APQP Fundamentals-Training

ADVANCED PRODUCT
QUALITY PLANNING
Presentation
by
Parveen Rohilla &
Puneet Sharma
1
Advanced Product Quality Planning
What this session is

about ???...
 Introduction to APQP
 Fundamentals of Quality Planning
 Phases of APQP
 APQP Status Reporting Guideline
2

about ???...
 Phases of APQP
3
Introduction to APQP
 What is APQP ?
 APQP is a structured method of
tracking, establishing & improving
the steps necessary to assure that
a product ( either new or changed )
satisfies the customer
4
APQP
Purpose of APQP :
 To facilitate communication with all
persons involved in a programme &
ensure that all required steps are
completed on time, at acceptable
cost & quality level.
5
Product Quality Planning
Benefits :
 Drives resources
 Promotes early identification of required
changes
 Avoids late changes
 Provides quality product on time at the
lowest cost
6
7
Product Quality Planning Cycle
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about ???...
 Phases of APQP
8
Fundamentals of APQP
 Organise Team  Control Plans
 Define the Scope  Concern
 Team-to-Team Resolution
 Training  Product Quality
 Customer - Timing Plan
Supplier  Plans Relative to
Involvement Timing Chart
 Simultaneous
Engineering
9
 Organise the Team :
 Assigning the responsibility to a Cross
Functional Team
 Define the Scope
 Leader selection for overseeing the Planning
Process ( Rotating Leader - Advantageous )
 Roles & Responsibilities of each area
 Identify customers - internal & external
 Define customer requirements
 Select the disciplines,team members, etc
10
 Define the Scope Contd…..
 Understand customer expectations

 Assess the feasibility of the proposed
design, performance and manufacturing
process
 Identify cost, timing & constraints that must
be considered
 Determine assistance required from the
customer
 Identify documentation process or method
11
• Team to Team :
Product Quality Planning Team must
communicate with customer and supplier teams
• Training
Success of Product Quality Plan is dependent
upon an effective training programme.
Training programme to address requirements
and skills development to fulfill customer needs
and expectations
12
 Customer & Supplier Involvement
 Customer initiates
 Supplier manages
 Simultaneous Engineering :
 Process where CFT teams strive for a
common goal
13
• Control Plan :
Written descriptions of the systems for
controlling parts & processes. Plans cover three
different phases :
• Prototype
• Pre-launch
• Production
14
 Concern Resolution :
 Concern may be encountered in the
planning process
 Documentation on matrix with assigned
responsibility & timing
 Disciplined problem- solving methods are
recommended in difficult situations
15
 Product Quality Timing Plan :
 Team’s first task should be development of timing
plan
 Type of product, complexity & customer
expectation should be considered in selecting timing
element
 All team members should agree with each event,
action & timing
 Timing chart should list tasks,assignments & events
(Critical Path Method recommended)
 Chart provides team for format for tracking progress
 Each event must have Start & Completion date
16
 Plans Relative to the Timing Charts
 Planning team to concentrate on defect
prevention
 Defect Prevention is driven by Simultaneous
Engineering
 Planning team must be prepared to modify
Quality Plan to meet customer expectations
 Team is responsible for assuring timing
meets or exceeds customer’s timing plan
17

about ???...
 Phases of APQP
18
PHASES OF APQP
 Plan & Define Programme
 Product Design & Development
 Process Design & Development
 Product & Process Validation
 Feedback, Assessment &

Corrective Action
19
Product Quality Planning Timing Chart
Concept
Initiation/
Approval Programme
Approval Prototype Pilot Launch
PLANNING PLANNING
PRODUCT DESIGN & DEV.
PROCESS DESIGN & DEVELOPMENT
PRODUCT & PROCESS VALIDATION
PRODUCTION
FEEDBACK ASSESSMENT & CORRECTIVE ACTION
20
Plan & Define Programme
Objectives :
• To determine customer needs
• To plan a quality programme
21
Input : Output :
 Voice of the Customer  Design Goals
 Market Research
 Historical Warranty and  Reliability & Quality Goals
Quality Information  Preliminary Bill of Material
 Team Experience
 Preliminary Process Flow
 Business Plan / Marketing
Chart
Strategy
 Product/Process Benchmark  Preliminary Listing of Special
Data Product & Process
 Product / Process Characteristics
Assumptions  Product Assurance Plan
 Product Reliability Studies
 Management Support
 Customer Inputs
22
Input : Output :
 Market Research
 Team Experience
Chart
Strategy
 Customer Inputs
23
Plan & Define Programme - Input
 Voice of Customer
 Market Research
 Customer Interview / Questionnaire
 Competitive Product Quality Studies
 Things Gone Right Reports
 Historical Warranty and Quality Information

