01 Apqp

Del
phi– TVS Di
eselSyst
emsLtd
Mannur,Tami
lnadu
Subcontractor Development
Training Program
*APQP *PPAP *CP *PFMEA*SPC
Mars Consultants
F5, Giri Apartment, #26A, Arcot Road,
Virugambakkam, Chennai – 600092
srini@marsconsultants.com
94440 84652, 94440 04929, 044-42072732
Objective
• Awareness on Advanced Product Quality Planning
• To understand APQP stages and Requirements
Mars Consultants Advanced Product Quality Planning

Introduction
APQP stands for Advanced Product Quality Planning
BIG THREE has published a manual on APQP
Structured method of defining and establishing the steps in

New Product Development
Promotes Simultaneous Engineering and Team Work
Execution is thru a Cross Functional Team (CFT)

compromising personnel at all functions and levels
This is to serve as a guideline for consistent approach to all

users

Benefits of APQP
Ø To direct resources to satisfy customers
Ø To promote early identification of required change
Ø To avoid late changes
Ø To provide a quality product on time at lowest cost
Ø Reduction in complexity of product quality planning
Ø Communicate Product Quality Planning

requirements to sub-contractors

Philosophy of APQP
• Spend a little extra time upstream,

so that downstream is error free
• How you spend the time is very

important

Fundamentals of APQP
• Organize a Team
• Define the Scope
• Team – To - Team
• Training
• Customer & Supplier Involvement
• Simultaneous Engineering
• Control Plans
• Concern Resolution
• Product Quality Timing Plan

Few Tips in Fundamentals of APQP
• Form a Cross Function Team (CFT) with a Project

Leader
• Team shall include all functions and all levels,

including customers and sub-contractors
• Define Roles & Responsibilities
• Identify and define Customer requirements &

Expectations
• Assess the feasibility of design, performance

requirements
• Prepare Gantt Chart (Road Map) with targets and

responsible person to meet the customer target date
• Conduct regular meetings to monitor the progress

and pro-actively communicate the progress to
customers
• Involve the customer and the supplier at all stages
• Focus towards Simultaneous Engineering. It would

help the development faster
Last but not the least…..

PROACTIVE APPROACH

Elements of good planning
Commitment
Training
Teamwork
Logical methodology
Sound techniques
Documentation
Communication
Feedback
Stages of APQP
PHASE I PLAN AND DEFINE

PHASE II Product design and development
PHASE III Process design and development
PHASE IV Product and process validation

Feedback, assessment and corrective
PHASE V action

PLAN & DEFINE PROGRAM - Inputs
1. Voice of Customer P
H
2. Business Plan & Marketing Strategy
A
3. Product / Process Benchmark Data
S
4. Product / Process Assumptions E
5. Product Reliability Studies
6. Customer Inputs
I

a. Market Research
Ø Customer Complaints
P
Ø Data / information from internal / external H
customers A
Ø Customer Interviews
S
b. Historical Warranty and Quality Information
E
Ø Things Gone Right / Things gone Wrong (TGR/TGW)
Ø Supplier and internal Quality Reports
Ø Customer Returns and Rejections I
c. Team Experience
P
2. Business Plan / Marketing Strategy
H
A
Ø Framework for Quality Plan
Ø May place Constraints viz. Timing, Cost, Investment
S
Ø Target Customers E

3. Product / Process Benchmark data P

ØIdentify appropriate benchmarks H
Ø Understand the reason for gaps between A
present and benchmark data S
Ø Develop plan to close the gap, match or exceed E
the benchmark

P
4. Product / Process Assumptions
H
Ø Certain features
A
Ø Process Concepts
S
Ø Tolerances
E

PLAN & DEFINE PROGRAM - Outputs
1. Design Goals P
2. Reliability & Quality Goals H
3. Preliminary Bill of materials A
4. Preliminary Process Flow Chart S
5. Preliminary Listing of special Product / process E
Characteristics
6. Product Assurance Plan
I
7. Management Support
PRODUCT DESIGN AND DEVELOPMENT
P
1. New Equipment, Tooling and Facilities H
requirement
A
2. Gages / Testing Equipment Requirement
S
3. Team Feasibility Commitment
E
II

