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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