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APQP Webinar PDF
APQP Webinar PDF
Mark A. Morris
ASQ Automotive Division Webinar
February 8, 2012
mark@MandMconsulting.com
www.MandMconsulting.com
Five Fundamental Principles
Do what
Actions comply
you say! with Procedures?
Be able to
Actions are
prove it! Effective?
Rules
of the Increase Profits
Game
Motivation and Intent
– Increase Marketability
Management
Responsibility
Measurement,
Resource
Analysis, and
Management
Improvement
Product
Realization
General Requirements
The Juran Trilogy® Diagram
PPAP Documentation Requirements
Significant Production Run
• Good Communication
• No Judgment; No Criticism
Product
Product
Design FMEA
Design FMEA
Process
Process
Process FMEA
Process FMEA
Customer Plant
Customer Plant Tool
Tool Design
Design
Control Plan
Control Plan Machinery FMEA
Machinery FMEA
Internal
Internal Processes
Processes
Process FMEA
Process FMEA
Internal
Internal Process
Process
Control Plan
Control Plan
Motivation for Specific FMEAs
Product Customer
Life Design FMEA
Cycle Satisfaction
Cost
Process
Process FMEA
R&M
Internal Processes
Process FMEA
First-Time
Capability
Internal Process
Control Plan
Three Phases of Control Plan
Phase 1 Product
Control Plan Design FMEA
for Phase 2
Prototype Control Plan
Process
Process FMEA for
Pre-Production
Internal Processes
Identify and Manage
Process FMEA
Deliverables
Required for Internal Process
Build & Buy-Off
Control Plan
Fundamentals of Quality Planning
PPAP Documentation Requirements
Significant Production Run
• Cost of Defects
• Risk of Defects
• Bracketing Strategies
• Protecting On-Time Delivery
• Cost of Stopping Production
• Cost of Recall Campaigns
• Benefits of Traceability
Practical Issues of Quality Planning
• APQP Outputs
– New Equipment, Tooling and Facilities Requirements
– Special Product and Process Characteristics
– Gages / Testing Equipment Requirements
– Team Feasibility Commitment
– Management Support
AIAG Model for Quality Planning
Process Design and Development
Input Documents Output Documents
• Design FMEA • Packaging standards & Specs
• Design for Mfg & Assy • Product and Process Quality
• Design Verification System Review
• Design Reviews • Process Flow Chart
• Prototype Build – Control Plan • Floor Plan Layout
• Engineering Drawings • Characteristic Matrix
• Engineering Specifications • Process FMEA
• Material Specifications • Pre-Launch Control Plan
• Drawing & Specification Changes • Process Instructions
• Measurement System Plan
• Preliminary Process Capability
Study Plan
• Management Support
AIAG Model for Quality Planning
Product and Process Validation
Input Documents Output Documents
• Packaging standards & Specs • Significant Production Run
• Product and Process Quality • Measurement Systems
System Review Evaluation
• Process Flow Chart • Preliminary Process Capability
• Floor Plan Layout Study
• Characteristic Matrix • Production Part Approval
• Process FMEA • Production Validation Testing
• Pre-Launch Control Plan • Packaging Evaluation
• Process Instructions • Production Control Plan
• Measurement System Plan • Quality Planning Sign-Off
• Preliminary Process Capability • Management Support
Study Plan
• Management Support
AIAG Model for Quality Planning
Production and Feedback
Input Documents Output Documents
• Significant Production Run • Reduced Variation
• Measurement Systems • Improved Customer Satisfaction
Evaluation • Improved Delivery and Service
• Preliminary Process Capability • Effective Use of Lessons
Study Learned and Best Practices
• Production Part Approval
• Production Validation Testing
• Packaging Evaluation
• Production Control Plan
• Quality Planning Sign-Off
• Management Support
Practical Issues of Quality Planning
• What is the cost of inspection?
• What is the risk of not inspecting?
• How often should we inspect?
• How many parts should we inspect?
• When does 100% inspection make sense?
• How should the need for destructive tests impact
our decisions?
Strategy for Actionable Data
Appendix F – Glossary
Appendix G – Index
Summary and Closure
APQP Model for Quality Planning
18 Components of PPAP
4 - 65
Agenda