SGM-APQP-kic-off14726.pptx

Slide 1供应商开发供应商开发Issue Date:July-08-1997SHANGHAI GM SUPPLIER QUALITY IMPROVEMENT PROCESS 上上 海海 GM 供供 应应 商商 质质 量量 改改 进进 程程 序序Continuous improvement(GP-8)持持 续续 改改 进进Performance monitoring成效监控成效监控Problem reporting&resolution(GP 5)问问 题题 报报 告告 与与 解解 决决Level I controlled shipping 一一 级级 发发 货货 控控 制制Level II controlled shipping 二二 级级 发发 货货 控控 制制Quality workshop 质质 量量 研研 讨班讨班Improvement meeting供应商质量改进会议供应商质量改进会议Early production containment(GP-12)初期生产次品遏制初期生产次品遏制Run at rate (GP 9)按预定能力生产按预定能力生产Production part approval process(PPAP)正式生产件审批正式生产件审批Prototype sample approval(GP-11)样件样件 审审 批批Pre production meeting 投产前会议投产前会议Advanced product quality planning(APQP)产品质量先期策划及控制计划产品质量先期策划及控制计划Sourcing decision 选定供应商选定供应商Potential supplier assessment (PSA)潜潜 在在 供供 应应 商商 评评 估估Start of productionPreliminary assessment(PA)初初 级级 评评 估估Life of part Time line Global sourcing全球采购全球采购Slide 2供应商开发供应商开发Issue Date:July-08-1997ADVANCED PRODUCT QUALITY PLANNING and CONTROL PLAN产产 品品 质质 量量 先先 期期 策策 划划 和和 控控 制制 计计 划划Shanghai GM 上上 海海 GMSupplier Development/Quality 供供 应应 商商 开开 发发/质质 量量Slide 3供应商开发供应商开发Issue Date:July-08-1997WHAT IS APQP?什么是什么是APQP？It is a formal structured process-Allows the establishment of the necessary steps to assure a quality product which will meet the customers requirements.它是一个正规而有序的方法-确立并建立必要的步骤来确保产品满足客户的要求。Introduction Introduction 简介简介简介简介Slide 4供应商开发供应商开发Issue Date:July-08-1997 Establish a quality plan which supports the development of products that meet customer requirements.制 定一 个产 品质量 计划 来支持 产 品开发以满 足顾 客 要 求.Timely completion of critical activities 按时 完 成 各 项 重 要 工 作 On time Production Part Approval 准 时 完 成 正式生 产 件 审 批 Ongoing conformance to specifications 自始至终达到 规范要 求 Continuous Improvement 不断改 善 产 品 质 量(精 益 求 精)Purpose 目的目的WHY APQP?为什么需要 APQP?Slide 5供应商开发供应商开发Issue Date:July-08-1997 Meet QS9000 requirements.满足 QS9000 质量要求。Increase customer satisfaction.提高客户的满意程度。Improve profit margin.提高公司利润。Increase success of company through a well-documented system for each project.建立一套完善的适用于每个项目的质量体系从而使公司走向成功。WHY APQP?(Continue)为什么需要为什么需要APQP?(续前续前)Purpose 目的目的Slide 6供应商开发供应商开发Issue Date:July-08-1997 Define the Scope 确定工 作范围 Plan and Define Program 计划与确定项 目 Product Design and Development 产 品 设 计与 开发 Process Design and Development 工 艺 设 计 与 开发 Product and Process Validation 产 品 及 工 艺 认 证 Feedback,Assessment and Corrective Action 反 馈,评 估 及 整改 措 施Key Steps关关 键键 步步 骤骤Process 程序程序Slide 7供应商开发供应商开发Issue Date:July-08-1997Set up a cross-functional project localization team建立国产化项目横向协调小组 Select project team leader 选 出 项 目 小 组 负 责 人 Define functional roles&responsibilities 确定职能 和 责 任 Identify internal and external customers 识别内 外 部客户 Define customer requirements 确定客户 要 求 Define the Scope 确定工作范围确定工作范围Slide 8供应商开发供应商开发Issue Date:July-08-1997Understand Customer Expectations了 解客户期 望Assess Feasibility of Proposed Design评 估 所 提 出 设 计 之可 行 性 Identify Costs,Timing,and Constraints 识别 所 需 费 用,时 间 和制约Determine Assistance Required