Advanced Product Quality Planning
oncept
!nitiation "
Approval
Program
Approval
Prototype
Planning
#esign $ #evelopment
Planning
Pilot
Product
Process
aunch
%alidation Product " Process
Production
&eed'ac Assessment $ orrective Action
Plan $
#efine
Program
Product
Process Product $
#esign $ #esign $ Process
%alidation
#ev.
#ev.
%erification %erification
A!A* APQP $ trl Plan +eference *uide, Page -
•
A structured method of defining the steps (process) necessary to assure that a
product satisfies the customer
•
The goal of APQP is to facilitate communication with everyone involved to
ensure that all required steps are completed on time.
•
Effective APQP depends upon top management commitment and support to
assure that customer satisfaction is achieved
1
Advanced Product Quality Planning
Phase/ !nputs $ 0utputs
• %oice of the ustomer
1 2aret +esearch
1 3istorical 4arranty and Quality
!nformation
1 Team E5perience
• 6usiness Plan and 2areting
7trategy
Phase 1
•
#esign *oals
•
+elia'ility and Quality *oals
•
Preliminary 6ill of 2aterial
•
Preliminary Process &low hart
•
Preliminary isting of 7pecial
Product and Process
haracteristics
•
Product Assurance Plan
•
2anagement 7upport
• Product8Process 6enchmar #ata
• Product8Process Assumptions
• Product +elia'ility 7tudies
• ustomer !nputs
• 7ervice
Phase 2
• 0utputs 'y #esign
+esponsi'le Activity
• #esign &2EA
• #&2 and #&A
• 0utputs 'y Advanced
Product Quality
Planning Team
1#esign for 2anufactura'ility
1#esign for Assem'ly
• #esign %erification
• #esign +eviews
• Prototype 6uild ontrol Plan
•
Pacaging 7tandards
•
Product 8 Process Quality 7ystem +eview
•
Process &low hart
• 2aterial 7pecifications
•
&loor Plan ayout
• #rawing and 7pecification hanges
•
haracteristics 2atri5
•
Process &ailure 2ode and Effects
Analysis
•
Pre"aunch ontrol Plan
•
Process !nstructions
•
2easurement 7ystems Analysis Plan
•
Preliminary Process apa'ility 7tudy Plan
•
Pacaging 7pecifications
• Engineering #rawings (including 2ath data)
• Engineering 7pecifications
Phase 3
•
9ew equipment, tooling and
facilities requirements
•
7pecial product and process
characteristics
•
*age and testing equipment
requirements
•
Team feasi'ility commitment
and management support
•
7u'contractor 'uild
•
7upplier 'uild
Thin Critical Paths
2
Advanced Product Quality Planning
!nputs 8 0utputs " Phase :
Phase 1 Inputs
• %oice of the ustomer
Phase 1 Outputs (= Phase 2 Inputs)
; 2aret +esearch
; 3istorical 4arranty and Quality
!nformation
• #esign *oals
• +elia'ility and Quality *oals
; Team E5perience
• Preliminary 6ill of 2aterial
• 6usiness Plan and 2areting
7trategy
• Product8Process 6enchmar
#ata
• Preliminary Process &low hart
Phase 1
• Preliminary isting of 7pecial
Product and Process haracteristics
• Product8Process Assumptions
• Product Assurance Plan
• Product +elia'ility 7tudies
• 2anagement 7upport
• ustomer !nputs
• 7ervice
3
Advanced Product Quality Planning
!nputs 8 0utputs " Phase <
• #esign &2EA
• #&2 and #&A
Phase 1 Outputs
(Phase 2 Inputs)
• #esign *oals
• +elia'ility and Quality
*oals
• Preliminary 6ill of
2aterial
• Preliminary Process
&low hart
• Preliminary isting of
7pecial Product and
Process haracteristics
Phase 2
Phase 2 Outputs
(Phase
3 Inputs)
• 0utputs
'y
#esign
+esponsi'le
Activity
• 0utputs 'y
Advanced
Product Quality
Planning Team
1#esign for
2anufactura'ility
1#esign for Assem'ly
• #esign %erification
• #esign +eviews
• Prototype 6uild ontrol Plan
• Engineering #rawings (including
2ath data)
• Engineering 7pecifications
• 2aterial 7pecifications
• #rawing and 7pecification
hanges
• Product Assurance Plan
• 9ew equipment, tooling and
facilities requirements
• 2anagement 7upport
• 7pecial product and process
characteristics
• *age and testing equipment
requirements
• Team feasi'ility commitment
and management support
• 7u'contractor 'uild
• 7upplier 'uild
4
Advanced Product Quality Planning
!nputs 8 0utputs " Phase =
Phase 2 Outputs (Phase 3 Inputs)
• 0utputs 'y #esign
+esponsi'le Activity
Phase 2 Design
Activity Outputs
• 0utputs 'y Advanced Product
Quality Planning Team
• #esign &2EA
• #&2 and #&A
• 9ew equipment, tooling and
facilities requirements
1#esign for 2anufactura'ility
1#esign for Assem'ly
• 7pecial product and process
characteristics
• #esign %erification
• #esign +eviews
Phase 3
• Prototype 6uild ontrol Plan
• *age and testing equipment
requirements
• Team feasi'ility commitment
and management support
• Engineering #rawings (including
2ath data)
• Phase 3 Outputs
• Engineering 7pecifications
• (Phase 4 Inputs)
• 2aterial 7pecifications
• #rawing and 7pecification hanges
Phase 2 APQP
Tea Outputs
•
Pacaging 7tandards
•
Product 8 Process Quality 7ystem +eview
•
Process &low hart
•
&loor Plan ayout
•
haracteristics 2atri5
•
Process &ailure 2ode and Effects Analysis
•
Pre"aunch ontrol Plan
•
Process !nstructions
•
2easurement 7ystems Analysis Plan
•
Preliminary Process apa'ility 7tudy Plan
•
Pacaging 7pecifications
• 7u'contractor 'uild
• 7upplier 'uild
5
Advanced Product Quality Planning
!nputs 8 0utputs " Phase >
Phase 3 Outputs
(Phase 4 Inputs)
• Pacaging 7tandards
Phase 4 Outputs
• Product 8 Process Quality
7ystem +eview
(Phase ! Inputs)
• Production Trial +un
• Process &low hart
• 2easurement 7ystems
Evaluation
• &loor Plan ayout
• haracteristics 2atri5
• Process &ailure 2ode and
Effects Analysis
• Preliminary Process apa'ility
7tudy
• Pre"aunch ontrol Plan
• Production Part Approval
(PPAP)
• Process !nstructions
• Production %alidation Testing
• 2easurement 7ystems
Analysis Plan
• Pacaging Evaluation
• Preliminary Process apa'ility
7tudy Plan
• Quality Planning 7ign"off
Phase 4
• Production ontrol Plan
• Pacaging 7pecifications
6
Advanced Product Quality Planning
!nputs 8 0utputs " Phase Phase 4 Outputs
(Phase ! Inputs)
• Production Trial +un
• 2easurement 7ystems
Evaluation
Phase ! Outputs
• Preliminary Process apa'ility
7tudy
• Production Part Approval
(PPAP)
• +educed %ariation
Phase !
• ustomer 7atisfaction
• #elivery and 7ervice
• Production %alidation Testing
• Pacaging Evaluation
• Production ontrol Plan
• Quality Planning 7ign"off
7
Advanced Product Quality Planning
%oice of the ustomer
•
E5ternal and
!nternal
ustomers
•
7tated, +eal and
Perceived
9eeds
•
ultural 9eeds
•
?nintended
?ses
•
&unctional
9eeds vs.
Technical
&eatures
8
Advanced Product Quality Planning
2aret +esearch
•
•
ustomer
interviews
ustomer
questionnaires
and surveys
•
2areting test and
positioning reports
•
9ew product
quality and
relia'ility studies
•
ompetitive
product quality
studies
•
@Things *one
+ight reports
Things -&ne %ight
The following is a list of vehicle features. Please read the entire list and place
an B ne5t to those features of your new vehicle that you Particularly "i#e$
%&& ' C&&rt
Interi&r Appearance
&ront +oom
&ront 7eat omf ort
Entry $ E5it f rom &ront
argo apacity
argo loading, unloading
*teri&r Appearance
7eat Appearance
!nstrument Panel
#oor Panels
arpeting
+an,ling
&ront %iew
7ide %iew
+ear %iew
Paint
2oldings
Advanced Product Quality Planning
3andling on 3ighway
3andling in ity , Paring
%isi'ility in +ear
7teering
6raes
9
3istorical 4arranty and Quality !nformation
•
@Things gone
4rong reports
Things -&ne .r&ng
Tell us a'out any trou'les you have had with the vehicle. 2ar a B in each
'o5 ne5t to any item you have had trou'le with.
•
4arranty reports
•
apa'ility
indicators
•
7upplier plant
internal quality
reports
•
Pro'lem
/teering ' +an,ling
resolution reports
7teering noisy
•
ustomer plant
returns and
reCections
•
&ield return
product analysis
*teri&r Paint
Paint mist or soray ov er 'ody f inish
olor dif f e rence 'et ween 'ody panels
?nev en color on one 'ody panel
Paint ot tape s tripes com ing of f , mis sing
+ust, corrosion
0ther paint trou'les. Please descri'e.
hipped paint
7cratched paint
7ags, runs in paint
# irt in paint
6ody paint on moldings, ornaments
7teering requires high or unev en ef f ort
onstant pull to one side
%ehicle v i'rates at speeds
6elow >- 2P3
A'ov e >- 2P3
7teering wheel spoes not correct ly positioned when f ront wheels st reight
0ther steering and handling pro'lems. Please descri'e.
