Automotive

Core
Tool
s 1
Automotive Core Tools

Advanced Product Quality

Planning ( APQP)

Failure Mode and Effects Analysis

(FMEA)

Control Plan

Production Part Approval Process

( P PA P ) Statistical Process Control

(SPC)
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Automotive Core Tools

Examples: AIAG “Blue Book” Manuals

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Automotive Core Tools
Examples: Other Manuals

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 Core Tools in IATF 16949:2016

APQP: 8.3.2.1

FMEA: 8.3.2.1, 8.3.5.2

Control Plan: 8.5.1.1, Annex A

Product Approval Process (PPAP):

7.3.6.3

SPC: 9.1.1.2, 9.1.1.3

MSA: 7.1.5.1.1
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 APQP
Advanced Product
Quality Planning

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7
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 APQP
What is it?
Management of product development

Why do we use it?

To understand what our customer wants
and fulfill those wants

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Advanced Product Quality Planning
CONCEPT
PROGRAM
INITIATION APPROVA
L PROTOTYPE PILOT LAUNCH
/
APPROVA
L PLANNING
PLANNING
PRODUCT DESIGN AND DEV.

PROCESS DESIGN AND DEVELOPMENT

PRODUCT & PROCESS VALIDA

TION
PRODUCTION

FEEDBACK AS SESSMENT AND CO RRECTIVE ACTION

Planning Product
INPUTS Design & Product
| Dev. Process Feedback,
Planning Design & & Assessment &
INPUTS Dev. INPUTS
OUTPUTS | Process Corrective
| Validatio
Product Process Action INPUTS
Design n
Design & |
& Dev. INPUTS Feedback,
OUTPUTS Dev. OUTPUTS
| Assessment &
Product & Corrective
Process Action
Validation
OUTPUTS
10 OUTPUTS
APQP Plan and Define Phase

Concept Initiation/Approval
Inputs:
• Voice of the Customer
• Market Research (Including OEM Vehicle Timing and
Volume Expectations
• Historical Warranty and Quality Information
• Team Experience
• Business Plan/Marketing Strategy
• Product/Process Benchmark Data
• Product/Process Assumptions
• Product Reliability Studies
• Customer Inputs

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APQP Plan and Define Phase

Concept Initiation/Approval

Outputs:
• Design Goals
• Reliability and Quality Goals
• Preliminary Bill of Materials
• Preliminary Process Flow Chart
• Preliminary Listing of Special Product and
Process Characteristics
• Product Assurance Plan
• Management Support

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APQP Pr od uct Design and D e v e lo p m e n t Phase

Program Approval
Design Outputs: APQP Outputs:
• Design Failure Mode and Effects
• New Equipment, Tooling and
Analysis (DFMEA)
Facilities Requirements
• Design for Manufacturability
• Special Product and
and Assembly
Process Characteristics
• Design Verification
• Gages / Testing
• Design Reviews Equipment Requirements
• Prototype Build -- Control Plan • Team Feasibility
Commitment & Management
• Engineering Drawings
Support
(Including
Math Data)
• Engineering Specifications
• Material Specifications
• Drawing and
Specification Changes 13
APQP Process Design and D e ve l o pm e n t Phase

Prototype

Outputs:
• Packaging Standards and Specifications
• Product/Process Quality System Review
• Process Flow Chart
• Floor Plan Layout
• Process Failure Mode and Effects Analysis
(PFMEA)
• Characteristics Matrix
• Pre-Launch Control Plan
• Process Instructions
• Measurement System Analysis Plan
• Management Support
• Preliminary Process Capability Study Plan
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APQP Pr od uct and Process Validation Phase

Pilot

Outputs:
• Significant Production Run
• Measurement Systems Evaluation
• Preliminary Process Capability Study
• Production Part Approval
• Production Validation Testing
• Packaging Evaluation
• Production Control Plan
• Quality Planning Sign-Off and Management
Support

