Documente Academic
Documente Profesional
Documente Cultură
Day 1:
Introductions & Objectives
General Outline
ANPQP structure
Using ANPQP
Categories details 1,2,3 and 4
University challenge
Day 2:
Categories details 5,6,7,8,9,10 and 11
How to work with Nissan.
How to work with Renault.
University challenge
Expectation review.
Exam/course evaluation
2
Alliance New Product Quality Procedure
Day 1 Review
Review of Day 1
4
Review of Day 1
5
ANPQP Category 5
Category Purpose:
7
5 - Manufacturing Process Development
8
5 - Manufacturing Process Development
Timing:
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
5.1 Process Failure Mode
& Effects Analysis
5.2 Manufacturing
Process Design
5.3 Tooling, Gauges &
Facility Management
5.4 Process Capability
Study and Improvement
5.5 Confirmation of Full
Volume Conditions
5.6 Activities during
Ramp-up
5.7 Identification and
Traceability
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5 - Manufacturing Process Development
10
5 – Manufacturing Process Development
5.1 – Analysis of Process Potential Failures and Effects
Activity Purpose:
Identify potential process failure modes, their associated causes
and their effects
Implement effective countermeasures to minimize the probability
of failure occurring
Notes:
The supplier must consider historical concerns, recurrence prevention,
and customer satisfaction targets on assemblies and sub-assemblies /
components when deciding the scope of the activity
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5 – Manufacturing Process Development
5.1 – Analysis of Process Potential Failures and Effects
Renault Supplier
Nissan
Product Prepare PFMEA and relevant documents
Technical
Specifications
Review the PFMEA and
Identify Potential
Countermeasures
Confirm Countermeasure
Effectiveness
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5 – Manufacturing Process Development
5.1 – Analysis of Process Potential Failures and Effects
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5 – Manufacturing Process Development
5.1 – Analysis of Process Potential Failures and Effects
L M H L M H L M H L M H L M H
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5 - Manufacturing Process Development
15
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
Activity Purpose:
Design a manufacturing process to achieve all Renault / Nissan
Quality, Cost and Delivery targets.
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5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
PFMEA
ANALYSE How to control
How often to control MSA
Maintenance
MANAGE How to ensure control
What to do if out of control Non-Conformance
Procedure
DOCUMENT Record & communicate the
output of the above stages
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5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
Process Flowchart
Does the flowchart describe how the product will move i.e. roller
conveyor, slide containers, etc?
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5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
Does the floor plan identify all required process and inspection
points?
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5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
Control Plan
Have all the controls identified in the PFMEA been included in the
control plan?
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5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
Work Instructions
Have all key points/care points and the reasons for them been
included?
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5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
• Implementation:
P/S
P/S : to list the defects
According to PDCA principle,
D : to apply adapted protective solutio
integrate the priority defects, to standardize them
set up the protections,
standardize them, measure A MQA
D C : To check the robustness of the
applied solutions
their efficiency, correct.
C A : To improve the situation
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5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
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Manufacturing Process Design Exercise
Exercise type:
• Group (3-4 people)
Materials Required:
• Example documents for Control Plan, Process Flowchart, Floor Plan Layout &
work Instruction
• Flipchart & pens
Instructions:
• Analyse the documents provided to find errors.
• Categorise the errors found based on the 4 main stages of the process –
Identify, Analyse, Manage, Document.
• Each group should write their findings on a flipchart
• Review all groups findings together before revealing answer slides
• After answers are revealed, compare Floor Plan Layout example to DCI to
reinforce the purpose of the DCI.
Time Allowed:
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• 30-45 minutes
Manufacturing Process Design Exercise
The part:
MAST-Assy
( Tier2 Parts)
CASE-BODY Assy
( Tier2 Parts)
Assemble
PCB-Assy
( Tier2 Parts) Tier1 : AZ Electronics Company
ROOF-ANT Assy
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Manufacturing Process Design Exercise
L
What to control
IDENTIFY
Where to control
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Manufacturing Process Design Exercise
L
How to control
ANALYSE
How often to control
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Manufacturing Process Design Exercise
L
How to ensure control
MANAGE
What to do if out of control
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Manufacturing Process Design Exercise
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5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
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5 – Manufacturing Process Development
5.2 – Manufacturing Process Design
L M H L M H L M H L M H L M H
Matrix Quality
(2) (2) (2)
Assurance (MQA) (R)
Process Flow Chart
(2) (2) (2) 3 2 2 2 2 2
(PFC)
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5 - Manufacturing Process Development
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5 – Manufacturing Process Development
5.3 – Tooling, Gauges and Facility Management
Activity Purpose:
The supplier must manage all necessary equipment to ensure
that Renault / Nissan requirements are achieved and maintained.