Advanced Product Quality Planning
10
6usiness Plan " 2areting 7trategy
• &ramewor for quality plan
• 2ay place constraints on timing, cost, investment,
positioning, +$# resources
• 7trategy defines target customer, ey sales points,
ey competitors
• 740T
17trengths
14eanesses
10pportunities
1Threats
• 0ld vs. 9ew
13ow deep and how far to go
Advanced Product Quality Planning
11
Product " Process 6enchmar #ata
• A requirement of Q7 D para. >.:
• Provides inputs to esta'lish performance targets
• 2ust address ey process(es)
• 2ust 'e measura'le
• 2ethods for successful 'enchmaringF
1!dentify appropriate 'enchmar(s)
1&ind reason for gap 'etween your status and 'enchmar
1#evelop a plan for closing gap, meeting or e5ceeding
'enchmar
Advanced Product Quality Planning
12
Product " Process Assumptions
• Assumptions
1&eatures
1#esign
1Process concepts
1Technical innovations
1Advanced materials
1+elia'ility assessments
19ew technology
• #ocument assumptions as part of proCect plan
• ?tiliGe as inputs to plan
• onsider alternate paths in case assumptions do not
play out
Advanced Product Quality Planning
13
Product +elia'ility 7tudies
• &requency of repairs or replacements within
designated time period(s)
1+epair or Throw"awayH
1+? evel (ine +eplacea'ility ?nit)
• ong range relia'ility and8or dura'ility tests
• 7tudies can 'e %E+I costly and lengthy
1E#TP (Environmental #esign riteria Test Plan)
ailures
Ma
r
k
e
t
Sh
a
r
e
Duraility
0T% = 0ean Tie eteen %eplaceent
0TO = 0ean Tie eteen Overhaul
0T = 0ean Tie eteen ailures
14
Advanced Product Quality Planning
ustomer !nputs
• 9e5t users provide information a'out
needs and e5pectations
• Possi'ility of previous conducted
reviews and studies
• ?sed to develop measure of customer
satisfaction
Advanced Product Quality Planning
15
!nter"+elationships
Q&#
usiness
Quality
O5ectives
Process
!mprovemen
t
Q07
J"#
7P
Tools
Pr&le
/&lving
ontrol
Plan
#0E
&2EA
7pecial 8 ritical
haracteristics
Pr&le
Preventi&n
&TA
+&TA
APQP
ustomer 7pecified
7pecial 8 ritical
haracteristics
Advanced Product Quality Planning
16
+elationships
ustomer
+equirements
#&2EA
P&2EA
ontrol Plan
4arrant
PPAP
onceptual
7tructural
4arrant 7ample
Product ondition
Time
Advanced Product Quality Planning
17
Typical Automotive Trilogy #evelopment
APQP Tieline
Pr&cess l& Diagra
(Inclu,es A"" Pr&cesses)
Pr&cess 0A
(On A"" Pr&cesses)
CC 0atri*
Critical Characteristics
' ailure ects Issues
Pr&cess C&ntr&l Plan
(Critical Pr&cesses r& 0A)
ustomer
+equirements
(drawing, +&Q, etc.),
Iour company/s
internal design 8
process
requirements
7ome Elements may
'e !ncluded 0n
Critical Characteristics
' Characteristic C&ntr&l Issues
Design 0A
(On Inten,e, 6se)
Advanced Product Quality Planning
18
#ocument ins
Pr&cess l& Chart
P0A
0peration 9um'er
0peration 9um'er
Product8Process haracteristic
!ncoming 7ources of %ariation
(%ariation lass)
C&ntr&l Plan
0peration 9um'er
Product8Process haracteristic
!ncoming 7ources of %ariation
(%ariation lass)
The APQP manual cites
these lins. !n some
companies, these are
not discrete documents.
The intent is to ensure
discrete documents
match.
0peration 9um'er
.&r# Instructi&n
0peration 9um'er
Advanced Product Quality Planning
19
#ocument ritical Paths
Deine All Critical 7
/pecial
Characteristics
Pr&cess l& Chart
P0A
D0A
2ay or may not identify
an input to the Process
&2EA
Provides input to control plan 'ased upon a ris analysis.
Provides inputs to the Process &2EA and may provide inputs to the wor instruction.
C&ntr&l Plan
.&r# Instructi&n
Advanced Product Quality Planning
20
Automotive Process &2EA
Process &ailure 2ode And Ef f ects Analy sis
ProcessF
ow " 3igh
0utside 7uppliers Af f ectedF
EngineerF
Primary Process +esponsi'ility F
2odel Iear8%ehicle(s)F
Part 9um'erF
0ther #iv . 0r People !nv olv edF
7cheduled Production +eleasedF
P&2EA #ateF
Approva lsF
Quality Assurance 2anager
Quality Assurance Engineer
0perations 2anager
7enior Adv isor
Part 9ame
0peration
9 um 'er
Proc es s & unc tion
Potential &ailure
2ode
7!+
Tae TPPE
4rong 2aterial
ontainer
2aterial 3eld !n
:
7torage Area
Potential Ef f ect s 0f & ailure
&ragmented  ontainer
Pot ent ial aus e 0f & ailure
!nsuf f icient 7upplier ontrol
?npredicta'le #eploy ment
!mproper 3andling
d
e
r
u
c
c
0
 urrent ontrols
2aterial ertif ic ation
y
t
ri
e
v
e
7
n
o
ti
c
e
t
e
#
9
P
+
:
D
<
:J
=
:
=
D
+ecommended
Actions And 7tatus
: " :
+ev .
Actions
Taen
+esponsi'le
Activ ity
+equired 4ith Each
2isidentif ied 2aterial
7hipment
+elease %erification
0ut 0f 7 pec
2aterial
ontaminated
&ragm ent ed ont ainer
7upplier Proc es s  ont rol
?npredicta'le #eploy ment
7upplier 2aterial
0pen 6o5es
%isual !nspection
:
D
K
L=
&ragmented ontainer
Engineering hange
+elease %erif ication
:
:
K
K
?npredicta'le #eploy ment
7upplier hange
-
:
:
-
:
:
=
=
&ragmented ontainer
2a te ri al
? np re di ct a' le # e pl oy m en t
2aterial
omposition
hange
<
2ov e To
?nreleased
Periodic Audit 0f
*reen M0NM Tag
ustomer 9otif ication
&ragmentation
Approv ed
?ntrained T0
?ntrained Personnel
7torage
hec &or *reen M0NM
Tag At Press
Trace ard
hec ist
Training
=
3old !n Approv ed
7torage ?ntil
9eeded
ontamination
&ragmentation
0pen ontainers
Process Pro'lems
3ouseeeping
Area 2aintenance
6o5es Nept !n 7ealed
7torage Area ?ntil
9eeded
6o5es ined 4ith
Plastic
iner 0n Pallets
!nside 7torage
P. 2. &acility
Advanced Product Quality Planning
21
Effects of hanging the Process &2EA
.&r#
Instructi&n
P0A
Change in Detecti&n
Change in Occurrence
Change in /everity
And
0r
C&ntr&l Plan
A change in the severity &
the eect & a p&tential
pr&le can &nly e
eecte, thr&ugh a ,esign
change$
Design Change
Other Acti&n
.hen a#ing a change t& a ,&cuent8 it is ip&rtant t& c&nsi,er the eects & that change &n
&ther ,&cuents$ Typically the engineering change syste in a c&pany an,7&r c&rrective acti&n
syste ensures these &ccur$ ut this is n&t alays the case$ %evie y&ur c&pany engineering
change pr&ce,ure 7 syste an, see i it ,&es s&$
Advanced Product Quality Planning
22
A orrective Action 7ystem
These are s&e typical
9chec#s: in the
aut&&tive &rl, in
resp&nse t& a
c&rrective acti&n$ A
change t& any &ne
,&cuent typically
,rives an ngineering
Change here the
engineering change
syste is use, t&
ensure that changes t&
any &ne ,&cuent
ensures appr&priate
changes t& &thers$
Advanced Product Quality Planning
23
Product Specific FMEA Approach
&2EA
revised in
response to
an J"#
investigation
6rand spaning new,
never 'efore product.
6rand spaning new
Process &2EA
developed.
Pr&cess
0A
&2EA
revised in
response to
an J"#
investigation
;ear 1
&2EA
revised in
response to
an J"#
investigation
;ear 2
opy of process &2EA
from a similar product
ear !""! # $%& 'ody
Inta(e manifold
Pr&cess
0A
Production Life
;ear 1
ear !"") # $%& 'ody
Inta(e manifold
&2EA
revised in
response to
an J"#
investigation
I do NOT recommend product specific FMEAs unless you really cannot
segregate your products into families for some reason.
Advanced Product Quality Planning
24
urrent ontrol Plans $ &2EAs
A &r Other 0anuacturing ntity
+eceiving/
2achine or
ell :
2achine
or ell <
2achine
or ell =
Pac
$ 7hip/
Pr&cess &2EA covers an equipment set/ or cost 'loc/
+ecommended 'y the &2EA Team
Device &2EA 8 Techn&l&gy 7 aily ontrol Plan/ O a flow of a technology/ or device/
!nternal or
E5ternal
ustomer
+eceiving/
Pac
$ 7hip/
overs entire flow while product is under the control of the &A6
including return of the product (if return is applica'le)
A Technology8&amily ontrol Plan 8 #evice &2EA follows an entire flow for a technology/
through a defined entity. This is in contrast with a process/ flow where there is an individual
ontrol Plan for each piece of equipment or a manufacturing cell/ (company definition). A
Technology/ consists of many similar devices.
+eceiving/ in &A6 &2EAs consists of what the &A6 loos at when materials arrive. +eceived
materials, such as gasses, liquid chemicals and related materials must 'e addressed. +egistrar
interpretation Q- :8:< (AE"A:)F @...7o in effect, suppliers control plans will include wafers,
gases, and chemicals...
25
Advanced Product Quality Planning
0ne Proposed Terminology
A &r Other 0anuacturing ntity
Pr&cess ontrol Plan 8 &2EA covers an
equipment set/ (cell) or individual equipment
+eceiving/
2achine or
ell :
2achine
or ell <
2achine
or ell =
Pac
$ 7hip/
Techn&l&gy ontrol Plan 8 &2EA " applies to devices, families
26
Advanced Product Quality Planning
<
C&rp&rate "evel 3 >>>>
?
+eceiving
&A6 :
&A6 <
ontrol
Plan $
&2EA
trl Plan $
&2EA
trl Plan $
&2EA
trl Plan $
&2EA
+esponsi'ility
O
&A6
+esponsi'ility
O
&A6
+esponsi'ility
O
A77I
+esponsi'ility
O
2aterialsH
7QAH
Assem'ly
&inal Pac
7hip
ontrol
Plan $
&2EA
.hite /pace Issue
ustomer
4arehouse
Advanced Product Quality Planning
27
#iscrete #ocuments
; Early on ! stressed that each APQP is unique 'oth 'etween companies and within a
company. The same is true of document changes. 0n the previous page ! discussed some
of the e5pected effects of a change to the process &2EA. 6ecause of the differences in
how companies structure their documentation it is only possi'le in a course document
such as this to address the effect of changing one document on another. Another reason
this is true is 'ecause every change to a process &2EA does not automatically require a
change to, for e5ample, the control plan. 4hen the evaluation is made it may turn out that
the ris/ num'er (the +P9) may 'e low and thus may not require a control.
; !n speaing of differences in company documentation, there are companies which (for
e5ample) com'ine their control plan and their process flow diagram into one document.
This said, there is no process flow diagram per se to change. 6ecause of the possi'le
permutations of how a document system is set up, it is ne5t to impossi'le in a course to
predict/ how a company will react within their documentation to a change in any given
document.
; Another e5ample is where a company uses the &ord #ynamic ontrol Plan (APQP and
ontrol Plan manual, page :) methodology where the control plan is com'ined with the
process &2EA.
; As we proceed through this presentation, eep in mind that where we discuss the changes
in one document and its effects on another you will have to loo at your company/s
documentation structure and determine equivalencies.
