Training Material on APQPCP
Q Nathan & Nathan Consultants Pvt. Ltd.,
COURSE MATERIAL
ON
ADVANCED PRODUCT QUALITY PLANNING &
CONTROL PLAN
(APQP & CP)
No.36, Muktha Building, 8th Main 18th Cross, Malleswaram, Bangalore 560 055
Ph: 080-3440703 / 3440704, Fax: 080-3311622
Email: [email protected]
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Training Material on APQPCP
ADVANCED PRODUCT QUALITY PLANNING AND
CONTROL PLAN (APQP & CP)
A P Q P STANDS FOR ADVANCED PRODUCT QUALITY PLANNING
BIG THREE HAS PUBLISHED A MANUAL ON APQP
THIS IS TO SERVE AS A GUIDELINE FOR CONSISTENT APPROACH TO ALL
USERS.
ISO/TS 16949 REFERS TO APQP IN THE FOLLOWING CLAUSES:
SL.NO. CLAUSE NO. DESCRIPTION
1. 7.1 PLANNING OF PRODUCT REALIZATION
2. 7.2.2.2 ORGANIZATION MANUFACTURING
FEASIBILITY
3 7.3 PRODUCT DESIGN AND DEVELOPMENT
4. 7.3.1.1 MULTI DISCIPLINARY APPROACH
CONTENTS OF A P Q P
1. PLAN AND DEFINE PROGRAM
2. PRODUCT DESIGN AND DEVELOPMENT PROGRAM
3. PROCESS DESIGN AND DEVELOPMENT PROGRAM
4. PRODUCT AND PROCESS VALIDATION PROGRAM
5. FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION
6. CONTROL PLAN METHODOLOGY
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Training Material on APQPCP
PHILOSOPHY:
- SPEND A LITTLE EXTRA TIME UPSTREAM, SO THAT LIFE
DOWNSTREAM IS ERROR FREE
- HOW YOU SPEND THE TIME IS VERY IMPORTANT
ELEMENTS OF GOOD PLANNING:
COMMITMENT
TRAINING
TEAMWORK
LOGICAL METHODOLOGY ROBUST DESIGN
SOUND TECHNIQUES
DOCUMENTATION
COMMUNICATION
FEEDBACK
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1.0 PLAN AND DEFINE PROGRAM
INPUTS
VOICE OF THE CUSTOMER
- MARKET RESEACH
- HISTORICAL WARRANTY AND QUALITY INFORMATION
- TEAM EXPERIENCE
BUSINESS PLAN / MARKETING STRATEGY
PRODUCT / PROCESS BENCHMARK DATA
PRODUCT / PROCESS ASSUMPTIONS
PRODUCT RELIABILITY
CUSTOMER INPUTS
OUTPUTS (BECOMING INPUTS FOR SECTION 2.0)
DESIGN GOALS
RELIABILITY AND QUALITY GOALS
PRELIMINARY BILL OF MATERIAL
PRELIMINARY PROCESS FLOW CHART
PRELIMINARY LISTING OF SPECIAL PRODUCT AND PROCESS
CHARACTERISTICS
PRODUCT ASSURANCE PLAN
MANAGEMENT SUPPORT
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Training Material on APQPCP
2.0 PRODUCT DESIGN AND DEVELOPMENT
INPUTS (DERIVED FROM THE OUTPUTS OF SECTION 1.0)
DESIGN GOALS
RELIABILITY AND QUALITY GOALS
PRELIMINARY BILL OF MATERIAL
PRELIMINARY PROCESS FLOW CHART
PRELIMINARY LISTING OF SPECIAL PRODUCT AND PROCESS
CHARACTERISTICS
PRODUCT ASSURANCE PLAN
MANAGEMENT SUPPORT
OUTPUTS BY DESIGN RESPONSIBLE ACTIVITY (BECOME INPUTS FOR
SECTION 3.0)
DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA)
DESIGN FOR MANUFACTURIBILITY AND ASSEMBLY
DESIGN VERIFICATION
DESIGN REVIEWS
PROTOTYPE BUILD – CONTROL PLAN
ENGINEERING DRAWINGS (INCLUDING MATH DATA)
ENGINEERING SPECIFICATIONS
MATERIAL SPECIFICATIONS
DRAWING AND SPECIFICATION CHANGES
OUTPUTS BY PRODUCT QUALITY PLANNING TEAM (BECOMES INPUTS FOR
SECTION 3.0)
NEW EQUIPMENT TOOLING AND FACILITIES REQUIREMENTS
SPECIAL PRODUCT AND PROCESS CHARACTERISTICS
GAGES / TESTING EQUIPMENT REQUIREMENT
EXPERIENCE FROM PREVIOUS DEVELOPMENTS
TARGETS FOR PRODUCTIVITY, PROCESS CAPABILITY AND COST
