Post on 21-Feb-2018
transcript
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APQPADVANCED PRODUCT QUALITY PLANNING
TRAINING COURSE
&
&
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KEY OBJE CTIV E TARGE T
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What is APQP ?
A = Advanced
P = Product Mass Products Q = Quality
P = Planning
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ADVANCED ?
Control Plan
FMEA
SPCMSA
Team Planning 5W 2H + Core Tools Implementation
APQP
Process Flow
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CSRCustomer Specific Requirements
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4M1E APQP 4M (APQP Phase 3)
MachineMaterial
MethodsEnvironmentMan
Process Flow Chart
Work Instructions
MSAPFMEA
Control Plan
skill Operator
spec MachineMaterial Handing
Fixture / Tooling Tool life
CustomerRequirements
CustomerSatisfaction
parameters
Check Sheets
SPC
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FAIL TO PLAN IS PLANNING TO FAIL !!!
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EXERCISE
Brain Storm With Your Group
Strength & Weakness of APQP Activity
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APQP
Management
Technical
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/
Time
Problem
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Core Team
Supporters
Sale
Purchase
Store
HR
Safety Supplier
Customer
Specialist
Engineering Production
QA - QC
Maintenance
Tooling
APQP Team Cross Functional Team
Multidisciplinary Approach
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RiskAnalysis
ManufacturingFeasibility
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Example : Mfg. Feasibility & Risk Analysis
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APQP TIMING PLANS
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APQP Monitoring Report
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APQP Timing Chart
Plan & DefineProgramme
Product Design &
Development
Verification
Product & ProcessValidation
Feedback Assessment& Corrective Action
Reliability &Quality Goals
Pre PFC
Pre SC of
Product &
Process
ManagementSupport
DFMEADrawing
Eng Spec
Material
Spec
Prototype CP
ManagementSupport
PFC + SCFloor Plant
PFMEA
Ppk Plan
Pre Launch CP
MSA Plan
Packing Std.
Training Plan
ManagementSupport
Training RecordProduction Trial
MSA Result
Ppk Result
Validation Test
Production CP
PPAP
Sign Off
ManagementSupport
CustomerSatisfaction
QCD
Reduction
Variation
Lesson Learned
ManagementSupport
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
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APQP : Phase 1
Plan and Define Program
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APQP Timing Chart
Plan & DefineProgramme
Product Design &
Development
Verification
Product & ProcessValidation
Feedback Assessment& Corrective Action
Reliability &
Quality Goals
Pre PFC
Pre SC of
Product &
Process
ManagementSupport
DFMEA
Drawing
Eng Spec
Material
Spec
Prototype CP
ManagementSupport
PFC + SC
Floor Plant
PFMEA
Ppk Plan
Pre Launch CP
MSA Plan
Packing Std.
Training Plan
ManagementSupport
Training Record
Production Trial
MSA Result
Ppk Result
Validation Test
Production CP
PPAP
Sign Off
ManagementSupport
Customer
Satisfaction
QCD
Reduction
Variation
Lesson Learned
ManagementSupport
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
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EXERCISE
Brain Storm With Your Group
What to Plan on Your APQP Activity
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PHASE1:
Requirements & Needs
Expectations
Claim Complaint
Quality Defect M/C Capacity
Delivery Performance
Target P-Q-C-D
Performance (2P)
Reliability & Warrantee
Benchmark
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Phase 1 : Outputs
Cycle Time
Productivity Cost Per Unit
Defect Rate (PPM or DPM)
Process Capability Product Performance
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APQP : Phase 2
Product Design & Development
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APQP Timing Chart
Plan & DefineProgramme
Product Design &
DevelopmentVerification
Product & ProcessValidation
Feedback Assessment& Corrective Action
Reliability &
Quality Goals
Pre PFC
Pre SC of
Product &
Process
ManagementSupport
DFMEA
Drawing
Eng Spec
Material
Spec
Prototype CP
ManagementSupport
PFC + SC
Floor Plant
PFMEA
Ppk Plan
Pre Launch CP
MSA Plan
Packing Std.Training Plan
ManagementSupport
Training Record
Production Trial
MSA Result
Ppk Result
Validation Test
Production CP
PPAPSign Off
ManagementSupport
Customer
Satisfaction
QCD
Reduction
Variation
Lesson Learned
ManagementSupport
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
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APQP : Phase 3
Process Design & Development
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APQP Timing Chart
Plan & DefineProgramme
Product Design &
DevelopmentVerification
Product & ProcessValidation
Feedback Assessment& Corrective Action
Reliability &
Quality Goals
Pre PFC
Pre SC of
Product &
Process
ManagementSupport
DFMEA
Drawing
Eng Spec
Material
Spec
Prototype CP
ManagementSupport
PFC + SC
Floor Plant
PFMEA
Ppk Plan
Pre Launch CP
MSA Plan
Packing Std.Training Plan
ManagementSupport
Training Record
Production Trial
MSA Result
Ppk Result
Validation Test
Production CP
PPAPSign Off
ManagementSupport
Customer
Satisfaction
QCD
Reduction
Variation
Lesson Learned
ManagementSupport
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
P Fl Ch t PFCP 3 O
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Process Flow Chart : PFC
FMEA
PHASE 3 : OUTPUTS
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Floor Plant Layout
PHASE 3 : OUTPUTS
Phase 3 O tp ts
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Phase 3 : Outputs
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FMEAFailure Mode & Effect Analysis
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FMEAFMEAFMEAFMEA
Prioritize()
Identify ()
Reduce ()
Risks !