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APQP F e e d b a c k , A s s e s s m e n t a n d C o r r e c t i v e A c t i o n Ph a s e

Launch

Outputs:
• Reduced Variation
• Improved Customer Satisfaction
• Improved Delivery and Service
• Effective Use of Lessons Learned/Best
Practice

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ADVANCED PRODUCT QUALITY PLANNING

Pitfalls
• APQP treated as a “Quality Department
Responsibility”
• APQP a separate process, not integrated into
product development
• Key stakeholders brought in late (quality, production,
suppliers)
• Milestones and deliverables ignored
• No top management involvement/support

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 FMEA
Failure Mode and Effects
Analysis

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 FMEA
What is it?
A risk analysis of a part or process

Why do we use it?

To find and fix a problem before
something breaks or someone gets hurt

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Types of FMEAs

Design FMEA

Process FMEA

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Types of FMEAs

Others:
System FMEA
Concept FMEA

Environmental FMEA
Machinery FMEA
Software FMEA

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 FMEA Process
Subsystem C Potential O S D
Current
Potential Potential l Cause(s)/ c e a e R. Recommended t Responsibility Action Results
Controls
Failure Effect(s) Mechanism(s) c v s P. Action(s) e & Target Actions S O D R.
Function Mode of Failure of Failure u Prevention Detection N. Completion Taken e c e P.
Requirements s r c Date v c t
N.

What can be
What are How bad done?
the Effects? is it?
–Design
What are the
Changes
Functions, Features
or Requirements?
– Process
Changes

– Special
Controls

How – Changes to
What are Standards,
often
the Procedures, or
does it
What can go Cause(s)? guides
happen?
wrong?
–No function
– Partial /
Over
/Degraded
Function How can this be How good is
prevented and this method at
–Intermittent
detected? detecting it?
Function
– Unintended
Function

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Risk Action Strategies

1st Priority is Severity. Severity has a direct impact on the customer.

2nd Priority is Criticality (Severity times Occurrence: S x O). Criticality

evaluates the risk that an event with a high impact on the customer
will occur.

3rd Priority is RPN. RPN evaluates the ability to detect and

contain poor quality.

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Failure Mode and Effects Analysis

Pitfalls
• FMEA started late in the development process (just in
time
for PPAP!)
• FMEA never updated after release
• FMEA not updated from nonconformity corrective actions
• Right side (action area) is blank
• RPN thresholds
• FMEA written by one person
• FMEA treated as a “Quality Department Responsibility”

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Control Plan

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 Control Plan
What is it?
A summary of controls used to make sure my
customer gets good product

Why do we use it?

To make sure controls are used and stay in
place

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 Control Plan

CONTROLPLA
Prototyp Pre-
e Plan Number Launch
Control
Production
N
Key Contact/Phone Date (Orig.) Date (Rev.)

Part Number/Latest Change Level CoreTeam CustomerEngineeringApproval/Date (If Req'd.)

Part Name/Description Supplier/Plant Approval/Date CustomerQuality Approval/Date(If Req'd.)

Supplier/Plant Supplier Code Other Approval/Date(If Req'd.) OtherApproval/Date(If Req'd.)

MACHINE,
CHARACTERISTICS METHODS
PART/ PROCESSNAME DEVICE, SPECIAL
PROCESS / OPERATION JIG,TOOL CHAR.P RODUCT/PROCESS EVALUATION/ SAMPLE REACTIO
NUMBER DESCRIPTION S, NO. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREME SIZE FREQ. CONTRO N
FORMFG. TOLERANCE NT L PLAN
TECHNIQUE METHOD

