ADVANCED PRODUCT

QUALITY PLANNING
As per 2nd Edition
Contents
ü What is APQP
ü Goals / Objective of APQP
ü Benefits of APQP
ü Elements of Good Planning
ü APQP Phases
ü Features of APQP
ü APQP Team requirement
ü Timing plan
ü Step by Step Approach for APQP
ü Control Plan Methodology
ü Common Mistakes
ü Conclusion
2
Assumptions

v We are all Learners - including the

faculty
v Learning is an interactive process
v We are open to new Ideas
v Every one present here is committed
to the success of this programme.
v “Show me” is a healthy attitude
v “ May be” is acknowledging thought
v Silence means non-involvement.

3
WHAT IS APQP ?

APQP is a structured method of defining and establishing the

steps necessary to assure that a product satisfies the customer.

Systematic, logical , step by step approach for new product

development .

APQP is an attempt to provide a common path and synchronization

of product development activities

Philosophy .
Spend A Little Extra Time Upstream, So That Life Downstream Is
Error Free.

4
GOALS/ OBJECTIVE OF APQP.

ü Effective Communication With Everyone Involved.

ü On Time Completion Of All Required Steps.

ü Minimal Or No Quality Problems.

ü Minimal Product Launch Quality Risks.

ü Reduce Variation

5
6
BENEFITS OF APQP.
ü Reduced No. Of Design / Process Changes.

ü Reduced Cost Of Development ( Other Wise It Has Occurred

Through Tool Modification, Rejections Due To Trial And Error)

ü Reduction In Lead Time. To avoid late changes

ü Increased Customer Satisfaction.

ü Robust Design Of The Process Makes The Ongoing Production

Problem Free

7
ELEMENTS OF GOOD PLANNING
ü Commitment.
ü Training .
ü Team Work.
ü Logical Methodology.
ü Sound Techniques.
ü Documentation.
ü Communication.
ü Feed Back

8
   PDCA CYCLE

   P L A N

AC T DO

CHECK

9
APQP PHASES .

ü Plan And Define The Program.

ü Product Design And Development.

ü Process Design And Development

ü Product And Process Validation.

ü Feed Back , Assessment & Corrective Action.

 
10
APQP PHASES .

11
Basics .
ü Do NOT try to write a procedure just like the APQP reference manual.
ü Look at what YOU are doing and relate it to the APQP process
described by the reference manual.
ü Be ready to explain ‘Equivalencies’ - Where and How and What your
system does which fulfills APQP timeline elements.

12
FEATURES OF APQP.
• APQP To Be Done By The Cross Functional Team Not By Individual.
• Simultaneous Engineering : Do All The Work Simultaneously In Order
To Achieve Common Goal .
• Customer And Supplier Involvement. Closely Work With The Customer
And Subcontractors.
• Quality Improvement Techniques To Be Used While Doing APQP.
• Good Communication System Both Internal And External To Be
Established.
• Effective Product Quality Planning Depends On A Company's Top
Management Commitment To The Effort Required In Achieving
Customer Satisfaction.

13
14
Team Organization
ü Cross-functional
ü Engineering (Typically the leader)
ü Quality Assurance
ü Purchasing
ü Manufacturing Engineering
ü Material Control
ü Sales/Marketing
ü Define roles of each Team Member
ü Participation is appropriate to the APQP Phase
ü Resources - Team defines ‘Needs’
ü *Should* involve customer or subcontractor participation (not always
feasible)

15
Team to Team Communication
ü Manage using the APQP process
ü Understanding of ‘How We Work As A Team’
ü Should have a Focus Person
ü Minute the meeting decisions & Distribute
ü Involve effectively your customers and suppliers.
ü Subcontractors should be encouraged to embrace APQP and TS 16949

Team work means not attending meeting. It is all

about involvement & Dependence on each other.

16
APQP Timing Plan
ü Should be developed by the Team
ü Identify individual tasks
ü Assign Responsibility & Target dates for each of tasks
ü Should be easy to track and update the status
ü Indicate the Milestones.

