Ø +919587789118 Ødharmvir032@gmail.

com
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APQP Second Edition rs

to i

Used Only Training Purpose

aud
Effective July and-2008
i ng
i n
Advanced product tra
nts
ul ta
ons
C
Quality Planning
al i ty
Qu
sh
An

Awareness training
1
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tors
i

Used Only Training Purpose

a u d
a nd
i ng
rai n
s t
tmethod to assure that a product
l
Advanced Product Quality Planningta n
n u
s(both internal and external)
o
satisfies the customer
C
a i t
Automotive industryy challenges Reduce R&D / NPD times Increasing
l quality requirements
customeru and
QChrysler APQP Task Force jointly developed in the late 80’s
n s
Ford, h
GM,
A to standardize their respective supplier quality systems .
Many industries outside the Automotive industry have embraced the
AIAG APQP process to achieve similar benefits

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Product Quality Planning

EP- Existing product NP- New product
tors
i

Used Only Training Purpose

EC- Existing Customer u d
NC- New Customer
a
EP NP and
i ng
PPAP
NC rai n
EC ts t
l tan
ns u APQP 100%
PPAP
CoEP NP
u al ity
h Q
An s
APQP 20%
NC EC

EP- Existing product NP- New product

NC- New Customer EC- Existing Customer
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Product Quality Planning

Existing Products tors
i

Used Only Training Purpose

a u d
After product launch, process monitoring and review is used …
a n d
• as a catalyst for continual improvement
i ng
rai n
• to prevent defects
s t
t for controlling characteristic
an
• as a means for enforcing plant-floor discipline
l t
variation
n s u
C o
New Products a l i ty
Q u
n s
For newh products, the existing process monitoring and review knowledge base…
A• acts as an input to the Product Development process
• brings the operator into the initial phases of product and process design

4
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What is APQP ?
ors
it

Used Only Training Purpose

v Advanced Product Quality Planning method to u d
assure
a and
that a product satisfies the customer (both an d
internal
i ng
external)
rai n
ts t
l ta n
vEach Advanced Product
su Quality Plan is unique and is a
living documentCon
al i ty
u
Q emphasis should be placed on identifying
n s h
vParticular
Acritical path activities and ensuring those are fully
resourced

5
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Benefits of APQP
v Higher Quality
tors
i

Used Only Training Purpose

v Reduced process variation aud
and
ng
v Enhanced confidence in supplier’s capabilities
i
r ai n
s t
v Better controlled process changes.
t
l tan
v Defect free launches
n s u
Product.
C o
a l ty
v Improved iCustomer satisfaction.
Q u
v Improved Delivery and Service.
ns h
Av Maximum ROI(Return of Invenstment)
v Minimum Waste.
v Minimum Cost of Non-conformance product.
6
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Product Quality Planning Cycle

PDCA Cycle tors
i

Used Only Training Purpose

P= Plan aud
and
D= Do
i ng
C= Check rai n
ts t
A= Act
l tan
n su
Co
a l i y
1. Plan and Define program
t
u and Development
2. ProductQDesign
n sh
A
3. Process Design and Development
4. Product & Process validation
5. Feed back, Assessment and Correction.

7
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APQP – timing chart and phases - AIAG
The Advanced Product Quality Planning process consists of four phases and five major activities and has

s
some 20+ supporting tools (e.g. DFMEA, PFMEA, CTQ, Special Characteristics, Control Plan, SPC) along
with ongoing feedback assessment and corrective action.
i tor

Used Only Training Purpose

aud
and
i ng
rai n
ts t
l tan
nsu
Co
al i ty
Qu
nsh
A

88
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APQP- Overview
Concept initiation / Program Approval
approval Prototype Pilot Launch

tors
i

Used Only Training Purpose

Planning a u d
Planning
a n d
Product Design and
i ng
Dev.
rai n
ts t
l tan
Process Design and Dev.
n u
s Product and Process
Co
a l i ty Validation
Q u Production
nsh
A Feedback Assessment and Corrective Action
Plan and Define Feedback
Product Design & Process Design and Product and
Program Assessment and
Development Development Process
Corrective Action
Verification Verification Validation

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APQP- Phases (Activity)

Phase 1 : Plan & Define Program
tors
i

Used Only Training Purpose

• Where do we want to go?
aud
a n d
i ng
Phase 2 : Product Design & Development Verification
ra i n
• Can we design one ?
ts t
lta n
n u
Phase 3 : Process Designs& Development Verification ?
• Can we make C o
one?
a l i ty
u
Q4 : Product & Process Validation?
ns h
Phase
A • Proof of Phases 2 and 3.
Phase 5 : Feedback Assessment & Corrective Action
• Production, continuous Improvement, Prevent Recurrence