 Things Gone Wrong Reports
 Problem Resolution Reports
 Customer Plant Returns & Rejections
 Field return product analysis
 Warranty reports
24
• Team Experience
• Past QFD Projects
• Management Comments or Directions
• Dealer comments
• Government requirements and regulations
25
Contd. …..
 Business Plan / Marketing Strategy :
It sets ‘Framework’ for Product Quality Plan
Business Plan Mktg. Strategy
 Timing  Target Customer
 Cost  Key sales point
 Resources  Key Competitors
 Investment
 Product / Process Benchmark Data :
Use of Benchmarking provides input for
‘Performance Targets’
26
Contd. …..
 Product / Process Assumptions
Assumption about product features, design,
or process concept including technical
innovations, advanced material, new
technology etc. to be utilised as ‘Inputs’
Frequency of repairs, replacement of
components and results of reliability /
durability tests are considered
27
Contd. …..
• Customer Inputs
• Data collected from next user can be used as
inputs to arrive upon measures of customer
satisfaction
28
Input : Output :
 Market Research
 Team Experience
Chart
Strategy
 Customer Inputs
29
Plan & Define Programme - Output
 Design Goals :
 Translate ‘Voice of Customer’ into
tentative and measurable design objectives
 Reliability & Quality Goals :
 Established based on customer wants &
expectations, programme objectives, reliability
benchmarks
 Quality goals are targets based on continual
improvements i.e. PPM,defect levels or scrap
reduction
30
 Preliminary Bill of Material

 Established based on product/process
assumptions
 Assist in identification of special characteristics
 Preliminary Process Flow Chart
 Description of anticipated mfg. process
developed from preliminary bill of material
31
 Preliminary Listing of Special Product &

Process Characteristics
Team to ensure that the listing is developed from
the following,
 Product assumptions based on the analysis of
customer needs and expectations.
 Identification of reliability goals/ requirements
 Identification of special process characteristics
from the anticipated manufacturing process
 Similar part FMEAs
32
Special Characteristics
All products and processes have features

described by characteristics which are
important and need to be controlled.
However, some characteristics called
special characteristics require extra efforts
to minimise the risk of potential adverse
consequences.
33
Special characteristics involve those
product and / or process characteristics that
affect vehicle safety, compliance with
government regulations, or customer
satisfaction. Special characteristics consist
of :
Critical Characteristics &
Significant Characteristics
34
CRITICAL CHARACTERISTICS are those
product or process requirements that affect
• compliance with government regulation
• or safe vehicle / product function
and
which require special actions / controls. Product or
process requirements can include dimension,
specification, tests, processes, assembly
sequences, tooling, joints, torques, welds,
attachments, components usage’s etc.
Symbol :  or <CC>
35
SIGNIFICANT CHARACTERISTICS are those

product, process, and / or test requirements
which are important for customer satisfaction
and
for which Quality Planning actions must be

summarised on a Control Plan.
Symbol : <SC>
36
• Product Assurance Plan
It translates design goals into design
requirements.
Plan should include
• Outlining of programme requirements
• Identification of reliability & durability goals &
requirements
• Development of preliminary engg. stds.
• Assessment of new technology, materials,
service requirements
37
• Management Support
•Interest, commitment & support of upper
management is key to success.
• Updating management formally, at every phase