from Customer 明确需要从客户处所得到的帮助 Identify Documentation Process/Method 确定文 件 记 录 之程 序 与方 法Define the Scope 确定工作范围确定工作范围(Continue 续前)Slide 9供应商开发供应商开发Issue Date:July-08-1997 ConceptInitiation/ApprovalProgramApproval PRODUCTDESIGN ANDDEVELOPMENT PROCESS DESIGN ANDDEVELOPMENTPrototypePilotLaunchPLANNINGPRODUCT DESIGN AND DEV.PROCESS DESIGN AND DEVELOPMENTPRODUCT AND PROCESS VALIDATIONPLANNINGPRODUCTIONFEEDBACK ASSESSMENT AND CORRECTIVE ACTIONPLAN AND DEFINEPROGRAM PRODUCTAND PROCESS VALIDATION FEEDBACK ASSESSMENT ANDCORRECTIVE ACTIONProduct Quality Planning Timing ChartSlide 10供应商开发供应商开发Issue Date:July-08-1997 概念概念 形成形成/审批审批项目审批项目审批 产品设计产品设计与开发与开发 工艺设计工艺设计与开发与开发手工样件手工样件小批量小批量投产投产 策策 划划产品设计与开发产品设计与开发工艺设计与开发工艺设计与开发产品及工艺认证产品及工艺认证策划策划 生产生产反馈，评估及整改措施反馈，评估及整改措施计划与确定计划与确定项目项目 产品及产品及工艺认证工艺认证反馈反馈,评估及评估及整改措施整改措施 产产 品品 质质 量量 策策 划划 时时 间间 表表Slide 11供应商开发供应商开发Issue Date:July-08-1997INPUTSOUTPUTS Voice of the Customer -Market Research -Historical Warranty and Quality Information -Team Experience Business Plan/Market Strategy Product/Process Benchmark Data Product/Process Assumptions Product Reliability Customer Inputs Design Goals Reliability and Quality Goals Preliminary BOM Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support1.0 PLAN AND DEFINE PROGRAMSlide 12供应商开发供应商开发Issue Date:July-08-19971.0 计计 划划 与与 确确 定定 项项 目目输入输入输出输出 客户呼声客户呼声 市场调查市场调查 担保和质量的历史记录担保和质量的历史记录 项目组经验项目组经验 企企 业经营业经营/市场销售计划市场销售计划 同类产品同类产品/工艺竞争资料工艺竞争资料 产品产品/生产工艺设想生产工艺设想 产品可靠性产品可靠性 客户输入客户输入设计目标可靠性及质量目标初步材料清单初步工艺流程图草拟产品与工艺特性产品保证计划管理层支持Slide 13供应商开发供应商开发Issue Date:July-08-1997Product Reliability 产品可靠性产品可靠性Key Words and Basic Concepts关键词和基本概念关键词和基本概念Study what data is available 研究现有的数据Use data from frequency of repair 使用维修频率的数据What are the long term durability goals 长远的耐用性目标是什么Slide 14供应商开发供应商开发Issue Date:July-08-1997Product Assurance Plan 产品保证计划产品保证计划 Design requirements.设计要求 Program requirements.项目要求 Reliability goals.可靠性目标 Technology used.采用的技术 FMEA.失效模式及后果分析Engineering requirements.工程要求Key Words and Basic Concepts关键词和基本概念关键词和基本概念Based on:基于Slide 15供应商开发供应商开发Issue Date:July-08-19972.0 PRODUCTION DESIGN AND DEVELOPMENTINPUTSOUTPUTS Design Goals Reliability and Quality Goals Preliminary BOM Preliminary Process Flow Chart Preliminary Listing of special Product and Characteristics Product Assurance Plan Management Support v By Design Responsible Activityv By Advanced Product Quality Planning TeamSlide 16供应商开发供应商开发Issue Date:July-08-19972.0 产产 品品 设设 计计 与与 开开 发发输入输入输出输出 v产品质量先期策划工作 小组设计目标可靠性及质量目标初步材料清单初步工艺流程图草拟产品 与工艺特性产品保证计划管理层支持设计工作小组Slide 17供应商开发供应商开发Issue Date:July-08-1997 Design FMEA Design for Manufacturability and Assembly Design Verification Design Reviews Prototype Build Engineering Drawings Material Specifications Drawing and Specification Changes2.0 PRODUCTION DESIGN AND DEVELOPMENTOUTPUTSv By Design Responsible Activityv By APQP Team New Equipment,Tooling and Facilities Requirements Special Product and Process Characteristics Prototype Control Plan Gages/Testing