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Materi training APQP

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Materi training APQP

  1. 1. Hendra Hendrasmara – Industrial Battery Development Dept. Cileungsi, 30 Sep 2014 1 Advanced Product Quality Planning
  2. 2. Hendra Hendrasmara – Industrial Battery Development Dept. APQP 2 • Memahami proses APQP • Mengidentifikasi input dan output 5 phase APQP • Memahami APQP sebagi methodology dalam “new Product Development”
  3. 3. 30 Sep 2014 – by Hendra Hendrasmara Hendra Hendrasmara – Industrial Battery Development Dept. 3
  4. 4. Advanced Product Quality Planning APQP (Advanced Product Quality Planning) adalah metode yang terstruktur mendefinisikan dan menetapkan langkah-langkah yang dibutuhkan untuk menjamin produk yang akan dihasilkan memenuhi atau sesuai dengan keinginan Customer. Hendra Hendrasmara – Industrial Battery Development Dept. 4
  5. 5. Advanced Product Quality Planning Apa itu Advanced ? Hendra Hendrasmara – Industrial Battery Development Dept. 5 Control Plan FMEA SPC MSA PPAP Team Planning 5W 2H + Core Tools Implementation
  6. 6. Advanced Product Quality Planning APQP dijelaskan dalam AIAG (Automotive Industry Action Group) 810-358-3003. Organisasi ini didirikan oleh visioner dari tiga produsen otomotif Amerika Utara terbesar - Chrysler, Ford, dan General Motors. Keanggotaan AIAG telah berkembang dengan masuknya perusahaan-perusahaan Jepang seperti Toyota, Honda dan Nissan, dan part suppliers serta services providers mereka. Hendra Hendrasmara – Industrial Battery Development Dept. 6
  7. 7. Advanced Product Quality Planning Hendra Hendrasmara – Industrial Battery Development Dept. 7 Tujuan dari product quality planning adalah untuk memfasilitasi komunikasi dengan semua orang yang terlibat untuk memastikan bahwa langkah-langkah yang diperlukan semua selesai tepat waktu. Perencanaan kualitas produk yang efektif tergantung pada komitmen manajemen puncak perusahaan untuk upaya yang diperlukan dalam mencapai kepuasan pelanggan.
  8. 8. APQP mengatur tahap-tahap perencanaan product (dan proses manufaktur), mulai dari tahap konsep sampai produksi massal. Beberapa manfaat dari Product Quality Plan adalah: • Mengatur Sumber Daya dalam upaya memenuhi kepuasan Customer (persyaratan customer) • Menghasilkan identifikasi awal terhadap kemungkinan perubahan • Menghindari adanya perubahan yang terlambat • Menyediakan produk yang berkualitas tepat waktu dan dengan cost yang serendah mungkin. Hendra Hendrasmara – Industrial Battery Development Dept. 8 Advanced Product Quality Planning
  9. 9. APQP dalam ISO/TS 16949 Hendra Hendrasmara – Industrial Battery Development Dept. 9 Phase Description Kalusul ISO/TS 16949 Phase 1 Plan define Program 7.3.1, 7.3.2, 7.3.2.1 Phase 2 Product Design and Development 7.3.2.1, 7.3.2.3, 7.3.3, 7.3.3.1, 7.3.4, 7.3.4.1 Phase 3 Process Design and Development 7.3.2.2, 7.3.3.2, 8.2.3.1 Phase 4 Product and Process Validation 7.3.5, 7.3.6.3 Phase 5 Feedback Assessment and Corrective Action 8.2.3.1
  10. 10. ORGANIZE THE TEAM Tahap awal yang harus dibvangun oleh pemasok adalah penetapan penanggung jawab untuk cross functional team. Product Quality Planning yang efektif membutuhkan keterlibatan seluruh perwakilan yang mencakup engineering, manufacturing, material control, procurement, quality, sales, pelayanan lapangan, serta subkontraktor dan pelanggan yang terkait. Hendra Hendrasmara – Industrial Battery Development Dept. 10 Dasar-dasar APQP
  11. 11. DEFINE THE SCOPE Hal ini penting untuk Product Quality Planning Team dalam tahap awal perencanaan produk untuk mengidentifikasi kebutuhan, harapan dan persyaratan pelanggan. Hendra Hendrasmara – Industrial Battery Development Dept. 11 Dasar-dasar APQP • Pilih pemimpin tim proyek yang bertanggung jawab untuk mengawasi proses perencanaan. • Tentukan peran dan tanggung jawab masing-masing area yang diwakili. • Mengidentifikasi pelanggan - internal dan eksternal. • Tentukan kebutuhan pelanggan. • Pilih ahli-ahli, individu, dan / atau subkontraktor yang harus ditambahkan ke tim. • Memahami harapan pelanggan, yaitu, desain, sistem pengujian. • Menilai kelayakan desain yang diusulkan, persyaratan kinerja dan proses manufaktur. • Mengidentifikasi biaya, waktu, dan kendala yang harus diperhatikan. • Tentukan bantuan yang diperlukan dari pelanggan. • Mengidentifikasi proses dokumentasi atau metode.
