apqp tool for manufacturing trainingg.ppt

apqp tool for manufacturing training

1. ADVANCED
PRODUCT QUALITY
PLANNING
Presentation
by
MQS OFFICE
1

2. ADVANCED PRODUCT QUALITY
PLANNING
What this session is about ???...
•Introduction to APQP
•Fundamentals of Quality Planning
•Phases of APQP
•APQP Status Reporting Guideline
2

3. ADVANCED PRODUCT QUALITY
PLANNING
What this session is about ???...
•Introduction to APQP
•Fundamentals of Quality Planning
•Phases of APQP
•APQP Status Reporting Guideline
3

4. INTRODUCTION TO APQP
•What is APQP ?
•APQP is a structured method of
tracking, establishing &
improving the steps necessary to
assure that a product ( either
new or changed ) satisfies the
customer
4

5. APQP
Purpose of APQP :
•To facilitate communication with
all persons involved in a
programme & ensure that all
required steps are completed on
time, at acceptable cost &
quality level.
5

6. PRODUCT QUALITY PLANNING
Benefits :
•Drives resources
•Promotes early identification of required changes
•Avoids Delay in implementation of changes
•Provides quality product on time at the lowest cost
6

7. PRODUCT QUALITY PLANNING
CYCLE
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PLAN

8. ADVANCED PRODUCT QUALITY
PLANNING
What this session is about ???...
•Introduction to APQP
•Fundamentals of Quality Planning
•Phases of APQP
•APQP Status Reporting Guideline
8

9. 23 ELEMENTS OF APQP
•Sourcing Decision
•Customer Input Requirements
•Design FMEA
•Design Review(s)
•Design Verification Plan
•Subcontractor APQP status
•Facilities, Tools & Gages
•Prototype Build Control Plan
•Prototype Builds
•Drawings and Specifications
•Team Feasibility Commitment
•Manufacturing Process Flow
Chart
•Process FMEA
•Measurement Systems
Evaluation
•Pre-Launch Control Plan
•Operator Process Instructions
•Packaging Specifications
•Production Trial Run
•Production Control Plan
•Preliminary Process Capability
Study
•Production Validation Testing
•Production Part Approval(PSW)
•PSW Part Delivery at MRD
9
 Elements of APQP as defined in the guideline are,Elements of APQP as defined in the guideline are,

10. FUNDAMENTALS OF APQP
•Organise the Team :
•Assigning the responsibility to a Cross Functional Team
•Define the Scope
•Leader selection for overseeing the Planning Process
( Rotating Leader - Advantageous )
•Roles & Responsibilities of each area
•Identify customers - internal & external
•Define customer requirements
•Select the disciplines,team members, etc
10

11. FUNDAMENTALS OF APQP
•Define the Scope Contd…..
•Understand customer expectations
•Assess the feasibility of the proposed design,
performance and manufacturing process
•Identify cost, timing & constraints that must be
considered
•Determine assistance required from the customer
•Identify documentation process or method
11

12. 12
•Training
Success of Product Quality Plan is dependent
upon an effective training program.
Training program to address requirements and
skills development to fulfill customer needs and
expectations
Fundamentals of APQP

13. FUNDAMENTALS OF APQP
•Customer & Supplier Involvement
•Customer initiates
•Supplier manages
•Simultaneous Engineering :
•Process where CFT teams strive for a common goal
13

14. 14
• Control Plan :
Written descriptions of the systems for
controlling parts & processes. Plans cover three
different phases :
• Prototype
• Pre-launch
• Production
Fundamentals of APQP

15. ADVANCED PRODUCT QUALITY
PLANNING
What this session is about ???...
•Introduction to APQP
•Fundamentals of Quality Planning
•Phases of APQP
•APQP Status Reporting Guideline
15

16. PHASES OF APQP
•Plan & Define Programme
•Product Design & Development
•Process Design & Development
•Product & Process Validation
•Feedback, Assessment & Corrective Action
16

17. PRODUCT QUALITY PLANNING TIMING
CHART
17
FEEDBACK ASSESSMENT & CORRECTIVE ACTION
PROCESS DESIGN & DEVELOPMENT
PLANNING PLANNING
PRODUCTION
PRODUCT & PROCESS VALIDATION
PRODUCT DESIGN & DEV.
Concept
Initiation/
ApprovalProgramme
ApprovalPrototype Pilot Launch