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Pre Planning (Fundamental of Product Quality Planning)

v Organization team, Appoint Leader, Appoint team members

tor s
i

Used Only Training Purpose

d
(Marketing, Design, Development, Quality, Production, Supplier
au
development, Logistics)
and
i ng
v Define roles and responsibility.
rai n
ts t
v Define scope for project
l tan
v Customer and Organization n u
s involvement
C o
a l
v Decide target, i ty
Quality goal.
Q u
s h
v Decide training needs.
An
v Decide potential supplier list.
v Product Quality Timing Plan.
v Make APQP timing plan (tentative)
11
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tors
i

Used Only Training Purpose

aud
and
i ng
rai n
ts t
l tan
nsu
Co
al i ty
Qu
nsh
A

12
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A Simple APQP Timing Plan

tors
i

Used Only Training Purpose

aud
d
Time

n
Program Event

g a Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

i ni n
1) Submit Team Feasibility Commitment Form
tra
nts
2) Source Selection by Aptiv P.O. Issued

ul ta
3) Initiate APQP Activity
ons
i ty C
al
4) Develop Product Quality Timing Plan

u
h Q
s
5) Complete Preliminary Process Flow Diagram

An
6) Complete Preliminary Listing of Special Product and Process
Characteristics

7) Design FMEA- Develop or Obtain Copy

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Type of APQP Phases

tors
i

Used Only Training Purpose

1- Planning (Plan and Define Program)d au d
g an
i ni n
tra
2 - Product and design development
nts
ul ta
3 - Process designo nsand development
i ty C
u al
h Q
A4ns
- Product and process validation

5 - Feedback assessment and correction action

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Phase-1 Plan and Define Program

Customer interviews, Customer questionnaires and
t o r s
i

Used Only Training Purpose

v Team feasibility study report surveys, Historical Warranty and Quality Information
a u d
d
Best Practices, warranty returns and rejections,
v Voice of the Customer
g a n
v Market Research
n i n
Market test and positioningireports,
t a
rBest Practices
Best Practices, Competitive
v Design Goals
t s
product quality studies.
n
u l ta
o n s
v Preliminary Listing of Special Product and Process Characteristics

i ty C
u a l
v Reliability and Quality Goals

h Q Bill of Material
v Preliminary
n s
Av Preliminary process Flow Chart
v Product Assurance Plan Finalization
v Management Support

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Phase-1 Inputs Phase -1 Outputs

(Phase 2 input)
tors
i

Used Only Training Purpose

• Voice of the Customer

aud • Design Goals

Phase-1 d
•Market Research
•Historical Warranty and Quality Information
g an • Reliability and Quality Goals

i n
• Preliminary Bill of material

i n
•Team Experience

a
• Preliminary Process Flow chart
• Business Plan and Marketing

s tr
t
• Preliminary listing of Special

n
• Product / Process Benchmark Data
• Product / Process Assumptions
ul ta Product and process Characteristics

• Product Reliability Studies

ons • Product Assurance Plan

C
• Management Support

ty
• Customer inputs

u a l i Activities
h Q
Ans • Determination of product, cost, Delivery, QMS requirements
• Feasibility Study, Risk analysis and mitigation plan
• Sourcing decision ( Supplier Selection)
• Project Planning (in house and outsourced) tasks, targets, time & teams)
• Techno-commercial agreements and contract reviews with customer and suppliers

16
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Phase-1 Plan and Define Program

tors
i

Used Only Training Purpose

Reliability Goals a u d
a n d
i n g
Translating the voice of customer in
r a i n
ts t
to reliability objectives such as
l tan Quality Goals
1. Failure free life period
ns u
2. Maintainability targets
C o
3. Service costs lity
4. ServicingQ u a Translating the voice of customer in

s h frequency

A5. nSpare part requirement

to reliability objectives such as
1. Part per million
2. DPMO, PPM, Yield
3. Cost of quality targets
4. Scrap reduction

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Phase-1 Plan and Define Program

Preliminary Bill of Material
tors
i

Used Only Training Purpose

a u d
Make Levels of Production -
Preliminary Process flow Diagram
a n d
i ngfor each product level
i n
1. System
a
Make process flow diagram
2. Sub-System
s tr : – Assembly process flow diagram
n t Level :- Assembly process flow diagram
1. System Level
2.aSub-System
t
3. Components

sul
Have Part-wise BOMs Which
Con 3. Components level :- process flow diagram
includes
a l i ty A typical process flow diagram would include
1. Material
Q u 1. Operation name

s h
A3. nQty.
2. Overall Sizes, 2. Incoming Sources of variation
3. Symbols for Activities
4. Material Standard 4. Production Characteristics
5. Process Parameters

A process flow chart along-with tentative shop layout at this stage would be an advantage

18
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Phase-2 Product & Design Development

v Prepare DFMEA tors
i

Used Only Training Purpose

aud
nd
v Design of manufacturability and assembly
a
i ng
v Design verification plan s train
ant
v Prototype controls u l
plan t
Con
i
v Engineering
al ty Drawing
Q u
h
vnsEngineering specification
A
v Material specification
v Design and specification changes

19
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Phase-2 Inputs Phase -2 Outputs

