Post on 21-Mar-2018
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A P Q P P P A P&
A V ManivannanPrincipal Consultant & Trainer
CSR
2
A most practical
workshop
A new product development & approval process
S O P for the Workshop on
APQP & PPAP ( as per IATF 16949 : 2016 ) with a focus on CSR
ProcessProgram Objectives
Methodology :
Class Room discussions
Team Exercises ( 20 exercises )
Group Presentations
Best practices on APQP & PPAP
Ice Breaking
The whole course to cover all the
phases with exercises
Evaluation during the sessions
Quiz
Final Test & Evaluation
Verbal Feed Back
Written Feed Back
Structure :
Performance Indicators
▪ Performance during the team presentations
▪ Final Test Marks
▪ Exercise marks during the Program
▪ Program feed-back
Type of Program :-
Technical
Management
Behavioral
Long-term
Hours
No. of Participants
Min. Max.
18 26
10 20
Short-term
Mixed Group : Yes No
Deliverables
Sri Padhmam Consultancy & Training
+91 94428 92185
office@sripadhmam.com
www.sripadhmam.com Target participants : Engineers & above
To familiarize the participants to apply the
concepts & Practices of Advanced Product Quality
Planning & Control Plan ( APQP ) 2nd edition –
Production Part Approval Process ( PPAP )
4th Edition.
To provide the skill sets on new product
development through APQP & PPAP
methodologies.
Also to familiarize on linkages to IATF 16949:2016
requirements.
Usage of APQP, PPAP & Control Plan Methodology
Better focus on Customer requirements
Enhanced skill index
• Origin of APQP
• Basic concepts & Principles
• Linkages to IATF 16949:2016
• Techniques of APQP process
- Quality Function Deployment ( QFD )
- Error proofing & PDCA cycle
- Process Flow for Lean management
- Characteristics matrix
- M E O S T for product validation
- Quality plan
- Gantt chart
- Quality planning sign-off
• Phase 4 of APQP : Linkage to PPAP
• Successful PPAP through structured APQP Process
• Five Phases of APQP – with exercises
• Control plan - Creation & management
• PPAP – How to interpret & Implement ?
• Situations Analysis on PPAP
4A glimpse
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APQP – Importance
APQP &
Control Plan IATF 16949 : 2016
Clause 8
Clause 8.3( inputs & outputs )
Phase 2 & 3 Product Design & Development
# Elements of APQP IATF Clause reference
1 Design FMEA 8.3.5.1
2 Process FMEA 8.3.5.2
3 Design Changes 8.3.6
4 Control plan 8.5.1.1
3
Advanced Product Quality Planning
0
1
2
3
4
5
Phase “0”
CFT formation & Scope definition
Plan & Define
Product design & development
Process design & development
Product & Process validation
Feed-back, assessment & corrective action
0
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Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Quality Function Deployment [ Q F D ]
CFT formation & Scope definition
✓ Prof. Yoji Akao
✓ 1980s
✓ Introduced QFD technique
7
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Quality Function Deployment [ Q F D ]
CFT formation & Scope definition
Harvard business review case study
7.5
+ A
cou
stic
w
ind
ow
Bench marking 1
Bench marking 2
8
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Success factors
CFT formation & Scope definition
Success of an NPD process
Voice of Customers( V O C )
Customer Inputs
Marketing Priorities
Field Conditions
Mfg. Feasibility
Designers’ Competence
QMS strength
Top Management Focus
Internal factors
External factors
10
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Needs & Expectations of the Customer
CFT formation & Scope definition
Prof. KanoJapan
11
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Design goals1.7
Plan & define
Bath tub curve
17
11
Refer Page #
18 to 21
In the workbook
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Preliminary Process Flow Chart ( PFC )1.10
Plan & define
Anticipated
manufacturing process !
Source(s) to prepare
22
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Product assurance plan1.12
Plan & define
Design goals
( section 1.7 )
Product Assurance Plan Design Requirements
23
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Management support1.13
Plan & define
✓ Involve your Top Management !
✓ Inform the Status !
✓ Gain support !
