产品质量先期策划及控制计划

AdvancedProductQualityPlanningandControlPlan产品质量先期策划及控制计划1WhatisAPQP?什么是产品质量先期策划APQP？ProductQualityPlanningisastructuredmethodofdefiningandestablishingthestepsnecessarytoassurethataproductsatisfiesthecustomer.产品质量先期策划是：一种定义并建立保证产品满足顾客要求的步聚的结构化方法WhatisthegoalofAPQP?什么是APQP的目标？Thegoalofproductqualityplanningistofacilitatecommunicationwitheveryoneinvolvedtoassurethatallrequiredstepsarecompletedontime.产品质量先期策划的目标是：加强相关人员之间的沟通以确保所有要求的步聚按时完成。APQP2WhatisthebenefitsofProductQualityPlanning?什么是产品质量策划的益处？Todirectresourcestosatisfythecustomer.向着使顾客满意的方向引导资源Topromoteearlyidentificationofrequiredchanges.促进及早识别需要进行的更改Toavoidlatechanges.避免事后更改Toprovideaqualityproductontimeatthelowestcost.以最低的成本及时提供高质量的产品APQP3ProductQualityPlanningCycle产品质量策划循环APQP4ThepurposeoftheProductQualityPlanningCycleistoemphasize:产品质量策划循环的目的是强调：Up-frontplanning:Thefirstthreequartersofthecyclearedevotedtoup-frontproductqualityplanningthroughproduct/processvalidation.策划：前四分之三循环含盖产品质量策划到产品/过程确认Theactofimplementation:Thefourthquarteristhestagewheretheimportanceofevaluatingtheoutputservestwofunctions:todetermineifcustomersaresatisfied,andtosupportthepursuitofcontinualimprovement.措施的实施：第四阶段对结果进行评价的重要性体现在两方面：是否达到顾客满意及对持续改进的追求。APQP5Depictingproductqualityplanningasacycleillustratesthenever-endingpursuitofcontinualimprovementthatcanonlybeachievedbytakingtheexperienceinoneprogramandapplyingthatacquiredknowledgetothenextprogram.将产品质量策划描绘成一个循环说明：只有将从一个项目中获取的经验及知识应用到下一个项目中才能实现对持续改进的永无止境的追求APQPAPQPAPQPAPQPAPQP6KeytoEffectiveProductQualityPlanning有效的产品质量策划其关键在于：－Supportfromthetopmanagementfor－来自于最高管理者的支持 concludingeachphaseofproductqualityplanning 质量策划每一阶段的总结

Note:theteamshouldinformtopmanagementaboutthecurrentstatus oftheprojectinordertokeepuptheinterestandunderpintop managementcommitmentandsupport.Theinformationshouldbein writtenform solvingproblemareasandconcerns 参与问题的解决

APQP7 finalassessmentoftheproductqualityplanningprocess (signing-off) 产品质量策划过程的最终评价(总结认定appendixF)－TeamandCommunicationSkill－团队技巧及沟通技巧

Note:Teamskillmeanstoworkinateamratherthanthinking“great, somebodyelsedoesit”.Communicationskillmeanstheabilitytopasson informationcomprehensivelyandwithoutlossofinformation.APQP8ResponsibilityMatrix职责矩阵APQP9ProductQualityPlanningTimingChart

APQP10Thetimingchartshowstheidealprocedureofproductqualityplanning.Theindividualphasesareshownastimebarsandtherespectivestartingpointsareshownasverticallines(conceptinitiation/approval,programapproval,prototype,pilot,launch)APQPAPQPAPQPAPQPAPQPAPQP11OrganizationofAPQPReferenceManualAPQP手手册册的的组组织织结结构构APQPPlanandDefineProgramSection1.0ProductDesignandDevelopmentSection2.0ProcessDesignandDevelopmentSection3.0ProductandProcessValidationSection4.0Feedback,AssessmentandCorrectiveActionSection5.0ControlPlanMethodologySection6.0OrganizetheteamDefinethescopeTeam-to-teamTrainingindevelopmenttechniquesCustomerandsupplierinvolvementSimultaneousEngineeringConcernresolutionMonitoringwithtimingplansystemsAPQP12OrganizingtheTeam组组织小小组Theresponsibilityforproductqualityplanningmustbeassignedtoacross-functionalteam.TheteamshouldcompriserepresentativesofthefunctionsDevelopment,Production,MaterialTesting,Purchasing,Quality,Sales,CustomerService,aswellassubcontractorsandcustomers.Team-to-TeamCo-operation小小组之之间的的合作作Theteammustestablishcommunicationchannelstoothercustomerandsupplierteams.Thismayincluderegularmeetingswithotherteams.APQP13TraininginDevelopmentTechniques开发技技术的的培训训Thesuccessoftheproductcontrolplandependsonaneffectivetrainingprogramwhichwillconveyalldefinedrequirementsanddevelopmenttechniquesnecessaryforthefulfillmentofcustomerrequirementsandexpectations.CustomerandSupplierInvolvement顾客及及供方方的参参与Ifnecessary,thecustomerandsubcontractormustbeinvolvedintheplanningprocess.Thesuppliershallrequestacross-functionalteamfromtheirsubcontractors.APQP14DefiningtheScopeoftheTeam:给小组组界定定范围围selectaprojectteamleader（（itmaybeadvantageoustorotatetheteamleaderduringtheplanningcycle)选一个个小组组长（（轮流流做桩桩较好好）definetherolesandresponsibilitiesofeacharearepresented定义各各方代代表的的角色色和职职责identifythecustomers-internalandexternal明确谁谁是内内部的的及外外部的的顾客客definingcustomerrequirements(useQFD,ifapplicable)定义顾顾客要要求(如如适用用，使使用QFD)APQP15definethedisciplines,individualsand/orsubcontractorsthatmustbeaddedtotheteam,andthosenotrequired明确部门门，各人人及哪些些供方必必须加到到小组中中来，哪哪些不必必understandcustomerexpectations搞搞清顾客客的期望望assessthefeasibility,performancerequirements,manufacturingprocess评价可行行性，性性能要求求，制造造过程identificationofcostsinvolved,timingandconstraints明确成本本，时间间及其他他方面的的限制determinationofassistancerequiredfromthecustomer明确需顾客客提供的邦邦助有哪些些identificationofdocumentationprocessormethod明确报告/记录的过过程和方法法APQP16SimultaneousEngineering同同步工程程Itisaprocesswherecrossfunctionalteamsstriveforacommongoal.各多功能小小组为共同同的目标努努力Itreplacethesequentialseriesofphaseswhereresultsaretransmittedtothenextareaforexecution.代代替按阶阶段排序Thepurposeistoexpeditetheintroductionofqualityproductssooner.其目的是加加速高质量量产品的引引入DesignforManufacturabilityandAssemblyisaSimultaneousEngineeringprocessdesignedtooptimizetherelationshipbetweendesignfunction,manufacturability,andeaseofassembly.APQP17ConcernResolution问题题的解决Duringtheplanningprocesstheteamwillhitondesignand/orprocessrelatedconcerns.Theseconcernsshouldbedocumentedinatablewithallocationoftheresponsibilitiesanddeadlinesfortheirresolution.Indifficultsituationsselectedmethodsforconcernresolutionmustbeemployed.AnalyticaltechniqueslistedinAppendixBofAPQPmanual:AssemblyBuildVariationAnalysis;Benchmarking;CauseandEffectDiagram;CharacteristicsMatrix;CriticalPathMethod;DesignofExperiments(DOE);DesignforManufacturabilityandAssembly;DesignVerificationPlanandReport(DVP&R);DimensionalControlPlan(DCP)orDynamicControlPlan;MistakeProofing