Equipment Requirements.Team Feasibility Commitment&management SupportSlide 18供应商开发供应商开发Issue Date:July-08-1997输出输出设计FMEA设计的制造/装配可行性设计验证设计评审手工样件制造工程图纸材料要求规范图纸与规范的变更v 产品质量先期策划工作 小组v设计工作小组新设备,工装及厂房要求产品及工艺特性手工样件控制计划量具,试验设备要求项目可行性书面承诺及 管理层支持2.0 产产 品品 设设 计计 与与 开开 发发Slide 19供应商开发供应商开发Issue Date:July-08-1997Team Feasibility Commitment 项目可行性承诺书项目可行性承诺书Customer:_ Part Name:_Part Number:_Feasibility Considerations:Our Product quality planning team has considered the following questions,not intended to be all-inclusive in performing a feasibility evaluation.The drawings and/or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements.All“no”answers are supported with attached with comments identifying our concerns and/or proposed changes to enable us to meet the specified requirements.ConclusionFeasible Product can be produced as specified with no revisions.Feasible Changes recommended(see attached).Not Feasible Design revision required to produce product within the specified requirements._ _Team member/Title/Date Team Member/Title/DateSign-offSlide 20供应商开发供应商开发Issue Date:July-08-1997Key words and Basic ConceptsKey Words and Basic Concepts关键词和基本概念关键词和基本概念Feasibility commitment 可行性承诺可行性承诺 Can it be manufactured?Can it be assembled?是否能制造是否能制造?是否能装配是否能装配?Can it be tested?Can it be delivered at specified volume?是否能测试是否能测试?是否能按指定的数量发运是否能按指定的数量发运?Will it satisfy the customer requirements?是否使客户满意是否使客户满意?Is the cost accepted to the customer?是否成本能为客户接收是否成本能为客户接收?Management support.管理层支持管理层支持Slide 21供应商开发供应商开发Issue Date:July-08-1997Key Words and Basic Concepts关键词和基本概念关键词和基本概念Prototype Build-Control Plan样件制造样件制造-控制计划控制计划 Assure that the product or service meets specification and report data as required.确保产品和服务能满足所要求的规范并根据要求提供数据确保产品和服务能满足所要求的规范并根据要求提供数据.Ensure that particular attention has been given to special product and process characteristics.保证对产品和工艺特性予以足够的重视保证对产品和工艺特性予以足够的重视.Use data and experience to establish preliminary process parameters and packaging requirements.利用已有的数据和经验设定初步工艺参数和包装要求利用已有的数据和经验设定初步工艺参数和包装要求.Communicate any concerns,deviations,and/or cost impact to the customer 与客户就任何建议与客户就任何建议,偏差和偏差和/或成本进行交流或成本进行交流.Control Plan should be prepared by APQP team控制计划应由控制计划应由APQP小组完成小组完成Slide 22供应商开发供应商开发Issue Date:July-08-1997Control Plans 控制计划控制计划 Prototype Control Plan-A description of the dimensional measurement,material and performance tests that will occur during Prototype build.样件控制计划样件控制计划-在样件制造过程中对产品的尺寸在样件制造过程中对产品的尺寸,材料和性能试验的描述材料和性能试验的描述.Pre-launch Control Plan-A description of the dimensional measurement,material and performance tests that will occur after Prototype and before full production.试生产控制计划试生产控制计划-在样件之后正式批量生产之前在样件之后正式批量生产之前,对产品的尺寸对产品的尺寸,材料和材料和 性能试验的描述性能试验的描述.Production Control Plan-Comprehensive documentation of product/process characteristic,process control,testing,and measurement system that will occur during mass production.