CUSTOMER REQUIREMENTS IF ANY
TEAM FEASIBILITY COMMITMENT AND MANAGEMENT SUPPORT
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Training Material on APQPCP
3.0 PROCESS DESIGN AND DEVELOPMENT
INPUTS (DERIVED FROM THE OUTPUTS OF SECTION 2.0)
DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA)
DESIGN FOR MANUFACTURIBILITY AND ASSEMBLY
DESIGN VERIFICATION
DESIGN REVIEWS
PROTOTYPE BUILD – CONTROL PLAN
ENGINEERING DRAWINGS (INCLUDING MATH DATA)
ENGINEERING SPECIFICATIONS
MATERIAL SPECIFICATIONS
DRAWING AND SPECIFICATION CHANGES
NEW EQUIPMENT TOOLING AND FACILITIES REQUIREMENTS
SPECIAL PRODUCT AND PROCESS CHARACTERISTICS
GAGES / TESTING EQUIPMENT REQUIREMENT
EXPERIENCE FROM PREVIOUS DEVELOPMENTS
TARGETS FOR PRODUCTIVITY, PROCESS CAPABILITY AND COST
CUSTOMER REQUIREMENTS IF ANY
TEAM FEASIBILITY COMMITMENT AND MANAGEMENT SUPPORT
OUTPUTS (BECOME INPUTS FOR SECTION 4.0)
PACKAGING STANDARDS
PRODUCT PROCESS QUALITY SYSTEM REVIEW
PROCESS FLOW CHART
FLOOR PLAN LAYOUT
CHARACTERISTICS MATRIX
PROCESS FAILURE MODE AND EFFECTS ANALYSIS (PFMEA)
PRE-LAUNCH CONTROL PLAN
PROCESS INSTRUCTION
PROCESS APPROVAL ACCEPTANCE CRITERIA
DATA FOR QUALITY, REALIBILITY, MAINTAINABILITY AND MEASURABILITY
RESULTS OF ERROR PROFFING ACTIVITIES, AS APPROPRIATE
METHOD OF RAPID DETECTION AND FEEDBACK OF
PRODCUT/MANUFACTURING PROCESS NONCONFORMITIES
MEASUREMENT SYSTEMS ANALYSIS PLAN
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Training Material on APQPCP
PRELIMINARY PROCESS CAPABILITY STUDY PLAN
PACKAGING SPECIFICATION
MANAGEMENT SUPPORT
4.0 PRODUCT AND PROCESS VALIDATION
INPUTS (DERIVED FROM THE OUTPUTS OF SECTION 3.0)
PACKAGING STANDARDS
PRODUCT PROCESS QUALITY SYSTEM REVIEW
PROCESS FLOW CHART
FLOOR PLAN LAYOUT
CHARACTERISTICS MATRIX
PROCESS FAILURE MODE AND EFFECTS ANALYSIS (PFMEA)
PRE-LAUNCH CONTROL PLAN
PROCESS INSTRUCTION
DATA FOR QUALITY, REALIBILITY, MAINTAINABILITY AND MEASURABILITY
RESULTS OF ERROR PROFFING ACTIVITIES, AS APPROPRIATE
METHOD OF RAPID DETECTION AND FEEDBACK OF
PRODCUT/MANUFACTURING PROCESS NONCONFORMITIES
MEASUREMENT SYSTEMS ANALYSIS PLAN
PRELIMINARY PROCESS CAPABILITY STUDY PLAN
PACKAGING SPECIFICATION
MANAGEMENT SUPPORT
OUTPUTS (BECOME INPUTS FOR SECTION 5.0)
PRODUCTION TRIAL RUN
MEASUREMENT SYSTEMS EVALUATION
PRELIMINARY PROCESS CAPABILITY STUDY
PRODUCTION PART APPROVAL
PRODUCTION VALIDATION TESTING
PACKAGING EVALUATION
PRODUCTION CONTROL PLAN
QUALITY PLANNING SIGN-OFF AND MANAGEMENT SUPPORT
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Training Material on APQPCP
5.0 FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION
INPUTS (DERIVED FROM THE OUTPUTS OF SECTION 4.0)
PRODUCTION TRIAL RUN
MEASUREMENT SYSTEMS EVALUATION
PRELIMINARY PROCESS CAPABILITY STUDY
PRODUCTION PART APPROVAL
PRODUCTION VALIDATION TESTING
PACKAGING EVALUATION
PRODUCTION CONTROL PLAN
QUALITY PLANNING SIGN-OFF AND MANAGEMENT SUPPORT
OUTPUTS
REDUCED VARIATION
CUSTOMER SATISFACTION
DELIVERY AND SERVICE
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Training Material on APQPCP
CONTROL PLANS
THIS IS A DESCRIPTION OF SYSTEMS FOR CONTROLLING PARTS AND
PROCESSESS.
