產(chǎn)品質(zhì)量先期策劃與控制計(jì)劃幻燈課件

AdvancedProductQualityPlanningandControlPlan產(chǎn)品質(zhì)量先期策劃及控制計(jì)劃1AdvancedProductQualityPlannWhatisAPQP?什么是產(chǎn)品質(zhì)量先期策劃APQP？ProductQualityPlanningisastructuredmethodofdefiningandestablishingthestepsnecessarytoassurethataproductsatisfiesthecustomer.產(chǎn)品質(zhì)量先期策劃是：一種定義并建立保證產(chǎn)品滿(mǎn)足顧客要求的步聚的結(jié)構(gòu)化方法WhatisthegoalofAPQP?什么是APQP的目標(biāo)？Thegoalofproductqualityplanningistofacilitatecommunicationwitheveryoneinvolvedtoassurethatallrequiredstepsarecompletedontime.產(chǎn)品質(zhì)量先期策劃的目標(biāo)是：加強(qiáng)相關(guān)人員之間的溝通以確保所有要求的步聚按時(shí)完成。APQP2WhatisAPQP?什么是產(chǎn)品質(zhì)量先期策劃APQP？WhatisthebenefitsofProductQualityPlanning?什么是產(chǎn)品質(zhì)量策劃的益處？Todirectresourcestosatisfythecustomer.向著使顧客滿(mǎn)意的方向引導(dǎo)資源Topromoteearlyidentificationofrequiredchanges.促進(jìn)及早識(shí)別需要進(jìn)行的更改Toavoidlatechanges.避免事后更改Toprovideaqualityproductontimeatthelowestcost.以最低的成本及時(shí)提供高質(zhì)量的產(chǎn)品APQP3WhatisthebenefitsofProducProductQualityPlanningCycle產(chǎn)品質(zhì)量策劃循環(huán)APQP4ProductQualityPlanningCycleThepurposeoftheProductQualityPlanningCycleistoemphasize:產(chǎn)品質(zhì)量策劃循環(huán)的目的是強(qiáng)調(diào)：Up-frontplanning:Thefirstthreequartersofthecyclearedevotedtoup-frontproductqualityplanningthroughproduct/processvalidation.策劃：前四分之三循環(huán)含蓋產(chǎn)品質(zhì)量策劃到產(chǎn)品/過(guò)程確認(rèn)Theactofimplementation:Thefourthquarteristhestagewheretheimportanceofevaluatingtheoutputservestwofunctions:todetermineifcustomersaresatisfied,andtosupportthepursuitofcontinualimprovement.措施的實(shí)施：第四階段對(duì)結(jié)果進(jìn)行評(píng)價(jià)的重要性體現(xiàn)在兩方面：是否達(dá)到顧客滿(mǎn)意及對(duì)持續(xù)改進(jìn)的追求。APQP5ThepurposeoftheProductQuaDepictingproductqualityplanningasacycleillustratesthenever-endingpursuitofcontinualimprovementthatcanonlybeachievedbytakingtheexperienceinoneprogramandapplyingthatacquiredknowledgetothenextprogram.將產(chǎn)品質(zhì)量策劃描繪成一個(gè)循環(huán)說(shuō)明：只有將從一個(gè)項(xiàng)目中獲取的經(jīng)驗(yàn)及知識(shí)應(yīng)用到下一個(gè)項(xiàng)目中才能實(shí)現(xiàn)對(duì)持續(xù)改進(jìn)的永無(wú)止境的追求APQPAPQPAPQPAPQPAPQP6DepictingproductqualityplanKeytoEffectiveProductQualityPlanning有效的產(chǎn)品質(zhì)量策劃其關(guān)鍵在于：－Supportfromthetopmanagementfor－來(lái)自于最高管理者的支持 concludingeachphaseofproductqualityplanning 質(zhì)量策劃每一階段的總結(jié)

Note:theteamshouldinformtopmanagementaboutthecurrentstatus oftheprojectinordertokeepuptheinterestandunderpintop managementcommitmentandsupport.Theinformationshouldbein writtenform solvingproblemareasandconcerns 參與問(wèn)題的解決

APQP7KeytoEffectiveProductQuali finalassessmentoftheproductqualityplanningprocess (signing-off) 產(chǎn)品質(zhì)量策劃過(guò)程的最終評(píng)價(jià)(總結(jié)認(rèn)定appendixF)－TeamandCommunicationSkill－團(tuán)隊(duì)技巧及溝通技巧

Note:Teamskillmeanstoworkinateamratherthanthinking“great, somebodyelsedoesit”.Communicationskillmeanstheabilitytopasson informationcomprehensivelyandwithoutlossofinformation.APQP8 finalassessmentoftheproduResponsibilityMatrix職責(zé)矩陣APQP9ResponsibilityMatrixAPQP9ProductQualityPlanningTimingChart

APQP10ProductQualityPlanningTiminThetimingchartshowstheidealprocedureofproductqualityplanning.Theindividualphasesareshownastimebarsandtherespectivestartingpointsareshownasverticallines(conceptinitiation/approval,programapproval,prototype,pilot,launch)

