APQP英文培训教程

1、Quality Planning CycleUpfront planning: The first (3) quarters of the cycle are devoted to up-front product quality planning through product / process validation.The act of implementation: The 4th quarter is the stage where the importance of evaluating the output serves (2) functions; to determine i

2、f customers are satisfied and to support the pursuit of continual improvement.The quality planning cycle is a never-ending cycle in the pursuit of continuous improvement. This can only be achieved by taking the experience in one program and applying that acquired knowledge to the next program.312345

3、PDCA Cycle (Also known as the Deming Management Cycle)What is Advanced Quality Planning (APQP)? Quality planning and more Total integration of quality tools with management functions Multi-disciplinary team approach to quality planning Tool to enable suppliers to not only meet but exceed customer re

4、quirementsWhat is a multi-disciplinary team?Who should be on the team? ActivityA team made up of a variety of functions within the organization, that have a role within the planning processWhat is Advanced Quality Planning (APQP)? Quality planning and more Total integration of quality tools with man

5、agement functions Multi-disciplinary team approach to quality planning Tool to enable suppliers to not only meet but exceed customer requirementsWhat is a multi-disciplinary team? EngineersWho should be on the team?A team made up of a variety of functions within the organization, that have a role wi

6、thin the planning process Quality team member(s) Production team members Management team members Purchasing group Maintenance and Tooling representativesInputsOutputsInputsOutputs*DesignResponsible*ManufacturingOnlyService Supplier (i.e. Heat Treat, Warehousing, Transportation)Define the ScopeXXXPla

7、n and defineSection 1.0XProduct Design and DevelopmentSection 2.0XFeasibilitySection 2.13XXXProcess Design and DevelopmentSection 3.0XXXProduct and Process ValidationSection 4.0XXXFeedback, Assessment and Corrective ActionSection 5.0XXXControl Plan MethodologySection 6.0XXX7.37.3The quality m

8、atrix for (3) types of suppliers. This matrix does not depict all the different types of product quality planning relationships that exist among suppliers, subcontractors and customer. Manufacturing and Service Suppliers can take exclusion to ISO/TS clause 7.3 part design, not process design. Proces

9、ses are designed by the organization.CONCEPTINITIATION/APPROVAL PROGRAM APPROVAL PROTOTYPE PILOT LAUNCHPLANNINGPRODUCTIONProduction INPUTS|Production OUTPUTSPlanning INPUTS|Planning OUTPUTSProduct Design &Dev. INPUTS|Product Design &Dev. OUTPUTSProcess Design &Dev. INPUTS|Process Design

10、&Dev. OUTPUTSProduct & ProcessValidation INPUTS |Product & ProcessValidation OUTPUTSPLANNINGPRODUCT DESIGN AND DEV.PROCESS DESIGN AND DEVELOPMENTPRODUCT & PROCESS VALIDATIONFEEDBACK ASSESSMENT AND CORRECTIVE ACTION5The success of APQP depends on meeting customer needs and expectation

11、s in a timely manner at a cost that represents value to the customer. The planning teams efforts should focus on problem prevention. Problem prevention is driven by “Simultaneous Engineering”. The APQP team is responsible for meeting or exceeding the customers timing plan.Advanced Product Quality Pl

12、anningTASKJulAugSepOctNovDecJanFebMarAprMayJunJulAugSepPlan and defineSection 1.0 Product Design & DevelopmentSection 2.0 FeasibilitySection 2.13 Process Design & DevelopmentSection 3.0 Product & Process ValidationSection 4.0 Feedback,Assessment & Corrective ActionSection 5.0 Product

13、ionPl anni ngC Cononc cepteptI I ni tini ti a ati on/ti on/ A Appppr ro ov valalP Pr ro og gr ramamA Appppr ro ov valalP Pr ro ot to ot ty yp pe eP Pi l oti l otL LaunchaunchA Appppr ro ov valalFeedback Assessment and Corrective ActionProduct and Process ValidationProcess Design and DevelopmentProdu

