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Advanced Product Quality Planning
A structuredmethod of defining the steps (process) necessary to assure that aproduct satisfies the customer
The goalof APQP is tofacilitate communication with everyone involved to
ensure that all required steps are completed on time.
EffectiveAPQP depends upon top management commitment and support to
assure that customer satisfaction is achieved
PlanningPlanning
oncept!nitiation "Approval
#esign $ #evelopment
%alidation
Production
&eed'ac Assessment $ orrective Action
ProgramApproval
Prototype
Pilot
aunch
Plan $#efine
Program
Product#esign $
#ev.%erification
Process#esign $
#ev.%erification
Product $Process
%alidation
Product
Process
Product " Process
A!A* APQP $ trl Plan +eference *uide, Page -
Advanced Product Quality Planning
1
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Advanced Product Quality Planning
Phase/ !nputs $ 0utputs %oice of the ustomer
1 2aret +esearch
1 3istorical 4arranty and Quality!nformation
1 Team E5perience
6usiness Plan and 2areting
7trategy
Product8Process 6enchmar #ata
Product8Process Assumptions
Product +elia'ility 7tudies
ustomer !nputs
7ervice
#esign *oals
+elia'ility and Quality *oals Preliminary 6ill of 2aterial
Preliminary Process &low hart
Preliminary isting of 7pecial
Product and Process
haracteristics
Product Assurance Plan
2anagement 7upport
Phase 1 Phase 2
0utputs 'y #esign+esponsi'le Activity
0utputs 'y Advanced
Product Quality
Planning Team
#esign &2EA
#&2 and #&A
1#esign for 2anufactura'ility
1#esign for Assem'ly
#esign %erification
#esign +eviews
Prototype 6uild ontrol Plan
Engineering #rawings (including 2ath data)
Engineering 7pecifications
2aterial 7pecifications
#rawing and 7pecification hanges
9ew equipment, tooling and
facilities requirements
7pecial product and processcharacteristics
*age and testing equipment
requirements
Team feasi'ility commitment
and management support
7u'contractor 'uild
7upplier 'uildPhase 3
Pacaging 7tandards
Product 8 Process Quality 7ystem +eview
Process &low hart
&loor Plan ayout
haracteristics 2atri5
Process &ailure 2ode and Effects
Analysis
Pre"aunch ontrol Plan
Process !nstructions
2easurement 7ystems Analysis Plan
Preliminary Process apa'ility 7tudy Plan
Pacaging 7pecifications Thin Critical Paths
2
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Advanced Product Quality Planning
!nputs 8 0utputs " Phase :
%oice of the ustomer
; 2aret +esearch
; 3istorical 4arranty and Quality
!nformation
; Team E5perience
6usiness Plan and 2areting
7trategy
Product8Process 6enchmar
#ata
Product8Process Assumptions
Product +elia'ility 7tudies
ustomer !nputs 7ervice
#esign *oals
+elia'ility and Quality *oals
Preliminary 6ill of 2aterial
Preliminary Process &low hart Preliminary isting of 7pecial
Product and Process haracteristics
Product Assurance Plan
2anagement 7upport
Phase 1
Phase 1 Inputs
Phase 1 Outputs (= Phase 2 Inputs)
3
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Advanced Product Quality Planning
!nputs 8 0utputs " Phase - 2P3 A'ov e >- 2P3
7teering wheel spoes not correct ly positioned when f ront wheels st reight
0ther steering and handling pro'lems. Please descri'e.
Advanced Product Quality Planning
3istorical 4arranty and Quality !nformation
@Things gone
4rong reports 4arranty reports
apa'ility
indicators
7upplier plant
internal qualityreports
Pro'lem
resolution reports
ustomer plant
returns and
reCections
&ield return
product analysis
Tell us a'out any trou'les you have had with the vehicle. 2ar a B in each
'o5 ne5t to any item you have had trou'le with.
*teri&r Paint
Things -&ne .r&ng
/teering ' +an,ling
10
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&ramewor for quality plan
2ay place constraints on timing, cost, investment,
positioning, +$# resources
7trategy defines target customer, ey sales points,
ey competitors 740T
17trengths
14eanesses
10pportunities1Threats
0ld vs. 9ew
13ow deep and how far to go
Advanced Product Quality Planning
6usiness Plan " 2areting 7trategy
11
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A requirement of Q7 D para. >.:
Provides inputs to esta'lish performance targets
2ust address ey process(es)
2ust 'e measura'le
2ethods for successful 'enchmaringF1!dentify appropriate 'enchmar(s)
1&ind reason for gap 'etween your status and 'enchmar
1#evelop a plan for closing gap, meeting or e5ceeding
'enchmar
Advanced Product Quality Planning
Product " Process 6enchmar#ata
12
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Assumptions
1&eatures
1#esign
1Process concepts
1Technical innovations
1Advanced materials1+elia'ility assessments
19ew technology
#ocument assumptions as part of proCect plan
?tiliGe as inputs to plan
onsider alternate paths in case assumptions do not
play out
Advanced Product Quality Planning
Product " Process Assumptions
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&requency of repairs or replacements within
designated time period(s)1+epair or Throw"awayH
1+? evel (ine +eplacea'ility ?nit)
ong range relia'ility and8or dura'ility tests
7tudies can 'e %E+I costly and lengthy1E#TP (Environmental #esign riteria Test Plan)
Advanced Product Quality Planning
Product +elia'ility 7tudies
0T = 0eanTie eteen ailures
0TO = 0eanTie eteen Overhaul0T% = 0eanTie eteen %eplaceent
Market Share
Durailityailures
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9e5t users provide information a'outneeds and e5pectations
Possi'ility of previous conducted
reviews and studies ?sed to develop measure of customer
satisfaction
Advanced Product Quality Planning
ustomer !nputs
15
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Advanced Product Quality Planning
!nter"+elationships
Q07
&2EA
&TA
+&TA
APQP
#0E
Process
!mprovemen
t
ontrol
Plan
7P
Tools
J"# Pr&le
/&lving
usiness
Quality
O5ectives
Pr&le
Preventi&n
Q
7pecial 8 ritical
haracteristics
ustomer 7pecified
7pecial 8 ritical
haracteristics
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Advanced Product Quality Planning
+elationships
ustomer+equirements
#&2EA P&2EA 4arrantontrol Plan
7tructuralonceptual 4arrant 7ample
PPAP
Product ondition
Time
17
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Advanced Product Quality Planning
Typical Automotive Trilogy #evelopment
Pr&cess l& Diagra(Inclu,es A"" Pr&cesses)
Pr&cess 0A
(On A"" Pr&cesses)
Pr&cess C&ntr&l Plan(Critical Pr&cesses r& 0A)
Design 0A(On Inten,e, 6se)
APQP Tieline
7ome Elements may
'e !ncluded 0n
Critical Characteristics' Characteristic C&ntr&l Issues
Critical Characteristics
' ailure ects Issues
CC 0atri*
ustomer
+equirements(drawing, +&Q, etc.),
Iour company/s
internal design 8
process
requirements
18
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Advanced Product Quality Planning
#ocument ins
Pr&cess l& Chart0peration 9um'er
Product8Process haracteristic
!ncoming 7ources of %ariation
(%ariation lass)
.&r# Instructi&n0peration 9um'er
P0A0peration 9um'er
C&ntr&l Plan0peration 9um'erProduct8Process haracteristic
!ncoming 7ources of %ariation
(%ariation lass)
The APQP manual cites
these lins.!n some
companies, these are
not discrete documents.