17
 APQP Timing Plan
APQP TIMING PLAN
DATE :
APQP NO: SAMPLE SUBMISSION DATE:
CUSTOMER : PILOT SUBMISSION DATE :

PART NAME :
No. of days Plan/ Month Month Month
SL.NO. ACTIVITIES RESPON. reqd actual 1W 2W 3W 4W 1W 2W 3W 4W 1W 2W 3W 4W
P
A
P
A
P
A
P
A
P
A
P
A
P
A
P
A
P
A
P
A

18
PHASE 1:- PLAN & DEFINE PROGRAM.
 Inputs
ü Voice Of The Customer
ü Market Research
ü Historical Warranty And Quality Information.
ü Team Experience.
ü Business Plan / Marketing Strategy.
ü Product / Process Benchmark Data.
ü Product / Process Assumptions.
ü Product Reliability Studies.
ü Customer Inputs.

19
Voice Of The Customer

ü Data & Information obtained from External and Internal Customers

ü Stated, Real and Perceived Needs
ü Functional Needs vs. Technical Features – QFD
ü Some of the methods to obtain VOC are
ü Market Research
ü Historical Warranty & Quality Information
ü Team Experience

20
Market Research

ü Customer interviews
ü Customer questionnaires and surveys
ü Marketing test and positioning reports
ü New product quality and reliability studies
ü Competitive product analysis
ü “Things Gone Right” – TGR reports

21
Historical Warranty & Quality Information.
ü Collect Past data on Warranty
ü Past In house rejection / rework data
ü Major Quality problems in existing products
ü Customer end rejection / rework data
ü Field Return Product analysis
ü Capability Indicators
ü Things Gone Wrong (TGW) Reports
ü Lessons Learned

22
Team Experience.
ü To identify past experiences on product development and ensure these
are deployed to new Products with appropriate corrective action.
ü Media commentary and analysis
ü Customer letters and suggestions
ü Things gone Right/Wrong reports
ü Dealer comments
ü Fleet operator comments
ü Field service reports

23
 

Team Experience-Continued.

ü Problems and issues reported from Internal customers

ü Internal evaluations using customers
ü Road trips
ü Management comments and/or direction
ü Government requirements and/or regulations
ü Contract review - issues

24
 Business Plan / Marketing Strategy.
ü Framework for quality plan
ü May place constraints on timing, cost, investment, positioning, R&D
resources
ü Strategy defines target customer, key sales points, key competitors
ü SWOT
Strengths
Weaknesses
Opportunities
Threats

25
  Product / Process Benchmark Data.
ü Obtain Benchmark Samples from Customer.
ü Review Competitors Product Samples
ü Collect Process related data through Various sources such as
Competitors, Customers, Internal Plants.
ü Provides inputs to establish performance targets
ü Must address key process(es)
ü Must be measurable
Methods for successful benchmarking:
ü Identify appropriate benchmark(s)
ü Find reason for gap between your status and benchmark
ü Develop a plan for closing gap, meeting or exceeding benchmark

26
Product / Process Assumptions.
Eg.
ü Assumptions Shrinkage
factor
ü Features
ü Design
ü Process concepts
ü Technical innovations
ü Advanced materials
ü Reliability assessments
ü New technology
ü Document assumptions as part of project plan
ü Utilize as inputs to plan
ü Consider alternate paths in case assumptions do not play out

27
Product Reliability Studies.

ü Frequency of repairs or replacements within designated time period(s)

ü Long range reliability and/or durability tests

MTBF = Mean Time Between Failures

MTBO = Mean Time Between Overhaul
MTBR = Mean Time Between Replacement
MTTR = Mean time to Repair

28
Customer Inputs.

ü Next users provide information about needs and expectations

ü Possibility of previous conducted reviews and studies by the customers
ü Used to develop measure of customer satisfaction

29
PHASE 1:- PLAN AND DEFINE PROGRAM.
Outputs.
ü Design Goals.
ü Reliability And Quality Goals.
ü Preliminary Bill Of Material.
ü Preliminary Process Flow Chart.
ü Preliminary Listing Of Special Product And Process Characteristics.
ü Product Assurance Plan.
ü Management Support.

