APQP - AIAG Manual

ADVANCEDPRODUCTQUALITYPLANNING(APQP)ANDCONTROLPLANReferenceManualIssuedJune1994,SecondPrintingFebruary1995(newcoveronly)Copyright©1994,©1995ChryslerCorporation,FordMotorCompany,andGeneralMotorsCorporationFOREWORDThisReferenceManualandReportingFormatweredevelopedbytheAdvancedProductQualityPlanning(APQP)andtheControlPlanteamsthatweresanctionedbyChrysler,Ford,GeneralMotorsSupplierQualityRequirementsTaskForce.TheTaskForcecharteristostandardizethereferencemanuals,procedures,reportingformats,andtechnicalnomenclatureusedbyChrysler,Ford,andGeneralMotorsintheirrespectivesupplierqualitysystems.Accordingly,thismanualandformat,approvedandendorsedbyChrysler,FordandGeneralMotors,shouldbeusedbysuppliersimplementingAPQPtechniquesintotheirdesign/manufacturingprocesses.Inthepast,Chrysler,Ford,andGeneralMotorseachhadtheirownguidelinesandformatsforensuringsupplierAPQPcompliance.Differencesbetweentheseguidelinesandformatsresultedinadditionaldemandsonsupplierresources.Toimproveuponthissituation,Chrysler,FordandGeneralMotorsagreedtodevelopanddistributethisManual.TheworkgroupresponsibleforthisManualwasledbyMikeMazurofFordMotorCompany.ThismanualprovidesgeneralguidelinesforpreparingplansandchecklistsforensuringthatAdvancedProductQualityPlanningisinactualitycarriedoutatthesupplier.ItdoesnotgivespecificinstructionsonhowtoarriveateachAPQPorControlPlanentry,ataskbestlefttoeachcomponentreviewteam.Whiletheseguidelinesareintendedtocoverallsituationsnormallyoccurringeitherintheearlyplanning,designphase,orprocessanalysis,therewillbequestionsthatarise.Thesequestionsshouldbedirectedtoyourcustomer’sSupplierQualityactivity.Ifyouareuncertainastohowtocontacttheappropriateactivity,contactyourbuyerinyourcustomer’sPurchasingoffice.TheTaskForcegratefullyacknowledges:theleadershipandcommitmentofVicePresidentsThomasT.StallkampatChrysler,NormanF.EhlersatFord,andG.RichardWagoner,Jr.ofGeneralMotors;theassistanceoftheAIAGinthedevelopment,production,anddistributionofthismanual;andtheguidanceofTaskForcePrincipalsRussellJacobs(Chrysler),RadleySmith(Ford),andDanReid(GeneralMotors).ThisprocedureiscopyrightedbyChrysler,FordandGeneralMotors,allrightsreserved,1994.AdditionalcopiescanbeorderedfromAIAG810-358-3003.SuppliersoftheAutomotiveIndustryhavepermissiontocopyanyformsand/orchecklists.June1994iiiACKNOWLEDGEMENTThisdocument,whichincludesareferencemanualandreportingformat,representstheconsensusofthemembersoftheAdvancedProductQualityPlanningandControlPlanteamssanctionedbytheChrysler,Ford,GeneralMotorsSupplierQualityRequirementsTaskForce.Teammembers,whosenamesappearbelow,wishtoacknowledgethemanycontributionsmadebyindividualsfromwithintheirrespectiveorganizations,individualswithoutwhosesupportandassistancethisdocumentwouldnothavebeenpossible.AdvancedProductQualityPlanningTeamMembersChryslerFordGeneralMotorsRobertRoushMichaelA.MazurR.DanReidAndyKucharskiRoderickA.MunroDavidL.KraushSuppliersPaulAnglinITTAutomotiveBrendaDusekHarvardIndustriesCharlesR.DykstraInvernessCastingDonaldGeisFederalMogulCorporationAlWaltonUnitedTechnologiesControlPlanTeamMembersFrederickN.BazFordBrendaDusekHarvardIndustriesRebeccaFrenchGeneralMotorsGaryHoytChryslerMaryAnnRaymondRobertBoschCorporationAdditionalAssistanceBeaAndersonChrysleriiiTableofContentsIntroduction1ProductQualityPlanningResponsibilityMatrix2FundamentalsofProductQualityPlanning3ProductQualityPlanningTimingChart51.0PlanandDefineProgram61.1VoiceoftheCustomer71.1.1MarketResearch81.1.2HistoricalWarrantyandQualityInformation81.1.3TeamExperience81.2BusinessPlan/MarketingStrategy91.3Product/ProcessBenchmarkData91.4Product/ProcessAssumptions91.5ProductReliabilityStudies91.6CustomerInputs91.7DesignGoals101.8ReliabilityAndQualityGoals101.9PreliminaryBillofMaterial101.10PreliminaryProcessFlowChart101.11PreliminaryListingofSpecialProductandProcessCharacteristics101.12ProductAssurancePlan111.13ManagementSupport112.0ProductDesignandDevelopment122.1DesignFailureModeandEffectsAnalysis(DFMEA)142.2DesignforManufacturabilityandAssembly142.3DesignVerification152.4DesignReviews152.5PrototypeBuild–ControlPlan152.6EngineeringDrawings(IncludingMathData)162.7EngineeringSpecifications162.8MaterialSpecifications162.9DrawingandSpecificationChanges162.10NewEquipment,ToolingandFacilitiesRequirements172.11SpecialProductandProcessCharacteristics172.12Gages/TestingEquipmentRequirements172.13TeamFeasibilityCommitmentandManagementSupport173.0ProcessDesignandDevelopment183.1PackagingStandards203.2Product/ProcessQualitySystemReview203.3ProcessFlowChart203.4FloorPlanLayout20TABLEOFCONTENTSPageNo.PageNo.iv3.5CharacteristicsMatrix203.6ProcessFailureModeandEffectsAnalysis(PFMEA)213.7Pre-LaunchControlPlan213.8ProcessInstructions213.9MeasurementSystemsAnalysisPlan223.10PreliminaryProcessCapabilityStudyPlan223.11PackagingSpecifications223.12ManagementSupport224.0ProductandProcessValidation244.1ProductionTrialRun254.2MeasurementSystemsEvaluation264.3PreliminaryProcessCapabilityStudy264.4ProductionPartApproval264.5ProductionValidationTesting264.6PackagingEvaluation274.7Pr