRODUCTION sora es neninnnnimnvenenneninanene 1 FUNDAMENTALS OF PRODUCT QUALITY PLANNING wovesennneaeeneveneuee sean 3 Organize she Fea... od Define the Scape a Teaun-to-Feam. od Trani. seo ond Customer andl Organization Involvement s Sim Baneoas Exginecring. 5 4 Control Plans SS 4 Concern Reso bein. 5 5 5 Product Qhatty Timing Plan : 5 Plans Relative to he Timing Cha ‘ 5 CHAPTER I PLAN AND DEFINE PROGRAM wsssssssaw a Iymopuction. . rithm 9 LIVeice of the Cusiomer 3 e 9 12 Business Plan and Marketing Strategy i 13 Product/Process Benchmark Date 3 Hi Lf Prodect/Pracess Asam piions a 2 LS Product Rebisbilty Suales. 5 3 “2 LE Customer Input S 2 17 Design Goals = s “BR LBReliabibity and Queliy Goals. ‘ 2 1.0 Prelineinayy Bll of Materia 3 -2 110 Prelowinany Process Flow Chart, 3 LH Preliminary Identificaton of Special Product and Process Chavacteristies. -B LID Proict Assuornee Pla. 2B 1.13 Management Support, 3 wis CHAPTER 2 PRODUCT DESIGN AND DEVELOPMENT 18 Iyropuction. £ . . av 21 Design Failure Mode an Effesy Analysis (D FMEA). g 18 2.2Design for Manufieturabiin: and Assembly is 24 Devign Vereation -. 3 “19 24 Devign Reviews: é 9 2.5 Prototype Bust! « Consol Plan 20 26 Engineering Drawings (Including Mask Data) 20 27 Engineering Spectfiasions. 2 2.8 Material Specifeusions 2 2.8Drawing and Specification Changes. 2 21O.New Equipment, Tooling and Facsites Requiremens = 21 Special Productand Process Characterisies 3 2 212 Gages/Fesang Equipment Reyeiremen 22 2.15 Team Feasthidty Commionentand Management Support 2 CHAPTER 3 PROCESS DESIGN AND DEVELOPMENT seccsssssuiasssseisinsnessiiinenaianiasnnnin dS yrRonuction. see . 2s 4.1 Packuging Standards ancl Specifications s 26 1.2 Produ ct!Pracese Quabty System Review 5 26 23 Process Flow Chart 26 2 Floor Plan Layout 5 26 2.5 Charwcserissies Matrix 2 26 Pracesr Failure Mode and Effect Analysis {PFMEA) 5 27 2-7 Pre-denutch Control Plan. 2 28 Pracest Instructions, 5 28 2.9 Measurement Syssenes Anciysis Plan, 28 210 Preloieinary Process Capability Study: Pla. g 20 LH Masegenens Support 20 CHAPTER 4 PRODUCT AND PROCESS VALIDATION. Ivopuenios. s a 4.1 Significant Production Run a8 42 Measurement Sistas Anelusis. 3 5 7 44 Preliminary Process Capa bili Stely 38 4.4 Produetion Part Approval. a ode O35 4.5 Produesion Vatdation Tossing 35 4.6 Pacha ng Everuation : O35 4.7 Production Controt Plan a3 4.8 Ouatity Plznning Sign -Off and Mangement Support . a5 (CHAPTER 5 FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION IyTRODUCTION. 39 5 Reduced Variation. 2 5 39 5.2 fmproved Customer Satisfaction 40 5.4 Improved Defivery and Sovice Loe 5 0 54 Effective Use of Lescons learn al’Best Practices. 40 CHAPTER 6 CONTROL PLAN METHODOLOGY yrRopuCTION. “e e . 3 6.1 Controf Pran Column Description s a 62 Process Analisis ; 3 30 ENDIX A PRODUCT QUALITY PLANNING CHECKLIST. ENDIX ANALYTICAL TECHNIQUES 2e2essssssssssssuiusaeuieinuaaneinaaanaeinnaeaninial® Assembly Bull Vari tion Analysis 5 39 Benchmariang Case amd Exfect Diagram Sos Characterieacs Magis. (Chteal Pate Method. 5 Design of Experiments (DOE). Design for Man ufecturabiliiy cal clsvem bly... Design Perification Plunand Repart (DVPAR) .. Mistake Proofing/Error-Proofing « . Process Flow Charting. Qua ly Function Deployment (OED). ENDIX © REFERENCE MATERIAL sumas nessun ENDIX D TEAM FEASIBILITY COMMITMENT. ENDIX E PRODUCT QUALITY PLANNI EN DIX F GLOSSARY. A A Al A a PRODUCT QUALITY PLANNING CYCLE Feedback Assessment and Corrective Action Plan and Define Product and Process Validation Product Design and Development Process Design and Development Introduction Introduction The purpose of this manual is ta communicate to organizations (internal and extemal) and supplies, common Produet Quality. Planni Contra! Plan guidelines developed jointly by Chrysler, Ford and General Motors. This manual provides guidelines designed ta praduce a product quality plan, which will support the develapment af a product or service that will satisfy the customer (sce Section 1.6). The following terms, used in this edition are used ta deseribe the supply chain, The term "organization" refers to the unit to which these guidelines apply. The term "supplict” replaces the term subcontractor that was used in the First Edition. Some of the expected benefits in using these guidelines are: and A reduction in the complexity of product quality planning