The intent is to ensure
discrete documentsmatch.
0peration 9um'er
19
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Advanced Product Quality Planning
#ocument ritical Paths
Pr&cess l& Chart
Provides inputs to the Process &2EA and may provide inputs to the wor instruction.
.&r# Instructi&n
P0A
C&ntr&l Plan
D0A2ay or may not identify
an input to the Process&2EA
Provides input to control plan 'ased upon a ris analysis.
Deine All Critical 7
/pecial
Characteristics
20
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Advanced Product Quality Planning
Automotive Process &2EAProcess &ailure 2ode And Ef f ects Analy sis ow " 3igh
ProcessF 0utside 7uppliers Af f ectedF EngineerF : " :
Primary Process +esponsi'ility F 2odel Iear8%ehicle(s)F Part 9um'erF
0ther #iv . 0r People !nv olv edF 7cheduled Production +eleasedF P&2EA #ateF +ev .
Approva lsF Quality Assurance 2anager Quality Assurance Engineer
0perations 2anager 7enior Adv isor
Part 9ame0peration9um'er Proc es s & unc tion
Potential &ailure2ode Potential Ef f ect s 0f & ailure Pot ent ial aus e 0f & ailure urrent ontrols 0
ccured
7everity
#etection
+P9 +ecommended
Actions And 7tatusActions
Taen+esponsi'le
Activ ity
7!+ Tae TPPE 4rong 2aterial &ragmented ontainer !nsuf f icient 7upplier ontrol 2aterial ertif ic ation : D < :J
ontainer 2aterial 3eld !n ?npredicta'le #eploy ment !mproper 3andling +equired 4ith Each
: 7torage Area 2isidentif ied 2aterial 7hipment
+elease %erification
0ut 0f 7 pec &ragm ent ed ont ainer 7upplier Proc es s ont rol Periodic Audit 0f = : = D
2aterial ?npredicta'le #eploy ment 7upplier 2aterial
ontaminated &ragmented ontainer 0pen 6o5es %isual !nspection : D K L=
2aterial ?npredicta'le #eployment
2aterial &ragmented ontainer Engineering hange +elease %erif ication : : K K
omposition ?npredicta'le #eploy ment 7upplier hange *reen M0NM Tag
hange ustomer 9otif ication
< 2ov e To ?nreleased &ragmentation ?ntrained T0 hec &or *reen M0NM - : : -
Approv ed ?ntrained Personnel Tag At Press
7torage Trace ard
hec ist
Training
= 3old !n Approv ed ontamination &ragmentation 0pen ontainers 6o5es Nept !n 7ealed : : = =
7torage ?ntil Process Pro'lems 3ouseeeping 7torage Area ?ntil
9eeded Area 2aintenance 9eeded
6o5es ined 4ith
Plastic
iner 0n Pallets
!nside 7torage
P. 2. &acility
21
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Advanced Product Quality Planning
Effects of hanging the Process &2EA
P0AChange in Detecti&n
Change in Occurrence
Change in /everity
.&r#Instructi&n
Design Change
C&ntr&l Plan
And
0r
Other Acti&nA change in the severity &
the eect & a p&tential
pr&le can &nly e
eecte, thr&ugh a ,esign
change$
.hen a#ing a change t& a ,&cuent8 it is ip&rtant t& c&nsi,er the eects & that change &n
&ther ,&cuents$ Typically the engineering change syste in a c&pany an,7&r c&rrective acti&n
syste ensures these &ccur$ ut this is n&t alays the case$ %evie y&ur c&pany engineering
change pr&ce,ure 7 syste an, see i it ,&es s&$
22
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Advanced Product Quality Planning
A orrective Action 7ystem
These are s&e typical9chec#s: in the
aut&&tive &rl, in
resp&nse t& a
c&rrective acti&n$ A
change t& any &ne
,&cuent typically
,rives an ngineering
Changehere the
engineering changesysteis use, t&
ensure that changes t&
any &ne ,&cuent
ensures appr&priate
changes t& &thers$
23
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Advanced Product Quality Planning
Product Specific FMEA Approach
Pr&cess
0A
6rand spaning new,
never 'efore product.
6rand spaning new
Process &2EA
developed.
Production Life
;ear 1
&2EArevised in
response to
an J"#
investigation
&2EArevised in
response to
an J"#
investigation
Pr&cess
0A
opy of process &2EA
from a similar product
;ear 1
&2EArevised in
response to
an J"#
investigation
I do NOT recommend product specific FMEAs unless you really cannot
segregate your products into families for some reason.
&2EA
revised in
response to
an J"#
investigation
ear !""! # $%& 'ody
Inta(e manifold
ear !"") # $%& 'ody
Inta(e manifold
;ear 2
24
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Advanced Product Quality Planning
urrent ontrol Plans $ &2EAs
A Technology8&amily ontrol Plan 8 #evice &2EAfollows an entire flow for a technology/
through a defined entity. This is in contrast with a process/ flow where there is an individual
ontrol Plan for each piece of equipment or a manufacturing cell/(company definition). A
Technology/ consists of many similardevices.
Device&2EA 8 Techn&l&gy 7 ailyontrol Plan/ O a flow of a technology/ or device/
Pr&cess &2EA covers an equipment set/ or cost 'loc/
+ecommended 'y the &2EA Team
A &r Other 0anuacturing ntity
+eceiving/ in &A6 &2EAs consists of what the &A6 loos at when materials arrive. +eceived
materials, such as gasses, liquid chemicals and related materials must 'e addressed. +egistrar
interpretation Q- :8:< (AE"A:)F @...7o in effect, suppliers control plans will include wafers,
gases, and chemicals...
2achine orell :
+eceiving/2achineor ell D PPAP)
3A+ATE+!7T!, +!T!A, *2 #E&!9!T!09F 7ee Ney Product haracteristic. (P>D PPAP)
3A+ATE+!7T!,NEI 09T+0 (Ns)F Those process parameters for which variation must 'e controlled around a target
value to ensure that a significant characteristic is maintained at its target value. Ns require ongoing monitoring per an approved
ontrol Plan and should 'e considered as candidates for process improvement. (P>D PPAP)
3A+ATE+!7T!, NEI P+0#?T (NP)F Those product features that affect su'sequent operations, product function, or
customer satisfaction. NPs are esta'lished 'y the customer engineer, quality representative, and supplier personnel from a review
of the #esign and Process &2EA/s and must 'e included in the ontrol Plan. Any NPs included in customer"released engineering
requirements are provided as a starting point and do not affect the supplier/s responsi'ility to review all aspects of the design,
manufacturing process, and customer application and to determine additional NPs. (P>D PPAP)
54
haracteristics !!