  12. 12. Team-to-Team Product Quality Planning Team harus membangun jalur komunikasi dengan tim pelanggan dan tim pemasok lainnya. Ini mungkin termasuk pertemuan rutin dengan tim lain. Tingkat kontak tim-to-tim tergantung pada sejumlah isu yang membutuhkan kesepakatan. Hendra Hendrasmara – Industrial Battery Development Dept. 12 Dasar-dasar APQP
  13. 13. Training Keberhasilan Product Quality Plan tergantung pada program pelatihan yang efektif untuk mengkomunikasikan semua persyaratan dan pengembangan keahlian untuk memenuhi kebutuhan dan harapan pelanggan. Hendra Hendrasmara – Industrial Battery Development Dept. 13 Dasar-dasar APQP
  14. 14. Customer and Organization Involved Pelanggan utama dapat memulai proses perencanaan kualitas dengan pemasok. Namun, pemasok memiliki kewajiban untuk membentuk tim lintas fungsional untuk mengelola proses Product Quality Planning. Pemasok harus mengharapkan kinerja yang sama dari subkontraktor mereka. Hendra Hendrasmara – Industrial Battery Development Dept. 14 Dasar-dasar APQP
  15. 15. Simultaneous Engineering Simultaneous Engineering adalah proses di mana cross functional team berusaha untuk mencapai tujuan bersama. Tujuannya adalah untuk mempercepat pengenalan produk-produk berkualitas lebih cepat. Product Quality Planning team menjamin bahwa area lain / tim lain merencanakan dan melaksanakan kegiatan yang mendukung tujuan bersama. Hendra Hendrasmara – Industrial Battery Development Dept. 15 Dasar-dasar APQP
  16. 16. Control Plans Control Plans adalah deskripsi yang tertulis untuk mengendalikan part dan proses. Terbagi dalam 3 phase : • Prototype Penjelasan mengenai pengukuran dimensi dan material, test performance yang akan terjadi selama pembuatan Prototype. • Pre-launch Penjelasan mengenai pengukuran dimensi dan material, test performance yang akan terjadi setelah Prototype dan sebelum mass Production. • Production Sebuah dokumentasi lengkap dari karakteristik produk / proses, kontrol proses, tes, dan sistem pengukuran yang akan terjadi selama produksi massal. Hendra Hendrasmara – Industrial Battery Development Dept. 16 Dasar-dasar APQP
  17. 17. Concern Resolution Permasalahan-permasalahan yang terjadi selama proses perencanaan harus didokumentasikan dalam matrik penanggungjawab dan target waktu. Meminta rekomendasi dari ahli sangat disarankan untuk masalah yang sulit. Hendra Hendrasmara – Industrial Battery Development Dept. 17 Dasar-dasar APQP
  18. 18. Keberhasilan program apapun tergantung pada pemenuhan kebutuhan dan harapan pelanggan pada waktu yang tepat dengan biaya yang sesuai. Hendra Hendrasmara – Industrial Battery Development Dept. 18 Dasar-dasar APQP Product Quality Timing Plan Plans Relative to the Timing Chart Suksesnya sebuah program bergantung kepada kepuasan pelanggan terutama waktu dan cost. Tim perencana harus memastikan product qulity planning bisa disesuaikan dengan harapan pelanggan
  19. 19. PRODUCT QUALITY PLANNING TIMING CHART Pilot Launch Hendra Hendrasmara – Industrial Battery Development Dept. 19 PLAN AND DEFINE PROGRAM PRODUCT DESIGN AND DEVELOPMENT VERIFICATION PROCESS DESIGN AND DEVELOPMENT VERIFICATION PRODUCT AND PROCESS VALIDATION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION Concept Initiation/Approval Program Approval Prototype PLANNING PLANNING PRODUCT DESIGN AND DEV. PROCESS DESIGN AND DEVELOPMENT PRODUCT AND PROCESS VALIDATION PRODUCTION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION Problem Time
  20. 20. Concept Initiation / Approval Program Approval PLANNING Hendra Hendrasmara – Industrial Battery Development Dept. 20 PLAN AND DEFINE PROGRAM 1.0 PLAN AND DEFINE PROGRAM INPUTS OUTPUTS • 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 Tujuan :  Menentukan kebutuhan pelanggan  Menentukan dan merencanakan Program quality • Voice of the Customer • Market Research • Historical Warranty and Quality Information • Team Experience • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs
  21. 21. Program Approval Prototype PRODUCT DESIGN AND DEV. Hendra Hendrasmara – Industrial Battery Development Dept. 21 PRODUCT DESIGN AND DEVELOPMENT VERIFICATION 2.0 PRODUCT DESIGN AND DEVELOPMENT INPUTS OUTPUTS • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support • 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 Tujuan :  Develop design features and characteristic  Review engineering requirement  Menilai masalah manufactur yang mungkin terjadi