APQPAPQPAPQPAPQPAPQPAPQP11ThetimingchartshowstheideOrganizationofAPQPReferenceManualAPQP手冊(cè)的組織結(jié)構(gòu)APQPPlanandDefineProgramSection1.0ProductDesignandDevelopmentSection2.0ProcessDesignandDevelopmentSection3.0ProductandProcessValidationSection4.0Feedback,AssessmentandCorrectiveActionSection5.0ControlPlanMethodologySection6.0OrganizetheteamDefinethescopeTeam-to-teamTrainingindevelopmenttechniquesCustomerandsupplierinvolvementSimultaneousEngineeringConcernresolutionMonitoringwithtimingplansystemsAPQP12OrganizationofAPQPReferenceOrganizingtheTeam組織小組Theresponsibilityforproductqualityplanningmustbeassignedtoacross-functionalteam.TheteamshouldcompriserepresentativesofthefunctionsDevelopment,Production,MaterialTesting,Purchasing,Quality,Sales,CustomerService,aswellassubcontractorsandcustomers.Team-to-TeamCo-operation小組之間的合作Theteammustestablishcommunicationchannelstoothercustomerandsupplierteams.Thismayincluderegularmeetingswithotherteams.APQP13OrganizingtheTeam組織小組APQP13TraininginDevelopmentTechniques開(kāi)發(fā)技術(shù)的培訓(xùn)Thesuccessoftheproductcontrolplandependsonaneffectivetrainingprogramwhichwillconveyalldefinedrequirementsanddevelopmenttechniquesnecessaryforthefulfillmentofcustomerrequirementsandexpectations.CustomerandSupplierInvolvement顧客及供方的參與Ifnecessary,thecustomerandsubcontractormustbeinvolvedintheplanningprocess.Thesuppliershallrequestacross-functionalteamfromtheirsubcontractors.APQP14TraininginDevelopmentTechniDefiningtheScopeoftheTeam:給小組界定范圍selectaprojectteamleader（itmaybeadvantageoustorotatetheteamleaderduringtheplanningcycle)選一個(gè)小組長(zhǎng)（輪流做樁較好）definetherolesandresponsibilitiesofeacharearepresented定義各方代表的角色和職責(zé)identifythecustomers-internalandexternal明確誰(shuí)是內(nèi)部的及外部的顧客definingcustomerrequirements(useQFD,ifapplicable)定義顧客要求(如適用，使用QFD)APQP15DefiningtheScopeoftheTeamdefinethedisciplines,individualsand/orsubcontractorsthatmustbeaddedtotheteam,andthosenotrequired明確部門(mén)，各人及哪些供方必須加到小組中來(lái)，哪些不必understandcustomerexpectations搞清顧客的期望assessthefeasibility,performancerequirements,manufacturingprocess評(píng)價(jià)可行性，性能要求，制造過(guò)程identificationofcostsinvolved,timingandconstraints明確成本，時(shí)間及其他方面的限制determinationofassistancerequiredfromthecustomer明確需顧客提供的邦助有哪些identificationofdocumentationprocessormethod明確報(bào)告/記錄的過(guò)程和方法APQP16definethedisciplines,indiviSimultaneousEngineering同步工程Itisaprocesswherecrossfunctionalteamsstriveforacommongoal.各多功能小組為共同的目標(biāo)努力Itreplacethesequentialseriesofphaseswhereresultsaretransmittedtothenextareaforexecution.代替按階段排序Thepurposeistoexpeditetheintroductionofqualityproductssooner.其目的是加速高質(zhì)量產(chǎn)品的引入

DesignforManufacturabilityandAssemblyisaSimultaneousEngineeringprocessdesignedtooptimizetherelationshipbetweendesignfunction,manufacturability,andeaseofassembly.APQP17SimultaneousEngineering同步工程AConcernResolution問(wèn)題的解決Duringtheplanningprocesstheteamwillhitondesignand/orprocessrelatedconcerns.Theseconcernsshouldbedocumentedinatablewithallocationoftheresponsibilitiesanddeadlinesfortheirresolution.Indifficultsituationsselectedmethodsforconcernresolutionmustbeemployed.AnalyticaltechniqueslistedinAppendixBofAPQPmanual:AssemblyBuildVariationAnalysis;Benchmarking;CauseandEffectDiagram;CharacteristicsMatrix;CriticalPathMethod;DesignofExperiments(DOE);DesignforManufacturabilityandAssembly;DesignVerificationPlanandReport(DVP&R);DimensionalControlPlan(DCP)orDynamicControlPlan;MistakeProofing(POKA-YOKE);ProcessFlowCharting;QualityFunctionDeployment(QFD);SystemFailureModeandEffectsAnalysis(SFMEA)APQP18ConcernResolution問(wèn)題的解決APQP18MethodforConcern-Resolution解決問(wèn)題的方法1.Recognizetheproblem,focusonitanddescribeitcomplains,defects,variations,scrap,audits,listofproblems2.Collectdatamultipledefectchart,qualitycontrolchart,dataprocessing3.EvaluatedataHistogram,pareto,processFMEA4.CauseandeffectsanalysisIshikawadiagram,problemanalysis,valueengineering,8Dreport,DOE5.WorkoutproblemresolutionproposalsBrainstorming,DOE,flowdiagram,visualizingproblemonpinwallAPQP19MethodforConcern-Resolution6.AssessproblemresolutionproposalsDecisiontree,cost-benefit-analysis,riskanalysis,nominalgroupmethod7.Decision8.Informthoseinvolvedandimplementsolutionactionplan,definitionoftargets,determinemeasurables9.Checkoutcometrenddiagram,pareto,audits10.RECOGNITIONAPQP206.AssessproblemresolutionpMonitoringwithTimingPlanSystems用時(shí)間計(jì)劃表來(lái)監(jiān)控ThefirstorderofAPQPteamfollowingorganizationalactivitiesshouldbethedevelopmentofaTimingPlan.APQP小組的組織工作完成后的第一個(gè)任務(wù)應(yīng)該是制定一個(gè)時(shí)間計(jì)劃表。Awell-organizedtimingchartshouldlisttasks,assignments,othereventsandtiming.(TheCriticalPathMethodmaybeappropriate)一個(gè)完善的時(shí)間表應(yīng)羅列出任務(wù)，負(fù)責(zé)人，和/或其他事件及時(shí)間。Tofacilitatestatusreporting,eacheventmusthavea“start”anda“completion”datewiththeactualpointofprogressrecorded.為輔助對(duì)完成狀態(tài)進(jìn)行報(bào)告，每一事件必須有“開(kāi)始”和“完成”日期并記錄實(shí)際進(jìn)展?fàn)顩rAPQP21MonitoringwithTimingPlanSyAttentionPlease注意！Planningteamsmustbepreparedtomodifyproductqualityplanstomeetcustomerexpectations.策劃小組必須準(zhǔn)備好對(duì)產(chǎn)品質(zhì)量計(jì)劃進(jìn)行修改以滿(mǎn)足顧客的期望TheProductQualityPlanningTeamisresponsibleforassuringthattimingmeetsorexceedsthecustomertimingplan.產(chǎn)品質(zhì)量先期策劃小組負(fù)責(zé)確保滿(mǎn)足或超出顧客時(shí)間計(jì)劃的要求。APQP22AttentionPlease注意！APQP22Section1.0PlanandDefineProgram階段1.0定義及確定項(xiàng)目Taskofthissection此階段的任務(wù):DeterminationofcustomerneedsandexpectationsFocussingallworkonthecustomer(finaluser,consumer)Translatingcustomerinputrequirementsintooutputrequirements(orbriefingspecificationintoofferspecification)Definingdevelopment,reliabilityandqualitygoalsAPQP23Section1.0PlanandDefinePInputVoiceofthecustomerMarketresearchHistoricalwarrantyandqualityinformationTeamexperienceBusinessplan/customermarketingstrategyProduct/processbenchmarkdataProduct/processassumptionsProductreliabilitystudiesCustomerinputsOutputDesigngoalsReliabilityandqualitygoalsPreliminarybillofmaterialPreliminaryprocessflowchartPreliminarylistingofspecialproductandprocesscharacteristicsProductassuranceplan(outputrequirements)PlanandDefineProgramSection1.0APQP24InputOutputPlanandDefinePro