30
Design Goals.
ü Translate VOC into tentative & Measurable Design objectives.
ü Design Goals could be
ü Cost
ü Performance
ü Design Failures

31
Reliability And Quality Goals.

ü Establish Reliability Goals based on

ü Customer wants / expectations
ü Reliability Benchmarks
ü Reliability goals should be expressed in terms of Probability.

ü Quality Goals are targets based on continual improvement

ü Eg. Of Quality goals are – Parts per Million, Defect levels, Scrap level,
Rework Level.

32
Preliminary Bill of Material
ü Establish a preliminary Bill of Material
ü Include a Initial Suppliers list
ü Establish initial BOM Cost.

Preliminary Process Flow Chart

ü Document anticipated manufacturing process in the form of Process
flow chart

33
Preliminary List of Special Product &
Process Characteristics
ü List the Initial Special characteristics.
Special Characteristics are generally identified by Customer
ü It can be also identified by Organization itself.
ü These can be identified based on following
ü Product assumptions
ü Reliability Goals / requirements
ü FMEA’s

34
Product Assurance Plan
ü Translates Design goals into Design requirements
ü Plan can be developed in any format
ü Plan should include.
ü Outlining of Program requirements
ü Identification of Reliability & Durability requirements
ü A s s e s s me n t o f n e w t e ch n o l o g y, c o m p l e x i t y, m a t e r i a l s ,
application, application, environment, packaging, service &
manufacturing requirements that may place the program at risk.
ü Development of preliminary engineering standards.

35
Management Support
ü Key to PQP team’s success is the interest, commitment & support of
senior management
ü Team should update management the status at every APQP phase.
ü Updates should be formal.
ü Management to support the team in terms of providing resources,
direction.

36
PHASE 2:- PRODUCT DESIGN & DEVELOPMENT
Inputs
ü  Output Of Plan And Define Program Phase.

Outputs by Design Responsible activity.

ü Design FMEA .
ü Design For Manufacturability And Assembly.
ü Design Verification.
ü Design Reviews.
ü Prototype Build - Control Plan.
ü Engineering Drawings.
ü Engg. Spec.
ü Material. Spec.
ü Drawing And Specification Changes.
37
PHASE 2:- PRODUCT DESIGN &
DEVELOPMENT
Outputs by APQP Team.
ü New Equipment , Tooling And Facilities Requirements.

ü Special Product And Process Characteristics. Gages / Testing

Equipment Requirements.

ü Team Feasibility Commitment And Management Support

38
Design FMEA
ü Disciplined analytical tool
Assess probability of failure

Effect of failure
ü DFMEA is a living document & should be updated continuously.
ü Must be continually updated
ü Focus on Critical Characteristics
ü Lessons Learned Incorporated
ü Check list (AIAG APQP Manual Appendix A-1)

39
 POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (DESIGN FMEA)
Page: Of
FMEA No.:- ______________

System/Subsystem/Comp Name ___________________________ Design Responsibility: _______________ Prepared By _______________

Model Year(s ________________ Key Date: FMEA Date(Orig): _________Rev:________

Core Team: ______________________

Item / Potential Potential SEV Potential Current Design Recommended Responsibility & Action Results

Occ

Det

RPN
Function Failure Effect(s) of cause(s) / Controls Action(s) Target

Class
M ode Failure M echanism(s) (Prevention / Completion Date Action Taken S E V O C C D E T RPN
of Failure Detection)

40
Design for Manufacturability & Assembly
ü Design, concept, function and sensitivity (tolerancing) to
manufacturing variation
ü Manufacturing and/or assembly process Use Tolerance
ü Dimensional tolerances analysis

