APQP-PPAP英文(共50頁).ppt

1、APQPPPAP APQPA Perspective on 8-D and PFMEA and Control Plan During APQP and AfterwardsMarketing & CommunicationsWhat 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 synchroni

2、zation of product development activities. APQP is an attempt to ensure communication both within a company and between a company and its customerMarketing & CommunicationsBenefits of APQP Ensures early planning takes place. Directs resources to the customer. Identifies required changes early in

3、the process. Provides quality product on time and at lowest cost. Enables cross-functional inputs and outputs. Addresses potential problems earlyMarketing & CommunicationsCustomer and Supplier Involvement Customer may initiate planning process. Supplier has the obligation to establish cross-func

4、tional team to manage process. Supplier should expect the same performance from their subcontractors.Marketing & CommunicationsDetermine Customer Requirements Print Purchase Request or Request for Quotation. Statement of Work (SOW) Customer visits and discussions. Product checklists.Marketing &a

5、mp; CommunicationsTraining Customer needs and expectations. Working as a team. Requirements of APQP FMEA APQP PPAPMarketing & CommunicationsAPQP Five Phase ProcessPlanningProduct Design and DevelopmentProcess Design and DevelopmentProduct and Process ValidationProductionFeedback Assessment and C

6、orrective ActionPilotLaunchConcept Initiation/ApprovalProgram ApprovalPrototypePlanningMarketing & CommunicationsLinks Between the ToolsContract Review Program PlanDFMEATeam Feasibility CommitmentProduce Process Flow DiagramsConduct Process FMEADevelop Control PlanWork Instruction DevelopmentPro

7、duct and Process ValidationEnsure Continuous ImprovementPhase IPhase IIPhase IIPhase IIIPhase IIIPhase IIIPhase IIIPhase IVPhase VDetermine Customer Expectations and Plan for QualityIdentify Key Characteristics Determine Risk and FeasibilityAssociate Characteristics with Process Steps and Identify K

8、ey CharacteristicsExpose Sources of Variation and Finalize Key CharacteristicsDetermine Methods to Improve Process and Control VariationImplement Control Plan and Standardize the ProcessEnsure Customer Expectations are MetExercise Management OversightMarketing & CommunicationsThe Target and The

9、GoalMarketing & CommunicationsLink Between the DocumentsProcess FlowOperation NumberProduct/ProcessCharacteristicIncoming Sourcesof VariationPFMEAControl PlanVariation ClassWork InstructionsMarketing & CommunicationsProcess Flow Diagrams Updated after production trial run. Need to indicate s

10、pecial characteristics generated at each step. Completed Along with Control Plan (APQP Process). Generally contains same information as process traveler.Marketing & CommunicationsProcess Flow Diagram ExampleMarketing & CommunicationsAPQP Links to PFMEAWork InstructionsPFMEAChange in detectio

11、nChange in occurenceChange in severityControl PlanDesign ChangeOther ActionororororMarketing & CommunicationsProcess FMEA Must follow flow of the process flow diagram. Must include ALL process special characteristics (as a minimum).Marketing & CommunicationsHow a PFMEA Works Where does the d

12、ata 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?Marketing & CommunicationsPFMEAs/Control Plans and 8-Ds During APQPPFMEAs should be driven by real data, including 8-Ds (internal and external), warranty and

13、returned part analysisPFMEAs should be completed by process experts and should be a driver of the control plans and work instructionsWork instructions (Post control log, process parameter logs, preventive maintenance, etc.) implement the control plan in the processWhen there is a quality problem the

14、re is an opportunity to improve the control plan and the work instructionsMarketing & CommunicationsAPQP Links to Control PlanFirst/Last PieceMistake ProofingControl PlanP/M ChecklistQuality ChecklistMarketing & CommunicationsControl Plans Includes product and process special characteristics

15、. Includes SPC requirements. Follows flow of process flow chart and PFMEA. May require customer approval.Marketing & CommunicationsTypes of Control Plans Prototype build control plan(s) Pre-launch control plan Production control planMarketing & CommunicationsPrototype Build Control Plan A de

16、scription of the dimensional measurements. Material tests Functional tests that will occur during prototype build.Marketing & CommunicationsPre-launch Control PlanDescription of dimensional measurements, materials, and functional tests.Adds additional product and process controls.Purpose is to c

17、ontain potential nonconformities utilizing: More frequent inspections and/or tests. More in-process and finsl inspection and/or check points. Statistical evaluations. Increased audits.Marketing & CommunicationsProduction Control Plan Up-date pre-launch control plan. Add: Sampling plans Control m

18、ethod SPC, inspection, attribute data and mistake proofing. Reaction plan Nonconformances clearly identified, quarantined and disposition made. Requires customer approval unless otherwise specified.Marketing & CommunicationsControl Plan Use Initial: To document and communicate initial process co

