APQP介绍

APQPIntroduction講師：顏光華蔡建河2003-08-13~15©TÜVRheinlandTaiwanLtd.@2003TÜVRheinlandTaiwanLtd.Allrightsreserved.先期產品品質規劃與管制計劃(APQP)APQPA(Advanced)先期的P(Product)產品Q(Quality)品質P(Planning)規劃CPC(Control)管制P(Plan)規劃APQP的淵源APQP的前身是福特汽車的AQP(AdvancedQualityPlanning)編輯APQP&CP(ControlPlan管制計劃)的時候，為了調合三大汽車廠及卡車廠本身的APQP需求，以福特的Mr.MikeMazur為主的團隊，參考各廠之特色，撰寫了APQPandControlPlan(先期產品品質規劃與管制計劃)先期產品品質規劃和管制計劃效益降低顧客與供應商在產品品質規劃方面之複雜性做為供應商與分包商在產品品質規劃需求上容易溝通之方法滿足顧客之資源指引推動早期明定變更之要求避免晚期變更準時提供低成本之合格產品WhatistheAIAG’sAPQPReferenceManual?APQP手冊的目的•ItIsGeneralInformation泛用資訊•ItDoesNotAddressSpecificManufacturerInformationorRequirements非強制要求•ItisNOTAuditable非稽核用•ItDoesNOTAddressAnySpecificIndustryorManufacturer不限產業Basics•DoNOTtrytowriteaprocedurejustliketheAPQPreferencemanual.不要100%copy該手冊•LookatwhatYOUaredoingandrelateittotheAPQPprocessdescribedbythereferencemanual.查核貴公司活動與手冊規定的關聯性•Bereadytoexplain‘Equivalencies’-WhereandHowandWhatyoursystemdoeswhichfulfillsAPQPtimelineelements.解釋貴公司做法與手冊規定的一致性TheTarget&Goal目標Continuousimprovement持續改善PrototypePre-launchMassproductionLSL規格下限USL規格上限產品品質規劃時序圖原型試作量試概念啟始認可規劃計畫認可產品研發製程發展製程研發/驗證產品研發/驗證計畫/定義研發守案生產生產階段/迴饋矯正產品/製程驗收產品/製程驗收生產計畫迴饋與矯正量產QS9000APQPInvolves:QS條文與APQP的關聯性•4.1ManagementResponsibility•4.2QualitySystem•4.3ContractReview•4.4DesignControl•4.5DocumentandDataControl•4.6Purchasing•4.9ProcessControl•4.10InspectionQS9000APQPInvolves:•4.11Inspection,MeasuringandTestEquipment•4.12InspectionandTestStatus•4.13ControlofNonconformingProduct•4.14CorrectiveAction•4.15Handling,Storage,PackagingandDelivery•4.16QualityRecords•4.18Training•4.19Servicing•4.20StatisticalTechniquesEachAPQPisUnique每一APQP都是獨一無二的•Becauseofproductandprogramdifferences產品及計劃不同•Timingandsequencearedependentuponcustomerneedsandexpectations依客戶需求及期望展開時間及順序•Productcomplexity產品複雜性Stamping沖壓Sub-assembly組立•New新產品•Modification設變ProgressiveFundamentals成功的基礎•KEY**OrganizeaCross-FunctionalTEAM組成跨功能小組•Definethescope定義範圍•Team-to-teamcommunications組對組溝通•Training訓練•Simultaneous(concurrent)engineering同步工程•ControlPlanPhases控制計劃階段Prototype,Pre-Launch,Production•Concernresolution解決問題•Includesanalyticaltechniques分析的技術TeamOrganization•Cross-functional跨功能小組•Engineering(Typicallytheleader),QualityAssurance,Purchasing,ManufacturingEngineering,MaterialControl,Sales/MarketingEtc.