A P Q P P P A P - spel.net.in Successful PPAP through structured APQP Process •Five Phases of APQP –with exercises ... 5 phased APQP approach Design Outputs Customer Requirements

A P Q P P P A P&

A V ManivannanPrincipal Consultant & Trainer

CSR

2

A most practical

workshop

A new product development & approval process

S O P for the Workshop on

APQP & PPAP ( as per IATF 16949 : 2016 ) with a focus on CSR

ProcessProgram Objectives

Methodology :

Class Room discussions

Team Exercises ( 20 exercises )

Group Presentations

Best practices on APQP & PPAP

Ice Breaking

The whole course to cover all the

phases with exercises

Evaluation during the sessions

Quiz

Final Test & Evaluation

Verbal Feed Back

Written Feed Back

Structure :

Performance Indicators

▪ Performance during the team presentations

▪ Final Test Marks

▪ Exercise marks during the Program

▪ Program feed-back

Type of Program :-

Technical

Management

Behavioral

Long-term

Hours

No. of Participants

Min. Max.

18 26

10 20

Short-term

Mixed Group : Yes No

Deliverables

Sri Padhmam Consultancy & Training

+91 94428 92185

[email protected]

www.sripadhmam.com Target participants : Engineers & above

To familiarize the participants to apply the

concepts & Practices of Advanced Product Quality

Planning & Control Plan ( APQP ) 2nd edition –

Production Part Approval Process ( PPAP )

4th Edition.

To provide the skill sets on new product

development through APQP & PPAP

methodologies.

Also to familiarize on linkages to IATF 16949:2016

requirements.

Usage of APQP, PPAP & Control Plan Methodology

Better focus on Customer requirements

Enhanced skill index

• Origin of APQP

• Basic concepts & Principles

• Linkages to IATF 16949:2016

• Techniques of APQP process

- Quality Function Deployment ( QFD )

- Error proofing & PDCA cycle

- Process Flow for Lean management

- Characteristics matrix

- M E O S T for product validation

- Quality plan

- Gantt chart

- Quality planning sign-off

• Phase 4 of APQP : Linkage to PPAP

• Successful PPAP through structured APQP Process

• Five Phases of APQP – with exercises

• Control plan - Creation & management

• PPAP – How to interpret & Implement ?

• Situations Analysis on PPAP

mailto:[email protected]

4A glimpse

An intellectual property from Sri Padhmam Consultancy & Training [email protected] +91 94428 92185 www.sripadhmam.com

APQP – Importance

APQP &

Control Plan IATF 16949 : 2016

Clause 8

Clause 8.3( inputs & outputs )

Phase 2 & 3 Product Design & Development

# Elements of APQP IATF Clause reference

1 Design FMEA 8.3.5.1

2 Process FMEA 8.3.5.2

3 Design Changes 8.3.6

4 Control plan 8.5.1.1

3

Advanced Product Quality Planning

0

1

2

3

4

5

Phase “0”

CFT formation & Scope definition

Plan & Define

Product design & development

Process design & development

Product & Process validation

Feed-back, assessment & corrective action

0

An intellectual property from Sri Padhmam Consultancy & Training [email protected] +91 94428 92185 www.sripadhmam.com5

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Quality Function Deployment [ Q F D ]


✓ Prof. Yoji Akao

✓ 1980s

✓ Introduced QFD technique

7

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Quality Function Deployment [ Q F D ]


Harvard business review case study

7.5

+ A

cou

stic

w

ind

ow

Bench marking 1

Bench marking 2

8

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Success factors


Success of an NPD process

Voice of Customers( V O C )

Customer Inputs

Marketing Priorities

Field Conditions

Mfg. Feasibility

Designers’ Competence

QMS strength

Top Management Focus

Internal factors

External factors

10

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Needs & Expectations of the Customer


Prof. KanoJapan

11

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Design goals1.7

Plan & define

Bath tub curve

17

11

Refer Page #

18 to 21

In the workbook

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Preliminary Process Flow Chart ( PFC )1.10

Plan & define

Anticipated

manufacturing process !

Source(s) to prepare

22

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Product assurance plan1.12

Plan & define

Design goals

( section 1.7 )

Product Assurance Plan Design Requirements

23

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Management support1.13

Plan & define

✓ Involve your Top Management !

✓ Inform the Status !

✓ Gain support !