A SINGLE CONTROL PLAN MAY APPLY TO A GROUP OR FAMILY OF
PRODUCTS THAT ARE PRODUCED BY THE SAME PROCESS
PREPARED FOR EACH PHASE OF THE PROCESS INCLUDING INCOMING,
IN-PROCESS, FINAL AND PRODUCT AUDIT REQUIREMENTS TO ASSURE
THAT ALL PROCESS OUTPUTS IN A STATE OF CONTROL.
PREPARED BY A MULTI-DISCIPLINARY TEAM
PROVISION FOR CUSTOMER APPROVAL.
REFER SPC REQUIREMENTS, MISTAKE PROOFING AS CONTROL
METHODS.
PREPARED FOR THREE DISTINCT PHASES
- PROTOTYPE
- PRE-LAUNCH
- PRODUCTION
CONTROLSHALL BE DERIVED FROM THE OUTCOME OF PROCESS FMEA
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Training Material on APQPCP
THE DOCUMENT SHALL BE REVIEWED & UPDATED – WHEN PROCESS IS
CHANGED, UNSTABLE OR NOT CAPABLE.
DESCRIBE THE CONTROLS REQUIRED ON PRODUCT AS WELL AS
PROCESS CHARACTERISTICS
IDENTIFY SPECIAL CHARACTERISTICS
(ALL SPECIAL CHARACTERISTICS MUST BE LISTED IN CONTROL PLAN)
IDENTIFY THE MEASUREMENT PROCESS
SPECIFY THE CORRECTIVE ACTION REQUIRED, WHENEVER THE
PROCESS GOES OUT OF CONTROL, SPECIFY THE PEOPLE RESPONSIBLE
TO CARRY OUT THIS.
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Training Material on APQPCP
CONTROL PLAN METHODOLOGY
A) GENERAL DATA
1. CONTROL PLAN NUMBER
2. ISSUE DATE, & REVISION DATE IF ANY
3. CUSTOMER INFORMATION (SEE CUSTOMER REQUIREMENTS)
4. ORGANIZATION’S NAME / SITE DESIGNATION
5. PART NUMBER (S)
6. PART NAME / DESCRIPTION
7. ENGINEERING CHANGE LEVEL
8. PHASE COVERED (PROTOTYPE, PRE-LAUNCH, PRODUCTION)
9. KEY CONTACT
10. PART/PROCESS STEP NUMBER
11. PROCESS NAME / OPERATION DESCRIPTION
B) PRODUCT CONTROL
12. PRODUCT RELATED SPECIAL CHARACTERISTICS
13. OTHER CHARACTERISTICS FOR CONTROL (NUMBER, PRODUCT
OR PROCESS)
14. SPECIFICATION / TOLERANCE
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Training Material on APQPCP
C) PROCESS CONTROL
15. PROCESS PARAMETERS
16. PROCESS – RELATED SPECIAL CHARACTERISTICS
17. MACHINES, JIGS, FIXTURES, TOOLS FOR MANUFACTURING
D) METHODS
18) EVALUATION MEASUREMENT TECHNIQUE
19) ERROR – PROOFING
20) SAMPLE SIZE AND FREQUENCY
21) CONTROL METHOD
E) REACTION PLAN & CORRECTIVE ACTIONS
22) REACTION PLAN (INCLUDE OR REFERENCE)
23) CORRECTIVE ACTION
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Training Material on APQPCP
RISK ASSESSMENT CHECK LIST YES NO
1) Quality History
Does the Organization have a history of high warranty or Things Gone
Wrong (TGWs) on current model or surrogate product?
Are there frequent Quality Rejects (QRs) and/or campaigns at the
receiving plant?
Was there a recall action due to a similar component or system?
.2) Organization Profile
Is it a new Organization or new manufacturing location?
Is the product or manufacturing technology new to the Organization
Manufacturing location?
Is the Organization’s historic launch performance poor?
Are the Organization’s resources stretched due to significant amount of
new business?
Is the Organization location under Q-1 probation?
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RISK ASSESSMENT CHECK LIST YES NO
3) Engineering Profile
Is it a new design?
Are the manufacturing techniques new to the industry?
Are similar products subject to numerous design changes that
threaten program timing?
Is there high product or process complexity?
Is the product strategically important due to high visibility or
functional performance?
4) Performance versus Targets
Will the design goals (weight, materials, functional performance,
etc.) and Reliability goals be difficult to achieve?
Will the quality goals (warranty, TGW, scrap rates, rework rates,
etc.) be difficult to achieve?