is required.
•Participation by management in quality planning

meetings is vital to ensuring the success of the
programme.
•Functional Goal of the team is to maintain
management support .
38
Concept
Initiation/
Approval Programme
PLANNING PLANNING
PRODUCTION
39
Product Design & Development
Objectives :
• To develop design features and
characteristics
• To critically review engineering
requirements
• To assess potential manufacturing
problems
40
Input : Output of Planning Phase is Input for this phase
Output by Design
Responsible Activity Output by APQP Team
 Design FMEA  New Equipment, Tooling and
Facilities Requirements
 DFMA
 Special Product and Process
 Design Reviews
Characteristics
 Prototype Build - Control Plan
 Prototype Control Plan
 Engineering Drawing
 Gages/Testing Equipment
 Engineering Specifications Requirements
 Material Specifications  Team Feasibility Commitment
 Drawing & Specs.Changes & Management Support
41
Output by Design
 DFMA
 Design Reviews
Characteristics
42
Product Design & Development - Output
 Design Failure Mode and Effects Analysis

 It is disciplined analytical technique to assess
the probability of failure & effect of such failure
 It is a living document continually updated
 A checklist for DFMEA is available for review
43
DESIGN FMEA CHECKLIST
Customer or Internal Part No._______________________________________

Person Due
Question Yes No Comment/Action Required
Responsible Date
1 Was the System FMEA and/or DFMEA prepared
using the Chrysler, Ford and General Motors
Potential Failure Mode and Effects Analysis
(FMEA) reference manual?
2 Have historical campaign and warranty data been
reviewed?
3 Have similar part DFEMAs been considered?
4 Does the SFMEA and/or DFMEA identify Special
Characteristics?
5 Have design characteristics that affectbhigh risk
priority failure modes been identified?
6 Have appropriate corrective actions been assigned to
high risk priority numbers?
7 Have appropriate corrective actions been assigned to
high severity numbers?
8 Have risk priorities been revised when corrective
actions have been completed and verified?
Revision Date __________
Prepared By
Page 1 of 1
44
• Design for Manufacturability & Assembly
It is a Simultaneous Engineering process
designed to optimise the relationship between
design function, manufacturability and ease of
assembly. Team to consider the following:
• Design, concept, function and sensitivity to
manufacturing variation
• Dimensional tolerances
• Process Adjustments
• Material Handling
• Performance requirements
• Manufacturing and/ or assembly process
• Number of components etc.
45
 Design Verification
Verifies that the product design meets the
customer requirements
 Design Reviews
 Regularly scheduled meetings led by design
engg. and must include other affected areas.
 It is an effective method to prevent problems &
misunderstandings.
 It provides a mechanism to monitor progress and
report to management.
They are a series of verification activities that are
more than an engineering inspection and should
include evaluation of:
46
• Design Reviews Contd…..
Design Reviews should include evaluation of
• Design/ Functional requirement considerations
• Formal reliability and confidence goals
• Component/ subsystem/ system duty cycles
• Computer simulation and bench test results
• DFMEAs
• Review of DFMA
• Design of Experiment (DOE) results
• Test failures
• Design Verification progress
A major function of Design Reviews is tracking of design

verification progress through DVP & R (Design
Verification Plan & Report)
47

 Is description of dimensional
measurements & material and functional
tests that will occur during prototype build
 Provides opportunity to evaluate how well
product meets Voice of Customer
objectives
48
• Engineering Drawings
Reviewed to determine
• that drawings have sufficient information for
a dimensional layout of individual parts.
• that drawings have identification for control
or datum surfaces.
• which characteristics affect fit, function,
durability and safety requirements
Dimensions are evaluated

• to assure feasibility & compatibility with
manufacturing and measuring standards
49
 Engineering Specifications
 Reviewed to identify functional, durability &
appearance requirements.
 Sample size, frequency & acceptance criteria
are generally defined in the in-process test
section of Engineering Specifications
(otherwise listed in control plan).
 Material Specifications
 These should be reviewed for Special
Characteristics related to physical properties,
performance, environmental, handling, and
storage requirements.
50
 Drawing and Specification Changes

 Team to ensure prompt documentation &
communication to affected areas
51
DESIGN INFORMATION CHECKLIST