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Control Plan Elements
IATF 16949 AnnexA
A.2 Elements of the control plan
The organization shall develop a control plan that includes, as a minimum, the following contents.
a) General data
⎯control plan number,
c) Process control
⎯ issue date and revision date, if any,
⎯ process parameters,
⎯ customer information (see customer requirements),
⎯ process-related special characteristics,
⎯ organization's name/site designation,
⎯ machines, jigs, fixtures, tools for manufacturing.
⎯ part number(s),
d) Methods
⎯ part name/description,
⎯ evaluation measurement technique,
⎯ engineering change level,
⎯ error-proofing,
⎯ phase covered (prototype, pre-launch, production),
⎯ sample size and frequency,
⎯ key contact,
⎯ control method.
⎯ part/process step number,
e) Reaction plan and corrective actions
⎯ process name/operation description.
⎯ reaction plan (include or reference),
b) Product control
⎯ corrective action.
⎯ product-related special characteristics,
⎯ other characteristics for control (number, product or process),
⎯ specification/tolerance.

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Control Plan

Pitfalls
• Control plan and PFMEA not aligned
• Control plan and operator instructions not aligned
• Control plan out of date
• Control plan not updated from nonconformity
corrective actions

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 PPA
P Part Approval
Production
Process

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 PPA
What is it? P
Requirements for approval of production parts.

Why do we use it?

To make sure that I understand all my customer
requirements, and that I can meet them under
actual production conditions.

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PPAP

1 Design Records
11 Initial Process Study
2 Authorized Engineering Change Documents
12 Qualified Laboratory Documentation
3 Customer Engineering Approval
13 Appearance Approval Report
4 Design FMEA
14 Sample Production Parts
5 Process Flow Diagrams
15 Master Samples
6 Process FMEA
16 Checking Aids
7 Control Plan
17 Customer-Specific Requirements (Records)
8 Measurement System Analysis Studies
18 Part Submission Warrant
9 Dimensional Results
Bulk Material Requirements Checklist
10 Material / Performance Test Results

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34
Production Part Approval Process

Pitfalls
• PPAP is treated as a separate process, rather than
integrated into product development
• Incomplete PPAP
• Assuming that submission levels are what’s required,
rather than what’s submitted

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 SPC
Statistical Process
Control

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 SPC
What is it?
A collection of statistical methods, especially
control charts, used to analyze and control a
process

Why do we use it?

To know when processes change and respond
accordingly
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Variatio
n

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Distributions can vary in Location

Location (Center): 3 key measures

Mean = Average or X

Median = Middle (by count)

Mode = Most often

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Distributions can vary in Spread

Spread: 3 key measures

Range = R

Standard Deviation =
 or s

Variance =  2

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Distributions can vary in Shape

Normal Distribution
68.25%

95.46%

99.73%

   X  2 3
3 2   

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Control vs. Capability Com mon and Special Causes

If only common causes of variation

are present, the output of a process
forms a distribution that is stable over
time and is predictable

If special causes of variation are

present, the process output is not
stable over time

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Control vs. Capability

Statistical Control
In- Control Out-of-Control
(Common Cause) (Special Cause)

Acceptable Case 1 Case 3

Variation
(Capability)
Unacceptable Case 2 Case 4

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Cp, Cpk, Pp & Ppk

Cp / Pp: can the car

fit into the garage?

Cpk / Ppk: does the

car fit into the garage?

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Measures of Process Capability
(Capability Index)
Within
Overall Subgroup
Within Variation Variation
Subgroup
Overall Variation Variation
if stable

Performance Ppk Cpk

Capability
Pp Cp
If centered

Overall Within
Kenneth J Kortge

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Capability Metrics – Acceptance Criteria

Typical:

Index  1.67 Acceptable

1.33 ≤ Index ≤ 1.67 May Be Acceptable

May require an improvement plan

Not
Index  1.33
Acceptable

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2 Types of Data

Va r i a b l e

Attribu
te
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Va ri a bl e s C h a r t s
Typical
:
Chart X-Bar & R Median Individual &
Type Moving Range
(MR)

Routine monitoring of Usually used as a

Primary manufacturing monitoring tool for Used when only one
Usage processes product or processes sample is possible

Plots the average size Plots the individual Plots the sample size
What Is and the range of the sizes of the parts and and the moving range
part sizes the median of the part of the sample size
Charted sizes

Sample Should be an odd

Subgroup Usually 3 to 6 One
Size number: 3, 5, 7, etc.