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haracteristics !! 3A+ATE+!7T!, P+0E77F ore team identified process varia'les (input varia'les) that have a cause and
effect relationship with the identified Product haracteristic(s) which can only 'e measured at the time of occurrence.
(L.=
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haracteristics !!!
3A+ATE+!7T!, 7A&ETI, 3+I7E+ #E&!9!T!09F 7pecifications which require special manufacturing control to
assure compliance with hrysler or government vehicle safety requirements. (P- PPAP)
3A+ATE+!7T!, 7!*9!&!A9T, 3+I7E+ #E&!9!T!09F 7pecial characteristics selected 'y the supplier through nowledge
of the product and process. (Q7"D)
3A+ATE+!7T!,7PE!AF Product and process characteristics designated 'y the customer, including governmental regulatory
and safety, and8or selected 'y the supplier through nowledge of the product and process. (P:> APQP)
3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @#iamond U#VF 7pecifications of a component, material, assem'ly or
vehicle assem'ly operation which are designated 'y hrysler as 'eing critical to function and having particular quality, relia'ility and
dura'ility significance. (Q7"D)
3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @#iamond U#VF 7pecific critical characteristics that are process driven
(controlled) and therefore require 7P to measure process sta'ility, capa'ility, and control for the life of the part. (Appendi5 Q7"
D) $ (Appendi5 APQP)
3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @Pentagon UPVF imited to highlighting ritical characteristics on
(Production) part drawings, tools and fi5ture, and tooling aid procedures where ongoing process control is not automatically
mandated. (Appendi5 Q7"D) $ (Appendi5 APQP)
3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @7hield U7VF Engineering designated specifications or product
requirements applica'le to component material, assem'ly operation(s) which require special manufacturing control to assure
compliance with governmental vehicle safety, emissions, noise, or theft prevention requirements. (Appendi5 Q7"D) $
(Appendi5 APQP)56
haracteristics !%
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haracteristics !% 3A+ATE+!7T!, 7PE!A, &0+# #E&!9!T!09 @ritical haracteristic U!nverted #eltaVF Those product
requirements (#imensions, 7pecifications, Tests) or process parameters which can affect compliance with
government regulations or safe %ehicle8Product &unction and which require specific producer, assem'ly, shipping or
monitoring actions and inclusion on the ontrol Plan. (Appendi5 Q7"D) $ (Appendi5 APQP)
3A+ATE+!7T!, 7PE!A, &0+# #E&!9!T!09 @7ignificant haracteristic " 7 U9oneVF Those product, process, and test
requirements that are important to customer satisfaction and for which quality planning actions shall 'e included in the ontrol Plan.
(Appendi5 Q7"D)
3A+ATE+!7T!, 7PE!A, &0+# #E&!9!T!09 @7ignificant8haracteristic " 78 U9oneVF haracteristics that are important to
the customer and that must 'e included on the ontrol Plan. (Appendi5 APQP)
3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @&it8&unction U&8&VF Product characteristic for which reasona'ly anticipated
variation is liely to significantly affect customer satisfaction with a product (other than 78) such as its fits, function, mounting or
appearance, or the a'ility to process or 'uild the product. (Appendi5 Q7"D) $ (Appendi5 APQP)
3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @7afety8ompliance U78VF Product characteristic for which reasona'lyanticipated variation could significantly affect customer the product/s safety or its compliance with government regulations (such asF
flamma'ility, occupant protection, steering control, 'raing, etc. . .), emissions, noise, radio frequency interference, etc. . .
(Appendi5 Q7"D)
3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @7afety8ompliance U7VF Product characteristic for which reasona'ly anticipated
variation could significantly affect customer the product/s safety or its compliance with government regulations (such asF
flamma'ility, occupant protection, steering control, 'raing, etc. . .), emissions, noise, radio frequency interference, etc. . .
(Appendi5 APQP)57
haracteristics %
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haracteristics %
3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @7tandard U9oneVF Product characteristic for which reasona'ly
anticipated variation is unliely to significantly affect a product/s safety, compliance with governmental regulations,
fit8function. (Appendi5 Q7"D) $ (Appendi5 APQP)
3A+ATE+!7T!, /PCIA", P+0E77 (e.g., C%ITICA"8 ;8 0AGO%8 /I-HIICAHT)F A process characteristic for which
variation must 'e controlled to some target value to ensure that variation in a special product characteristic is maintained to its target
value during manufacturing and assem'ly. (P-K &2EA)
3A+ATE+!7T!, /PCIA", P+0#?TF ore team compilation of important product characteristics from all sources. All
7pecial haracteristics must 'e listed on the ontrol Plan. (L.= :D APQP)
3A+ATE+!7T!, /PCIA", P+0#?T (e.g., C%ITICA"8 ;8 0AGO%8 /I-HIICAHT)F A product characteristic for which
reasona'ly anticipated variation could significantly affect a product/s safety or compliance with governmental standards or
regulations, or is liely to significantly affect customer satisfaction with a product. (P-- &2EA)
3A+ATE+!7T!, 7PE!A, T00!9*, 3+I7E+ #E&!9!T!09 @Pentagon UPVF ritical tooling sym'ol used to identify
special characteristics of fi5tures, gages, developmental parts, and initial product parts. (Q7"D)
09T+0 !TE2 PA+T, &0+# #E&!9!T!09F Product drawings8specifications containing ritical haracteristics. &ord #esign and
Quality Engineering approval is required for changes to ontrol !tem &2EA/s and ontrol Plans. (Q7"D)
58
Phase : ProCect +eview
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ProCect Title ustomer
2odel8Iear Part #ate
0ur advanced qual ity planning team has considered the foll owing questions in Phase :
of our APQP process. The documents provided have 'een used as a 'asis for analyGingthe a'i lity to meet al l specifi ed requirements. All 90 answers are supported with attached
com ments identifying our concerns and8or proposed changes to ena'le us to meet
speci fied requirements.
Ies 9o hecl ist !tem
:. 3as historic al data and e5perience conc erning customer needs 'een consideredH
. 3ave the product8process assumptions 'een i dentifi ed and chal langedH
-. 3ave product relia'ility studies 'een conductedHL. 3ave there 'en appropriate customer inputs into the processH
K. #o the design goals reflec t the data generatedH
J. #o the qual ity and reli a'il ity goals reflect appropriate standardsH
D. !s the prelimi nary 'ill of materials suffic ientl y thoroughH
:. #oes the prelim inary process flow c hart relate to the primary 602 and
produc t8process assumptionsH
::. Are all specia l product and process characteristics litedH
:
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Phase 1I Plan an, De(ine Pr&gra
2anageme
nt
Purchasing
Engineering
Quality
)a'oratory
7ales
Production
3+
2aintenance
2aterials
2!7
0utput
#esign *oals+elia'ility and Quality *oalsPreliminary 602Preliminary process flow chartPreliminary list of special product andprocess characteristics.