(POKA-YOKE);ProcessFlowCharting;QualityFunctionDeployment(QFD);SystemFailureModeandEffectsAnalysis(SFMEA)APQP18MethodforConcern-Resolution解决决问题的方方法1.Recognizetheproblem,focusonitanddescribeitcomplains,defects,variations,scrap,audits,listofproblems2.Collectdatamultipledefectchart,qualitycontrolchart,dataprocessing3.EvaluatedataHistogram,pareto,processFMEA4.CauseandeffectsanalysisIshikawadiagram,problemanalysis,valueengineering,8Dreport,DOE5.WorkoutproblemresolutionproposalsBrainstorming,DOE,flowdiagram,visualizingproblemonpinwallAPQP196.AssessproblemresolutionproposalsDecisiontree,cost-benefit-analysis,riskanalysis,nominalgroupmethod7.Decision8.Informthoseinvolvedandimplementsolutionactionplan,definitionoftargets,determinemeasurables9.Checkoutcometrenddiagram,pareto,audits10.RECOGNITIONAPQP20MonitoringwithTimingPlanSystems用用时间计计划表来来监控ThefirstorderofAPQPteamfollowingorganizationalactivitiesshouldbethedevelopmentofaTimingPlan.APQP小组的的组织工工作完成成后的第第一个任任务应该该是制定定一个时时间计划划表。Awell-organizedtimingchartshouldlisttasks,assignments,othereventsandtiming.(TheCriticalPathMethodmaybeappropriate)一个完善善的时间间表应罗罗列出任任务，负负责人，，和/或或其他事事件及时时间。Tofacilitatestatusreporting,eacheventmusthavea““start”anda““completion”datewiththeactualpointofprogressrecorded.为辅助对对完成状状态进行行报告，，每一事事件必须须有““开始””和““完成成”日日期并记记录实际际进展状状况APQP21AttentionPlease注意意！Planningteamsmustbepreparedtomodifyproductqualityplanstomeetcustomerexpectations.策划小组组必须准准备好对对产品质质量计划划进行修修改以满满足顾客客的期望望TheProductQualityPlanningTeamisresponsibleforassuringthattimingmeetsorexceedsthecustomertimingplan.产品质量量先期策策划小组组负责确确保满足足或超出出顾客时时间计划划的要求求。APQP22Section1.0PlanandDefineProgram阶段1.0定定义及确确定项目目Taskofthissection此此阶段的的任务:DeterminationofcustomerneedsandexpectationsFocussingallworkonthecustomer(finaluser,consumer)Translatingcustomerinputrequirementsintooutputrequirements(orbriefingspecificationintoofferspecification)Definingdevelopment,reliabilityandqualitygoalsAPQP23InputVoiceofthecustomerMarketresearchHistoricalwarrantyandqualityinformationTeamexperienceBusinessplan/customermarketingstrategyProduct/processbenchmarkdataProduct/processassumptionsProductreliabilitystudiesCustomerinputsOutputDesigngoalsReliabilityandqualitygoalsPreliminarybillofmaterialPreliminaryprocessflowchartPreliminarylistingofspecialproductandprocesscharacteristicsProductassuranceplan(outputrequirements)PlanandDefineProgramSection1.0APQP24阶段1.0定定义及确确定项目目输入：l·1顾顾客的呼呼声1·1··1市场场调研1·1··2保修修记录和和质量信信息l·l··3小组组经验1．2业业务计划划／营销销策略1．3产产品／过过程指标标l．4产产品／过过程设想想1．5产产品可靠靠性研究究1．6顾顾客输入入输出：1．7设设计目标标1．8可可靠性和和质量目目标l．9初初始材料料清单l．10初始过过程流程程图1．