ü Performance requirements
ü Number of components (complexity)
DFM/DFA
ü Process adjustments
Checklists
ü Material handling

41
Design Verification
ü Inspection methods
ü Testing methods
ü Ensure that all design outputs meet design input requirements
Alternate calculations
CAD/math data
Review design stage documents before release

42
Design Reviews
Design review should be performed by the Team. Following are to be
reviewed.

ü functional requirement(s)
ü Component/subsystem/system duty cycles
ü Computer simulation and bench test results
ü DFMEA(s)
ü Review of the DFM and DFA
ü Test failures
ü Design verification progress

43
Prototype Build Control Plan

ü A description of the dimensional measurements, Material tests,

Functional tests that will occur during prototype build
ü Use Prototype control plan as a basis for Prototype building and
verification.
ü Should be developed considering DFMEA as an input.

44
Prototype Build

ü Make -buy decisions

ü Part inspections
ü Assemble prototypes
ü Perform layout inspection
ü Validation testing
ü Redesign as required
ü Update DFMEA if required

45
Engineering Drawings

ü Review for special and/or critical characteristics

ü Review drawings for:
ü Dimensions for form, fit, function, durability, government S&R
ü Control or datum surfaces/locators identified.
ü Evaluate dimensions for feasibility to manufacture and inspect.

ü Compatibility of math data with two-way communications

46
Engineering Specifications

ü Review and understand controlling specifications

ü Identify functional, durability and appearance requirements
ü Should define:
ü Sample size
ü Frequency
ü Acceptance criteria

47
Material Specifications

ü Review Material Specifications

ü Special Characteristics relating to
ü Physical properties
ü Performance
ü Environmental
ü Handling
ü Storage
ü Include in Control Plan

48
Drawing & Specification Changes

ü Ensure changes to drawing & specifications are documented.

ü Changes are to be properly communicated to all areas.
ü Adopt “Control of Documents” Process.

49
APQP Team Outputs

7.3 Organization to identify, document & review the manufacturing

process design input requirements including:
Product design output data
Targets for productivity, process capability & cost
Customer requirements, if any
Experience from previous developments
• New Equipment , Tooling And Facilities Requirements.
ü Special Product And Process Characteristics.
ü Gages / Testing Equipment Requirements.
ü Team Feasibility Commitment And Management Support.

50
New Equipment Tooling & Facilities
Requirements

ü Preliminary identification of new equipment, tooling and facilities

ü Address these items on the timing chart
ü Address capability requirements
ü Establish delivery times
ü Complete check list in AIAG APQP & Control Plan reference manual APQ

51
Special Product & Process Characteristics
ü Upgrade preliminary list started in Phase 1 from information gathered
through review and development of design features
ü Additional sources
ü DFMEA
ü PFMEA
ü Previous history
ü Must be on control plans for prototype, pre-launch and production
ü Listing should be a team consensus

52
Gage / Testing Equipment Requirements

ü Preliminary identification of inspection, test and measurement

equipment
ü Highlight these Requirements on timing chart
ü Complete in time to conduct measurement systems analysis

53
Team Feasibility Commitment &
Management Support
ü APQP team to assess the feasibility of the proposed design
ü Use Team feasibility commitment form for evaluation
ü Ensure that the Proposed design can be manufactured, assembled,
tested, packed & delivered, at an acceptable cost and schedule
ü Complete Program review checklist. Use Design Information checklist
ü Open issues that require resolution with assigned responsibility and
timing
ü Management Support
ü Report project status to management
ü Recommend continue or drop project depending on feasibility(Only
for Self initiated product)
ü Cover open issues and concerns
ü Management support as required
54
 TEAM FEASIBILITY COMMITMENT
Date:
Customer : Part name :

Feasibility Considerations

Our product quality planning team has considered the following questions, not intended to be
all-inclusive in performing a feasibility evaluation. The drawings and/or specifications provided
have been used as a basis for analyzing our concerns and/or proposed changes to enable us
to meet specified requirements.