Product assurance plan2anagement 7upport
Advanced Product Quality Planning
Phase : +esponsi'ility2atri5
This form is on course dis60
APQP Ph < P d t # i d # l t
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PlanningPlanning
#esign $ #evelopment
%alidation
Production
&eed'ac Assessment $ orrective Action
ProgramApproval
Prototype
Product#esign $
#ev.%erification
Product
Process
Product " Process
Advanced Product Quality Planning
APQP Phase
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Advanced Product Quality Planning
Phase < 0utputs
0utputs 'y #esign +esponsi'le Activity
0utputs 'y Advanced Product Quality
Planning Team
62
0utputs 'y #esign +esponsi'le Activity
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#esign &2EA
#&2 and #&A1#esign for 2anufactura'ility
1#esign for Assem'ly
#esign %erification
#esign +eviews Prototype 6uild " ontrol Plan
Engineering #rawings (including 2ath data)
Engineering 7pecifications
2aterial 7pecifications
#rawing and 7pecification hanges
Advanced Product Quality Planning
0utputs'y #esign +esponsi'le Activity
63
Additional 0 tp ts ' #esign +esponsi'le Acti it
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?pdated special characteristics list
Prototype parts 'uild12ae " 6uy decisions
1Parts inspection
1Assem'ly of prototype(s)
Prefera'ly manufacturing, not model shop
1!nspection layout
1Prototype validation testing
+edesign as required and design review
?pdate #&2EA (and 7ystem evel &2EA if appropriate) &easi'ility report
Advanced Product Quality Planning
Additional 0utputs'y #esign +esponsi'le Activity
64
&2EAs
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Advanced Product Quality Planning
&2EAs
65
#&2EA
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#isciplined analytical tool
1Assess pro'a'ility of failure
1Effect of failure
2ust 'e continuallyupdated
auses changes and8or additions to previously
selected special product and8or process
characteristics
!f you do not have design control, you 2?7T(should)
have customer #&2EA
hec list (A!A* APQP 2anual Appendi5 A":)
Advanced Product Quality Planning
#&2EA
66
P&2EA E5ample
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Process &ailure 2ode And Ef f ects Analy sis ow " 3igh
ProcessF 0utside 7uppliers Af f ectedF EngineerF : " :
Primary Process +esponsi'ility F 2odel Iear8%ehicle(s)F Part 9um'erF
0ther #iv . 0r People !nv olv edF 7cheduled Production +eleasedF P&2EA #ateF +ev .
Approv alsF Quality Assurance 2anager Quality Assuranc e Engineer
0perations 2anager 7enior Adv isor
Part 9ame0peration9 um 'er Proc es s &unc tion
Potential &ailure2ode Pot ent ial Ef f ects 0f & ailure Pot ential aus e 0f & ailure urrent ontrols 0
ccured
7everity
#etection
+P9 +ecommended
Actions And 7tatusActions
Taen+esponsi'le
Activ ity
7!+ Tae TPPE 4rong 2aterial &ragment ed ontainer !nsuf f icient 7upplier ontrol 2aterial ertif ication : D < :J
ontainer 2aterial 3eld !n ?npredicta'le #eploy ment !mproper 3andling +equired 4ith Each
: 7torage Area 2isidentif ied 2aterial 7hipment
+elease %erification
0ut 0f 7 pec & ragment ed ont ainer 7upplier Proc ess ont rol Periodic Audit 0f = : = D
2aterial ?npredicta'le #eploy ment 7upplier 2aterial
ontaminated &ragmented ontainer 0pen 6o5es %isual !nspection : D K L=2aterial ?npredicta' le #eployment
2aterial &ragmented ontainer Engineering hange +elease %erif ication : : K K
omposition ?npredicta'le #eploy ment 7upplier hange *reen M0NM Tag
hange ustomer 9otif ication
< 2ov e To ?nreleased &ragmentation ?ntrained T0 hec &or *reen M0NM - : : -
Approv ed ?ntrained Personnel Tag At Press
7torage Trace ard
hec ist
Training
= 3old !n Approv ed ontamination &ragmentation 0pen ontainers 6o5es Nept !n 7ealed : : = =
7torage ?ntil Process Pro'lems 3ouseeeping 7torage Area ?ntil9eeded Area 2aintenance 9eeded
6o5es ined 4ith
Plastic
iner 0n Pallets
!nside 7torage
P. 2. &acility
Advanced Product Quality Planning
P&2EA E5ample
67
#&2 and #&A
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Advanced Product Quality Planning
#&2and #&A #esign, concept,
function and
sensitivity
(tolerancing)
tomanufacturing
variation
2anufacturing
and8or assem'ly
process
#imensional
tolerances
Performance
requirements
9um'er of
components
(comple5ity)
Process
adCustments
2aterial
handling
68
#esign %erification
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!nspection methods
Testing methods
Ensure that all design outputs meet
design input requirements1Alternate calculations
1A#8math data
1+eview design stage documents 'efore release
Advanced Product Quality Planning
#esign %erification
69
#esign +eviews Evaluations
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#esign8functional requirement(s) and considerations
&ormal relia'ility and confidence goals
omponent8su'system8system duty cycles
omputer simulation and 'ench test results
#&2EA(s) +eview of the #&2 and #&A
#esign of e5periments (#0E) and assem'ly 'uild
variation results
Test failures
#esign verification progress
2a582in 'uilds
Advanced Product Quality Planning
#esign +eviews " Evaluations
70
#esign +eview Tracing
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Trac verification progress using a
design verification plan and report (#%P$+
" &ord $ hrysler)
Product8process validation of
components
Advanced Product Quality Planning
#esign +eview Tracing
71
Early Process &low #iagram
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Advanced Product Quality Planning
Early Process &low #iagram
72
Process &low #iagram E5ample
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Pro#ess Flow Dia(ram &%%ro$ed *y+Part ,umber+ Date+ 4//9- .& Mana(er
Part Des#ri%tion+ e$0 + 1 %erations Mana(er
Pre%ared *y+ )enior &d$isor.& 3n(ineer
)te% Fabri#ation
Mo$e
)tore
Ins%e#t
%eration Des#ri%tion Item 5ey Produ#t 1hara#teristi# Item 5ey 1ontrol 1hara#teristi#
! Move "OK" Vinyl Material 1.0 Material Specs 1.0 Material Certification Tag
From Storage Area and
Load Into Press.
