FMEA潜在失效模式及后果分析A

SGMSupplierAPQPOverview-GMGlblAddPdtGMGlobalAdvancedProductQualityPlanningQyg通用全球产品质量先期策划通用全球产品质量先期策划BryanHuang03-10-20Page1APQP-BryanHuang全球采购供应商质量改进程序全球采购改进会议改进会议质量研讨会二级发货控制发货控制时间线一级发货控制供应商质量过程和测量(GP-5)绩效监控持续改进(GP8)按节拍生产(GP-9)零件生命期时间线早期生产遏制(GP-12)持续改进(GP-8)GM全球APQP生产件审批(PPAP)样件批准(GP-11)预生产会议GM全球APQP经验先期产品质量策划(APQP)选点决定Page2APQP-BryanHuangPrimary开始生产潜在供应商评审背景定义产品质量先期策划--APQP采用系统化方法确定和建立必要的步骤，明确相关方职责以确保满足顾客对产品的要确相关方职责，以确保满足顾客对产品的要求目的促进参与各方相互信任和支持并充分联系目的促进参与各方相互信任和支持，并充分联系以确保所要求的步骤按时完成。范围适所有新零件范围适用于所有新零件优点有效利用资源，使顾客满意促进对所需更改进行早期识别并实施，避免后期更改保证在满足所需能力和项目进度要求下交付合保证在满足所需能力和项目进度要求下交付合格产品Page3APQP-BryanHuang供应商高级管理层的支持是APQP成功实施的关键！APQP项目概览保密要求供应商的所有信息都是保密的GM工程部和采购部的所有信息都是保密的，包括项目时间进度表GM主要职责采购--Buyer选择潜在供应商供应商质量APQP项目经理主要职责供应商质量--APQP项目经理--与buyer和PE紧密合作--负责供应商的质量，能力和时间进度--确保更新管理层信息工程--产品的设计和发布供应商主要职责主动符合AIAGAPQP要求和GM全球APQP任务要求•开发每个零件/系统的详细计划--产品设计、防错•保持项目进度--设计完成、样件交付、PPAP早期识别项目问题和促进纠正整改保持与GM沟通项目状态和问题--可制造性评估书要求分供方满足APQP要求Page4APQP-BryanHuang要求分供方满足APQP要求APQPAPQP--5steps:APQP5steps:1.Plan&definetheprogram计划和确定项目2Productdesignanddevelopment产品设计和开发2.Productdesignanddevelopment产品设计和开发3.Processdesignanddevelopment过程设计和开发4Pdtdlidti产品和过程验证4.Productandprocessvalidation产品和过程验证5.Feedback,assessment&correctiveaction反馈，评估和纠正措施Page5APQP-BryanHuangAPQP项目概览概念提项目Lh/概念提出/批准项目批准样件试生产投产Pilot/Pre-LaunchPrototypeLaunch/ProductionProductDesignandDevelopment产品设计和开发Planning策划FeedbackAssessmentandCorrectiveAction反馈评估和纠正措施ProcessDesignandDevelopment过程设计和开发ProductandProcessValidation产品和过程确认Feedback,AssessmentandCorrectiveAction反馈，评估和纠正措施计划与定义项目定点前活动产品设计和开发验证过程设计和开发验证产品和过程确认反馈、评估和纠正措施Page6APQP-BryanHuang施Product&ProcessDevelopment-1.0Plan&DefinetheProgram计划和确定项目Output:designgoals;reliabilitygoals;qualitytargets;PreliminaryBOM;Preliminaryprocessflowchart;preliminarylistingofspecialcharacteristics;anygov,environmentalorsafetyregulations.输出：设计目标;可靠性目标;质量目标;初始原材料和分供方清单;初始过程流程图;初始特殊特性清单;政府安全环保法规等流程图;初始特殊特性清单;政府安全、环保法规等。Page7APQP-BryanHuangProduct&ProcessDevelopment-2.0ProductDesign&Development产品设计和开发1BeginswithDFMEA始于DFMEA1.BeginswithDFMEA始于DFMEA2.Designoutputshallberesultofeffortstosimplify,optimize,innovateandreducewastewith:QFD,DFM/DFA,VE,DOE,GD&T,DFMEA,CostAnalysis,feedbackfromtesting,production,andthefield)设计输出g,p,)3.Designverification(toensuredesignoutputmeetplanneddesigninputasdefinedinphase1)设计验证4.Designreviews(formaldocumentreview)设计评审5.Prototypebuildcontrolplan样件控制计划6.Finalizationof工程文件–EngineeringdrawingsincludingCADdata–Engineeringspecifications–Materialspecifications7.Newequipment,tooling&facilities(includedinoveralltimingplan)新设备、工装和设施施8.Finalizationofspecialcharacteristics特殊特性9.Anynewinspection,measuringandtestequipmentdevice检测、测量设备小组可行性承诺Page8APQP-BryanHuang10.Teamfeasibilitystatement(compulsoryasperQS9000)小组可行性承诺Product&ProcessDevelopment-3.0ProcessDesignandDevelopment过程设计与开发1.Customerpackagingandlabelingstandards顾客包装和标签要求2.Reviewofthecurrentqualitymanagementsystemtoensureitssuitabilityfortheprospectiveproductandassociatedprocesses质量体系评估3.finalizationoftheprocessflowchart(detectanybottlenecks,suchas,materialflowproblemsandmanpower).过程流程图pp)4.Floorplanlayoutwithanemphasisonminimizingmaterialtravel布局图–acceptabilityofinspectionpoints,controlchartlocations,visualaidlocations,reworkareasandstorageareasg–emphasisplacedonutlizingfloorspaceforVAactivities.5.CompletionofPFMEA完成PFMEA–preventiveactionsdevelopedtocontrolpotentialproblemspreventiveactionsdevelopedtocontrolpotentialproblems6.Completionofpre-launchcontrolplan(additionalproduct/processcontrols)试生产控制计划Page9APQP-BryanHuangProduct&ProcessDevelopment-3.0ProcessDesignandDevelopment过程设计与开发7.MSAtoencompassalloftheinspectionmeasuringandtestequipmentdesignatedonthecontrolplan.测量系统分析–NotjustlimitedtoR&R–NotjustlimitedtoVariablesProcessmonitoringandoperatorinstructions(contents:?)–MSAnecessaryforgenericdevice?8.Processmonitoringandoperatorinstructions过程监控和操作指导9.Preventivemaintenance预防性维护–proceduredescribesplannedmaintenanceactivities–scheduledmaintenanceactivities–predictivemaintenancemethods(reviewofmanufacturersrecommendations;toolwear;fluidanalysis;vibrationanalysis)–availabilityofreplacementpartsforkeymanufacturingequipment.10.Preliminaryprocesscapabilityrequirements过程能力要求Page10APQP-BryanHuangProduct&ProcessDevelopment-4.0Product&ProcessValidation产品和过程验证1.Productiontrialrun--resultsusedfor:试运行2MSA2.MSA3.PreliminaryProcessCapabilityStudy初始过程能力研究4.PPAP5.Productionvalidationtesting(engineeringtests)验证试验6.Packingevaluation包装7.Finalizationofproductioncontrolplan(dynamic)控制计划7.Finalizationofproductioncontrolplan(dynamic)控制计划8.Qualityplanningsign-off质量策划认可Page11APQP-BryanHuangProduct&ProcessDevelopment-5.0Feedback,Assessment&CorrectiveAction反馈、评估和纠正措施反馈、评估和纠正措施•Reviewtheresults(feedback)ANDinstigatecorrectiveactions•Continuouslyassess&improve持续评估和改进–variation(SPCorotherstatisticaltechniques)–customersatisfaction(productaudits,warrantyanalysis,customercomplaints,(p,yy,p,benchmarkdetails,etc.)–deliveryandservice(100%ontimemet?)Page12APQP-BryanHuangProductApproval•FunctionalEvaluation•PrototypeS