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APQP Workbook Training

This document provides an overview of New Product Quality Planning using Advanced Product Quality Planning (APQP). It discusses the fundamentals of APQP including organizing a team, defining the scope, training, and developing control plans. The document outlines PACCAR's new program expectations for suppliers including industry-leading quality and technology. It also reviews the key elements of APQP like design reviews, process flow charts, control plans, and validation. Appendices provide due dates for APQP reporting and a list of reference materials.

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Francisco
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686 views31 pages

APQP Workbook Training

This document provides an overview of New Product Quality Planning using Advanced Product Quality Planning (APQP). It discusses the fundamentals of APQP including organizing a team, defining the scope, training, and developing control plans. The document outlines PACCAR's new program expectations for suppliers including industry-leading quality and technology. It also reviews the key elements of APQP like design reviews, process flow charts, control plans, and validation. Appendices provide due dates for APQP reporting and a list of reference materials.

Uploaded by

Francisco
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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New Product Quality Planning

Overview
• Project Management Quality Planning
– Product Development Activity
– Plan-Do-Check-Act
• Why APQP
• PACCAR New Program Objectives
• Project Management Quality Planning
– Early Supplier & Stakeholder Involvement
– Benefits
– Fundamentals
• APQP Workbook Training
– Getting Starting
– Training Modules
• Appendices
– Appendix A - Workbook and Reporting Due Dates
– Appendix B – Reference Material
Product Development Activity
Project Management Quality Planning
Fundamentals of Product Quality Planning

• Organize the Team


• Define the Scope
• Team-to-Team
• Training
• Customer and Organization Involvement
• Simultaneous Engineering
• Control Plan
• Concern Resolution
• Product Quality Timing Plan
• Plans Relative to the Timing Chart
New Program Expectations
PACCAR Supplier Expectations
• Global Capabilities / Local Support
• Industry Leading Technology
• 50 PPM Quality / Zero Warranty
• Six Sigma Commitment
• Global Supply Capacity & Investment
• Exclusive and Proprietary Products
• Reduced Product Complexity
• Design Collaboration and Integration
• Lowest Total Cost Solutions
• Aftermarket Support
• On-Time Delivery
Product Quality
• Design and Deliver Products That
Consistently Exceed Customer
Expectations:
– Structured Method to Translate
Design to Manufacturing – APQP
– Reduced Development Cost and
Improved Timing
– Eliminate Late Design Changes
– Meet Time to Market Expectations
– 100% Compliance to PACCAR
Quality Requirements
• Goal –
– 0 Production PPM
Manufacturing Quality
• Develop and Validate Supplier
Processes That Meet Customer
Requirements for Volume and
Quality:
– Statistical Confidence Processes
Produce Conforming Product – PPAP
– Error Proofing
– Manufacturing Capacity – Production
Intent Runs
– Verification of Process Stability
– Rapid Containment and Corrective
Actions for Failures
• Goals –
– 100% On Time PPAP Submission
– 100% PPAP Approval
– 100% Corrective Action Response
Delivery Quality (North America)
• Development and Validation of Supply
Chain and Logistics Systems That
Meet Customer Material
Requirements 100% of the Time:
– Capacity Verification
– Electronic Order Systems
– PACCAR Production Forecasts
– Supplier Product Planning
– Inventory Management With Lead
Time Buffers – PACCAR VMI
– Supply Chain Flexibility
• Goals –
– 100% Delivery Reliability
– On Time and Accurate Quantities
Zero Warranty
• Design and Manufacture Products
That Exceed Customer
Expectations for Product Life:
– Controlled Process Variation
– Reliability Testing
– Rapid Response to Customer Claims
– Continuous Improvement and
Corrective Actions for Failures
• Goals –
– Zero Claims
– Zero Cost
Why APQP

“Occasionally, an organization may find that as operations


begin, some features of the product or process design are in
error, have been overlooked, or have been poorly executed
resulting in failures….over time, this becomes the chronic
level of performance. What is the source of this chronic
level? In a sense, it was planned that way, not on purpose of
course, but by error or omission…”

Dr. Joseph Juran


APQP
Advanced Product Quality Planning
• Definition
– Structured method of defining and establishing the
quality plan necessary to assure the product satisfies the
customer