2 Auto Injection Mold Cover 2.0 Tearstrip In Cover 2.1 Tool Setup
In Tool # 2.2 Machine Setup
3.0 Hole Diameter In Cover 2.1 Tool Setup
2.2 Machine Setup
4.0 Flange Thickness In Cover 2.1 Tool Setup
2.2 Machine Setup
5.0 Pressure Control Protrusions 2.1 Tool Setup
Height 2.2 Machine Setup
- Visually Inspect Cover 6.0 Pressure Control Protrusions 2.1 Tool SetupFilled Out 2.2 Machine Setup
7.0 Cover - Flash Free 2.1 Tool Setup
2.2 Machine Setup
8.0 Cover Filled Out 2.1 Tool Setup
2.2 Machine Setup
9.0 Free Of Foreign Material 2.2 Machine Setup
Advanced Product Quality Planning
g p
73
ontrol Plan 2ethodology
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Aids in the manufacturing of products according to
customer requirements
Provide structured approaches
ontain a written summary of the system used in
minimiGing process and product variation
&orms provided in the A!A* hand'oo are e5amples
of how to document
Alternate formats can 'e used if they contain
necessary information
2ust 'e maintained and used throughout the product
life cycle
Advanced Product Quality Planning
ontrol Plan 2ethodology
74
ontrol Plan ?se
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!nitialF To document and communicate
initial process control
9e5tF *uidance in controlling processes
and to ensure product quality
astFA living document reflecting
current methods of control and
measurement systems used
Advanced Product Quality Planning
ontrol Plan ?se
75
ontrol Plan
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Ensure ontrol Plan is aligned to, and
correlates with, #&2EA, Process &low,
P&2EA
ontrol 2ethods appropriate to
variation type(s)
!ncorporates essons earned,
7tatistical #ata
?se A"J ontrol Plan checlist
in APQP manual to evaluate
Advanced Product Quality Planning
ontrol Plan
76
Prototype 6uild ontrol Plan
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A description of the dimensional
measurements
2aterial tests1&unctional tests that will occur during prototype
'uild
1#epending upon product comple5ity, several
prototype 'uilds may 'e necessary and may
require updates to the control plan
Advanced Product Quality Planning
Prototype 6uild ontrol Plan
77
7tandard ontrol Plan E5ample
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ontrol Plan 9um'er Ney ontact 8 Phone #ate (0rig.) #ate (+ev.)
Part 9o.8 atest hange 9o. ore Team ustomer Engineering Approval8#ate
Part 9ame8#escription 7upplier8Plant Apoproval8#ate ustomer Quality Approval8#ate
7upplier8Plant 7upplier ode 0ther Approval8date (!f +eqd) 0ther Approval8date (!f +eqd)
haracteristics 2ethods
Part8Process9um'er
Process 9ame80peration
#escription
2achine,#evice,
ig, Toolsfor 2fg. 9o. Product Process
7pecialhar.lass
Product8Process7pec8
Tolerance
Evaluation2easurement
Tec hnique 7iGe&requ"ency
ontrol2ethod
+eactionPlan
Advanced Product Quality Planning
7tandard ontrol Plan E5ample
This form is on course dis 78
&ord/s #imensional ontrol Plan (#P)
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Advanced Product Quality Planning
&ord s #imensional ontrol Plan (#P)
79
ontrol Plan E5ample (*2)
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Process ontrol Plan
7upplier 9ameF 7upplier odeF Part 9um'erF7upplier +ep.F TelephoneF Part #escriptionF
TitleF #ateF >8-8D= Engineering hange etterF Process Plan Ef fectiv e #ateF >8-8D=
Ney Product ontrol haracterist ics *age 7tudy Process apa'ility Process Perf ormance ontrols
(7hort Term apa'ilit y) (ong Term apa'ility )
W:X WX W-X WLX WKX WJX WDX W:X W::X W:X W:-X W:LX W:KX W:JX
!t em Ney P roduct Ney ontrol 0perat ion *age Att r.8 ast +$+ Y *age Proc ess Y Proces s p or #ev Proc ess Y Process p or #ev Ty pe 0f &req. 0f 0perat or Process
haracteristic8 haracteristics #escription 0peration %aria'le #ate +$+ apa'ility apa'ility &rom Perf orm. Perf orm &rom ontrol !nspect. 7et"?p Audit
7pec #ate Target89om. #ate Target89om. 2ethod *age 2ethod
!nstruction and
(Proced. ) &requency
:. %iny l 2aterial hec Ev ery *reen M0NM
7pec %endor 6o5 +elease,
ert(s). Each 6o5
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2ae "'uy decisions
Part inspections
Assem'le prototypes
Perform layout inspection
%alidation testing (4ho will do testingH)
+edesign as required
?pdate #&2EA and 7&2EA if required
Advanced Product Quality Planning
Prototype 6uild
81
ustomer or 7upplier Engineering #rawings
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+eview for special and8or critical characteristics
+eview controlling drawings when engineering drawings
are none5istent
+eview drawings forF
1#imensions for form, fit, function, dura'ility, government 7$+
1ontrol or datum surfaces8locators for function gages and
equipment
1&easi'ility8compati'ility with industry standards
ompati'ility of math data with two"way communications
(.ritten aivers accepta'le)
Advanced Product Quality Planning
(including math data)
82
ustomer or 7upplier Engineering 7pecifications
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+eview and understand controlling specifications
!dentify functional, dura'ility and appearance
requirements
7hould defineF
17ample siGe
1&requency
1Acceptance criteria
0therwise, determined 'y supplier and included in
control plan
Advanced Product Quality Planning
ustomer or 7upplier Engineering 7pecifications
83
2aterial 7pecifications
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+eview 2aterial 7pecifications for
7pecial haracteristics1Physical properties
1Performance
1Environmental
13andling
17torage
!nclude in ontrol Plan
Advanced Product Quality Planning
2aterial 7pecifications
84
#rawing and 7pecifications hanges
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hange control requirement applies
Ensure proper communication
Q7 D Element >.- #ocument and #ata
ontrol/ applies(requires a hange ontrol system)
Advanced Product Quality Planning
#rawing and 7pecifications hanges
85
APQP Team 0utputs
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Advanced Product Quality Planning
APQP Team 0utputs
9ew equipment, tooling and facilities
requirements
7pecial product and process characteristics
*age and testing equipment requirements
Team feasi'ility commitment and managementsupport
7u'contractor 'uild
7upplier 'uild
86
9ew Equipment, Tooling and &acilities +equirements
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Advanced Product Quality Planning
q p , g q
Preliminary identification of new equipment, tooling
and facilities
Address these items on the timing chart
Address capa'ility requirements
Esta'lish delivery times omplete chec list in A!A* APQP $ ontrol Plan reference manual
Appendi5 A"=
87
7pecial Product and Process haracteristics ist
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Advanced Product Quality Planning
p
?pgrade preliminary list started in Phase : from
information gathered through review anddevelopment of design features
1Additional sources
#&2EA
7&2EA if applica'le
P&2EA
Previous history
2ust 'e on control plans for prototype, pre"launch
and production
isting should 'e a team consensus
These ay &verlap
88
*ageand Testing Equipment +equirements
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Advanced Product Quality Planning
g g q p q
Preliminary identification of inspection, test and
measurement equipment
+equirements on timing chart
1omplete in time to conduct measurement
systems analysis1Equipment 'uilder
1Pilot 'uild
1Production trial run
89
Team &easi'ility, ommitment and 2anagement 7upport
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Advanced Product Quality Planning
y g pp
Team feasi'ility commitment
omplete program review chec list, includingF
1#esign feasi'ility
1an 'e manufactured, assem'led, tested and pacaged
1an 'e delivered in the right quantities on schedule at accepta'le
cost
1+eview design information chec list in A!A* APQP +eference manual Appendi5 A" chec list
Advanced Product Quality Planning
101
Process &low hart
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?pdate process flow chart
(E5ample in A!A* APQP +eference manual Appendi5 A"L)
#escri'es current or proposed process flow
?sed to analyGe sources of variation
3elps analyGe total process
9eeded for process &2EA, characteristics matri5 and
control plan +eference A!A* APQP +eference manual Appendi5 A"L chec list
Advanced Product Quality Planning
102
Pro#ess Flow Dia(ram
Process &low #iagram E5ample
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Pro#ess Flow Dia(ram &%%ro$ed *y+Part ,umber+ Date+ 4//9- .& Mana(er
Part Des#ri%tion+ e$0 + 1 %erations Mana(er
Pre%ared *y+ )enior &d$isor.& 3n(ineer
)te% Fabri#ation
Mo$e
)tore
Ins%e#t
%eration Des#ri%tion Item 5ey Produ#t 1hara#teristi# Item 5ey 1ontrol 1hara#teristi#
! Move "OK" Vinyl Material 1.0 Material Specs 1.0 Material Certification Tag
From Storage Area and
Load Into Press.
