APQP Training presentation
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Advanced product quality planning (APQP) is a framework for developing new products with a focus on meeting customer requirements. It involves 5 phases - planning, product design, process design, validation, and feedback. Key aspects of APQP include establishing cross-functional teams, using tools like FMEAs to prevent issues, designing control plans and statistical process control methods, conducting validation trials, and promoting continuous improvement. APQP aims to standardize quality planning processes for increased collaboration with suppliers.
APQP Training presentation
- 1. Advanced product quality planning (APQP) Training for beginners Overview and APQP implementation
- 2. Advanced product quality planning is a framework of procedures and techniques to develop products.
- 3. APQP What is it? • Advanced Product Quality Planning • Framework (Methodology) for developing New Product • Originally Automotive Industry • Up front Quality Planning • Validation • Focus on meeting Customer Requirements • Similar to DFFS (Design for Six Sigma)
- 4. Why APQP? • Standardised approach to make it easier for suppliers • Build components fit for purpose • Plan how it is to be designed • For communication and collaboration • Prevent risks, variation, oversight and issues • Continuous improvement
- 5. The process Plan & Define Product Design & Development Process Design & Development Product & Process Validation Feedback, Assessment & CA
- 6. APQP > Plan • Phase 1: Plan and define Establish Team Establish Communications APQP Training Customer Requirements & Scope Historical Data (Int & Ext) Benchmark Data (Product & Process) Assumptions (Product & Process) Market Opportunity Competitors Customer Design Inputs Design Goals Quality & Reliability Goals IPR / Patents Manufacturing Feasability Pricing Preliminary BOM Preliminary Process Flowchart Preliminary Key Characteristics Marketing Strategy Management Review
- 7. APQP > Do • Phase 2 - Product Design & Development Block Diagram Design FMEA Drawings Specifications Materials Specifications BOM Warranty / Maintenance Design Verification Design review Change Control Make or Buy Decisions Supplier Selection Tooling, Measurement & Test Equip. Pricing Review Prototype Prototype Customer Approval Update Designs Management Review
- 8. APQP > Do • Phase 3 - Process Design & Development Process Flowchart Floor Plan Key Characteristics (Product & Process) Control Plans Process FMEA Process Capability Plan Packaging Specifications Work Instructions Quality System Review Management Review
- 9. APQP > Check • Phase 4 - Product & Process Validation Materials Inspections Trial Production Run (Not Pilot) Measurement Systems Evaluation Process Capability Study Production Validation Testing Packaging Evaluation Production Part Approval Customer Approval Production Control Plan Quality Plan Management Review
- 10. APQP > Act • Phase 5 – Feedback, Assessment & CA Production SPC / Reduction of Variation Continuous Improvement Non- Conformance Management Delivery / Service / Warranty Monitoring Customer Satisfaction Reporting Management Review
- 11. SPC: Statistical process control
- 12. SPC / Reduction of variation SPC / Reduction of variation • Establish Engineering Tolerances (Phase 2) • Establish Key Characteristics (KCs / KPs) (Phase 1&3) • Determine Process Steps for Measurement (Phase 3) • Raise Control Plans (Phase 3) • Select Control Charts (Phase 3) • Perform Gauge Variation Study’s (Phase 4 or Earlier) • Test Control Plan / Charts (Phase 4) • Implement Control Plan (Phase 5)
- 13. APQP > FMEA • Failure Modes and Effects Analysis • Failure Mode – What can go wrong • Effects Analysis - Consequences • US Military – 1950s • Systems, subsystems, assembly, parts • Process, sub-process, tasks
- 14. FMEA > Spreadsheets versus Risk Manager • Engage leadership with Risk Manager • Collect risks from across your business • Risk Manager integrates with other modules e.g. Issue Manager, for a systematic approach to assessing risks • Roles and responsibilities are communicated and shared within the system, with a full audit trail • Demonstrate compliance and due diligence in a robust, incorruptible
- 15. Gauge variation study • Gauge R&R • Variation due to Measurement Process • Reproducibility – variation due to different Operators • Repeatability – variation due to Gauge itself • Measurement Variation = R+R • Total Variation = MV + Product Variation • Typically use Three Test Operators, each measuring Five Parts, Ten Times. (50 measurements / Operator)
- 16. Document Manager and Record Management • QMS Documentation (Processes, SOPs, WIs) • Planning Documentation (Phase 1) • Design Documentation (Phase 2&3) • Flowcharts / Block diagrams • Drawings • Specifications • Records of Reviews • Records of Approvals • Production Part Approval
- 17. Issue Manager • Historical Data (Lessons Learnt) (Phase 1) • Planning Control (Phase 1,2,3,4) • Non-Conformance Management (Phase 5)
- 18. Audit Manager • Historical Data (Lessons Learnt) (Phase 1) • Planning Control – Process Checklists (Phase 1,2,3,4) • Planning Control – Process Validation (Phase 1,2,3,4) • Audit - Continuous Improvement (Phase 5) • In Process Inspections (Phase 5)
- 19. Training Records Manager • Records staff competency • Demonstrate and test competency
- 20. Aizlewood’s Mill, Nursery Street, Sheffield S3 8GG +44 114 282 3338 [email protected] Request a live demonstration of our software for APQP here: http://quality.eqms.co.uk/eqms-software- demonstration
Editor's Notes
- #2: Advanced product quality planning (or APQP) is a framework of procedures and techniques used to develop products in industry, particularly the automotive industry. How do we build components from when we receive the scope from the customer, how we design it, what deliverables we have up until we launch it into mass production. All components that deliver to the automotive OEMs need to follow the APQP process. APQP came about because there were so many suppliers who not only supply to one car manufacturer but to multiple car manufacturers and they did not want to have to follow through your four different set of processes and so the car manufacturers actually got together and said, “OK, we may be competitors but we better come up with something to help our suppliers here”.
- #7: Establish Team Establish Communications APQP Training Customer Requirements & Scope Historical Data (Int & Ext) Benchmark Data (Product & Process) Assumptions (Product & Process) Market Opportunity Competitors Customer Design Inputs Design Goals Quality & Reliability Goals IPR / Patents Manufacturing Feasability Pricing Preliminary BOM Preliminary Process Flowchart Preliminary Key Characteristics Marketing Strategy Management Review
- #8: Block Diagram Design FMEA Drawings Specifications Materials Specifications BOM Warranty / Maintenance Design Verification Design review Change Control Make or Buy Decisions Supplier Selection Tooling, Measurement & Test Equip. Pricing Review Prototype Prototype Customer Approval Update Designs Management Review
- #9: Process Flowchart Floor Plan Key Characteristics (Product & Process) Control Plans Process FMEA Process Capability Plan Packaging Specifications Work Instructions Quality System Review Management Review
- #10: Materials Inspections Trial Production Run (Not Pilot) Measurement Systems Evaluation Process Capability Study Production Validation Testing Packaging Evaluation Production Part Approval Customer Approval Production Control Plan Quality Plan Management Review
- #11: Production SPC / Reduction of Variation Continuous Improvement Non- Conformance Management Delivery / Service / Warranty Monitoring Customer Satisfaction Reporting Management Review