Person Due
Responsible Date
A. General
Does the design require:
1  New materials?
2  Special tooling?
3 Has assembly build variation analysis been
considered?
4 Has Design of Experiments been considered?
5 Is there a plan for prototypes in place?
6 Has a DFMEA been completed?
7 Has a DFMA been completed?
8 Have risk priorities been revised when corrective
actions have been completed and verified?
9 Has the Design Verification Plan been completed?
10 If yes, was it completed by a cross functional team?
11 Are all specified tests, methods, equipment and
acceptance criteria clearly defined and understood?
12 Have Special Characteristics been selected?
13 Is bill of material complete?
14 Are Special Characteristics properly documented?
Prepared By
Page 1 of 4
52
DESIGN INFORMATION CHECKLIST
Person Due
Responsible Date
B. Engineering Drawings
15 Have dimensions that affect fit, function and durability
been identified?
16 Are reference dimensions identified to minimise
inspection layout time?
17 Are sufficient control points and datum surfaces
identified to design functional gages?
18 Are tolerance compatible with accepted
manufacturing standards?
19 Are there any requirements specified that cannot be
evaluated evaluated using known inspection
techniques?
C.Engineering Performance specifications
20 Have all Special Characteristics been identified?
21 Is test loading sufficient to provide all conditions, I.e.,
production validation and end use?
Contd….
D. Material Specification
28 Are special material chracteristics identified?
29 Are specified materials, heat treatment and surface
treatments compatible with durability requirements in
the identified environment?
Contd…. Revision Date __________
Prepared By
Page 2 of 4
53
Output by Design
 DFMA
 Design Reviews
Characteristics
54
 New Equipment, Tooling & Facilities

Requirements
 Team addresses identified reqmts. of above
by adding the items to the Timing Chart
 Also capability and availability of the same to
be ensured by the team
 Facilities progress should be monitored to
assure completion to plan
55
NEW EQUIPMENT, TOOLING AND TEST EQUIPMENT CHECKLIST

Person Due
Responsible Date
Has tool and equipment design provided for:
1  Flexible system, e.g. cell mfg.?
2  Quich change?
3  Volume fluctuations?
4  Mistake Proofing?
Have lists been prepared identifying:
5  New Equipment?
6  New tooling?
7  New test equipment?
Has acceptance criteria been agreed upon for:
8  New Equipment?
9  New tooling?
10  New test equipment?
11 Willa preliminary capability study be conducted at
the tooling and/or equipment manufacturer?
12 Has test equipment feasibility and accuracy been
established?
13 Is a preventive maintenace plan complete for
equipment and tooling?
14 Are setup instructions for new equipment and tooling
complete and understandable?
Contd….
Prepared By
Page 1 of 2
56
• Special Product & Process Characteristics
Team to build on list of preliminary special
product and process characteristics identified in
Phase I and reach consensus through the
evaluation of technical information.
These are documented on appropriate Control
Plans
• Gauges/Testing Equipment Requirements
These are identified and requirements added to
the Timing Chart
57
 Team Feasibility Commitment and Manage

ment Support
 In this phase, feasibility of the proposed
design is assessed. The team must be
satisfied that proposed design can be
manufactured, assembled, tested, packaged
and delivered in sufficient quantity at an
accepted cost to customer on schedule
 The team consensus on feasibility should be
documented along with all open issues that
require resolution and management support
58
Concept
Initiation/
Approval Programme
PLANNING PLANNING
PRODUCTION
59
Process Design & Development
Objectives :
• To develop a comprehensive and
effective manufacturing system
• To ensure that the manufacturing
systems meets customer requirements
60
Process Design and Development
Inputs : Outputs of Product Design & Development
phase are inputs for this phase
Outputs :
 Packaging Standards  Pre-Launch Control Plan
 Product/Process Quality  Process Instructions
System Review  Measurement Systems
Analysis Plan
 Process Flow Chart
 Preliminary Process
 Floor Plan Layout
Capability Study Plan
 Characteristics Matrix  Packaging Specifications
 Process failure Mode &  Management Support
Effects Analysis
61
 Packaging Standards
 Packaging design to ensure product
integrity at the point of use
 Product / Process Quality System
Review
 Team reviews Quality System Manual of
the manufacturing location & updates for
additional controls/ procedural changes
required for the product
62
 Process Flow Chart

 It is a schematic representation of the
proposed Process Flow
 It is useful in,
analysing total process rather than individual
steps in the process
conducting PFMEA &
 designing Control Plans
63
 Floor Plan Layout