Advanced Product Quality Planning
28
Automotive #ocumentation #evelopment
Pr&cess l& Diagra
Critical 7 /pecial
Characteristics
#evelop Pr&cess
l& "isting
Enter Every 2aCor/
Process from &low
isting into 0A
&r
Pr&cess
0A
#evelop &2EA(s)
Element for Every
Process
*ive careful consideration
to defining ontrol Plan
stagesF
Prototype
Pre"launch
Production
#evelop the
C&ntr&l Plan with
ritical
characteristics
Pr&cess
C&ntr&l Plan
hec for ustomer
+equirements.
*ive careful consideration
to what you consider a
0a5&r/ process.
?se the appropriate +P9
num'ers and
considerations of other
appropriate information
8data to determine
Critical haracteristics.
#evelop control
mechanisms appropriate
for Critical
characteristics.
29
Advanced Product Quality Planning
6ase #ocumentation
• ritical haracteristics 2atri5
• Process &low #iagram
• #esign &2EA
• Process &2EA
• ontrol Plan
Advanced Product Quality Planning
30
The ontrol Plan
•
A ontrol Plan is a written description of systes for parts and processes
•
!t is Pr&cess D&inate,
•
Three 9Types: or Phases
1Pr&t&type *A +esign Output
• ?sed #uring Prototype 6uild
• #imensional 2easurements
• 2aterial and Performance Tests
1Pre"aunch
• ?pdate After Prototype and 6efore Production
1Pr&,ucti&n
• omprehensive
• Process ontrols
• Test and 2easurement 7ystems ?sed
• +eaction Plan
• 7ampling Plans
• 7P +equirements
Advanced Product Quality Planning
31
E5ample ontrol Plans
•
E5ample ontrol Plans included in the APQP 2anual (starting on page >K)F
1 @uipent
• 7et"?p #ominant Process
• 2achine #ominant Process
• &i5ture8Pallet #ominant Process
• Tooling #ominant Process
1 Pe&ple
• 0perator #ominant Process
1 0aterial
• 2aterial or omponent #ominant Process
1 0eth&,s
• Preventive 2aintenance #ominant Process
1 nvir&nent
• limate #ominant Process
Advanced Product Quality Planning
32
ontrol Plan #ata 7ources
Prototy pe " Pre"aunch " Production (circle)
ontrol Plan
PA+T 9A2EF
PA+T 9?26E+F
P+0#?T E9*!9EE+!9*
#E7!*9ATE#
09T+0 !T E2
P+0#?E+F
E9# !TE2 A9# ?7T02E+F
7?PP!E+ 0#EF
PA9TF
90.
Process &low
Process name
2achine
#evice ig
Tools for
2anufacturing
9o.
haracteristics
Process
Product
Parameters
haracteristics
in to
haracteristics
2atri5
Process
Engineering
lass
) YES
Product8Process
7pecification
&!+7T !77?E# #ATEF
+E%!E4 8 APP+0%A (7!*9 8 #ATE)
+E%!7!09 #ATEF
?7T02E+ 7QA APP+0%A (7!*9 8 #ATE)
ATE7T #+A4!9*87PE. #ATEF
?7T02E+ E9*. APP+0%A (7!*9 8 #ATE)
( X ) NO
2ethods
Evaluation
2ethods
7ample 7iGe8
&requency
Analysis
2ethods
+EAT!097 !& 0?T 0& 09T+0
09#!T!097 A+E E90?9TE+E#
P&2EA,
#rawing
Process
Engineering
in to flow
diagram $ P&2EA
(
Process
Engineering
Quality
Engineering
#rawing
Process
Engineering,
Quality
Engineering
9ote that in your company, you might la'el departments or functional areas
differently, or you may assign responsi'ilities differently. Process
Engineering in one company is called 2anufacturing Engineering in another
company. !n addition, your company may use multi"functional input where in
this e5ample a single source is identified. Iour tas is to identify where, in
your company, you derive the required information for each column.
Advanced Product Quality Planning
33
&ord/s oncept to ustomer (T)
Initiate, in 1B4$ Technically &s&lete$
Advanced Product Quality Planning
34
A 7imple APQP 7equence
%esp&nsi4ility
g
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)leent
2aret +esearch !nformation
Quality 3istory +eview
Engineering +esearch #ata
Advanc ed Qu ali ty Pl anni ng 7c hedul e
Prelimi nary Product8 Process #esign
&easi'il ity Analysis
#esign &2EA
Process &2EA
Prototype 6uild and %erification
7ignificant haracteristics
&inal Product an d Process #esign
2easurement and T est Equi pment 9eeds $ osts
Process ontrol Plan
Process &low hart
Audi t and QA 4or !nstruct ions
0rder Produc tion To oli ng, * ages, Te st Equip ment
7el ec t $ +ate 7uppl iers
T rain Quality Personnel
7upplier P74 +eview $ 7ign"0ff
7et"?p $ #e"6ug Production and !nspec tion Equipment
Preliminary apa'ility 7tudies &or Production Processes
Proce ss 0pti mi Gatio n (#esign 0f E5perim ents)
Process +eview (P&2EA 4al Through)
Product Training
4or !nstructions (2anufac turing)
2easurment and T est Equipment %erific ation
Pacaging
Part /aple .arrant
A O A ssistanc e
! O !nput
+ O +esponsi'il ity
& O 7achs " &lorence
T O 7achs " Troy
Advanced Product Quality Planning
35
Q7 D
• APQP !nvolvesF
1 >.: 2anagement +esponsi'ility
1 >.< Quality 7ystem
1 >.= ontract +eview
1 >.> #esign ontrol
1 >.- #ocument and #ata ontrol
1 >.D Process ontrol
1 >.: +eceiving (!ncoming)
1 >.:: !nspection, 2easuring and Test Equipment
1 >.:< !nspection and Test 7tatus
1 >.:= ontrol of 9onconforming Product
1 >.:> orrective Action
1 >.:- 3andling, 7torage, Pacaging and #elivery
1 >.:L Quality +ecords
1 >.:J Training
1 >.:D 7ervicing
1 >.< 7tatistical Techniques
36
Advanced Product Quality Planning
Automotive #ocumentation #evelopment
#evelop Process
&low isting
hec for ustomer
+equirements.
Enter Every
2aCor/ Process
from &low isting
into &2EA &orm
*ive careful consideration
to what you consider a
0a5&r/ process.
#evelop &2EA(s)
Element for Every
Process
*ive careful consideration
to defining ontrol Plan
stagesF
Prototype
Pre"launch
Production
#evelop the
ontrol Plan with
ritical
characteristics
?se the appropriate +P9
num'ers and
considerations of other
appropriate information
8data to determine
Critical haracteristics.
#evelop control
mechanisms appropriate
for Critical
characteristics.
37
Advanced Product Quality Planning
APQP #esign $ Process ontrols
• #esign +eviews
• #esign %erification
• #esign %alidation
• Process %alidation
• #esign &2EA
• Process &2EA
• Prototype %alidation
Advanced Product Quality Planning
38
Product Quality Planning +esponsi'ility 2atri5
APQP Phases
#efine the 7c ope
Plan and #efine (7ection :.)
Product #esign and #evelopment (7ection <.)
&easi'i lity (7ection <.:=)
Process #esign $ #evelopm ent (7ec tion =.)
Product and Process %alidation (7ection >.)
&eed'ac , Assessmen t and orrective Act ion (7ec tion -.)
ontrol Pl an 2ethodol ogy (7ectio n L.)
#esign







2anufacturing

7ervice 7upplier












AIA- APQP ' Ctrl Plan %eerence -ui,e8 Page 2
Advanced Product Quality Planning
39
Product Quality Planning heclists
• #esign &2EA
• #esign !nformation
• 9ew Equipment, Tooling and Test Equipment
• Product8Process Quality
• &low Plan
• Process &low hart
• Process &2EA
• ontrol Plan
hec ists for these line items are in the
A!A*/s APQP $ ontrol Plan reference manual
contained as a group " Appendi5 A starting on
page L=. ?se themR
Advanced Product Quality Planning
40
6enefits of APQP
• Ensures early planning taes place
• #irects resources to the customer
• !dentifies required changes early in the
process
• Provides quality product on time and at
lowest cost
• Ena'les cross"functional inputs and outputs
• Addresses potential pro'lems early in
1#esign
12anufacturing
Advanced Product Quality Planning
41
Progressive &undamentals
•
;EE
0rganiGe a ross"&unctional TA0
• #efine the scope
• Team"to"team communications
• Training
• 7imultaneous (concurrent) engineering
• ontrol Plan Phases
1Prototype
1Pre"aunch
1Production
• oncern resolution
1!ncludes analytical techniques
Advanced Product Quality Planning
42
Teams
/all TeasF
ig TeasF
C&unicati&nF
Advanced Product Quality Planning
43
Training
•ustomer Needs and Expectations
•4oring as a Team
•*roup process sills
•#evelopment sills
•+equirements of APQP
•&2EA
•APQP
•PPAP
Advanced Product Quality Planning
44
%ec&en,e, /tatistical C&urses
Basic Business
Advanced
Business
O**ice- S"a**- .
Manae!en"
Se$ec"ed S"a**- .
Manae!en"
S"a"is"ica$
%&cess '&n"&$
%&duc"i&n /$&&%&duc"i&n S"a** .
Manae!en"A$$ &* ua$i"#
. Enineein
Measue!en"
S#s"e! Ana$#sis
esin &*
E+,ei!en"s
%&duc"i&n S"a** .
Manae!en"A$$ &* ua$i"#
. Enineein
S,eci*ic %&duc"i&n
S"a**ua$i"# Eninees.
A Manae
. %&duc"
Enineein
*Your APQP Team should attend as many classes as time will allow
45
Advanced Product Quality Planning
Product Quality Planning Timing hart
oncept
!nitiation "
Approval
Program
Approval
Prototype
Planning
#esign $ #evelopment
Planning
Pilot
Product
Process
aunch
%alidation Product " Process
Production
&eed'ac Assessment $ orrective Action
Plan $
#efine
Program
Product
Process Product $
#esign $ #esign $ Process
#ev.
%alidation
#ev.