19、ntrol. Next: Guidance in controlling processes and to ensure product quality. Last A living document reflecting current methods of control and measurement systems used.Marketing & CommunicationsMultiple Molds, Tools, Dies and Patterns Complete dimensional layer required from one part from each c

20、avity as a minimum. Supplier must identify specific cavity for each part submitted.Marketing & CommunicationsPart Submission Status Never ship production parts before receiving customer approval. Supplier must ensure that future production continues to meet customer requirements. No production p

21、arts can be shipped until approval is received.Marketing & CommunicationsAutomotive Documentation DevelopmentDevelop Process Flow ListingCheck for Customer RequirementsEnter Every “Major” Process from Flow Listing into FMEA Form Give careful consideration to what you consider a “Major” processDe

22、velop FMEA Element for Every ProcessUse the appropriate RPN numbers and considerations of other appropriate information / data to determine Critical characteristicsDevelop the Control Plan with Critical CharacteristicsDevelop control mechanisms appropriate for Critical characteristics.Give careful c

23、onsideration to defining Control Plan stagesPrototype Pre-launch ProductionMarketing & CommunicationsMarketing & Communications Provides Proof of Capability Made up of Documents from APQP Marketing & CommunicationsPPAP Purpose Ensure that customer design record and specification requirem

24、ents are understood. Ensure that the process has the potential for producing product meeting those requirementsMarketing & CommunicationsPPAP Scope Production parts - generally 300 pieces. Includes internal and external sources for information. Submission required prior to first production shipm

25、ent.Marketing & Communications Base Documentation Critical characteristics matrix. Process flow diagram. Design FMEA (supplied by customer). Process FMEA. Control plan.Marketing & CommunicationsGeneral Supplier is responsible for meeting all applicable specifications. Do not submit parts and

26、 documentation results if they are outside specification. Take corrective action to meet all design record requirements. Contact customer if unable to meet all requirements Comply with customer developed material specifications and/or approved source list.Marketing & CommunicationsGeneral Suppli

27、ers are required to complete and maintain copies of all documentation identified in “requirements for approval” regardless of submission level. Records of PPAP are to be retained for the life of the part plus one calendar year.Marketing & CommunicationsElements of a PPAPPart submission warrantSu

28、bcontractor warrantsDesign record (customer/design documentation)Sample/Master sample (Master sample retained by supplier)Dimensional analysisTest dataFlow diagramControl planPFMEAMeasurement Systems Analysis (GR&R)Capability studiesMarketing & CommunicationsParts Submission Warrant Upon sat

29、isfactory completion of all required measurements and tests, enter all required information on the warrant. A separate is required for each part number. Responsible supplier official verifies Measurements and tests conform to customer requirements Required documentation is available for proper submi

30、ssion level. Signs warrant and provided date, title and telephone number.Marketing & CommunicationsMarketing & CommunicationsPart Weight Determine part weight without packaging or shipping material. Report weight in kilograms to three decimal places. Weight determination Weigh 10 parts rando

31、mly selected and report the average weight. For parts less than 0.100 kilogram, weigh 10 parts together and report the average weight.Marketing & CommunicationsMaster Sample Retain same as PPAP, or Until new master sample is produced for the purpose of a customer approval. Identify master sample

32、 by: Part number Drawing level or revision level Customer approval dateMarketing & CommunicationsPreliminary Process Capability Studies Characteristics identified in the control plan. Usually 100 pieces minimum. May be 30 if run is less. Ppk 1.67 is acceptable unless otherwise specified. Ppk 1.6

33、7 requires action plan unless otherwise specified.Marketing & CommunicationsProduction Trial Run Production tooling, equipment, environment, facilities and cycle time. Process Instructions and control plans. Minimum quantity set by the customer. Generally 300 parts.Marketing & Communications

34、Production Trial Run Product Used For Preliminary process capability studies. MSA (if not completed earlier) Final Feasibility. Process review. Production Validation Testing. PPAP Packaging evaluation First time capability Quality planning sign-offMarketing & CommunicationsMeasurement System Ana

35、lysis (MSA) Complete studies as defined in the MSA plan. Minimum are those identified in the control plan. Subjected to evaluation prior to or during production trial.Marketing & CommunicationsPackaging Evaluation Packaging must conform to specifications developed by customer or supplier. Assess

36、 protection of product. Customer specified packaging must be evaluated by team. Pilot or production trial run parts usually used in evaluation.Marketing & CommunicationsFloor Plan Layout Determine acceptability of inspection and test points. Control chart locations Visual aides Interim repair stations Nonconforming material storage Keyed to material flow and control planMarketing & CommunicationsReview and Sign-Off Process in