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1、APQPPPAP APQP APerspectiveon8 DandPFMEAandControlPlanDuringAPQPandAfterwards WhatisAPQP APQPisa defined processforaproductdevelopmentsystemforFord Daimler Chrysler GMandtheirsuppliers APQPisanattempttoprovideacommonpathandsynchronizationofproductdevelopmentactivities APQPisanattempttoensurecommunica
2、tionbothwithinacompanyandbetweenacompanyanditscustomer BenefitsofAPQP Ensuresearlyplanningtakesplace Directsresourcestothecustomer Identifiesrequiredchangesearlyintheprocess Providesqualityproductontimeandatlowestcost Enablescross functionalinputsandoutputs Addressespotentialproblemsearly Customeran
3、dSupplierInvolvement Customermayinitiateplanningprocess Supplierhastheobligationtoestablishcross functionalteamtomanageprocess Suppliershouldexpectthesameperformancefromtheirsubcontractors DetermineCustomerRequirements PrintPurchaseRequestorRequestforQuotation StatementofWork SOW Customervisitsanddi
4、scussions Productchecklists Training Customerneedsandexpectations Workingasateam RequirementsofAPQPFMEAAPQPPPAP APQPFivePhaseProcess Planning ProductDesignandDevelopment ProcessDesignandDevelopment ProductandProcessValidation Production FeedbackAssessmentandCorrectiveAction Pilot Launch ConceptIniti
5、ation Approval ProgramApproval Prototype Planning LinksBetweentheTools ContractReviewProgramPlan DFMEA TeamFeasibilityCommitment ProduceProcessFlowDiagrams ConductProcessFMEA DevelopControlPlan WorkInstructionDevelopment ProductandProcessValidation EnsureContinuousImprovement PhaseI PhaseII PhaseII
6、PhaseIII PhaseIII PhaseIII PhaseIII PhaseIV PhaseV DetermineCustomerExpectationsandPlanforQuality IdentifyKeyCharacteristics DetermineRiskandFeasibility AssociateCharacteristicswithProcessStepsandIdentifyKeyCharacteristics ExposeSourcesofVariationandFinalizeKeyCharacteristics DetermineMethodstoImpro
7、veProcessandControlVariation ImplementControlPlanandStandardizetheProcess EnsureCustomerExpectationsareMet ExerciseManagementOversight TheTargetandTheGoal LinkBetweentheDocuments ProcessFlowDiagrams Updatedafterproductiontrialrun Needtoindicatespecialcharacteristicsgeneratedateachstep CompletedAlong
8、withControlPlan APQPProcess Generallycontainssameinformationasprocesstraveler ProcessFlowDiagramExample APQPLinkstoPFMEA ProcessFMEA Mustfollowflowoftheprocessflowdiagram MustincludeALLprocessspecialcharacteristics asaminimum HowaPFMEAWorks WheredoesthedataforthePFMEAcomefrom Whattypesofpeopleareapa
9、rtofthePFMEAteam Whattypesofactivitiesshouldwespendalotoftimeon PFMEAs ControlPlansand8 DsDuringAPQP PFMEAsshouldbedrivenbyrealdata including8 Ds internalandexternal warrantyandreturnedpartanalysisPFMEAsshouldbecompletedbyprocessexpertsandshouldbeadriverofthecontrolplansandworkinstructionsWorkinstru
10、ctions Postcontrollog processparameterlogs preventivemaintenance etc implementthecontrolplanintheprocessWhenthereisaqualityproblemthereisanopportunitytoimprovethecontrolplanandtheworkinstructions APQPLinkstoControlPlan ControlPlans Includesproductandprocessspecialcharacteristics IncludesSPCrequireme
11、nts FollowsflowofprocessflowchartandPFMEA Mayrequirecustomerapproval TypesofControlPlans Prototypebuildcontrolplan s Pre launchcontrolplanProductioncontrolplan PrototypeBuildControlPlan Adescriptionofthedimensionalmeasurements MaterialtestsFunctionalteststhatwilloccurduringprototypebuild Pre launchC
12、ontrolPlan Descriptionofdimensionalmeasurements materials andfunctionaltests Addsadditionalproductandprocesscontrols Purposeistocontainpotentialnonconformitiesutilizing Morefrequentinspectionsand ortests Morein processandfinslinspectionand orcheckpoints Statisticalevaluations Increasedaudits Product
13、ionControlPlan Up datepre launchcontrolplan Add SamplingplansControlmethodSPC inspection attributedataandmistakeproofing ReactionplanNonconformancesclearlyidentified quarantinedanddispositionmade Requirescustomerapprovalunlessotherwisespecified ControlPlanUse Initial Todocumentandcommunicateinitialp
14、rocesscontrol Next Guidanceincontrollingprocessesandtoensureproductquality LastAlivingdocumentreflectingcurrentmethodsofcontrolandmeasurementsystemsused MultipleMolds Tools DiesandPatterns Completedimensionallayerrequiredfromonepartfromeachcavityasaminimum Suppliermustidentifyspecificcavityforeachpa
15、rtsubmitted PartSubmissionStatus Nevershipproductionpartsbeforereceivingcustomerapproval Suppliermustensurethatfutureproductioncontinuestomeetcustomerrequirements Noproductionpartscanbeshippeduntilapprovalisreceived AutomotiveDocumentationDevelopment DevelopProcessFlowListing CheckforCustomerRequire
16、ments EnterEvery Major ProcessfromFlowListingintoFMEAForm Givecarefulconsiderationtowhatyouconsidera Major process DevelopFMEAElementforEveryProcess UsetheappropriateRPNnumbersandconsiderationsofotherappropriateinformation datatodetermineCriticalcharacteristics DeveloptheControlPlanwithCriticalCharacteristics DevelopcontrolmechanismsappropriateforCriticalcharacteristics GivecarefulconsiderationtodefiningControlPlanstages PrototypePre launchProduction ProvidesProofofCapabilityMadeupofDocumentsfro