(Phase 3 input)
• Design Goals

tors
i

Used Only Training Purpose

• Design Failure Mode and
d
• Reliability and Quality Goals
• Preliminary Bill of material
d a
• Output by Designu Effects Analysis (DFMEA)
• Design For
• Preliminary Process Flow chart
g an
Responsible activity Manufacturability and Assembly

n
(Design Outputs)
i
• Design Verification
• Preliminary listing of Special

rai n
• Outputs by • Design Reviews

t
Advanced Product • Proto type Build – control Plan

ts
Product Characteristics and Quality Planning
n
• Engineering Drawing
process Parameters
Phase-2ult
a Team (APQP Outputs) • Engineering Specifications
• Product Assurance Plan
o n s • Material Specifications
• Drawing and Specification
• Management Support

i ty C Changes

ua l
h Q Activities Outputs by APQP Team

Ans
1. Product Drawing including Engineering , material & Test Spec.
• New Equipment, Tooling and
Facilities Requirements
2. Design for manufacturability and Assembly • Special Product and Process
Characteristics
3. Special product and process Characteristics Determination
• Gauge / Testing equipment
4. Design Failure mode and Effect analysis Requirement s
5. Prototype Build and Testing • Team Feasibility Commitment &
Management Support

20
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Phase-2 Product & Design Development

tors
i

Used Only Training Purpose

Design for Manufacturing & Assembly
aud
1. Design for Resting. Location, Clamping and Processing
and
2. Design of Fits (Clearance, Transition, Press)
i n g
ra i n
t
3. Design of Allowances for Processing
4. Design of tolerances for processing
n ts
u l ta
s
5. Design of Poka yoke for Mfg and assembly.
6. Tolerance Analysis
C o n
l i ty
7. Design for Measurability
a
Q u
s
Design h Verification Plan and Report (DVP & R)
A1.n Highly Correlated Virtual Analysis FEA,(Failure effects analysis) etc.
2. Degradation Testing
3. Pass-fail Testing Make Levels of Production -
4. Test to Failure
1. System , 2. Sub-System, 3. Components
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Phase-2 Product & Design Development

Design Reviews
tors
i

Used Only Training Purpose

aud
To Know whether customer requirements are being met or not.and
i ng
r ai n
ts t
Use of design review Checklist Initiate Corrections

lta n
Engineering specification s
n u
Technical Data
C o
a l i
1. System, Sub Systemty Assembly Drawings
Q u
s h
2. Component Drawings
An
3. Material Standards
4. Inspection and test Standards
5. Engineering Data

22
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Phase-2 Product & Design Development

Prototype Control Plan
tors
i

Used Only Training Purpose

a u d
1. Define prototype manufacturing process
a n d
2. Define Dimensional, Material and
i ng
performance Characteristics for each system, DVP=
rai nDesign Verification Plan,
subsystem and component.
s t
t CC= Critical Characteristics,
3. Define Inspection and control method.
l tan
n s u
Prototype Buildity C
o SP=Special Characteristics,
u a l
h Q samples
2. n
A s
1. Make prototype
Dimensional verification
3. Material verification
4. Performance test.
5. Reliability test as per DVP

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Phase-2 Product & Design Development

Product Changes
tors
i

Used Only Training Purpose

a u d
1. Specification Changes
a n d
2. Material Changes
i ng
3. Inspection and test standard changes DVP=
rai nDesign Verification Plan,
s t
t CC= Critical Characteristics,
n
4. Validation of changes
5. Change approvals
u l ta
o n s
i ty C SP=Special Characteristics,
Critical and Special
u a l
Q
Characteristics
h
1. n s
A at system,CCsub-system
Finalize and SC for product and process
and component levels
2. Indicate SC, CC on drawings & standards
3. Decide control mechanism for SC, CC.

24
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Phase-2 Product & Design Development

tors
i

Used Only Training Purpose

Facility, Tooling Requirement
aud
1. Manufacturing Facility Planning
and
i ng
2. System wise assembly fixture plan
rai n
3. Sub-system wise Assembly fixture plan
ts t
4. Component wise tooling plan
l tan
n su
C o
a
Gauges, Instrumentl i ty Requirement
Q u
sh
A2. nSub-system wise Gauging plan
1. Component wise Gauging plan

3. System wise Gauging plan

4. Instrumentation Planning
5. Test Equipment Planning

25
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Phase-3 Process design and development

v Packaging Standards and specification
tors
i

Used Only Training Purpose

v Product process Quality system review aud
g and
v Process flow chart finalization
i ni n
tra
v Characteristic matrix
n ts
v Process ( PFMEA n ) sult
a
C o
v
ua lityof pre launch control plan
Preparation
vnsh Qinstruction for all the activity
Work
A
v MSA planning
v Process capability study planning

