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Advanced Product Quality Planning (APQP)

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Advanced Product Quality Planning (APQP) is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer. It provides a set of detailed requirements to be undertaken at each stage in the APQP system. APQP is used when a new and/or significantly changed product or process could lead to a failure that would expose the supplier to customer dissatisfaction, safety concerns, or unplanned increase of cost to produce. 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, of high quality and at acceptable cost.

This presentation can be used to brief your employees to create awareness of the APQP quality standard. Alternatively, the presentation can be used to supplement your IAFT 16949:2016 and/or ISO 9001:2015 materials for the training of QA professionals and internal auditors.

NOTE: This presentation includes a free copy of Control Plan template (Excel format).

LEARNING OBJECTIVES

1. Provide background knowledge on APQP.
2. Gain an overview of the APQP process and the key activities.
3. Define the 5 phases of APQP, including the input and output requirements.
4. Learn how to define a Control Plan.

CONTENTS

1. OVERVIEW OF APQP
About AIAG
Introduction to APQP
Background of APQP
Working in Silos Results in Poor Quality Design
What is Quality Planning?
What is APQP?
APQP Acronyms
Goal of APQP
Benefits of APQP to the Customer
Benefits of APQP to the Supplier
Roadblocks to APQP
APQP Process Flow
The 5 Phases of APQP

2. APQP PROCESS
The APQP Process is Based on the Plan-Do-Study-Act (PDSA) Cycle
APQP Timing Chart
APQP Phases & Key Activities
Preparing for APQP
Phase 1: Plan & Define Program
Phase 2: Product Design & Development
Phase 3: Process Design & Development
Phase 4: Product & Process Validation
Phase 5: Feedback, Assessment & Corrective Action
List of APQP Elements
Core Tools
APQP: Key Takeaways

3. CONTROL PLAN
Control Plan
Control Plan Template
Control Plan: Tool Interaction
Anatomy of the Control Plan
Example of Control Plan
Control Plan: Reviewer's Checklist
Control Plan & APQP

To download this complete presentation, visit: https://www.oeconsulting.com.sg

Published in: Business

Advanced Product Quality Planning (APQP)

