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    [精选]APQP与PPAP概述(英文版)jwy.pptx

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    [精选]APQP与PPAP概述(英文版)jwy.pptx

    APQPPPAP APQPA Perspective on 8-D and PFMEA and Control Plan During APQP and AfterwardsWhat is APQP?APQP is a defined process for a product development system for Ford,Daimler-Chrysler,GM and their suppliers.APQP is an attempt to provide a common path and synchronization of product development activities.APQP is an attempt to ensure communication both within a company and between a company and its customerBenefits of APQPEnsures early planning takes place.Directs resources to the customer.Identifies required changes early in the process.Provides quality product on time and at lowest cost.Enables cross-functional inputs and outputs.Addresses potential problems earlyCustomer and Supplier InvolvementCustomer may initiate planning process.Supplier has the obligation to establish cross-functional team to manage process.Supplier should expect the same performance from their subcontractors.Determine Customer RequirementsPrintPurchase Request or Request for Quotation.Statement of Work(SOW)Customer visits and discussions.Product checklists.TrainingCustomer needs and expectations.Working as a team.Requirements of APQPFMEAAPQPPPAPAPQP Five Phase ProcessPlanningProduct Design and DevelopmentProcess Design and DevelopmentProduct and Process ValidationProductionFeedback Assessment and Corrective ActionPilotLaunchConcept Initiation/ApprovalProgram ApprovalPrototypePlanningLinks Between the ToolsContract Review Program PlanDFMEATeam Feasibility CommitmentProduce Process Flow DiagramsConduct Process FMEADevelop Control PlanWork Instruction DevelopmentProduct and Process ValidationEnsure Continuous ImprovementPhase IPhase IIPhase IIPhase IIIPhase IIIPhase IIIPhase IIIPhase IVPhase VDetermine Customer Expectations and Plan for QualityIdentify Key Characteristics Determine Risk and FeasibilityAssociate Characteristics with Process Steps and Identify Key CharacteristicsExpose Sources of Variation and Finalize Key CharacteristicsDetermine Methods to Improve Process and Control VariationImplement Control Plan and Standardize the ProcessEnsure Customer Expectations are MetExercise Management OversightThe Target and The GoalLink Between the DocumentsProcess Flow DiagramsUpdated after production trial run.Need to indicate special characteristics generated at each step.Completed Along with Control Plan(APQP Process).Generally contains same information as process traveler.Process Flow Diagram ExampleAPQP Links to PFMEAProcess FMEAMust follow flow of the process flow diagram.Must include ALL process special characteristics(as a minimum).How a PFMEA WorksWhere does the data for the PFMEA come from?What types of people are a part of the PFMEA team?What types of activities should we spend a lot of time on?PFMEAs/Control Plans and 8-Ds During APQPPFMEAs should be driven by real data,including 8-Ds(internal and external),warranty and returned part analysisPFMEAs should be completed by process experts and should be a driver of the control plans and work instructionsWork instructions(Post control log,process parameter logs,preventive maintenance,etc.)implement the control plan in the processWhen there is a quality problem there is an opportunity to improve the control plan and the work instructionsAPQP Links to Control PlanControl PlansIncludes product and process special characteristics.Includes SPC requirements.Follows flow of process flow chart and PFMEA.May require customer approval.Types of Control PlansPrototype build control plan(s)Pre-launch control planProduction control planPrototype Build Control PlanA description of the dimensional measurements.Material testsFunctional tests that will occur during prototype build.Pre-launch Control PlanDescription of dimensional measurements,materials,and functional tests.Adds additional product and process controls.Purpose is to contain potential nonconformities utilizing:More frequent inspections and/or tests.More in-process and finsl inspection and/or check points.Statistical evaluations.Increased audits.Production Control PlanUp-date pre-launch control plan.Add:Sampling plansControl methodSPC,inspection,attribute data and mistake proofing.Reaction planNonconformances clearly identified,quarantined and disposition made.Requires customer approval unless otherwise specified.Control Plan UseInitial:To document and communicate initial process control.Next:Guidance in controlling processes and to ensure product quality.Last A living document reflecting current methods of control and measurement systems used.Multiple Molds,Tools,Dies and PatternsComplete dimensional layer required from one part from each cavity as a minimum.Supplier must identify specific cavity for each part submitted.Part Submission StatusNever ship production parts before receiving customer approval.Supplier must ensure that future production continues to meet customer requirements.No production parts can be shipped until approval is received.Automotive Documentation DevelopmentDevelop Process Flow ListingCheck for Customer RequirementsEnter Every “Major”Process from Flow Listing into FMEA Form Give careful consideration to what you consider a“Major”processDevelop FMEA Element for Every ProcessUse the appropriate RPN numbers and considerations of other appropriate information/data to determine Critical characteristicsDevelop the Control Plan with Critical CharacteristicsDevelop control