2 Auto Injection Mold Cover 2.0 Tearstrip In Cover 2.1 Tool Setup
In Tool # 2.2 Machine Setup
3.0 Hole Diameter In Cover 2.1 Tool Setup
2.2 Machine Setup
4.0 Flange Thickness In Cover 2.1 Tool Setup
2.2 Machine Setup
5.0 Pressure Control Protrusions 2.1 Tool Setup
Height 2.2 Machine Setup
- Visually Inspect Cover 6.0 Pressure Control Protrusions 2.1 Tool SetupFilled Out 2.2 Machine Setup
7.0 Cover - Flash Free 2.1 Tool Setup
2.2 Machine Setup
8.0 Cover Filled Out 2.1 Tool Setup
2.2 Machine Setup
9.0 Free Of Foreign Material 2.2 Machine Setup
Advanced Product Quality Planning
103
&loor Plan ayout
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#etermine accepta'ility of inspection and test points
ontrol chart location(s) %isual aides
!nterim repair stations
(rewor)
9onconforming material storage
Neyed to material flow and control plan
+eference A!A* APQP +eference manual Appendi5 A"-
Advanced Product Quality Planning
y
104
haracteristics2atri5
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#isplays relationship 'etweenF
1Process parameter
12anufacturing stations +eference A!A* APQP +eference manual Appendi5 6, page J 0utputs
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Production trial run
2easurement system evaluation(complete)
Preliminary process capa'ility study
Production part approval
Production validation testing
Pacaging evaluation
Production control plan
Quality planning sign"off and management
support
Advanced Product Quality Planning120
4or instructions for operating personnel
Process !nstructions
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4or instructions for operating personnel
7ourcesF[ &2EAs
[ ontrol plans
[ Engineering drawings and specifications
[ 2aterial specifications
[ %isual standards
[ !ndustry standards
[ Process flow chart
[ &loor plan layout
[ haracteristic matri5
[ Pacaging standards
[ Process parameters
[ Producer e5pertise
[ 3andling requirements
[ 0perators of process
[ Accessi'le operators
[ !nclude set"up parameters
[ +eference Q7 D Element >.D Process ontrol/
Advanced Product Quality Planning121
2easurement 7ystems Analysis (27A)
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omplete studies as defined in the 27A
plan
2inimum are those identified in the
control plan
7u'Cected to evaluation prior to or
during production trial
Advanced Product Quality Planning122
27A 7tudies
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2easurement uncertainty determined
1*age +$+, 6ias, 7ta'ility, and inearity
*age + $ + acceptance guidelines
1U :Y accepta'le
1:"=Y may 'e accepta'le, evaluate total variation1V=Y unaccepta'le, measuring system needs
improvement
%erify study performed correctly
Advanced Product Quality Planning123
2easurement 7ystems Analysis PlanEnsures *ageFinearity
Accuracy
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0easureent
Instruent nvir&nent
0aterial Inspect&r 0eth&,s
7ample
Preparation
7ample
ollection
Paralla5
+eproduci'ility
Training
Practice
Ergonomic
s
Test 2ethod
4ormanship
7amples
7tandards
#iscrimination
+epeata'ility
6ias
ali'ration
inearity
%i'ration
ighting
Temperature
3umidityThese are some of the varia'les in a
measurement system. 4hat others can
you thin ofH
Accuracy
+epeata'ility
+eproduci'ility
orrelation for duplicate gages*ages may 'e needed prior to gage sign"off at su'contractor plant or any in"house
pilot runs
124
2easurement Precision
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Advanced Product Quality Planning
ndica"es
%&&
%ecisi&n
125
% i i
2easurement 6ias $ +epeata'ility
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%ecise !,ecise
Accua"e
naccua"e!ias
Y&u can c&ec" *& BiasY&u canNOc&ec" *& !,ecisi&n
126
Preliminary Process apa'ility7tudy Plan
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2ust include characteristics identified in control
plan &ew characteristics for simple component
2any characteristics for comple5 product with
many parts +eference A!A* &undamental 7P +eference 2anual
Advanced Product Quality Planning127
Pacaging Evaluation
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Pacaging must conform to specifications
developed 'y customer or supplier
Assess protection of product
ustomer specified pacaging must 'e
evaluated 'y team
Pilot or production trial run parts usually
used in evaluation
Advanced Product Quality Planning128
Pacaging7pecifications
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&or individual products
ustomer pacaging
*eneric standards where appropriate
2ust ensure delivery quality ompati'le with all material handling
equipment used
Advanced Product Quality Planning129
PPAP
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Advanced Product Quality Planning
APQP "aunch in,ers PPAP /uissi&n
7u'"7et
PPAP
The n, Pr&,uct & APQPF
130
Production PartApproval Process
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PPAP Production parts are manufactured at
the production site using production
tooling, gaging, equipment, operators,etc
Parts from production run are analyGed.
Test results and records from APQP aresu'mitted with Part 7u'mission 4arrant.