14、ct Design and Dev.Planning Outputs: (Become Inputs for Phase 2) Design Goals Reliability and Quality Goals Preliminary BOM Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support (Including program timing, planning f

15、or resources and staffing to support required capacity)Inputs: Voice of the Customer Market Research Historical Warranty and Quality Info Team Experience Business Plan / Marketing Strategy Product Process Benchmark Data Product / Process Assumptions Product Reliability Studies Customer InputIn a pro

16、cess based system, we have inputs (customer requesting something), with a series of events / actions that led to outputs (customers request fulfilled). A transformation occurs. ProductionPl anni ngC Cononc cepteptI I ni tini ti a ati on/ti on/ A Appppr ro ov valalP Pr ro og gr ramamA Appppr ro ov va

17、lalP Pr ro ot to ot ty yp pe eP Pi l oti l otL LaunchaunchA Appppr ro ov valalFeedback Assessment and Corrective ActionProduct and Process ValidationProcess Design and DevelopmentProduct Design and Dev.Planning Outputs: (Become Inputs for Phase 2) Design Goals Reliability and Quality Goals Prelimina

18、ry BOM Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support (Including program timing, planning for resources and staffing to support required capacity)Inputs: Voice of the Customer Market Research Historical Warr

19、anty and Quality Info Team Experience Business Plan / Marketing Strategy Product Process Benchmark Data Product / Process Assumptions Product Reliability Studies Customer Input1.1 Voice of the Customer1.1.1 Market Research1.1.2 Historical Warranty & Quality Information1.1.3 Team Experience1.2 Bu

20、siness Plan/Marketing Strategy1.3 Product/Process Benchmark Data1.4 Product/Process Assumptions1.5 Product Reliability Studies1.6 Customer Inputs1.7 Design Goals 1.8 Reliability and Quality Goals 1.9 Preliminary Bill of Material 1.10 Preliminary Process Flow Chart1.11 Preliminary Listing of Special

21、Product and Process Characteristics 1.12 Product Assurance Plan 1.13 Management Support 1.1 Voice of the Customer The “Voice of the Customer” encompasses complaints, recommendations, data and information obtained from internal and / or external customers. Some methods for gathering the appear in the

22、 following paragraphs.1.1.1 Market Research The organizations product quality planning team may need to obtain market research data and information reflecting Voice of the Customer. The following can assist in identifying customer concerns and wants:Customer interviewsCustomer questionnaires and sur

23、veysMarket test and positioning reportsNew product quality and reliability studiesCompetitive product quality studiesBest PracticesLessons Learned1.1.2 Historical Warranty and Quality Information A list of historical customer concerns and wants should be prepared to assist the potential for recurren

24、ce during design, manufacture, installation and use of the product. Many of the following items can assist the team in identifying customer concerns and wants: Best Practices Lessons Learned Warranty Reports Capability Indicators Supplier plant internal quality reports Problem resolution reports Cus

25、tomer plant returns and rejections Field return product analysis1.1.3 Team Experience The team may use and information as appropriate, including the following: Input from higher system level or past Quality Functional Deployment (QFD) projects. Media commentary and analysis: magazine and newspaper r

26、eports, etc. Customer letters and suggestions TGR / TGW reports (lessons learned) Dealer comments Fleet Operators comments Field service reports Internal evaluations using surrogate customers Road trips Management comments or direction Problems and issues reported from internal customers Government

27、requirements and regulations Contract review1.2 Business Plan / Marketing Strategy The customer business plan and marketing strategy will set the framework for the product quality plan. The business plan may place constraints (e.g. timing, cost, investment, product positioning, research and developm

28、ent), on the team that affect the direction taken. The marketing strategy will define the target customer, the key sales points, and key competitors.1.3 Product / Process Benchmark Data The use of benchmarking will provide input to establishing product / process performance targets. R & D may al

