ADVANCE PRODUCT
QUALITY PLANNING
by : Wahyu Epifanto
APQP|
WHAT IS IT?
A structured methodology for the design and development
of new and modified products from concept through to
production
It provides a set of detailed requirements to be
undertaken at each stage in the APQP system
It involves the utilization of various techniques to be
employed to identify and resolve problems before going
into full production
APQP|
WHAT IS IT?
The goal is to facilitate communication
with everyone involved to assure that all
required steps are completed on time.
Effective planning depends on a company’s
top management commitment to
achieving customer satisfaction.
APQP Timing Chart
Program
Approval
Concept
Initiation/Approval
Prototype
Pilot
Launch
Planning
Planning
Product Design & Dev.
Process Design & Development
Product & Process Validation
Production
Feedback Assessment and Corrective Action
Plan & Define
Program
Product Design &
Development
Verification
Process Design
& Development
Verification
Product &
Process
Validation
Feedback
Assessment &
Corrective
action
HASIL SURVEY :
1.
Harga tidak mahal
2.
Rasa Gurih
3.
Lembut / Tidak Alot
4.
Minyak tidak banyak
5.
Ukuran besar (Diameter + 5cm)
6.
Warna, tidak gosong
7.
Bentuknya rapih
TIDAK LENGKAP
LENGKAP
BAKWAN TIDAK AKAN LAKU,
BAKWAN AKAN LAKU,
KARENA TIDAK SESUAI DENGAN
KEBUTUHAN KONSUMEN
KARENA SESUAI DENGAN
KEBUTUHAN KONSUMEN
Cara Membuatnya :Bahan – bahan :
Dipotong :
1.
Tepung
Alat :
1.
Kol
2.
Air 1.
Pisau
2.
Wortel
3.
Kol 2.
Talenan
3.
Toge
4.
Wortel
3. Mangkok/Baskom
4.
Daun Bawang 5.
Toge
6.
Daun Bawang
Buat Adonan :
7.
Garam
Alat :
1.
Tepung
8.
Minyak
1. Mangkok /Baskom
2.
Air
9.
Cabe
2.
3.
Garam
Sendok
Alat-Alat :
Digoreng :
Talenan Alat :
1.
Pisau
Minyak
1.
Sendok 2.
Wajan
Kompor
Mangkok/Baskom
3. Gas
Wajan 4.
Wajan
Kompor
Sajikan
Gas
Alat:
1.
Piring
1.
Cabe
Piring
BOD
PURCHASING
WAREHOUSE
PRODUKSI
1.MEMBELI
BAHAN
YG FRESH
QUALITY
CONTROL
MAINTENANCE
1.MEMASTIKAN
BAKWAN
BERKUALITAS
2. MURAH
2. MENYIMPAN
BAHAN
DELIVERY
- CARI
CUSTOMER
- PROMOSI
2. BERSIHKAN
3.MEMBUAT
ADONAN
- TDK ENCER
- TAKARAN
4. MENGORENG
BAKWAN
- SUHU
- MINYAK
5.KEMASAN
- TDK PENYOK
- KUAT
- TIDAK RUSAK
HRD
MEMBAYAR
GAJI
KARYAWAN
1.MERAWAT
ALAT-ALAT
1.MEMOTONG
BAHAN
- 1CM
KEUANGAN
MENGONTROL
PEMAKAIAN
DAN
PENGELUARAN
1.MEMASARKAN
BAKWAN
- WARNA
- RASA
- UKURAN
- BENTUK
1.MENSORTIR
BAHAN
PEMASARAN
MENCARI
ORANG
1.MENGANTAR
KAN BAKWAN
- TEPAT
WAKTU
MENGONTROL
ABSENSI
MENGEMBANG
KAN ORANG
APQP
PHASE
1 1
PHASE
PLANNING
Concept
Initiation/Approval
Program
Approval
Prototype
Pilot
Launch
PHASE 2
Planning
Planning
Product Design & Dev.
PHASE 3
Process Design & Development
Product & Process Validation
PHASE 4
Production
Feedback Assessment and Corrective Action
PHASE 5
Plan & Define
Program
Product Design
& Development
Verification
Process
Design &
Developmen
t Verification
Product &
Process
Validation
Feedback
Assessment
& Corrective
action
PHASE 1 |PLANNING
Phase 1 Inputs
•
Phase 1 Outputs
Voice of the costumer
•
Market Research
•Design Goals
•
Historical Warranty
and Quality
Information
•Reliability & Quality Goals
•
Team Experience
•
Business Plan/MKT
Strategy
•
Product/process
Assumptions
•
Product Reliability Studies
•
Cuctomer Inputs
•Preliminary Process Flow
Chart
PLANNING
•Preliminary Listing of
special Product & Process
Characteristics
•Product Assurance Plan
•Management Support
APQP
PHASE 1
PHASE 2
APQP Phase 2: Product Design & Dev.
Concept
Initiation/Approval
Program
Approval
Prototype
Pilot
Launch
Planning
Planning
Product Design & Dev.