Advanced Product Quality Planning131
Purpose of PPAP
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&or the supplier to demonstrateF
; All design records and specification.
; +equirements are properly understood.
;The process has the capa'ility to produceproduct that meets requirements.
Advanced Product Quality Planning132
Production Part Approval Process (PPAP)
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Production Part Approval Process
Parts produced at production site usingF
1Production tooling1Production gages
1Process
10perators
1Environment
1Process settings
&eeds
7peeds
ycle times
Pressures
Temperatures
!ntent is to validate (prove) that products made using production equipment
meet engineering requirements
!f su'mission level is not nown, contact customer
#efault level is =
ustomer approval is required prior to quantity production
+eference A!A* Production Part Approval Process reference manual
Advanced Product Quality Planning133
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Advanced Product Quality Planning134
PPAP7cope
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Production parts " generally = pieces/
7ervice su'contractors " fulfill requirements
6ul material
!ncludes internaland e5ternalsources for
information 7u'mission required prior to first production
shipment
PPAP 2anual 7ection !.= @ustomer 9otification and7u'mission +equirements (starting on page ::) for
guidance
Advanced Product Quality Planning135
Application
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Something
Changed
A!A* PPAP 2anual #efines
4hen PPAP 7u'mission is+equired
; 9ew part
; orrection to discrepancy in previous
su'mission; #esign or process change
; hange in source of su'contracted
materials or services
; Transfer or rearrangement of tooling $
equipment
Advanced Product Quality Planning136
2ethodology
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Approver evaluates
PPAP pacage.1evel - at supplier site
Approver determine
part su'missionstatus.
9otify supplier and
manufacturing of
status.
Advanced Product Quality Planning
6uyer enters PPAP
su'mission date onpurchase order.
Approver determines
su'mission level.1#efault level =
1#efault level > for raw material
7upplier su'mits PPAP
1PPAPA.5lselectronicsu'mission (#elphi)
137
#&2EA
7upplier #ata +eceived 4arrant
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#&2EA
ontrol Plan
Early Production ontainment
Plan (Pre"aunch ontrol Plan)
Process capa'ility studies
*age 2easurement 7ystemAnalysis
a' Accreditation $ scope
+estricted $ +eporta'le
2aterials form !nterim 4orsheet, if required
Advanced Product Quality Planning
4arrant
Appearance
Approval +eport(AA+), as required
7ample Parts
Print8#esign +ecord
Engineering hange
#ocuments
hec fi5tures8aids
Process &low#iagram
P&2EA
138
&low hart
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inage of Product haracteristics from
#&2EAto 0perational 7teps.
0peration num'ers consistent with P&2EA,
ontrolPlan, 0perator !nstructions.
Ensure identification ofinspection and rewor.
?se A"L Process &low hartcheclist in APQP manual to
evaluate.
Advanced Product Quality Planning139
#&2EA
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Assess &easi'ility, +is, #esign !ntent
!ssues onfirm 2anufacturing Process
apa'ility onsidered
&ocus on ritical haracteristics
essons earned !ncorporated
?se A": #esign &2EA heclist
in APQP 2anual to Evaluate
Advanced Product Quality Planning140
i ith #&2EA P &l
P&2EA
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inage with #&2EA, Process &low,
ontrol Plan, 0perator !nstructions, etc #egree to which high +P9/s are
addressed with preventive strategies
Action Plans assigned,
implemented, effectiveness
assessed and +P9 recalculated
?se A"K Process &2EA
checlist in APQP manual
Advanced Product Quality Planning
'P()&*+
141
Pre"aunch ontrol Plan
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Early Production ontainment +equirements
1:.Additional controls included for properduration or quantity.
1
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?pdate pre"launch control plan (living document)
AddF
17ampling plans
1ontrol method
17P, inspection, attri'ute data and mistae"proofing
1+eaction plan
9onconformances clearly identified, quarantined and
disposition made
+equires customer approval unless otherwise
specified +eference A!A* APQP +eference manual Appendi5 A"J, 6 and *
Advanced Product Quality Planning143
Production %alidationTesting
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Engineering tests validate products manufactured
withF1Production tools
1Production processes
1Production operators
Performed under end"use operating conditions 2ultiple validationsfor multiple intended uses +eference Q7 D Element >.>.J
Advanced Product Quality Planning144
Production Trial +un
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Production tooling, equipment,
environment, facilities and cycle time
Process instructions and control plans
2inimum quantity set 'y customer
(an 'e increased 'y team)
*enerally = parts
Advanced Product Quality Planning145
Production Trial +un Product ?sed &orF
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Preliminary process capa'ility studies
27A (if not completed earlier) &inal feasi'ility
Process review
Production validation testing
PPAP
Pacaging evaluation
&irst time capa'ility
Quality planning sign"off #esign changes (if required)
Advanced Product Quality Planning146
Pp vs. p
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In 1991, the ASQC/AIAG Task Force published the "FundamentalStatistical rocess Control" re!erence manual, hich shos thecalculations !or Cpk as ell as pk# These should be used toeliminate con!usion about calculatin$ Cpk# So hich %alue is bestto report, Cpk or pk& Althou$h the' sho similar in!ormation,the' ha%e sli$htl' di!!erent uses#
Advanced Product Quality Planning
(stimated si$maand the related capabilit' indices )Cp, Cpk, and Cr* areused to measure the potential capabilit' o! a s'stem to meet customerneeds# +se it hen 'ou ant to anal'e a s'stem-s aptitude to per!orm#
Actual orcalculated si$ma)si$ma o! the indi%iduals* and the related indices)p, pk, and r* are used to measure the per!ormance o! a s'stem to meet
customer needs# +se it hen 'ou ant to measure a s'stem-s actual processper!ormance#
147
Preliminary Process apa'ility 7tudies
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haracteristics identified in the control plan
?sually : pieces minimum
2ay 'e = if run is less
Pp \ :.LK is accepta'le unless otherwise
specified Pp ] :.LK requires action plan unless
otherwise specified +eference A!A* &undamental 7P +eference 2anual
1:. at spec limit
1Z"= sigma O :.LK
1Allows flop/ within spec limit
Advanced Product Quality Planning148
Process Analysis Animation
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Advanced Product Quality Planning
lsar$c&
ourtesy of The Red Road
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3istogram Animation
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Advanced Product Quality Planning
lsar$c&
ourtesy of The Red Road
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150
Process apa'ility Animation
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Advanced Product Quality Planning
lsar$c&
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Process apa'ility Animation
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Advanced Product Quality Planning
lsar$c&
ourtesy of The Red Road
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C ilit I t t ti C l i
Process apa'ility 7tudies
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Capaility Interpretati&n C&nclusi&n
Pp V :.LK Process pro'a'lymeets customerrequirements
urrent control plansufficient
:.==UPpU:.LK Process may notmeet customerrequirements
Additional controlsneeded until pV:.==achieved
PpU:.== Process will not
meet customerrequirements
:Y inpection is
needed until pV:.==achieved
Advanced Product Quality Planning153
Part 7u'mission 7tatus Possi'ilities
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Advanced Product Quality Planning
&ull Production Approval
!nterim Approval1AuthoriGe shipment to #elphi
without &ull Production Approval
1orrective Action Plan is required.