%erification %erification
A!A* APQP $ trl Plan +eference *uide, Page -
Advanced Product Quality Planning
46
Timing Plan ontents
• !dentify individual tass
• Trac resources 'y tas
• Esta'lishes dependencies 'etween tass
• #etermine critical path
• Trac specific tass or groups of tass
• 7tatus reports
ID
Task Name
1
Visit 1
Dur
5d
Start
4/28/97
Finish
!ri"
#a$
une
u"$
u&ust
&%r
May
'un
'ul
&u(
Se!tem'er
) e%
5/2/97
2
Plant Tour and Gather Information
2d
4/28/97
4/29/97
100%
3
Meet with Teams
2d
4/28/97
4/29/97
100%
4
Feasibility Determination
2d
/!/97
/2/97
5
Initial Pro"e#t Plan De$elo%ed
!d
/2/97
/2/97
100%
Advanced Product Quality Planning
47
ProCect Plan Elements
S
S
S
S
0issi&n
/c&pe
O5ectives
%e@uireents
•
S
S
S
+& t& easure
Deiniti&ns an, speciicati&ns
0ar#et analysis
ach ite ,&es n&t8 h&ever8 have
t& resi,e in 9&ne &&#:$
easiility
• Tie
• %es&urces
• Plant space
• tc$
S
S
S
S
C&nsi,er this a 9laun,ry list: &r an
in,e*$
;&u sh&ul, have (at least) an in,e*
& the pr&5ect plan ith the l&cati&n
an, &ner (resp&nsiility) & each
eleent clearly i,entiie,$
Tieline
C&ntr&l syste
Tea
C&st stiate
Advanced Product Quality Planning
48
ProCect Plan #efinitions !
• 2ission " *oal, customer and approach
• 7cope " 4hat will and will not 'e included
(with
consideration to availa'le technology)
• 0'Cectives " Technical, profit, performance, quality, etc.
• +equirements " #elivera'les
• #efinition and specification " riteria it must meet
• 2aret analysis " E5pected annual production volume,
length of run, start (delivery) target date, target price (apan),
ey sales points, ey competitors, etc.
Advanced Product Quality Planning
49
ProCect Plan #efinitions !!
•
Preliminary &easi'ility " #egree to which current tooling and
equipment can 'e used
•
Timeline " 2aCor milestones and detail tas schedule
•
ontrol system " Answers questions such asF
13ow will progress 'e measuredH
14ho will receive reportsH
13ow are changes handledH
14hat limits are there on authority, responsi'ility, and
accounta'ilityH
•
Team " 4ho, from where and who is the team leaderH
1eare & Tur .arsF
•
ost estimate " Estimate with assumptions. 0ften all/ information is
not availa'le.
Advanced Product Quality Planning
50
ProCect Plan 7ummary 7heet
r&a,
ProCect 
Title
ustomer
2odel8Iear
Part 
#ate
ProCect 2ission
ProCect 7cope
ProCect 0'Cectiv es
ontractural +equirements
Product #ef inition $ 7pec.
urrent apa'ility
Timeline
ontrol 7y stem
Team # ef inition
/peciic
Prelim. ost Estimate
Pr&5ect vs D'D
(Design ' Devel&pent)
Advanced Product Quality Planning
51
Analytical Techniques
•
Assem'ly 6uild %ariation Analysis
•
6enchmaring
•
ause $ Effect #iagram
•
haracteristics 2atri5
•
ritical Path 2ethod
•
#esign of E5periments (#0E)
•
#esign for 2anufactura'ility $ Assem'ly (#&2 $ #&A)
•
#esign %erification Plan $ +eport (#%P$+ " hrysler $ &ord)
•
#imensional (#ynamic) ontrol Plan (#P)
•
2istae Proofing (Poa"Ioe)
•
Process &low harting
•
Quality &unction #eployment (Q&#)
•
7ystem &ailure 2ode $ Effects Analysis (7&2EA)
See AIAG’s APQP & Control Plan reference manual appendi !" pa#es $% thru $
Advanced Product Quality Planning
52
ritical haracteristics 2atri5
Advanced Product Quality Planning
53
haracteristics !
•3A+ATE+!7T!F A distinguishing feature, dimension or property of a process or its output (product) on which varia'le or
attri'ute data can 'e collected. (P=D APQP)
•3A+ATE+!7T!, +!T!A, 3+I7E+ #E&!9!T!09F haracteristics applica'le to a component, material, assem'ly, or
vehicle assem'ly operation which are designated 'y hrysler orporation Engineering as 'eing critical to part function and having
particular quality, relia'ility and8or dura'ility significance. These include characteristics identified 'y the shield, pentagon, and
diamond. (>D PPAP)
•3A+ATE+!7T!, +!T!A (!9%E+TE# #ETA), &0+# #E&!9!T!09F Those product requirements (dimensions, performance
tests) or process parameters that can affect compliance with government regulations or safe vehicle8product function, and which
require specific supplier, assem'ly, shipping, or monitoring and included on ontrol Plans. (P>D PPAP)
•3A+ATE+!7T!, +!T!A, *2 #E&!9!T!09F 7ee Ney Product haracteristic. (P>D PPAP)
•3A+ATE+!7T!, NEI 09T+0 (Ns)F Those process parameters for which variation must 'e controlled around a target
value to ensure that a significant characteristic is maintained at its target value. Ns require ongoing monitoring per an approved
ontrol Plan and should 'e considered as candidates for process improvement. (P>D PPAP)
•3A+ATE+!7T!, NEI P+0#?T (NP)F Those product features that affect su'sequent operations, product function, or
customer satisfaction. NPs are esta'lished 'y the customer engineer, quality representative, and supplier personnel from a review
of the #esign and Process &2EA/s and must 'e included in the ontrol Plan. Any NPs included in customer"released engineering
requirements are provided as a starting point and do not affect the supplier/s responsi'ility to review all aspects of the design,
manufacturing process, and customer application and to determine additional NPs. (P>D PPAP)
54
haracteristics !!
•
3A+ATE+!7T!, P+0E77F ore team identified process varia'les (input varia'les) that have a cause and
effect relationship with the identified Product haracteristic(s) which can only 'e measured at the time of occurrence.
(L.= < APQP)
•3A+ATE+!7T!, P+0#?TF &eatures or properties of a part, component or assem'ly that are descri'ed on drawings or other
primary engineering information. (L.= :D APQP)
•3A+ATE+!7T!, P+0#?T, +!T!A (#), 3+I7E+ #E&!9!T!09F A defect which is critical to part function and having
particular quality, relia'ility, and dura'ility significance. (Q7"D)
•3A+ATE+!7T!, P+0#?T, 2A0+, 3+I7E+ #E&!9!T!09F A defect not critical to function, 'ut which could materially
reduce the e5pected performance of a product, unfavora'ly affect customer satisfaction, or reduce production efficiency. (Q7"D)
•3A+ATE+!7T!, P+0#?T, 2!90+, 3+I7E+ #E&!9!T!09F A defect, not classified as critical or maCor, which reflects a
deterioration from esta'lished standards. (Q7"D)
•3A+ATE+!7T!, P+0#?T, 7A&ETI8E2!77!09890!7E (7), 3+I7E+ #E&!9!T!09F A defect which will affect compliance
with hrysler orporation and *overnment %ehicle 7afety8Emission89oise requirements. (Q7"D)
•3A+ATE+!7T!, 7A&ETI, 3+I7E+ #E&!9!T!09 @7hield U7VF 7pecifications of a component, material, assem'ly or vehicle
assem'ly operation which require special manufacturing control to assure compliance with hrysler orporation and government
vehicle safety requirements. (Q7"D)
55
haracteristics !!!
•
3A+ATE+!7T!, 7A&ETI, 3+I7E+ #E&!9!T!09F 7pecifications which require special manufacturing control to
assure compliance with hrysler or government vehicle safety requirements. (P- PPAP)
•3A+ATE+!7T!, 7!*9!&!A9T, 3+I7E+ #E&!9!T!09F 7pecial characteristics selected 'y the supplier through nowledge
of the product and process. (Q7"D)
•3A+ATE+!7T!, 7PE!AF Product and process characteristics designated 'y the customer, including governmental regulatory
and safety, and8or selected 'y the supplier through nowledge of the product and process. (P:> APQP)
•3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @#iamond U#VF 7pecifications of a component, material, assem'ly or
vehicle assem'ly operation which are designated 'y hrysler as 'eing critical to function and having particular quality, relia'ility and
dura'ility significance. (Q7"D)
•3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @#iamond U#VF 7pecific critical characteristics that are process driven
(controlled) and therefore require 7P to measure process sta'ility, capa'ility, and control for the life of the part. (Appendi5  Q7"
D) $ (Appendi5  APQP)
•3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @Pentagon UPVF imited to highlighting ritical characteristics on
(Production) part drawings, tools and fi5ture, and tooling aid procedures where ongoing process control is not automatically
mandated. (Appendi5  Q7"D) $ (Appendi5  APQP)
•3A+ATE+!7T!, 7PE!A, 3+I7E+ #E&!9!T!09 @7hield U7VF Engineering designated specifications or product
requirements applica'le to component material, assem'ly operation(s) which require special manufacturing control to assure
compliance with governmental vehicle safety, emissions, noise, or theft prevention requirements. (Appendi5  Q7"D) $
56
(Appendi5  APQP)
haracteristics !%
•
3A+ATE+!7T!, 7PE!A, &0+# #E&!9!T!09 @ritical haracteristic U!nverted #eltaVF Those product
requirements (#imensions, 7pecifications, Tests) or process parameters which can affect compliance with
government regulations or safe %ehicle8Product &unction and which require specific producer, assem'ly, shipping or
monitoring actions and inclusion on the ontrol Plan. (Appendi5  Q7"D) $ (Appendi5  APQP)
•3A+ATE+!7T!, 7PE!A, &0+# #E&!9!T!09 @7ignificant haracteristic " 7 U9oneVF Those product, process, and test
requirements that are important to customer satisfaction and for which quality planning actions shall 'e included in the ontrol Plan.
(Appendi5  Q7"D)
•3A+ATE+!7T!, 7PE!A, &0+# #E&!9!T!09 @7ignificant8haracteristic " 78 U9oneVF haracteristics that are important to
the customer and that must 'e included on the ontrol Plan. (Appendi5  APQP)
•3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @&it8&unction U&8&VF Product characteristic for which reasona'ly anticipated
variation is liely to significantly affect customer satisfaction with a product (other than 78) such as its fits, function, mounting or
appearance, or the a'ility to process or 'uild the product. (Appendi5  Q7"D) $ (Appendi5  APQP)
•3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @7afety8ompliance U78VF Product characteristic for which reasona'ly
anticipated variation could significantly affect customer the product/s safety or its compliance with government regulations (such asF
flamma'ility, occupant protection, steering control, 'raing, etc. . .), emissions, noise, radio frequency interference, etc. . .
(Appendi5  Q7"D)
•3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @7afety8ompliance U7VF Product characteristic for which reasona'ly anticipated
variation could significantly affect customer the product/s safety or its compliance with government regulations (such asF
flamma'ility, occupant protection, steering control, 'raing, etc. . .), emissions, noise, radio frequency interference, etc. . .