  22. 22. Prototype Pilot PROCESS DESIGN AND DEVELOPMENT Hendra Hendrasmara – Industrial Battery Development Dept. 22 PROCESS DESIGN AND DEVELOPMENT VERIFICATION 3.0 PROCESS DESIGN AND DEVELOPMENT INPUTS OUTPUTS • 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 • Packaging Specifications • Management Support • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support Tujuan :  Mengembangkan proses manufactur yang komprehensif dan efektif  Pastikan kapabilitas proses untuk memenuhi kebutuhan pelanggan
  23. 23. Pilot Launch Hendra Hendrasmara – Industrial Battery Development Dept. 23 PRODUCT AND PROCESS VALIDATION Prototype PRODUCT AND PROCESS VALIDATION 4.0 PRODUCT AND PROCESS VALIDATION Tujuan :  Validasi produk  Validasi control plan  Pastikan produk sesuai kebutuhan pelanggan  Identifikasi masalah INPUTS OUTPUTS • Production Trial Run • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign- Off and Management Support • 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 • Packaging Specifications • Management Support
  24. 24. 5.0 FEEDBACK ASSESMENT AND CORRECTIVE ACTION Pilot Launch INPUTS OUTPUTS Hendra Hendrasmara – Industrial Battery Development Dept. 24 PLANNING PRODUCTION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION • Production Trial Run • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign- Off and Management Support • Reduced Variation • Customer Satisfaction • Delivery and Service Tujuan :  Mengevaluasi semua variasi (data variabel dan data attribut)  Mengevaluasi efektivitas Product quality planning  Penggunaan Control Plan dan Corrective action
  25. 25. APQP PROCESS FLOW Hendra Hendrasmara – Industrial Battery Development Dept. 25 Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  26. 26. Hendra Hendrasmara – Industrial Battery Development Dept. 26 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan APQP PROCESS FLOW Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  27. 27. INPUT Hendra Hendrasmara – Industrial Battery Development Dept. 27 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs APQP PROCESS FLOW Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  28. 28. Hendra Hendrasmara – Industrial Battery Development Dept. 28 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 INPUT OUTPUT APQP PROCESS FLOW Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  29. 29. Hendra Hendrasmara – Industrial Battery Development Dept. 29 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support INPUT INPUT OUTPUT OUTPUT APQP PROCESS FLOW Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  30. 30. Hendra Hendrasmara – Industrial Battery Development Dept. 30 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support • 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 • Packaging Specifications • Management Support INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT APQP PROCESS FLOW Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  31. 31. APQP PROCESS FLOW Hendra Hendrasmara – Industrial Battery Development Dept. 31 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support • 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 • Packaging Specifications • Management Support • Production Trial Run • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign-Off and Management Support INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  32. 32. APQP PROCESS FLOW Hendra Hendrasmara – Industrial Battery Development Dept. 32 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support • 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 • Packaging Specifications • Management Support • Production Trial Run • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign-Off and Management Support • Reduced Variation • Customer Satisfaction • Delivery and Service INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  33. 