ADVANCED PRODUCT QUALITY PLANNING (APQP) AND CONTROL PLAN Reference Manual Issued June 1994, Second Printing February 1995 (new cover only) Copyright 1994, 1995 Chrysler Corporation, Ford Motor Company, and General Motors Corporation FOREWORD This Reference Manual and Reporting Format were developed by the Advanced Product Quality Planning (APQP) and the Control Plan teams that were sanctioned by Chrysler, Ford, General Motors Supplier Quality Requirements Task Force. The Task Force charter is to standardize the reference manuals, procedures, reporting formats, and technical nomenclature used by Chrysler, Ford, and General Motors in their respective supplier quality systems. Accordingly, this manual and format, approved and endorsed by Chrysler, Ford and General Motors, should be used by suppliers implementing APQP techniques into their design/manufacturing processes. In the past, Chrysler, Ford, and General Motors each had their own guidelines and formats for ensuring supplier APQP compliance. Differences between these guidelines and formats resulted in additional demands on supplier resources. To improve upon this situation, Chrysler, Ford and General Motors agreed to develop and distribute this Manual. The work group responsible for this Manual was led by Mike Mazur of Ford Motor Company. This manual provides general guidelines for preparing plans and checklists for ensuring that Advanced Product Quality Planning is in actuality carried out at the supplier. It does not give specific instructions on how to arrive at each APQP or Control Plan entry, a task best left to each component review team. While these guidelines are intended to cover all situations normally occurring either in the early planning, design phase, or process analysis, there will be questions that arise. These questions should be directed to your customers Supplier Quality activity. If you are uncertain as to how to contact the appropriate activity, contact your buyer in your customers Purchasing office. The Task Force gratefully acknowledges: the leadership and commitment of Vice Presidents Thomas T. Stallkamp at Chrysler, Norman F. Ehlers at Ford, and G. Richard Wagoner, Jr. of General Motors; the assistance of the AIAG in the development, production, and distribution of this manual; and the guidance of Task Force Principals Russell Jacobs (Chrysler), Radley Smith (Ford), and Dan Reid (General Motors). This procedure is copyrighted by Chrysler, Ford and General Motors, all rights reserved, 1994. Additional copies can be ordered from AIAG 810-358-3003. Suppliers of the Automotive Industry have permission to copy any forms and/or checklists. June 1994 i ii ACKNOWLEDGEMENT This document, which includes a reference manual and reporting format, represents the consensus of the members of the Advanced Product Quality Planning and Control Plan teams sanctioned by the Chrysler, Ford, General Motors Supplier Quality Requirements Task Force. Team members, whose names appear below, wish to acknowledge the many contributions made by individuals from within their respective organizations, individuals without whose support and assistance this document would not have been possible. Advanced Product Quality Planning Team Members ChryslerFordGeneral Motors Robert RoushMichael A. MazurR. Dan Reid Andy KucharskiRoderick A. MunroDavid L. Kraush Suppliers Paul AnglinITT Automotive Brenda DusekHarvard Industries Charles R. DykstraInverness Casting Donald GeisFederal Mogul Corporation Al WaltonUnited Technologies Control Plan Team Members Frederick N. BazFord Brenda DusekHarvard Industries Rebecca FrenchGeneral Motors Gary HoytChrysler Mary Ann RaymondRobert Bosch Corporation Additional Assistance Bea AndersonChrysler iii Table of Contents Introduction1 Product Quality Planning Responsibility Matrix2 Fundamentals of Product Quality Planning3 Product Quality Planning Timing Chart5 1.0Plan and Define Program6 1.1Voice of the Customer7 1.1.1Market Research8 1.1.2Historical Warranty and Quality Information8 1.1.3Team Experience8 1.2Business Plan/Marketing Strategy9 1.3Product/Process Benchmark Data9 1.4Product/Process Assumptions9 1.5Product Reliability Studies9 1.6Customer Inputs9 1.7Design Goals10 1.8Reliability And Quality Goals10 1.9Preliminary Bill of Material10 1.10Preliminary Process Flow Chart10 1.11Preliminary Listing of Special Product and Process Characteristics10 1.12Product Assurance Plan11 1.13Management Support11 2.0Product Design and Development12 2.1Design Failure Mode and Effects Analysis (DFMEA)14 2.2Design for Manufacturability and Assembly14 2.3Design Verification15 2.4Design Reviews15 2.5Prototype Build Control Plan15 2.6Engineering Drawings (Including Math Data)16 2.7Engineering Specifications16 2.8Material Specifications16 2.9Drawing and Specification Changes16 2.10New Equipment, Tooling and Facilities Requirements17 2.11Special Product and Process Characteristics17 2.12Gages/Testing Equipment Requirements17 2.13Team Feasibility Co