Is the program timing compressed?
Are the cost targets aggressive?
TEAM FEASIBILITY COMMITMENT
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Training Material on APQPCP
Date: ____________________
Customer Part Name
Part Number
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 the ability to meet all specified requirements. All “NO” answers are supported with attached comments
identifying our concerns and/or proposed changes to enable us to meet the 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?
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 and stable?
Are Cpk’s greater than 1.33?
Conclusion
Feasible Product can be produced as specified with no revisions
Feasible Changes recommended (see attached).
Design revision required to produce product within the specified
Not Feasible
requirements.
Sign – Off
Team Member/Title/Date Team Member/Title/Date
Team Member/Title/Date Team Member/Title/Date
Team Member/Title/Date Team Member/Title/Date
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Training Material on APQPCP
QUALITY PLANNING SUMMARY AND SIGN-OFF
DATE: ___________________
PRODUCT NAME PART NUMBER
CUSTOMER MANUFACTURING PLANT
1. PRELIMINARY PROCESS CAPABILITY
STUDY:
QUANTITY
REQUIRED ACCEPTABLE PENDING*
Ppk – SPECIAL CHARACTERISTICS
2. CONTROL PLAN APPROVAL (If Required) APPROVED: YES/NO* DATE APPROVED:
3. INITIAL PRODUCTION SAMPLES
CHARACTERISTIC CATEGORY
QUANTITY
CHARACTERISTI
SAMPLES
CS PER SAMPLE
ACCEPTABLE PENDING*
DIMENSIONAL
VISUAL
LABORATORY
PERFORMANCE
4. GAUGE & TEST EQUIPMENT
MEASUREMENT SYSTEM ANALYSIS
QUANTITY
REQUIRED ACCEPTABLE PENDING*
SPECIAL CHARACTERISTIC
5. PROCESS MONITORING QUANTITY
REQUIRED ACCEPTABLE PENDING*
PROCESS MONITORING
INSTRUCTIONS
PROCESS SHEETS
VISUAL AIDS
6. PACKAGING / SHIPPING QUANTITY
REQUIRED ACCEPTABLE PENDING*
PACKING APPROVAL
SHIPPING TRIALS
7. SIGN-OFF
Team Member/Title/Date Team Member/Title/Date
Team Member/Title/Date Team Member/Title/Date
Team Member/Title/Date Team Member/Title/Date
*REQUIRES PREPARATION OF AN ACTION PLAN TO TRACK PROGRESS
PRODUCT QUALITY PLANNING SUMMARY AND SIGN-OFF
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Training Material on APQPCP
INSTRUCTIONS:
1. Under “required”, for each item indicate the number of characteristics required.
Under “acceptable”, for each item indicate the quantity that was accepted per Chrysler, Ford and
General Motors Production Part Approval Process manual or customer requirements.
Under “pending”, for each item indicate the quantity not accepted. Attach action plan for each item.
2. Indicate if control plan has been approved by the customer (if required) by circling ‘Yes’ or ‘No’. If
Yes, indicate date approved. If No, attach action plan.
3. Under “samples”, indicate the quantity of samples inspected for each item.
Under “Characteristics per sample”, for each item indicate the number of characteristics inspected on
each sample for each category.
Under “acceptable”, for each item indicate the quantity of characteristics acceptable on all samples.
Under “pending”, for each item indicate the quantity of characteristics not accepted. Attach action
plan for each item.
4. Under “required”, for each item indicate the number of characteristics required.
Under “acceptable”, for each item indicate the quantity acceptable per Chrysler, Ford and General
Motors Measurement Systems Analysis Reference Manual.
Under “pending”, for each item indicate quantity not accepted. Attach action plan for each item.
5. Under “required”, for each item indicate the quantity required.
Under “acceptable”, for each item indicate the quantity accepted.
Under “pending”, for each item indicate quantity not accepted. Attach action plan for each item.
6. Under “required”, for each item indicate ‘yes’ or ‘no’ to indicate if item is required.
Under “acceptable”, for each item indicate ‘yes’ or ‘no’ to indicate acceptance.
Under “pending”, if answer under “acceptable” is ‘no’ – attach action plan.
7. Each team member should sign form and indicate title and date of signature.
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Training Material on APQPCP
CONTROL PLAN
Prototype Pre-launch Production Key Contact / Phone Date (Org.) Date (Rev.)
Control Plan Number S. Specs 555-8888
Part Number / Latest Change Level Core Team Customer Engg. 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, Characteristics Special Methods Reaction
Plan
Process Operation Description Device, No. Product Process Char. Product/Process Evaluation Sample Control
Number Jig. Tools specification / Measurement Size Freq Method
For Mfg. Tolerance Technique .
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