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Phase-3 Inputs
• Output by Design

tors
i

Used Only Training Purpose

Responsible activity
• Design Failure Mode and
aud
• Outputs by Advanced • New Equipment, Tooling and

d
Product Quality Facilities Requirements
n
Effects Analysis (DFMEA)
• Design For
g a
Planning Team • Special Product and Process
Manufacturability and Assembly
i ni n Characteristics

a
• Gauge / Testing equipment

r
• Design Verification
• Design Reviews
t s t
Phase-3 Requirement s

n
• Team Feasibility Commitment &

a
• Proto type Build – control Plan
• Engineering Drawing

sul t Management Support

n
• Engineering Specifications
• Material Specifications
Co
y
Phase 3 Outputs (Input for Phase 4)

l i
• Drawing and Specification

a t • Packaging Standards and Specifications

u
Changes

Q
• Product/ Process Quality System Review

nsh •
•
Process Flow Chart
Floor Plan Layout
A •
•
Characteristics Matrix
Process Failure mode and Effect Analysis (PFMEA)
• Pre- Launch Control Plan
Phase -3 Outputs • Process Instructions
• Measurement System Analysis Plan
(Phase 4 input) • Preliminary Process Capability Study Plan
• Management Support

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Phase-3 Process design and development

Phase-3 Inputs Phase-3 Outputs
(Input Phase-4)ditors

Used Only Training Purpose

• Design Failure Mode and

d au
n
Effects Analysis (DFMEA)
• Design For Manufacturability and
g a • Packaging Standards & Specifications
Assembly
i ni n • Product/process Quality System Review

a
• Process Flow Chart
r
• Design Verification
• Design Reviews
ts t • Floor Plan Layout

n
• Characteristics Matrix PFMEA
a
• Proto type Build – control Plan
• Engineering Drawing

sul t
Phase-4
• Pre-lunch Control Plan

n
• Engineering Specifications • Process Instructions,
• Material Specifications
Co • Measurement System Analysis Plan (MSA)

al
• Drawing and Specification
i ty •
•
Preliminary Process Capability Study Plan (SPC)
Management Support
u
Changes

h Qof APQP Team Activities

An s
Outputs
• Process Flow diagram and Charts for Child Parts,
• New Equipment, Tooling and Facilities Requirements Sub-Assemblies and Assemblies
• Special Product and Process Characteristics • Tool, Fixture, Dies, Moulds and gauges design
• Prototype Control Plan Gages • Process Failure Mode and Effect Analysis
• Gauge / Testing equipment Requirement s • Manufacturing Flow and Layout Design
• Team Feasibility Commitment & Management Support • Work Instructions
•Pre-launch Control plan 6

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System Level Assembly Process Design

Assembly Process Design Outputs

tors
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
aud
3. Tools, Fixtures, Dies, Moulds
1. Process
and
4. Gauges, Templates, Master Samples flow
i ng
Diagram
5. Instruments
r a i n
6. Test Equipments
ts t
7. Material Handling and Storage
l tan
8. Machine
ns u
C o
9. Man Knowledge, Skills, Competency
10. Safety
a l i ty
u
QWork
11. Documentation, Records 2. Process
s h
12. Standard
nProcess Capability
parameter
A13.
14. Measurability
sheet/Setup
15. Maintainability checklist
16. Reliability
17. Productivity
18. Cost

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System Level Assembly Process Design

Assembly Process Design Outputs
Tool Design
tors
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
aud
3. Tools, Fixtures, Dies, Moulds
a n d
4. Gauges, Templates, Master Samples
i n g
5. Instruments
a i n
r Cutting Programmers
t
1. Tool Assembly/ Past Drawings
6. Test Equipments
n s
t Bill of material
2. Tool Profile
7. Material Handling and Storage
ul ta3. Tools
8. Machine
o ns 4. Tools Poka Yoke List

i t C
9. Man Knowledge, Skills, Competency
y 5. Tools low cost automations
10. Safety

u a l 6. Tool Maintenance plan

Q
11. Documentation, Records

s h Capability
12. Standard
13.nProcess
Work

A14. Measurability
15. Maintainability
16. Reliability
17. Productivity
18. Cost

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System Level Assembly Process Design

Assembly Process Design Outputs
Gauge Design
tors
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
a u d
3. Tools, Fixtures, Dies, Moulds
n d
1. Checking Fixture/Gauge/Template
a
4. Gauges, Templates, Master Samples
i n g bill of material
Assembly/Part Drawing
5. Instruments
r a i n
2. Checking Fixture
6. Test Equipments
t t
sGauge low cost automations
3. Gauge Poka Yoke List
7. Material Handling and Storage
l t n
a 5. Gauge Reifications & Maintenance Plan
4.
8. Machine
ns u
C o
9. Man Knowledge, Skills, Competency
10. Safety
a l i ty
Q u
11. Documentation, Records

s h Capability
12. Standard
13.nProcess
Work

A14. Measurability
15. Maintainability
16. Reliability
17. Productivity
18. Cost

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System Level Assembly Process Design

Assembly Process Design Outputs

tor s
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
a u d
3. Tools, Fixtures, Dies, Moulds
Characteristics Tolerance a n d
4. Gauges, Templates, Master Samples
i n g
5. Instruments
ra i n
6. Test Equipments
t s t criteria for errors
1. Instrument Selection Least Count, Range make
7. Material Handling and Storage
l t n
2. Acceptance
a
8. Machine
n u 3. Calibration Plan
s 4. Acceptance criteria for gauge R&R , Bias,
C o
9. Man Knowledge, Skills, Competency
10. Safety
a l i ty Linearity and Stability.

