APQPPPAP APQP APerspectiveon8 DandPFMEAandControlPlanDuringAPQPandAfterwards WhatisAPQP APQPisa defined processforaproductdevelopmentsystemforFord Daimler Chrysler GMandtheirsuppliers APQPisanattempttoprovideacommonpathandsynchronizationofproductdevelopmentactivities APQPisanattempttoensurecommunicationbothwithinacompanyandbetweenacompanyanditscustomer BenefitsofAPQP Ensuresearlyplanningtakesplace Directsresourcestothecustomer Identifiesrequiredchangesearlyintheprocess Providesqualityproductontimeandatlowestcost Enablescross functionalinputsandoutputs Addressespotentialproblemsearly CustomerandSupplierInvolvement Customermayinitiateplanningprocess Supplierhastheobligationtoestablishcross functionalteamtomanageprocess Suppliershouldexpectthesameperformancefromtheirsubcontractors DetermineCustomerRequirements PrintPurchaseRequestorRequestforQuotation StatementofWork SOW Customervisitsanddiscussions Productchecklists Training Customerneedsandexpectations Workingasateam RequirementsofAPQPFMEAAPQPPPAP APQPFivePhaseProcess Planning ProductDesignandDevelopment ProcessDesignandDevelopment ProductandProcessValidation Production FeedbackAssessmentandCorrectiveAction Pilot Launch ConceptInitiation Approval ProgramApproval Prototype Planning LinksBetweentheTools ContractReviewProgramPlan DFMEA TeamFeasibilityCommitment ProduceProcessFlowDiagrams ConductProcessFMEA DevelopControlPlan WorkInstructionDevelopment ProductandProcessValidation EnsureContinuousImprovement PhaseI PhaseII PhaseII PhaseIII PhaseIII PhaseIII PhaseIII PhaseIV PhaseV DetermineCustomerExpectationsandPlanforQuality IdentifyKeyCharacteristics DetermineRiskandFeasibility AssociateCharacteristicswithProcessStepsandIdentifyKeyCharacteristics ExposeSourcesofVariationandFinalizeKeyCharacteristics DetermineMethodstoImproveProcessandControlVariation ImplementControlPlanandStandardizetheProcess EnsureCustomerExpectationsareMet ExerciseManagementOversight TheTargetandTheGoal LinkBetweentheDocuments ProcessFlowDiagrams Updatedafterproductiontrialrun Needtoindicatespecialcharacteristicsgeneratedateachstep CompletedAlongwithControlPlan APQPProcess Generallycontainssameinformationasprocesstraveler ProcessFlowDiagramExample APQPLinkstoPFMEA ProcessFMEA Mustfollowflowoftheprocessflowdiagram MustincludeALLprocessspecialcharacteristics asaminimum HowaPFMEAWorks WheredoesthedataforthePFMEAcomefrom WhattypesofpeopleareapartofthePFMEAteam Whattypesofactivitiesshouldwespendalotoftimeon PFMEAs ControlPlansand8 DsDuringAPQP PFMEAsshouldbedrivenbyrealdata including8 Ds internalandexternal warrantyandreturnedpartanalysisPFMEAsshouldbecompletedbyprocessexpertsandshouldbeadriverofthecontrolplansandworkinstructionsWorkinstructions Postcontrollog processparameterlogs preventivemaintenance etc implementthecontrolplanintheprocessWhenthereisaqualityproblemthereisanopportunitytoimprovethecontrolplanandtheworkinstructions APQPLinkstoControlPlan ControlPlans Includesproductandprocessspecialcharacteristics IncludesSPCrequirements FollowsflowofprocessflowchartandPFMEA Mayrequirecustomerapproval TypesofControlPlans Prototypebuildcontrolplan s Pre launchcontrolplanProductioncontrolplan PrototypeBuildControlPlan Adescriptionofthedimensionalmeasurements MaterialtestsFunctionalteststhatwilloccurduringprototypebuild Pre launchControlPlan Descriptionofdimensionalmeasurements materials andfunctionaltests Addsadditionalproductandprocesscontrols Purposeistocontainpotentialnonconformitiesutilizing Morefrequentinspectionsand ortests Morein processandfinslinspectionand orcheckpoints Statisticalevaluations Increasedaudits ProductionControlPlan Up datepre launchcontrolplan Add SamplingplansControlmethodSPC inspection attributedataandmistakeproofing ReactionplanNonconformancesclearlyidentified quarantinedanddispositionmade Requirescustomerapprovalunlessotherwisespecified ControlPlanUse Initial Todocumentandcommunicateinitialprocesscontrol Next Guidanceincontrollingprocessesandtoensureproductquality LastAlivingdocumentreflectingcurrentmethodsofcontrolandmeasurementsystemsused MultipleMolds Tools DiesandPatterns Completedimensionallayerrequiredfromonepartfromeachcavityasaminimum Suppliermustidentifyspecificcavityforeachpartsubmitted PartSubmissionStatus Nevershipproductionpartsbeforereceivingcustomerapproval Suppliermustensurethatfutureproductioncontinuestomeetcustomerrequirements Noproductionpartscanbeshippeduntilapprovalisreceived AutomotiveDocumentationDevelopment DevelopProcessFlowListing CheckforCustomerRequirements EnterEvery Major ProcessfromFlowListingintoFMEAForm Givecarefulconsiderationtowhatyouconsidera Major process DevelopFMEAElementforEveryProcess UsetheappropriateRPNnumbersandconsiderationsofotherappropriateinformation datatodetermineCriticalcharacteristics DeveloptheControlPlanwithCriticalCharacteristics DevelopcontrolmechanismsappropriateforCriticalcharacteristics GivecarefulconsiderationtodefiningControlPlanstages PrototypePre launchProduction ProvidesProofofCapabilityMadeupofDocumentsfro