YES NO CONSIDERATION
Is product adequately defined (application requirements, etc.) to enable
feasibility evaluation?
Can Engineering Performance Specifications be met as written?
Can product be manufactured to tolerances specified on drawing?
Can product be manufactured with Cpk's that meet requirements?
Is there adequate capacity to produce product?
Does the design allow the use of efficient material handling techniques?
Can the product be manufactured without incurring any unusual?
* Costs for capital equipment?
* Costs for tooling?
* Alternative manufacturing methods?
Is statistical process control required on product?
Is statistical process control presently used on similar products?
Where statistical process control is used on similar products:
Are the processes in control & stable?
Are Cpk's greater than 1.33?

Conclusion
Feasible Product can be produced as specified with no revisions.
Feasible Changes recommended (see attached)
Not Feasible Design revisions required to produce product within the
specified requirements.
Sign - off

55
PHASE 3:- PROCESS DESIGN & DEVELOPMENT
Inputs
ü Output Of Product Design And Development.

Outputs.
ü Packaging Standards.
ü Product / Process Quality System Review.
ü Process Flow Chart.
ü Characteristics Matrix.
ü Process FMEA
ü Pre launch Control Plan
ü Process Instructions.

56
PHASE 3:- PROCESS DESIGN & DEVELOPMENT
Outputs.
ü Measurement System Analysis Plan (MSA)
ü Preliminary Process Capability Study Plan.
ü Packaging Specifications.
ü Management Support.

57
Packaging Standards
ü A unit that provides protection and containment of items plus ease of
handling by manual or mechanical means

ü Usually customer Provides Packaging standards.

ü Developed during prototype or pre-launch runs
ü Should ensure product integrity at point of use

58
Product/Process Quality System Review
ü Team must review existing quality system manual / Procedures to
ensure that changes resulting from APQP (if any) are reflected
ü Must comply with Quality system requirements.
ü Changes must be reflected in control plan
ü Opportunity to improve the existing Quality system based on customer
input, team expertise and previous experience

59
Process Flow Chart
ü Update process flow chart
ü It is also Used to analyze sources of variation
ü Helps analyze total process
ü Needed for process FMEA, characteristics matrix and control plan
ü Reference AIAG APQP Reference manual Appendix A-6 check list

60
 PROCESS FLOW CHART

PFC NO - PROCESS / FAMILY NO _______

REV NO ______ DATE _______ PART/FAMILY NAME :
PAGE______

CHARACTERISTICS
PROCESS PROCESS SYMBOL INCOMING SOURCE MACHINE/
NUMBER SEQUENCE OF VARIATION PRODUCT PROCESS EQUIPMENT

61
Floor Plan Layout
ü Determine acceptability of inspection and test points
ü Control chart location(s)
ü Visual aides
ü Interim repair stations - (rework)
ü Nonconforming material storage
ü Keyed to material flow and control plan
ü Reference AIAG APQP Reference manual Appendix A-5
ü Capacity

62
 Roller

Grinder Heat
#2 treatment

3 4
5
2
Grinder
Cleaning
#1

1 6

Loader Deburring

NC area

FG
Inspection
Incoming
Inspection

Packing

IN

OUT

63
Characteristics Matrix
ü Displays relationship between:
ü Process parameter
ü Manufacturing stations
ü Should be developed based on Process Flow Chart.
ü Supports in identifying the special characteristics

64
 Characteristics Matrix
Part No.
Part Description

Op. No.

Charcteristic.dim 10 20 30 40

ID X C

OD X L

Length 1 X

Dia 2 X

c- Chart. Used for clamping

L- Used for Location

X- Created or changed

65
Process FMEA
ü Process FMEA to be conducted before production:
ü Is a disciplined review and analysis to anticipate, resolve or monitor
potential failure modes.
ü Develop a prioritized list of action plans for reducing the potential
failure modes.
ü Take actions for High RPN’s.
ü Ensure linkage between Process Flow chart, Control Plan & Operating
instructions.