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Attribu t e Charts
Typical
:
Chart Type P Chart nP Chart C Chart U Chart
Primary Used for Used for Used for Used for
Usage analyzing analyzing the analyzing analyzing
proportion or number nonconformities nonconformities
percent nonconforming or defects per unit
nonconforming or or defective
defective parts parts

What is Plots the Plots the Plots the count Plots the average
proportion or number of of all number of
Charted percent of the nonconforming nonconformities nonconformities
nonconforming items found in the in each sample
units sample

Sample Variable Fixed Fixed Variable

Subgroup
Size

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X & R Chart

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How Control Charts Work

UCLX

LCLX

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Special Cause Criteria

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Special Cause Criteria

1. Most measurements cluster around the center (average) line

2. A few measurements approach the edges (control limits)
3. No measurements outside the control limits
4. Same number of measurements on both sides of the center
(mirror image)
5. Random (no patterns)

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Statistical Process Control

Pitfalls
• Ignoring out of control conditions
• Comparing control limits to spec limits
• Making process adjustments without understanding
the source of the special cause variation
• Putting SPC charts on everything

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 MSA
Measurement Systems
Analysis
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 MSA
What is it?
A collection of statistical methods used to assess how
much I can trust the information from a gauge

Why do we use it?

Since all my information about a part/process
comes from gauges, I need to know when the
gauge information is dependable, and do
something when it’s not

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Bias: difference between the measurement
and the "true" value

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Stability: change in bias over time

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Linearity: change in bias across expected range of
measurements

Note that unacceptable linearity can happen in a variety of ways.

Do not assume a constant bias.

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Gage Repeatability and Reproducibility = GRR = R&R

Variable, replicable measurements

Typical:

10 Parts
3 Appraisers
3 Trials

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GRR / R&R

2
GRR =
2
Reproducibility
2
+ Repeatability

% Total Variation vs. % Tolerance

Number of Distinct Categories

(NDC) 61
Repeatability: gage-induced variation

Appraiser A

Repeatability

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Reproducibility: operator-induced variation

Reproducibility

Appraiser A C B

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The Effect of Measurement Error
“Observed” “Actual”
Total Variation = Process Variation + Measurement Variation

2 2
2 Total =  Process + Measurement

Think of a
right triangle

Measurement
Variation

P
Kenneth J Kortge
r
o 64
The Effect of Measurement Error

Total Variation = Process Variation + Measurement Variation

2 2
2 Tota =  Process + Measurement
l

Measurement
Variation

W
Kenneth J Kortge
h
a 65
Gage R&R Acceptance Criteria (Typical)

% R&R
Under 10% error – Acceptable
10% - 30% error – May be acceptable based upon importance
of application, cost of measurement device, cost of repair, etc.
Over 30% error – Not Acceptable. Every effort should be
made to improve the measurement system

Number of Distinct Categories (NDC):

Greater than or equal to 5 – Acceptable
Less than 5 – Generally Not Acceptable

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Measurement Systems Analysis

Pitfalls
• Using MSA to obtain a number, rather than to understand
gage variation
• Not documenting a conclusion and any actions needed,
as part of the study
• Not conducting MSA for all gages on the control plan
(IATF 16949 requirement)
• Not validating Software (IATF 16949 requirement)
• Using wrong analysis method (non-replicable, attribute,
etc.)

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Automotive Core Tools

Advanced Product Quality

Planning ( APQP)

Failure Mode and Effects Analysis

(FMEA)

Control Plan

Production Part Approval Process

( P PAP ) Statistical Process Control

(SPC)
ASQ Automotive Division 68 Webinar
QUESTIONS

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