正式生产控制计划正式生产控制计划-在批量生产过程中在批量生产过程中,对产品工艺特性对产品工艺特性,过程控制过程控制,测试和测试和 计量系统制定的综合计量系统制定的综合 性文件性文件.Slide 23供应商开发供应商开发Issue Date:July-08-19972.0 PRODUCTION DESIGN AND DEVELOPMENTExample of Control PlanPrototypePre-LaunchProductionControl Plan NumberPart Number/Latest Change LevelSupplier/PlantPart Name/DescriptionSupplier CodePart/ProcessNumberProcess Name/OperationDescriptionMachine,Jig,Device,ToolsFor MfgKey Contact/PhoneCore TeamSupplier/Plant Approval/DateOther Approval/Date(If required)Date(Orig.)Date(Orig.)Customer Engineering Approval/Date(If required)Customer Quality Approval/Date(If required)Other Approval(If required)Reaction PlanControl MethodSampleMethodSizeFreq.Evaluation Measurement TechniqueProduct/ProcessSpecification/ToleranceSpecialChar.ClassCharacteristicsNo.ProductProcessSlide 24供应商开发供应商开发Issue Date:July-08-19972.0 产品设产品设 计计 与与 开开 发发 控控 制制 计计 划划 样样 件件 投投 产产 前前生生 产产 控控 制制 计计 划划 号号 零零 件件 号号/最最 新新 更更 改改 等等 级级 供供 应应 商商 零零 件件 名名/说说 明明 供供 应应 商商 编编 码码 零零 件件/工工 序序 号号 工工 序序 名名 称称/操操 作作 描描 述述 制制 造造 用用 机机 器器 设设 备备,夹夹 具具 工工 装装 主主 要要 联联 系系 人人/电电 话话 核核 心心 小小 组组 供供 应应 商商/工工 厂厂 批批 准准/日日 期期 其其 他他 批批 准准/日日 期期(如如 需需 要要)日日 期期(编编 制制)日日 期期(修修 订订)客客 户户 工工 程程 批批 准准/日日 期期(如如 需需 要要)客客 户户 质质 量量 批批 准准/日日 期期(如如 需需 要要)其其 他他 批批 准准/日日 期期(如如 需需 要要)反反 应应 计计 划划 控控 制制 方方 法法 取取 样样 方方 法法 大大 小小 频频 次次 评评 价价/测测 量量 技技 术术 产产 品品/工工 序序 规规 范范/公公 差差 特特 殊殊 特特 性性 分分 类类 特特 性性 编编 号号 产产 品品 过过 程程Slide 25供应商开发供应商开发Issue Date:July-08-1997Special Product/Process Characteristic特殊产品特殊产品/工艺特性工艺特性 The customer requirements.客户要求 Reliability goals可靠性目标 Special processes.特殊生产工艺 Similar product FMEAs类似产品的FMEA Key Words and Basic Concepts关键词和基本概念关键词和基本概念Characteristics normally designed by the customer as significant.产品的特征通常由客户作为重点标明Based on:基于:Slide 26供应商开发供应商开发Issue Date:July-08-1997Design FMEA Example2.0 PRODUCTION DESIGN AND DEVELOPMENTSystemSubsystemComponent Design ResponsibilityModel Year(s)/Vehicle(s)199x/lion 4dr/Wagon Key DateCore TeamFMEA NumberPage ofPrepared ByFMEA Date(Orig.)Item FunctionPotentialEffect(s)ofFailurePotentialFailureModeSEV.C l a s sPotentialCause(s)ofMechanism(s)of FailureO c c u rCurrentDesignControlD e t e c tR.P.N.Recommended ActionResponsibility&TargetCompletion ActionAction ResultsActions TakenS e vO c cD e tR.P.N.Front Door L.H.H8HX-0000-A Ingress to and Energy from Vehicle Occupant protection from weather noise,and side impact Support anchorage for door hardware including mirror,hinge latch and window regulatorCorrodedinteriorlower doorpanelsDeteriorated lifeof door leading to:Unsatisfactory appearance due to through paint over time Impaired function of interior door hardware7Upper edge of protectivewax application specifiedfor inner door panels istoo lowInsufficient wax thicknessspecifiedInappropriate waxformulation specifiedEntrapped air preventswax from entering corner/edge access6425Vehicle general durability test vahT-118.T-109.T-301Vehicle generaldurability testing-as abovePhysical and Chem Lab test-Report No.1265Design aid investigationwith non-functionalspray head7 2947 1962 288 280Add LaboratoryacceleratedcorrosiontestingAdd