66
 POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA)

Item Process Responsibilty FMEA Number

Page of
Model Year(s) Vehicle(s) ______________ Key Date ___________________________ Prepared By
FMEA Date (Org.) ( Rev.) _____
Core Team

Process S C Potential D Recommended Responsibilty

O
Function Potential Potential e l Cause (s) / c Current e R. Action (s) & Target Actions S O D R.
Failure Effect (s) of v a Mechanism (s) c Process t P. Completion Date Taken e c e P.
Requirements Mode Failure s of Failure u Controls e N. v c t N.
s r Detection / Prevention c

67
Pre-launch Control Plan
ü Description of dimensional measurements, materials and functional
tests
ü Adds additional product and/or process controls
ü Purpose is to contain potential nonconformities utilizing:
ü More frequent inspections and/or tests
ü More in-process and final inspection and/or check points
ü Statistical evaluations
ü Increased audits
ü Reference AIAG APQP Reference manual Appendix A-8 check list

68
 Control Plan – Sample Format
Prototype Pre- launch Production key Contact /Phone Date (orig.) Date (Rev)

Part Number / Latest Change Level Core Team Customer Engineering Approval/ Date ( if Reqd.)

Part Name/Description : Supplier/ Plant Approval Date Customer Quality Approval Date ( if reqd)

Supplier / plant Supplier Code Other Approval / Date (If Reqd.) Other Approval / Date (If Reqd.)

Part/ Process Name / Machine, Device Characteristics Methods

Process Operation Jig, Tools for NO Product Process Special Product/Process Evaluation/
Number Number Mfg. Char. Specification/ Measurement Size Freq. Control Method Reaction Plan
Class Tolerance Technique

69
Process Instructions
ü Work instructions for operating personnel
ü Following are the Sources based on which instructions to be prepared:
ü FMEAs
ü Control plans
ü Engineering drawings and specifications, Material specifications
ü Visual standards , Industry standards
ü Process flow chart
ü Floor plan layout
ü Characteristic matrix
ü Packaging standards

70
Process Instructions
ü Process parameters
ü Producer expertise
ü Handling requirements
ü Operators of process
ü Accessible operators
ü Include set-up parameters

71
Measurement System Analysis Plan
ü Develop a MSA study plan for all the measurement systems.
ü Plan to ensure all the measurement systems are assessed for
Repeatability, Reproducibility, Linearity, Bias & Stability, as applicable.

Preliminary Process Capability Study Plan

ü Develop a Preliminary Process Capability study plan for all the Special
characteristics or those identified in Control plan.
ü Decide the type of study, SPC tool used, Sample size, Frequency of
data collection.

72
Management Support
ü Update senior Management on status of the Product development
ü Review the critical issues, pending tasks, and future plan
ü Reinforce the commitment for product development.

73
PHASE:- 4 PRODUCT AND PROCESS VALIDATION
Inputs
ü Output Of Process Design And Development Phase.
 
Outputs.
ü Production Trial Run.
ü Measurement System Analysis.
ü Preliminary Process Capability Study.
ü Production Part Approval.
ü Production Validation Testing.
ü Packaging Evaluation.
ü Production Control Plan.
ü Quality Planning Sign Off And Management Support.

74
Production Trial Run
ü Use Production tooling, equipment, environment, facilities and cycle
time
ü Produce parts as per Process instructions and control plans
ü Minimum quantity set by customer - (Can be increased by team) -
Generally 300 parts

75
Production Trial Run Product Used for:
ü Preliminary process capability studies
ü MSA (if not completed earlier)
ü Final feasibility
ü Process review
ü Production validation testing
ü PPAP
ü Packaging evaluation
ü First time capability
ü Quality planning sign-off
ü Design changes (if required)

76
Measurement Systems Evaluation
ü Complete studies as defined in the MSA plan
ü Minimum are those identified in the control plan
ü Subjected to evaluation prior to or during production trial
ü Take corrective actions if the results are not meeting the set
acceptance criteria.