APQP Meeting
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A P
Q P
Product D & D
Design FMEA2.1
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
CFT
Customer inputs
Lessons learnt
Data & information
USE
Boundary diagram
Parameter diagram
Interface matrix
25
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A P
Q P
Product D & D
Design for Manufacturability & Assembly ( DFA & DFM )
2.2
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Cost & Manufacturing Efforts
“User friendly designs”
25
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A P
Q P
Product D & D
Design for Manufacturability & Assembly ( DFA & DFM )
2.2
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
# Focus during DFMA analysis What will be ideal ?
1 No.of parts Less More
2 Common parts Less More
3 Assembly adjustments Less More
4 Self-fastening parts Less More
5 Setting related activities Less More
6 Self-locating parts Less More
7 Masters for setting Less More
8 Standard parts Less More
9 Handling of parts Less More
10 Re-orientation while assembly Less More
Team based exercise : 07
25
Answers Template
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A P
Q P
Product D & D
Design for Manufacturability & Assembly ( DFA & DFM )
2.2
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
D F A & D F M immediate outputs ?
Sub-system drawings
System level drawing
Child part drawings
25
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A P
Q P
Product D & D
Design verification2.3
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 55 phased
APQP approach
Design
Outputs
CustomerRequirements
1. Design Review 2. Documents Review 3. Tests
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# Statement True False Evln
1 Proto samples are not produced, when the customer is not particular about them
2 Pre-launch samples are produced to prove the new product’s concept
3Proto samples shall be produced, even when sufficient real-time facilities are not present
4 Proto-type control plans must have all the ‘process’ related information also
5 At times, even a single unit shall be produced as a proto-type sample
6 The first control plan during the APQP journey is Prototype control plan
7 It is mandatory, that the proto-type control plan to be approved by the Customer
8 Prototype samples shall be used for Road-proving purpose also, always
9 The input for Prototype control plans is only Design FMEA, not Process FMEA
10 Generally, Proto samples are verified 100 %
11Prototype control plans must cover performance test related information, as applicable
12Outputs derived immediately after Proto build are Packaging requirements & Process parameters
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A P
Q P
Product D & D
Prototype Control Plan2.5
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5Team based exercise : 08
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Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Key activities & the outputs2.0
Product D & D
# Description
Spe
cifi
cati
on
s
Do
cum
en
ts /
Li
sts
Act
ivit
ies
Har
d w
are
s
1 Proto-type samples
2 Engineering specification
3 Proto build
4 DFA & DFM
5 Special Characteristics
6 DFMEA & related documents
7 Material specifications
8 Design review
9 Engineering drawings
10 DVP & R
# Description
Spe
cifi
cati
on
s
Do
cum
en
ts /
Li
sts
Act
ivit
ies
Har
d w
are
s
11
12
13
14
15
16
17
18
19
20
List out
Team based exercise : 09
31
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A P
Q P
Process D & D
Product / process Quality system review3.2
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
J R Q M S
Joint Review on QMS
Q M SContract
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A P
Q P
Process D & D
Floor plan layouts3.4
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Purpose ?
To decide what comes Where in the Shop Floor !
Focus ?
Material Travel
Material Handling
Space utilization
Health & Safety
IATF 16949 Clause #
8.3.5.2 ( e )
33
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A P
Q P
Process D & DPhase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Characteristics matrix3.5
Dim
#
Description Tolerance Operation #
10 20 30 40
1 ID 22.5 20 microns X C X
2 Facing 5 microns X C C
3 Boring 67 dia 25 microns X L
4 Chamfering 0.5 x 45 X
5 OD turning 45 18 microns X
X : Characteristics created / changed by this operation. To match PFDC Characteristics at an operation is used for ClampingL : Characteristics at an operation used for Location
Process FMEA !!!
Inputs
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A P
Q P
Process D & DPhase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
CFT
Customer inputs
Lessons learnt
Data & information
USE
Design FMEA
PFD
Characteristics matrix
Process FMEA3.6
Better to focus on Product design solutions !!!
35
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A P
Q P
Process D & DPhase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Clause # 10.2.4 – Error proofing ( EP )
Shall have a documented process to identify
Method to identify EP shall be documented in P FMEA
Test frequency shall be in the control plan
Challenge parts for EP
EP failures shall have a reaction plan
EP failures testing records
Pre-launch Control plan3.7
37
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A P
Q P
Process D & DPhase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Process instructions3.8
Standard Operating Procedures [ S O Ps ]
# Description Input Output No link
1 PFD & Floor plan layouts
2 Design FMEA
3 Process FMEA
4 Set-up Instructions & First piece approval instructions
5 Design & Quality goals
6 Characteristics matrix
7 Capability norms ( 1.33 or 1.67 ) & MSA acceptance criteria
8 Process & Product parameters identified by the APQP team
9 Handling requirements
10 Operators’ knowledge on the process
11 Details from the equipment manufacturers
12 Packaging requirements
13 Current controls ( P & D ) identified in the FMEAs
14 Customer’s inputs relevant to the manufacturing stages
Team based exercise : 12
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A P
Q P
Process D & DPhase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
MSA Plan & Preliminary process capability plan
3.9 & 3.10
Pre-Launch Control Plan
Timing Plan ( for period )
J R Q M S
MSA & Capability Studies : Reference documents ?