  1. 1. © Operational Excellence Consulting. All rights reserved. APQPAdvanced Product Quality Planning © Operational Excellence Consulting. All rights reserved.
  2. 2. © Operational Excellence Consulting. All rights reserved. 2 Learning Objectives Provide background knowledge on APQP Gain an overview of the APQP process and the key activities Define the 5 phases of APQP, including the input and output requirements Learn how to define a Control Plan NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: http://www.oeconsulting.com.sg
  3. 3. © Operational Excellence Consulting. All rights reserved. 3 Contents 2 3 APQP Process Control Plan 1 Overview of APQP
  4. 4. © Operational Excellence Consulting. All rights reserved. 4 Working in silos results in poor quality design How the customer explained it How the project leader understood it How the analyst designed it How the programmer wrote it What the beta testers received How the business consultant described it How the project was documented What operations installed How the customer was billed How it was supported What marketing advertised What the customer really need
  5. 5. © Operational Excellence Consulting. All rights reserved. 5 What is APQP? §  Advance Product Quality Planning (APQP) is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer §  It provides a set of detailed requirements to be undertaken at each stage in the APQP system §  It involves the utilization of various techniques to be employed to identify and resolve problems before going into full production
  6. 6. © Operational Excellence Consulting. All rights reserved. 6 Goal of APQP §  The goal of product quality planning is to facilitate communication with everyone involved to assure that all required steps are completed on time §  Effective product quality planning depends on a company’s top management commitment to the effort required in achieving customer satisfaction
  7. 7. © Operational Excellence Consulting. All rights reserved. 7© Operational Excellence Consulting. All rights reserved. 7 Benefits of APQP to the Customer Higher quality product delivered to the customer. Timing is significantly reduced for new product launch. Effective communication between customer and supplier improves PPAP process. Establishes confidence in the supplier base to deliver the product on time and at a competitive price.
  8. 8. © Operational Excellence Consulting. All rights reserved. 8 Benefits of APQP to the Supplier Enhances customer satisfaction to launch a product on time. Meets the customer specific requirements. APQP enforces a structured, standardized and well documented system. Meets regulatory requirements (IATF 16949:2016) and is one of the 5 core tools. APQP connects all stakeholders with effective communications. Effective APQP improves profit margins! APQP is not limited to Automotive, as all industries can improve their design and process development.
  9. 9. © Operational Excellence Consulting. All rights reserved. 9 “It is most important that top management be quality-minded. In the absence of sincere manifestation of interest at the top, little will happen below.” Joseph M. Juran
  10. 10. © Operational Excellence Consulting. All rights reserved. 10© Operational Excellence Consulting. All rights reserved. 10 APQP Process Flow Phase 0 Prepare for APQP Phase 1 Plan & Define Program Phase 2 Product Design & Development Phase 5 Feedback, Assessment & Corrective Action Phase 4 Product & Process Validation Phase 3 Process Design & Development
  11. 11. © Operational Excellence Consulting. All rights reserved. 11 The 5 Phases of APQP •  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 & Quality goals •  Preliminary Bill of Materials •  Preliminary Process Flow Chart •  Preliminary list 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 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 •  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 •  Improved Customer Satisfaction •  Improved Delivery and Service Prepare for APQP Feedback, Assessment & Corrective Action Product & Process Validation Process Design & Development Product Design & Development Plan & Define Program INPUT INPUT OUTPUT INPUT OUTPUT INPUT OUTPUT OUTPUT INPUT OUTPUT 4 5321
  12. 12. © Operational Excellence Consulting. All rights reserved. 12 “Quality has to be caused, not controlled.” Philip B. Crosby
  13. 13. © Operational Excellence Consulting. All rights reserved. 13© Operational Excellence Consulting. All rights reserved. 13 The APQP Process is Based on the Plan-Do- Study-Act (PDSA) Cycle Plan and define Feedback, Assessment and corrective action Product and process validation Product design and development Process design and development
  14. 14. © Operational Excellence Consulting. All rights reserved. 14 APQP Timing Chart Planning Planning Feedback, Assessment & Corrective Action Product Design & Development Process Design & Development Product & Process Validation Concept Initiation/ Approval Program Approval Prototype LaunchPilot Production
  15. 15. © Operational Excellence Consulting. All rights reserved. 15 Core Tools §  Tools and techniques that have the greatest impact on product and process success are called the Core Tools §  The Core Tools are: •  Advanced Product Quality Planning (APQP) •  Failure Mode and Effects Analysis (FMEA) •  Measurement Systems Analysis (MSA) •  Statistical Process Control (SPC) •  Production Part Approval Process (PPAP)
  16. 16. © Operational Excellence Consulting. All rights reserved. 16 APQP: Key Takeaways §  APQP is cross-functional planning and execution to produce product that fully meets the customer’s expectations the first time §  AIAG APQP Key Activities are Planning, Product Design, Process Design, Validation and Production §  Phase approach ensures activities are completed in the appropriate order §  Can be applied to different manufacturing environments – High Volume, Low Volume and ETO
  17. 17. © Operational Excellence Consulting. All rights reserved. 17 “In the race for quality, there is no >inish line.” David Kearns, former CEO of Xerox
  18. 18. © Operational Excellence Consulting. All rights reserved. 18 Control Plan §  What is It? •  A document that describes how to control the critical inputs (FMEA) so as to continue to meet customer expectations §  Why use it? •  Needed gaging, testing and error-proofing •  Sampling and frequencies •  How to react when something fails a test or inspection §  When to use it? •  Implementing a new process •  Implementing a process change Since processes are expected to be continuously updated and improved, the control plan is a living document!
  19. 19. © Operational Excellence Consulting. All rights reserved. 19 Control Plan Template CONTROL PLAN Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.) Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.) Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.) Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.) PART/ PROCESS NUMBER PROCESS NAME/ OPERATION DESCRIPTION MACHINE, DEVICE JIG, TOOLS FOR MFG. CHARACTERISTICS SPECIAL CHAR. CLASS METHODS REACTION PLANNO. PRODUCT PROCESS PRODUCT/PROCESS EVALUATION/ SAMPLE CONTROL METHODSPECIFICATION/ MEASUREMENT SIZE FREQ. TOLERANCE TECHNIQUE Prototype Pre-launch Production
  20. 20. © Operational Excellence Consulting. All rights reserved. END OF PREVIEW To download this presentation, please visit: www.oeconsulting.com.sg

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