APQP Meeting


A P

Q P

Product D & D

Design FMEA2.1

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

CFT

Customer inputs

Lessons learnt

Data & information

USE

Boundary diagram

Parameter diagram

Interface matrix

25


A P

Q P

Product D & D

Design for Manufacturability & Assembly ( DFA & DFM )

2.2

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Cost & Manufacturing Efforts

“User friendly designs”

25


A P

Q P

Product D & D


2.2

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

# Focus during DFMA analysis What will be ideal ?

1 No.of parts Less More

2 Common parts Less More

3 Assembly adjustments Less More

4 Self-fastening parts Less More

5 Setting related activities Less More

6 Self-locating parts Less More

7 Masters for setting Less More

8 Standard parts Less More

9 Handling of parts Less More

10 Re-orientation while assembly Less More

Team based exercise : 07

25

Answers Template


A P

Q P

Product D & D


2.2

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

D F A & D F M immediate outputs ?

Sub-system drawings

System level drawing

Child part drawings

25


A P

Q P

Product D & D

Design verification2.3

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 55 phased

APQP approach

Design

Outputs

CustomerRequirements

1. Design Review 2. Documents Review 3. Tests

26

# Statement True False Evln

1 Proto samples are not produced, when the customer is not particular about them

2 Pre-launch samples are produced to prove the new product’s concept

3Proto samples shall be produced, even when sufficient real-time facilities are not present

4 Proto-type control plans must have all the ‘process’ related information also

5 At times, even a single unit shall be produced as a proto-type sample

6 The first control plan during the APQP journey is Prototype control plan

7 It is mandatory, that the proto-type control plan to be approved by the Customer

8 Prototype samples shall be used for Road-proving purpose also, always

9 The input for Prototype control plans is only Design FMEA, not Process FMEA

10 Generally, Proto samples are verified 100 %

11Prototype control plans must cover performance test related information, as applicable

12Outputs derived immediately after Proto build are Packaging requirements & Process parameters


A P

Q P

Product D & D

Prototype Control Plan2.5

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5Team based exercise : 08

27

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Key activities & the outputs2.0

Product D & D

# Description

Spe

cifi

cati

on

s

Do

cum

en

ts /

Li

sts

Act

ivit

ies

Har

d w

are

s

1 Proto-type samples

2 Engineering specification

3 Proto build

4 DFA & DFM

5 Special Characteristics

6 DFMEA & related documents

7 Material specifications

8 Design review

9 Engineering drawings

10 DVP & R

# Description

Spe

cifi

cati

on

s

Do

cum

en

ts /

Li

sts

Act

ivit

ies

Har

d w

are

s

11

12

13

14

15

16

17

18

19

20

List out


31


A P

Q P

Process D & D

Product / process Quality system review3.2

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

J R Q M S

Joint Review on QMS

Q M SContract

32


A P

Q P

Process D & D

Floor plan layouts3.4

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Purpose ?

To decide what comes Where in the Shop Floor !

Focus ?

Material Travel

Material Handling

Space utilization

Health & Safety

IATF 16949 Clause #

8.3.5.2 ( e )

33


A P

Q P

Process D & DPhase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Characteristics matrix3.5

Dim

#

Description Tolerance Operation #

10 20 30 40

1 ID 22.5 20 microns X C X

2 Facing 5 microns X C C

3 Boring 67 dia 25 microns X L

4 Chamfering 0.5 x 45 X

5 OD turning 45 18 microns X

X : Characteristics created / changed by this operation. To match PFDC Characteristics at an operation is used for ClampingL : Characteristics at an operation used for Location

Process FMEA !!!

Inputs

34


A P

Q P


Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

CFT

Customer inputs

Lessons learnt

Data & information

USE

Design FMEA

PFD

Characteristics matrix

Process FMEA3.6

Better to focus on Product design solutions !!!