()
Severity ()
Occurrence ()
Detection ()
Reduce ()
Phase 3 : Outputs
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FMEA Assessment Method
1
2
3
4
5
(Failure)
Failure
1-10
Failure
1-10
1-10
PFC Steps Failure Severity Occurrence Detection
100%
0%
S O DRPN =
Example : PFMEA
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Example :PFMEA
(s)
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S-Severity
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S Severity
Please see in appendix : A
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D-DETECTION
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D DETECTION
D-DETECTION
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D-DETECTION
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CPControl Plans
Control Plan
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Prototype Pre-launch Production
Control Plan
prototype
Production ControlPlan
Control Plan
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Control Plan
Work InstructionsPHASE 3 : OUTPUTS
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Work InstructionsPHASE 3 : OUTPUTS
Phase 3 : Outputs
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Phase 3 : Outputs
MSA Control Plan
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MSA Control Plan
70 WAX
1
B 2+0.5
3
SPC
(X bar-RChart)
/
/
/
MSA
MSA Control Plan
Ph 3 O t t
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Phase 3 : Outputs
(Ppk Study Plan) (SC) Control Plan , , CSR
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APQP : Phase 4
Product & Process Validation
APQP Timing Chart
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APQP Timing Chart
Plan & DefineProgramme
Product Design &
DevelopmentVerification
Product & ProcessValidation
Feedback Assessment& Corrective Action
Reliability &
Quality GoalsPre PFC
Pre SC of
Product &
Process
ManagementSupport
DFMEA
DrawingEng Spec
Material
Spec
Prototype CP
ManagementSupport
PFC + SC
Floor PlantPFMEA
Ppk Plan
Pre Launch CP
MSA Plan
Packing Std.Training Plan
ManagementSupport
Training Record
Production TrialMSA Result
Ppk Result
Validation Test
Production CP
PPAP FileSign Off
ManagementSupport
Customer
SatisfactionQCD
Reduction
Variation
Lesson Learned
ManagementSupport
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
Phase 4 : Outputs
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Phase 4 : Outputs
(Significant production run) 4M 1E
Dimension Check Data Performance Test (If require)
Master Sample
Target Cycle Time
( MSA)
Phase 4 : Outputs
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Phase 4 : Outputs
(MSA)
MSA Selection Procedure
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DataType
Variable data Attribute data
Focus
Accuracy Precision
Gauge Linearity
Stability Gauge R&R Study Attribute
Agreement Analysis
Bias Study
Attribute R&R
Product Decision :
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Good Bad
Accept (Type II Error: )
Reject (Type I Error: )
TYPE I ERROR = TYPE II ERROR =
Variation of Measurement System
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Variation of Measurement System
Man (AV)Machine (EV)
Method Material (PV)
Environment
Product, Process MS
PHASE 4 : OUTPUTS
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Process Capability Study
23.423.122.822.522.221.921.6
LSL USL
LSL 21.5
Target *USL 23.5
Sample Mean 22.5308
Sample N 125
StDev (Within) 0.184908
StDev (O v erall) 0.188657
Process Data
C p 1.80
C PL 1.86
C PU 1.75
C pk 1.75
Pp 1.77PPL 1.82
PPU 1.71
Ppk 1.71
C pm *
O v erall Capability
Potential (Within) C apability
PPM < LSL 0.00
P PM > U SL 0.00
PPM Total 0.00
O bserved Performance
PPM < LSL 0.01
P PM > U SL 0.08
PPM Total 0.09
Exp. Within Performance
PP M < LSL 0.02
P PM > U SL 0.14
PPM Total 0.16
Exp. Ov erall Performance
Within
Overall
Process Capability of Daimeter
OK ?
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Ppk > 1.67 Acceptable
Ppk < 1.67 > 1.33 Needs Controls
Ppk < 1.33 100% Check
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CpkPPM (Part Per Million)
DPM (Defect Per Million)
Cpk PPM
0.67 45,600
1.00 2,700
1.33 64
1.67 1
2.00 0.002
Phase 4 : Outputs
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(Production Control Plan)
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Control Plan
(ECR, ECN)
(Process Change) (Unstable) (Uncap ability) , ,
PPAP File
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PSW: Part Submission Warrant Sample Parts
Dimension Check / Performance Test
Material Performance Test
Engineering Drawing / Design Record
Engineering Change Documents
Check Fixtures / Checking Aids Manual
Process Flow Chart
FMEA
Control Plan
Process Capability Study (Ppk, Cpk) Measurement System Analysis
Lab Accreditation & Scope
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APQP : Phase 5
Feedback, Assessment & Corrective Action
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Q & A
end of presentation
FEEDBACK or CONTACT US
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Thank YouCONTACT US:
NUKOOL THANUANRAM
SENIOR CONSULTANT & INSTRUCTORE-MAIL: NUKOOL2001@GMAIL.COM
MOBILE PHONE: 081 400 3954TWITTER & FACEBOOK: NUKOOL2001