(Appendi5  APQP)
57
haracteristics %
•
3A+ATE+!7T!, 7PE!A, *2 #E&!9!T!09 @7tandard U9oneVF Product characteristic for which reasona'ly
anticipated variation is unliely to significantly affect a product/s safety, compliance with governmental regulations,
fit8function. (Appendi5  Q7"D) $ (Appendi5  APQP)
•3A+ATE+!7T!, /PCIA", P+0E77 (e.g., C%ITICA"8 ;8 0AGO%8 /I-HIICAHT)F A process characteristic for which
variation must 'e controlled to some target value to ensure that variation in a special product characteristic is maintained to its target
value during manufacturing and assem'ly. (P-K &2EA)
•3A+ATE+!7T!, /PCIA", P+0#?TF ore team compilation of important product characteristics from all sources. All
7pecial haracteristics must 'e listed on the ontrol Plan. (L.= :D APQP)
•3A+ATE+!7T!, /PCIA", P+0#?T (e.g., C%ITICA"8 ;8 0AGO%8 /I-HIICAHT)F A product characteristic for which
reasona'ly anticipated variation could significantly affect a product/s safety or compliance with governmental standards or
regulations, or is liely to significantly affect customer satisfaction with a product. (P-- &2EA)
•3A+ATE+!7T!, 7PE!A, T00!9*, 3+I7E+ #E&!9!T!09 @Pentagon UPVF ritical tooling sym'ol used to identify
special characteristics of fi5tures, gages, developmental parts, and initial product parts. (Q7"D)
•09T+0 !TE2 PA+T, &0+# #E&!9!T!09F Product drawings8specifications containing ritical haracteristics. &ord #esign and
Quality Engineering approval is required for changes to ontrol !tem &2EA/s and ontrol Plans. (Q7"D)
58
Phase : ProCect +eview
ProCec t 
2odel8Iear
Title
Part 
ustomer
#ate
0ur advanced qual ity plan ning team has con sidered the foll owing questions in Phase :
of our APQP process. The documents provided have 'een used as a 'asis for analyGing
the a'i lity to meet al l specifi ed requirements. All 90 answers are supported with attac hed
com ments identifying our c oncerns and8or proposed c hanges to ena'l e us to meet
speci fied requirements.
Ies
:.
<.
=.
>.
-.
L.
K.
J.
D.
:.
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:<.
9o
hec l ist !tem
3as historic al data a nd e5perience conc erning cu stomer needs 'een c onsideredH
3as full co nsideration 'een gi ven to the overall 'usiness plan and m areting strategyH
3ave product8process 'enc hmar data 'een con sideredH
3ave the product8process assumpti ons 'een i dentifi ed and chal langed H
3ave product relia'ility studies 'een conductedH
3ave there 'en appropriate customer inputs into the processH
#o the design goals reflec t the data generatedH
#o the qual ity and reli a'il ity goal s reflect ap propriate standardsH
!s the prelimi nary 'ill of materials suffic ientl y thoroughH
#oes the prelim inary process flow c hart relate to the primary 602 and
produc t8proc ess assump tio nsH
Are a ll spe c ia l produ c t a nd proc ess c ha rac teri sti c s lit edH
#oes the produ5ct assurance pl an inc lude an d outl ine of program requirements, goals,
factors that may p lac e the p rogram at ris, &2EA, and p relimi nary enginering
standa rds requi rementsH
&e asi ' le
&ea si 'l e
9ot &easi'le
P ro du c t c a n ' e p ro du c ed as sp ec i f ie d wi th no re vi si o ns.
h ang es rec om me nd ed (7e e atta ch ed )
#esign revision required to produce product within specified requirements
T eam 2em'er8T itle8#ate
T eam 2em'er8T itle8#ate
T eam 2em'er8T itle8#ate
T eam 2em'er8T itle8#ate
59
Advanced Product Quality Planning
This form is on course dis
Phase : +esponsi'ility 2atri5
Phase 1I Plan an, De(ine Pr&gra
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Preliminary 602
Preliminary process flow chart
Preliminary list of special product and
process characteristics.
Product assurance plan
2anagement 7upport
Advanced Product Quality Planning
This form is on course dis
60
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APQP Phase <F Product #esign and #evelopment
Program
Approval
Prototype
Planning
Planning
#esign $ #evelopment
Product
Process
%alidation Product " Process
Production
&eed'ac Assessment $ orrective Action
Product
#esign $
#ev.
%erification
Advanced Product Quality Planning
61
Phase < 0utputs
• 0utputs 'y #esign +esponsi'le Activity
• 0utputs 'y Advanced Product Quality
Planning Team
Advanced Product Quality Planning
62
0utputs 'y #esign +esponsi'le Activity
•
#esign &2EA
•
#&2 and #&A
1#esign for 2anufactura'ility
1#esign for Assem'ly
•
#esign %erification
•
#esign +eviews
•
Prototype 6uild " ontrol Plan
•
Engineering #rawings (including 2ath data)
•
Engineering 7pecifications
•
2aterial 7pecifications
•
#rawing and 7pecification hanges
Advanced Product Quality Planning
63
Additional 0utputs 'y #esign +esponsi'le Activity
• ?pdated special characteristics list
• Prototype parts 'uild
12ae " 6uy decisions
1Parts inspection
1Assem'ly of prototype(s)
• Prefera'ly manufacturing, not model shop
1!nspection layout
1Prototype validation testing
• +edesign as required and design review
• ?pdate #&2EA (and 7ystem evel &2EA if appropriate)
• &easi'ility report
Advanced Product Quality Planning
64
&2EAs
Advanced Product Quality Planning
65
#&2EA
• #isciplined analytical tool
1Assess pro'a'ility of failure
1Effect of failure
• 2ust 'e continually updated
• auses changes and8or additions to previously
selected special product and8or process
characteristics
• !f you do not have design control, you 2?7T
have customer #&2EA
• hec list (A!A* APQP 2anual Appendi5 A":)
Advanced Product Quality Planning
(should)
66
P&2EA E5ample
Process &ailure 2ode And Ef f ects Analy sis
ProcessF
ow " 3igh
0utside 7uppliers Af f ectedF
EngineerF
Primary Process +esponsi'ility F
2odel I ear8%ehicle(s)F
Part 9um'erF
0ther #iv . 0r People !nv olv edF
7cheduled Production +eleasedF
P&2EA #ateF
Approv alsF
Part 9ame
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9 um 'er
Quality Assurance 2anager
Quality Assuranc e Engineer
0perations 2anager
7enior Adv isor
Proc es s & unc tion
Potential &ailure
2ode
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7!+
Tae TPPE
ontainer
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Pot ent ial Ef f ects 0f & ailure
Pot ential  aus e 0f & ailure
&ragment ed ontainer
!nsuf f icient 7upplier  ontrol
?npredicta'le #eploy ment
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ustomer 9otif ication
&ragmentation
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Tag At Press
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P. 2. &acility
67
Advanced Product Quality Planning
•
#esign, concept,
function and
sensitivity
(tolerancing) to
manufacturing
variation
•
2anufacturing
and8or assem'ly
process
•
#imensional
tolerances
•
Performance
requirements
•
9um'er of
components
(comple5ity)
•
Process
adCustments
•
2aterial
handling
#&2 and #&A
Advanced Product Quality Planning
68
#esign %erification
• !nspection methods
• Testing methods
• Ensure that all design outputs meet
design input requirements
1Alternate calculations
1A#8math data
1+eview design stage documents 'efore release
Advanced Product Quality Planning
69
#esign +eviews " Evaluations
• #esign8functional requirement(s) and considerations
• &ormal relia'ility and confidence goals
• omponent8su'system8system duty cycles
• omputer simulation and 'ench test results
• #&2EA(s)
• +eview of the #&2 and #&A
• #esign of e5periments (#0E) and assem'ly 'uild
variation results
• Test failures
• #esign verification progress
• 2a582in 'uilds
Advanced Product Quality Planning
70
#esign +eview Tracing
• Trac verification progress using a
design verification plan and report (#%P$+
" &ord $ hrysler)
• Product8process validation of
components
Advanced Product Quality Planning
71
Early Process &low #iagram
Advanced Product Quality Planning
72
Process &low #iagram E5ample
Pro#ess Flow Dia(ram
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73
Advanced Product Quality Planning
ontrol Plan 2ethodology
• Aids in the manufacturing of products according to
customer requirements
• Provide structured approaches
• ontain a written summary of the system used in
minimiGing process and product variation
• &orms provided in the A!A* hand'oo are e5amples
of how to document
• Alternate formats can 'e used if they contain
necessary information
• 2ust 'e maintained and used throughout the product
life cycle
Advanced Product Quality Planning
74
ontrol Plan ?se
• !nitialF To document and communicate
initial process control
• 9e5tF *uidance in controlling processes
and to ensure product quality
• astF A living document reflecting
current methods of control and
measurement systems used
Advanced Product Quality Planning
75
ontrol Plan
• Ensure ontrol Plan is aligned to, and
correlates with, #&2EA, Process &low,
P&2EA
• ontrol 2ethods appropriate to
variation type(s)
• !ncorporates essons earned,
7tatistical #ata
• ?se A"J ontrol Plan checlist
in APQP manual to evaluate
Advanced Product Quality Planning
76
Prototype 6uild ontrol Plan
• A description of the dimensional
measurements
• 2aterial tests
1&unctional tests that will occur during prototype
'uild
1#epending upon product comple5ity, several
prototype 'uilds may 'e necessary and may
require updates to the control plan
Advanced Product Quality Planning
77
7tandard ontrol Plan E5ample
ontrol Plan 9um'er
Ney ontac t 8 Phone
#ate (0rig.)