 Developed and reviewed to determine
acceptability of inspection points, control
chart location, applicability of visual aids,
interim repair stations & storage areas to
contain defective material.
64
PROCESS FLOW CHART CHECKLIST

Person Due
Responsible Date
1 Does the flow chart illustrate the sequence of
production and inspection stations?
2 Were all the appropriate FMEAs (SFMEA,
DFMEA) available and used as aids to develop the
process flow chart?
3 Is the flow chart keyed to product and process
checks in the control plan?
4 Does the flow chart describe how the product will
move, i.e., roller conveyor, slide containers,etc.?
5 Has the pull system/optimisation been considered for
this process?
6 Have provisions been made to identify and inspect
reworked products before being used?
7 Have potential quality problems due to handling and
outside processing been identified and corrected?
Prepared By
Page 1 of 1
65
• Characteristics Matrix
It is an analytical technique for displaying
relationship between product/ process
characteristics & manufacturing stations.
66
Example of Characteristics Matrix
Dimensions
A B C D E F G H I
OP 05 
OP 10   
C
OP 20    
CL L T1 T1 T1 T1
OP 30 
CL
Legend
‘  ’ indicates a characteristic is cut or changed
‘C’ indicates a characteristic is used for clamping

‘L’ indicates a characteristic is used for location in a subsequent operation
‘A’ affects a subsequent operation or other characteristic
‘T’ indicates relationships within an operation, such as common tools or tool head
‘M’ characteristic is automatically monitored
67
 Process Failure Mode & Effect Analysis

 Conducted during product quality planning
& before production
 It is a disciplined review & analysis of a
new/ revised process to assess the
probability of failure & effect of such failure
 It is a living document continually updated
 A checklist for PFMEA is available for
review
68
 Pre-Launch Control Plan
 It is description of dimensional measurements
& material and functional tests that will occur
after prototype & before full production
 Includes additional product/ process controls
until validation of production process
 Purpose is to contain potential non-
conformances during or prior to initial
production runs such as, more frequent
inspection, more in-process check points,
statistical evaluations, increased audits etc.
69
 Process Instructions
 Team to ensure that understandable process
instructions provide sufficient detail for all
operating personnel
 These instructions should be developed from
FMEAs, Control Plans, Engg. Drawings, Process
Flow Charts, Handling Requirements etc.
 It should be posted
 It should include set-up parameters such as
machine speeds, feeds, cycle time etc.
 It should be accessible to operators &
supervisors
70
 Measurement System Analysis Plan

 The Plan should ensure responsibility for
ensuring gauge linearity, accuracy,
repeatability, reproducibility & correlation for
duplicate gauges
 Preliminary Process Capability Study
Plan
 Characteristics identified in control plan are
the basis for preliminary process capability
study plan
71
 Packaging Specification
 Individual product packaging is designed
and developed
 Packaging to maintain product quality
during packing,transit and unpacking
 Should also have compatibility with
material handling equipment
72
• Management Support
Formal review at the conclusion of this phase to
inform management of programme status and
gain their commitment in resolution of any open
issues
73
Concept
Initiation/
Approval Programme
PLANNING PLANNING
PRODUCTION
74
Product and Process Validation
Objectives :
• To validate the manufacturing process
• To ensure that customer expectations
will be met
• To identify additional concerns
75
Inputs : Outputs of Process Design & Development
phase are Inputs for this phase
Outputs:
 Production Trial Run  Production Validation
Testing
 Measurement  Packaging Evaluation
Systems Evaluation  Production Control
 Preliminary Process Plan
Capability Study  Quality Planning Sign-
 Production Part Off & Management
Support
Approval
76
 Production Trial Run
 Must be conducted using production tooling,
equipment, environment, facility and cycle
time
 Team to decide min. quantity for trial run
 Results of this are used for,
Preliminary Process Capability Study,
Measurement Systems Evaluation, Final
Feasibility, Process Review, Production Validation
Testing, Production Part Approval, Packaging
Evaluation, First Time Capability and Quality
Planning Sign-off
77
 Measurement System Evaluation
 Specified measurement devices & methods
should be used for the respective
characteristics.
 The devices be evaluated during or prior to
the production trial run
 Preliminary Process Capability Study
 It provide assessment of the readiness of the
process for production
78
 Production Part Approval
 It is validation of product made from
production tools & processes meeting
engineering requirements
 Production Validation Testing
 It is similar to Production Part Approval but
the validation is through engineering tests
79
• Packaging Evaluation
Test methods & where feasible test shipments
must assess the protection of the product from
normal transportation damage and adverse
environmental factors
80
 Production Control Plan
 It is a written description of the systems for
controlling parts and processes
 It is logical extension of pre-launch control
plan
 It is a living document
 It is updated based on experience gained
 Mass production provides opportunity to
evaluate output & revise the control plan
81
 Quality Planning Sign-off
 Team to ensure that all control plans &
process flow charts are being followed by
reviewing at the manufacturing locations
 A review of the following is required prior to
the first shipment
 Control Plans
 Process Instruction
 Gauge & Test Equipment
 A formal sign-off is done
82
• Quality Planning Sign-off. Contd...
Management support is required prior to sign-
off. Team should be able to show that all
requirements are met & concerns documented.
In scheduled management reviews,
management is informed of programme status
and their commitment gained to assist in open
issues.
83
Concept
Initiation/
Approval Programme
PLANNING PLANNING
PRODUCTION
84
Feedback, Assessment & Corrective Action
Inputs : Outputs of Product & Process

