[精选]APQP-PPAP(英文版).pptx

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1、APQP PPAP 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 mon path and synchronization of product development activit

2、ies.APQP is an attempt to ensure munication both within a pany and between a pany and its customerMarketing&municationsBenefits of APQP Ensures early planning takes place.Directs resources to the customer.Identifies required changes early in the process.Provides quality product on time and at lowest

3、 cost.Enables cross-functional inputs and outputs.Addresses potential problems earlyMarketing&municationsCustomer and Supplier Involvement Customer may initiate planning process.Supplier has the obligation to establish cross-functional team to manage process.Supplier should expect the same performan

4、ce from their subcontractors.Marketing&municationsDetermine Customer Requirements Print Purchase Request or Request for Quotation.Statement of Work SOW Customer visits and discussions.Product checklists.Marketing&municationsTraining Customer needs and expectations.Working as a team.Requirements of A

5、PQP FMEA APQP PPAPMarketing&municationsAPQP Five Phase ProcessPlanningProduct Design and DevelopmentProcess Design and DevelopmentProduct and Process ValidationProductionFeedback Assessment and Corrective ActionPilot LaunchConcept Initiation/ApprovalProgram ApprovalPrototypePlanningLinks Between the

6、 ToolsContract Review Program PlanDFMEATeam Feasibility mitmentProduce Process Flow DiagramsConduct Process FMEADevelop Control PlanWork Instruction DevelopmentProduct and Process ValidationEnsure Continuous ImprovementPhase IPhase IIPhase IIPhase IIIPhase IIIPhase IIIPhase IIIPhase IVPhase VDetermi

7、ne 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 VariationI

8、mplement Control Plan and Standardize the ProcessEnsure Customer Expectations are MetExercise Management OversightThe Target and The GoalMarketing&municationsLink Between the DocumentsProcess Flow Diagrams Updated after production trial run.Need to indicate special characteristics generated at each

9、step.pleted Along with Control Plan APQP Process.Generally contains same information as process traveler.Marketing&municationsProcess Flow Diagram ExampleMarketing&municationsAPQP Links to PFMEAProcess FMEA Must follow flow of the process flow diagram.Must include ALL process special characteristics

10、 as a minimum.Marketing&municationsHow a PFMEA Works Where does the data for the PFMEA e 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 APQP PFMEAs should be driven by real data,including 8-Ds inte

11、rnal and external,warranty and returned part analysis PFMEAs should be pleted by process experts and should be a driver of the control plans and work instructions Work instructions Post control log,process parameter logs,preventive maintenance,etc.implement the control plan in the process When there

12、 is a quality problem there is an opportunity to improve the control plan and the work instructionsAPQP Links to Control PlanControl Plans Includes product and process special characteristics.Includes SPC requirements.Follows flow of process flow chart and PFMEA.May require customer approval.Marketi

13、ng&municationsTypes of Control Plans Prototype build control plan s Pre-launch control plan Production control planMarketing&municationsPrototype Build Control Plan A description of the dimensional measurements.Material tests Functional tests that will occur during prototype build.Marketing&municati

14、onsPre-launch Control Plan Description 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.Sta

15、tistical evaluations.Increased audits.Marketing&municationsProduction Control Plan Up-date pre-launch control plan.Add:Sampling plans Control method SPC,inspection,attribute data and mistake proofing.Reaction plan Nonconformances clearly identified,quarantined and disposition made.Requires customer

16、approval unless otherwise specified.Marketing&municationsControl Plan Use Initial:To document and municate 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.Marketing&

17、municationsMultiple Molds,Tools,Dies and Patterns plete dimensional layer required from one part from each cavity as a minimum.Supplier must identify specific cavity for each part submitted.Marketing&municationsPart Submission Status Never ship production parts before receiving customer approval.Sup

18、plier must ensure that future production continues to meet customer requirements.No production parts can be shipped until approval is received.Marketing&municationsAutomotive Documentation DevelopmentDevelop Process Flow ListingCheck for Customer RequirementsEnter Every“Major Process from Flow Listi