Q u
11. Documentation, Records
5. Measurement System Analysis Plan

s h Capability
12. Standard
13.nProcess
Work
A14. Measurability
15. Maintainability
16. Reliability
17. Productivity
18. Cost

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System Level Assembly Process Design

Assembly Process Design Outputs

to r s
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
Selection of material HandlingaEquipment u d
3. Tools, Fixtures, Dies, Moulds
a n d
4. Gauges, Templates, Master Samples
2. Selection ofin i n
1. Selection of Materialg Storage Layout.
a
5. Instruments
r
bins design of special purpose
racks,treturnable
s
6. Test Equipments

a n t bins (input/output/WIP)
packing, layout of material
7. Material Handling and Storage
8. Machine
s ul t storage

C o n
9. Man Knowledge, Skills, Competency
3. Manufacturing/Purchase of material storage
schemes
10. Safety
al i ty 4. L a y o u t o f m a t e r i a l s t o r a g e b i n s
Q u
11. Documentation, Records
(input/output/WIP)
s h Capability
12. Standard
13.nProcess
Work

A14. Measurability
15. Maintainability
16. Reliability
17. Productivity
18. Cost

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System Level Assembly Process Design

Assembly Process Design Outputs
Selection of machine
tors
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters 1. Machine capability calculations
aud
3. Tools, Fixtures, Dies, Moulds
n d
2. Process parameter Finalization
a
4. Gauges, Templates, Master Samples
i n g
5. Instruments
r a i n
6. Test Equipments
t s t
7. Material Handling and Storage
l ta n
8. Machine
n s uMachine TBM & CBM Plan
C o
9. Man Knowledge, Skills, Competency
10. Safety
a l i ty 1. Machine spares availability.
u
QWork
11. Documentation, Records 2. Machine MTBF & MTTR in targets.

s h
12. Standard
n
3. Machine maintenance instruction
A13. Process Capability
14. Measurability TBM = Time based maintenance
15. Maintainability
CBM = Condition-based maintenance
16. Reliability
17. Productivity MTBF = Mean Time Between Failure
18. Cost MTTR = Mean Time To Repair

34
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System Level Assembly Process Design

Assembly Process Design Outputs
Knowledge
to rs
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
1. Product knowledge au d
3. Tools, Fixtures, Dies, Moulds
a
2. Process knowledge n d
4. Gauges, Templates, Master Samples
i n g
3. Defect knowledge
5. Instruments
r a i n
5. t Safe working conditions
4. Documentation knowledge
s
6. Test Equipments

a n t
t
7. Material Handling and Storage
8. Machine
su l 6. Supervisor & Operator training plan
9. Man Knowledge, Skills, o
C n
Competency
10. Safety
a l i ty
u
QWork
11. Documentation, Records
Skills Competency
s h
12. Standard
13.nProcess
A14. Measurability
Capability 1. Setting skills
2. Operating skills
1. Productivity target
achievement
15. Maintainability 3. Inspection skills 2. Quality target
16. Reliability 4. Maintenance skills achievement
17. Productivity
18. Cost
Skills & Competency Development Plan
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System Level Assembly Process Design

Assembly Process Design Outputs

tors
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
a u d
3. Tools, Fixtures, Dies, Moulds
a n d
4. Gauges, Templates, Master Samples
i n g
5. Instruments
ra i n
6. Test Equipments
ts t
7. Material Handling and Storage
l tan
8. Machine
nsu Safety
Co
9. Man Knowledge, Skills, Competency

al
10. Safety
i ty 1. PPE (Personal Protective Equipment)
11.
Qu
Documentation, Records

h
2. Safety Instructions safety Poka-yoke

Ans
12.
13.
Standard Work
Process Capability
14. Measurability
15. Maintainability
16. Reliability
17. Productivity
18. Cost

36
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System Level Assembly Process Design

Process Documentation
Assembly Process Design Outputs

tors
i

Used Only Training Purpose

1. Process Sequence/Flow
d
1. Product Drawings
2. Process Parameters 2.
d au Process Parameter Sheets
3. Tools, Fixtures, Dies, Moulds

g an3. Stage wise Drawings

n
4. Gauges, Templates, Master Samples 4. Process Flow Diagram / Chart
5. Instruments
ai ni 5. Control Plan & Process FMEA
6. Test Equipments
s tr 6. Work Instructions

ant 7. Set - up Instructions

t
7. Material Handling and Storage
8. Machine
sul 8. Inspection , Rework and Re - inspection

