APQP

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APQP

  1. 1. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)By: Pankaj Nalwa
  2. 2. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)APQP, but for what?Purpose of APQP is to produce a product quality plan which will supportdevelopment of a product or service that will satisfy the customer.In simple words, APQP is intended to ensure that the supplier / manufacturer meetsall of the customers requirements on time.How to achieve this purpose?By : Up-front quality planning Evaluating the output to determine if customer are satisfied & support continualimprovement.APQP, but for what?Purpose of APQP is to produce a product quality plan which will supportdevelopment of a product or service that will satisfy the customer.In simple words, APQP is intended to ensure that the supplier / manufacturer meetsall of the customers requirements on time.How to achieve this purpose?By : Up-front quality planning Evaluating the output to determine if customer are satisfied & support continualimprovement.By: Pankaj Nalwa
  3. 3. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Product Quality Planning CycleBy: Pankaj Nalwa
  4. 4. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)The purpose of Product Quality Planning Cycle is to emphasize: Up-front planning.The first three quarters of the cycle are devoted to up-front product quality planningthrough product / process validation. The act of implementation.The fourth quarter is the stage where importance of evaluating the output serves twofunctions: to determine customer satisfaction and to support the pursuit of continualimprovement.The purpose of Product Quality Planning Cycle is to emphasize: Up-front planning.The first three quarters of the cycle are devoted to up-front product quality planningthrough product / process validation. The act of implementation.The fourth quarter is the stage where importance of evaluating the output serves twofunctions: to determine customer satisfaction and to support the pursuit of continualimprovement.By: Pankaj Nalwa
  5. 5. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)PQP usually doesn’t work effectively in organizations.By: Pankaj Nalwa
  6. 6. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)PDCAPlanDoActAlwaysAlwaysSometimesCheckSometimesBy: Pankaj Nalwa
  7. 7. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)If quality is to become a business strategy, top management mustunderstand quality as a planning strategy and provide leadership forcarrying out this strategy.By: Pankaj Nalwa
  8. 8. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Advanced product Quality Planning (APQP) is a structuredapproach to the design and development of new products andmanufacturing processes, designed to ensure that: Suppliers understand the requirements of clients, end users andconsumers. The proposed product or process design satisfies thoserequirements. The supplier has the ability to consistently meet the clientsrequirements for quality, cost and delivery.Advanced product Quality Planning (APQP) is a structuredapproach to the design and development of new products andmanufacturing processes, designed to ensure that: Suppliers understand the requirements of clients, end users andconsumers. The proposed product or process design satisfies thoserequirements. The supplier has the ability to consistently meet the clientsrequirements for quality, cost and delivery.By: Pankaj Nalwa
  9. 9. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Roadblocks for APQP. Lack of commitment from Top Management. Lack of discipline. Undefined priorities. Undefined responsibilities. Lack of accountability. Personal egos and lack of team spirit. Unclear approach. Lack of resources. Lack of knowledge.Roadblocks for APQP. Lack of commitment from Top Management. Lack of discipline. Undefined priorities. Undefined responsibilities. Lack of accountability. Personal egos and lack of team spirit. Unclear approach. Lack of resources. Lack of knowledge.By: Pankaj Nalwa
  10. 10. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)The APQP process includes five main functions: Planning of APQP elements. Execution of APQP elements. Monitoring the “Quality-of-Event” of the execution of the elements, as well as thetiming, by the team in-between FPDS milestones. Issues Resolution Status ReportingThe APQP process includes five main functions: Planning of APQP elements. Execution of APQP elements. Monitoring the “Quality-of-Event” of the execution of the elements, as well as thetiming, by the team in-between FPDS milestones. Issues Resolution Status ReportingBy: Pankaj Nalwa
