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QUALITY PLANNING
APQP
Presented by:
Quality Growth Services Pvt. Ltd.
H-13, Kirti Nagar,
Nagar,
New Delhi - 110 015
Why Plan
Identify ways to improve Continual improvement
QGS/ISO-TS-APQP 2
What gets in the way of planning
Lack of management Personal egos
commitment Lack of team spirit
Lack of discipline Adhock approach
Time management issues
Lack of knowledge
Unclear priorities
Lack of resources
Unclear responsibilities
Unclear directions
Lack of accountability
Lack of faith in systematic Non-competitive operating
approach environment
QGS/ISO-TS-APQP 3
QGS/ISO-TS-APQP 4
What is Advanced Product
Quality Planning
Quality planning and more
Total integration of quality tools with management functions
Multi-disciplinary team approach to quality planning
Tool to enable suppliers to not only meet but exceed customer
requirements
To promote early identification of required changes
To avoid late changes
To provide a quality product on time at the lowest cost
Facilitate communication with everyone involved
Developing easily understandable formats by supplier and customer
QGS/ISO-TS-APQP 5
Fundamentals of Product
Quality Planning
Organize the team - Multi-disciplinary team from Engineering,
Manufacturing, Quality, Materials, Sales, Service, Sub-contractors and
Customers
Define the Scope - Team Leader, Roles and Responsibilities, Customer
(Internal / External), Customer Requirements, Additional Members,
Feasibility Assessment , Cost , Timings, Constraints, Customer
Assistance & documentation
Team-To-Team - Establish line of communication with customer team and
other in-house teams
Training - Identifications and organizing for providing training
Customer and Supplier Involvement - Identification of issues needs
interaction with customer / sub-contractor and resolution
QGS/ISO-TS-APQP 6
Fundamentals of Product
Quality Planning (Cont’d.)
Simultaneous Engineering - A process to strive for common goal. Parallel
working
Control Plans - Prototype, pre-launch and production
Concern Resolution - Documenting, responsibility assigned. Use of
disciplined problem solving method in difficult situations
Product Quality Timing Plan - Developing activity plan for all activities.
Review of activities and corrective actions
Plans Relative to the Timing Chart - Sub plans for associated activities!
QGS/ISO-TS-APQP 7
Introduction
When is APQP appropriate?
For development of new product
Incorporating changes in the product
(Your responsibility will be dependent on the nature of what your company supplies)
Concept
Initiation / Approval
Programme Prototype Pilot Launch
Approval
PLANNING
PLANNING
PRODUCTION
QGS/ISO-TS-APQP 8
Product Quality Planning
Responsibility Matrix
ASSIST IN DEFINING THE SCOPE OF PLANNING AND RESPONSIBILITY
Phase Responsibility Interfaces
Plan & Define Programme
INPUTS
• Voice of Customers (- - - - - - - - - - - - - - - - - - - - - - - - - -)
• Business Plan / Marketing Strategy
• Product / Process Benchmark Data
• Product & Process Assumptions
• Product Reliability Studies
• Customer Inputs
OUTPUTS
• Design Goals
• Reliability & Quality Goals
• Preliminary Bill of Material
• Preliminary Process Flow Chart
• Preliminary Listing of Special Product
& Process Characteristics
• Product Assurance Plan
QGS/ISO-TS-APQP 9
QGS/ISO-TS-APQP 10
Product Quality Planning
Responsibility Matrix
ASSIST IN DEFINING THE SCOPE OF PLANNING AND RESPONSIBILITY
Phase Responsibility Interfaces
Process Design & Development
• Packaging Standards
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• PFMEA
• Pre-launch Control Plan
• Measurement System Analysis Plan
• Packaging Specifications
Product and Process Validation
• Production Trial Run
• PPAP
• Production Control Plan
• Quality Planning Sign-off
QGS/ISO-TS-APQP 11
QGS/ISO-TS-APQP 12
Plan and Define
QGS/ISO-TS-APQP 13
MARKET RESEARCH
Team obtains data and information reflecting the voice of customer to
identify concerns, wants for translating into product process
characteristics. Can be in the form of
Customer interviews
Customer questionnaire and surveys
Market test and positioning reports
New product quality and reliability studies
Competitive product quality studies
Things Gone Right (TGR) reports
QGS/ISO-TS-APQP 14
Plan and Define (Cont’d.)
TEAM EXPERIENCE
The team may use other source of information such as:
Input from higher system level or past Quality Function Deployment (QFD) projects
Media commentary and analysis: magazine and newspaper reports, etc.
Customer letters and suggestions
TGR / TGW reports
Dealer comments
Fleet Operator’s comments
Field service reports
Internal evaluations using surrogate customers
Road trips
Management comments or direction
Problems and issues reported from internal customers
Government requirements and regulations
Contract review
QGS/ISO-TS-APQP 16
Plan and Define (Cont’d.)
QGS/ISO-TS-APQP 18
Plan and Define (Cont’d.)