階段1.0定義及確定項(xiàng)目

輸入：l·1顧客的呼聲1·1·1市場(chǎng)調(diào)研1·1·2保修記錄和質(zhì)量信息l·l·3小組經(jīng)驗(yàn)1．2業(yè)務(wù)計(jì)劃／營(yíng)銷(xiāo)策略1．3產(chǎn)品／過(guò)程指標(biāo)l．4產(chǎn)品／過(guò)程設(shè)想1．5產(chǎn)品可靠性研究1．6顧客輸入

輸出：1．7設(shè)計(jì)目標(biāo)1．8可靠性和質(zhì)量目標(biāo)l．9初始材料清單l．10初始過(guò)程流程圖1．11初始特殊產(chǎn)品特性及特殊過(guò)程特性清單l·12產(chǎn)品保證計(jì)劃l·13管理者支持25階段1.0定義及確定項(xiàng)目輸入：輸出：2526261.1The‘VoiceoftheCustomer’The‘VoiceoftheCustomer’encompassescomplaint,recommendations,dataandinformationobtainedfrominternaland/orexternalcustomers.1.1.1Marketresearch:Thefollowingsourcescanassistinidentifyingcustomerconcerns/wantsandtranslatingthoseconcernsintoproductandprocesscharacteristics:CustomerinterviewsCustomerquestionnairesandsurveysMarkettestandpositioningreportsNewproductqualityandreliabilitystudiesCompetitiveproductqualitystudiesThingsGoneRight(TGR)reportsAPQP271.1The‘VoiceoftheCustomel·1顧客的呼聲