Validation phase are Inputs for this phase
Outputs :
 Reduced Variation
 Customer Satisfaction
 Delivery and Service
85
 Reduced Variation
 Identification of Process Variation using
‘Control Charts’ & ‘Statistical Techniques’
 Analysis & Corrective Actions
 Continuous Improvement reducing
‘Special’ as well as ‘Common’ Causes of
Variation
86
COMMON CAUSES
It refers to the many sources of chance variation that
are always present in varying degrees in different
process. The output of a process which contains
common causes of variation forms a pattern which is
stable over time and is predictable and therefore
provides the basis for subsequent process
improvement. It is,
• due to many small sources
• stable
• relatively predictable
• permanent - unless action taken
87
SPECIAL CAUSES
It refers to any assignable factors which are often
irregular and unstable and hence, unpredictable. A
particular source may continue to reappear intermittently
unless positive action is taken to eliminate it.
It is,
• due to one or a few major sources
• may be irregular
• unpredictable
• may reappear unless action taken
88
• Customer Satisfaction
•The Product or Service must perform in the
customer environment - evaluation of
effectiveness of quality planning efforts
•Based on learning, necessary corrective action
to be carried out to achieve customer
satisfaction
89
• Delivery and Service

•Problem Solving & Continuous Improvement
through spares availability and service in terms
of delivery, cost and quality
•Feedback at this stage provides necessary
knowledge to achieve customer satisfaction by
reducing process, inventory and quality costs
90
Advance Product Quality Planning
What this session is ???…...

 Phases of APQP
91
92
APQP Status Reporting Guideline
What is APQP Status Reporting Guideline ?

This is a specific guideline evolved based on
APQP disciplines
Objectives of the guideline is to,
 Reinforce APQP as the basis of quality planning
 Develop a ‘Program Status Reporting Format’ for APQP
evaluation
 Link APQP evaluation process to Vehicle Development
Programme
 Define ‘Roles & Responsibilities’ for concerned
personnel involved in APQP Process
 Make APQP procedures common for suppliers & in-
house manufacturing / assembly operations
93
APQP Status Report Form at Date:
Review No.:
Diamond Point:
Supplier Program
Location Model Year
Supplier Code Lead Part No.
Risk Assessment Part Name
New: Site Technology Process Eng. Level
Other Risks User Plant(s)
T eam Members Company/T itle Phone/Fax
Build Level Material Quantity No.of P.I.P.C.

