WELCOME
TO
TRAINING PROGRAMME
ON
PRODUCT QUALITY
PLANNING
( APQP )
BY
PRO-QUALITY ASSOCIATES
DELHI
APQP- 00 P QA 1/ 11
( ADVANCED ) PRODUCT QUALITY PLANNING
STRUCTURED METHOD OF IDENTIFYING AND ESTABLISHING
THE STEPS NECESSARY TO ASSURE THAT A PRODUCT MEETS
THE CUSTOMER REQUIREMENTS
GOAL
TO FACILITATE COMMUNICATION WITH EVERYONE
INVOLVED TO ASSURE THAT ALL REQUIRED STEPS ARE
COMPLETED ON TIME.
EACH PRODUCT QUALITY PLAN IS UNIQUE AND IS
DEPENDENT ON CUSTOMER NEEDS AND EXPECTATIONS.
APQP- 00 P QA 2/ 11
P- D- C - A APPROACH
AT STRATEGIC, PROCESS AND ACTIVITY LEVEL
ACT PLAN
CHECK DO
PLAN PLAN ALL ACTIVITIES OF THE PROCESS IDENTIFYING:-
INPUTS, OUTPUTS, COMPETENCE & RESOURCES
REQUIREMENT, ACTIVITIES & THEIR SEQUENCE,
CONTROL PARAMETERS AND THEIR MEASUREMENTS,
OPPORTUNIYIES FOR IMPROVEMENT.
DO PROVISION OF COMPETENCE & RESOURCES, EXECUTION
OF PROCESS AS PLANNED
CHECK MONITORING & MEASUREMENT, COLLECTION & ANALYSIS
OF DATA , IDENTIFICATION OF ACTIONS NEEDED TO
ACHIEVE PLANNED RESULTS
ACT IMPLEMENT ACTIONS TO ACHIEVE PLANNED RESULTS
AND IMPROVE
APQP- 00 P QA 3/ 11
STEPS OF PRODUCT QUALITY PLANNING
(PLAN)
ORGANISE THE TEAM
IT REQUIRES INVOLVEMENT OF MORE THAN JUST THE
QUALITY DEPARTMENT.
THE FUNCTIONS WHO CAN EFFECTIVELY CONTRIBUTE TO
THE PROCESS OF QUALITY PLANNING ( REPRESENTATIVES
FROM ENGINEERING,MANUFACTURING, MATERIAL
CONTROL, QUALITY, SALES, FIELD SERVICE, SUPPLIERS,
CUSTOMERS, AS APPROPRIATE - CROSS FUNCTIONAL TEAM
( CFT )
SELECT TEAM LEADER
ESTABLISH COMMUNICATIONS WITH
CUSTOMER AND SUPPLIER TEAMS
DEFINE CUSTOMER REQUIREMENTS AND
EXPECTATIONS
DEFINE STATUTORY AND REGULATORY
REQUIREMENTS
CONSIDER COMPANY & CUSTOMER
OBJECTIVES
APQP- 00 P QA 4/ 11
(DO)
STUDY :-
- CUSTOMER EXPERIENCE OF THE PRODCT ( TGW /
TGR )
- COMPETITOR INFORMATION
- TEAM MEMBERS’ PAST EXPERIENCE ON SIMILAR
PRODUCTS (CAPABILITY, PRODUCTIVITY, QUALITY)
- FIELD FAILURE DATA.
- CORRECTIVE ACTION / PROBLEM RESOLUTION
REPORTS
- APPLICABLE STATUTORY & REGULATORY
REQUIREMENTS.
- APPLICABLE PRODUCT STANDARDS.
DRAW PRODUCT QUALITY PLANNING
SCHEDULE ( PQPS ) LISTING :-
- STUDY OF AVAILABLE DOCUMENTS AND INFORMATION ON
THE PRODUCT
- PRODUCT FEASIBILITY ASSESSMENT AND IDENTIFY ADDL.
INFORMATION AND RESOURCE REQUIREMENT
- ESTABLISHMENT OF QUALITY, PRODUCTIVITY AND
RELIABILITY GOALS
- PREPARATION OF PROCESS FLOW DIAGRAM ( PFD )
- IDENTIFICATION OF SPECIAL CHARACTERISTICS –
PRODUCT & PROCESS
APQP- 00 P QA 5/ 11
- PRODUCT DESIGN ACTIVITIES
PRELIMINARY PRODUCT DESIGN
DESIGN FAILURE MODE & EFFECTS ANALYSIS ( DFMEA )
DESIGN REVIEWS AND CORRECTION
DESIGN VERIFICATION AND APPROVAL FOR
DEVELOPMENT
PROTOTYPE BUILD- CONTROL PLAN
DESIGN VALIDATION AND APPROVAL
ENGINEERING DRAWINGS / SPECIFICATIONS- SPECIAL
CHARACTERISTICS
- PACKAGING DESIGN AND DEVELOPMENT
- REVIEW OF PRODUCT FEASIBILITY AND IDENTIFICATION OF
ADDITIONAL RESOURCES
- REVIEW OF PROCESS FLOW DIAGRAM
- CONDUCTING PROCESS FAILURE MODE & EFFECTS ANALYSIS
( PFMEA )
- REVISION OF PFD AND MAKING PRE-LAUNCH CONTROL PLAN
( PROCESS DESIGN ), TAKING MAKE OR BUY DECISION.
