Professional Documents
Culture Documents
to the
Training Seminar
on
APQPCP
Nathan & Nathan Consultants Pvt. Ltd. NNCPL/PPT/001 1.
APQPCP
This program is designed to provide a working knowledge of the
INTRODUCTION
WHAT IS APQP?
OUTPUTS
Design goals
Reliability and quality goals
Preliminary bill of material
Preliminary process flow chart
Preliminary listing of special product and process
characteristics
Product assurance plan
Management support
INPUTS
Design goals
Reliability and quality goals
Preliminary process flow chart
Preliminary listing of special product and process characteristics
Product assurance plan
Management support
Customer requirement ( special ch., identification, traceability,etc)
Use of information
targets for product quality, life, reliability, durability, maintainability,
timing and cost )
Packaging standards
specifications and drawings
Product process quality system review
Process flow chart
Floor plan layout
Process approval acceptance criteria
Data for quality, reliability, maintainability and measurability
Results of error proofing activities
Methods of rapid detection and feedback of product/manufacturing
process non conformities
Characteristics matrix
Process failure mode and effects analysis (PFMEA)
Pre-launch control plan
Process instruction
Measurement systems analysis plan
Preliminary process capability study plan
Packaging specification
Management support
Nathan & Nathan Consultants Pvt. Ltd. NNCPL/PPT/001 17.
PRODUCT & PROCESS VALIDATION APQPCP
OBJECTIVES
Packaging standards
Product process quality system review
Process flow chart
Floor plan layout
Characteristics matrix
Process Failure Mode and Effects Analysis (PFMEA)
Pre-launch control plan
Process instruction
Measurement Systems Analysis Plan
Preliminary process capability study plan
Packaging specification
Management support
INPUTS
OUTPUTS
Reduced variation
Customer satisfaction
Delivery and service
TEAM LEADER
Each program has a team leader, but a team leader may manage
one or more programs. The team leader:
Team Composition
Team should be cross-functional; it is not composed of only people
from the Quality Department. Typical members might come from:
-Engineering
-Manufacturing
-Material Control
-Purchasing
-Sales
-Field Service
-Subcontractors
-Quality
-Industrial Engineering
-Maintenance
-Customers(as appropriate)
-Finance
Market Research
Customer interviews
Customer questionnaires and surveys
New Product quality and reliability studies
Competitive product quality studies
Things Gone Right (TGR) reports
Focus Group discussions
Asses customer and wants and the potential for their recurrence
EXERCISE 1 :
EXERCISE 2 :
The Business Plan Marketing Strategy are the basis of the Product
Quality plan
The Business Plan may define the direction the team will take
regard to:
-Timing
-Cost
-Investment
-Product positioning
-Research and development (R&D)
-Target objectives for obsolescence
Technical innovations
Advanced materials
Reliability assessments
New technology
OUTPUTS
DESIGN GOALS
Product assumptions
Functional performance
Dimensions
Weight
Materials
Aesthetic
EXERCISE 3 :
APQP Requirements
- APQP Scope
CLICK HERE
COMPONENT
SUBSYSTEM
SYSTEM
INPUTS
Design goals
Reliability and quality goals
Preliminary bill of material
Preliminary process flow chart
Preliminary listing of special product and process
characteristics
Product assurance plan
Management support
OBJECTIVES
EXERCISE 4 :
EXERCISE 5 :
OBJECTIVE
To ensure that the Design Output meets the Design Input requirements
To develop a Design Verification Plan
OBJECTIVES
Design Reviews are regularly scheduled meetings led by engineering and are intended
to prevent problems and misunderstandings and to monitor the progress of design
activities and report to management.
Design Reviews are more than engineering inspection; they are evaluations of :
Design/functional requirement considerations
Formal reliability and confidence goals
Component / subsystem / system duty cycles
Computer simulation and bench test results
DFMEAs
Review for the Design for Manufacturibility and Assembly effort
Design of Experiments (DOE) and assembly build variation results
Test failures
Design Verification progress
Safety Concerns
OBJECTIVES
OBJECTIVES
OBECTIVES
The product Quality planning team ensures the timely identification &
review of these characteristics
The relevant documents where they have to be identified are reviewed
Their designation symbols are consistent with the supplier’s system
There is an assessment of potential risks with these characteristics and
corrective actions are initiated in advance through Statistical Studies,
Mistake proofing, etc.