No. No.
Required Date SC's CC's P.I.S.T . % %
APQP Elements GYR Focus Supplier

Closed Resp. Remarks
Status Element Need T iming Date Engineer
Rating Date Date Initials
1) Sourcing Decision
2) Customer Input Requirements
3) Design FMEA
4) Design Review(s)
5) Design Verification Plan
6) Subcontractor APQP Status
7) Facilities, T ools and Gages
8) Prototype Build Control Plan
9) Prototype Builds
10) Drawings and Specifications
11) T eam Feasibility Commitment
12) Manufacturing Process Flow Chart
13) Process FMEA
14) Measurement Systems Evaluation
15) Pre-Launch Control Plan
16) Operator Process Instructions
17) Packaging Specifications
18) Production T rial Run
19) Production Control Plan
20) Preliminary Process Capability Study
21) Production Validation T esting
22) Production Part Approval (PSW)
23) PSW Part Delivery at MRD
COMMENT S
94
Status Reporting Process
Component
Subsystem
Vehicle Review
System
APQP status reporting is done for all

Components, Subsystems, Systems and
reports are forwarded to the next higher level
95
APQP Status Report Form at Date:
Review No.:
Diamond Point:
Supplier Program
Location Model Year
Build Level Material Quantity No.of P.I.P.C.

No. No.
Required Date SC's CC's P.I.S.T . % %
APQP Elements GYR Focus Supplier

Closed Resp. Remarks
Status Element Need T iming Date Engineer
Rating Date Date Initials
3) Design FMEA
4) Design Review(s)
9) Prototype Builds
13) Process FMEA
COMMENT S
96
APQP Elements GYR Focus
Status Element Need
 Rating Date
1) Sourcing Decision
2) Customer Input Requirements
3) Design FMEA
4) Design Review(s)
5) Design Verification Plan
6) Subcontractor APQP Status
7) Facilities, Tools and Gages
8) Prototype Build Control Plan
9) Prototype Builds
10) Drawings and Specifications
11) Team Feasibility Commitment
The
Thestatus
statusofofall
allthe
thedisciplines
disciplines
12) Manufacturing Process Flow Chart are
aresummarised
summarisedon onAPQP
APQPstatus
status
13) Process FMEA report
reportas
asGreen,
Green, Yellow
YellowororRed
Red
14) Measurement Systems Evaluation
15) Pre-Launch Control Plan
16) Operator Process Instructions
17) Packaging Specifications
18) Production Trial Run
19) Production Control Plan
20) Preliminary Process Capability Study
21) Production Validation Testing
22) Production Part Approval (PSW)
23) PSW Part Delivery at MRD
97
23 Elements of APQP
 23 Elements of APQP as defined in the guideline are,
 Sourcing Decision  Process FMEA
 Customer Input Requirements  Measurement Systems
 Design FMEA Evaluation
 Pre-Launch Control Plan
 Design Review(s)
 Operator Process
 Design Verification Plan Instructions
 Subcontractor APQP status  Packaging Specifications
 Facilities, Tools & Gages  Production Trial Run
 Prototype Build Control Plan  Production Control Plan
 Prototype Builds  Preliminary Process
 Drawings and Specifications Capability Study

 Production Validation Testing
Team Feasibility Commitment
 Production Part
 Manufacturing Process Flow Approval(PSW)
Chart
 PSW Part Delivery at MRD
98
APQP Elements Description & Expectations
 Sourcing Decision
 It is a formal customer commitment to work
with the supplier on the programme
 It is expected that sourcing decision is
completed & communicated to the supplier
before the Programme Need Date
99
 Customer Input Requirements
 Design Goals
 are translation of Voice of Customer into
tentative & measurable design objectives
Initial system & component design and
specifications including
– product assumptions, functional performance,
dimensions, weight & materials
100
APQP Elements Description & Expectations ( Contd. )
 Customer Input Requirements Contd...

 Reliability & Quality Goals
TGR, TGW, Life Reliability Targets, Warranty
Targets, Incoming Quality Targets
 Programme Timing :
It is a plan that lists tasks, assignments, events
& timing required to provide a product that
meets customer needs & expectations.
101
APQP Elements Description & Expectations Contd.
 Customer Input Requirements Contd...
 Programme Timing Contd. ..
The following programme timing dates must be
communicated,
– Programme Status Reviews
– Design freeze
– Prototype builds
– Material Required Dates
– Job # 1
 Affordable cost targets
To be communicated for vehicle, system, sub-
systems and components
 Capacity Planning Volumes
 A key contact personnel within customer
102
 Subcontractor APQP Status

 A summary of APQP status of suppliers
 Cascading of this process is required
103
 PSW at Part Delivery at MRD