18. 18
Plan & Define Programme
Objectives :
• To determine customer needs
• To plan a quality programme

19. PLAN & DEFINE PROGRAMME
Input :
•Voice of the Customer
•Market Research
•Historical Warranty and
Quality Information
•Team Experience
•Business Plan / Marketing
Strategy
•Product/Process
Benchmark Data
•Product / Process
Assumptions
•Product Reliability Studies
•Customer Inputs
Output :
•Design Goals
•Reliability & Quality Goals
•Preliminary Bill of Material
•Preliminary Process Flow
Chart
•Preliminary Listing of
Special Product & Process
Characteristics
•Product Assurance Plan
•Management Support
19

20. PLAN & DEFINE PROGRAMME
Input :
•Voice of the Customer
•Market Research
•Historical Warranty and
Quality Information
•Team Experience
•Business Plan / Marketing
Strategy
•Product/Process
Benchmark Data
•Product / Process
Assumptions
•Product Reliability Studies
•Customer Inputs
Output :
•Design Goals
•Reliability & Quality Goals
•Preliminary Bill of Material
•Preliminary Process Flow
Chart
•Preliminary Listing of
Special Product & Process
Characteristics
•Product Assurance Plan
•Management Support
20

21. PLAN & DEFINE PROGRAMME - INPUT
•Voice of Customer
•Market Research
•Customer Interview / Questionnaire
•Competitive Product Quality Studies
•Things Gone Right Reports
•Historical Warranty and Quality Information
•Things Gone Wrong Reports
•Problem Resolution Reports
•Customer Plant Returns & Rejections
•Field return product analysis
•Warranty reports
21

22. 22
Plan & Define Programme - Input
• Past QFD Projects
• Management Comments or Directions
• Dealer comments
• Government requirements and regulations

23. PLAN & DEFINE PROGRAMME - INPUT
Contd. …..
•Business Plan / Marketing Strategy :
It sets ‘Framework’ for Product Quality Plan
•Product / Process Benchmark Data :
Use of Benchmarking provides input for
‘Performance Targets’
23
BusinessBusiness PlanPlan
 TimingTiming

CostCost

ResourcesResources

InvestmentInvestment
Mktg. StrategyMktg. Strategy
 Target CustomerTarget Customer
 Key sales pointKey sales point
 Key CompetitorsKey Competitors

24. PLAN & DEFINE PROGRAMME - INPUT
•Product Reliability Studies
Frequency of repairs, replacement of
components and results of reliability /
durability tests are considered
24

25. 25
Contd. …..
• Customer Inputs
• Data collected from next user can be used as
inputs to arrive upon measures of customer
satisfaction
Plan & Define Programme - Input

26. PLAN & DEFINE PROGRAMME - OUTPUT
•Design Goals :
• Translate ‘Voice of Customer’ into tentative and
measurable design objectives
•Reliability & Quality Goals :
•Established based on customer wants & expectations,
programme objectives, reliability benchmarks
•Quality goals are targets based on continual improvements
i.e. PPM,defect levels or scrap reduction
26

27. PLAN & DEFINE PROGRAMME - OUTPUT
•Preliminary Bill of Material
•Established based on product/process assumptions
•Assist in identification of special characteristics
•Preliminary Process Flow Chart
•Description of anticipated mfg. process developed from
preliminary bill of material
27

28. PLAN & DEFINE PROGRAMME - OUTPUT
•Preliminary Listing of Special Product & Process
Characteristics
Team to ensure that the listing is developed from the following,
•Product assumptions based on the analysis of customer needs
and expectations.
•Identification of reliability goals/ requirements
•Identification of special process characteristics from the
anticipated manufacturing process
•Similar part FMEAs
28

29. 29
Special Characteristics
All products and processes have features
described by characteristics which are
important and need to be controlled.
However, some characteristics called
special characteristics require extra efforts
to minimise the risk of potential adverse
consequences.