laboratoryacceleratedcorrosion testingConduct Designof Experimentson wax thicknessNoneAdd teamevaluation using productspray equip.and specifiedwaxA Tage-BodyEngrg8X 09 30Combine withtest for waxupper edgeverification A TateBody Engrg9X 01 15Body Engrg&Assy Ops8X 11 15Based on testresults(Test No)1481)upperedge spec raised125mmTest results(Test No.1481)show specified thickness is adequate.DOE show 25%variation in specified thickness is acceptable 7 2 2 28 7 2 2 28 7 1 3 21xT.Fender-Car Product Dev.Children-Manufacturing,Ford-Assy Ops(Dalton,Fraser,Henley Assembly PlantsBody Engineering9X 03 01 ER123411A.Tate-X6412-Body Engr8X 03 22Slide 27供应商开发供应商开发Issue Date:July-08-19973.0 Process Design and DevelopmentINPUTSOUTPUTS Design FMEA Design for Manufacturability/Assembly Design Verification Design Reviews Prototype Build Engineering Drawings Material Specifications Drawing and Specification Changes New Equipment,Tooling and Facilities Requirements Special Product and Process Characteristics Prototype Control Plan Gages/Testing Equipment Requirements.Team Feasibility Commitment&Management Support Packaging Standards Product/Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics matrix Process FMEA Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Study Plan Preliminary Process Capability Study Plan Packaging Specification Management SupportSlide 28供应商开发供应商开发Issue Date:July-08-1997输入输入输出输出设计FMEA设计的制造/装配可行性设计验证设计评审手工样件制造工程图纸材料要求规范图纸与规范的变更新设备，工装及厂房要求产品及工艺特性手工样件控制计划量具、试验设备要求项目可行性书面承诺及 管理层支持包装标准产品、工艺质量体系评审工艺流程图工厂平面图特性矩阵工艺FMEA试生产控制计划工艺指导书测量系统分析计划初步工艺能力研究计划包装规范管理层支持3.0 生产工艺设计与开发生产工艺设计与开发Slide 29供应商开发供应商开发Issue Date:July-08-1997Characteristic Matrix特性矩阵特性矩阵 Shows the relationship between process parameters and the operations.显示工艺参数和操作之间的关系 The more relationship there is the more important the characteristic.关系越多,特性就越重要Key Words and Basic Concepts关键词和基本概念关键词和基本概念Example:例如Slide 30供应商开发供应商开发Issue Date:July-08-19973.0 Process Design and Development Process ResponsibilityModel Year(s)/Vehicle(s)Key DateCore TeamFMEA NumberPage ofPrepared By FMEA Date(Orig.)ProcessFunctionRequirementsPotentialEffect(s)ofFailurePotentialFailureModeSEV.C l a s sPotentialCause(s)ofMechanism(s)of FailureO c c u rCurrentProcessControlD e t e c tR.P.N.Recommended ActionResponsibility&TargetCompletion ActionAction ResultsActions TakenS e vO c cD e tR.P.N.Manual application ofwax in sidedoorTo cover inner door,lower surfacesat minimumwaxthickness to retardcorrosionInsufficientwax coverageover specifiedsurfaceDeteriorated lifeof door leading to:Unsatisfactory appearance due to through paint over time Impaired function of interior door hardware7Manually inserted sprayhead not inserted farenoughVisual check each hour-1/shift for filmthickness(depth meter)and coverageAdd positivedepth stop tosprayerMFG Engrg9X 10 15Stop added,sprayerchecked on lineExample of Process FMEA852807 2 5 70AutomatesprayerMFG Engrg9X 12 15Rejected due tocomplexity