“顧客的呼聲”包括來(lái)自?xún)?nèi)部和／或外部顧客的抱怨、建議、資料和信息。以下各段提供了收集這種信息的一些方法。1·1·1市場(chǎng)調(diào)研產(chǎn)品質(zhì)量策劃小組可能需要獲取反映顧客時(shí)聲的市場(chǎng)調(diào)研資料和信息。以下來(lái)源有助于識(shí)別顧客關(guān)注的事項(xiàng)／需求，并將這些關(guān)注事項(xiàng)轉(zhuǎn)變?yōu)楫a(chǎn)品和過(guò)程特性：對(duì)顧客的采訪(fǎng)；顧客意見(jiàn)征詢(xún)與調(diào)查；市場(chǎng)調(diào)查和預(yù)測(cè)報(bào)告；新產(chǎn)品質(zhì)量和可靠性研究；競(jìng)爭(zhēng)產(chǎn)品質(zhì)量的研究；運(yùn)行情況良好（TGR）報(bào)告。28l·1顧客的呼聲281.1.2Historicalwarrantyandqualityinformation:Thelistofhistoricalcustomerconcerns/wantsshouldbepreparedtassessthepotentialforrecurrenceduringthedesign,manufacture,installationanduseoftheproduct.Ascertainingcustomerconcernscanbesupportedby:ThingsGoneWrong(TGW)reportsWarrantyreportsSupplierplantinternalqualityreportsCustomerplantreturnsandrejectionsFieldreturnsandproductanalysisAPQPAPQP291.1.2Historicalwarrantyand1·1·2保修記錄和質(zhì)量信息為廠評(píng)定在產(chǎn)品的設(shè)計(jì)、制造、安裝和使用當(dāng)中再發(fā)生不合格的可能性，應(yīng)制定一份以往顧客所關(guān)注問(wèn)題儒要的清單，這些應(yīng)作為其它設(shè)計(jì)要求的擴(kuò)展來(lái)考慮并且應(yīng)包括在對(duì)顧客需要的分析中。以下項(xiàng)目中的許多內(nèi)容有助于小組識(shí)別顧客關(guān)注問(wèn)題／需要，并優(yōu)選出適當(dāng)?shù)慕鉀Q方案：運(yùn)行情況不良（TGW）報(bào)告；保修報(bào)告；能力指數(shù)；供方工廠內(nèi)部質(zhì)量報(bào)告；問(wèn)題解決報(bào)告；顧客工廠退貨和廢品；現(xiàn)場(chǎng)退貨產(chǎn)品分析。301·1·2保修記錄和質(zhì)量信息301.1.3TeamExperience:MediacommentaryandanalysisInputfrompastQualityFunctionDeploymentprojectsGovernmentrequirementsandregulationsRoadtripsManagementcommentsordirection.APQPAPQP311.1.3TeamExperience:APQPAPQPl·l·3小組經(jīng)驗(yàn)小組適當(dāng)時(shí)可利用包括如下內(nèi)容的任何信息來(lái)源：來(lái)自更高層體系或過(guò)去質(zhì)量功能開(kāi)發(fā)（QFD）項(xiàng)目的輸入；媒介的評(píng)論和分析：雜志和報(bào)刊報(bào)告等；顧客的信件和建議；運(yùn)行情況良好（TGR）／運(yùn)行情況不良（TGW）報(bào)告；銷(xiāo)售商意見(jiàn)；車(chē)隊(duì)負(fù)責(zé)人的意見(jiàn)；現(xiàn)場(chǎng)服務(wù)報(bào)告；利用指定的顧客代理所作的內(nèi)部評(píng)價(jià)；道路行駛體驗(yàn)；管理者的意見(jiàn)或指示；由內(nèi)部顧客報(bào)告的問(wèn)題和議題；政府的要求和法規(guī)；合同評(píng)審。32l·l·3小組經(jīng)驗(yàn)321.2BusinessPlan/CustomerMarketingStrategyThecustomerbusinessplanandmarketingstrategywillsettheframeworkfortheproductionqualityplan.Thebusinessplanmayplacethefollowingconstraintsontheteam:TimingCostInvestmentProductpositioningResearchanddevelopment(R&Dresources)Themarketingstrategywilldefinethetargetcustomer,thekeysalespoints,andkeycompetitors.APQPAPQP331.2BusinessPlan/CustomerMar1．2業(yè)務(wù)計(jì)劃／營(yíng)銷(xiāo)策略顧客業(yè)務(wù)計(jì)劃和營(yíng)銷(xiāo)策略將成為產(chǎn)品質(zhì)量計(jì)劃的設(shè)定框架。業(yè)務(wù)計(jì)劃可將限制性要求施加給小組（諸如進(jìn)度、成本、投資、產(chǎn)品定位、研究與開(kāi)發(fā)（R＆D）資源）而影響其執(zhí)行方向。營(yíng)銷(xiāo)策略將確定目標(biāo)顧客、主要的銷(xiāo)售網(wǎng)點(diǎn)和主要的競(jìng)爭(zhēng)者。341．2業(yè)務(wù)計(jì)劃／營(yíng)銷(xiāo)策略341.3Product/processBenchmarkDataTheuseofBenchmarkingwillprovideinputtoestablishingproduct/processperformancetargets.Onemethodtosuccessfulbenchmarkingis:IdentifytheappropriatebenchmarksUnderstandthereasonforthegagbetweenyourcurrentstatusandthebenchmarkDevelopaplantoeitherclosethegap,matchthebenchmark,orexceedthebenchmark1.4Product/processAssumptionsTherewillbeassumptionsthattheproducthascertainfeatures,design,orprocessconcepts.Theseincludetechnicalinnovations,advancematerials,reliabilityassessments,andnewtechnology.Allshouldbeutilizedasinputs.APQP351.3Product/processBenchmark1．3產(chǎn)品／過(guò)程指標(biāo)基準(zhǔn)確定（參見(jiàn)附錄B）將成為建立產(chǎn)品／過(guò)程能力目標(biāo)提供輸入。研究和開(kāi)發(fā)也可提供基準(zhǔn)和概念。成功的基準(zhǔn)確定方法為；識(shí)別合適的基準(zhǔn)；了解你目前狀況和基準(zhǔn)之間產(chǎn)生差距的原因；制定一縮小差距、符合基準(zhǔn)或超過(guò)基準(zhǔn)的計(jì)劃。l．4產(chǎn)品／過(guò)程設(shè)想設(shè)想產(chǎn)品具有某些特性、某種設(shè)計(jì)和工藝過(guò)程概念，它們包括技術(shù)革新、先進(jìn)的材料、可靠性評(píng)定和新技術(shù)。所有這些都應(yīng)用作輸入。361．3產(chǎn)品／過(guò)程指標(biāo)361.5ProductReliabilityStudies.Thistypeofdataconsidersfrequencyofrepairofreplacementofcomponentswithindesignatedperiodsoftimeandtheresultsoflongtermreliability/durabilitytests.1.6CustomerInputsTheendusersoftheproductcanprovideviableinformationrelatingtotheirneedandexpectations.Thisinputshouldbeusedbythecustomerand/orsuppliertodevelopagreeduponmeasuresofcustomersatisfaction.1.7DesignGoalsDesigngoalsareatranslationofthe“VoiceoftheCustomer”intotentativeandmeasurabledesignobjectivesAPQP371.5ProductReliabilityStudie1．