•Participationappropriateforphasebeingconducted依階段有不同參加人員•Resources-Teamdefines‘Needs’小組定義需求•*Should*involvecustomerorsubcontractorparticipation(notalwaysfeasible)客戶或供應商的參與DefineScope•Selectteammembersandfunctions選擇組員及功能•Definerolesandresponsibilities定義權責•Identifyexternalcustomerneeds,expectationsandrequirements鑑別外部客戶需求•Identifyinternalcustomerneeds,expectationsandrequirements鑑別內部客戶需求•Completepreliminaryfeasibilitystudy完成初期可行性評估•Identifycosts,timingandconstraints鑑別成本,時間及限制•Identifydocumentationprocessandmethod鑑別文件及方法•Developprogramplan(ifprojectisago)發展開發計劃Team-to-TeamCommunication•ManageusingtheAPQPprocess使用APQP過程管理•Understandingof‘HowWeWorkAsATeam’了解如何以小組方式運作•ShouldhaveaFocusPerson&DistributedMinutes應有核心人員及分發紀錄•Customerteams,Internalteams,Subcontractorsteams•SubcontractorsshouldbeencouragedtoembraceAPQPandQS9000分包商應被鼓勵使用APQP,QS-9000Training•Customerneedsandexpectations客戶需求•WorkingasaTeam以小組方式運作•Developmentskills開發技巧•RequirementsofAPQP•FMEA•PPAP•SPCRecommendedStatisticalCourses建議的統計課程•BasicBusiness基本業務⃗AdvancedBusiness進階業務Office,Staff,&Management⃗SelectedStaff,&Management•StatisticalProcessControl⃗MSA⃗DesignofExperiment統計製程管制量測系統分析實驗計劃法ProductionFloor,ProductionStaff&Management,AllofQuality&Engineering*YourAPQPTeamshouldattendasmanyclassesastimewillallowProductionStaff&Management,AllofQuality&EngineeringSpecificProductionStaff,Quality&Engineering,QAmanager,productengineerCustomerandSupplierInvolvement客戶及廠商的參與•Customermayinitiatetheplanningprocess由客戶啟動計劃過程•Supplierhastheobligationtoestablishcross-functionalteamtomanageprocess廠商有義務建立跨功能小組來管理過程•Suppliershouldexpectthesameperformancefromtheirsubcontractors廠商應要求其供應商有相同表現Simultaneous(Concurrent)Engineering同步工程•Requirescross-functionalteamparticipation需要跨功能小組參與•Replacespriorsystemofsequentialphases取代過去順序式的做法•Expeditenewproductintroduction加速新產品導入•APQPteamensuresthatotherfunctionsandteamsplanandexecuteactivitiessupportcommongoals確保其他小組計劃並執行支援活動CustomerRequirements客戶要求•WaystoDetermineCustomerRequirements來源•Print圖面•PurchaseRequestorRequestforQuotation採購單•QFD-QualityFunctionDeployment品質機能展開•ServiceEngineers售服工程師•VerbalCommunications口頭溝通•DevelopmentEngineers開發工程師•ProductCheckList查檢表BaseDocumentation文件•CriticalCharacteristicsMatrix特性矩陣•ProcessFlowDiagram流程圖•DesignFMEA•ProcessFMEA•ControlPlanChickenorEgg先有雞先有蛋?•WhichisFirst?Second?Third?ControlPlan?ProcessFlowDiagram?DesignFMEA?ProcessFMEA?ProcessDocumentation(‘Work’Instructions)?•WhyDoesitMatter?為何重要TypicalAutomotiveTrilogyDevelopment開發三部曲APQPTimelineProcessFlowDiagram(IncludesALLProcesses)DesignFMEAProcessFMEA(OnALLProcesses)CriticalCharacteristics&FailureEffectsIssuesProcessControlPlan(CriticalProcessesfromFMEA)CriticalCharacteristics&CharacteristicControlIssuesSomeElementsmaybeIncludedOnTheLinks連接•E