11初始始特殊产产品特性性及特殊殊过程特特性清单单l·12产品保保证计划划l·13管理者者支持25261.1The‘‘VoiceoftheCustomer’The‘‘VoiceoftheCustomer’encompassescomplaint,recommendations,dataandinformationobtainedfrominternaland/orexternalcustomers.1.1.1Marketresearch:Thefollowingsourcescanassistinidentifyingcustomerconcerns/wantsandtranslatingthoseconcernsintoproductandprocesscharacteristics:CustomerinterviewsCustomerquestionnairesandsurveysMarkettestandpositioningreportsNewproductqualityandreliabilitystudiesCompetitiveproductqualitystudiesThingsGoneRight(TGR)reportsAPQP27l·1顾顾客的呼呼声“顾客的呼呼声”包括来自自内部和和／或外外部顾客客的抱怨怨、建议议、资料料和信息息。以下下各段提提供了收收集这种种信息的的一些方方法。1·1··1市场场调研产品质量量策划小小组可能能需要获获取反映映顾客时时声的市市场调研研资料和和信息。。以下来来源有助助于识别别顾客关关注的事事项／需需求，并并将这些些关注事事项转变变为产品品和过程程特性：：对顾客的的采访；；顾客意见见征询与与调查；；市场调调查和和预测测报告告；新产品品质量量和可可靠性性研究究；竞争产产品质质量的的研究究；运行情情况良良好（（TGR））报告告。281.1.2Historicalwarrantyandqualityinformation:Thelistofhistoricalcustomerconcerns/wantsshouldbepreparedtassessthepotentialforrecurrenceduringthedesign,manufacture,installationanduseoftheproduct.Ascertainingcustomerconcernscanbesupportedby:ThingsGoneWrong(TGW)reportsWarrantyreportsSupplierplantinternalqualityreportsCustomerplantreturnsandrejectionsFieldreturnsandproductanalysisAPQPAPQP291·1··2保修修记录和和质量信信息为厂评定定在产品品的设计计、制造造、安装装和使用用当中再再发生不不合格的的可能性性，应制制定一份份以往顾顾客所关关注问题题儒要的的清单，，这些应应作为其其它设计计要求的的扩展来来考虑并并且应包包括在对对顾客需需要的分分析中。。以下项目目中的许许多内容容有助于于小组识识别顾客客关注问问题／需需要，并并优选出出适当的的解决方方案：运行情况况不良（（TGW）报告告；保修报告告；能力指数数；供方工厂厂内部质质量报告告；问题解决决报告；；顾客工厂厂退货和和废品；；现场退货货产品分分析。301.1.3TeamExperience:MediacommentaryandanalysisInputfrompastQualityFunctionDeploymentprojectsGovernmentrequirementsandregulationsRoadtripsManagementcommentsordirection.APQPAPQP31l·l·3小组经验验小组适当时时可利用包包括如下内内容的任何何信息来源源：来自更高层层体系或过过去质量功功能开发（（QFD））项目的输输入；媒介的评论论和分析：：杂志和报报刊报告等等；顾客的信件件和建议；；运行情况良良好（TGR）／运运行情况不不良（TGW）报告告；销售商意见见；车队负责人人的意见；；现场服务报报告；利用指定的的顾客代理理所作的内内部评价；；道路行驶体体验；管理者的意意见或指示示；由内部顾客客报告的问问题和议题题；政府的要求求和法规；；合同评评审。。321.2BusinessPlan/CustomerMarketingStrategyThecustomerbusinessplanandmarketingstrategywillsettheframeworkfortheproductionqualityplan.Thebusinessplanmayplacethefollowingconstraintsontheteam:TimingCostInvestmentProductpositioningResearchanddevelopment(R&Dresources)Themarketingstrategywilldefinethetargetcustomer,thekeysalespoints,andkeycompetitors.APQPAPQP331．2业务务计划划／营营销策策略顾客业业务计计划和和营销销策略略将成成为产产品质质量计计划的的设定定框架架。业业务计计划可可将限限制性性要求求施加加给小小组（（诸如如进度度、成成本、、投资资、产产品定定位、、研究究与开开发（（R＆＆D））资源源）而而影响响其执执行方方向。。营销销策略略将确确定目目标顾顾客、、主要要的销销售网网点和和主要要的竞竞争者者。341.3Product/processBenchmarkDataTheuseofBenchmarkingwillprovideinputtoestablishingproduct/processperformancetargets.Onemethodtosuccessfulbenchmarkingis:IdentifytheappropriatebenchmarksUnderstandthereasonforthegagbetweenyourcurrentstatusandthebenchmarkDevelopaplantoeitherclosethegap,matchthebenchmark,orexceedthebenchmark1.4Product/processAssumptionsTherewillbeassumptionsthattheproducthascertainfeatures,design,orprocessconcepts.Theseincludetechnicalinnovations,advancematerials,reliabilityassessments,andnewtechnology.Allshouldbeutilizedasinputs.APQP351．3产品品／过过程指指标基准确确定（（参见见附录录B））将成成为建建立产产品／／过程程能力力目标标提供供输入入。研研究和和开发发也可可提供供基准准和概概念。。成功功的基基准确确定方方法为为；识别合适的的基准；了解你目前前状况和基基准之间产产生差距的的原因；制定一缩小小差距、符符合基准或或超过基准准的计划。。