  11. 11. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Prepare forAPQPPlan and DefineProgramProductDesign andDevelopmentProduct &ProcessValidationProcessDesign andDevelopmentFeedback,Assessment &Corrective ActionProcess Flow for APQP• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing PlanBy: Pankaj Nalwa
  12. 12. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Phase 1: Planning and defining the programThis phase is meant to determine customer needs and expectations. Purpose of thisphase is to ensure that the customer’s needs and expectations are fully understoodbefore proceeding with the “design & development of the product” or “manufacturingprocess associated with product”.By: Pankaj Nalwa
  13. 13. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Prepare forAPQPPlan and DefineProgramProductDesign andDevelopmentProduct &ProcessValidationProcessDesign andDevelopmentFeedback,Assessment &Corrective ActionProcess Flow for APQP• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer InputsINPUT• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer InputsBy: Pankaj Nalwa
  14. 14. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Prepare forAPQPPlan and DefineProgramProductDesign andDevelopmentProduct &ProcessValidationProcessDesign andDevelopmentFeedback,Assessment &Corrective ActionProcess Flow for APQP• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer InputsINPUT• Design Goals• Reliability andQuality Goals• Preliminary Billof Material• PreliminaryProcess FlowChart• PreliminaryListing of SpecialProduct andProcessCharacteristics• ProductAssurance Plan• ManagementSupportOUTPUT• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer Inputs• Design Goals• Reliability andQuality Goals• Preliminary Billof Material• PreliminaryProcess FlowChart• PreliminaryListing of SpecialProduct andProcessCharacteristics• ProductAssurance Plan• ManagementSupportBy: Pankaj Nalwa
  15. 15. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Phase 2: Product design and developmentIn this phase, design features and characteristics are developed into near final form.This phase focuses on developing the design of the product or service, and onensuring that it is feasible and will meet the customer’s expectations.By: Pankaj Nalwa
  16. 16. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Prepare forAPQPPlan and DefineProgramProductDesign andDevelopmentProduct &ProcessValidationProcessDesign andDevelopmentFeedback,Assessment &Corrective ActionProcess Flow for APQP• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer InputsINPUT• Design Goals• Reliability andQuality Goals• Preliminary Bill ofMaterial• Preliminary ProcessFlow Chart• Preliminary Listingof Special Productand ProcessCharacteristics• Product AssurancePlan• ManagementSupportOUTPUT• Design Failure Modeand Effects Analysis(DFMEA)• Design forManufacturability andAssembly• Design Verification• Design Reviews• Prototype Build –Control Plan• Engineering Drawings(Including Math Data)• EngineeringSpecifications• Material Specifications• Drawing andSpecification Changes• New Equipment, Toolingand FacilitiesRequirements• Special Product andProcess Characteristics• Gages/TestingEquipment Requirements• Team FeasibilityCommitment andManagement SupportINPUTOUTPUT• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer Inputs• Design Goals• Reliability andQuality Goals• Preliminary Bill ofMaterial• Preliminary ProcessFlow Chart• Preliminary Listingof Special Productand ProcessCharacteristics• Product AssurancePlan• ManagementSupport• Design Failure Modeand Effects Analysis(DFMEA)• Design forManufacturability andAssembly• Design Verification• Design Reviews• Prototype Build –Control Plan• Engineering Drawings(Including Math Data)• EngineeringSpecifications• Material Specifications• Drawing andSpecification Changes• New Equipment, Toolingand FacilitiesRequirements• Special Product andProcess Characteristics• Gages/TestingEquipment Requirements• Team FeasibilityCommitment andManagement SupportBy: Pankaj Nalwa