5產(chǎn)品可靠性研究這一類(lèi)型的數(shù)據(jù)考慮了在一規(guī)定時(shí)間內(nèi)零件修理和更換的頻率，以及長(zhǎng)期可靠性／耐久性試驗(yàn)的結(jié)果。1．6顧客輸入產(chǎn)品的后續(xù)顧客可提供與他們的需要和期望有關(guān)的有價(jià)值信息，此外，后續(xù)產(chǎn)品顧客可能已進(jìn)行部分或全部前面已提到的評(píng)審和研究。顧客和/或供方應(yīng)使用這些輸入以開(kāi)發(fā)統(tǒng)一的衡量顧客滿(mǎn)意的方法。1．7設(shè)計(jì)目標(biāo)設(shè)計(jì)目標(biāo)就是將顧客的呼聲轉(zhuǎn)化為初步并具體的設(shè)計(jì)任務(wù)。設(shè)計(jì)目標(biāo)的正確選擇確保顧客的呼聲不會(huì)消失在隨后的設(shè)計(jì)活動(dòng)中。381．5產(chǎn)品可靠性研究381.8ReliabilityandQualityGoalsReliabilitygoalsareestablishedbasedoncustomerwantsandexpectations,programobjectives,andreliabilitybenchmarks.Someexamples:nonsafetyrelateddefectsservicefriendlinessQualitygoalsaretargetsbasedoncontinualimprovement.Someexamples: ppmvalues defectlevelsreductionofscrap1.9PreliminaryBillofMaterialTheteamshouldestablishapreliminarybillofmaterialbasedonproduct/processassumptionsandincludeanearlysubcontractorlist.APQPAPQP391.8ReliabilityandQualityGo1．8可靠性和質(zhì)量目標(biāo)可靠性目標(biāo)是在顧客需要和期望、項(xiàng)目目標(biāo)及可靠性基準(zhǔn)的基礎(chǔ)上制定的。顧客需要和期望可以是無(wú)安全問(wèn)題和可維修性。有些可靠性基準(zhǔn)可以是競(jìng)爭(zhēng)者產(chǎn)品的可靠性、顧客的報(bào)告或在一設(shè)定時(shí)間內(nèi)修理的頻率?？偟目煽啃阅繕?biāo)可用概率和置信度表示。質(zhì)量目標(biāo)是基于持續(xù)改進(jìn)的目標(biāo)，諸如（PPM）零件／百萬(wàn)缺陷水平或廢品降低率。l．9初始材料清單小組在產(chǎn)品／過(guò)程設(shè)想的基礎(chǔ)上應(yīng)制定一份初始材料清單，并包括早期分承包方名單。為了識(shí)別初始特定產(chǎn)品／過(guò)程特性，有必要事先選定合適的設(shè)計(jì)和制造過(guò)程。401．8可靠性和質(zhì)量目標(biāo)401.10PreliminaryProcessFlowChartTheanticipatedmanufacturingprocessshouldbedescribedusingaprocessflowchartdevelopedfromthepreliminarybillofmaterialandproduct/processassumptions.1.11PreliminaryListingofSpecialProductandProcessCharacteristicsSpecialproductandprocesscharacteristicsareidentifiedbythecustomerinadditiontothoseselectedbythesupplierthroughknowledgeoftheproductandprocess.Theteamshouldassurethatapreliminarylistofspecialproductsandprocesscharacteristicsresultingfromtheanalysisoftheinputpertainingtocustomerneedsandexpectationsisdeveloped.Thislistingcanbedevelopedfromthefollowingitems:ProductassumptionsbasedontheanalysisofcustomerneedsandexpectationsIdentificationofreliabilitygoals/requirementsAPQP411.10PreliminaryProcessFlow1．8可靠性和質(zhì)量目標(biāo)可靠性目標(biāo)是在顧客需要和期望、項(xiàng)目目標(biāo)及可靠性基準(zhǔn)的基礎(chǔ)上制定的。顧客需要和期望可以是無(wú)安全問(wèn)題和可維修性。有些可靠性基準(zhǔn)可以是競(jìng)爭(zhēng)者產(chǎn)品的可靠性、顧客的報(bào)告或在一設(shè)定時(shí)間內(nèi)修理的頻率?？偟目煽啃阅繕?biāo)可用概率和置信度表示。質(zhì)量目標(biāo)是基于持續(xù)改進(jìn)的目標(biāo)，諸如（PPM）零件／百萬(wàn)缺陷水平或廢品降低率。l．9初始材料清單除了由供方根據(jù)產(chǎn)品和過(guò)程經(jīng)驗(yàn)中選擇外，特殊的產(chǎn)品和過(guò)程特性均由顧客確定。在這一階段，小組應(yīng)確保制定出通過(guò)對(duì)有關(guān)顧客需要和期望的輸入的分析而得出的特殊產(chǎn)品和過(guò)程特性的初始明細(xì)表。這一明細(xì)表的制定基于（但不限于）以下方面：基于顧客需要和期望分析的產(chǎn)品設(shè)想；可靠性目標(biāo)／要求的確定；從預(yù)期的制造過(guò)程中確定的特殊過(guò)程特性；類(lèi)似零件的失效模式及后果分析（FMFA）。421．8可靠性和質(zhì)量目標(biāo)42IdentificationofspecialprocesscharacteristicsfromtheanticipatedmanufacturingprocessSimilarpartFMEAsNote:Specialcharacteristiccanaffectthesafefunctioningofthevehicleandcompliancewithgovernmentregulationssuchasflammability,occupantprotection,steeringcontrol,braking,emissions,noise,EMCetc.Duringtheproductdesignanddevelopmentphase,thelistshouldberefined,reviewed,andconsensusreached.Theoutputisrequiredtobedocumentedintheprototypecontrolplan.Duringprocessdesignanddevelopment,thelistshouldbeconvertedintoamatrixwhichdisplaystherelationshipbetweentheprocessparametersandthemanufacturingstationsandthisdocumentedintheproductioncontrolplan.1.12ProductAssurancePlanTheProductAssurancePlantranslatesdesigngoalsintodesignrequirements.TheamountofeffortdevotedtotheProductAssuranceAPQP43IdentificationofspecialprocPlanbytheteamdependsoncustomerneeds,expectations,andrequirements.TheProductAssurancePlancanbedevelopedinanyformatandshouldinclude,butisnotlimited,tothefollowingactions:

OutliningofprogramrequirementsIdentificationofreliability,durability,apportionment/allocationgoalsand/orrequirementsAssessmentofnewtechnology,materials,application,environment,packaging,service,andmanufacturingrequirementsoranyotherfactorthatmayplacetheprogramatriskDevelopmentofFailureModeAnalysisDevelopmentofpreliminaryengineeringstandardsrequirementsTheProductAss.PlanisanimportantpartoftheProductQualityPlan.1.13ManagementSupportAPQP44Planbytheteamdependsoncul·12產(chǎn)品保證計(jì)劃產(chǎn)品保證計(jì)劃將設(shè)計(jì)目標(biāo)轉(zhuǎn)化為設(shè)計(jì)要求。產(chǎn)品質(zhì)量策劃小組在產(chǎn)品保證計(jì)劃上所作的努力的程度取決于顧客的需要、期望和要求。本手冊(cè)對(duì)制定產(chǎn)品保證計(jì)劃的方法不作規(guī)定，產(chǎn)品保證計(jì)劃可采用任何清晰易懂的格式，它可包括（但不限于）以下措施：概述項(xiàng)目要求；可靠性、耐久性和分配目標(biāo)和／或要求的確定；新技術(shù)、復(fù)雜性、材料、應(yīng)用、環(huán)境、包裝、服務(wù)和制造要求或其它任何會(huì)給項(xiàng)目帶來(lái)風(fēng)險(xiǎn)的因素的評(píng)定；進(jìn)行失效模式分析（FMA）（參見(jiàn)附錄H）；制定初始工程標(biāo)準(zhǔn)要求。產(chǎn)品保證計(jì)劃是產(chǎn)品質(zhì)量計(jì)劃的重要組成部分。l·13管理者支持產(chǎn)品質(zhì)量策劃小組成功的關(guān)鍵之一是高層管理者對(duì)此工作的興趣、承諾和支持，小組在每一產(chǎn)品質(zhì)量策劃階段結(jié)束時(shí)應(yīng)將新情況報(bào)告給管理者以保持其興趣，并進(jìn)一步促進(jìn)他們的承諾和支持。在小組的要求下，可以更頻繁地報(bào)告新情況和／或要求幫助，這種新情況報(bào)告是正式的，留有提問(wèn)和解答的機(jī)會(huì)。45l·12產(chǎn)品保證計(jì)劃45Section2.0ProductDesignandDevelopment階段2.0產(chǎn)品設(shè)計(jì)及開(kāi)發(fā)Taskofthissection:此階段的任務(wù)AcomprehensiveandcriticalreviewofengineeringrequirementandotherrelatedtechnicalinformationPreliminaryfeasibilityanalysistoassessthepotentialproblems,anddevelopmentoftherespectivecontrolplanforprototypeVerifythattheproductorservicemeetstheobjectivesofthecustomer(designverification)APQP46Section2.0ProductDesignaInputDesigngoalsReliabilityandqualitygoalsPreliminarybillofmaterialPreliminaryprocessflowchartPreliminarylistingofspecialproductandprocesscharacteristicsProductassuranceplanOutputDesignFMEADesignverificationDesignreviewsPrototypebuild-controlplanEngineeringdrawingsEngineeringspecificationsMaterialspecificationsNewequipment,toolingandfacilitiesrequirementsSpecialproductandprocesscharacteristicsGages/testequipmentrequirementsTeamfeasibilitycommitmentandmanagementsupportProductDesignandDevelopmentSection2.0APQP47InputOutputProductDesignand