l．4产品品／过程设设想设想产品具具有某些特特性、某种种设计和工工艺过程概概念，它们们包括技术术革新、先先进的材料料、可靠性性评定和新新技术。所所有这些都都应用作输输入。361.5ProductReliabilityStudies.Thistypeofdataconsidersfrequencyofrepairofreplacementofcomponentswithindesignatedperiodsoftimeandtheresultsoflongtermreliability/durabilitytests.1.6CustomerInputsTheendusersoftheproductcanprovideviableinformationrelatingtotheirneedandexpectations.Thisinputshouldbeusedbythecustomerand/orsuppliertodevelopagreeduponmeasuresofcustomersatisfaction.1.7DesignGoalsDesigngoalsareatranslationofthe“VoiceoftheCustomer””intotentativeandmeasurabledesignobjectivesAPQP371．5产品品可靠性研研究这一类型的的数据考虑虑了在一规规定时间内内零件修理理和更换的的频率，以以及长期可可靠性／耐耐久性试验验的结果。。1．6顾客客输入产品的后续续顾客可提提供与他们们的需要和和期望有关关的有价值值信息，此此外，后续续产品顾客客可能已进进行部分或或全部前面面已提到的的评审和研研究。顾客客和/或供供方应使用用这些输入入以开发统统一的衡量量顾客满意意的方法。。1．7设计计目标设计目标就就是将顾客客的呼声转转化为初步步并具体的的设计任务务。设计目目标的正确确选择确保保顾客的呼呼声不会消消失在随后后的设计活活动中。381.8ReliabilityandQualityGoalsReliabilitygoalsareestablishedbasedoncustomerwantsandexpectations,programobjectives,andreliabilitybenchmarks.Someexamples:nonsafetyrelateddefectsservicefriendlinessQualitygoalsaretargetsbasedoncontinualimprovement.Someexamples:ppmvaluesdefectlevelsreductionofscrap1.9PreliminaryBillofMaterialTheteamshouldestablishapreliminarybillofmaterialbasedonproduct/processassumptionsandincludeanearlysubcontractorlist.APQPAPQP391．8可靠靠性和质量量目标可靠性目标标是在顾客客需要和期期望、项目目目标及可可靠性基准准的基础上上制定的。。顾客需要要和期望可可以是无安安全问题和和可维修性性。有些可可靠性基准准可以是竞竞争者产品品的可靠性性、顾客的的报告或在在一设定时时间内修理理的频率。。总的可靠靠性目标可可用概率和和置信度表表示。质量量目标是基基于持续改改进的目标标，诸如（（PPM））零件／百百万缺陷水水平或废品品降低率。。l．9初始始材料清单单小组在产品品／过程设设想的基础础上应制定定一份初始始材料清单单，并包括括早期分承承包方名单单。为了识识别初始特特定产品／／过程特性性，有必要要事先选定定合适的设设计和制造造过程。401.10PreliminaryProcessFlowChartTheanticipatedmanufacturingprocessshouldbedescribedusingaprocessflowchartdevelopedfromthepreliminarybillofmaterialandproduct/processassumptions.1.11PreliminaryListingofSpecialProductandProcessCharacteristicsSpecialproductandprocesscharacteristicsareidentifiedbythecustomerinadditiontothoseselectedbythesupplierthroughknowledgeoftheproductandprocess.Theteamshouldassurethatapreliminarylistofspecialproductsandprocesscharacteristicsresultingfromtheanalysisoftheinputpertainingtocustomerneedsandexpectationsisdeveloped.Thislistingcanbedevelopedfromthefollowingitems:ProductassumptionsbasedontheanalysisofcustomerneedsandexpectationsIdentificationofreliabilitygoals/requirementsAPQP411．8可靠靠性和质量量目标可靠性目标标是在顾客客需要和期期望、项目目目标及可可靠性基准准的基础上上制定的。。顾客需要要和期望可可以是无安安全问题和和可维修性性。有些可可靠性基准准可以是竞竞争者产品品的可靠性性、顾客的的报告或在在一设定时时间内修理理的频率。。总的可靠靠性目标可可用概率和和置信度表表示。质量量目标是基基于持续改改进的目标标，诸如（（PPM））零件／百百万缺陷水水平或废品品降低率。。l．9初初始材料料清单除了由供供方根据据产品和和过程经经验中选选择外，，特殊的的产品和和过程特特性均由由顾客确确定。在在这一阶阶段，小小组应确确保制定定出通过过对有关关顾客需需要和期期望的输输入的分分析而得得出的特特殊产品品和过程程特性的的初始明明细表。。这一明明细表的的制定基基于（但但不限于于）以下下方面：：基于顾客客需要和和期望分分析的产产品设想想；可靠靠性性目目标标／／要要求求的的确确定定；；从预预期期的的制制造造过过程程中中确确定定的的特特殊殊过过程程特特性性；；类似似零零件件的的失失效效模模式式及及后后果果分分析析（（FMFA））。。