APQP: Advanced Product/Project Quality Planning

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APQP

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  • 1. APQP ADVANCED PRODUCT QUALITY PLANNING TRAINING COURSE Nukool Thanuanram Senior Consultant and Trainer Alternative Training & Consulting Mobile : 081 400 3954 E-Mail : nukool2001@gmail.com Twitter & Facebook : nukool2001

2. KEY OBJECTIVE TARGET 3. APQP Advanced Product Quality Planning 4. What is APQP ? A = Advanced P = Product Mass Products Q = Quality P = Planning 5. ADVANCED ? Control Plan FMEA SPC MSA Team Planning 5W 2H + Core Tools Implementation APQP PPAP Process Flow 6. CSR Customer Specific Requirements 7. 4M1E APQP 4M (APQP Phase 3) MachineMaterial MethodsEnvironmentMan Process Flow Chart Work Instructions MSA PFMEA Control Plan skill Operator spec Machine Material Handing Fixture / Tooling Tool life Customer Requirements Customer Satisfaction parameters Check Sheets SPC 8. ? APQP Project Planning Activity Cross Functional Team (Experiences) Target Quality Cost Delivery . Management Support Mass Production by 9. FAIL TO PLAN IS PLANNING TO FAIL !!! 10. EXERCISE Brain Storm With Your Group Strength & Weakness of APQP Activity 11. APQP Management Technical 12. / 1 2 3 4 5 Time Problem 13. Core Team Supporters Sale Purchase Store HR Safety Supplier Customer Specialist Engineering Production QA - QC Maintenance Tooling APQP Team Cross Functional Team Multidisciplinary Approach 14. Risk Analysis Manufacturing Feasibility 15. Example : Mfg. Feasibility & Risk Analysis 16. APQP TIMING PLANS 17. APQP Monitoring Report 18. APQP Timing Chart Plan & Define Programme Product Design & Development Verification Product & Process Validation Feedback Assessment & Corrective Action Reliability & Quality Goals Pre PFC Pre SC of Product & Process Management Support DFMEA Drawing Eng Spec Material Spec Prototype CP Management Support PFC + SC Floor Plant PFMEA Ppk Plan Pre Launch CP MSA Plan Packing Std. Training Plan Management Support Training Record Production Trial MSA Result Ppk Result Validation Test Production CP PPAP Sign Off Management Support Customer Satisfaction QCD Reduction Variation Lesson Learned Management Support Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 19. APQP : Phase 1 Plan and Define Program 20. APQP Timing Chart Plan & Define Programme Product Design & Development Verification Product & Process Validation Feedback Assessment & Corrective Action Reliability & Quality Goals Pre PFC Pre SC of Product & Process Management Support DFMEA Drawing Eng Spec Material Spec Prototype CP Management Support PFC + SC Floor Plant PFMEA Ppk Plan Pre Launch CP MSA Plan Packing Std. Training Plan Management Support Training Record Production Trial MSA Result Ppk Result Validation Test Production CP PPAP Sign Off Management Support Customer Satisfaction QCD Reduction Variation Lesson Learned Management Support Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 21. EXERCISE Brain Storm With Your Group What to Plan on Your APQP Activity 22. PHASE 1: Requirements & Needs Expectations Claim Complaint Quality Defect M/C Capacity Delivery Performance Target P-Q-C-D Performance (2P) Reliability & Warrantee Benchmark 23. Phase 1 : Outputs Cycle Time Productivity Cost Per Unit Defect Rate (PPM or DPM) Process Capability Product Performance 24. APQP : Phase 2 Product Design & Development 25. APQP Timing Chart Plan & Define Programme Product Design & Development Verification Product & Process Validation Feedback Assessment & Corrective Action Reliability & Quality Goals Pre PFC Pre SC of Product & Process Management Support DFMEA Drawing Eng Spec Material Spec Prototype CP Management Support PFC + SC Floor Plant PFMEA Ppk Plan Pre Launch CP MSA Plan Packing Std. Training Plan Management Support Training Record Production Trial MSA Result Ppk Result Validation Test Production CP PPAP Sign Off Management Support Customer Satisfaction QCD Reduction Variation Lesson Learned Management Support Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 26. APQP : Phase 3 Process Design & Development 27. APQP Timing Chart Plan & Define Programme Product Design & Development Verification Product & Process Validation Feedback Assessment & Corrective Action Reliability & Quality Goals Pre PFC Pre SC of Product & Process Management Support DFMEA Drawing Eng Spec Material Spec Prototype CP Management Support PFC + SC Floor Plant PFMEA Ppk Plan Pre Launch CP MSA Plan Packing Std. Training Plan Management Support Training Record Production Trial MSA Result Ppk Result Validation Test Production CP PPAP Sign Off Management Support Customer Satisfaction QCD Reduction