30. 30
Special Characteristics
Special characteristics involve those
product and / or process characteristics that
affect vehicle safety, compliance with
government regulations, or customer
satisfaction. Special characteristics consist
of :
Critical Characteristics &
Significant Characteristics

31. 31
Special Characteristics
CRITICAL CHARACTERISTICS are those
product or process requirements that affect
• compliance with government regulation
• or safe vehicle / product function
Symbol :  or <CC>

32. 32
Special Characteristics
SIGNIFICANT CHARACTERISTICS are those
product, process, and / or test requirements which
are important for customer satisfaction
and
for which Quality Planning actions must be
summarised on a Control Plan.
Symbol : <SC>

33. PRODUCT QUALITY PLANNING TIMING
CHART
33
FEEDBACK ASSESSMENT & CORRECTIVE ACTION
PROCESS DESIGN & DEVELOPMENT
PLANNING PLANNING
PRODUCTION
PRODUCT & PROCESS VALIDATION
PRODUCT DESIGN & DEV.
Concept
Initiation/
Approval
Prototype Pilot Launch
Programme
Approval

34. 34
Objectives :
• To develop design features and
characteristics
• To critically review engineering
requirements
• To assess potential manufacturing
problems
Product Design & Development

35. PRODUCT DESIGN &
DEVELOPMENT
Output by Design
Responsible Activity
•Design FMEA
•DFMA
•Design Reviews
•Prototype Build - Control Plan
•Engineering Drawing
•Engineering Specifications
•Material Specifications
•Drawing & Specs.Changes
Output by APQP Team
•New Equipment, Tooling and
Facilities Requirements
•Special Product and Process
Characteristics
•Prototype Control Plan
•Gages/Testing Equipment
Requirements
•Team Feasibility
Commitment &
Management Support
35
Input : Input : Output of Planning Phase is Input for this phaseOutput of Planning Phase is Input for this phase

36. PRODUCT DESIGN &
DEVELOPMENT
Output by Design
Responsible Activity
•Design FMEA
•DFMA
•Design Reviews
•Prototype Build - Control Plan
•Engineering Drawing
•Engineering Specifications
•Material Specifications
•Drawing & Specs.Changes
Output by APQP Team
•New Equipment, Tooling and
Facilities Requirements
•Special Product and Process
Characteristics
•Prototype Control Plan
•Gages/Testing Equipment
Requirements
•Team Feasibility
Commitment &
Management Support
36
Input : Input : Output of Planning Phase is Input for this phaseOutput of Planning Phase is Input for this phase

37. PRODUCT DESIGN & DEVELOPMENT -
OUTPUT
•Design Failure Mode and Effects Analysis
•It is disciplined analytical technique to assess the probability
of failure & effect of such failure
•It is a living document continually updated
•A checklist for DFMEA is available for review
37

38. 38
Customer or Internal Part No._______________________________________
Yes NoComment/Action Required
Person
Responsible
Due
Date
1Was the System FMEA and/or DFMEA prepared
using the Chrysler, Ford and General Motors
Potential Failure Mode and Effects Analysis
(FMEA) reference manual?
2Have historical campaign and warranty data been
reviewed?
3Have similar part DFEMAs been considered?
4Does the SFMEA and/or DFMEA identify Special
Characteristics?
5Have design characteristics that affectbhigh risk
priority failure modes been identified?
6Have appropriate corrective actions been assigned to
high risk priority numbers?
7Have appropriate corrective actions been assigned to
high severity numbers?
8Have risk priorities been revised when corrective
actions have been completed and verified?
Revision Date __________
Prepared By
Question
DESIGN FMEA CHECKLIST
Page 1 of 1

39. 39
Product Design & Development - Output
• Design for Manufacturability & Assembly
(DFM)
It is a Simultaneous Engineering process
designed to optimise the relationship between
design function, manufacturability and ease of
assembly. Team to consider the following:
• Design, concept, function and sensitivity to
manufacturing variation
• Dimensional tolerances
• Process Adjustments
• Material Handling
• Performance requirements
• Manufacturing and/ or assembly process
• Number of components etc.

40. PRODUCT DESIGN & DEVELOPMENT -
OUTPUT
•Design Verification
Verifies that the product design meets the customer
requirements
40

41. 41
Product Design & Development - Output
• Design Reviews Contd…..
Design Reviews should include evaluation of
• Design/ Functional requirement considerations
• Formal reliability and confidence goals
• Component/ subsystem/ system duty cycles
• Computer simulation and bench test results
• DFMEAs
• Review of DFMA
• Design of Experiment (DOE) results
• Test failures
• Design Verification progress
A major function of Design Reviews is tracking of design
verification progress through DVP & R (Design
Verification Plan & Report)

42. PRODUCT DESIGN & DEVELOPMENT -
OUTPUT
•Prototype Build - Control Plan
•Is description of dimensional measurements & material
and functional tests that will occur during prototype build
•Provides opportunity to evaluate how well product meets
Voice of Customer objectives
42