  17. 17. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Phase 3: Process design and developmentThis phase concentrates on developing a manufacturing system and related controlplans to achieve quality products.This phase focuses on creating a process that will ensure the design that wasdeveloped in the previous phase at the same quality level, quantity and cost, and atthe same time assuring that any other customer requirements and expectations willbe met.Activities of this phase make sure that the product represents a value to customer.Phase 3: Process design and developmentThis phase concentrates on developing a manufacturing system and related controlplans to achieve quality products.This phase focuses on creating a process that will ensure the design that wasdeveloped in the previous phase at the same quality level, quantity and cost, and atthe same time assuring that any other customer requirements and expectations willbe met.Activities of this phase make sure that the product represents a value to customer.By: Pankaj Nalwa
  18. 18. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Prepare forAPQPPlan and DefineProgramProductDesign andDevelopmentProduct &ProcessValidationProcessDesign andDevelopmentFeedback,Assessment &Corrective ActionProcess Flow for APQP• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer InputsINPUT• Design Goals• Reliability andQuality Goals• Preliminary Bill ofMaterial• Preliminary ProcessFlow Chart• Preliminary Listingof Special Productand ProcessCharacteristics• Product AssurancePlan• ManagementSupportOUTPUT• Design Failure Modeand Effects Analysis(DFMEA)• Design forManufacturability andAssembly• Design Verification• Design Reviews• Prototype Build –Control Plan• Engineering Drawings• EngineeringSpecifications• Material Specifications• Drawing andSpecification Changes• New Equipment, Toolingand FacilitiesRequirements• Special Product andProcess Characteristics• Gages/TestingEquipment Requirements• Team FeasibilityCommitment andManagement SupportINPUTOUTPUT• PackagingStandards• Product/ProcessQuality SystemReview• Process Flow Chart• Floor Plan Layout• CharacteristicsMatrix• Process FailureMode and EffectsAnalysis (PFMEA)• Pre-Launch ControlPlan• Process Instructions• MeasurementSystems AnalysisPlan• PreliminaryProcess CapabilityStudy Plan• PackagingSpecifications• ManagementSupportINPUTOUTPUT• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer Inputs• Design Goals• Reliability andQuality Goals• Preliminary Bill ofMaterial• Preliminary ProcessFlow Chart• Preliminary Listingof Special Productand ProcessCharacteristics• Product AssurancePlan• ManagementSupport• Design Failure Modeand Effects Analysis(DFMEA)• Design forManufacturability andAssembly• Design Verification• Design Reviews• Prototype Build –Control Plan• Engineering Drawings• EngineeringSpecifications• Material Specifications• Drawing andSpecification Changes• New Equipment, Toolingand FacilitiesRequirements• Special Product andProcess Characteristics• Gages/TestingEquipment Requirements• Team FeasibilityCommitment andManagement Support• PackagingStandards• Product/ProcessQuality SystemReview• Process Flow Chart• Floor Plan Layout• CharacteristicsMatrix• Process FailureMode and EffectsAnalysis (PFMEA)• Pre-Launch ControlPlan• Process Instructions• MeasurementSystems AnalysisPlan• PreliminaryProcess CapabilityStudy Plan• PackagingSpecifications• ManagementSupportBy: Pankaj Nalwa
  19. 19. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Phase 4: Product and process validationThis phase concentrates on validating the manufacturing process through evaluationof production trial run and all the activities related to it.This phase focuses on methods and techniques for determining that the long-termproduction process is capable of meeting all the requirements that have beenresearched and documented through the previous phases.Phase 4: Product and process validationThis phase concentrates on validating the manufacturing process through evaluationof production trial run and all the activities related to it.This phase focuses on methods and techniques for determining that the long-termproduction process is capable of meeting all the requirements that have beenresearched and documented through the previous phases.By: Pankaj Nalwa