+eCected1orrected su'mission required
'efore production quantities may 'e
shipped.
154
!nterim Part lasses
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Parts fromproduction tooling and
require rewor to meet
specs.
CCParts not from
production tooling, partsmeet specs.
DDParts do not meetspecs.
Parts do not meetspecs and vehicles with
class E parts require
retrofit to mae them
salea'le.
Advanced Product Quality Planning
1 AAParts from
production toolingand meet specs, not
all PPAP
requirements have
'een met.1
155
P i i i l d f ll d
+eview and 7ign"0ff
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Process instructions in place and followed
&low charts in place and followed
*+$+ plans e5ist and are followed
Pu'lish final feasi'ility report
0'tain formal sigh"off
7chedule and conduct management review
0'tain management commitment to assist in
open issues
Advanced Product Quality Planning156
ProCect Title ustomer
Phase > ProCect +eview
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2odel8Iear Part #ate
0ur advanced quality planning team has considered the f ollowing questions in Phase >
of our APQP process . The documents prov ided hav e 'een used as a 'asis f or analy Gingthe a'ility to meet all specif ied requirements. All 90 answers are supported with attached
comments identif y ing our concerns and8or proposed changes to ena'le us to meet
specified requirements.
Ies 9o hec li st !tem
:. 3as the production trial run 'een conducted and does it indicate the need for any changeH
. 3as the produc tion part 'een approvedH-. 3as the production validation testing indicated any pro'lemsH
L. 3as the evaluation of the pacaging of test shipments, where feasi'le, and test methods
indicated any difficultyH
K. 3as the control plan methodology chec list indicated any pro'lems with that documentH
&easi'le Product can 'e produced as specified with no revisions.
&easi'l e hanges recommended (7ee attached)
9ot &easi'le #esign revision required to produce product within specified requirements
Team 2em'er8Title8#ate Team 2em'er8Title8#ate
Team 2em'er8Title8#ate Team 2em'er8Title8#ate
Advanced Product Quality PlanningThis form is on course dis157
Phase > +esponsi'ility2atri5
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Phase 4I Pr&,uct an, Pr&cess Jali,ati&n
2anageme
nt
Purchasing
Engineering
Quality
)a'oratory
7ales
Production
3+
2aintenanc
e
2aterials
2!7
0utput
Production Trial +un
2easurement 7ystems Evaluation
Preliminary Process apa'ility 7tudyProduction Part Approval
Production %alidation Testing
Pacaging Evaluation
Production ontrol Plan
Quality Planning 7ign"0ff
2anagement 7upport
Advanced Product Quality PlanningThis form is on course dis158
APQP Phase -F &eed'ac, Assessment and orrective Action
PlanningPlanning
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Advanced Product Quality Planning
The results of continuing production are evaluated for common
or specialcauses of variationduring this phase to ensure that
the products satisfy customer satisfaction requirements
The effectivenessof the quality process should 'e evaluated
during this process step
1!ncludes continual improvement efforts
1!ncludes delivery and service performance
gg
#esign $ #evelopment
%alidation
Production
&eed'ac Assessment $ orrective Action
aunch
Product
ProcessProduct " Process
&eed'acAssessment $
orrective Action
159
ontinuing Production
ontinuing
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Advanced Product Quality Planning
Production
#etermining
0ngoing
apa'ility
ontinuing
Production
#evelop $ !mplement
orrective Action Plan
2easure #elivery $
7ervice
2easure
ustomer
7atisfaction
p V
or O :.==
Attend ustomer Q07
2eeting As +equired
ontinuous
!mprovement
Plan $
&eed'ac
#evelop Q07
2easurement
#evelop #elivery $
7ervice 2easurement
Plan
&r,:s Interpretati&n
160
+ d d i ti
Phase - 0utputs
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+educed variation
ustomer satisfaction
#elivery and service
Advanced Product Quality Planning161
!d tif i ti
+educing %ariation
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!dentify process variation
tae corrective action to reduce
variation
#evelop proposal for customer review
*ain customer decision to implement,
negotiate or change design
Advanced Product Quality Planning162
P d t i t f i
ustomer 7atisfaction
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Product or service must perform in
customer/s environment
7upplier must participate
7upplier and customer must 'e
partners +eference Q7 D Element >.:.L
Advanced Product Quality Planning163
4arrant
ustomer 7atisfaction 2etrics
stomer rating
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4arranty
a'our claims
oncerns reports
9onconforming
material reports orrective actions
0n time delivery
Tech calls
Advanced Product Quality Planning
ustomer rating
+eturns
PP2
+esponse time
0n"siterepresentative
2aret share
ost control (totalcost)
164
ontinues the supplier customer partnership
#elivery and 7ervice
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ontinues the supplier " customer partnership
in pro'lem solving and continuousimprovement
+eplacement parts and services are
important
eads to possi'le price reduction fromF
1!nventory cost reduction
1Process cost reduction
1ost of quality reduction
1+eference Q7 D Element >.:-
Advanced Product Quality Planning165
Phase - +esponsi'ility 2atri5
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Phase !I ee,ac#8 Assessent an, C&rrective Acti&n
2anagement
Purchasing
Engineering
Quality
)a'oratory
7ales
Production
3+
2aintenance
2aterials
2!7
0utput
+educed %ariationustomer 7atisfaction#elivery and 7ervice
Advanced Product Quality PlanningThis form is on course dis
166
Phase - ProCect +eview
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ProCect Title ustomer
2odel8Iear Part #ate
0ur advanced quality planning team has considered the following questions in Phase -
of our APQP process. The documents provided have 'een used as a 'asis f or analyGing
the a'ility to meet all specif ied requirements. All 90 answers are supported with attached
comments identif y ing our concerns and8or proposed changes to ena'le us to meet
specif ied requirements.
Ies 9o hecl ist !tem
:. 3as a system for reducing future variation 'een developed and is it i n placeH
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A!A* PPAP 2anual #efines +equirements
APQP Product and Process %alidation
7upplier su'mits PPAP to proper level
PPAP pacage evaluated and status
determined 7upplier and customer manufacturing site
notified of PPAP approval status
Advanced Product Quality Planning168
A : #esign &2EA hec ist
APQP 2anual Appendi5 A " hec ists
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A": #esign &2EA hec ist
A"< #esign !nformation heclist
A"= 9ew Equipment, Tooling and Test
Equipment heclist
A"> Product 8 Process Quality heclist A"- &loor Plan hec ist
A"L Process &low hart heclist
A"K Process &2EA heclist