Con
9. Man Knowledge, Skills, Competency
9.
10.
Instructions
Maintenance Instructions
10. Safety
a l i ty 11. Safety Instructions
u
11. Documentation, Records
QWork
12. PM plan, MSA & SPC Plan

s h
12. Standard
13.nProcess
13. Calibration and Re - verification Plan

A14. Measurability
Capability
Process Records
14. Inspection Checklists

15. Maintainability
16. Reliability 1. Production & Inspection Reports, 2. SPC & MSA results,
17. Productivity 3. Operator Training Records, 4. Operator Skill Matrix
18. Cost 5. Tool History Card, 6. Machine History Card, 7. 8D reports

37
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System Level Assembly Process Design

Assembly Process Design Outputs
Standard work
to rs
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
Standard work is the practiceaof u d
, ad
setting,
c o m m u n i c a t i n g , f o l l o w i nagn
3. Tools, Fixtures, Dies, Moulds

gstandard work begins

nd improving
n
4. Gauges, Templates, Master Samples
5. Instruments standards. Establishing
with creating, a i n i
6. Test Equipments
t r clarifying, and sharing information
smost efficient method to perform a task
n t
about the
a is currently known with everyone performing
t
7. Material Handling and Storage
8. Machine
ulthat
s that process.
Con
9. Man Knowledge, Skills, Competency
10. Safety
a l i ty
u
11. Documentation, Records Examples of standardized work include specific

h Q Work task procedures like how to install a bolt, line

s
12. Standard
13.nProcess setup/changeover processes, and safety
A14. Measurability
Capability
procedures such as lockout/tag out.
15. Maintainability
The form should show the three elements that
16. Reliability
constitute standardized work: the current takt time (and cycle time) for
17. Productivity
18. Cost
the job, the work sequence, and the amount of required standard in-
process stock to ensure smooth operations
38
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System Level Assembly Process Design

Assembly Process Design Outputs
Process Capability Targets
tors
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
1. Identification of special and a u d
3. Tools, Fixtures, Dies, Moulds
a n d Process
critical

g
characteristics that that need
n
4. Gauges, Templates, Master Samples
5. Instruments
a i n i
capability study.
6. Test Equipments
tr
2. Plan ongoing process capability study
s Size, Sampling Frequency,
n t
(Sample
a control chart, control limits)
t
7. Material Handling and Storage
8. Machine
sul
Con
9. Man Knowledge, Skills, Competency
10. Safety
a l i ty Two sided table

Q u
11. Documentation, Records
Sigma l PPM out of
s h
12. Standard Work
13.nProcess
Cpk /Ppk
evel tolerance
A14. MeasurabilityCapability 1.33 4.0 63.342
15. Maintainability
16. Reliability 1.50 4.5 6.795
17. Productivity
1.67 5.0 0.573
18. Cost

39
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System Level Assembly Process Design

Assembly Process Design Outputs
Measurability tor s
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
a u d
3. Tools, Fixtures, Dies, Moulds
a n d
1. Instrument Selection Least Count, Range make

3. Calibration Plannin
4. Gauges, Templates, Master Samples
g
2. Acceptance criteria for errors
5. Instruments
tra i
s
6. Test Equipments
t and Stability.
4. Acceptance criteria for gauge R&R , Bias,
7. Material Handling and Storage
l a n
5.t Measurement System Analysis Plan
Linearity
8. Machine
nsu
Co
9. Man Knowledge, Skills, Competency
10. Safety
a l i ty
u
11. Documentation, Records
Q
s h
12. Standard Work
n
A14. Measurability
13. Process Capability

15. Maintainability
16. Reliability
17. Productivity
18. Cost

40
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System Level Assembly Process Design

Assembly Process Design Outputs Maintainability
o r
t of s
i

Used Only Training Purpose

1. Process Sequence/Flow
2. Process Parameters
to u
d
Maintainability is the measure of the ability
an item to be retained in or restored a
3. Tools, Fixtures, Dies, Moulds
a n d a specified
4. Gauges, Templates, Master Samples
i g
condition when maintenance is performed by
n skill levels using
5. Instruments
r a i n
personnel having specified
6. Test Equipments
t t
prescribed procedures and resources at each
s level of maintenance and repair
7. Material Handling and Storage
l ta n
prescribed
8. Machine
n u
s Machine TBM & CBM Plan
Co
9. Man Knowledge, Skills, Competency

al
10. Safety
i ty 1. Machine spares availability.
Qu
11. Documentation, Records
2. Machine MTBF & MTTR in targets.
sh
12. Standard Work
n
3. Machine maintenance instruction
A
13. Process Capability
14. Measurability TBM = Time based maintenance
15. Maintainability
CBM = Condition-based maintenance
16. Reliability ( �ढ㮈�rial )
17. Productivity MTBF = Mean Time Between Failure
18. Cost MTTR = Mean Time To Repair

41
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System Level Assembly Process Design