33. Hendra Hendrasmara – Industrial Battery Development Dept. 33 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support • 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 • Packaging Specifications • Management Supportc • Production Trial Run • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign-Off and Management Support • Reduced Variation • Customer Satisfaction • Delivery and Service INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT FMEA APQP PROCESS FLOW Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  34. 34. APQP PROCESS FLOW Hendra Hendrasmara – Industrial Battery Development Dept. 34 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support • 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 • Packaging Specifications • Management Support • Production Trial Run • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign-Off and Management Support • Reduced Variation • Customer Satisfaction • Delivery and Service INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT FMEA APQP Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  35. 35. APQP PROCESS FLOW Hendra Hendrasmara – Industrial Battery Development Dept. 35 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support • 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 • Packaging Specifications • Management Support • Production Trial Run • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign-Off and Management Support • Reduced Variation • Customer Satisfaction • Delivery and Service INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT FMEA APQP SPC Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  36. 36. APQP PROCESS FLOW Hendra Hendrasmara – Industrial Battery Development Dept. 36 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support • 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 • Packaging Specifications • Management Support • Production Trial Run • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign-Off and Management Support • Reduced Variation • Customer Satisfaction • Delivery and Service INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT FMEA APQP MSA SPC Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  37. 37. APQP PROCESS FLOW Hendra Hendrasmara – Industrial Battery Development Dept. 37 • Organize the Team • Define the Scope • Establish Team-to- Team Communication • Provide Core Tools Training • Involve Customers and Suppliers • Implement Simultaneous Engineering • Develop Control Plan Format • Decide on Concern Resolution • Develop Product Quality Timing Plan • Voice of the Customer • Business Plan/Marketing Strategy • Product/Process Benchmark Data • Product/Process Assumptions • Product Reliability Studies • Customer Inputs • 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 • Design Failure Mode and Effects Analysis (DFMEA) • Design for Manufacturability and Assembly • Design Verification • Design Reviews • Prototype Build – Control Plan • Engineering Drawings (Including Math Data) • Engineering Specifications • Material Specifications • Drawing and Specification Changes • New Equipment, Tooling and Facilities Requirements • Special Product and Process Characteristics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support • 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 • Packaging Specifications • Management Support • Production Trial Run • Measurement Systems Evaluation • Preliminary Process Capability Study • Production Part Approval • Production Validation Testing • Packaging Evaluation • Production Control Plan • Quality Planning Sign-Off and Management Support • Reduced Variation • Customer Satisfaction • Delivery and Service INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT FMEA APQP MSA SPC PPAP Prepare for APQP Plan and Define Program Product Design and Development Product and Process Validation Process Design and Development Feedback, Assessment and Corrective Action
  38. 38. ANALYTICAL TECHNIQUES Hendra Hendrasmara – Industrial Battery Development Dept. 38 1. Assembly Build Variation Analysis 2. Benchmarking 3. Cause and Effect Diagram 4. Characteristics Matrix 5. Critical Path Method 6. Design of Experioments (DoE) 7. Design for Manufacturability and Assembly 8. Design Verification Plan and Report (DVP&R) 9. Mistake Proofing / ErrorProofing 10. Process Flow Charting 11. Quality Function Deployment (QFD)

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