APQPPPAP,APQP,A Perspective on 8-D and PFMEA and Control Plan During APQP and Afterwards,What is APQP?,APQP is a defined process for a product development system for Ford, Daimler- Chrysler, GM and their suppliers. APQP is an attempt to provide a common path and synchronization of product development activities. APQP is an attempt to ensure communication both within a company and between a company and its customer,Marketing & Communications,Benefits of APQP,Ensures early planning takes place. Directs resources to the customer. Identifies required changes early in the process. Provides quality product on time and at lowest cost. Enables cross-functional inputs and outputs. Addresses potential problems early,Marketing & Communications,Customer and Supplier Involvement,Customer may initiate planning process. Supplier has the obligation to establish cross-functional team to manage process. Supplier should expect the same performance from their subcontractors.,Marketing & Communications,Determine Customer Requirements,Print Purchase Request or Request for Quotation. Statement of Work (SOW) Customer visits and discussions. Product checklists.,Marketing & Communications,Training,Customer needs and expectations. Working as a team. Requirements of APQP FMEA APQP PPAP,Marketing & Communications,APQP Five Phase Process,Planning,Product Design and Development,Process Design and Development,Product and Process Validation,Production,Feedback Assessment and Corrective Action,Pilot,Launch,Concept Initiation/Approval,Program Approval,Prototype,Planning,Links Between the Tools,Contract Review Program Plan,DFMEA,Team Feasibility Commitment,Produce Process Flow Diagrams,Conduct Process FMEA,Develop Control Plan,Work Instruction Development,Product and Process Validation,Ensure Continuous Improvement,Phase I,Phase II,Phase II,Phase III,Phase III,Phase III,Phase III,Phase IV,Phase V,Determine Customer Expectations and Plan for Quality,Identify Key Characteristics,Determine Risk and Feasibility,Associate Characteristics with Process Steps and Identify Key Characteristics,Expose Sources of Variation and Finalize Key Characteristics,Determine Methods to Improve Process and Control Variation,Implement Control Plan and Standardize the Process,Ensure Customer Expectations are Met,Exercise Management Oversight,The Target and The Goal,Marketing & Communications,Link Between the Documents,Process Flow Diagrams,Updated after production trial run. Need to indicate special characteristics generated at each step. Completed Along with Control Plan (APQP Process). Generally contains same information as process traveler.,Marketing & Communications,Process Flow Diagram Example,Marketing & Communications,APQP Links to PFMEA,Process FMEA,Must follow flow of the process flow diagram. Must include ALL process special characteristics (as a minimum).,Marketing & Communications,How a PFMEA Works,Where does the data for the PFMEA come from? What types of people are a part of the PFMEA team? What types of activities should we spend a lot of time on?,PFMEAs/Control Plans and 8-Ds During APQP,PFMEAs should be driven by real data, including 8-Ds (internal and external), warranty and returned part analysis PFMEAs should be completed by process experts and should be a driver of the control plans and work instructions Work instructions (Post control log, process parameter logs, preventive maintenance, etc.) implement the control plan in the process When there is a quality problem there is an opportunity to improve the control plan and the work instructions,APQP Links to Control Plan,Control Plans,Includes product and process special characteristics. Includes SPC requirements. Follows flow of process flow chart and PFMEA. May require customer approval.,Marketing & Communications,Types of Control Plans,Prototype build control plan(s) Pre-launch control plan Production control plan,Marketing & Communications,Prototype Build Control Plan,A description of the dimensional measurements. Material tests Functional tests that will occur during prototype build.,Marketing & Communications,Pre-launch Control Plan,Description of dimensional measurements, materials, and functional tests. Adds additional product and process controls. Purpose is to contain potential nonconformities utilizing: More frequent inspections and/or tests. More in-process and finsl inspection and/or check points. Statistical evaluations. Increased audits.,Marketing & Communications,Production Control Plan,Up-date pre-launch control plan. Add: Sampling plans Control method SPC, inspection, attribute data and mistake proofing. Reaction plan Nonconformances clearly identified, quarantined and disposition made. Requires customer approval unless otherwise specified.,Marketing & Communications,Control Plan Use,Initial: To document and communicate initial process control. Next: Guidance in controlling processes and to ensure product quality. Last A living document reflectin