  20. 20. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Prepare forAPQPPlan and DefineProgramProductDesign andDevelopmentProduct &ProcessValidationProcessDesign andDevelopmentFeedback,Assessment &Corrective ActionProcess Flow for APQP• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer InputsINPUT• Design Goals• Reliability andQuality Goals• Preliminary Bill ofMaterial• Preliminary ProcessFlow Chart• Preliminary Listingof Special Productand ProcessCharacteristics• Product AssurancePlan• ManagementSupportOUTPUT• Design Failure Modeand Effects Analysis(DFMEA)• Design forManufacturability andAssembly• Design Verification• Design Reviews• Prototype Build –Control Plan• Engineering Drawings• EngineeringSpecifications• Material Specifications• Drawing andSpecification Changes• New Equipment, Toolingand FacilitiesRequirements• Special Product andProcess Characteristics• Gages/TestingEquipment Requirements• Team FeasibilityCommitment andManagement SupportINPUTOUTPUT• Packaging Standards• Product/ProcessQuality System Review• Process Flow Chart• Floor Plan Layout• Characteristics Matrix• Process Failure Modeand Effects Analysis(PFMEA)• Pre-Launch ControlPlan• Process Instructions• MeasurementSystems Analysis Plan• Preliminary ProcessCapability Study Plan• PackagingSpecifications• Management SupportINPUTOUTPUT• Production TrialRun• MeasurementSystemsEvaluation• PreliminaryProcess CapabilityStudy• Production PartApproval• ProductionValidation Testing• PackagingEvaluation• ProductionControl Plan• Quality PlanningSign-Off andManagementSupportINPUTOUTPUT• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer Inputs• Design Goals• Reliability andQuality Goals• Preliminary Bill ofMaterial• Preliminary ProcessFlow Chart• Preliminary Listingof Special Productand ProcessCharacteristics• Product AssurancePlan• ManagementSupport• Design Failure Modeand Effects Analysis(DFMEA)• Design forManufacturability andAssembly• Design Verification• Design Reviews• Prototype Build –Control Plan• Engineering Drawings• EngineeringSpecifications• Material Specifications• Drawing andSpecification Changes• New Equipment, Toolingand FacilitiesRequirements• Special Product andProcess Characteristics• Gages/TestingEquipment Requirements• Team FeasibilityCommitment andManagement Support• Packaging Standards• Product/ProcessQuality System Review• Process Flow Chart• Floor Plan Layout• Characteristics Matrix• Process Failure Modeand Effects Analysis(PFMEA)• Pre-Launch ControlPlan• Process Instructions• MeasurementSystems Analysis Plan• Preliminary ProcessCapability Study Plan• PackagingSpecifications• Management Support• Production TrialRun• MeasurementSystemsEvaluation• PreliminaryProcess CapabilityStudy• Production PartApproval• ProductionValidation Testing• PackagingEvaluation• ProductionControl Plan• Quality PlanningSign-Off andManagementSupportBy: Pankaj Nalwa
  21. 21. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Phase 5: Feedback, assessment and corrective action.At this point, output is evaluated for all special and common cause variation. This isalso the time to evaluate the effectiveness of the quality planning effort itself.In this phase, variation can be studied and reduced over the time.Results of organization’s continuous improvement philosophy will be most visible.Phase 5: Feedback, assessment and corrective action.At this point, output is evaluated for all special and common cause variation. This isalso the time to evaluate the effectiveness of the quality planning effort itself.In this phase, variation can be studied and reduced over the time.Results of organization’s continuous improvement philosophy will be most visible.By: Pankaj Nalwa
  22. 22. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Prepare forAPQPPlan and DefineProgramProductDesign andDevelopmentProduct &ProcessValidationProcessDesign andDevelopmentFeedback,Assessment &Corrective ActionProcess Flow for APQP• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer InputsINPUT• Design Goals• Reliability andQuality Goals• Preliminary Bill ofMaterial• Preliminary ProcessFlow Chart• Preliminary Listingof Special Productand ProcessCharacteristics• Product AssurancePlan• ManagementSupportOUTPUT• Design Failure Modeand Effects Analysis(DFMEA)• Design forManufacturability andAssembly• Design Verification• Design Reviews• Prototype Build –Control Plan• Engineering Drawings• EngineeringSpecifications• Material Specifications• Drawing andSpecification Changes• New Equipment, Toolingand FacilitiesRequirements• Special Product andProcess Characteristics• Gages/TestingEquipment Requirements• Team FeasibilityCommitment andManagement SupportINPUTOUTPUT• Packaging Standards• Product/Process QualitySystem Review• Process Flow Chart• Floor Plan Layout• Characteristics Matrix• Process Failure Modeand Effects