42IdentificationofspecialprocesscharacteristicsfromtheanticipatedmanufacturingprocessSimilarpartFMEAsNote:Specialcharacteristiccanaffectthesafefunctioningofthevehicleandcompliancewithgovernmentregulationssuchasflammability,occupantprotection,steeringcontrol,braking,emissions,noise,EMCetc.Duringtheproductdesignanddevelopmentphase,thelistshouldberefined,reviewed,andconsensusreached.Theoutputisrequiredtobedocumentedintheprototypecontrolplan.Duringprocessdesignanddevelopment,thelistshouldbeconvertedintoamatrixwhichdisplaystherelationshipbetweentheprocessparametersandthemanufacturingstationsandthisdocumentedintheproductioncontrolplan.1.12ProductAssurancePlanTheProductAssurancePlantranslatesdesigngoalsintodesignrequirements.TheamountofeffortdevotedtotheProductAssuranceAPQP43Planbytheteamdependsoncustomerneeds,expectations,andrequirements.TheProductAssurancePlancanbedevelopedinanyformatandshouldinclude,butisnotlimited,tothefollowingactions:OutliningofprogramrequirementsIdentificationofreliability,durability,apportionment/allocationgoalsand/orrequirementsAssessmentofnewtechnology,materials,application,environment,packaging,service,andmanufacturingrequirementsoranyotherfactorthatmayplacetheprogramatriskDevelopmentofFailureModeAnalysisDevelopmentofpreliminaryengineeringstandardsrequirementsTheProductAss.PlanisanimportantpartoftheProductQualityPlan.1.13ManagementSupportAPQP44l·12产品保保证计划划产品保证证计划将将设计目目标转化化为设计计要求。。产品质质量策划划小组在在产品保保证计划划上所作作的努力力的程度度取决于于顾客的的需要、、期望和和要求。。本手册册对制定定产品保保证计划划的方法法不作规规定，产产品保证证计划可可采用任任何清晰晰易懂的的格式，，它可包包括（但但不限于于）以下下措施：：概述项目目要求；；可靠性、、耐久性性和分配配目标和和／或要要求的确确定；新技术、、复杂性性、材料料、应用用、环境境、包装装、服务务和制造造要求或或其它任任何会给给项目带带来风险险的因素素的评定定；进行失效效模式分分析（FMA））（参见见附录H）；；制定初始始工程标标准要求求。产品保证证计划是是产品质质量计划划的重要要组成部部分。l·13管理者者支持产品质量量策划小小组成功功的关键键之一是是高层管管理者对对此工作作的兴趣趣、承诺诺和支持持，小组组在每一一产品质质量策划划阶段结结束时应应将新情情况报告告给管理理者以保保持其兴兴趣，并并进一步步促进他他们的承承诺和支支持。在在小组的的要求下下，可以以更频繁繁地报告告新情况况和／或或要求帮帮助，这这种新情情况报告告是正式式的，留留有提问问和解答答的机会会。45Section2.0ProductDesignandDevelopment阶段2.0产品品设计及开开发Taskofthissection:此阶段段的任务AcomprehensiveandcriticalreviewofengineeringrequirementandotherrelatedtechnicalinformationPreliminaryfeasibilityanalysistoassessthepotentialproblems,anddevelopmentoftherespectivecontrolplanforprototypeVerifythattheproductorservicemeetstheobjectivesofthecustomer(designverification)APQP46InputDesigngoalsReliabilityandqualitygoalsPreliminarybillofmaterialPreliminaryprocessflowchartPreliminarylistingofspecialproductandprocesscharacteristicsProductassuranceplanOutputDesignFMEADesignverificationDesignreviewsPrototypebuild-controlplanEngineeringdrawingsEngineeringspecificationsMaterialspecificationsNewequipment,toolingandfacilitiesrequirementsSpecialproductandprocesscharacteristicsGages/testequipmentrequirementsTeamfeasibilitycommitmentandmanagementsupportProductDesignandDevelopmentSection2.0APQP47阶段段2.0产产品品设设计计及及开开发发由设设计计负负责责部部门门的的输输出出：：设计计失失效效模模式式及及后后果果分分析析（（DFMEA））可制制造造性性和和装装配配设设计计