CUSTOMER INPUTS
User of product provides valuable information relating to the needs and
expectations of customers. Additionally, user may have conducted
various studies and reviews on the product. Should be used to develop
agreed upon measures of customer satisfaction
DESIGN GOALS
A translation of the voice of customer into tentative and measurable
design objectives. Assures that voice of customer is not lost
RELIABILITY AND QUALITY GOALS
Reliability goals are established based on customer wants and
expectations, programme objectives and reliability benchmarks. Should
be expressed in terms of probability and confidence limits
Quality goals are targets based on continual improvement
QGS/ISO-TS-APQP 19
QGS/ISO-TS-APQP 22
Product Design and Development
Feasible design must permit meeting production volumes,
schedules, ability to meet engineering requirements with
quality, reliability, investment cost, weight, unit cost and timing
objectives
Design planning process to assure comprehensive and critical
review
QGS/ISO-TS-APQP 23
QGS/ISO-TS-APQP 24
Product Design and Development
Design for Manufacturability and Assembly
DFMA is a simultaneous engineering process to optimize the
relationship between design function, manufacturability and ease
of assembly
The scope of customer needs and expectations determine the
extent of the activity. The following shall be considered:
⌧Design, concept, function and sensitivity to manufacturing variation
⌧Manufacturing and / or assembly process
⌧Dimensional tolerances
⌧Performance requirements
⌧Number of components
⌧Process adjustments
⌧Material Handling
⌧Teams knowledge, experience, the product / process, government
regulations and service requirements are other factors
QGS/ISO-TS-APQP 25
QGS/ISO-TS-APQP 26
Product Design and Development
Design Review (Contd.)
Shall evaluate
⌧Design / Functional requirement(s) considerations
⌧Formal reliability and confidence goals
⌧Component / subsystem / system duty cycles
⌧Computer simulation and bench test results
⌧DFMEA(s)
⌧Review of the Design for Manufacturability and Assembly effort
⌧Design of Experiments (DOE) and assembly build variation results (Refer
to Appendix B)
⌧Test failures
⌧Design Verification progress
⌧A major function of design review is the tracking of design verification
progress
QGS/ISO-TS-APQP 27
QGS/ISO-TS-APQP 28
Product Design and Development
Engineering Drawings
Customer design do not preclude the responsibility to review the
following in the engineering drawings
⌧Special characteristics (Governmental, Regulatory and Safety)that must
be shown on the control plan
⌧In case customer drawings do not exist, review which characteristic affect
fit function durability and/or governmental, regulatory and safety
requirements
⌧Drawing should be reviewed to determine
• adequacy of informations for dimensional layout of the individual part
• control / datum services / locators clearly identified
• dimensional evaluation to assure feasibility and compatibility with
manufacturing and measuring standards
• In case of math data, it has two way communication compatibility
QGS/ISO-TS-APQP 29
QGS/ISO-TS-APQP 31
QGS/ISO-TS-APQP 34
Process Design and Development
Packaging Standard
Incorporate customer packaging standard into packaging
specifications for the product. If not provided packaging design
should ensure product integrity at point of use
Product / Process Quality System Review
Team should review the quality system. Additional controls /
procedural changes should be updated. Also an opportunity to
improve the existing quality system based on customer input,
team expertise, previous experience
QGS/ISO-TS-APQP 35
QGS/ISO-TS-APQP 37
QGS/ISO-TS-APQP 38
Process Design and Development
Pre-launch Control Plan
A description of the dimensional measurements, material and
functional tests that will occur after prototype and before full
production. Should include additional product / process controls to
be implemented until the production process is validated. The
purpose is to contain potential non-conformances during or prior
to initial production runs. Examples
⌧More frequent inspection
⌧More in-process and final check points
⌧Statistical evaluations
⌧Increased audits
QGS/ISO-TS-APQP 39
QGS/ISO-TS-APQP 41
QGS/ISO-TS-APQP 42
Process Design and Development
QGS/ISO-TS-APQP 43
QGS/ISO-TS-APQP 44
Process Design and Development
Management Support
The Product Quality Planning Team is required to schedule
the formal review designed to reinforce management
commitment at the conclusion of the process design and
development phase. The purpose of this review is to inform
upper management of program status and gain their
commitment to assist in resolution of any open issues
QGS/ISO-TS-APQP 45
QGS/ISO-TS-APQP 46
Product and Process Validation
Production Trial Run
The validation of the effectiveness of the manufacturing
process begins with the production trial run. The minimum
quantity for a production trial run is usually set by the customer
but can be exceeded by the Product Quality Planning Team.
Output of the production trial run (product) is used for:
⌧Preliminary process capability study
⌧Measurement system evaluation
⌧Final feasibility
⌧Process review
⌧Production validation testing
⌧Production part approval
⌧Packaging evaluation
⌧First time capability (FTC)
⌧Quality Planning sign-off
QGS/ISO-TS-APQP 47
QGS/ISO-TS-APQP 48
Product and Process Validation
Measurement Systems Evaluation
Evaluate the measurement devices and methods used to
check the characteristics specified in the Control Plan
Preliminary Process Capability Study
Perform preliminary process capability studies on the
characteristics specified in the control plan (Preliminary process
capability study plan). This assessment help to evaluate
process readiness for production
QGS/ISO-TS-APQP 49
QGS/ISO-TS-APQP 50
Product and Process Validation
Packing Evaluation
Assess the protection of the product from normal transportation
damages and adverse environmental factors. Use test
shipments & methods where feasible
Production Control Plan
A written description of the systems for controlling parts and
processes.
A living document and should be updated to reflect the addition
/ deletion of controls based on experience gained by producing
parts (Approval of the procuring organization(s) may be
required).
Logical extension of the pre-launch control plan.
Mass production provides the producer the opportunity to
evaluate output, review the control plan and make appropriate
changes.
QGS/ISO-TS-APQP 51
QGS/ISO-TS-APQP 53
QGS/ISO-TS-APQP 56
Feedback, Assessment and
Corrective Action
Customer Satisfaction
Detailed planning activities and demonstrated process capability
of a product or service do not always guarantee customer
satisfaction. The product or service must perform in the customer
environment. The product usage stage requires supplier
participation. It is in this stage where the most can be learned by
both the supplier and customer. The effectiveness of the Product
Quality Planning efforts can be evaluated in this stage. The
supplier and customer must be partners in making the changes
necessary to correct deficiencies to achieve customer satisfaction
QGS/ISO-TS-APQP 57
QGS/ISO-TS-APQP 58