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Presentation on APQP and Control Plan

Presentation on APQP and Control Plans


APQP: Reference Manual
A

Advanced

Product

Quality

Planning

and Control Plan Manual

Presentation on APQP and Control Plans


What is APQP:

Advanced Product Quality Planning (APQP)


Advanced Product Quality Planning (APQP) is a structured
method for defining and executing the actions necessary to
ensure a product satisfies the customer. APQP is a program
and supplier-led and is required of all system, subsystem and
component manufacturing locations. This includes both
internal and external suppliers to Ford, GM and Chrysler
Effective product quality planning depends on a company'
top management commitment to the effort required in
achieving customer satisfaction

Presentation on APQP and Control Plans


What is APQP:
Each Product Quality Plan is unique.
The actual timing and sequence of execution is dependent
on customer needs and expectations and/or other practical
matters.
The earlier a work practice, tool, and/or analytical
technique can be implemented in the Product Quality
Planning Cycle, the better.

Presentation on APQP and Control Plans


Purpose of APQP:
The purpose of APQP manual is to communicate to internal and
external suppliers and subcontractors of Ford, GM and Chrysler
about the common product development guidelines as developed by
Big 3s.
This manual is developed keeping in view the following benefits:
A reduction in complexity of product quality planning for
suppliers and customers
A means for suppliers to easily communicate product quality
planning requirements to sub contractors

Presentation on APQP and Control Plans

Check / Study: Confirmation


product and validation process

CHECK

ACT
Act: Continual
improvement

Do: Product/ process


development and
prototype verification

PLAN
Plan : Technology and concept
development

DO

Plan and Define


Product design and
development
Process Design and
development
Product and
process Validation
Feedback
Assessments and
corrective action

Presentation on APQP and Control Plans


Goal of APQP:
The Goal of APQP
The goal of APQP is to facilitate communication between all
persons and activities involved in a program and ensure that
all required steps are completed on time, with a high
quality-of-event, at acceptable cost and quality levels.

Presentation on APQP and Control Plans


Benefits of APQP:
To direct resources to satisfy the customer.
To promote early identification of required
changes.
To avoid late changes.
To provide a quality product on time at the lowest
cost.

Presentation on APQP and Control Plans


Product Quality planning Responsibility matrix:
APQP Part
Define the scope
Plan and define
Product design and
development
Feasibility
Process design and
development
Product and Process
Validation
Feedback , Assessment
and corrective actions
Control Plan methodology

Design
responsible

Manufacturing
Only

Service supplier, ( heat


treatment , ware hosing,
transportation etc..)

Presentation on APQP and Control Plans


Organize the team :
Define the scope:

Team to team coordination:


Training
Customer and supplier involvement:
Simultaneous engineering:
Control plans:
Concern resolution:
Product quality timing plan

Presentation on APQP and Control Plans


Control Plans:

Separate Control Plans cover three distinct phases.


Prototype A description of the dimensional
measurements and material and performance tests that will
occur during Prototype build.
Pre-launch A description of the dimensional
measurements and material and performance tests that will
occur after Prototype and before full Production.
Production A comprehensive documentation of
products/process characteristics, process controls, tests,
and measurement systems that will occur during mass
production.

Presentation on APQP and Control Plans


APQP Phases:

Presentation on APQP and Control Plans


APQP Phase 1: Plan and Define Program

Presentation on APQP and Control Plans


APQP Phase 1: Plan and Define Program
Output of This Phase Are:
Design Goals
Reliability and Quality Goals
Preliminary Bill of Material
Preliminary Process Flow Chart
Preliminary Listing Of Special Product and Process
Characteristics
Product Assurance Plan
Management Support
These out put of this phase will become the input for
phase 2 of APQP

Presentation on APQP and Control Plans


APQP Phase 2: Product Design and Development

Presentation on APQP and Control Plans


APQP Phase 2: Product Design and Development
Out put by the Design Responsible Activity
Design Failure Mode and Effects Analysis (DFMEA)
Design for Manufacture and Assembly
Design Verification
Design Reviews
Prototype Build Control Plan
Engineering Drawings (Including Math Data)
Engineering Specifications
Material Specifications
Drawing and Specification Changes

Presentation on APQP and Control Plans


APQP Phase 2: Product Design and Development
Out put by the APQP Team
New Equipment, Tooling and Facilities Requirements
Special Product and Process Characteristics
Gages/Testing Equipment Requirements
Team Feasibility Commitment and Management Support

Presentation on APQP and Control Plans


APQP Phase 3: Process Design and Development

Presentation on APQP and Control Plans


APQP Phase 3: Process Design and Development
Out put of this phase are:
Packaging Standards
Product/Process Quality System Review
Process Flow Chart
Floor Plan Layout
Characteristics Matrix
Process Failure Mode and Effects Analysis (PFMEA)
Pre-Launch Control Plan
Process Instructions
Measurement Systems Analysis Plan
Preliminary Process Capability Study Plan
Management Support
These out puts are the input for next phase of APQP

Presentation on APQP and Control Plans

APQP Phase 1: Plan and Define Program


Example of Preliminary Process Flow Chart
Start
Receipt of Material from Customer at
10)

(WS

Not OK
Aside reject. React as defined in
control plan

Verify the material for quantity and size ( I


10)
OK
Material Issue to Sub supplier for Job
work (WS 20)