Productivity
Assembly Process Design Outputs

tors
i

Used Only Training Purpose

1. Process Sequence/Flow
d
1. Cycle time,
2. Process Parameters 2.
a u
Throughput time
d
Time
3. Tools, Fixtures, Dies, Moulds

g
3.
a n
Bottleneck Cycle time,

n
4. Gauges, Templates, Master Samples
i
4. Set up time Output Rate
5. Instruments
1.rai n Movement
6. Test Equipments
t
Travel ts 2. Man Movement
Material
7. Material Handling and Storage
l tan
8. Machine
nsu 3. Man Motions and Ergonomics

Co
9. Man Knowledge, Skills, Competency
1. Loading, Unloading,

ual
10. Safety
ity
11. Documentation, Records
2. Locating Clamping.

h Q Task 3. Processing & Inspection.

s
12. Standard Work 4. Set-up, Rework and Re-inspection
An
13. Process Capability
14. Measurability
5. Autonomous Maintenance

15. Maintainability 1. Customer Demand Available time

Takt Time
16. Reliability
17. Productivity
18. Cost WIP 1. No of Pieces between two stations

42
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APQP- Phase-4 Product and Process Validation

Phase-4 Inputs Phase-4 Outputsitors

Used Only Training Purpose

d aud
(Input Phase-5)
n
• Packaging Standards and Specifications
• Product/ Process Quality System Review
g a
• Process Flow Chart
i ni n • Significant Production run (PPAP)

• Floor Plan Layout

tra • Measurement System Evaluation

n ts • Preliminary Process Capability Study

a
• Characteristics Matrix

ul t
• Process Failure mode and Effect Analysis (PFMEA)
s
• Production Part Approval (PPAP)

n
• Production Validation Testing
o
• Pre- Launch Control Plan
• Process Instructions
ity C Phase-4 • Packaging evaluation

ual
• Measurement System Analysis Plan
• Production Control Plan

h Q
• Preliminary Process Capability Study Plan
• Quality planning sign –off

Ans
• Management Support
and Management Support

Activities
1. Production Control Plan 2. Production Line Setting and Production Trial Run
3. MSA Evaluation & Preliminary process capability (SPC) study
4.Production Part Approval Process(PPAP) 5. Product validation and testing 6. Approval and Sign Off

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APQP- Phase-4 Product and Process Validation

Production Part Approval Process(PPAP)

to r s
i

Used Only Training Purpose

a u d
PPAP Preparation Preparation for Significant Product
a n d
i n g
ra i n
t s t
n
Documentation Readiness Documentation Readiness

u l t a
o n s
1. Design Records
C
2. Engineering ChangeyRecords,
i t
1. Production Tooling

u a l approvals, If required. 3. Production Environment

if any. 2. Production Equipment

Q
3. Customer Engineering

5. n s h
4. Design FMEA (Controlled Conditions)
A Process Flow Diagram
6. Process FMEA
4. Production Operators
5. Production facility
7. Production Control Plan 6. Production gauges
7. Production Material Availability

44
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APQP- Phase-4 Product and Process Validation

PPAP Documentation
tors
i

Used Only Training Purpose

1. Design Records - Ballooned Drawing
a ud
2. Engineering Change Records, if any.
a n dPPAP
g
1 – 7 Before
3. Customer Engineering approvals, If required.
4. Design FMEA
i n i n(Preparation)
5.Process Flow Diagram
tra
ts
6. Process FMEA
7. Production Control Plan

l tan
nsu
8. Dimensional Results - Layout Inspection
9. Material test results (TC)
Co 8 – 13 During PPAP
ity
10. Performance test results

ual
11. Measurement System Analysis (MSA) (PPAP Results)
Q
12. Initial Process Capability Studies (SPC)

h
s
13. Appearance Approval Report

An
14. Qualified Laboratory Documentation 14 – 16 During PPAP
15. Checking Aids
16. Master Sample
(Quality Documentation)
17. Records of compliance with Customer Specific Requirements
18. Sample Product
17 – 19 After PPAP
19. Part Submission Warrant (Administrative)

45
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APQP- Phase-4 Product and Process Validation

Production Validation Testing
tors
i

Used Only Training Purpose

1. Performance tests- Run-@-Rate
aud
2. Endurance tests
and
3. Appearance Evaluation-as applicable
i ng
rai n
ts t
Packaging Evaluations
l ta n
ns u
Test Shipments for assessing protection of the
C o damage and
y
product from normal transportation

a l
adverse environmentali tfactors
u
Q sign-off
n s
Quality hplanning
A
Verify Process Flow Charts, Verify Control plan
Verify Process Instructions and linkages
Verify Monitoring and Measuring Devices
Verify capacity as per run@rate.