77
Preliminary Process Capability Study
ü The study provides an assessment of the readiness of the process for
production.
ü Characteristics identified in the control plan
ü Usually 100 pieces minimum
ü May be 30 if run is less
ü Ppk  1.67 is acceptable unless otherwise specified
ü Ppk < 1.67 requires action plan unless otherwise specified
ü Reference AIAG Fundamental SPC Reference Manual

78
79
Production Part Approval
ü Production parts are manufactured at the production site using
production tooling, gaging, equipment, operators, etc
ü Parts from production run are analyzed.
ü Test results and records from APQP are submitted with Part Submission
Warrant.

Purpose of PPAP
ü For the supplier to demonstrate:
ü All design records and specification.
ü Requirements are properly understood.
ü The process has the capability to produce product that meets
requirements.

80
Production Part Approval
ü Parts produced at production site using:
ü Production tooling
ü Production gages
ü Process
ü Operators
ü Environment
ü Process settings – Feeds, Speeds, Cycle times, Pressures,Temperatures
ü Intent is to validate (prove) that products made using production
equipment meet engineering requirements
ü If submission level is not known, contact customer
ü Default level is 3
ü Customer approval is required prior to quantity production
ü Reference AIAG Production Part Approval Process reference manual
81
Production Validation Testing
ü Engineering tests validate products manufactured with:
ü Production tools
ü Production processes
ü Production operators
ü Performed under end-use operating conditions
ü Multiple validations for multiple intended uses

82
Packaging Evaluation
ü Packaging must conform to specifications developed by customer or
supplier
ü Assess protection of product
ü Customer specified packaging must be evaluated by team
ü Pilot or production trial run parts usually used in evaluation

Drop Test
Burst Test

83
Production Control Plan
ü Update pre-launch control plan (living document)
ü Update considering production:
ü Sampling plans
ü Control method
ü SPC, inspection, attribute data and mistake-proofing
ü Reaction plan
ü Requires customer approval unless otherwise specified
ü Reference AIAG APQP Reference manual

84
Quality Planning Sign off & Management
Support
ü Process instructions in place and followed
ü Flow charts in place and followed
ü GR&R plans exist and are followed
ü Ensure control plans exist and approved
ü Ensure Special characteristics are identified in all documents.
ü Obtain formal sigh-off
ü Schedule and conduct management review
ü Identify and document pending/open issues
ü Obtain management commitment to assist in open issues

85
 QUALITY PLANNING SIGN OFF
Part No. Date
Part Description

(To be filled after PPAP approva l & be fore part is re lease d for Bulk production)
SL. YES/ RESP/
CHECK POINTS ACTION PLAN REMARKS/STATUS
NO. NO. TARGET
Is drawing, BOM & Other
1 design doc's available and
approved

Is all action taken on concerns

2
highlighted during TFC

Is all the factilities such as

3 Gauges/Jigs & fixtures/Dies,
etc. are available for production
Is actions recommended in
4
process FMEA implemented
Is control plan adequate and
5
approved for production
Is process control chart
6
approved

Is Special characteristics
7
identified and clearly defined

Is controls to be exercised over

8
special characteristics defined

Is packing instruction /
9
standards approved
10 Is PPAP approved

Is the part fully developed to

11 ensure achievement of targeted
performance
Is MSA Studies performed and
12
approved.
Is Process capability levels
13
acceptable
Is actions taken on the quality
14 problems highlighted in the
product input stage

CFT SIGN OFF

1__________________________ 5__________________________
2__________________________ 6__________________________
3__________________________ 7__________________________
4__________________________ 84__________________________

86
PHASE 5:- FEED BACK, ASSESSMENT &
CORECTIVE ACTIONS
Inputs
ü Outputs of Product & Process validation.

 
Outputs.
ü Reduced Variation.
ü Customer Satisfaction
ü Delivery & Service

87
PHASE 5:- FEED BACK,
ASSESSMENT and CORECTIVE ACTIONS
ü Post Production Launch activities.
ü Monitor the achievement of Design goals, Reliability goals, Quality
goals.
ü Monitor the achievement of the estimates during RFQ Stage.
Monitor the variances – eg: Estimated cycle time v/s actual cycle
time, Est. Material wt v/s actual material used, etc..
ü Take corrective actions where results are not satisfactory.

