APQP-PPAP(1)

1、APQPPPAP 精品資料網1APQPA Perspective on 8-D and PFMEA and Control Plan During APQP and Afterwards 精品資料網2What is APQP?APQP is a defined process for a product development system for Ford, Daimler- Chrysler, GM and their suppliers. APQP is an attempt to provide a common path and synchronization of product

2、development activities.APQP is an attempt to ensure communication both within a company and between a company and its customer 精品資料網Benefits of APQPEnsures early planning takes place.Directs resources to the customer.Identifies required changes early in the process.Provides quality product on time a

3、nd at lowest cost.Enables cross-functional inputs and outputs.Addresses potential problems early 精品資料網Customer and Supplier InvolvementCustomer may initiate planning process.Supplier has the obligation to establish cross-functional team to manage process.Supplier should expect the same performance f

4、rom their subcontractors. 精品資料網Determine Customer RequirementsPrintPurchase Request or Request for Quotation.Statement of Work (SOW)Customer visits and discussions.Product checklists. 精品資料網TrainingCustomer needs and expectations.Working as a team.Requirements of APQPFMEAAPQPPPAP 精品資料網APQP Five Phase

5、 ProcessPlanningProduct Design and DevelopmentProcess Design and DevelopmentProduct and Process ValidationProductionFeedback Assessment and Corrective ActionPilotLaunchConcept Initiation/ApprovalProgram ApprovalPrototypePlanning 精品資料網Links Between the ToolsContract Review Program PlanDFMEATeam Feasi

6、bility CommitmentProduce Process Flow DiagramsConduct Process FMEADevelop Control PlanWork Instruction DevelopmentProduct and Process ValidationEnsure Continuous ImprovementPhase IPhase IIPhase IIPhase IIIPhase IIIPhase IIIPhase IIIPhase IVPhase VDetermine Customer Expectations and Plan for QualityI

7、dentify Key Characteristics Determine Risk and FeasibilityAssociate Characteristics with Process Steps and Identify Key CharacteristicsExpose Sources of Variation and Finalize Key CharacteristicsDetermine Methods to Improve Process and Control VariationImplement Control Plan and Standardize the Proc

8、essEnsure Customer Expectations are MetExercise Management Oversight 精品資料網The Target and The Goal 精品資料網Link Between the Documents 精品資料網Process Flow DiagramsUpdated after production trial run.Need to indicate special characteristics generated at each step. Completed Along with Control Plan (APQP Proc

9、ess).Generally contains same information as process traveler. 精品資料網Process Flow Diagram Example 精品資料網APQP Links to PFMEA 精品資料網Process FMEAMust follow flow of the process flow diagram.Must include ALL process special characteristics (as a minimum). 精品資料網How a PFMEA WorksWhere does the data for the PF

10、MEA come from?What types of people are a part of the PFMEA team?What types of activities should we spend a lot of time on? 精品資料網PFMEAs/Control Plans and 8-Ds During APQPPFMEAs should be driven by real data, including 8-Ds (internal and external), warranty and returned part analysisPFMEAs should be c

11、ompleted by process experts and should be a driver of the control plans and work instructionsWork instructions (Post control log, process parameter logs, preventive maintenance, etc.) implement the control plan in the processWhen there is a quality problem there is an opportunity to improve the cont

12、rol plan and the work instructions 精品資料網APQP Links to Control Plan 精品資料網Control PlansIncludes product and process special characteristics.Includes SPC requirements.Follows flow of process flow chart and PFMEA.May require customer approval. 精品資料網Types of Control PlansPrototype build control plan(s) P

13、re-launch control planProduction control plan 精品資料網Prototype Build Control PlanA description of the dimensional measurements.Material testsFunctional tests that will occur during prototype build. 精品資料網Pre-launch Control PlanDescription of dimensional measurements, materials, and functional tests.Add

14、s additional product and process controls.Purpose is to contain potential nonconformities utilizing:More frequent inspections and/or tests.More in-process and finsl inspection and/or check points.Statistical evaluations.Increased audits. 精品資料網Production Control PlanUp-date pre-launch control plan.Ad

15、d:Sampling plansControl methodSPC, inspection, attribute data and mistake proofing.Reaction planNonconformances clearly identified, quarantined and disposition made.Requires customer approval unless otherwise specified. 精品資料網Control Plan UseInitial: To document and communicate initial process contro