46
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APQP- Phase-5 Feedback Assessment & Correction Action
Phase-5 Inputs Phase-5 Outputs
to rs
i

Used Only Training Purpose

• Significant Production run
a u d
• Measurement System Evaluation
a n d
i n gVariation
• Preliminary Process Capability Study
r a i n
• Reduce
• Production Part Approval
t t
s • Improved Delivery and Service
• Improved Customer Satisfaction
• Production Validation Testing
l t n
aPhase-5 • Effective use of Lessons Learn /
• Packaging evaluation
ns u
• Production Control Plan C o
• Quality planninga l i y
t–off and
Best Practices

Q uSupport
sign

s h
Management
n
A Activities
1. Planning of review stages 2. Project Monitoring and reporting 3. Analysis of
Inspection, Test, Measurement, Monitoring, Verification and validation Results 4.
Customer Complaint Handling 5. Corrective Actions 6. Continual Improvements

47
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APQP- Phase-5 Feedback Assessment & Correction Action

Reduce Variation
tors
i

Used Only Training Purpose

a u d
a nd
1. Use of Control Charts and other Statistical Techniques to reduce variation
2. Analysis and action on Special Causes
i n g
3. Analysis and action on Common Causes tr a i n
n ts
u l ta
o n s
ty C
Improved Customer Satisfaction
i
a l
uon initial Complaints, Warranty Complaints
h Q
n s
1. Feedback
A2. Resolution of Complaints
3. Implementation of Best practices

48
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APQP- Phase-5 Feedback Assessment & Correction Action

Improved Delivery and Service

tors
i

Used Only Training Purpose

1. Capacity Enhancements aud
and
2. Inventory and Lead time reduction
i ng
3. Cost Reduction Projects
ra i n
ts t
4. Response time improvement
l tan
n u
s / Best Practices
Effective Use of LessonsC o
Learnt
a li ty
1. Review of u
h Q TGW/TGR

A2.n s
Data From warranty and Other Performance metrics
3. Corrective Action plans
4. Read-across with similar products and Processes
5. DFMEA and PFMEA studies

49
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Control Plan
to rs
i

Used Only Training Purpose

What is the Control plan ?
au d
a n d of quality
i ngquality standard are
A Control Plan is a method for documenting the functional elements

ra i n
control that are to be implemented in order to assure that
met for a particular product or service.
ts t
l tan
n su
Type of the Control plan C o
?
a l i ty
Q u sector, IATF-16949 and APQP. The three Type Control plan.
n s h
For the automotive
A
1- Prototype 2- Pre-Launch 3- Production

50
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Control Plan
tors
i

Used Only Training Purpose

Raw material
aud
and
i ng
rai n
ts t
l tan
nsu
Final product Co
al i ty
Qu
nsh
A

51
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AIAG Control Plan Format

tors
i

Used Only Training Purpose

aud
and
i ng
rai n
ts t
l tan
nsu
Co
al i ty
Qu
nsh
A

52
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AIAG Control Plan Format

tors
i

Used Only Training Purpose

aud
a n d
i n g
ra i n
ts t
l tan
n s u
C o
a l i ty
Prototype- A description of the dimensional measurements
Q u
material and performance tests occurring during Prototype build
n s h
A

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AIAG Control Plan Format

tors
i

Used Only Training Purpose

a u d
a n d
i ng
r ai n
t s t
l ta n
n s u
C o
a l i ty
Pre-Launch- A description of the dimensional measurements,
Qumaterial and performance tests that will occur after Prototype
sh
An
and before normal Production.

54
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AIAG Control Plan Format

tors
i

Used Only Training Purpose

a u d
a n d
i ng
r a i n
t s t
l tan
n s u
C o
al i ty
Production- A comprehensive documentation of
Qu product/process characteristics, process controls, tests, and
nsh measurement systems occurring during normal production
A

55
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AIAG Control Plan Format

tors
i

Used Only Training Purpose

Raw material
aud
and
i ng
r ai n
ts t
l ta n
n s u
Special, Characteristic, Classification
C o
a l i ty
Legend for class : C - Critical;
Q u
ns h M - Major;
A
S - Significant;
Mn - Minor

56
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AIAG Control Plan Format

tors
i

Used Only Training Purpose

aud
and
g
1 1

n
1 6

i
0 1
2 7

rai n 1

t
2

s
8 1

t
3

n
3

ta
1

l
4 5 9

u
4

ons
i ty C
ual
h Q
Ans

57
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AIAG Control Plan Format

tors
i

Used Only Training Purpose

aud
and
i ng
rai n
ts t
l tan
nsu
Co
al i ty
Qu
nsh
A

58
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AIAG Control Plan Format

tors
i

Used Only Training Purpose

aud
and
i ng
rai n
ts t
l tan
nsu
Co
al i ty
Qu
nsh
A

59
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AIAG Control Plan Format

tors
i

Used Only Training Purpose

aud
and
i ng
rai n
ts t
l tan
nsu
Co
al i ty
Qu
nsh
A

60
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PPAP Submission
tors
i

Used Only Training Purpose

aud
and
i ng
rai n
ts t
Sub Set
l tan
nsu
Co
al i ty
Q u
nsh
AAPQP Launch Binders PPAP Submission

The End Product of APQP

61
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Thank you for your i tors

Used Only Training Purpose

aud
and
kind Attention nts trai ni ng

ul ta
ons
i ty C
ual
h Q
Ans

62
62
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