39
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A P
Q P
Product & process validationPhase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Significant Production Run4.1
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A P
Q P
Product & process validationPhase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Significant Production Run4.1
Understood by the organization
Organization to demonstrate through PPAP….
✓ Its potentiality ……………………………...
✓ Its consistency …………………………….
of the manufacturing processes
in meeting the requirements
Actual production runQuoted production
rate
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A P
Q P
Product & process validationPhase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
# Statement True False Evln
1 PPAP run must use the Pre-launch Control plan
2 If Customer specified Packaging are used, APQP team need not evaluate the packaging
3 Number of units to be produced during PPAP run may also be specified by the Customer
4 PPAP run must be produced as consecutive units
5 Quality planning sign-off must be done prior to PPAP lot despatch to the customer
6 Additional controls ( such as robust statistical evaluation ) must be identified during PPAP run
7 MSA studies must be completed during the PPAP time
8 Master samples mean ‘First-off’ samples also
9 Production Control plan ( PCP ) must include controls on the Special characteristics also
10 IATF 16949:2016 – Clause 8.1.5.5 is dealing with the PCP
11 PCPs & the Reaction plans are the same
12 Both D & P FMEAs will provide inputs to the PCPs
13 Bulk materials means components such as Fasteners
14 Customer Engineering design record must cover all the Technical requirements in it
Team based exercise : 14
46
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A P
Q P
Product & process validationPhase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Significant Production Run4.1
Run at rate
• After PPAP
• 1000 parts generally
• Run at full speed
• Focus on FPY%
• Use audit checklists
• Identify all bottlenecks
• Focus on Process capability
• Ensure MSA results
• Use PFMEA and PCP for audits
How to perform ? Checklists
Click for hyperlink
Snap allowed !
47
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
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A P
Q P
Management support4.8
✓ Involve your Top Management !
✓ Inform the Status !
✓ Gain support !
APQP Meeting
Product & Process validation
S
Snaps allowed !
34
Best practice # 1
Supplier PPAP approval – a TVS model
Snaps allowed !
35
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Tricky Part of PPAP ?
Pass Through Characteristics
Black Box Items
ROHS & MD systems
Part Weight Criteria
Checked & Marked Prints
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Marked Prints
An engineering drawing – modified, signed and dated by the customer engineer
73.00
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Accelerated Learning Process Matching Exercise
PPAP : Accelerated Learning Match the following in a MOST Logical way !
Ref. Criteria Ref. CriteriaRight
Answers
A Appearance items 1 Stability First & then Performance target
B Initial process Studies 2 NABL certification
C Customer wants 2.0 as Ppk target 3 Take as 3, if Customer has not specified it
D Qualified Laboratory Documentation 4 Re run the PPAP before bulk Production
E Initial process study results are not satisfactory 5 Conduct MSA study and include them in Checking aid list
F Default PPAP level 6Randomly selected 10 parts’ average weight in 4
decimals, written in Kgs
G PPAP target date is advanced by the Customers now 7 Master samples & Limit Samples
H New Vernier and an Air gauge introduced now 8 Inform your Customer before taking any actions
I Part weight in PSW 9 Amend the Timing Plan and speed-up related actions
J Tool has not been used for 16 months, after the PPAP approval 10 Quality Goal and include in the JRQMS ( QMS Contract )
P
P
A
PTeam based exercise : 18
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Please study the situations carefully and decide your action(s).
You may have certain ( logically acceptable ! ) assumptions and conclude.
Must justify your conclusions
Let us have a healthy discussion to enhance our PPAP understanding
Situation Analysis
• PPAP submission level is 2
• The Quality system review & agreement ( JRQMS ) must be kept in mind
Issue the A 3
sheet
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A
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Team based exercise : 20