Part 9o.8 atest hange 9o.
ore Team
ustomer Engineering Approval8#ate
Part 9ame8#esc ription
7upplier8Plant Apoproval8#ate
ustomer Quality Approval8#ate
0ther Approval8date (!f +eqd)
0ther Approval8date (!f +eqd)
7upplier8Plant
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harac teristic s
Part8
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Advanced Product Quality Planning
7iGe
&requ"
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This form is on course dis
+eaction
Plan
78
&ord/s #imensional ontrol Plan (#P)
Advanced Product Quality Planning
79
ontrol Plan E5ample
(*2)
Process ontrol Plan
7upplier 9ameF
7upplier +ep.F
7upplier odeF
TelephoneF
TitleF
#ateF >8-8D=
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80
Prototype 6uild
• 2ae "'uy decisions
• Part inspections
• Assem'le prototypes
• Perform layout inspection
• %alidation testing (4ho will do testingH)
• +edesign as required
• ?pdate #&2EA and 7&2EA if required
Advanced Product Quality Planning
81
ustomer or 7upplier Engineering #rawings
(including math data)
• +eview for special and8or critical characteristics
• +eview controlling drawings when engineering drawings
are none5istent
• +eview drawings forF
1#imensions for form, fit, function, dura'ility, government 7$+
1ontrol or datum surfaces8locators for function gages and
equipment
1&easi'ility8compati'ility with industry standards
• ompati'ility of math data with two"way communications
(.ritten aivers accepta'le)
Advanced Product Quality Planning
82
ustomer or 7upplier Engineering 7pecifications
• +eview and understand controlling specifications
• !dentify functional, dura'ility and appearance
requirements
• 7hould defineF
17ample siGe
1&requency
1Acceptance criteria
• 0therwise, determined 'y supplier and included in
control plan
Advanced Product Quality Planning
83
2aterial 7pecifications
• +eview 2aterial 7pecifications for
7pecial haracteristics
1Physical properties
1Performance
1Environmental
13andling
17torage
• !nclude in ontrol Plan
Advanced Product Quality Planning
84
#rawing and 7pecifications hanges
• hange control requirement applies
• Ensure proper communication
• Q7 D Element >.- #ocument and #ata
ontrol/ applies (requires a hange ontrol system)
Advanced Product Quality Planning
85
APQP Team 0utputs
• 9ew equipment, tooling and facilities
requirements
• 7pecial product and process characteristics
• *age and testing equipment requirements
• Team feasi'ility commitment and management
support
• 7u'contractor 'uild
• 7upplier 'uild
Advanced Product Quality Planning
86
9ew Equipment, Tooling and &acilities +equirements
• Preliminary identification of new equipment, tooling
and facilities
• Address these items on the timing chart
• Address capa'ility requirements
• Esta'lish delivery times
•
omplete chec list in A!A* APQP $ ontrol Plan reference manual
Appendi5 A"=
Advanced Product Quality Planning
87
7pecial Product and Process haracteristics ist
• ?pgrade preliminary list started in Phase : from
information gathered through review and
development of design features
1 Additional sources
• #&2EA
• 7&2EA if applica'le
These ay &verlap
• P&2EA
• Previous history
• 2ust 'e on control plans for prototype, pre"launch
and production
• isting should 'e a team consensus
Advanced Product Quality Planning
88
*age and Testing Equipment +equirements
• Preliminary identification of inspection, test and
measurement equipment
• +equirements on timing chart
1omplete in time to conduct measurement
systems analysis
1Equipment 'uilder
1Pilot 'uild
1Production trial run
Advanced Product Quality Planning
89
Team &easi'ility, ommitment and 2anagement 7upport
•
Team feasi'ility commitment
•
omplete program review chec list, includingF
1#esign feasi'ility
1an 'e manufactured, assem'led, tested and pacaged
1an 'e delivered in the right quantities on schedule at accepta'le
cost
1+eview design information chec list in A!A* APQP +eference manual Appendi5 A"<
as part of feasi'ility inputs
•
0pen issues that require resolution with assigned responsi'ility
and timing.
•
2anagement 7upport
1+eport proCect status to management
1+ecommend continue or drop proCect depending on feasi'ility
1over open issues and concerns
12anagement support as required
Advanced Product Quality Planning
90
7u'contractor Pilot 6uild
• 7upplier participated, if appropriate
• 7ample quantity required
• hec that it is according toF
14or instructions
1ontrol plan
• 4here to 'e produced
Advanced Product Quality Planning
91
7upplier Pilot 7ample 6uild
• Parts availa'ility
• Tooling and equipment availa'ility
• 2easurement equipment availa'ility
Advanced Product Quality Planning
92
Phase < +esponsi'ility 2atri5
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Prototype ontrol Plan
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Team &easi'ility ommittment
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Advanced Product Quality Planning
93
!7
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Phase < ProCect +eview
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0ur advanced qual ity plann ing team has considered the foll owing questions in Phase <
of our APQP process. The documents provided have 'een used as a 'asis for analyGing
the a'i lity to meet all speci fied requirements. All 90 answers are supported with attac hed
com ments identifying ou r conc erns and8or proposed c hanges to ena'le us to meet
speci fied requirements.
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an engineering performance specifi cati ons 'e met as writtenH
an product 'e manufac tured to tolerances speci fied on the drawingH
an product 'e manufac tured with ps which meet requirementsH
!s there adequate capacity to produce productH
an the product 'e manufa ctured without inc urring any unusualF
osts for tooli ngH
osts for capi tal equi pmentH
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!s 7tatistical Process ontrol required on the productH
4here 7tatistical Process ontrol is used on similar productH
Are th e p roc esses in c ont rol and sta' le H
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Advanced Product Quality Planning
94
APQP Phase =F Process #esign and #evelopment
Prototype
Planning
#esign $ #evelopment
Pilot
Planning
Product
Process
%alidation
Product " Process
Production
&eed'ac Assessment $ orrective Action
Process
#esign $
#ev.
%erification
Advanced Product Quality Planning
95
Phase = 0utputs
• Pacaging 7tandards
• Product 8 Process Quality 7ystem +eview
• Process &low hart
• &loor Plan ayout
• haracteristics 2atri5
• Process &ailure 2ode and Effects Analysis
• Pre"aunch ontrol Plan
• Process !nstructions
• 2easurement 7ystems Analysis Plan
• Preliminary Process apa'ility 7tudy Plan
• Pacaging 7pecifications
Advanced Product Quality Planning
96
Typical #esign +esponsi'ility 0utputs
• #&2A
• #&28#&A
• #%
• #esign +eviews
• Prototype 6uild
• Engineering #rawings
• Engineering 7pecifications
• 2aterial 7pecifications
• #rawing and 7pecification hanges
Advanced Product Quality Planning
97
Typical APQP Team 0utputs
• 9ew Equipment
• &acilities
• Etc.
Advanced Product Quality Planning
98
Process #esign and #evelopment 0utputs
•
Pacaging standards
•
Product and process quality
system review
1 ?pdate tooling, equipment and
facilities list
•
Process flow chart
1 ?pdate process flow chart
•
&loor plan layout
•
haracteristics matri5
•
P&2EA
•
Pre"launch control plan
•
Process instructions
•
2easurement systems
analysis plan
•
Preliminary process
capa'ility study plan
(Typically : Parts)
•
2anagement support
•
Additional 0utputs
1 ?pdate P&2EA
1 Quote in"house gages, tooling and
equipment
1 0rder gages, tooling and
equipment
1 #elivery of gages in time for 27A
plan
1 #elivery of equipment
• 2ust consider approval at
equipment su'contractor, in"
house installation, de'ugging and
process potential studies (runoff)
1 7u'contractor pilot 'uild
1 7upplier pilot 'uild
Advanced Product Quality1Planning
7ala'le
unitsH
99
Pacaging 7tandards
• &rom customer
• #eveloped during prototype or pre"
launch runs
Advanced Product Quality Planning
100
Product and Process Quality 7ystem +eview
• Team must review e5isting quality systems manual to
ensure that changes resulting from APQP (if any) are
reflected
• 2ust comply with Q7 D
• hanges must 'e reflected in control plan
•
+eference A!A* APQP +eference manual Appendi5 A"> chec list
Advanced Product Quality Planning
101
Process &low hart
• ?pdate process flow chart
(E5ample in A!A* APQP +eference manual Appendi5 A"L)
• #escri'es current or proposed process flow
• ?sed to analyGe sources of variation
• 3elps analyGe total process
• 9eeded for process &2EA, characteristics matri5 and
control plan
•
+eference A!A* APQP +eference manual Appendi5 A"L chec list
Advanced Product Quality Planning
102
Process &low #iagram E5ample
Pro#ess Flow Dia(ram
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103
Advanced Product Quality Planning
&loor Plan ayout
•
#etermine accepta'ility of inspection and test points
•
ontrol chart location(s)
•
%isual aides
•
!nterim repair stations
(rewor)
•
9onconforming material storage
•
Neyed to material flow and control plan
•
+eference A!A* APQP +eference manual Appendi5 A"-
Advanced Product Quality Planning
104
haracteristics 2atri5
• #isplays relationship 'etweenF
1Process parameter
12anufacturing stations
•
+eference A!A* APQP +eference manual Appendi5 6, page J<
Advanced Product Quality Planning
105
Process &2EA
• To the e5tent possi'le, potential failure modes
have 'een considered and addressed
• 2ay 'e started after design &2EA in Phase <
• 9eeds to 'e updated regularly
• 2ust 'e done prior to committing new tools and
equipment
• iving document
• Typically starte, t&& lateF
•
+eference A!A* APQP +eference manual Appendi5 A"K
Advanced Product Quality Planning
106
Automotive Process &2EA
Process &ailure 2ode And Ef f ects Analy sis
ProcessF
ow " 3igh
0utside 7uppliers Af f ectedF
EngineerF
Primary Process +esponsi'ility F
2odel I ear8%ehicle(s)F
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0ther #iv . 0r People !nv olv edF
7cheduled Production +eleasedF
P&2EA #ateF
Approv alsF
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0peration
9 um 'er
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0perations 2anager
7enior Adv isor
Proc es s & unc tion
Potential &ailure
2ode
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7!+
Tae TPPE
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7torage Area
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&ragment ed ontainer
!nsuf f icient 7upplier  ontrol
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Advanced Product Quality Planning
107
Pre"launch ontrol Plan
• #escription of dimensional measurements, materials
and functional tests
• Adds additional product and8or process controls
• Purpose is to contain potential nonconformities
utiliGingF
12ore frequent inspections and8or tests
12ore in"process and final inspection and8or
chec points
17tatistical evaluations
1!ncreased audits
1+eference A!A* APQP +eference manual Appendi5 A"J chec list
Advanced Product Quality Planning
108
Automotive ontrol Plan
ontrol Plan 9um'er
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Advanced Product Quality Planning
7iGe
&requ"
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Plan
109
Additional Phase = 0utputs
• ?pdated equipment, tools and facility lists
• ?pdated process flow chart, P&2EA and control plan
• Quotes for in"house tooling, equipment and gages
• 7election of potential new su'contractors
• Quote and delivery of gages in time for 27A plan
• Equipment 'uild and runoffs
• *eneration of a su'contractor pilot 'uild
• *eneration of a supplier pilot 'uild
Advanced Product Quality Planning
110
?pdated Tool, Equipment and &acilities ists
• !nformation from P&2EA and other
sources
• Address on timing chart
• Address capa'ility requirements
•
+eference A!A* APQP +eference manual Appendi5 A"= chec list
Advanced Product Quality Planning
111
Quoting !n"3ouse Tooling, Equipment and *ages
• #elivery timing for pilot 'uild or production
trial run
• !nclude capa'ility requirements
• !nclude trial run8runoff8prove"out requirements
• *age delivery for 27A plan and runoff
•
+eference A!A* APQP +eference manual Appendi5 A"=
Advanced Product Quality Planning
112
7electing Potential 9ew 7u'contractors
• +esponsi'le for planning, tracing and
follow"up for su'contracted wor
• Provide technical resources for tool and
gage design, fa'rication and full
dimensional inspection
Advanced Product Quality Planning
113
7u'contractor Pilot 7ample 6uild
• 7upplier participation, if appropriate
• 6uild sample quantity required
12achine trial runs
1Pilot run(s)
• !n accordance with appropriate wor
instructions
• !n accordance with control plan
• Production tooling and equipment, if possi'le
Advanced Product Quality Planning
114
7upplier Pilot 6uild
• Provide for customer participation, if
specified
• have process instructions in place
• 3ave control plan in place
• Provide required quantity
• omplete 27A
• *enerate required documentation as
planned
Advanced Product Quality Planning
115
ProCect +eview !!!