PRODUCT DESIGN AND DEVELOPMENT
2. Team Feasibility Commitment & Management Support

P
• Assess the feasibility of proposed design H
• Look for manufacturability, assembly, packaging A
and delivery commitments
S
• Use the Team Feasibility Commitment Checklist E
II

PROCESS DESIGN AND DEVELOPMENT
1. Packaging Standards
2. Product / Process Quality System Review P
3. Process Flow Chart H
4. Floor Plan Layout
5. Characteristics Matrix
A
6. PFMEA S
7. Pre-launch Control Plan
8. Process Instructions
E
9. Measurement System Analysis Plan
10. Preliminary Process Capability Study Plan III
11. Packaging Specifications
1. Packaging Standards
P
• Follow Customer Specific Packaging standards H
• Ensure Product Integrity at point of use A
S
E
II

2. Product / Process Quality System Review

P
• Review Quality System Manual, Procedures and Quality /
H
Control Plan A
• An opportunity to improve the existing Quality systems S
• Use Quality System Review Checklist E
III

3. Process Flow Chart

• Schematic representation of current or proposed process
P
flow H
• Can be used to analyse the source of variation of machines, A
materials, method or manpower
S
• Helps to analyse the total process rather than individual
E
process
• Assists to focus on the process when conducting PFMEA and

designing Control Plan III
• Use Process Flow Chart Checklist
4. Floor Plan Layout

• Should be developed, reviewed to determine the
P
acceptability of H
- Inspection points
A
- Control Chart Locations
- Applicability of visual aids S
- Rework points E
- Storage area
- Use Floor Plan Checklist for guidance
III

Floor Plan Layout Checklist
Checkpoint Yes / No Comments Resp Target

Does the flow plan identify all required process and inspection points
Have clearly identified areas for all material, tools, and equipments at each operation been
considered
Are process and inspection areas are of adequate size, properly lighted
Are inspection points logically located to prevent shipment of non conforming products
Have controls been established to eliminate the potential for an operation, including outside
processing to contaminate or mix with similar parts
Have Final Inspection / Final Audits facilities been provided
Have control adequate to prevent movement of nonconforming incoming material to storage
or point of use

5. Characteristics Matrix
• Recommended analytical technique for displaying the
P
relationship between the PROCESS PARAMETERS and H
MANUFACTURING STATIONS
A
Operation Nos
Dimension
No
Description Specification
10 20 30 40
S
1 ID X C X E
2 Face X C L
C – Characteristics at an operation used for clamping III

L - Characteristics at an operation used for locating
X – Characteristics created or changed by this operation
6. Potential Failure Mode & Effect Analysis (PFMEA)

P
• Should be conducted before production
H
• Disciplined review and analysis of new / revised
process
A
• Considered to anticipate, resolve or monitor S
potential process problems E
• A LIVING DOCUMENT and needs to be reviewed
and updated as new failure modes are discovered III
• Use PFMEA Checklist to assist in its evaluation

P
• Description of dimensional measurements,
materials and functional tests that will occur after
H
production A
• include additional product / process controls to S
be implemented until production process is E
validated
• Purpose is to contain potential nonconformances III
during production process


P
• Emphasis on Pre-launch Control Plan is:
H
- More frequent Inspection
A
- More In-process and Final Check points
- Statistical Evaluations
S
- Increased audits
E
• Use Control Plan Checklist to assist evaluation
III

8. Process Instructions P
• Understandable process instruction H
• Sufficient detail for all operating personnel who
have direct responsibility for the process
A
• Shall include parameters such as machine speed, S
feed, cycle time etc E
• Accessible to operators and incharges
III

8. Process Instructions
• Instruction shall be developed from following P
sources H
- PFMEA - Control Plan - Drawings A
- Material Specification, Visual Standards
- Process Floor Chart, Floor Plan Layout S
- Characteristics Matrix E
- Packaging Standards
- Process Parameters
- Expertise and knowledge of operators III
- Handling Requirements
PRODUCT & PROCESS VALIDATION
1. Production Trial Run P