88
Reduced Variation

ü Identify & monitor process variation

ü Take corrective action to reduce variation
ü Develop proposal for customer review
ü Gain customer decision to implement, negotiate or change design

89
Customer satisfaction
ü Product or service must perform in customer’s environment
ü Supplier must participate
ü Supplier and customer must be partners

Customer Satisfaction Metrics

ü Warranty ü Customer rating
ü Labour claims ü Returns
ü Concerns reports ü PPM
ü Nonconforming material reports ü Response time
ü Corrective actions ü On-site representative
ü On time delivery ü Market share
ü Tech calls ü Cost control (total cost)

90
Delivery & Service
ü Continues the supplier - customer partnership in problem solving and
continuous improvement
ü Replacement parts and services are important
ü Leads to possible price reduction from:
ü Inventory cost reduction
ü Process cost reduction
ü Cost of quality reduction

91
CONTROL PLAN METHODOLOGY –

ü This is A description of systems for controlling parts and processes.

ü A single control plan may apply to group of family of products that are
produced by the same process.
ü Prepared for each phase of the process including incoming, in process,
outgoing, and periodic requirements to assure that all process outputs
will be in a state of control.
ü Prepared by cross functional team.
ü Provision for customer approval.
ü Prepared For Three Distinct Phases
ü Prototype
ü Pre launch
ü Production

92
CONTROL PLAN METHODOLOGY.

ü Control plan shall be derived from outcome of process failure mode

and effect analysis.

ü The document shall be reviewed and updated - when process is

changed, unstable or not capable.

ü Describe the controls required on product as well as process

characteristics.

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CONTROL PLAN METHODOLOGY.
ü Identify The Measurement Process.

ü Specify The Corrective Actions Required, Whenever The Process Goes

Out Of Control, Specify The People Responsible To Carry Out This.

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 DOCUMENT LINKS- PFC, FMEA & CP
PROCESS NO. / PRODUCT PROCESS
DESCRIPTION SYMBOL Ma chine CHARACTERISTICS CHARACTERISTICS

Process Faliure Effect of Sev Class Potential Occ Current Process Det RPN Actions
no. & Desc. Mode Failure Cause Control

Process Machine, Product Process Class Specifications Evaluation / Sample Freq Control Resp Reaction
no. & Desc. Tools & Jigs Charc Charc. Measurement Tech. Size Method Plan

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Common Mistakes
ü No team approach towards implementing APQP
ü APQP timing plan is generally prepared only at the beginning of
project. Later on no review for status and updation.

ü Poor Linkage between Process Flow Chart, FMEA, Control Plan, Process
Instructions.

ü PFC, FMEA & Control plan – these documents are generally prepared by
Engineering. Hence inadequacy in process controls.

ü Poor or absence of Management reviews.

ü Generally Process documents are prepared after the Production trial

run is completed. This indicates poor process planning.

ü High rejections / reworks during Bulk production, due to poor process

planning.

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Common Mistakes
ü Production trial run is done using proto tools, in order to meet the
customer commitment of sample delivery

ü FMEA’s are normally done by one person. No real team effort.

ü In some cases, FMEA are not prepared at all. It is just prepared for
audit purposes.

ü Cost estimates (Normally done at RFQ Stage) are not validated during
Production trial run – This can lead to Major loss to organization.

ü “We plan, but never achieved – hence stopped doing plan”

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Any Questions

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Thank You

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