Analysis(PFMEA)• Pre-Launch ControlPlan• Process Instructions• Measurement SystemsAnalysis Plan• Preliminary ProcessCapability Study Plan• PackagingSpecifications• Management SupportINPUTOUTPUT• Production Trial Run• MeasurementSystems Evaluation• Preliminary ProcessCapability Study• Production PartApproval• Production ValidationTesting• Packaging Evaluation• Production ControlPlan• Quality PlanningSign-Off andManagement SupportINPUTOUTPUT• Reduced Variation• CustomerSatisfaction• Delivery andServiceOUTPUTINPUT• Organize the Team• Define the Scope• Establish Team-to-TeamCommunication• Provide Core ToolsTraining• Involve Customersand Suppliers• ImplementSimultaneousEngineering• Develop ControlPlan Format• Decide on ConcernResolution• Develop ProductQuality Timing Plan• Voice of theCustomer• BusinessPlan/MarketingStrategy• Product/ProcessBenchmark Data• Product/ProcessAssumptions• Product ReliabilityStudies• Customer Inputs• Design Goals• Reliability andQuality Goals• Preliminary Bill ofMaterial• Preliminary ProcessFlow Chart• Preliminary Listingof Special Productand ProcessCharacteristics• Product AssurancePlan• ManagementSupport• Design Failure Modeand Effects Analysis(DFMEA)• Design forManufacturability andAssembly• Design Verification• Design Reviews• Prototype Build –Control Plan• Engineering Drawings• EngineeringSpecifications• Material Specifications• Drawing andSpecification Changes• New Equipment, Toolingand FacilitiesRequirements• Special Product andProcess Characteristics• Gages/TestingEquipment Requirements• Team FeasibilityCommitment andManagement Support• Packaging Standards• Product/Process QualitySystem Review• Process Flow Chart• Floor Plan Layout• Characteristics Matrix• Process Failure Modeand Effects Analysis(PFMEA)• Pre-Launch ControlPlan• Process Instructions• Measurement SystemsAnalysis Plan• Preliminary ProcessCapability Study Plan• PackagingSpecifications• Management Support• Production Trial Run• MeasurementSystems Evaluation• Preliminary ProcessCapability Study• Production PartApproval• Production ValidationTesting• Packaging Evaluation• Production ControlPlan• Quality PlanningSign-Off andManagement SupportBy: Pankaj Nalwa
  23. 23. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)An important phase of APQP is the development of “Control Plan”.What is a Control Plan?It is a written description of the system for controlling parts and processes. Controlplan describes the actions that are required at each phase of the process includingreceiving, in-process, out-going and periodic requirements to assure that all processoutputs will be in state of control.When to generate this document and for how long to use it?Control plan is maintained and used throughout the product life cycle. Early inproduct life cycle, its primary purpose is to document and communicate the initialplan for process control. Subsequently, it guides manufacturing in how to control theprocess and ensure product quality.The control plan remains a living document, reflecting the current methods of control,and measurement systems used. It is updated as measurement systems and controlmethods are evaluated and improved.An important phase of APQP is the development of “Control Plan”.What is a Control Plan?It is a written description of the system for controlling parts and processes. Controlplan describes the actions that are required at each phase of the process includingreceiving, in-process, out-going and periodic requirements to assure that all processoutputs will be in state of control.When to generate this document and for how long to use it?Control plan is maintained and used throughout the product life cycle. Early inproduct life cycle, its primary purpose is to document and communicate the initialplan for process control. Subsequently, it guides manufacturing in how to control theprocess and ensure product quality.The control plan remains a living document, reflecting the current methods of control,and measurement systems used. It is updated as measurement systems and controlmethods are evaluated and improved.By: Pankaj Nalwa