2. Measurement System Evaluation H
3. Preliminary Process Capability study
A
4. Production part approval
5. Production validation testing
S
6. Packaging Evaluation E
7. Production Control Plan
8. Quality Planning sign-off IV
9. Management support
1. Production Trial Run

• To be conducted using
P
- Production Toolings H
- Equipments A
- Environment including operators S
- Facility E
- Cycle time
Ø Minimum quantity for trail run is usually set by
the customer / CFT Team
IV

2. Measurement System Evaluation

• Specified Measurement devices and methods to
P
be used H
3. Preliminary Process Capability Study A
• To be performed on characteristics identified in S
Control Plan
E
4. Production Part Approval
• To validate that products made from production
tools and processes meet Engg requirements IV

5. Production Validation Testing P

• Engg Tests to validate that products made from H
production tools and processes meet Engg
requirements
A
6. Packaging Evaluation S
7. Production Control Plan E
• Description of systems for controlling parts and
processes IV
• Logical Extension of Pre-launch Control Plan

FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION
1. Reduced Variation P
2. Customer Satisfaction H
3. Delivery & Service
A
S
E

1. Reduced Variation P
• Control Charts H
• Analysis and Corrective action to reduce A
variation
S
• Reduction or Elimination of common cause
results in cost reduction E
• Value Analysis
V

2. Customer Satisfaction P
• Repeated Business H
• Further Development
A
3. Delivery & Service
S
• On-Time Delivery with right quantity E

The Climax
?
… Clarifications / Comments

Gratitude
… lets have a beginning. GOOD LUCK!!!

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Del

• Awareness on Advanced Product Quality Planning

• To understand APQP stages and Requirements

Mars Consultants Advanced Product Quality Planning

BIG THREE has published a manual on APQP

Structured method of defining and establishing the steps in

Promotes Simultaneous Engineering and Team Work

Execution is thru a Cross Functional Team (CFT)

This is to serve as a guideline for consistent approach to all

Mars Consultants Advanced Product Quality Planning

Ø To promote early identification of required change

Ø To avoid late changes

Ø To provide a quality product on time at lowest cost

Ø Reduction in complexity of product quality planning

Ø Communicate Product Quality Planning

Mars Consultants Advanced Product Quality Planning

• Spend a little extra time upstream,

• How you spend the time is very

Mars Consultants Advanced Product Quality Planning

Mars Consultants Advanced Product Quality Planning

• Form a Cross Function Team (CFT) with a Project

• Team shall include all functions and all levels,

• Define Roles & Responsibilities

• Identify and define Customer requirements &

• Assess the feasibility of design, performance

• Prepare Gantt Chart (Road Map) with targets and

• Conduct regular meetings to monitor the progress

• Involve the customer and the supplier at all stages

• Focus towards Simultaneous Engineering. It would

Last but not the least…..

Mars Consultants Advanced Product Quality Planning

PHASE I PLAN AND DEFINE

PHASE IV Product and process validation

Mars Consultants Advanced Product Quality Planning

Mars Consultants Advanced Product Quality Planning

Mars Consultants Advanced Product Quality Planning

3. Product / Process Benchmark data P

Mars Consultants Advanced Product Quality Planning

Mars Consultants Advanced Product Quality Planning

Mars Consultants Advanced Product Quality Planning

2. Team Feasibility Commitment & Management Support

Mars Consultants Advanced Product Quality Planning

Mars Consultants Advanced Product Quality Planning

2. Product / Process Quality System Review

Mars Consultants Advanced Product Quality Planning

3. Process Flow Chart

• Assists to focus on the process when conducting PFMEA and

4. Floor Plan Layout

Mars Consultants Advanced Product Quality Planning

Floor Plan Layout Checklist

Checkpoint Yes / No Comments Resp Target

Mars Consultants Advanced Product Quality Planning

C – Characteristics at an operation used for clamping III

6. Potential Failure Mode & Effect Analysis (PFMEA)

7. Pre-launch Control Plan

Mars Consultants Advanced Product Quality Planning

7. Pre-launch Control Plan

Mars Consultants Advanced Product Quality Planning

Mars Consultants Advanced Product Quality Planning

1. Production Trial Run P

1. Production Trial Run

Mars Consultants Advanced Product Quality Planning

2. Measurement System Evaluation