- Time schedules
- Testing requirements
- Packaging requirements
- Delivery requirements
- Cost objectives
- Quality Objectives
The team agrees that the proposed design is suitable for its
intended use and can be manufactured, assembled, tested,
packaged, and delivered in sufficient quantity and acceptable
cost and quality on schedule
Suppliers have completed risk assessment and determined
which suppliers will do a feasibility assessment
The team provides a feasibility document to the customer
INPUTS
Design goals
Reliability and quality goals
Preliminary process flow chart
Preliminary listing of special product and process characteristics
Product assurance plan
Management support
Customer requirement ( special ch., identification, traceability,etc)
Use of information
targets for product quality, life, reliability, durability, maintainability,
timing and cost )
PACKAGING STANDARDS
To ensure that the existing Quality System can meet the requirements
of the new product
To identify the system modification, additions to be done for meeting
the Quality Assurance requirements
To ensure that the team activity considers this element and it is timed
The responsibility for review of the system is defined
The review considers all aspects of the Quality System (Ref: ISO
9000/QS 9000)
The identification of new/modified documents, resources, training, etc.
are completed on time and action initiated for their completion
OBJECTIVES
Customer Prints
In-Process Prints
Plant Layout
Problems reports and Logs
System and / or Design FMEA
Process FMEA from a similar product or process
Note: The Process flowchart and the appropriate updates to the Floor Plan shall be
completed at this level. Other documents that will be partially or fully completed at
the same time as the Process Flowchart include the following :
Floor Plan
Characteristics Matrix (optional)
List of Special Product and Process Characteristics
Process flow
In-process prints
EXERCISE 6 :
CLICK HERE
List all the characteristics in order on the top row of the matrix
List all the operations in order by OP# on the left column of the matrix
Place a relationship symbols in interior cells in the Matrix RELATIONSHIP
SYMBOLS
Using the following symbols indicates the relationships between operations and
characteristics
OBJECTIVES
The primary objective of the Process Failure Mode Effects Analysis (PFMEA) is to
reduce manufacturing risk by :
Aiding in the analysis of new manufacturing and assembly processes
Assuring that potential manufacturing and / or assembly process failure modes
and effects are considered.
Identifying process deficiencies and provide for the development of controls to
resolve the problems by :
- Eliminating or reducing the frequency of unacceptable products
- Increasing the detection of unacceptable products
Identifying critical characteristics and significant characteristics contributing to
the development of a complete manufacturing control plan
Establishing priorities for process improvement activities
Providing automatic process design documentation to guide the development
of future manufacturing and assembly processes.
The Team Leader and APQP team should manage the construction of the process
FMEA and assess the finished document to ensure that the following expectations
are met :
CLICK HERE
The data or inputs that will be used to develop the Pre-launch Control Plan may
include some or all of the following. This data will be reviewed By the cross-
functional team during their meetings.
Advance Product Quality Planning and Control Plan AIAG Reference Manual
Customer Prints
Inspection Plans and Sampling Frequency
Work Instructions for similar parts or processes
List of special characteristics
List of Machines, tools, Jigs or Fixtures
List of Gaging with data showing calibration, discrimination, accuracy,
repeatability and reproducibility
Performance Testing Requirements
Design Reviews
Optimisation Data (e.g., QFD, DOE, etc.,)
Process Flow Chart
System and / or Design FMEA
Process FMEA
The Team Leader and APQP Team should manage the construction of the
Production Control Plan and assess the finished document to ensure that
the following expectations are met :
REACTION INSTRUCTIONS
If Non-Conforming material is detected.