43. 43
Product Design & Development - Output
• Engineering Drawings
Reviewed to determine
• that drawings have sufficient information for
a dimensional layout of individual parts.
• that drawings have identification for control
or datum surfaces.
• which characteristics affect fit, function,
durability and safety requirements
Dimensions are evaluated
• to assure feasibility & compatibility with
manufacturing and measuring standards

44. PRODUCT DESIGN & DEVELOPMENT -
OUTPUT
•Engineering Specifications
•Reviewed to identify functional, durability & appearance
requirements.
•Sample size, frequency & acceptance criteria are generally
defined in the in-process test section of Engineering
Specifications (otherwise listed in control plan).
•Material Specifications
•These should be reviewed for Special Characteristics
related to physical properties, performance, environmental,
handling, and storage requirements.
44

45. PRODUCT DESIGN & DEVELOPMENT -
OUTPUT
•Drawing and Specification Changes
•Team to ensure prompt documentation &
communication to affected areas
45

46. 46
Product Design & Development - Output
Customer or Internal Part No._______________________________________
Yes NoComment/Action Required
Person
Responsible
Due
Date
A. General
Does the design require:
1 New materials?
2 Special tooling?
3Has assembly build variation analysis been
considered?
4Has Design of Experiments been considered?
5Is there a plan for prototypes in place?
6Has a DFMEA been completed?
7Has a DFMA been completed?
8Have risk priorities been revised when corrective
actions have been completed and verified?
9Has the Design Verification Plan been completed?
10If yes, was it completed by a cross functional team?
11Are all specified tests, methods, equipment and
acceptance criteria clearly defined and understood?
12Have Special Characteristics been selected?
13Is bill of material complete?
14Are Special Characteristics properly documented?
Revision Date __________
Prepared By
DESIGN INFORMATION CHECKLIST
Question
Page 1 of 4

47. PRODUCT DESIGN &
DEVELOPMENT - OUTPUT
47
Customer or Internal Part No._______________________________________
Yes NoComment/Action Required
Person
Responsible
Due
Date
B. Engineering Drawings
15Have dimensions that affect fit, function and durability
been identified?
16Are reference dimensions identified to minimise
inspection layout time?
17Are sufficient control points and datum surfaces
identified to design functional gages?
18Are tolerance compatible with accepted
manufacturing standards?
19Are there any requirements specified that cannot be
evaluated evaluated using known inspection
techniques?
C.Engineering Performance specifications
20Have all Special Characteristics been identified?
21Is test loading sufficient to provide all conditions, I.e.,
production validation and end use?
Contd….
D. Material Specification
28Are special material chracteristics identified?
29Are specified materials, heat treatment and surface
treatments compatible with durability requirements in
the identified environment?
Contd…. Revision Date __________
Prepared By
DESIGN INFORMATION CHECKLIST
Question
Page 2 of 4

48. PRODUCT DESIGN &
DEVELOPMENT
Output by Design
Responsible Activity
•Design FMEA
•DFMA
•Design Reviews
•Prototype Build - Control Plan
•Engineering Drawing
•Engineering Specifications
•Material Specifications
•Drawing & Specs.Changes
Output by APQP Team
•New Equipment, Tooling and
Facilities Requirements
•Special Product and Process
Characteristics
•Prototype Control Plan
•Gages/Testing Equipment
Requirements
•Team Feasibility
Commitment &
Management Support
48
Input : Input : Output of Planning Phase is Input for this phaseOutput of Planning Phase is Input for this phase

49. PRODUCT DESIGN & DEVELOPMENT -
OUTPUT
•New Equipment, Tooling & Facilities Requirements
•Team addresses identified reqmts. of above by adding the
items to the Timing Chart
•Also capability and availability of the same to be ensured
by the team
•Facilities progress should be monitored to assure
completion to plan
49