  24. 24. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Cross Functional Team (CFT) is required to develop Control Plan by utilizing allavailable information to gain better understanding of process, like:• Process flow diagram• Design / Process failure mode and effect analysis (FMEA)• Special characteristics• History of similar parts• Team’s knowledge of process• Design review• Optimization methodsCross Functional Team (CFT) is required to develop Control Plan by utilizing allavailable information to gain better understanding of process, like:• Process flow diagram• Design / Process failure mode and effect analysis (FMEA)• Special characteristics• History of similar parts• Team’s knowledge of process• Design review• Optimization methodsBy: Pankaj Nalwa
  25. 25. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Collect &Interpret DataSelectMeasuresIsProcessStable?Investigate &Fix SpecialCausesNoDefineProcessDevelop ControlPlanIsProcessCapable?ImproveProcessCapabilityIsProcessStable?Investigate &Fix SpecialCausesNoYesNoYesBy: Pankaj Nalwa
  26. 26. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Monitor variables for out ofcontrol conditionsDevelop alarm andrecording strategyFinalize process samplingplanFinalize process samplingplanDocument control plan foreach key variableIdentify Opportunities forMistake ProofingBy: Pankaj Nalwa
  27. 27. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Control PlanPreliminaryAnalysisMeasurementSystemProcessMapsFMEAMeasurementSystem AnalysisCalibrationRequirementsSampling & Testing PlansCustomer requirementsShort TermCapabilityControl PlanProceduresImprovementActivitiesSPC PlansOperatingWindowsDOEsMaintenance SchedulesTraining MaterialsSOPsLong TermCapabilityReaction plansTrouble shooting AidsBy: Pankaj Nalwa
  28. 28. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)PHASE – I (Planning & Defining the program)Wk1Wk2Wk3Wk4Wk5Wk6Voice of customerHistorical data (Internal & External)Bench mark data (Product & Process)Assumptions (Product & Process)Customer design inputsCustomer design inputsDesign goalsReliability & quality goalsPreliminary bill of materialPreliminary process flow diagramPreliminary list of special characteristicsManagement review & supportBy: Pankaj Nalwa
  29. 29. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)PHASE – II (Product design & development)Wk Wk Wk Wk Wk WkBlock diagramDesign FMEAEngineering drawing (for Prototype)Engineering specifications (for Prototype)Material specifications (for Prototype)Material specifications (for Prototype)Final bill of materialDesign verificationDesign reviewChanges in drawing & specificationsMake or buy decisionSupplier selection & allocationBy: Pankaj Nalwa
  30. 30. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)PHASE – II (Product design & development)Wk Wk Wk Wk Wk WkPreparation of inspection standards for BOPProcurement of BOPPrototype control planIdentification of new equipment, tooling,gauges, test facilitiesAcquisition of new equipment, tooling,gauges & test facilitiesAcquisition of new equipment, tooling,gauges & test facilitiesPrototype samplesPrototype approval from customerChanges in drawing & specificationsTeam feasibility & commitmentFinal drawing & specificationsManagement review & supportBy: Pankaj Nalwa
  31. 31. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)PHASE – III (Process design & development)Wk Wk Wk Wk Wk WkFinal process flow diagramFloor plan layoutFinal special characteristics (Product &Process)Process FMEAPrelaunch control planPrelaunch control planProcess control standards / WorkinstructionsM.S.A. planPreliminary process capability study planPackaging standards & specificationsQuality system review (Product &Process)Management review & supportBy: Pankaj Nalwa
  32. 32. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)PHASE – IV (Product & process validation)Wk Wk Wk Wk Wk WkMaterial for trial production (Pilot lot)Trial production run (Pilot lot)Measurement system analysisProcess capability studyProcess validation testingPackaging evaluationPackaging evaluationPPAP documents compilation & submissionCustomer approvalRelease : Production control planQuality planning & summary sign offInitial supply control initiationManagement review & supportRegular productionBy: Pankaj Nalwa
  33. 33. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)PHASE – V (Feedback assessment & corrective action)Wk Wk Wk Wk Wk WkReduction of variationContinual improvementDelivery of regular productBy: Pankaj Nalwa
  34. 34. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)Notes:Thanks for the participation.slideshare.net/pankajnalwapankajnalwa@gmail.comBy: Pankaj NalwaThanks for the participation.slideshare.net/pankajnalwapankajnalwa@gmail.com

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