APQP-PPAP(3)

APQPPPAPAPQPAPerspectiveon8-DandPFMEAandControlPlanDuringAPQPandAfterwardsWhatisAPQP?•APQPisadefinedprocessforaproductdevelopmentsystemforFord,Daimler-Chrysler,GMandtheirsuppliers.•APQPisanattempttoprovideacommonpathandsynchronizationofproductdevelopmentactivities.•APQPisanattempttoensurecommunicationbothwithinacompanyandbetweenacompanyanditscustomerBenefitsofAPQP•Ensuresearlyplanningtakesplace.•Directsresourcestothecustomer.•Identifiesrequiredchangesearlyintheprocess.•Providesqualityproductontimeandatlowestcost.•Enablescross-functionalinputsandoutputs.•AddressespotentialproblemsearlyCustomerandSupplierInvolvement•Customermayinitiateplanningprocess.•Supplierhastheobligationtoestablishcross-functionalteamtomanageprocess.•Suppliershouldexpectthesameperformancefromtheirsubcontractors.DetermineCustomerRequirements•Print•PurchaseRequestorRequestforQuotation.•StatementofWork(SOW)•Customervisitsanddiscussions.•Productchecklists.Training•Customerneedsandexpectations.•Workingasateam.•RequirementsofAPQP•FMEA•APQP•PPAPAPQPFivePhaseProcessPlanningProductDesignandDevelopmentProcessDesignandDevelopmentProductandProcessValidationProductionFeedbackAssessmentandCorrectiveActionPilotLaunchConceptInitiation/ApprovalProgramApprovalPrototypePlanningLinksBetweentheToolsContractReviewProgramPlanDFMEATeamFeasibilityCommitmentProduceProcessFlowDiagramsConductProcessFMEADevelopControlPlanWorkInstructionDevelopmentProductandProcessValidationEnsureContinuousImprovementPhaseIPhaseIIPhaseIIPhaseIIIPhaseIIIPhaseIIIPhaseIIIPhaseIVPhaseVDetermineCustomerExpectationsandPlanforQualityIdentifyKeyCharacteristicsDetermineRiskandFeasibilityAssociateCharacteristicswithProcessStepsandIdentifyKeyCharacteristicsExposeSourcesofVariationandFinalizeKeyCharacteristicsDetermineMethodstoImproveProcessandControlVariationImplementControlPlanandStandardizetheProcessEnsureCustomerExpectationsareMetExerciseManagementOversightTheTargetandTheGoalLinkBetweentheDocumentsProcessFlowOperationNumberProduct/ProcessCharacteristicIncomingSourcesofVariationPFMEAControlPlanVariationClassWorkInstructionsProcessFlowDiagrams•Updatedafterproductiontrialrun.•Needtoindicatespecialcharacteristicsgeneratedateachstep.•CompletedAlongwithControlPlan(APQPProcess).•Generallycontainssameinformationasprocesstraveler.ProcessFlowDiagramExampleAPQPLinkstoPFMEAWorkInstructionsPFMEAChangeindetectionChangeinoccurenceChangeinseverityControlPlanDesignChangeOtherActionororororProcessFMEA•Mustfollowflowoftheprocessflowdiagram.•MustincludeALLprocessspecialcharacteristics(asaminimum).HowaPFMEAWorks•WheredoesthedataforthePFMEAcomefrom?•WhattypesofpeopleareapartofthePFMEAteam?•Whattypesofactivitiesshouldwespendalotoftimeon?PFMEAs/ControlPlansand8-DsDuringAPQP•PFMEAsshouldbedrivenbyrealdata,including8-Ds(internalandexternal),warrantyandreturnedpartanalysis•PFMEAsshouldbecompletedbyprocessexpertsandshouldbeadriverofthecontrolplansandworkinstructions•Workinstructions(Postcontrollog,processparameterlogs,preventivemaintenance,etc.)implementthecontrolplanintheprocess•WhenthereisaqualityproblemthereisanopportunitytoimprovethecontrolplanandtheworkinstructionsAPQPLinkstoControlPlanFirst/LastPieceMistakeProofingControlPlanP/MChecklistQualityChecklistControlPlans•Includesproductandprocessspecialcharacteristics.•IncludesSPCrequirements.•FollowsflowofprocessflowchartandPFMEA.•Mayrequirecustomerapproval.TypesofControlPlans•Prototypebuildcontrolplan(s)•Pre-launchcontrolplan•ProductioncontrolplanPrototypeBuildControlPlan•Adescriptionofthedimensionalmeasurements.•Materialtests–Functionalteststhatwilloccurduringprototypebuild.Pre-launchControlPlan•Descriptionofdimensionalmeasurements,materials,andfunctionaltests.•Addsadditionalproductandprocesscontrols.•Purposeistocontainpotentialnonconformitiesutilizing:–Morefrequentinspectionsand/ortests.–Morein-processandfinslinspectionand/orcheckpoints.–Statisticalevaluations.–Increasedaudits.ProductionControlPlan•Up-datepre-launchcontrolplan.•Add:–Samplingplans–Controlmethod–SPC,inspection,attributedataandmistakeproofing.–Reactionplan•Nonconformancesclearlyidentified,quarantinedanddispositionmade.•Requirescustomerapprovalunlessotherwisespecified.ControlPlanUse•Initial:Todocumentandcommunicateinitialprocesscontrol.•Next:Guidanceincontrollingprocessesandtoensureproductquality.•LastAlivingdocumentreflectingcurrentmethodsofcontrolandmeasurementsystemsused.MultipleMolds,Tools,DiesandPatterns•Completedimensionallayerrequiredfromonepartfromeachcavityasaminimum.•Suppliermustidentifyspecificcavityforeachpartsubmitted.PartSubmissionStatus•Nevershipproductionpartsbeforereceivingcustomerapproval.•Suppliermustensurethatfutureproductioncontinuestomeetcustomerrequirements.•Noproductionpartscanbeshippeduntilapprovalisreceived.AutomotiveDocumentationDevelopmentDevelopProcessFlowListingCheckforCustomerRequirementsEnterEvery“Major”ProcessfromFlowListingintoFMEAFormGivecarefulconsiderationtowhatyouconsidera“Major”processDevelopFMEAElementforEveryProcessUsetheappropriateRPNnumbersandconsiderationsofo