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5 – Manufacturing Process Development
5.3 – Tooling, Gauges and Facility Management
Create a plan
Specify the related to the Implement Validate the
required procurement of the the plan equipment, tools,
Supplier
Sheet Sheet
Renault
Nissan
Review Review /
Technical
Approve
Specifications
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5 – Manufacturing Process Development
5.3 – Tooling, Gauges and Facility Management
L M H L M H L M H L M H L M H
Gauge Specification and
3 2 2 3 1 1
Approval Sheet (GSAS)
37
5 - Manufacturing Process Development
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5 – Manufacturing Process Development
5.4 – Process Capability Study and Improvement
Activity Purpose:
Evaluate, monitor and manage process capabilities in order to
continuously achieve Renault / Nissan targets.
Note:
All product shall be subjected to additional confirmation activities
until capability requirements are achieved
The supplier shall continuously monitor and reduce variation in both
product and manufacturing process characteristics.
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5 – Manufacturing Process Development
5.4 – Process Capability Study and Improvement
Process Process
Capability Capability
Study Plan Study Result
Renault/Nissan
Technical
Specifications Review Review
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5 – Manufacturing Process Development
5.4 – Process Capability Study and Improvement
Quality Target
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5 – Manufacturing Process Development
5.4 – Process Capability Study and Improvement
L M H L M H L M H L M H L M H
Process Capability Study
3 2 2
Plan (PCSP)
Process Capability Study
(2) 2 2 (2) 2 2 (2) (2) (2)
Results (PCSR)
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5 - Manufacturing Process Development
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5 – Manufacturing Process Development
5.5 – Confirmation of Full Volume Conditions
Activity Purpose:
Conduct a manufacturing trial to confirm that the process
achieves Renault / Nissan targets
Note:
Examples of manufacturing trial are:
– Run @ Rate trial
– significant production trial
– line speed demonstration
– T2000
– Capacity Audit
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5 – Manufacturing Process Development
5.5 – Confirmation of Full Volume Conditions
Supplier
Full Volume
Confirmation Audit
Results – Self Audit
Renault/Nissan
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5 – Manufacturing Process Development
5.5 – Confirmation of Full Volume Conditions
L M H L M H L M H L M H L M H
Full Volume
Confirmation Audit 3 3 3
Results (FVCAR)
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5 - Manufacturing Process Development
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5 – Manufacturing Process Development
5.6 – Activities During Ramp-up
Activity Purpose:
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5 – Manufacturing Process Development
5.6 – Activities During Ramp-up
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5 – Manufacturing Process Development
5.6 – Activities During Ramp-up
L M H L M H L M H L M H L M H
Ramp-up Activity
Concern and (2) (2) (2)
Countermeasure Report
50
5 - Manufacturing Process Development
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5 – Manufacturing Process Development
5.7 – Identification and Traceability
Activity Purpose:
To ensure that all products / parts are identified and controlled for
traceability purposes.
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ANPQP Category 6
Product Confirmation
6 - Product Confirmation
Category Purpose:
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6 - Product Confirmation
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6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation
Activity Purpose:
The supplier shall carry out:
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6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation
Inspection Report
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6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation
Test Details
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6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation
Engineering Product/Process
Development Results Design Verification Validation Results
(where applicable) Results (Off Tool) (Off Process)
Test Details
INSPECTION REPORT
Activity Purpose:
Part is grained
Raw material is mass production
Assembly line
Operators
Work Instructions
Toolings
Inspection facilities (gauges…)
Specific facilities (production facilities…)
Parameters / Process tuning
Full Capacity facilities
Cycle time
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6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation
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6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation
APPEARANCE APPROVAL
Activity Purpose:
Confirm that product meets Renault / Nissan appearance
requirements.
Obtain Appearance Approval from Renault / Nissan
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6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation
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6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation
L M H L M H L M H L M H L M H
Appearance Approval
(1) (1) (1)
Report (N)
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ANPQP Category 7
Category Purpose:
PPA
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7 - Production Part Approval
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7 - Production Part Approval
7.1 - Production Part Approval
Activity Purpose:
Confirm that product and mass production process meets
Renault/Nissan requirements
Obtain Production Part Approval from Renault / Nissan
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7 - Production Part Approval
7.1 - Production Part Approval
Start Mass
Supplier
Complete and
submit the PSW Identify reason Production
with all necessary for failure to
supporting achieve full
documentation approval
Review
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7 - Production Part Approval
7.1 - Production Part Approval
L M H L M H L M H L M H L M H
Part Submission
1 1 1
Warrant
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ANPQP Category 8
Category Purpose:
Implement a process that provides prompt and systematic activities
to:
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8 - Non Conforming Product Management
Activity:
Timing:
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8 - Non Conforming Product Management
8.1 - Non Conforming Product Management
Activity Purpose:
When non conforming product is identified, the supplier must have
a process that provides prompt and systematic activities to
identify the root cause of the concern, implement robust
countermeasures and prevent delivery of further suspect
product.