35


A P

Q P


Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Clause # 10.2.4 – Error proofing ( EP )

Shall have a documented process to identify

Method to identify EP shall be documented in P FMEA

Test frequency shall be in the control plan

Challenge parts for EP

EP failures shall have a reaction plan

EP failures testing records

Pre-launch Control plan3.7

37


A P

Q P


Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Process instructions3.8

Standard Operating Procedures [ S O Ps ]

# Description Input Output No link

1 PFD & Floor plan layouts

2 Design FMEA

3 Process FMEA

4 Set-up Instructions & First piece approval instructions

5 Design & Quality goals

6 Characteristics matrix

7 Capability norms ( 1.33 or 1.67 ) & MSA acceptance criteria

8 Process & Product parameters identified by the APQP team

9 Handling requirements

10 Operators’ knowledge on the process

11 Details from the equipment manufacturers

12 Packaging requirements

13 Current controls ( P & D ) identified in the FMEAs

14 Customer’s inputs relevant to the manufacturing stages


38


A P

Q P


Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

MSA Plan & Preliminary process capability plan

3.9 & 3.10

Pre-Launch Control Plan

Timing Plan ( for period )

J R Q M S

MSA & Capability Studies : Reference documents ?

39


A P

Q P

Product & process validationPhase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Significant Production Run4.1


A P

Q P


Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


Understood by the organization

Organization to demonstrate through PPAP….

✓ Its potentiality ……………………………...

✓ Its consistency …………………………….

of the manufacturing processes

in meeting the requirements

Actual production runQuoted production

rate

42


A P

Q P


Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

# Statement True False Evln

1 PPAP run must use the Pre-launch Control plan

2 If Customer specified Packaging are used, APQP team need not evaluate the packaging

3 Number of units to be produced during PPAP run may also be specified by the Customer

4 PPAP run must be produced as consecutive units

5 Quality planning sign-off must be done prior to PPAP lot despatch to the customer

6 Additional controls ( such as robust statistical evaluation ) must be identified during PPAP run

7 MSA studies must be completed during the PPAP time

8 Master samples mean ‘First-off’ samples also

9 Production Control plan ( PCP ) must include controls on the Special characteristics also

10 IATF 16949:2016 – Clause 8.1.5.5 is dealing with the PCP

11 PCPs & the Reaction plans are the same

12 Both D & P FMEAs will provide inputs to the PCPs

13 Bulk materials means components such as Fasteners

14 Customer Engineering design record must cover all the Technical requirements in it


46


A P

Q P


Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


Run at rate

• After PPAP

• 1000 parts generally

• Run at full speed

• Focus on FPY%

• Use audit checklists

• Identify all bottlenecks

• Focus on Process capability

• Ensure MSA results

• Use PFMEA and PCP for audits

How to perform ? Checklists

Click for hyperlink

Snap allowed !

47

Run at rate details.pdf

Support items/Run at rate details.pdf

Phase 0

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5


A P

Q P

Management support4.8

✓ Involve your Top Management !

✓ Inform the Status !

✓ Gain support !

APQP Meeting

Product & Process validation

S

Snaps allowed !

34

Best practice # 1

Supplier PPAP approval – a TVS model

Snaps allowed !

35

36

Tricky Part of PPAP ?

Pass Through Characteristics

Black Box Items

ROHS & MD systems

Part Weight Criteria

Checked & Marked Prints


P

P

A

P

53

37

Marked Prints

An engineering drawing – modified, signed and dated by the customer engineer

73.00


P

P

A

P

53

38


Accelerated Learning Process Matching Exercise

PPAP : Accelerated Learning Match the following in a MOST Logical way !

Ref. Criteria Ref. CriteriaRight

Answers

A Appearance items 1 Stability First & then Performance target

B Initial process Studies 2 NABL certification

C Customer wants 2.0 as Ppk target 3 Take as 3, if Customer has not specified it

D Qualified Laboratory Documentation 4 Re run the PPAP before bulk Production

E Initial process study results are not satisfactory 5 Conduct MSA study and include them in Checking aid list

F Default PPAP level 6Randomly selected 10 parts’ average weight in 4

decimals, written in Kgs

G PPAP target date is advanced by the Customers now 7 Master samples & Limit Samples

H New Vernier and an Air gauge introduced now 8 Inform your Customer before taking any actions

I Part weight in PSW 9 Amend the Timing Plan and speed-up related actions

J Tool has not been used for 16 months, after the PPAP approval 10 Quality Goal and include in the JRQMS ( QMS Contract )

P

P

A

PTeam based exercise : 18

56

39

Please study the situations carefully and decide your action(s).

You may have certain ( logically acceptable ! ) assumptions and conclude.

Must justify your conclusions

Let us have a healthy discussion to enhance our PPAP understanding

Situation Analysis

• PPAP submission level is 2

• The Quality system review & agreement ( JRQMS ) must be kept in mind

Issue the A 3

sheet


P

P

A

P