50. 50
Product Design & Development - Output
Customer or Internal Part No._______________________________________
Yes NoComment/Action Required
Person
Responsible
Due
Date
Has tool and equipment design provided for:
1 Flexible system, e.g. cell mfg.?
2 Quich change?
3 Volume fluctuations?
4 Mistake Proofing?
Have lists been prepared identifying:
5 New Equipment?
6 New tooling?
7 New test equipment?
Has acceptance criteria been agreed upon for:
8 New Equipment?
9 New tooling?
10 New test equipment?
11Willa preliminary capability study be conducted at
the tooling and/or equipment manufacturer?
12Has test equipment feasibility and accuracy been
established?
13Is a preventive maintenace plan complete for
equipment and tooling?
14Are setup instructions for new equipment and tooling
complete and understandable?
Contd….
Revision Date __________
Prepared By
NEW EQUIPMENT, TOOLING AND TEST EQUIPMENT CHECKLIST
Question
Page 1 of 2

51. 51
Product Design & Development - Output
• Special Product & Process Characteristics
Team to build on list of preliminary special
product and process characteristics identified in
Phase I and reach consensus through the
evaluation of technical information.
These are documented on appropriate Control
Plans
• Gauges/Testing Equipment Requirements
These are identified and requirements added to
the Timing Chart

52. PRODUCT DESIGN & DEVELOPMENT -
OUTPUT
•Team Feasibility Commitment and Management Support
•In this phase, feasibility of the proposed design is assessed.
The team must be satisfied that proposed design can be
manufactured, assembled, tested, packaged and
delivered in sufficient quantity at an accepted cost to
customer on schedule
•The team consensus on feasibility should be documented
along with all open issues that require resolution and
management support
52

53. PRODUCT QUALITY PLANNING TIMING
CHART
53
FEEDBACK ASSESSMENT & CORRECTIVE ACTION
PROCESS DESIGN & DEVELOPMENT
PLANNING PLANNING
PRODUCTION
PRODUCT & PROCESS VALIDATION
PRODUCT DESIGN & DEV.
Concept
Initiation/
Approval
Prototype Pilot Launch
Programme
Approval

54. 54
Objectives :
• To develop a comprehensive and
effective manufacturing system
• To ensure that the manufacturing
systems meets customer requirements
Process Design & Development

55. PROCESS DESIGN AND DEVELOPMENT
•Packaging Standards
•Product/Process Quality
System Review
•Process Flow Chart
•Floor Plan Layout
•Characteristics Matrix
•Process failure Mode &
Effects Analysis
•Pre-Launch Control Plan
•Process Instructions
•Measurement Systems
Analysis Plan
•Preliminary Process
Capability Study Plan
•Packaging
Specifications
•Management Support
55
Outputs :Outputs :
Inputs :Inputs : Outputs of Product Design & Development Outputs of Product Design & Development
phase are inputs for this phasephase are inputs for this phase

56. PROCESS DESIGN AND DEVELOPMENT
•Packaging Standards
•Packaging design to ensure product integrity at the point
of use
•Product / Process Quality System Review
•Team reviews Quality System Manual of the
manufacturing location & updates for additional
controls/ procedural changes required for the product
56

57. PROCESS DESIGN AND DEVELOPMENT
•Process Flow Chart
•It is a schematic representation of the proposed Process
Flow
•It is useful in,
•analysing total process rather than individual steps in the
process
•conducting PFMEA &
• designing Control Plans
57

58. PROCESS DESIGN AND DEVELOPMENT
•Floor Plan Layout
•Developed and reviewed to determine acceptability of
inspection points, control chart location, applicability of
visual aids, interim repair stations & storage areas to
contain defective material.
58

59. 59
Product Design & Development - Output
Customer or Internal Part No._______________________________________
Yes NoComment/Action Required
Person
Responsible
Due
Date
1Does the flow chart illustrate the sequence of
production and inspection stations?
2Were all the appropriate FMEAs (SFMEA,
DFMEA) available and used as aids to develop the
process flow chart?
3Is the flow chart keyed to product and process
checks in the control plan?
4Does the flow chart describe how the product will
move, i.e., roller conveyor, slide containers,etc.?
5Has the pull system/optimisation been considered for
this process?
6Have provisions been made to identify and inspect
reworked products before being used?
7Have potential quality problems due to handling and
outside processing been identified and corrected?
Revision Date __________
Prepared By
PROCESS FLOW CHART CHECKLIST
Question
Page 1 of 1

60. PROCESS DESIGN AND DEVELOPMENT
•Process Failure Mode & Effect Analysis
•Conducted during product quality planning & before
production
•It is a disciplined review & analysis of a new/ revised
process to assess the probability of failure & effect of
such failure
•It is a living document continually updated
•A checklist for PFMEA is available for review
60