Checking of material after processing at


Vendors end (I 20)

Not OK

Aside reject. React as defined in


control plan

OK
Storage (WS 30)

Double disc grinding operation (WS 40)


Not OK
Aside reject. React as defined in
control plan

Inspection as per control plan (I 30)


OK
Center less grinding operation (WS 50)
Not OK
Inspection as per control plan (I 40)
OK
A

Aside reject. React as defined in


control plan

Presentation on APQP and Control Plans


APQP Phase 4: Product and Process Validation

Presentation on APQP and Control Plans


APQP Phase 4: Product and Process Validation
The out put to This Stage Are:
Production Trial Run
Measurement Systems Evaluation
Preliminary Process Capability Study
Production Validation Testing
Packaging Evaluation
Production Control Plan
Quality Planning Sign-Off and Management Support
These form input to stage 5 of APQP

Presentation on APQP and Control Plans


APQP Phase 5: feedback, Assessment & corrective actions

Presentation on APQP and Control Plans


APQP Phase 5: feedback, Assessment & corrective actions
The out put to this phase are:
Reduced Variation
Customer Satisfaction
Delivery and Service

Presentation on APQP and Control Plans


Control Plan
The purpose of this Control Plan methodology is to aid in
the manufacture of quality products according to customer
requirements.
It does this by providing a structured approach for the
design, selecting and implementation of value-added control
methods for the total system.
Controls Plans provide a written summary description of
the systems used minimizing process and product variation.

Presentation on APQP and Control Plans


Control Plan
In effect, the Control Plan describes the actions that are
required at each phase of the process including:
Receiving,
In-process
Out-going
and periodic requirements to assure that all process outputs
will be in a state of controls.

Presentation on APQP and Control Plans


Control Plan
The Control Plan must be developed using a Multi disciplinary
Approach / cross functional approach
The information such as:
Process Flow charts
DFMEA/ PFMEA
Special/ Significant
Characteristics list
Lessons learned from similar
parts (TGWs and TGRs)

Teams Knowledge of the


process
Design reviews
Use of tools as QFD, DOE etc..

Must be used for development of control plans

Presentation on APQP and Control Plans


Man

Material

Operator Variation

Machine

Dimensions

Skilled /
unskilled /
partially skilled

Equip.

Material Holding
Metallurgy

Communication

Fixture
Chemistry

Tooling

Team Work

Customer
Requirements

TEAM WORK AND CONTINUAL IMPROVEMENT


Set up

instructions

Preventive
Maintenance

Gauge calibration
OK Yes / No

Temperature

Gauge setting OK
Yes / No

Hard and soft


Master condition
OK Yes / No

Ergonomics

Lightning &
Cleanliness

Humidity

Templates
condition OK Yes /
No
New gauges
required Yes / No

Methods

Measurement

Environment

Continual Improvement Loop

Customer
satisfaction:

Presentation on APQP and Control Plans


Control Plan Format

Presentation on APQP and Control Plans

Control Plan Format: filled

Presentation on APQP and Control Plans


Control Plan
Set up Dominant Process:
Variables are Set up
Examples: Injection Moulding etc..
Controlling methods for this kind of process should be:
First piece approval
Verification of M/c setting
Authorized set up cards etc..

Presentation on APQP and Control Plans


Control Plan
Machine Dominant Process:
Variables are ; Machine parameters
Examples: Electronic industries, wave soldering m/c etc..
Controlling methods for this kind of process should be:
self adjusting devices
X bar R charts on product characteristics
deployment of error proofing methods
use of statistical sampling plans

Presentation on APQP and Control Plans


Control Plan
Fixture Dominant Process:
Variables are ; Jig to Jig, Fixture to Fixture variation
Examples: Machining of metal castings,
Controlling methods for this kind of process should be:
loading instructions for fixtures
Fixture adjustment methods
Maintenance of Fixtures etc..

Presentation on APQP and Control Plans


Control Plan
Tooling Dominant Process:
Variables are ; Tool Life, tool design
Examples: Machining of Bearing Rings etc..
Controlling methods for this kind of process should be:
Tool verification templates
Tool life monitoring
First off approval
Error proofing methods for tool life monitoring
use of X bar R charts

Presentation on APQP and Control Plans


Control Plan
Operator Dominant Process:
Variables are ; operator to Operator variation, Operator skill ,
Training and experience
Examples: Fixing of Head lamps etc..
Controlling methods for this kind of process should be:
Trained operator
Authorized persons
Checking of assembly etc..

Presentation on APQP and Control Plans


Control Plan
Material Dominant Process:
Variables are ; Variance in Material lot to lot or component to
component
Examples: use of shelf life items
Controlling methods for this kind of process should be:
Testing and inspection of material
Use of Trend charts
lab reports etc..

Presentation on APQP and Control Plans


Control Plan
Preventive maintenance Dominant Process:
Variables are ; Equipment maintenance
Examples: Painting (dirt free painting equipment ) etc..
Controlling methods for this kind of process should be:
Scheduled maintenance programs
equipment history reports analysis
Warning devices for monitoring etc..

Presentation on APQP and Control Plans


Control Plan
Climate Dominant Process:
Variables are ; Temperature, Humidity, noise, Vibration etc..
Examples: Injection Molding (Humidity Control),
Controlling methods for this kind of process should be:
Planned and periodic checks
First off approval and subsequent monitoring etc..