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1、APQPIntroduction講師 顏光華蔡建河2003 08 13 15 05 04 2020 T VRheinlandTaiwanLtd 2003T VRheinlandTaiwanLtd Allrightsreserved 先期產品品質規劃與管制計劃 APQP APQPA Advanced 先期的P Product 產品Q Quality 品質P Planning 規劃CPC Control 管制P Plan 規劃 APQP的淵源 APQP的前身是福特汽車的AQP AdvancedQualityPlanning 編輯APQP CP ControlPlan管制計劃 的時候 為了調合三大汽
2、車廠及卡車廠本身的APQP需求 以福特的Mr MikeMazur為主的團隊 參考各廠之特色 撰寫了APQPandControlPlan 先期產品品質規劃與管制計劃 先期產品品質規劃和管制計劃效益 降低顧客與供應商在產品品質規劃方面之複雜性做為供應商與分包商在產品品質規劃需求上容易溝通之方法滿足顧客之資源指引推動早期明定變更之要求避免晚期變更準時提供低成本之合格產品 WhatistheAIAG sAPQPReferenceManual APQP手冊的目的 ItIsGeneralInformation泛用資訊ItDoesNotAddressSpecificManufacturerInformati
3、onorRequirements非強制要求ItisNOTAuditable非稽核用ItDoesNOTAddressAnySpecificIndustryorManufacturer不限產業 Basics DoNOTtrytowriteaprocedurejustliketheAPQPreferencemanual 不要100 copy該手冊LookatwhatYOUaredoingandrelateittotheAPQPprocessdescribedbythereferencemanual 查核貴公司活動與手冊規定的關聯性Bereadytoexplain Equivalencies Wher
4、eandHowandWhatyoursystemdoeswhichfulfillsAPQPtimelineelements 解釋貴公司做法與手冊規定的一致性 TheTarget Goal目標 Continuousimprovement持續改善 Prototype Pre launch Massproduction LSL規格下限 USL規格上限 產品品質規劃時序圖 QS9000APQPInvolves QS條文與APQP的關聯性 4 1ManagementResponsibility4 2QualitySystem4 3ContractReview4 4DesignControl4 5Docu
5、mentandDataControl4 6Purchasing4 9ProcessControl4 10Inspection QS9000APQPInvolves 4 11Inspection MeasuringandTestEquipment4 12InspectionandTestStatus4 13ControlofNonconformingProduct4 14CorrectiveAction4 15Handling Storage PackagingandDelivery4 16QualityRecords4 18Training4 19Servicing4 20Statistica
6、lTechniques EachAPQPisUnique每一APQP都是獨一無二的 Becauseofproductandprogramdifferences產品及計劃不同Timingandsequencearedependentuponcustomerneedsandexpectations依客戶需求及期望展開時間及順序Productcomplexity產品複雜性Stamping沖壓Sub assembly組立New新產品Modification設變 ProgressiveFundamentals成功的基礎 KEY OrganizeaCross FunctionalTEAM組成跨功能小組De
7、finethescope定義範圍Team to teamcommunications組對組溝通Training訓練Simultaneous concurrent engineering同步工程ControlPlanPhases控制計劃階段Prototype Pre Launch ProductionConcernresolution解決問題Includesanalyticaltechniques分析的技術 TeamOrganization Cross functional跨功能小組Engineering Typicallytheleader QualityAssurance Purchasin
8、g ManufacturingEngineering MaterialControl Sales MarketingEtc Participationappropriateforphasebeingconducted依階段有不同參加人員Resources Teamdefines Needs 小組定義需求 Should involvecustomerorsubcontractorparticipation notalwaysfeasible 客戶或供應商的參與 DefineScope Selectteammembersandfunctions選擇組員及功能Definerolesandrespon
9、sibilities定義權責Identifyexternalcustomerneeds expectationsandrequirements鑑別外部客戶需求Identifyinternalcustomerneeds expectationsandrequirements鑑別內部客戶需求Completepreliminaryfeasibilitystudy完成初期可行性評估Identifycosts timingandconstraints鑑別成本 時間及限制Identifydocumentationprocessandmethod鑑別文件及方法Developprogramplan ifpro
10、jectisago 發展開發計劃 Team to TeamCommunication ManageusingtheAPQPprocess使用APQP過程管理Understandingof HowWeWorkAsATeam 了解如何以小組方式運作ShouldhaveaFocusPerson DistributedMinutes應有核心人員及分發紀錄Customerteams Internalteams SubcontractorsteamsSubcontractorsshouldbeencouragedtoembraceAPQPandQS9000分包商應被鼓勵使用APQP QS 9000 Tra
11、ining Customerneedsandexpectations客戶需求WorkingasaTeam以小組方式運作Developmentskills開發技巧RequirementsofAPQPFMEAPPAPSPC RecommendedStatisticalCourses建議的統計課程 BasicBusiness基本業務 AdvancedBusiness進階業務Office Staff Management SelectedStaff ManagementStatisticalProcessControl MSA DesignofExperiment統計製程管制量測系統分析實驗計劃法 P
12、roductionFloor ProductionStaff Management AllofQuality Engineering YourAPQPTeamshouldattendasmanyclassesastimewillallow ProductionStaff Management AllofQuality Engineering SpecificProductionStaff Quality Engineering QAmanager productengineer CustomerandSupplierInvolvement客戶及廠商的參與 Customermayinitiate
13、theplanningprocess由客戶啟動計劃過程Supplierhastheobligationtoestablishcross functionalteamtomanageprocess廠商有義務建立跨功能小組來管理過程Suppliershouldexpectthesameperformancefromtheirsubcontractors廠商應要求其供應商有相同表現 Simultaneous Concurrent Engineering同步工程 Requirescross functionalteamparticipation需要跨功能小組參與Replacespriorsystemo
14、fsequentialphases取代過去順序式的做法Expeditenewproductintroduction加速新產品導入APQPteamensuresthatotherfunctionsandteamsplanandexecuteactivitiessupportcommongoals確保其他小組計劃並執行支援活動 CustomerRequirements客戶要求 WaystoDetermineCustomerRequirements來源Print圖面PurchaseRequestorRequestforQuotation採購單QFD QualityFunctionDeployment
15、品質機能展開ServiceEngineers售服工程師VerbalCommunications口頭溝通DevelopmentEngineers開發工程師ProductCheckList查檢表 BaseDocumentation文件 CriticalCharacteristicsMatrix特性矩陣ProcessFlowDiagram流程圖DesignFMEAProcessFMEAControlPlan ChickenorEgg先有雞先有蛋 WhichisFirst Second Third ControlPlan ProcessFlowDiagram DesignFMEA ProcessFME
16、A ProcessDocumentation Work Instructions WhyDoesitMatter 為何重要 TypicalAutomotiveTrilogyDevelopment開發三部曲 APQPTimeline ProcessFlowDiagram IncludesALLProcesses DesignFMEA ProcessFMEA OnALLProcesses CriticalCharacteristics FailureEffectsIssues ProcessControlPlan CriticalProcessesfromFMEA CriticalCharacteristics CharacteristicControlIssues SomeElementsmaybeIncludedOn TheLinks連接 EachFlowChart element withhistoricalissuemusthaveamatchingFMEAelement Asa trilogy remember thelinksmustallmatch 流程 歷史事件及FMEA的