階段2.0產(chǎn)品設(shè)計(jì)及開(kāi)發(fā)由設(shè)計(jì)負(fù)責(zé)部門(mén)的輸出：

設(shè)計(jì)失效模式及后果分析（DFMEA）可制造性和裝配設(shè)計(jì)設(shè)計(jì)驗(yàn)證設(shè)計(jì)評(píng)審樣件制造工程圖樣（包括數(shù)學(xué)數(shù)據(jù)工程規(guī)范材料規(guī)范圖樣和規(guī)范的更改由產(chǎn)品質(zhì)量先期策劃小組的輸出：新設(shè)備

工裝和設(shè)施要求特殊產(chǎn)品和過(guò)程特性樣件制造-控制計(jì)劃量具／試驗(yàn)設(shè)備要求小組可行性承諾和管理者支持

48階段2.0產(chǎn)品設(shè)計(jì)及開(kāi)發(fā)由設(shè)計(jì)負(fù)責(zé)部門(mén)的輸出：由49492.1DesignFailureModeandEffectsAnalysisThedesignFMEAisadisciplinedanalyticaltechniquethatassessestheprobabilityoffailureaswellastheeffectofsuchfailure.TheDesignFMEAChecklistinappendixA-1shouldalsobereviewedtoassurethattheappropriatedesigncharacteristicshavebeenconsidered.2.2DesignforManufacturabilityandAssemblyDesignforManufacturabilityandAssemblyisaSimultaneousEngineeringprocessdesignedtooptimizetherelationshipbetweendesignfunction,manufacturability,andeaseofassembly.Ataminimum,theitemslistedhereshouldbeconsideredbytheProductQualityPlanningTeam:Design,concept,function,andsensitivitytomanufacturingvariationManufacturingand/orassembleprocessAPQP502.1DesignFailureModeandEf2．1設(shè)計(jì)失效模式和后果分析DFMEA是一種評(píng)定失效可能性及其失效影響的分析技術(shù)，DFMEA的一種形式為系統(tǒng)失效模式及后果分析（SFMEA），DFMEA是一種動(dòng)態(tài)文件，隨顧客需要和期望不斷更新，DFMEA的制定為小組提供了評(píng)審以前選擇的產(chǎn)品和過(guò)程特性和作出必要補(bǔ)充、改變和刪減的機(jī)會(huì)?？巳R斯勒、福特和通用汽車(chē)公司的潛在失效模式及后果分析參考手冊(cè)應(yīng)作為一種可接受的DFMEA的方法，還應(yīng)評(píng)審附錄A一1中的設(shè)計(jì)FMEA清單，以保證已考慮合適的設(shè)計(jì)特性。2．2可制造性和裝配設(shè)計(jì)可制造性和裝配設(shè)計(jì)是一種同步技術(shù)過(guò)程，用來(lái)優(yōu)化設(shè)計(jì)功能、可制造性和易于裝配之間的關(guān)系。第一章中所確定的顧客需要和期望范圍將決定供方產(chǎn)品質(zhì)量策劃小組進(jìn)行此活動(dòng)的程度。本手冊(cè)不包括或涉及制定可制造性和裝配設(shè)計(jì)計(jì)劃的正式方法。產(chǎn)品質(zhì)量策劃小組至少要考慮以下所列的項(xiàng)目：設(shè)計(jì)、概念、功能和對(duì)制造變差的敏感性；制造和／或裝配過(guò)程；尺寸公差；性能要求；部件數(shù)；過(guò)程調(diào)整；材料搬運(yùn)。產(chǎn)品質(zhì)量策劃小組的知識(shí)、經(jīng)驗(yàn)、產(chǎn)品／過(guò)程、政府法規(guī)和服務(wù)要求有可能需要考慮其它因素。512．1設(shè)計(jì)失效模式和后果分析51DimensionaltolerancesPerformancerequirementsNumberofcomponentsProcessadjustmentsMaterialHandling2.3DesignVerificationDesignverificationverifiesthattheproductdesignmeetsthecustomerrequirementsderivedfromtheactivitiesdescribedinsectionDesignReviewsDesignreviewsareregularlyscheduledmeetingledbythesupplier’sdesignengineeringactivityandmustincludeotheraffectedareas.Designreviewsareaseriesofverificationactivitiesthataremorethananengineeringinspection.APQPAPQP52DimensionaltolerancesAPQPAPQPAtaminimumDesignReviewsshouldincludeevaluationof:Design/functionalrequirementsFormalreliabilityandconfidencegoalsComputersimulationandbenchtestresultsDesignFMEAsReviewoftheDesignForManufacturabilityandAssemblyeffortApplicationofDesignofExperiments(DOE)andassemblybuildvariationresultsTestfailureDesignVerificationprogressAPQPAPQP53APQPAPQP532．3設(shè)計(jì)驗(yàn)證設(shè)計(jì)驗(yàn)證檢驗(yàn)產(chǎn)品設(shè)計(jì)是否滿(mǎn)足第一章所述活動(dòng)的顧客要求。2．4設(shè)計(jì)評(píng)審設(shè)計(jì)評(píng)審是以供方設(shè)計(jì)技術(shù)活動(dòng)為主并且應(yīng)包括其它被影響領(lǐng)域的定期安排的會(huì)議。設(shè)計(jì)評(píng)審為防止問(wèn)題和誤解的有效方法，而且還是監(jiān)測(cè)進(jìn)展雙向管理者報(bào)告的途徑。設(shè)計(jì)評(píng)審不只是技術(shù)檢驗(yàn)，而是一系列的驗(yàn)證活動(dòng)。至少設(shè)計(jì)評(píng)審應(yīng)包括以下方面的評(píng)價(jià)：設(shè)計(jì)／功能要求的考慮；正式的可靠性和置信度目標(biāo)；部件／子系統(tǒng)／系統(tǒng)工作循環(huán)；計(jì)算機(jī)模擬和臺(tái)架試驗(yàn)結(jié)果；設(shè)計(jì)失效模式及后果分析（DFMEA）；可制造性和裝配設(shè)計(jì)的評(píng)審；試驗(yàn)設(shè)計(jì)（DOE）和裝配產(chǎn)生的變差結(jié)果（參見(jiàn)附錄B）；破壞性試驗(yàn)；設(shè)計(jì)驗(yàn)證進(jìn)展；