16、l.Next: Guidance in controlling processes and to ensure product quality.Last A living document reflecting current methods of control and measurement systems used. 精品資料網Multiple Molds, Tools, Dies and PatternsComplete dimensional layer required from one part from each cavity as a minimum.Supplier mus

17、t identify specific cavity for each part submitted. 精品資料網Part Submission StatusNever ship production parts before receiving customer approval.Supplier must ensure that future production continues to meet customer requirements.No production parts can be shipped until approval is received. 精品資料網Automo

18、tive Documentation DevelopmentDevelop Process Flow ListingCheck for Customer RequirementsEnter Every “Major Process from Flow Listing into FMEA Form Give careful consideration to what you consider a “Major processDevelop FMEA Element for Every ProcessUse the appropriate RPN numbers and consideration

19、s of other appropriate information / data to determine Critical characteristicsDevelop the Control Plan with Critical CharacteristicsDevelop control mechanisms appropriate for Critical characteristics.Give careful consideration to defining Control Plan stagesPrototype Pre-launch Production 精品資料網 精品資

20、料網Provides Proof of CapabilityMade up of Documents from APQP 精品資料網PPAP PurposeEnsure that customer design record and specification requirements are understood.Ensure that the process has the potential for producing product meeting those requirements 精品資料網PPAP ScopeProduction parts - generally 300 pi

21、eces.Includes internal and external sources for information.Submission required prior to first production shipment. 精品資料網 Base DocumentationCritical characteristics matrix.Process flow diagram.Design FMEA (supplied by customer).Process FMEA.Control plan. 精品資料網GeneralSupplier is responsible for meeti

22、ng all applicable specifications.Do not submit parts and documentation results if they are outside specification.Take corrective action to meet all design record requirements.Contact customer if unable to meet all requirementsComply with customer developed material specifications and/or approved sou

23、rce list. 精品資料網GeneralSuppliers are required to complete and maintain copies of all documentation identified in “requirements for approval regardless of submission level.Records of PPAP are to be retained for the life of the part plus one calendar year. 精品資料網Elements of a PPAPPart submission warrant

24、Subcontractor warrantsDesign record (customer/design documentation)Sample/Master sample (Master sample retained by supplier)Dimensional analysisTest dataFlow diagramControl planPFMEAMeasurement Systems Analysis (GR&R)Capability studies 精品資料網Parts Submission WarrantUpon satisfactory completion of all

25、 required measurements and tests, enter all required information on the warrant.A separate is required for each part number.Responsible supplier official verifiesMeasurements and tests conform to customer requirementsRequired documentation is available for proper submission level.Signs warrant and p

26、rovided date, title and telephone number. 精品資料網 精品資料網Part WeightDetermine part weight without packaging or shipping material.Report weight in kilograms to three decimal places.Weight determinationWeigh 10 parts randomly selected and report the average weight.For parts less than 0.100 kilogram, weigh

27、 10 parts together and report the average weight. 精品資料網Master SampleRetain same as PPAP, orUntil new master sample is produced for the purpose of a customer approval.Identify master sample by:Part numberDrawing level or revision levelCustomer approval date 精品資料網Preliminary Process Capability Studies

28、Characteristics identified in the control plan.Usually 100 pieces minimum.May be 30 if run is less.Ppk 1.67 is acceptable unless otherwise specified.Ppk 1.67 requires action plan unless otherwise specified. 精品資料網Production Trial RunProduction tooling, equipment, environment, facilities and cycle tim

29、e.Process Instructions and control plans.Minimum quantity set by the customer.Generally 300 parts. 精品資料網Production Trial Run Product Used ForPreliminary process capability studies.MSA (if not completed earlier)Final Feasibility.Process review.Production Validation Testing.PPAPPackaging evaluationFir

30、st time capabilityQuality planning sign-off 精品資料網Measurement System Analysis (MSA)Complete studies as defined in the MSA plan.Minimum are those identified in the control plan.Subjected to evaluation prior to or during production trial. 精品資料網Packaging EvaluationPackaging must conform to specifications developed by customer or supplier.Assess protection of product.Customer specified packaging must be evaluated by team.Pilot or production trial run parts usually used in evaluation. 精品資料網Floor Plan LayoutDetermine acceptability of inspection and test points.Control chart locationsVisual aid