61. PROCESS DESIGN AND DEVELOPMENT
•Pre-Launch Control Plan
•It is description of dimensional measurements & material
and functional tests that will occur after prototype &
before full production
•Includes additional product/ process controls until
validation of production process
•Purpose is to contain potential non-conformances
during or prior to initial production runs such as, more
frequent inspection, more in-process check points,
statistical evaluations, increased audits etc.
61

62. PROCESS DESIGN AND DEVELOPMENT
•Process Instructions
•Team to ensure that understandable process instructions
provide sufficient detail for all operating personnel
•These instructions should be developed from
•FMEAs, Control Plans, Engg. Drawings, Process Flow Charts,
Handling Requirements etc.
•It should be posted
•It should include set-up parameters such as machine
speeds, feeds, cycle time etc.
•It should be accessible to operators & supervisors
62

63. PROCESS DESIGN AND DEVELOPMENT
•Measurement System Analysis Plan
•The Plan should ensure responsibility for ensuring gauge
linearity, accuracy, repeatability, reproducibility &
correlation for duplicate gauges
•Preliminary Process Capability Study Plan
•Characteristics identified in control plan are the basis for
preliminary process capability study plan
63

64. PROCESS DESIGN AND DEVELOPMENT
•Packaging Specification
•Individual product packaging is designed and
developed
•Packaging to maintain product quality during
packing,transit and unpacking
•Should also have compatibility with material handling
equipment
64

65. 65
Process Design and Development
• Management Support
Formal review at the conclusion of this phase to
inform management of programme status and
gain their commitment in resolution of any open
issues

66. PRODUCT QUALITY PLANNING TIMING
CHART
66
FEEDBACK ASSESSMENT & CORRECTIVE ACTION
PROCESS DESIGN & DEVELOPMENT
PLANNING PLANNING
PRODUCTION
PRODUCT & PROCESS VALIDATION
PRODUCT DESIGN & DEV.
Concept
Initiation/
Approval
Prototype Pilot Launch
Programme
Approval

67. 67
Objectives :
• To validate the manufacturing process
• To ensure that customer expectations
will be met
• To identify additional concerns
Product and Process Validation

68. PRODUCT AND PROCESS
VALIDATION
Outputs:
•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
& Management Support
68
Inputs :Inputs : Outputs of Process Design & Development Outputs of Process Design & Development
phase are Inputs for this phasephase are Inputs for this phase

69. PRODUCT AND PROCESS
VALIDATION
•Production Trial Run
•Must be conducted using production tooling, equipment,
environment, facility and cycle time
•Team to decide min. quantity for trial run
•Results of this are used for,
•Preliminary Process Capability Study, Measurement Systems
Evaluation, Final Feasibility, Process Review, Production
Validation Testing, Production Part Approval, Packaging
Evaluation, First Time Capability and Quality Planning Sign-off
69

70. PRODUCT AND PROCESS
VALIDATION
•Measurement System Evaluation
•Specified measurement devices & methods should be used
for the respective characteristics.
•The devices be evaluated during or prior to the production
trial run
•Preliminary Process Capability Study
•It provide assessment of the readiness of the process for
production
70

71. PRODUCT AND PROCESS
VALIDATION
•Production Part Approval
•It is validation of product made from production tools &
processes meeting engineering requirements
•Production Validation Testing
•It is similar to Production Part Approval but the validation
is through engineering tests
71

72. 72
Product and Process Validation
•
Packaging Evaluation
Test methods & where feasible test shipments
must assess the protection of the product from
normal transportation damage and adverse
environmental factors

73. PRODUCT AND PROCESS
VALIDATION
•Production Control Plan
•It is a written description of the systems for controlling
parts and processes
•It is logical extension of pre-launch control plan
•It is a living document
•It is updated based on experience gained
•Mass production provides opportunity to evaluate output
& revise the control plan
73

74. PRODUCT AND PROCESS
VALIDATION
•Quality Planning Sign-off
•Team to ensure that all control plans & process flow charts
are being followed by reviewing at the manufacturing
locations
•A review of the following is required prior to the first
shipment
• Control Plans
• Process Instruction
• Gauge & Test Equipment
•A formal sign-off is done
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75. PRODUCT QUALITY PLANNING TIMING
CHART
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FEEDBACK ASSESSMENT & CORRECTIVE ACTION
PROCESS DESIGN & DEVELOPMENT
PLANNING PLANNING
PRODUCTION
PRODUCT & PROCESS VALIDATION
PRODUCT DESIGN & DEV.
Concept
Initiation/
Approval
Prototype Pilot Launch
Programme
Approval