29、so provide benchmarks and concept ideas. One method to successful benchmarking is: Identify the appropriate benchmarks Understand the reason for the gap between your current status and the benchmark Develop a plan to either close the gap, match the benchmark, or exceed the benchmark.1.4 Product / Pr

30、ocess Assumptions There will be assumptions that the product has certain features, design, or process concepts. These include technical innovations, advanced materials, reliability assessments, and new technology. All should be utilized as inputs.1.5 Product Reliability Studies This type data consid

31、ers frequency of repair or replacement of components within designated periods of time and the results of long-term reliability / durability tests.1.6 Customer Inputs The next users of the product can provide valuable information relating to their needs and expectations. In addition, the next produc

32、t users may have already conducted some or all of the aforementioned reviews and studies. These inputs should be used by the customer and / or organization to develop agreed upon measures of customer satisfaction.1.7 Design Goals 1.8 Reliability and Quality Goals 1.9 Preliminary Bill of Material 1.1

33、0 Preliminary Process Flow Chart 1.11 Preliminary Listing of Special Product and Process Characteristics 1.12 Product Assurance Plan 1.13 Management Support 1.7 Design Goals Design goals are a translation of the Voice of the Customer into measureable design objectives. He proper selection of design

34、goals assures that the Voice of the Customer is not lost in subsequent design activity. The Voice of the Customer also includes regulatory requirements such as materials composition reporting and polymetric part marking.1.8 Reliability and Quality Goals Reliability goals are established based on cus

35、tomer wants and expectations, program objectives, and benchmarks. An example of customer wants and expectations could include no safety failures. Some reliability benchmarks could be competitor product reliability, warranty data, or frequency of repairs over a set time period. Quality goals should b

36、e based on metrics such as parts per million, problem levels or scrap reduction.1.9 Preliminary Bill of Material The team should establish a preliminary bill of material based on product / process assumptions and include a potential supplier list. In order to identify the preliminary special product

37、 / process characteristics it is necessary to have selected the appropriate design and manufacturing process.1.10 Preliminary Process Flow Chart The anticipated manufacturing process should be described using a process flow chart developed from the preliminary bill of material and product / process

38、assumptions.Decision Activity / Decision Start/Stop Document Activity1.11 Preliminary listing of Special Product / Process Characteristic Special product and process characteristics are identified by the customer in addition to those selected by the supplier through knowledge of the product and proc

39、ess. At this stage, the should assure that a preliminary list of special product and process characteristics resulting from the analysis of the in puts pertaining to customer needs and expectations. This listing could be developed from, but is not limited to the following: Product assumptions based

40、on the analysis of customer needs and expectations Identification of reliability goals / requirements Identification of special process characteristics from the anticipated manufacturing process. Similar part FMEAs1.12 Product Assurance Plan The product assurance plan translates design goals into de

41、sign requirements. The amount of effort devoted to the product assurance plan by the product quality planning team depends on the customer needs, expectations, and requirements. This manual does not prescribe a method for preparing a product assurance plan. The product assurance plan can be develope

42、d in any understandable format and should include, but not limited to, the following actions: Outlining of program requirements Identification of reliability, durability and apportionment / allocation goals and / or requirements. Assessment of new technology, complexity, materials, application, envi

43、ronment, packaging, service and manufacturing requirements, or any other factor that may place the program at risk. Development of Failure Mode Analysis (FMA) referenced in Appendix H) Development of preliminary engineering standards requirements.1.13 Management Support One of the keys to the succes

44、s of APQP is the interest, commitment and support of upper management. Participation by management in product quality planning meetings is vital to ensuring the success of the program. Management should be updated at the conclusion of every product quality planning phase to reinforce their commitmen

45、t and support. Updates and / or request for assistance can occur more frequently as required. A primary goal of APQP is to maintain management support by demonstrating that all planning requirements have been met and / or concerns documented and scheduled for resolution, including program timing and

46、 planning for resources and staffing to support required capacity. This phase covers the elements of the APQP process during which design features and characteristics are developed into near final form. All design factors should be considered by the organization in the APQP process even if the desig