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8 - Non Conforming Product Management
8.1 - Non Conforming Product Management
Notification of
Concern Review
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8 - Non Conforming Product Management
8.1 - Non Conforming Product Management
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8 - Non Conforming Product Management
8.1 - Non Conforming Product Management
t0 t0 + t0 + t0 +
Incident claim sent
48Hours max 10Days max 30Days max
by RENAULT with
supplier admitted S S S
liability Olivier Nishimura-san
80 + 81 80 R R R
1 2 3 4 5 6 7 8
Initial Perma- Follow up
Concern Similar Part Temporary Final Action
Analysis nent action
Details Conside- Imediate analysis confirmati
(of non Action Standardiz
ration Action on
detection) ation
P D C A
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8 - Non Conforming Product Management
8.1 - Non Conforming Product Management EUR
Rank
A B
General Vehicle / Powertrain
Definition Important Product / Part Concern
Product / Part concern
Excluding items in Rank A, any
A concern on a Special product / part that is non-
Description
Characteristic conforming to the agreed
specification.
Fax / E-mail / Telephone Response required within Response required within
reply 24 hours 24 hours
Response required within Response required within
8D-CCR reply
30 days 30 days
Detailed root cause
Yes Yes
analysis required
Nissan Audit / Review Yes Depending upon concern
Supplier 8D-CCR
Yes Depending upon concern
presentation at Nissan
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8 - Non Conforming Product Management
8.1 - Non Conforming Product Management JPN
Supplier response requirements:
Rank
A B C
Damage for
Concern which has a
Concern relating to merchantability or
Judgment Criteria risk for Safety or
Safety or Regulation high dissatisfaction
Regulation
with customers
Fax/E-mail/Telephone
Within 24 hours Within 24 hours Not required
reply
Within 10 working Within 10 working Within 10 working
8D-CCR reply
days. days. days.
Depending upon Depending upon
Nissan Audit / Review Yes
concern concern
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8 - Non Conforming Product Management
8.1 - Non Conforming Product Management NA
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8 - Non Conforming Product Management
8.1 - Non Conforming Product Management
L M H L M H L M H L M H L M H
8D Concern and
Countermeasur e Report (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2)
Summary
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ANPQP Category 9
Change Management
9 - Change Management
Category Purpose:
Manage potential risks associated with changes to product, process
and/or facility site
Activities:
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9 - Change Management
86
9 - Change Management
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9 - Change Management
REMINDER
The supplier must inform Renault/Nissan and obtain agreement
about any change relative to its commitments, e.g. :
Product, material,
Process,
Control Plan, Gauges,
Facility site change/transfer/relocation,
Change within/to a tier n supplier (facility site change, resourcing,
including changes to sub-supplied services as heat treatment, …)
Delivery/loading site/warehouse change,
Organisation,
...
88
9 - Change Management
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9 - Change Management
90
9 – Change Management
9.1 - Design Change Management
Activity Purpose:
Manage the introduction of Design Changes in order to ensure that
there is no negative impact on quality, cost or delivery.
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9 – Change Management
9.1 - Design Change Management
Renault/Nissan Supplier
Review Design Change
Request Prepare and submit Design Change Request
Y
Y
Joint DR? Joint DR
Amend
Proposal? End
Approval?
Y
CAD Update and submit CAD data & associated
documents
Y
Approval ?
Y Design Note Implement activities required to introduce change
Release
D-Note Prepare and submit documents required for part
Part Submission
Warrant approval
Approval?
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9 – Change Management
9.1 - Design Change Management
L M H L M H L M H L M H L M H
Design Change Request
(1) (1) (1) (1) (1) (1) (1) (1) (1)
(DCR)
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9 - Change Management
94
9 – Change Management
9.2 – Process/Facility Site Change Request
Activity Purpose:
• To manage the introduction of Process / Facility Site changes in
order to ensure that there is no negative impact on quality, cost or
delivery.
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Process/Facility Site Change
Management Exercise
Exercise
Process / Facility Site Change Management
Exercise type:
• Group (4—6 people)
Materials required:
• Flipchart & pens
Instructions:
• In groups, make a list of the activites that should be done
before a change takes place and after a change takes place.