19、ng 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 CharacteristicsD

20、evelop control mechanisms appropriate for Critical characteristics.Give careful consideration to defining Control Plan stagesPrototype Pre-launch ProductionMarketing&municationsMarketing&munications Provides Proof of Capability Made up of Documents from APQP Marketing&municationsPPAP Purpose Ensure

21、that customer design record and specification requirements are understood.Ensure that the process has the potential for producing product meeting those requirementsMarketing&municationsPPAP Scope Production parts-generally 300 pieces.Includes internal and external sources for information.Submission

22、required prior to first production shipment.Marketing&munications Base Documentation Critical characteristics matrix.Process flow diagram.Design FMEA supplied by customer.Process FMEA.Control plan.Marketing&municationsGeneral Supplier is responsible for meeting all applicable specifications.Do not s

23、ubmit 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 requirements ply with customer developed material specifications and/or approved source list.Marketing&municationsGeneral Suppl

24、iers are required to plete 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.Marketing&municationsElements of a PPAP Part submission warrant Subcontractor

25、warrants Design record customer/design documentation Sample/Master sample Master sample retained by supplier Dimensional analysis Test data Flow diagram Control plan PFMEA Measurement Systems Analysis GR&R Capability studiesMarketing&municationsParts Submission Warrant Upon satisfactory pletion of a

26、ll required measurements and tests,enter all required information on the warrant.A separate is required for each part number.Responsible supplier official verifies Measurements and tests conform to customer requirements Required documentation is available for proper submission level.Signs warrant an

27、d provided date,title and telephone number.Marketing&municationsMarketing&municationsPart Weight Determine part weight without packaging or shipping material.Report weight in kilograms to three decimal places.Weight determination Weigh 10 parts randomly selected and report the average weight.For par

28、ts less than 0.100 kilogram,weigh 10 parts together and report the average weight.Marketing&municationsMaster Sample Retain same as PPAP,or Until new master sample is produced for the purpose of a customer approval.Identify master sample by:Part number Drawing level or revision level Customer approv

29、al dateMarketing&municationsPreliminary Process Capability Studies Characteristics 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.Marketing&municationsProduc

30、tion Trial Run Production tooling,equipment,environment,facilities and cycle time.Process Instructions and control plans.Minimum quantity set by the customer.Generally 300 parts.Marketing&municationsProduction Trial Run Product Used For Preliminary process capability studies.MSA if not pleted earlie

31、r Final Feasibility.Process review.Production Validation Testing.PPAP Packaging evaluation First time capability Quality planning sign-offMarketing&municationsMeasurement System Analysis MSA plete studies as defined in the MSA plan.Minimum are those identified in the control plan.Subjected to evalua

32、tion prior to or during production trial.Marketing&municationsPackaging Evaluation Packaging 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 evalua

33、tion.Marketing&municationsFloor Plan Layout Determine acceptability of inspection and test points.Control chart locations Visual aides Interim repair stations Nonconforming material storage Keyed to material flow and control planMarketing&municationsReview and Sign-Off Process instructions in place

34、and followed!Flow charts in place and followed!GR&R plans exist and are followed Publish final feasibility report Obtain formal sign-off Schedule and conduct management review Obtain management mitment to assist in open issuesMarketing&municationsQuality Problemsyes nonoyesnoyesnoyesCause unknown Us

35、e PFMEANote:When a customer problem occurs,follow customer prescribed methodologyWhen to use 8-D When the cause is unknown When you need to get input from several parties When customers dictate useNote:We use voting techniques,X to Y variable testing,and IS/IS Not to determine the root cause.However

36、,you still may not know what the root cause is?Update the PFMEA&Control PlansProcess FlowPFMEA Control PlanWork InstructionScrap,Rework DataWarranty&Assembly Plant DataAfter the 8-D is pleted,the PMEA and the control plan should be revised and updated as applicable 9、静夜四无邻，荒居旧业贫。6 月-236 月-23Thursday

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