mechanisms appropriate for Critical characteristics.Give careful consideration to defining Control Plan stagesPrototype Pre-launch ProductionProvides Proof of CapabilityMade up of Documents from APQP PPAP PurposeEnsure that customer design record and specification requirements are understood.Ensure that the process has the potential for producing product meeting those requirementsPPAP ScopeProduction parts-generally 300 pieces.Includes internal and external sources for information.Submission required prior to first production shipment.Base DocumentationCritical characteristics matrix.Process flow diagram.Design FMEA(supplied by customer).Process FMEA.Control plan.GeneralSupplier is responsible for meeting all applicable specifications.Do not submit parts and documentation results if they are outside specification.Take corrective action to meet all design record requirements.Contact customer if unable to meet all requirementsComply with customer developed material specifications and/or approved source list.GeneralSuppliers are required to complete and maintain copies of all documentation identified in“requirements for approval”regardless of submission level.Records of PPAP are to be retained for the life of the part plus one calendar year.Elements of a PPAPPart submission warrantSubcontractor warrantsDesign record(customer/design documentation)Sample/Master sample(Master sample retained by supplier)Dimensional analysisTest dataFlow diagramControl planPFMEAMeasurement Systems Analysis(GR&R)Capability studiesParts Submission WarrantUpon satisfactory completion of all required measurements and tests,enter all required information on the warrant.A separate is required for each part number.Responsible supplier official verifiesMeasurements and tests conform to customer requirementsRequired documentation is available for proper submission level.Signs warrant and provided date,title and telephone number.Part WeightDetermine part weight without packaging or shipping material.Report weight in kilograms to three decimal places.Weight determinationWeigh 10 parts randomly selected and report the average weight.For parts less than 0.100 kilogram,weigh 10 parts together and report the average weight.Master SampleRetain same as PPAP,orUntil new master sample is produced for the purpose of a customer approval.Identify master sample by:Part numberDrawing level or revision levelCustomer approval datePreliminary Process Capability StudiesCharacteristics identified in the control plan.Usually 100 pieces minimum.May be 30 if run is less.Ppk 1.67 is acceptable unless otherwise specified.Ppk 1.67 requires action plan unless otherwise specified.Production Trial RunProduction tooling,equipment,environment,facilities and cycle time.Process Instructions and control plans.Minimum quantity set by the customer.Generally 300 parts.Production Trial Run Product Used ForPreliminary process capability studies.MSA(if not completed earlier)Final Feasibility.Process review.Production Validation Testing.PPAPPackaging evaluationFirst time capabilityQuality planning sign-offMeasurement System Analysis(MSA)Complete studies as defined in the MSA plan.Minimum are those identified in the control plan.Subjected to evaluation prior to or during production trial.Packaging EvaluationPackaging must conform to specifications developed by customer or supplier.Assess protection of product.Customer specified packaging must be evaluated by team.Pilot or production trial run parts usually used in evaluation.Floor Plan LayoutDetermine acceptability of inspection and test points.Control chart locationsVisual aidesInterim repair stationsNonconforming material storageKeyed to material flow and control planReview and Sign-OffProcess instructions in place and followed!Flow charts in place and followed!GR&R plans exist and are followedPublish final feasibility reportObtain formal sign-offSchedule and conduct management reviewObtain management commitment to assist in open issuesQuality ProblemsyesnonoyesnoyesnoyesCause unknownUse PFMEANote:When a customer problem occurs,follow customer prescribed methodologyWhen to use 8-DWhen the cause is unknownWhen you need to get input from several partiesWhen customers dictate useNote:We use voting techniques,X to Y variable testing,and IS/IS Not to determine the root cause.However,you still may not know what the root cause is?9、静夜四无邻,荒居旧业贫。3月-233月-23Tuesday,March 14,202310、雨中黄叶树,灯下白头人。00:22:1600:22:1600:223/14/2023 12:22:16 AM11、以我独沈久,愧君相见频。3月-2300:22:1600:22Mar-2314-Mar-2312、故人江海别,几度隔山川。00:22:1600:22:1600:22Tuesday,March 14,202313、乍见翻疑梦,相悲各问年。3月-233月-2300:22:1600:22:16March 14,202314、他乡生白发,旧国见青山。14 三月 202312:22:16 上午00:22:163月-2315、比不了得就不比,得不到的就不要。三月 2312:22 上午3月-2300:22March 14,202316、行动出成果,工作出财富。2023/3/14 0:22:1600:22:1614 March 202317、做前,能够环视四周;做时,你只能或者最好沿着以脚为起点的射线向前。12:22:16 上午12:22 上午00:22:163月-239、没有失败,只有暂时停止成功!。3月-233月-23Tuesday,March 14,202310、很多事情努力了未必有结果,但是不努力却什么改变也没有。00:22:1600:22:1600:223/14/2023 12:22:16 AM11、成功就是日复一日那一点点小小努力的积累。3月-2300:22:1600:22Mar-2314-Mar-2312、世间成事,不求其绝对圆满,留一份不足,可得无限完美。00:22:1600:22:1600:22Tuesday,March 14,202313、不知香积寺,数里入云峰。3月-233月-2300:22:1600:22:16March 14,202314、意志坚强的人能把世界放在手中像泥块一样任意揉捏。14 三月 202312:22:16 上午00:22:163月-2315、楚塞三湘接,荆门九派通。三月 2312:22 上午3月-2300:22March 14,202316、少年十五二十时,步行夺得胡马骑。2023/3/14 0:22:1600:22:1614 March 202317、空山新雨后,天气晚来秋。12:22:16 上午12:22 上午00:22:163月-239、杨柳散和风,青山澹吾虑。3月-233月-23Tuesday,March 14,202310、阅读一切好书如同和过去最杰出的人谈话。00:22:1600:22:1600:223/14/2023 12:22:16 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