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APQP PPAPAPQPAPerspectiveon8-DandPFMEAandControlPlanDuringAPQPandAfterwardsWhatisAPQP?APQPisa"defined"processforaproductdevelopmentsystemforFord,Daimler-Chrysler,GMandtheirsuppliers.APQPisanattempttoprovideacommonpathandsynchronizationofproductdevelopmentactivities.APQPisanattempttoensurecommunicationbothwithinacompanyandbetweenacompanyanditscustomerBenefitsofAPQPEnsures

earlyplanningtakesplace.Directs

resourcestothecustomer.Identifiesrequiredchangesearlyintheprocess.Provides

qualityproductontimeandatlowestcost.Enables

cross-functional

inputsandoutputs.Addresses

potentialproblemsearlyCustomerandSupplierInvolvementCustomermayinitiateplanningprocess.Supplierhastheobligationtoestablishcross-functionalteamtomanageprocess.Suppliershouldexpectthesameperformancefromtheirsubcontractors.DetermineCustomerRequirementsPrintPurchaseRequestorRequestforQuotation.StatementofWork(SOW)Customervisitsanddiscussions.Productchecklists.TrainingCustomerneedsandexpectations.Workingasateam.RequirementsofAPQPFMEAAPQPPPAPAPQPFivePhaseProcessPlanningProductDesignandDevelopmentProcessDesignandDevelopmentProductandProcessValidationProductionFeedbackAssessmentandCorrectiveActionPilotLaunchConceptInitiation/ApprovalProgramApprovalPrototypePlanningLinksBetweentheToolsContractReviewProgramPlanDFMEATeamFeasibilityCommitmentProduceProcessFlowDiagramsConductProcessFMEADevelopControlPlanWorkInstructionDevelopmentProductandProcessValidationEnsureContinuousImprovementPhaseIPhaseIIPhaseIIPhaseIIIPhaseIIIPhaseIIIPhaseIIIPhaseIVPhaseVDetermineCustomerExpectationsandPlanforQualityIdentifyKeyCharacteristicsDetermineRiskandFeasibilityAssociateCharacteristicswithProcessStepsandIdentifyKeyCharacteristicsExposeSourcesofVariationandFinalizeKeyCharacteristicsDetermineMethodstoImproveProcessandControlVariationImplementControlPlanandStandardizetheProcessEnsureCustomerExpectationsareMetExerciseManagementOversightTheTargetandTheGoalLinkBetweentheDocumentsProcessFlowDiagramsUpdatedafterproductiontrialrun.Needtoindicatespecialcharacteristicsgeneratedateachstep.CompletedAlongwithControlPlan(APQPProcess).Generallycontainssameinformationasprocesstraveler.ProcessFlowDiagramExampleAPQPLinkstoPFMEAProcessFMEAMustfollowflowoftheprocessflowdiagram.MustincludeALLprocessspecialcharacteristics(asaminimum).HowaPFMEAWorksWheredoesthedataforthePFMEAcomefrom?WhattypesofpeopleareapartofthePFMEAteam?Whattypesofactivitiesshouldwespendalotoftimeon?PFMEAs/ControlPlansand8-DsDuringAPQPPFMEAsshouldbedrivenbyrealdata,including8-Ds(internalandexternal),warrantyandreturnedpartanalysisPFMEAsshouldbecompletedbyprocessexpertsandshouldbeadriverofthecontrolplansandworkinstructionsWorkinstructions(Postcontrollog,processparameterlogs,preventivemaintenance,etc.)implementthecontrolplanintheprocessWhenthereisaqualityproblemthereisanopportunitytoimprovethecontrolplanandtheworkinstructionsAPQPLinkstoControlPlanControlPlansIncludesproductandprocessspecialcharacteristics.IncludesSPCrequirements.FollowsflowofprocessflowchartandPFMEA.Mayrequirecustomerapproval.TypesofControlPlansPrototypebuildcontrolplan(s)Pre-launchcontrolplanProductioncontrolplanPrototypeBuildControlPlanAdescriptionofthedimensionalmeasurements.MaterialtestsFunctionalteststhatwilloccurduringprototypebuild.Pre-launchControlPlanDescriptionofdimensionalmeasurements,materials,andfunctionaltests.Addsadditionalproductandprocesscontrols.Purposeistocontainpotentialnonconformitiesutilizing:Morefrequentinspectionsand/ortests.Morein-processandfinslinspectionand/orcheckpoints.Statisticalevaluations.Increasedaudits.ProductionControlPlanUp-datepre-launchcontrolplan.Add:SamplingplansControlmethodSPC,inspection,attributedataandmistakeproofing.ReactionplanNonconformancesclearlyidentified,quarantinedanddispositionmade.Requirescustomerapprovalunlessotherwisespecified.ControlPlanUseInitial:Todocumentandcommunicateinitialprocesscontrol.Next:Guidanceincontrollingprocessesandtoensureproductquality.LastAlivingdocumentreflectingcurrentmethodsofcontrolandmeasurementsystemsused.MultipleMolds,Tools,DiesandPatternsCompletedimensionallayerrequiredfromonepartfromeachcavityasaminimum.Suppliermustidentifyspecificcavityforeachpartsubmitted.PartSubmissionStatusNevershipproductionpartsbeforereceivingcustomerapproval.Suppliermustensurethatfutureproductioncontinuestomeetcustomerrequirements.Noproductionpartscanbeshippeduntilapprovalisreceived.AutomotiveDocumentationDevelopmentDevelopProcessFlowListingCheckforCustomerRequirementsEnterEvery“Major”ProcessfromFlowListingintoFMEAFormGivecarefulconsiderationtowhatyouconsidera“Major”processDevelopFMEAElementforEveryProcessUsetheappropriateRPNnumbersandconsiderationsofotherappropriateinformation/datatodetermineCriticalcharacteristicsDeveloptheControlPlanwithCriticalCharacteristicsDevelopcontrolmechanismsappropriateforCriticalcharacteristics.GivecarefulconsiderationtodefiningControlPlanstagesPrototypePre-launchProductionProvidesProofofCapabilityMadeupofDocumentsfromAPQPPPAPPurposeEnsurethatcustomerdesignrecordandspecificationrequirementsareunderstood.EnsurethattheprocesshasthepotentialforproducingproductmeetingthoserequirementsPPAPScopeProductionparts-generally300pieces.Includesinternalandexternalsourcesforinformation.Submissionrequiredpriortofirstproductionshipment.BaseDocumentationCriticalcharacteristicsmatrix.Processflowdiagram.DesignFMEA(suppliedbycustomer).ProcessFMEA.Controlplan.GeneralSupplierisresponsibleformeetingallapplicablespecifications.Donotsubmitpartsanddocumentationresultsiftheyareoutsidespecification.Takecorrectiveactiontomeetalldesignrecordrequirements.ContactcustomerifunabletomeetallrequirementsComplywithcustomerdevelopedmaterialspecificationsand/orapprovedsourcelist.GeneralSuppliersarerequiredtocompleteandmaintaincopiesofalldocumentationidentifiedin“requirementsforapproval””regardlessofsubmissionlevel.RecordsofPPAParetoberetainedforthelifeofthepartplusonecalendaryear.ElementsofaPPAPPartsubmissionwarrantSubcontractorwarrantsDesignrecord(customer/designdocumentation)Sample/Mastersample(Mastersampleretainedbysupplier)DimensionalanalysisTestdataFlowdiagramControlplanPFMEAMeasurementSystemsAnalysis(GR&R)CapabilitystudiesPartsSubmissionWarrantUponsatisfactorycompletionofallrequiredmeasurementsandtests,enterallrequiredinformationonthewarrant.Aseparateisrequiredforeachpartnumber.ResponsiblesupplierofficialverifiesMeasurementsandtestsconformtocustomerrequirementsRequireddocumentationisavailableforpropersubmissionlevel.Signswarrantandprovideddate,titleandtelephonenumber.PartWeightDeterminepartweightwithoutpackagingorshippingmaterial.Reportweightinkilogramstothreedecimalplaces.WeightdeterminationWeigh10partsrandomlyselectedandreporttheaverageweight.Forpartslessthan0.100kilogram,weigh10partstogetherandreporttheaverageweight.MasterSampleRetainsameasPPAP,orUntilnewmastersampleisproducedforthepurposeofacustomerapproval.Identifymastersampleby:PartnumberDrawinglevelorrevisionlevelCustomerapprovaldatePreliminaryProcessCapabilityStudiesCharacteristicsidentifiedinthecontrolplan.Usually100piecesminimum.Maybe30ifrunisless.Ppk>1.67isacceptableunlessotherwisespecified.Ppk<1.67requiresactionplanunlessotherwisespecified.ProductionTrialRunProductiontooling,equipment,environment,facilitiesandcycletime.ProcessInstructionsandcontrolplans.Minimumquantitysetbythecustomer.Generally300parts.ProductionTrialRunProductUsedForPreliminaryprocesscapabilitystudies.MSA(ifnotcompletedearlier)FinalFeasibility.Processreview.ProductionValidationTesting.PPAPPackagingevaluationFirsttimecapabilityQualityplanningsign-offMeasurementSystemAnalysis(MSA)CompletestudiesasdefinedintheMSAplan.Minimumarethoseidentifiedinthecontrolplan.Subjectedtoevaluationpriortoorduringproductiontrial.PackagingEvaluationPackagingmustconformtospecificationsdevelopedbycustomerorsupplier.Assessprotectionofproduct.Customerspecifiedpackagingmustbeevaluatedbyteam.Pilotorproductiontrialrunpartsusuallyusedinevaluation.FloorPlanLayoutDetermineacceptabilityofinspectionandtestpoints.ControlchartlocationsVisualaidesInterimrepairstationsNonconformingmaterialstorageKeyedtomaterialflowandcontrolplanReviewandSign-OffProcessinstructio