• Stop Process
• Isolate Non-conforming Material. Place in proper Quarantine Area
• Correct Problem
• Inform Supervisor if problem persists
Note all out of control conditions on control chart (only for charted Characteristics)
INPUTS
Packaging standards
Product process quality system review
Process flow chart
Floor plan layout
Characteristics matrix
Process Failure Mode and Effects Analysis (PFMEA)
Pre-launch control plan
Process instruction
Measurement Systems Analysis Plan
Preliminary process capability study plan
Packaging specification
Management support
Nathan & Nathan Consultants Pvt. Ltd. NNCPL/PPT/001 94.
PRODUCTION TRIAL RUN APQPCP
OBJECTIVES
Manage and assess the production trial run to ensure meeting the following
expectations :
The pre-launch control plan is followed during the production trial run.
The trial run must be used to confirm or add linkages between product and
process characteristics.
Note : Linkages should be captured in the PFMEA.
Corrective design and process actions must be established for concerns
identified during the trial run.
OBJECTIVES
The data or inputs that will be used to develop the Pre-launch Control Plan may
include some or all of the following. This data will be reviewed by the cross-
functional during their meetings.
Advanced Product Quality Planning and Control Plan AIAG Reference Manual
Customer Prints
In-process Prints
Customer and Internal Specifications
Inspection Plans and Sampling Frequency
Work Instructions for similar parts or processes
List of Special Characteristics
List of Machines, tools, Jigs or Fixtures
List of Gaging with data showing calibration, discrimination, accuracy, repeatability
and reproducibility
Performance Testing Requirements
Design Reviews
Optimisation Data (e.g, QFD, DOE etc.,)
Process Flow Chart
System and / or Design FMEA
Process FMEA
The Team Leader and APQP Team should manage the construction of the
Production Control Plan and assess the finished document to ensure that the
following expectations are met :
Process data have been used to confirm cause and effect relationships between
product and process characteristics. The PFMEA should be a primary tool for
exposing deficiencies and potential product/ process relationships.
The Production Control Plan and PFMEA are consistent in defining current
process controls
The APQP team should review all the activities have been
successfully completed and make a formal sign-off.
Management support is necessary prior to the quality
planning sign-off. The format given below is an example of
the documentation required to do this sign-off.
OBJECTIVES
REDUCED VARIATION
ORIGIN
A ‘Failure’ is that a component, assembly or system which does not meet the
requirements or function in accordance with design intent. Ex: Not meeting the
specification
FAILURE MODE:
WHAT IS FMEA ?
TYPES OF FMEA
• Design FMEA
• Process FMEA
• System FMEA
ASSUMPTION – 1 :
STEPS :
• Assemble a team (cross functional)
• Assign responsibilities
• Develop flowchart for risk assessment
• Collect data/information
• Arrive at RPN for each potential causes of failure
• Based on pareto rankings of RPN’s for respective potential cause of
failure, priortise preventive action directed fist at highest ranked
RPN’s and severity rank.
ASSUMPTION – 3 :
DEFINITION :
DEFINITION :
DEFINITION :
ACTIONS ON
• Fmea number
• System, sub system or component name and
number
• Design responsibility
• Prepared by
• Mode year (s) / vehicle(s)
• Key date
• Fmea date
• Core team
• Item / function
• Potential failure mode
• Effect(s) of failure
• Severity
• Classification
DESIGN FMEA
• Fmea number
• Item
• Process responsibility
• Prepared by
• Mode year(s) / vehicle(s)
• Key date
• Fmea date
• Core team
• Process function/requirements
• Potential failure mode
• Potential effect(s) of failure
• Severity (s)
• Classification
• Potential cause (s) / mechanism (s) or failure
• Occurrence(O)
• Current design controls
• Detection (d)
• Risk priority number (RPN)
• Recommended action (s)
• Responsibility and target completion date
• Action taken
• Resulting RPN
Headlamp aim is one of the final operations during car and truck
assembly. An aiming device, which contains two bubble levels,
attaches to the headlamp. The operator adjusts the headlamps by
turning aiming Screws until bubbles center the level. Proper
headlamp aim is an FMVSS requirement and therefore a Special
Product Characteristic. The Special Process Characteristic is
operator knowledge and control, ensuring the two bubble levels
center during aiming. The Special Product Characteristic is
measured by shining the headlamps on a headlamp aim board
that measures beam pattern.