Advanced Product Quality Planning: Campodarsego, 4-8 April 2005

Chrysler, Ford, General Motors and Plexus QS-9000 Training System™
ADVANCED PRODUCT
QUALITY PLANNING
Campodarsego, 4-8 April 2005
Slide 1 - Page(s) © 1998 Plexus Corporation, Chrysler Corporation, Ford Motor Company, General Motors Corporation Third Edition
Advanced Product Quality Planning
Changing Customer Expectations
Without satisfied customers, a

business risks having no business.
Without delighted customers, a
business risks having no future.
Arnie Weimerskirch
Why plan?
 Identify ways to improve
 Means for tracking and checking
 Contingency planning
 Worst case planning
 Without a plan ...
What gets in the way of

planning?
 Lack of discipline
 Time management issues
 Unclear priorities
 Unclear responsibilities
 Lack of accountability
What is Advanced Product

Quality Planning (APQP)?
 Quality planning and more
 Total integration of quality tools with
management functions
 Multi-disciplinary team approach to quality
planning
 Tool to enable suppliers to not only meet
but exceed customer requirements
What is APQP?
 APQP is an attempt to ensure communication
both within a company and between a
company and their customer.
 APQP is an attempt to provide a common path
and synchronization of product development
activities.
 APQP is a ‘defined’ process for a product
development ‘system’ for Ford, GM, Chrysler
and their suppliers.
Slide 7 - Page(s) 4 © 1998 Plexus Corporation, Chrysler Corporation, Ford Motor Company, General Motors Corporation Third Edition
PRODUCT QUALITY PLANNING TIMING CHART

CONCEPT
INITIATION PROGRAM
/ APPROVAL
PROTOTYPE PILOT LAUNCH
APPROVA
L
PLANNING
PLANNING
PRODUCT DESIGN AND DEV.
PROCESS DESIGN AND DEVELOPMENT
PRODUCT & PROCESS VALIDATION
PRODUCTION
FEEDBACK ASSESSMENT AND CORRECTIVE ACTION
Planning
INPUTS Product Design &
| Dev. INPUTS
Planning | Process Design &
OUTPUTS Dev. INPUTS Product & Process
Product Design & | Validation INPUTS
Dev. OUTPUTS Production
Process Design & | INPUTS
Dev. OUTPUTS Product & Process |
Validation OUTPUTS Production
OUTPUTS
Slide 8 - Page(s) 5 © 1998 Plexus Corporation, Chrysler Corporation, Ford Motor Company, General Motors Corporation Third Edition
APQP
 It follows in all his phases the industrialization

of a new product, from his initial conception to
the beginning of the mass production
APQP- The structure
PLAN AN DEFINE PROGRAM -
Section 1.0
PRODUCT DESIGN AND DEVELOPMENT - Section
2.0
PROCESS DESIGN AND DEVELOPMENT- Section 3.0
PRODUCT AND PROCESS VALIDATION - Sezione

4.0
FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION -
Sezione 5.0
© 1998 Plexus Corporation, Chrysler Corporation, Ford Motor Company, General Motors Corporation Third Edition
Slide 10 - Page(s)8
APQP - Program
 The process is divided in 49 “tasks”, or
“performs”.
 Single events or complex activity whose
accomplishment has the only purpose the
production of a product which fully fulfill the
customer requirements all time.
PLAN AND DEFINE

1.1 Voice of the Customer
1.1.1 Market Research
1.1.2 Historical Warranty & Quality Information
1.1.3 Team Experience
1.2 Business Plan/Marketing Strategy
1.3 Product/Process Benchmark Data
1.4 Product/Process Assumptions
1.5 Product Reliability Studies
1.6 Customer Inputs
1.7 Design goals
1.8 Reliability and quality goals
1.9 Preliminary bill of material
1.10 Preliminary process flow chart
1.11 Preliminary listing of special product and process
characteristics
1.12 Product assurance plan
1.13 Management support
Slide 12 - Page(s)8 © 1998 Plexus Corporation, Chrysler Corporation, Ford Motor Company, General Motors Corporation Third Edition
PRODUCT DESIGN AND DEVELOPMENT

2.1 Design Failure Mode and Effects Analysis (DFMEA)
2.2 Design for Manufacturability and Assembly
2.3 Design Verification
2.4 Design Reviews
2.5 Prototype Build - Control Plan
2.6 Engineering drawings (including math data)
2.7 Engineering Specifications
2.8 Material Specifications
2.9 Drawing and Specification changes
2.10 New equipment, tooling and facilities requirements
2.11 Special product and process Characteristics
2.12 Gages/testing equipment requirements
2.13 Team feasibility committment and management support
PROCESS DESIGN AND DEVELOPMENT

3.1 Packaging standards
3.2 Product/process quality system review
3.3 Process Flow chart
3.4 Floor plan layout
3.5 Characteristics Matrix
3.6 Process Failure Mode and Effects Analysis (PFMEA)
3.7 Pre-launch control plan
3.8 Process Istructions
3.9 Measurement System Analysis Plan (MSA)
3.10 Preliminary Process capability study plan
3.11 Packaging Specifications
3.12 Management Support
PRODUCT AND PROCESS VALIDATION

4.1 Production trial run
4.2 Measurement Systems evaluation
4.3 Preliminary process capability study plan
4.4 Production Part Approval
4.5 Production validation testing
4.6 Packaging evaluation
4.7 Production Control Plan
4.8 Quality Planning sign-off and management support
FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION
5.1 Reduced Variation
5.2 Customer Satisfaction
5.3 Delivery and service
The Key Linkages for Special Characteristics In APQP
Design Data
FMEA’s
Control Plan(s)
Operator Instructions
PPAP
Mistake Proofing

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Chrysler, Ford, General Motors and Plexus QS-9000 Training System™

Changing Customer Expectations

Without satisfied customers, a

What gets in the way of

What is Advanced Product

PRODUCT QUALITY PLANNING TIMING CHART

PROCESS DESIGN AND DEVELOPMENT

PRODUCT & PROCESS VALIDATION

FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

 It follows in all his phases the industrialization

APQP- The structure

PLAN AN DEFINE PROGRAM -

PROCESS DESIGN AND DEVELOPMENT- Section 3.0

PRODUCT AND PROCESS VALIDATION - Sezione

FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION -

PLAN AND DEFINE

PRODUCT DESIGN AND DEVELOPMENT

PROCESS DESIGN AND DEVELOPMENT

PRODUCT AND PROCESS VALIDATION

4.2 Measurement Systems evaluation

4.3 Preliminary process capability study plan

4.4 Production Part Approval

4.5 Production validation testing

4.6 Packaging evaluation

4.7 Production Control Plan

4.8 Quality Planning sign-off and management support

FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION

5.1 Reduced Variation

5.2 Customer Satisfaction

5.3 Delivery and service

The Key Linkages for Special Characteristics In APQP

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