• Goal
– Facilitate communication with everyone involved to
assure all required steps are completed on time

• Benefits
– Direct resources
– Early identification of changes
– Avoid late changes
– Provide quality product on time at lowest cost
Advanced Quality Planning
Early Supplier Involvement

Project Life Cycle


Pre-
Concept Development Pilot Production
Launch
Increasing

$ Value
RISK
Time
New Product Quality Planning
Initiator:
• Supplier Quality / Advanced Quality &
Project Management
Purpose / Use:
• Checklist to Assess Launch Deliverables
• Updated Monthly
• Timing: Supplier Selection - Launch
Prerequisite Activities:
• APQP Form Roll-Out
• SharePoint Set-Up
Outcome:
• Quality Plan for New Product
Introduction
Retention Requirements:
• PACCAR Extranet SharePoint
• Communication to NA or EU Team
Lessons Learned

• Kickoff APQP Once Supplier Sourcing is Complete


• APQP Kickoff Should Include Input from ALL
Stakeholders
• A Key Output from the Meeting is the Quality Plan
Timeline
APQP
Advanced Product Quality Planning

• Affects new programs / parts or major changes to


existing programs and parts

• 21 Key elements included in a tollgate process


APQP
Advanced Product Quality Planning

• Part & Process Information • Process Flow Chart


• External Customer Input • Tooling Review
• Internal Customer Input • Materials/Sub-Tier
• Commercial Sourcing • Measurement Systems
• Part Styling Analysis
• Prototype Build • Packaging
• Prototype Control Plan • Product & Process Quality
• Design Information • New Equipment & Fixturing
• DFMEA • Process FMEA
• Supplier Readiness • Quality Validation
• DVP&R • Volume Validation
• Design Reviews • Preliminary Process Studies
• Floor Plan • Production Control Plan
• Control Plan • PPAP
• Capacity Analysis
APQP Workbook Training

• Getting Started
– Quality Dashboard
– Header Section
– Element Summary
– Comments and Risk Definitions
– Corrective Actions
– Part Numbers
– Project Plan
– Training Modules – APQP Key Elements
APQP Workbook – Quality Dashboard
APQP Workbook – Header Section

Automatic
Drop Down
Risk Rating Ranking
APQP Workbook – Element Summary

Element
Summary
Status
APQP Workbook – Comments & Risk
Definitions
APQP Workbook – Corrective Actions
APQP Workbook – Part Numbers
APQP Workbook – Project Plan
Training Modules
External Customer Input Packaging Specs and Shipping plan
Internal Customer Input Process Flow Chart
Commercial Sourcing Tooling Purchase Orders
Part Styling Materials
Prototype Build MSA
Proto Control Plan Product Process Quality
Design Information New Equipment and Tooling
DFMEA Process FMEA
Supplier Readiness Quality Validation Build
DVP (design Verification Plan) Volume Validation Builds
Design Reviews Preliminary Process Studies
Floor Plan Layout Production Control Plan
Control Plan PPAP
Capacity Analysis
SQM / AQM APQP Reporting

• Supplier APQP Status will be Summarized and Reported in


the Program APQP Supplier Status Report
• Key or Critical Information from the APQP Status Reports
and On-Site Visits will be Communicated to the Appropriate
Functional Groups and Program Manager
• Key or Critical Information will also be Reported in the SQM
Monthly APQP Report and Weekly Sig Events as Needed
• The Lead PACCAR SQM for the Project will be Responsible
For Summarizing and Publishing the Project’s APQP Report
a
APQP
Questions?
Appendix A - Due Dates for Reporting

• Monthly Supplier Updates Due First Working Day*


– December 1 In the Example Shown Below
• Significant Event Updates are Due 2nd Week
– December 8 in the Example Shown Below

*Minimum requirement, the respective


SQM may require more frequent
reporting.
Appendix B – Reference Material
• AIAG Publications (www.aiag.org)
• ISO/TS16949:2002
• PACCAR CDP0188 – PCP for Vehicle Engineering
• Advanced Product Quality & Control Plan Manual –
Edition 2
• MSA Manual – Edition 3
• FMEA Manual – Edition 4
• PPAP Manual – Edition 4
• Statistical Process Control – Edition 2
• ISO 21500 – Project Management
• PMBoK – Edition 4

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