ESTABLISHING TOOLING AND GAUGING REQUIREMENT
- ESTABLISHING OPERATION AND INSPECTION STANDARDS
- TOOL & GAUGE DESIGN AND DEVELOPMENT
TOOL AND GAUGE DESIGN
FABRICATION
INSPECTION
TRYOUT AND TOOL CORRECTION
APQP- 00 P QA 6/ 11
- SUPPLIER DEVELOPMENT AND MATERIAL / COMPONENT
PROCUREMENT FOR PILOT LOT
- MANUFACTURE OF PILOT LOT AND
CONDUCT AND ESTABLISH PROCESS CAPABILITY
CONDUCT PROCESS VALIDATION
CONDUCT MEASUREMENT SYSTEM ANALYSIS
CARRYOUT NECESSARY PROCESS AND TOOLING
CORRECTIONS AND ESTABLISH MANUFACTURING
PROCESSES
- COLATION AND APPROVAL OF IDENTIFIED RECORDS
- CUSTOMER APPROVAL IF REQUIRED
- REVISION AND FINALISATION OF PRODUCTION CONTROL
PLANS AND OTHER OPERATING DOCUMENTS.
- PRODUCT QUALITY PLANNING SIGN OFF.
(CHECK)
CONTINUOUS MONITORING OF EVERY
ACTIVITY OF P Q P S
(ACT)
TAKE NECESSARY ACTIONS TO CORRECT THE
SITUATION
APQP- 00 P QA 7/ 11
FEASIBILITY ASSESSMENT
STRUCTURED APPROACH TO ASSESSING FEASIBILITY OF
MEETING CUSTOMER REQUIREMENTS ( AT REGULAR
SUPPLY LEVELS ) WITHIN ORGANISATION’S ESTABLISHED
CAPABILITIES AND CAPACITIES AND IDENTIFICATION OF
ADDITIONAL RESOURCE REQUIREMENTS.
TO BE CONDUCTED BY THE IDENTIFIED CROSS FUNCTIONAL
TEAM (CFT) BEFORE TENDERING AND / OR ORDER
ACCEPTANCE
MAINTAIN RECORDS
IDENTIFICATION OF SPECIAL
CHARACTERISTICS
PRODUCT CHARCTERISTICS AFFECTING FFFSAG
FIT
FUNCTION
FORM
SAFETY
APPEARANCE
GOVERNMENT REGULATIONS
PROCESS NEEDS
USE OF CUSTOMER SPECIFIC SYMBOLS IF THESE
CHARACTERISTICS ARE IDENTIFIED BY THE CUSTOMER
CFT TO REVIEW THESE AND IDENTIFY ANY ADDITIONAL
CHRACTERISTICS AS REQUIRED.
APQP- 00 P QA 8/ 11
PRELIMINARY PROCESS FLOW DIAGRAM -PFD
COVERING ALL PRODUCTION PROCESSES FROM MATERIAL
RECEIPT TILL DESPACH
IN SEQUENCE
IDENTIFYING PRODUCT AND CONTROL
CHARCTERISTICS
HANDLING, MOVEMENT, INSPECTION AND
STORAGE REQUIREMENTS
FAILURE MODE AND EFFECTS ANALYSIS -FMEA
FAILURE MODE – WHAT CAN GO WRONG
CAUSES – EFFECTIVENESS OF CONTROLS
EFFECTS - SEVERITY OF FAILURE
OCCURANCE - PROBABILITY OF FAILURE
DETECTABILITY ( OF FAILURE )
EVALUATION CRITERIA ( TABLES )
RISK PRIORITY NUMBER ( RPN )
ACTION PLAN & RESULTANT RPN
REVIEW AND REVISION OF PFD
APQP- 00 P QA 9/ 11
AS A RESULT OF PFMEA
CONTROL PLAN
A PROCESS ENGINEERING DOCUMENT-RESULTANT OF
PRODUCT QUALITY PLANNING ACTIVITY
FOR –
PROTOTYPE , PRELAUNCH AND PRODUCTION STAGES
CONTAINING –
a) General Data
- control plan number
- issue date & revision date if any
- customer information
- supplier name / site designation
- part number
- part name / description
- engineering change level
- phase covered ( proto, prelaunch, etc. )
- key contact
- part / process step number
- process name / operation description
b) Product control
- product related special characteristics
- other characteristics for control ( number, product or process )
- specifications and tolerance
c) Process control
- process parameters
- process related special characteristics
- machines,jigs,fixtures,tools for manufacturing
d) Methods
- evaluation / measurement technique
- error-proofing
- sample size and frequency
APQP- 00 P QA 10/ 11
- control method
e) Reaction plan and corrective action
- reaction plan ( include or reference )
- corrective action
PPAP
Establishing process through a series of production trials in
accordance with the approved Control Plans using production
tooling at normal production speeds.
Conducted at Pilot stage and getting formal approval of
authorized functions of all listed documents and data together
with the product samples.
Formal release for regular production . This covers Supplier
items too.
APQP SIGN-OFF
APQP- 00 P QA 11/ 11