 Latest date that fully approved PSW
material to be received at customer’s plant
for trial run
 Customer’s material MRD must be
included in the supplier’s timing plan
 Production Part Approval requirements
must be completed prior to user plant MRD
104
APQP Status Report Format Date:
Review No.:
Diamond Point:
Supplier Program
Location Model Year
Build Level
Risk Assessment Material
Required Date
Quantity No.of
No.
SC's
No.
CC's
P.I.P.C.
P.I.S.T . % %
New:
APQP Elements
Site Technology
GYR
Status Element
Focus
Rating
Supplier
Process
Closed Resp.
Need T iming Date Engineer
Date Date Initials
Remarks
3) Design FMEA
4) Design Review(s)
Other Risks
9) Prototype Builds
13) Process FMEA
COMMENT S
105
APQP Risk Assessment
 Assessment of APQP Requirement

 Team to conduct the Assessment after
formation of the team
 The purpose of the assessment is to
determine if all of the elements in the APQP
process must be completed
 4 Major Areas assessed are,
Quality History
Supplier Profile
Engineering Profile
Performance v/s Targets
106
4 Major Areas for ‘Assessment’
1. Quality History
 High Warranty on current model
 Quality Rejects at the receiving plant
2. Supplier Profile
 New supplier/ New mfg. location/ New
Technology
 Poor launch performance
 Stretched resources
107
4 Major Areas for ‘Assessment’ Contd.
3. Engineering profile
 Manufacturing Technology new for the
Industry
 High Product or Process Complexity
 Strategically Important Product
4. Performance v/s Targets
 Design / Reliability / Quality goals difficult to
achieve
 Programme timing is compressed
 Cost targets are aggressive
108
Advance Product Quality Planning
What we learnt in this

session ???
 Phases of APQP
109

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ADVANCED PRODUCT

What this session is

What this session is

What this session is

 Understand customer expectations

What this session is

 Plan & Define Programme

 Product Design & Development

 Process Design & Development

 Product & Process Validation

 Feedback, Assessment &

PRODUCT DESIGN & DEV.

PROCESS DESIGN & DEVELOPMENT

PRODUCT & PROCESS VALIDATION

FEEDBACK ASSESSMENT & CORRECTIVE ACTION

 Historical Warranty and Quality Information

 Preliminary Bill of Material

 Preliminary Listing of Special Product &

All products and processes have features

SIGNIFICANT CHARACTERISTICS are those

for which Quality Planning actions must be

• Updating management formally, at every phase

•Participation by management in quality planning

PRODUCT DESIGN & DEV.

PROCESS DESIGN & DEVELOPMENT

PRODUCT & PROCESS VALIDATION

FEEDBACK ASSESSMENT & CORRECTIVE ACTION

 Design Failure Mode and Effects Analysis

Customer or Internal Part No._______________________________________

Revision Date __________

A major function of Design Reviews is tracking of design

 Prototype Build - Control Plan

Dimensions are evaluated

 Drawing and Specification Changes

Product Design & Development - Output

Revision Date __________

 New Equipment, Tooling & Facilities

Product Design & Development - Output

 Team Feasibility Commitment and Manage

PRODUCT DESIGN & DEV.

PROCESS DESIGN & DEVELOPMENT

PRODUCT & PROCESS VALIDATION

FEEDBACK ASSESSMENT & CORRECTIVE ACTION

 Process Flow Chart

 Floor Plan Layout

Product Design & Development - Output

Revision Date __________

‘C’ indicates a characteristic is used for clamping

 Process Failure Mode & Effect Analysis

 Measurement System Analysis Plan

PRODUCT DESIGN & DEV.

PROCESS DESIGN & DEVELOPMENT

PRODUCT & PROCESS VALIDATION

FEEDBACK ASSESSMENT & CORRECTIVE ACTION

PRODUCT DESIGN & DEV.

PROCESS DESIGN & DEVELOPMENT

PRODUCT & PROCESS VALIDATION

FEEDBACK ASSESSMENT & CORRECTIVE ACTION

Inputs : Outputs of Product & Process

• Delivery and Service

What this session is ???…...

What is APQP Status Reporting Guideline ?

T eam Members Company/T itle Phone/Fax