设计计验验证证设计计评评审审样件件制制造造工程程图图样样（（包包括括数数学学数数据据工程程规规范范材料料规规范范图样样和和规规范范的的更更改改由产品质量量先期策划划小组的输输出：新设备工装和设施施要求特殊产品和和过程特性性样件制造-控制计划划量具／试验验设备要求求小组可行性性承诺和管管理者支持持48492.1DesignFailureModeandEffectsAnalysisThedesignFMEAisadisciplinedanalyticaltechniquethatassessestheprobabilityoffailureaswellastheeffectofsuchfailure.TheDesignFMEAChecklistinappendixA-1shouldalsobereviewedtoassurethattheappropriatedesigncharacteristicshavebeenconsidered.2.2DesignforManufacturabilityandAssemblyDesignforManufacturabilityandAssemblyisaSimultaneousEngineeringprocessdesignedtooptimizetherelationshipbetweendesignfunction,manufacturability,andeaseofassembly.Ataminimum,theitemslistedhereshouldbeconsideredbytheProductQualityPlanningTeam:Design,concept,function,andsensitivitytomanufacturingvariationManufacturingand/orassembleprocessAPQP502．1设计计失效模式式和后果分分析DFMEA是一种评评定失效可可能性及其其失效影响响的分析技技术，DFMEA的的一种形式式为系统失失效模式及及后果分析析（SFMEA），，DFMEA是一种种动态文件件，随顾客客需要和期期望不断更更新，DFMEA的的制定为小小组提供了了评审以前前选择的产产品和过程程特性和作作出必要补补充、改变变和删减的的机会。克克莱斯勒、、福特和通通用汽车公公司的潜在在失效模式式及后果分分析参考手手册应作为为一种可接接受的DFMEA的的方法，还还应评审附附录A一1中的设计计FMEA清单，以以保证已考考虑合适的的设计特性性。2．2可制制造性和装装配设计可制造性和和装配设计计是一种同同步技术过过程，用来来优化设计计功能、可可制造性和和易于装配配之间的关关系。第一一章中所确确定的顾客客需要和期期望范围将将决定供方方产品质量量策划小组组进行此活活动的程度度。本手册册不包括或或涉及制定定可制造性性和装配设设计计划的的正式方法法。产品质质量策划小小组至少要要考虑以下下所列的项项目：设计、概念念、功能和和对制造变变差的敏感感性；制造和／或或装配过程程；尺寸公差；；性能要求；；部件数；过程调整；；材料搬搬运。。产品质质量策策划小小组的的知识识、经经验、、产品品／过过程、、政府府法规规和服服务要要求有有可能能需要要考虑虑其它它因素素。51DimensionaltolerancesPerformancerequirementsNumberofcomponentsProcessadjustmentsMaterialHandling2.3DesignVerificationDesignverificationverifiesthattheproductdesignmeetsthecustomerrequirementsderivedfromtheactivitiesdescribedinsectionDesignReviewsDesignreviewsareregularlyscheduledmeetingledbythesupplier’’sdesignengineeringactivityandmustincludeotheraffectedareas.Designreviewsareaseriesofverificationactivitiesthataremorethananengineeringinspection.APQPAPQP52AtaminimumDesignReviewsshouldincludeevaluationof:Design/functionalrequirementsFormalreliabilityandconfidencegoalsComputersimulationandbenchtestresultsDesignFMEAsReviewoftheDesignForManufacturabilityandAssemblyeffortApplicationofDesignofExperiments(DOE)andassemblybuildvariationresultsTestfailureDesignVerificationprogressAPQPAPQP532．．3设设计计验验证证设计计验验证证检检验验产产品品设设计计是是否否满满足足第第一一章章所所述述活活动动的的顾顾客客要要求求。。2．．4设设计计评评审审设计计评评审审是是以以供供方方设设计计技技术术活活动动为为主主并并且且应应包包括括其其它它被被影影响响领领域域的的定定期期安安排排的的会会议议。。设设计计评评审审为为防防止止问问题题和和误误解解的的有有效效方方法法，，而而且且还还是是监监测测进进展展双双向向管管理理者者报报告告的的途途径径。。设计评审审不只是是技术检检验，而而是一系系列的验验证活动动。至少少设计评评审应包包括以下下方面的的评价：：设计／功功能要求求的考虑虑；正式的可可靠性和和置信度度目标；；部件／子子系统／／系统工工作循环环；计算机模模拟和台台架试验验结果；；设计失效效模式及及后果分分析（DFMEA）；；可制造性性和装配配设计的的评审；；试验设计计（DOE）和和装配产产生的变变差结果果（参见见附录B）；破坏性试试验；设计验证证进展；；54设计评审审的重要要功能是是跟踪设设计验证证进展。。供方应应通过使使用计划划和报告告格式，，即由克克莱斯勒勒和福特特汽车公公司制定定的设计计验证计计划和报报告（DVP＆＆R）来来跟踪设设计验证证进展。。计划和和报告是是保证以以下方面面的正式式方法：：设计验证证；通过采用用综合的的试验计计划和报报告对部部件和总总成的产产品和过过程确认认。产品质量量策划小小组不只只限于所所列项目目，适当当时小组组应考虑虑并使用用附录B中所列列的分析析技术。。