• Review all groups lists together before revealing the answer
slides
Time Allowed:
• ~20 minutes
97
Exercise
Process / Facility Site Change Management
98
Exercise
Process / Facility Site Change Management
100
9 – Change Management
9.2 - Process - Facility Site Change Request
Renault/Nissan Supplier
Review Process Change Prepare & submit Process/ Facility Site
Request Change request
Y
Determine Change
Contingency Reqmts Amend
Proposal? End
Y
Authorise supply of
Supply of post change product
post change product
101
9 – Change Management
9.2 - Process - Facility Site Change Request
L M H L M H L M H L M H L M H
Process/ Facility Site
(1) (1) (1)
Change Request
The supplier shall not carry out any facility site transfers between
the suppliers' initial "off-process" trials and SOP.
102
ANPQP Category 10
Category Purpose:
Implement Renault/Nissan specific requirements for logistics &
packaging
Notes:
- The documentation used to communicate the content of this activity
with Renault/Nissan is specific by each company.
- For detailed guidelines on specific requirements, see the "Other
Supply Requirement" on ASG (Alliance Supplier Guide))
104
10 – Logistics and Packaging
10.1 - Logistics and Packaging
Activity:
Timing:
105
10 – Logistics and Packaging
10.1 - Logistics and Packaging
What is purpose of the output from this activity?
– Validate Packaging & logistics capability to preserve Parts
quality.
106
ANPQP Category 11
Environemental Requirements
11 – Environmental Requirement
Activities:
Timing:
108
11 - Environmental Requirements
11.1 - Environmental Requirements
Activity Purpose:
To confirm that the supplied products conform with the
environmental regulations of each market.
Note:
IMDS ID nbr needs to report with Inspection Report
109
11 - Environmental Requirements
11.1 - Environmental Requirements
Principle of IMDS :
Successive sending of material and substances declarations:
① Request for Request for Request for ① Request for
declaration declaration declaration Declaration
③ Accept (or reject) Accept (or reject) Accept (or reject) ③ Accept (or reject)
the Declaration the Declaration the Declaration the Declaration
The Declaration are completed and implemented until the part is in its final definition.
Each Supplier can accept or reject the Declarations proposed by TIER N Suppliers
110
11 - Environmental Requirements
11.1 - Environmental Requirements
L M H L M H L M H L M H L M H
International Material
1 1 1
Data System (IMDS)
111
University Challenge
University Challenge
Exercise type:
• Group (half of class)
Materials required:
• Flipchart & pens
Instructions:
• Split the class into 2 teams.
• Each team must write down 5 questions about ANPQP that they want the other team
to answer on a flipchart.
• Once the questions are completed, hold a quiz with the Trainer as a referee. Trainer
to keep track of scores from day 1 and 2 to determine overall winner
Rules:
• Each team has 15 minutes to come up with 5 questions. The opposition team gets a
point for every question missing after 15 minutes.
• Swap questions and allow a further 5 minutes for revision before starting the quiz.
• If a team gets a question wrong, the other team gets a point unless they do not know
the correct answer to the question.
113
ANPQP in Action
ANPQP in Action
116
ANPQP Milestones vs. Nissan
Project Milestones
Vehicle Production Trial with
Issue of Spec. Off-Tool Parts to confirm
Part
Issue of RFQ
Tender achievement of Design targets
Submission
(S-Lot or V3P Process)
Warrant
118
ANPQP in Action
ANPQP in Action - Renault
120
ANPQP in Action - Renault
Product Supplier Test Plan & Reports
Product AMDEC
Definition
FTA
AFB / AFT Inspection Reports
122
The core team
Logistics representative
Examples of contributors :
123
Renault ANPQP management in Phase 4
ANPQP Phase 4
– The PDT Pilot through the ANPQP IS and the PSW Status report.
– The authorization to present the PSW is given by the PSW status Report at least and
at the latest before the PPC and MA Project Milestones.
– The Plant SQA manager (Or his deputy) of the Renault assembly/machining plant.
125
Basics
126
key points to approve a PSW
127
What status for the PSW for PPC?
To resume: Approved
PSW Status
Interim Approval Refused
At least 1 K10
ANPQP Outputs 100% K0 At least 1 K50
No K50
Authorized with
BOP Deliveries Authorized Not authorized
concessions
Vehicle / powertrain unit /
Saleable Saleable with concessions Not saleable
accessoiries saleable
128
THE KEY PRINCIPE : 1 approved PSW for each Part Reference,
Supplier site, Renault assembly/machining site.
ILN
International Logistic Network
Plant 1
Plant 2
PSW New validations ? Suppliers
signed recommendations ?
by the At least the following criteria are
PSW All criteria are taken SQA 1 reviewed:
signed by into account to Assembly/ Machining, Logistics
the SQA 1 approve the PSW. (DCL) and Capacity Level for the
PSW plant 2.
signed by
the SQA 2
129
Some particular cases : Main points
130
Summary
Training Objectives
132
Summary
133
ANPQP Training
Expectations Review