Variation Lesson Learned Management Support Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 28. Process Flow Chart : PFC FMEA PHASE 3 : OUTPUTS 29. Floor Plant Layout PHASE 3 : OUTPUTS 30. Phase 3 : Outputs 31. FMEA Failure Mode & Effect Analysis 32. FMEAFMEAFMEAFMEA Prioritize () Identify () Reduce () Risks ! () Severity () Occurrence () Detection () Reduce () Phase 3 : Outputs 33. FMEA Assessment Method 1 2 3 4 5 (Failure) Failure 1-10 Failure 1-10 1-10 PFC Steps Failure Severity Occurrence Detection 100% 0% S O DRPN = 34. Example : PFMEA (s) 35. FMEA Format : Form C 36. S-Severity Please see in appendix : A 37. O-Occurrence 38. D-DETECTION 39. D-DETECTION 40. CP Control Plans 41. Prototype Pre-launch Production Control Plan prototype Production Control Plan 42. Control Plan 43. Work InstructionsPHASE 3 : OUTPUTS 44. Phase 3 : Outputs 45. MSA Control Plan 70 WAX 1 B 2+0.5 3 SPC (X bar-R Chart) / / / MSA MSA Control Plan 46. Phase 3 : Outputs (Ppk Study Plan) (SC) Control Plan , , CSR 47. Control Plan 70 WAX 1 SC 2+0.5 3 SPC / / / Ppk Specification 48. APQP : Phase 4 Product & Process Validation 49. APQP Timing Chart Plan & Define Programme Product Design & Development Verification Product & Process Validation Feedback Assessment & Corrective Action Reliability & Quality Goals Pre PFC Pre SC of Product & Process Management Support DFMEA Drawing Eng Spec Material Spec Prototype CP Management Support PFC + SC Floor Plant PFMEA Ppk Plan Pre Launch CP MSA Plan Packing Std. Training Plan Management Support Training Record Production Trial MSA Result Ppk Result Validation Test Production CP PPAP File Sign Off Management Support Customer Satisfaction QCD Reduction Variation Lesson Learned Management Support Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 50. Phase 4 : Outputs (Significant production run) 4M 1E Dimension Check Data Performance Test (If require) Master Sample Target Cycle Time ( MSA) 51. Phase 4 : Outputs (MSA) 52. MSA Selection Procedure Data Type Variable data Attribute data Focus Accuracy Precision Gauge Linearity Stability Gauge R&R Study Attribute Agreement Analysis Bias Study Attribute R&R 53. Product Decision : Good Bad Accept (Type II Error: ) Reject (Type I Error: ) TYPE I ERROR = TYPE II ERROR = 54. Variation of Measurement System Man (AV)Machine (EV) Method Material (PV) Environment Product, Process MS 55. Process Capability Study 23.423.122.822.522.221.921.6 LSL USL LSL 21.5 Target * USL 23.5 Sample Mean 22.5308 Sample N 125 StDev (Within) 0.184908 StDev (O v erall) 0.188657 Process Data C p 1.80 C PL 1.86 C PU 1.75 C pk 1.75 Pp 1.77 PPL 1.82 PPU 1.71 Ppk 1.71 C pm * O v erall C apability Potential (Within) C apability PPM < LSL 0.00 PPM > USL 0.00 PPM Total 0.00 O bserv ed Performance PPM < LSL 0.01 PPM > USL 0.08 PPM Total 0.09 Exp. Within Performance PPM < LSL 0.02 PPM > USL 0.14 PPM Total 0.16 Exp. O v erall Performance Within Overall Process Capability of Daimeter OK ? PHASE 4 : OUTPUTS 56. Ppk > 1.67 Acceptable Ppk < 1.67 > 1.33 Needs Controls Ppk < 1.33 100% Check 57. Cpk PPM (Part Per Million) DPM (Defect Per Million) Cpk PPM 0.67 45,600 1.00 2,700 1.33 64 1.67 1 2.00 0.002 58. Phase 4 : Outputs (Production Control Plan) 59. Control Plan (ECR, ECN) (Process Change) (Unstable) (Uncap ability) , , 60. PPAP File PSW: Part Submission Warrant Sample Parts Dimension Check / Performance Test Material Performance Test Engineering Drawing / Design Record Engineering Change Documents Check Fixtures / Checking Aids Manual Process Flow Chart FMEA Control Plan Process Capability Study (Ppk, Cpk) Measurement System Analysis Lab Accreditation & Scope 61. APQP : Phase 5 Feedback, Assessment & Corrective Action 62. APQP Timing Chart Plan & Define Programme Product Design & Development Verification Product & Process Validation Feedback Assessment & Corrective Action Reliability & Quality Goals Pre PFC Pre SC of Product & Process Management Support DFMEA Drawing Eng Spec Material Spec Prototype CP Management Support PFC + SC Floor Plant PFMEA Ppk Plan Pre Launch CP MSA Plan Packing Std. Training Plan Management Support Training Record Production Trial MSA Result Ppk Result Validation Test Production CP PPAP File Sign Off Management Support Customer Satisfaction QCD Reduction Variation Lesson Learned Management Support Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 63. 5 : Reduced Variation SPC MSA Six Sigma TPM Customer Satisfaction Survey Customer Feedback Management Delivery and Service Improvement Update FMEA CP WI Check Point Lessons Learned + Best Practices 64. Q & A end of presentation 65. FEEDBACK or CONTACT US Nukool2001 66. Thank You CONTACT US: NUKOOL THANUANRAM