552.5PrototypeBuild-ControlPlanPrototypecontrolplansareadescriptionofthedimensionalmeasurementsandmaterialandfunctionalteststhatwilloccurduringprototypebuild.Allprototypesshouldshouldbereviewedwithrespecttothefollowingaspects:Assurethattheproductorservicemeetsspecificationandreportdataasrequired.Ensurethatparticularattentionhasbeengiventospecialproductsandprocesscharacteristics.Usedataandexperiencetoestablishpreliminaryprocessparametersandpackagingrequirements.Communicateanyconcerns,deviationsand/orcostimpacttothecustomer.APQP562．5样件件制造——控制计划样件控制计计划是对样样件制造过过程中的尺尺寸测量和和材料与功功能试验的的描述，产产品质量策策划小组要要确保制定定样件控制制计划。控控制计划方方法论见第第六章所述述。附录A－8和第第六章中的的控制计划划检查清单单可帮助制制定样件控控制计划。。样件的制造造为小组和和顾客提供供了一个极极好的机会会来评价产产品或服务务满足顾客客愿望的程程度。产品品质量策划划小组负责责的所有样样件都应被被评审以便便：保证产品或或服务符合合所要求的的规范和报报告数据；；保证已对特特殊产品和和过程特性性给予了特特别的注意意；使用数据和和经验以制制定初始过过程参数和和包装要求求；将关注问题题、变差和和／或费用用影响传达达给顾客。。572.6EngineeringDrawingsCustomerdesignsdonotprecludetheplanningteam’sresponsibilitytoreviewengineeringdrawings.Theteamshouldreviewengineeringdrawingsinordertodeterminewhichcharacteristicsaffectfit,function,durabilityand/orgovernmentalregulatorysafetyrequirements.Drawingshouldbereviewedtodetermineifthereissufficientinformationforadimensionallayoutoftheindividualpart.Controlordatumsurfaces/locatorsshouldbeclearlyidentified.Theteamshouldassurethatmathdataiscompatiblewiththecustomerssystem.2.7EngineeringSpecificationThesuppliershoulddeterminewhichcharacteristicsaffectorcontroltheresultsthatfulfilmeetingfunctional,durability,andappearancerequirements.Thesizeandfrequencyofsamples,unlessspecified,aretobedeterminedbythesupplierhimself.APQP582．6工工程图样样（包括括数学数数据）顾客设计计不排除除策划小小组以如如下方式式评审技技术图样样的职责责。工程程图样可可包括应应在控制制计划上上出现的的特殊（（政府法法规和安安全性））特性。。如没有有顾客工工程图样样，应由由策划小小组评审审控制图图样以决决定哪些些特性影影响配合合、功能能、耐久久性和／／或政府府法规中中的安全全要求。。应对工程程图样进进行评审审来确定定是否具具有足够够的数据据以对每每个零件件进行全全尺寸检检验。应应能清楚楚地标识识控制或或基准平平面／定定位面，，以便能能为现行行的控制制过程设设计适当当的功能能量具和和装备，，应评价价尺寸以以保证可可行性和和工业制制造和测测量标准准相一致致。适当当时，小小组应保保证数学学数据和和顾客的的系统兼兼容以进进行有效效的双向向交流。。2．7工工程规范范对控控制制规规范范详详细细的的评评审审和和了了解解将将有有助助于于产产品品质质量量策策划划小小组组识识别别有有关关部部件件或或总总成成的的功功能能、、耐耐久久性性和和外外观观的的要要求求。。样样本本容容量量、、频频率率和和这这些些参参数数的的接接受受标标准准一一般般在在技技术术规规范范的的生生产产过过程程中中试试验验一一章章中中予予以以确确定定，，否否则则样样本本容容量量和和频频率率由由供供方方决决定定并并列列入入控控制制计计划划中中，，在在这这两两种种情情况况下下，，供供方方应应确确定定哪哪些些特特性性影影响响或或控控制制满满足足功功能能、、耐耐久久性性及及外外观观要要求求。。592.8MaterialSpecificationsInadditiontodrawingsandperformancespecifications,materialspecificationsshouldbereviewedforSpecialCharacteristicsrelatingtophysicalproperties,performance,environmental,handling,andstoragerequirements.2.9DrawingandSpecificationChangeTheteammustensurethatdrawingandspecificationchangesarepromptlycommunicatedandproperlydocumentedtoallaffectedareas.2.10Newequipment,ToolingandFacilitiesRequirementsTheDesignFMEA,ProductAssurancePlanand/orDesignReviewsmayidentifynewequipmentandfacilitiesrequirements.Theteamshouldaddresstheserequirementsbyaddingtheit