Process Design & Development
PHASE 3
Product & Process Validation
Production
PHASE 4
Feedback Assessment and Corrective Action
Plan & Define
Program
PHASE 5
Product Design
& Development
Verification
Process
Design &
Developmen
t Verification
Product &
Process
Validation
Feedback
Assessment
&
Corrective
action
PHASE 2 |PRODUCT
DESIGN & DEVELOPMENT
Phase 2 Inputs
Phase 2 Outputs
•Design Goals
•Design FMEA
•Reliability & Quality
Goals
•Design for
Manufactturability and
assembly
•Preliminary Bill of
Material
•Preliminary Listing of
Special Product & Process
Characteristic
•Product Assurance Plan
•Management Support
•Design Verification
PRODUCT &
DESIGN
DEVELOPMENT
•Design Reviews
•Prototype CP
•Engineering Drawings
•Engineering
Spesifications
•Material Spesifications
•Drawing & Spec. Changes
PHASE 2 |PROCESS
DESIGN & DEVELOPMENT
Phase 2 Inputs
Phase 2 Outputs
•Design Goals
•Reliability & Quality
Goals
•New equipment, Tooling
and Facilities Requirement
•Preliminary Bill of
Material
•Preliminary Listing of
Special Product & Process
Characteristic
•Product Assurance Plan
•Management Support
PROCESS
DESIGN &
DEVELOPMENT
•Special Product and Process
Characterictics
•Gages/Testing Equipment
Requirements
•Team Feasibility
Commitment and
Management Support
APQP
APQP Phase 3: Process Design & Validation
PHASE 1
Concept
Initiation/Approval
Program
Approval
Prototype
Pilot
Planning
Planning
PHASE 2
Launch
Product Design & Dev.
Process Design & Development
PHASE33
PHASE
Product & Process Validation
Production
PHASE 4
PHASE 5
Feedback Assessment and Corrective Action
Plan & Define
Program
Product Design
&
Development
Verification
Process
Design &
Developmen
t
Verification
Product &
Process
Validation
Feedback
Assessment
&
Corrective
action
PHASE 3 |PROCESS
DESIGN & DEVELOPMENT
Phase 3 Inputs
Phase 3 Outputs
•Packaging Standards & Specs.
Phase 2 Design
Outputs
•Prod/Proc. Quality System Review
•Process Flow Chart
•Floor Plan Layout
Process Design &
Development
•Characteristics Matrix
•PFMEA
•Pre-launch CP
•Process Instructions
•MSA Plan
Phase 2 APQP
Outputs
•Preliminary Process Capability
Study Plan
•Management Support (including
operator staffing & training plan)
APQP
APQP Phase 4: Product & Process Validation
PHASE 1
PHASE 2
Concept
Initiation/Approval
Program
Approval
Prototype
Pilot
Launch
Planning
Planning
Product Design & Dev.
PHASE 3
Process Design & Development
Product & Process Validation
Production
PHASE44
PHASE
Feedback Assessment and Corrective Action
PHASE 5
Plan & Define
Program
Product Design
& Development
Verification
Process
Design &
Developmen
t Verification
Product &
Process
Validation
Feedback
Assessment
&
Corrective
action
PHASE 4 |Product
& Process Validation
Phase 4 Inputs
Phase 4 Outputs
•Packaging Standards & Specs.
•Prod/Proc. Quality System
Review
•Significant production Run
•Measurement Systems
Evaluations
•Process Flow Chart
•Floor Plan Layout
•Characterictics Matrix
•PFMeA
•Pre –Launch CP
Product and
Process
Validation
•Preliminary Process Capability
Study
•PPAP
•Production Validation
•Process Instructions
•Testing
•MSA Plan
•Packaging Evaluation
•Preliminary process Capability
Study Plan
•Production CP
•Management support (including
operator staffing & training plan)
•Quality Planning Sign off and
management Support
APQP
PHASE 1
Feedback Assessment & Corrective Action
Concept
Initiation/Approval
PHASE 2
Program
Approval
Prototype
Pilot
Launch
Planning
Planning
Product Design & Dev.
PHASE 3
Process Design & Development
s
Product & Process Validation
Production
PHASE 4
PHASE55
PHASE
Feedback Assessment and Corrective Action
Plan &
Define
Program
Product Design
&
Development
Verification
Process
Design &
Developme
nt
Verification
Product &
Process
Validation
Feedback
Assessmen
t&
Corrective
action
PHASE 5|Feedback
Assessment & Corrective Action
Phase 5 Inputs
Phase 5 Outputs
•Significant Production
Run
•Measurement Systems
Evaluation
•Preliminary Process
Capability Study
•PPAP
•Production Validation
Testing
•Packaging Evaluation
•Production CP
•Quality Planning Sign-off
and ManagementnSuport
•Reduced Variation
Feedback
Assessment
& Corrective
Action
•Improved Customer
Satisfication
•Improved Delivery and
Service
•Effective Use of Lessons
Learned/Best Practices
QUALITY MANAGEMENT SYSTEM
Continual improvement of
the quality management system
5
Management
Responsibility
Customers
Customers
8
6
Measurement,
analysis and
improvement
Resource
management
Requirements
Input
7
Product
Realisation
Product
Satisfaction
Output