542．3設(shè)計(jì)驗(yàn)證54設(shè)計(jì)評(píng)審的重要功能是跟蹤設(shè)計(jì)驗(yàn)證進(jìn)展。供方應(yīng)通過(guò)使用計(jì)劃和報(bào)告格式，即由克萊斯勒和福特汽車(chē)公司制定的設(shè)計(jì)驗(yàn)證計(jì)劃和報(bào)告（DVP＆R）來(lái)跟蹤設(shè)計(jì)驗(yàn)證進(jìn)展。計(jì)劃和報(bào)告是保證以下方面的正式方法：設(shè)計(jì)驗(yàn)證；通過(guò)采用綜合的試驗(yàn)計(jì)劃和報(bào)告對(duì)部件和總成的產(chǎn)品和過(guò)程確認(rèn)。產(chǎn)品質(zhì)量策劃小組不只限于所列項(xiàng)目，適當(dāng)時(shí)小組應(yīng)考慮并使用附錄B中所列的分析技術(shù)。55設(shè)計(jì)評(píng)審的重要功能是跟蹤設(shè)計(jì)驗(yàn)證進(jìn)展。供方應(yīng)通過(guò)使用計(jì)劃和報(bào)2.5PrototypeBuild-ControlPlanPrototypecontrolplansareadescriptionofthedimensionalmeasurementsandmaterialandfunctionalteststhatwilloccurduringprototypebuild.Allprototypesshouldshouldbereviewedwithrespecttothefollowingaspects:Assurethattheproductorservicemeetsspecificationandreportdataasrequired.Ensurethatparticularattentionhasbeengiventospecialproductsandprocesscharacteristics.Usedataandexperiencetoestablishpreliminaryprocessparametersandpackagingrequirements.Communicateanyconcerns,deviationsand/orcostimpacttothecustomer.APQP562.5PrototypeBuild-Control2．5樣件制造——控制計(jì)劃樣件控制計(jì)劃是對(duì)樣件制造過(guò)程中的尺寸測(cè)量和材料與功能試驗(yàn)的描述，產(chǎn)品質(zhì)量策劃小組要確保制定樣件控制計(jì)劃?？刂朴?jì)劃方法論見(jiàn)第六章所述。附錄A－8和第六章中的控制計(jì)劃?rùn)z查清單可幫助制定樣件控制計(jì)劃。樣件的制造為小組和顧客提供了一個(gè)極好的機(jī)會(huì)來(lái)評(píng)價(jià)產(chǎn)品或服務(wù)滿(mǎn)足顧客愿望的程度。產(chǎn)品質(zhì)量策劃小組負(fù)責(zé)的所有樣件都應(yīng)被評(píng)審以便：保證產(chǎn)品或服務(wù)符合所要求的規(guī)范和報(bào)告數(shù)據(jù)；保證已對(duì)特殊產(chǎn)品和過(guò)程特性給予了特別的注意；使用數(shù)據(jù)和經(jīng)驗(yàn)以制定初始過(guò)程參數(shù)和包裝要求；將關(guān)注問(wèn)題、變差和／或費(fèi)用影響傳達(dá)給顧客。572．5樣件制造——控制計(jì)劃572.6EngineeringDrawingsCustomerdesignsdonotprecludetheplanningteam’sresponsibilitytoreviewengineeringdrawings.Theteamshouldreviewengineeringdrawingsinordertodeterminewhichcharacteristicsaffectfit,function,durabilityand/orgovernmentalregulatorysafetyrequirements.Drawingshouldbereviewedtodetermineifthereissufficientinformationforadimensionallayoutoftheindividualpart.Controlordatumsurfaces/locatorsshouldbeclearlyidentified.Theteamshouldassurethatmathdataiscompatiblewiththecustomerssystem.2.7EngineeringSpecificationThesuppliershoulddeterminewhichcharacteristicsaffectorcontroltheresultsthatfulfilmeetingfunctional,durability,andappearancerequirements.Thesizeandfrequencyofsamples,unlessspecified,aretobedeterminedbythesupplierhimself.APQP582.6EngineeringDrawingsAPQP582．6工程圖樣（包括數(shù)學(xué)數(shù)據(jù)）顧客設(shè)計(jì)不排除策劃小組以如下方式評(píng)審技術(shù)圖樣的職責(zé)。工程圖樣可包括應(yīng)在控制計(jì)劃上出現(xiàn)的特殊（政府法規(guī)和安全性）特性。如沒(méi)有顧客工程圖樣，應(yīng)由策劃小組評(píng)審控制圖樣以決定哪些特性影響配合、功能、耐久性和／或政府法規(guī)中的安全要求。應(yīng)對(duì)工程圖樣進(jìn)行評(píng)審來(lái)確定是否具有足夠的數(shù)據(jù)以對(duì)每個(gè)零件進(jìn)行全尺寸檢驗(yàn)。應(yīng)能清楚地標(biāo)識(shí)控制或基準(zhǔn)平面／定位面，以便能為現(xiàn)行的控制過(guò)程設(shè)計(jì)適當(dāng)?shù)墓δ芰烤吆脱b備，應(yīng)評(píng)價(jià)尺寸以保證可行性和工業(yè)制造和測(cè)量標(biāo)準(zhǔn)相一致。適當(dāng)時(shí)，小組應(yīng)保證數(shù)學(xué)數(shù)據(jù)和顧客的系統(tǒng)兼容以進(jìn)行有效的雙向交流。2．7工程規(guī)范對(duì)控制規(guī)范詳細(xì)的評(píng)審和了解將有助于產(chǎn)品質(zhì)量策劃小組識(shí)別有關(guān)部件或總成的功能、耐久性和外觀的要求。樣本容量、頻率和這些參數(shù)的接受標(biāo)準(zhǔn)一般在技術(shù)規(guī)范的生產(chǎn)過(guò)程中試驗(yàn)一章中予以確定，否則樣本容量和頻率由供方?jīng)Q定并列入控制計(jì)劃中，在這兩種情況下，供方應(yīng)確定哪些特性影響或控制滿(mǎn)足功能、耐久性及外觀要求。592．6工程圖樣（包括數(shù)學(xué)數(shù)據(jù)）592.8MaterialSpecificationsInadditiontodrawingsandperformancespecifications,materialspecificationsshouldbereviewedforSpecialCharacteristicsrelatingtophysicalproperties,performance,environmental,handling,andstoragerequirements.2.9DrawingandSpecificationChangeTheteammustensurethatdrawingandspecificationchangesarepromptlycommunicatedandproperlydocumentedtoallaffectedareas.2.10Newequipment,ToolingandFacilitiesRequirementsTheDesignFMEA,ProductAssurancePlanand/orDesignReviewsmayidentifynewequipmentandfacilitiesrequirements.TheteamshouldaddresstheserequirementsbyaddingtheitemstotheTimingChartaswellasinsurethatnewequipmentandtoolingiscapableanddeliveredontime.Facilitiesprogressshouldbemonitoredonanongoingbasis.RefertotheNewEquipment,ToolingandTestEquipmentChecklistinAppendixA-3.APQP602.8MaterialSpecificationsAPQ2．8材料規(guī)范除了圖樣和性能規(guī)范外，對(duì)于涉及到物理特性、性能、環(huán)境、搬運(yùn)和貯存要求的特殊特性應(yīng)評(píng)審材料規(guī)范，這些特性也應(yīng)包括在控制計(jì)劃中。2．9圖樣和規(guī)范的更改當(dāng)需要更改圖樣和規(guī)范時(shí)，小組應(yīng)保證這些更改能立即通知到所有受影響的領(lǐng)域并用適當(dāng)?shù)臅?shū)面形式通知這些部門(mén)。2·10新設(shè)備、工裝和設(shè)施要來(lái)DFMEA，產(chǎn)品保證計(jì)劃和／或設(shè)計(jì)評(píng)審可能提出新設(shè)備和設(shè)施的要求。產(chǎn)品質(zhì)量策劃小組應(yīng)在進(jìn)度圖表上增加這些以強(qiáng)調(diào)此要求項(xiàng)目。小組應(yīng)保證新的裝備和工裝可使用并能及時(shí)供貨。要監(jiān)測(cè)設(shè)施進(jìn)度情況，以確保能在計(jì)劃的試生產(chǎn)前完工。新設(shè)備、工裝和試驗(yàn)設(shè)備清單參見(jiàn)附錄A－3。612．8材料規(guī)范612.11SpecialProductandProcessCharacteristicsThisbuildsonthelistingofpreliminaryspecialproductandprocesscharacteristicsdescribedinsection1.0.ForthedocumentationandupdatingofspecialcharacteristicstheformsControlPlanSpecialCharacteristicsandDataPointCo-ordinatescanbeused.Theseformscanbeusedaswellasanyotherformthataccomplishedthesamedocumentationrequirement.2.12Gages/TestingEquipmentRequirementsGages/testingequipmentrequirementsmayalsobeidentifiedatthistimeandshouldbeaddedtotheTimingChart.Progressshouldthenbemonitored.APQP622.11SpecialProductandProce2·11特殊產(chǎn)品和過(guò)程特性在第一章所述的質(zhì)量策劃階段，小組應(yīng)通過(guò)了解顧客的愿望的基礎(chǔ)上識(shí)別初始特殊產(chǎn)品和過(guò)程特性進(jìn)行了標(biāo)識(shí)。產(chǎn)品質(zhì)量策劃小組應(yīng)根據(jù)特性明細(xì)通過(guò)評(píng)價(jià)技術(shù)信息