76. FEEDBACK, ASSESSMENT & CORRECTIVE ACTION
Outputs :
•Reduced Variation
•Customer Satisfaction
•Delivery and Service
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Inputs :Inputs : Outputs of Product & Process Outputs of Product & Process
Validation phase are Inputs for this phaseValidation phase are Inputs for this phase

77. FEEDBACK, ASSESSMENT & CORRECTIVE ACTION
•Reduced Variation
•Identification of Process Variation using ‘Control Charts’
& ‘Statistical Techniques’
•Analysis & Corrective Actions
•Continuous Improvement reducing ‘Special’ as well as
‘Common’ Causes of Variation
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78. ADVANCE PRODUCT QUALITY
PLANNING
What this session is ???…...
•Introduction to APQP
•Fundamentals of Quality Planning
•Phases of APQP
•APQP Status Reporting Guideline
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79. APQP STATUS REPORTING GUIDELINE
What is APQP Status Reporting Guideline ?
This is a specific guideline evolved based on
APQP disciplines
Objectives of the guideline is to,
•Reinforce APQP as the basis of quality planning
•Develop a ‘Program Status Reporting Format’ for
APQP evaluation
•Link APQP evaluation process to Vehicle
Development Programme
•Define ‘Roles & Responsibilities’ for concerned
personnel involved in APQP Process
•Make APQP procedures common for suppliers & in-
house manufacturing / assembly operations
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80. 80
Date:
Review No.:
Diamond Point:
Supplier Program
Location Model Year
Supplier Code Lead Part No.
Risk Assessment Part Name
New: Site Technology Process Eng. Level
User Plant(s)
Team Members Company/Title Phone/Fax
Build Level Material Quantity P.I.P.C.
No.
SC's
No.
CC's %
SupplierClosedResp.
Element NeedTimingDateEngineer
Rating DateDate Initials
1) Sourcing Decision
2) Customer Input Requirements
3) Design FMEA
4) Design Review(s)
5) Design Verification Plan
6) Subcontractor APQP Status
7) Facilities, Tools and Gages
8) Prototype Build Control Plan
9) Prototype Builds
10) Drawings and Specifications
11) Team Feasibility Commitment
12) Manufacturing Process Flow Chart
13) Process FMEA
14) Measurement Systems Evaluation
15) Pre-Launch Control Plan
16) Operator Process Instructions
17) Packaging Specifications
18) Production Trial Run
19) Production Control Plan
20) Preliminary Process Capability Study
21) Production Validation Testing
22) Production Part Approval (PSW)
23) PSW Part Delivery at MRD
COMMENTS
Status
APQP Elements GYR Focus
APQP Status Report Format
Remarks
Other Risks
No.of
P.I.S.T. %Required Date

81. APQP ELEMENTS DESCRIPTION & EXPECTATIONS
•Sourcing Decision
•It is a formal customer commitment to work with the
supplier on the programme
•It is expected that sourcing decision is completed &
communicated to the supplier before the Programme
Need Date
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82. •Customer Input Requirements
•Design Goals
• are translation of Voice of Customer into tentative &
measurable design objectives
•Initial system & component design and specifications
including
• product assumptions, functional performance, dimensions,
weight & materials
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83. APQP ELEMENTS DESCRIPTION & EXPECTATIONS ( CONTD. )
•Customer Input Requirements Contd...
•Reliability & Quality Goals
•TGR, TGW, Life Reliability Targets, Warranty Targets,
Incoming Quality Targets
•Programme Timing :
•It is a plan that lists tasks, assignments, events & timing
required to provide a product that meets customer needs
& expectations.
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84. APQP ELEMENTS DESCRIPTION & EXPECTATIONS CONTD.
•Subcontractor APQP Status
•A summary of APQP status of suppliers
•Cascading of this process is required
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85. APQP ELEMENTS DESCRIPTION & EXPECTATIONS CONTD.
•PSW at Part Delivery at MRD
•Latest date that fully approved PSW material to be
received at customer’s plant for trial run
•Customer’s material MRD must be included in the
supplier’s timing plan
•Production Part Approval requirements must be
completed prior to user plant MRD
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86. ADVANCE PRODUCT QUALITY
PLANNING
THANKS
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