47、n is owned or shared by the customer. This step includes prototype build to verify that the product or service meets the objectives of the Voice of the Customer. A feasibility design must permit meeting production volumes, schedules and be consistent with the ability to meet engineering requirements

48、, along with quality, reliability, investment cost, weight, unit cost and timing objectives. In this phase, the APQP process is designed to assure a comprehensive and critical review of engineering requirements and other related technical information.CONCEPTINITIATION/APPROVAL PROGRAM APPROVAL PROTO

49、TYPE PILOT LAUNCHPLANNINGPRODUCTIONProduction INPUTS|Production OUTPUTSPlanning INPUTS|Planning OUTPUTSProduct Design &Dev. INPUTS|Product Design &Dev. OUTPUTSProcess Design &Dev. INPUTS|Process Design &Dev. OUTPUTSProduct & ProcessValidation INPUTS |Product & ProcessValidati

50、on OUTPUTSPLANNINGPRODUCT DESIGN AND DEV.PROCESS DESIGN AND DEVELOPMENTPRODUCT & PROCESS VALIDATIONFEEDBACK ASSESSMENT AND CORRECTIVE ACTION5PG p. 3PG p. 3Jack could fail to lift VehicleJack could fail to hold vehicle for time necessary to make changesJack could fail to return vehicle to ground

51、position safelyPG p. 3Jack could fail to lift VehicleJack could fail to hold vehicle for time necessary to make changesJack could fail to return vehicle to ground position safelyNot designed robust enoughMissing componentsComponent not robust enoughWorn gear linkComponent not robust enoughIneffectiv

52、e setup instruction / No instructionsPG p. 3Jack could fail to lift VehicleJack could fail to hold vehicle for time necessary to make changesJack could fail to return vehicle to ground position safelyNot designed robust enoughMissing componentsComponent not robust enoughWorn gear linkComponent not r

53、obust enoughIneffective setup instruction / No instructionsDissatisfied Customer / Poor designDissatisfied Customer / Incorrect Kit AssemblyInjury or Dissatisfied Customer / Poor design specification: materialInjury or Dissatisfied Customer / Poor design specification: materialInjury or Dissatisfied

54、 Customer / Poor design specification: materialDissatisfied Customer / Incorrect Kit Assembly or removed from vehiclePrototype control plans are a description of the dimensional measurements and material and functional test that will occur during the prototype phase. Methodology is described in Sect

55、ion 6.The prototype parts provide an excellent opportunity for the team and customer to evaluate how well the product or service meets the Voice of the Customer objectives. The organization should review the following:Assure that the product or service meets specification and report data as required

56、Ensure that particular attention is given to special product and process characteristicsUse data and experience to establish preliminary process parameters and packaging requirementsCommunicate any concerns, deviations, and / or cost impact to the customerA special characteristics matrix is as a too

57、l to capture all the special characteristics of the process. This form when used, will be considered and extension of the control plan. Supplemental form K and L.Sanity check for Design Review Process58Note: An alternative form can be used as long as at a minimum it contains the information included

58、 in the form above. Customer approval is required.58Note: An alternative form can be used as long as at a minimum it contains the information included in the form above. Customer approval is required.123456789141011121315161718192021222324252614Review pages 50 thru 58 in participants manual. Defines

59、 each of the numbered items.58Note: An alternative form can be used as long as at a minimum it contains the information included in the form above. Customer approval is required.123456789141011121315161718192021222324252614Review pages 50 thru 58 in participants manual. Defines each of the numbered

60、items.Review A-8 Control Plan checklistProductionPlanningPl anni ngC Cononc cepteptI I ni tini ti a ati on/ti on/A Appppr ro ov valalP Pr ro og gr ramamA Appppr ro ov valalP Pr ro ot to ot ty yp pe eP Pi l oti l otL LaunchaunchFeedback Assessment and Corrective ActionProduct and Process ValidationProcess Design and DevelopmentProduct Design and Dev.OutputsPackaging Stan