for the ‘customers and organizations, ‘A means for omganizations to sasily communicate produst quality planning requirements to suppliers. This reference manual contains guidelines that support the requiremeris as described in ISO/TS 16949. and applicable custamer-specitic requirements. All forms in this manual are provided as examples only The purpose is to assist the organization’s praduct quality planning team in developing the appropriate communication forms to support mesting customer requirements, needs, and expectations. The Product Quality Planning Cycle shown on the facing page is a graphic depiction of a typical program. The various phases are sequenced to represent planned timing to execute the functions described. The purpose of the Product Quality Plaming Cyele is to emphasize: Up-front planning. The first three quarters of the cyele are devated to ‘up-front product quality planning through produetiprocess validation The act of implementation, The fourth quarter is the slage where the importance of evaluating the output serves two functions: to determine ff customers are satisfied, and to support the pursuit of continual improvement Depicting product quality planning as a cycle illustrates the never-ending pursuit of continual improvement that can only be achieved by taking the experience in one program and applying that acquired knowledge to the next program. Introduction PRODUCT QUALITY PLANNING RESPONSIBILITY MATRIX The matrix shown below depicts the Product Quality Planning Functions for three types of organizations. It is to assist organizations in defining the scope of their planning responsibilities. Refer to Fundamentals of Product Quality Plamni on the next page, The matrix docs not depict all the different types of product quality planning rlationships that could exist among organizations, supplicrs, and customers, “Design Responsible Define the Seope Plan and Define Chapter 1.0 Product Design and Development Chapter 2.0 Feasibility Section 2.13 x Process Design and Development Chapter 3.0 Product and Process Validation & Chapter 4.0 Feedback, Assessment and Corrective x Astion Chapter 5.0 Control Plan Methodology Chapter 6.0 * Refer to Section | “Scope” of ISO/TS 16949. * Manufacturing ‘Only ab x Organization ie. Heat Treat, Warehousing, ‘Transportation, ete. x x Introduction Fundamentals of Product Quality Planning Organize the Team Define the Scope Product Quality Planning is a structured method of defining and establishing the steps necessary lo assure that a product satisfies the customer, The goal of product quality plaming is to facilitate communication with everyene involved to assure that all required steps are completed on time. Effective product quality planning depends on a company’s top management commitment 1a the effort required in achieving customer satisfaction. Some of the benefits of product quality planning are: '* To direct resources to satisfy the eustomer. © Topromote early idemtification of required changes. + Toavoid late changes * Toprovide a quality product on time at the lowest cast The work practices, tools, and analytical techniques described in this manual are listed ina logical sequence to make it easy to follow. Each Product Quality Plan is nique. ‘The actual timing and sequence of sxscution is dependent on customer needs and expectations and/or other practical matters. ‘The earlier a work practice, tool, andior analytical technique can be implemented in the Product Qua lity Planning Cycle, the beter The organization's first step in product quality planning is to assign a process owner for the APQP project. In addition, a crass fune ial team should be established to assure effective procket quality planning. The cam should include representatives from multiple finstions such as esting, manufacturing, material control, purchasing, quality, human resourees, sales, field service, supplier, and customers, as appropriate. Itis important for the organization's product quality planning team in the earliest stage of the pmduct program to identify customer needs, expectations, and requirements, At a minimum, the team must meet to: ‘© Select a project team leader responsible for overseeing the planning process. (In some cases il may be advantageous to rolate the team Icader during the planning

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