• !nclude in control plan
• 2anufacturing location/s quality system
manual should 'e reviewed
• Procedures and control plans to 'e
updated to reflect changes
• "ast chance to eliminate pro'lems
'efore ramp"up
Advanced Product Quality Planning
116
Phase = +esponsi'ility 2atri5
Phase 3I Pr&cess Design ' Devel&pent
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Pre"aunch ontrol Plan
Process !nstructions
2easurement 7ystems Analysis Plan
Preliminary Process apa'ility 7tudy Plan
Pacaging 7pecifications
2anagement 7upport
117
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Advanced Product Quality Planning
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ProCec t 
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Title
Part 
ustomer
#ate
0ur advanced quality planning team has c onsidered the f ollowing questions in Phase =
of our APQP process . The documents prov ided hav e 'een used as a 'asis f or analy Ging
the a'ility to meet all specif ied requirements. All 90 answers are supported with attached
comments identify ing our concerns and8or proposed changes to ena'le us to meet
specif ied requirements.
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#oes pacaging design ensure product integrity at point of use and meet customer specsH
!s the product process quality checlist completed for the system reviewH
#oes the process flow chart indicate any pro'lems with the processH
#oes the floor plan checlist indicate any pro'lems with the acepta'ility of inspection
points, control chart loc ations, applic a'il ity of visual ai ds, interim repair stations, and
storage area to c ontain d efecti ve materialsH
Is a characteristics atri* a ppr&priate an, has &ne een c &nstructe,>
#oes the process &2EA chec list indicate any pro'lems and is there a system for
periodic review of the P&2EAH
#oes the control plan chec list indicate that all dimensional requirements, material, and
functional tests that will occur after the prototype, and 'efore full production, are includedH
Are c le ar proc ess in struc ti ons in app ropria te det ai l and are t hey c ross"referenc ed to al l
appropriate source sH
#oes the measurement systems analysis plan include responsi'ility to ensure gage linearity,
accuracy, repeatra'ility, reproduca'ility, and correlation for duplicate gagesH
3as the prelimi nary process capa' ili ty study plan 'een c omple tedH
#o the pac aging spec ific ations resulting from the pa caging design assure that product
performanc e and c haracteristic s will remai n unc hanged during pac ing, transit, unpac ing,
and will i t have compata'ility with all material handling equipment, inc luding ro'otsH
&e asi ' le
&e asi 'l e
9ot &easi'le
P ro du c t c a n ' e p ro du c ed as sp ec i f ie d wi th no re vi si o ns.
h ange s rec om men ded (7e e attac hed )
#esign revision required to produce product within specified requirements
Team 2em'er8T itle8#ate
Team 2em'er8T itle8#ate
Team 2em'er8T itle8#ate
Team 2em'er8T itle8#ate
118
This form is on course dis
Advanced Product Quality Planning
APQP Phase >F Product and Process %alidation
Planning
#esign $ #evelopment
Planning
Pilot
Product
aunch
Process
%alidation
Product " Process
Production
&eed'ac Assessment $ orrective Action
Product $
Process
%alidation
Advanced Product Quality Planning
119
Phase > 0utputs
• Production trial run
• 2easurement system evaluation (complete)
• Preliminary process capa'ility study
• Production part approval
• Production validation testing
• Pacaging evaluation
• Production control plan
• Quality planning sign"off and management
support
Advanced Product Quality Planning
120
Process !nstructions
•
4or instructions for operating personnel
•
7ourcesF
[
&2EAs
[
ontrol plans
[
Engineering drawings and specifications
[
2aterial specifications
[
%isual standards
[
!ndustry standards
[
Process flow chart
[
&loor plan layout
[
haracteristic matri5
[
Pacaging standards
[
Process parameters
[
Producer e5pertise
[
3andling requirements
[
0perators of process
[
Accessi'le operators
[
!nclude set"up parameters
[
+eference Q7 D Element >.D Process ontrol/
Advanced Product Quality Planning
121
2easurement 7ystems Analysis (27A)
• omplete studies as defined in the 27A
plan
• 2inimum are those identified in the
control plan
• 7u'Cected to evaluation prior to or
during production trial
Advanced Product Quality Planning
122
27A 7tudies
• 2easurement uncertainty determined
1*age +$+, 6ias, 7ta'ility, and inearity
• *age + $ + acceptance guidelines
1U :Y accepta'le
1:"=Y may 'e accepta'le, evaluate total variation
1V=Y unaccepta'le, measuring system needs
improvement
• %erify study performed correctly
Advanced Product Quality Planning
123
2easurement 7ystems Analysis Plan Ensures *ageF
inearity
 Accuracy
 +epeata'ility
 +eproduci'ility
 orrelation for duplicate gages
 *ages may 'e needed prior to gage sign"off at su'contractor plant or any in"house
pilot runs

0aterial
Inspect&r
7ample
ollection
0eth&,s
Test 2ethod
Training
7ample
Preparation
4ormanship
Paralla5
Practice
7amples
+eproduci'ility
Ergonomic
s
7tandards
0easureent
%i'ration
#iscrimination
6ias
+epeata'ility
ali'ration
inearity
Instruent
Temperature
ighting
3umidity
nvir&nent
These are some of the varia'les in a
measurement system. 4hat others can
you thin ofH
124
2easurement Precision
ndica"es
%&&
%ecisi&n
Advanced Product Quality Planning
125
2easurement 6ias $ +epeata'ility
%ecise
!,ecise
Accua"e
naccua"e
!ias
Y&u can c&ec" *& Bias
Y&u can NO c&ec" *& !,ecisi&n
126
Preliminary Process apa'ility 7tudy Plan
• 2ust include characteristics identified in control
plan
• &ew characteristics for simple component
• 2any characteristics for comple5 product with
many parts
•
+eference A!A* &undamental 7P +eference 2anual
Advanced Product Quality Planning
127
Pacaging Evaluation
• Pacaging must conform to specifications
developed 'y customer or supplier
• Assess protection of product
• ustomer specified pacaging must 'e
evaluated 'y team
• Pilot or production trial run parts usually
used in evaluation
Advanced Product Quality Planning
128
Pacaging 7pecifications
• &or individual products
• ustomer pacaging
• *eneric standards where appropriate
• 2ust ensure delivery quality
• ompati'le with all material handling
equipment used
Advanced Product Quality Planning
129
PPAP
7u'"7et
APQP "aunch in,ers
PPAP /uissi&n
• The n, Pr&,uct & APQPF
Advanced Product Quality Planning
130
Production Part Approval Process
PPAP
• Production parts are manufactured at
the production site using production
tooling, gaging, equipment, operators,
etc
• Parts from production run are analyGed.
• Test results and records from APQP are
su'mitted with Part 7u'mission 4arrant.
Advanced Product Quality Planning
131
Purpose of PPAP
•&or the supplier to demonstrateF
; All design records and specification.
; +equirements are properly understood.
; The process has the capa'ility to produce
product that meets requirements.
Advanced Product Quality Planning
132
Production Part Approval Process (PPAP)
•
Production Part Approval Process
•
Parts produced at production site usingF
1Production tooling
1Production gages
1Process
10perators
1Environment
1Process settings
•
&eeds
•
7peeds
•
ycle times
•
Pressures
•
Temperatures
•
!ntent is to validate (prove) that products made using production equipment
meet engineering requirements
•
!f su'mission level is not nown, contact customer
•
#efault level is =
•
ustomer approval is required prior to quantity production
•
+eference A!A* Production Part Approval Process reference manual
Advanced Product Quality Planning
133
Advanced Product Quality Planning
134
PPAP 7cope
• Production parts " generally = pieces/
• 7ervice su'contractors " fulfill requirements
• 6ul material
• !ncludes internal and e5ternal sources for
information
• 7u'mission required prior to first production
shipment
• PPAP 2anual 7ection !.= @ustomer 9otification and
7u'mission +equirements (starting on page ::) for
guidance
Advanced Product Quality Planning
135
Application
A!A* PPAP 2anual #efines
4hen PPAP 7u'mission is
+equired
; 9ew part
Something
Changed
; orrection to discrepancy in previous
su'mission
; #esign or process change
; hange in source of su'contracted
materials or services
; Transfer or rearrangement of tooling $
equipment
Advanced Product Quality Planning
136
2ethodology
• 6uyer enters PPAP
su'mission date on
purchase order.
• Approver evaluates
PPAP pacage.
• Approver determines
su'mission level.
• Approver determine
part su'mission
status.
1#efault level =
1#efault level > for raw material
• 7upplier su'mits PPAP
1PPAPA.5ls electronic
su'mission (#elphi)
1evel - at supplier site
• 9otify supplier and
manufacturing of
status.
Advanced Product Quality Planning
137
7upplier #ata +eceived
• 4arrant
• #&2EA
• Appearance
Approval +eport
(AA+), as required
• ontrol Plan
• 7ample Parts
• Process capa'ility studies
• Print8#esign +ecord
• *age 2easurement 7ystem
Analysis
• Early Production ontainment
Plan (Pre"aunch ontrol Plan)
• Engineering hange
#ocuments
• hec fi5tures8aids
• Process &low
#iagram
• a' Accreditation $ scope
• +estricted $ +eporta'le
2aterials form
• !nterim 4orsheet, if required
• P&2EA
Advanced Product Quality Planning
138
&low hart
• inage of Product haracteristics from
#&2EA to 0perational 7teps.
• 0peration num'ers consistent with P&2EA,
ontrol Plan, 0perator !nstructions.
• Ensure identification of
inspection and rewor.
• ?se A"L Process &low hart
checlist in APQP manual to
evaluate.
Advanced Product Quality Planning
139
#&2EA
• Assess &easi'ility, +is, #esign !ntent
!ssues
• onfirm 2anufacturing Process
apa'ility onsidered
• &ocus on ritical haracteristics
• essons earned !ncorporated
• ?se A": #esign &2EA heclist
in APQP 2anual to Evaluate
Advanced Product Quality Planning
140
P&2EA
• inage with #&2EA, Process &low,
ontrol Plan, 0perator !nstructions, etc
• #egree to which high +P9/s are
addressed with preventive strategies
• Action Plans assigned,
implemented, effectiveness
assessed and +P9 recalculated
• ?se A"K Process &2EA
checlist in APQP manual
*+
&
)
(
'P
Advanced Product Quality Planning
141
Pre"aunch ontrol Plan
• Early Production ontainment +equirements
1:. Additional controls included for proper
duration or quantity.
1<. P&2EA and statistical data used to
determine what additional controls
necessary.
• 7hort Term apa'ility
• ong Term apa'ility on similar process
Advanced Product Quality Planning
142
Production ontrol Plan
• ?pdate pre"launch control plan (living document)
• AddF
17ampling plans
1ontrol method
17P, inspection, attri'ute data and mistae"proofing
1+eaction plan
• 9onconformances clearly identified, quarantined and
disposition made
• +equires customer approval unless otherwise
specified
•
+eference A!A* APQP +eference manual Appendi5 A"J, 6 and *
Advanced Product Quality Planning
143
Production %alidation Testing
• Engineering tests validate products manufactured
withF
1Production tools
1Production processes
1Production operators
• Performed under end"use operating conditions
• 2ultiple validations for multiple intended uses
•
+eference Q7 D Element >.>.J
Advanced Product Quality Planning
144
Production Trial +un
• Production tooling, equipment,
environment, facilities and cycle time
• Process instructions and control plans
• 2inimum quantity set 'y customer
(an 'e increased 'y team)
• *enerally = parts
Advanced Product Quality Planning
145
Production Trial +un Product ?sed &orF
• Preliminary process capa'ility studies
• 27A (if not completed earlier)
• &inal feasi'ility
• Process review
• Production validation testing
• PPAP
• Pacaging evaluation
• &irst time capa'ility
• Quality planning sign"off
• #esign changes (if required)
Advanced Product Quality Planning
146
Pp vs. p
In 1991, the ASQC/AIAG Task Force published the "Fundamental
Statistical rocess Control" re!erence manual, hich shos the
calculations !or Cpk as ell as pk# These should be used to
eliminate con!usion about calculatin$ Cpk# So hich %alue is best
to report, Cpk or pk& Althou$h the' sho similar in!ormation,
the' ha%e sli$htl' di!!erent uses#
(stimated si$ma and the related capabilit' indices )Cp, Cpk, and Cr* are
used to measure the potential capabilit' o! a s'stem to meet customer
needs# +se it hen 'ou ant to anal'e a s'stem-s aptitude to per!orm#
Actual or calculated si$ma )si$ma o! the indi%iduals* and the related indices
)p, pk, and r* are used to measure the per!ormance o! a s'stem to meet
customer needs# +se it hen 'ou ant to measure a s'stem-s actual process
per!ormance#
Advanced Product Quality Planning
147
Preliminary Process apa'ility 7tudies
• haracteristics identified in the control plan
• ?sually : pieces minimum
• 2ay 'e = if run is less
• Pp \ :.LK is accepta'le unless otherwise
specified
• Pp ] :.LK requires action plan unless
otherwise specified
•
+eference A!A* &undamental 7P +eference 2anual
1:. at spec limit
1Z"= sigma O :.LK
1Allows flop/ within spec limit
Advanced Product Quality Planning
148
Process Analysis Animation
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ourtesy of The Red Road
httpF88www.sci.fi8^leo8
Advanced Product Quality Planning
149
3istogram Animation
lsar$c&
ourtesy of The Red Road
httpF88www.sci.fi8^leo8
Advanced Product Quality Planning
150
Process apa'ility Animation
lsar$c&
ourtesy of The Red Road
httpF88www.sci.fi8^leo8
Advanced Product Quality Planning
151
Process apa'ility Animation
lsar$c&
ourtesy of The Red Road
httpF88www.sci.fi8^leo8
Advanced Product Quality Planning
152
Process apa'ility 7tudies
Capaility
Pp V :.LK
Interpretati&n
C&nclusi&n
Process pro'a'ly urrent control plan
meets customer sufficient
requirements
:.==UPpU:.LK Process may not Additional controls
needed until pV:.==
meet customer
achieved
requirements
PpU:.==
Process will not
meet customer
requirements
:Y inpection is
needed until pV:.==
achieved
153
Advanced Product Quality Planning
Part 7u'mission 7tatus Possi'ilities
• &ull Production Approval
• !nterim Approval
1AuthoriGe shipment to #elphi
without &ull Production Approval
1orrective Action Plan is required.
• +eCected
1orrected su'mission required
'efore production quantities may 'e
shipped.
Advanced Product Quality Planning
154
!nterim Part lasses
1 A Parts from
• C Parts not from
production tooling
and meet specs, not
all PPAP
requirements have
'een met.
1Parts from
production tooling and
require rewor to meet
specs.
production tooling, parts
meet specs.
• D Parts do not meet
specs.
•  Parts do not meet
specs and vehicles with
class E parts require
retrofit to mae them
salea'le.
155
Advanced Product Quality Planning
+eview and 7ign"0ff
• Process instructions in place and followed
• &low charts in place and followed
• *+$+ plans e5ist and are followed
• Pu'lish final feasi'ility report
• 0'tain formal sigh"off
• 7chedule and conduct management review
• 0'tain management commitment to assist in
open issues
Advanced Product Quality Planning
156
Phase > ProCect +eview
ProCect 
2odel8Iear
Title
Part 
ustomer
#ate
0ur adv anced quality planning team has considered the f ollowing questions in Phase >
of our APQP process . The documents prov ided hav e 'een used as a 'asis f or analy Ging
the a'ility to meet all specif ied requirements. All 90 answers are supported with attached
comm ents identif y ing our concerns and8or proposed changes to ena'le us to meet
specified requirements.
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3as the production trial run 'een conducted and does it indicate the need for any changeH
#oes the eval uation of the measurement systems indi cate any need to mod ify the
control plan characteristicsH
#oes the preli mi nary proce ss ca pa'i li ty study indi cate any potentia l p ro'lemsH
3as the produc tion part 'een ap provedH
3as the production validation testing indicated any pro'lemsH
3as the evaluation of the pacaging of test shipments, where feasi'le, and test methods
indicated any difficultyH
3as the control plan methodology chec list indicated any pro'lems with that documentH
&easi'le
&easi 'l e
9ot &easi'le
Product can 'e produced as specified with no revisions.
hanges rec omm ended (7ee attac hed)
#esign revision required to produce product within specified requirements
Team 2em'er8Title8#ate
Team 2em'er8Title8#ate
Team 2em'er8Title8#ate
Team 2em'er8Title8#ate
Advanced Product Quality Planning
This form is on course dis
157
Phase > +esponsi'ility 2atri5
Phase 4I Pr&,uct an, Pr&cess Jali,ati&n
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Production %alidation Testing
Pacaging Evaluation
Production ontrol Plan
Quality Planning 7ign"0ff
2anagement 7upport
Advanced Product Quality Planning
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APQP Phase -F &eed'ac, Assessment and orrective Action
Planning
Planning
#esign $ #evelopment
Product
Process
aunch
%alidation Product " Process
Production
&eed'ac Assessment $ orrective Action
&eed'ac
Assessment $
orrective Action
•
The results of continuing production are evaluated for common
or special causes of variation during this phase to ensure that
the products satisfy customer satisfaction requirements
•
The effectiveness of the quality process should 'e evaluated
during this process step
1!ncludes continual improvement efforts
1!ncludes delivery and service performance
Advanced Product Quality Planning
159
ontinuing Production
ontinuing
Production
ontinuing
Production
2easure
ustomer
7atisfaction
#evelop #elivery $
7ervice 2easurement
Plan
#etermining
0ngoing
apa'ility
p V
or O :.==
#evelop $ !mplement
orrective Action Plan
#evelop Q07
2easurement
ontinuous
!mprovement
Plan $
&eed'ac
2easure #elivery $
7ervice
Attend ustomer Q07
2eeting As +equired
&r,:s Interpretati&n
160
Advanced Product Quality Planning
Phase - 0utputs
• +educed variation
• ustomer satisfaction
• #elivery and service
Advanced Product Quality Planning
161
+educing %ariation
• !dentify process variation
• tae corrective action to reduce
variation
• #evelop proposal for customer review
• *ain customer decision to implement,
negotiate or change design
Advanced Product Quality Planning
162
ustomer 7atisfaction
• Product or service must perform in
customer/s environment
• 7upplier must participate
• 7upplier and customer must 'e
partners
•
+eference Q7 D Element >.:.L
Advanced Product Quality Planning
163
ustomer 7atisfaction 2etrics
• 4arranty
• ustomer rating
• a'our claims
• +eturns
• oncerns reports
• PP2
• 9onconforming
material reports
• +esponse time
• orrective actions
• 0n"site
representative
• 0n time delivery
• 2aret share
• Tech calls
• ost control (total
cost)
Advanced Product Quality Planning
164
#elivery and 7ervice
• ontinues the supplier " customer partnership
in pro'lem solving and continuous
improvement
• +eplacement parts and services are
important
• eads to possi'le price reduction fromF
1!nventory cost reduction
1Process cost reduction
1ost of quality reduction
1+eference Q7 D Element >.:Advanced Product Quality Planning
165
Phase - +esponsi'ility 2atri5
Phase !I ee,ac#8 Assessent an, C&rrective Acti&n
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Advanced Product Quality Planning
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ProCec t 
2odel8Iear
Title
Part 
ustomer
#ate
0ur advanc ed quality planning team has c onsidered the f ollowing questions in Phase of our APQP process. The documents provided have 'een used as a 'asis f or analy Ging
the a'ility to m eet all specif ied requirements. All 90 answers are supported with attached
comments identif y ing our concerns and8or proposed changes t o ena'le us to m eet
specif ied requirements.
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hec l ist !tem
3as a system for reduci ng future variation 'een developed a nd is it i n pla ceH
!s there a system for ensuring continuing customer satisfactionH
!s there a process in pl ace for monitoring del ivery and service so that it c ontinues
to m et c ustomer needsH
&e asi 'l e
&ea si 'l e
9ot &easi'le
P ro du c t c a n ' e p ro du c ed as sp ec i f ie d wi t h n o re vi si o ns.
h an ge s rec om men ded (7e e atta ch ed )
#esign revision required to produce product within specified requirements
T eam 2em'er8T itle8#ate
T eam 2em'er8T itle8#ate
T eam 2em'er8T itle8#ate
T eam 2em'er8T itle8#ate
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Advanced Product Quality Planning
167
7ummary
• A!A* PPAP 2anual #efines +equirements
• APQP Product and Process %alidation
• 7upplier su'mits PPAP to proper level
• PPAP pacage evaluated and status
determined
• 7upplier and customer manufacturing site
notified of PPAP approval status
Advanced Product Quality Planning
168
APQP 2anual Appendi5 A " hec ists
•
A": #esign &2EA hec ist
•
A"< #esign !nformation heclist
•
A"= 9ew Equipment, Tooling and Test
Equipment heclist
•
A"> Product 8 Process Quality heclist
•
A"- &loor Plan hec ist
•
A"L Process &low hart heclist
•
A"K Process &2EA heclist
•
A"J ontrol Plan heclist
Advanced Product Quality Planning
169