The AIAG APQP ModelWhat is APQP? Advance Product Quality Planning is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer. 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.
Why Product Quality Planning?The bulk of cost of a product is committed at the early stagesof a development cycle even though they are not expendeduntil later.The cost of fixing a design and faulty decisions at later stagesis exponentially greater than at an earlier stage.The opportunity costs of being late to market are very high,ex., lower market share, lower margins.Cross-functional teams typically provide a better qualitysolution to complex dynamic product development problemsthan single individuals.Early simultaneous involvement in product development bycross-functional teams using structured development processsaves time and money over the product life cycle.
Fundamentals of ProductQuality PlanningOrganizing the teamDefine the scopeTeam-to-Team CommunicationTrainingCustomer, supplier and subcontractorinvolvementSimultaneous Concurrent EngineeringControl plansConcern ResolutionTiming plan and chart
Product Quality Planning Chart Concept ProgramInitiation/Approval Approval Prototype Pilot Launch Planning Planning Product Design and Dev. Process Design and Development Product and Process Validation Production Feedback Assessment and Corrective Action Plan and Product Process Product Feedback Define Design and Design and and Process Assessment and Program Development Development Validation Corrective Action
1.0 Plan and Define Program Inputs Objectives Concept Program Voice of the CustomerInitiation/Approval Approval Determine customer needs. - Market Research Define and plan a quality - Historical Warranty program. and Quality Information Planning - Team Experience Business Plan/Marketing strategy Product/Process Benchmark Data Product Reliability Studies Customer Inputs Outputs Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flowchart Preliminary Listing of Special Product and Process Characteristics Plan and Product Assurance Plan Define Management Support Program
Breakout – Quality Planning Product Description: PPASS (Personal Portable Automotive Sound System)This is a new option for all mid to high price range vehiclesthat allows an individuals personal MP3 or IPOD system tobe integrated with the sound system of suitably equippedautomotive vehicles. This product is a universal MP3 / IPODholder combined with a short-range wireless link that hasalready been developed by the automotive industry.
Breakout – Quality Planning PPASS Design Goals & Parameters• Dashboard will have a built-in wireless interface receiver that links with the any PPASS transmitter• Must integrate with a wireless transmitter with a dimension of .5” X 1.0” X .2”• Maximum holder dimension: 3” X 4.5” X 1.5”• Universal fixture for 98% of all types of players• Safely positioned in vehicle during vehicle operation, and is to be located within three (3) feet of the sound system.• Robust materials of construction (portable) with an expected lifetime of 3 years• Single neutral color – go will all interiors
2.0 Product Design and Development Program Objectives Approval Prototype Inputs Develop design features and The outputs of Section 1.0 characteristics Review engineering requirements Assess potential manufacturing problems that could occurProduct Design and Dev. Outputs 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 Product New Equipment, Tooling and Facilities Requirements Design and Special Product and Process Characteristics Development Team Feasibility Commitment and Management Support
Breakout – Quality PlanningDevelop a design for the PersonalPortable Automotive Sound System(PPASS) unit. Your team (4 to 6 people)has 20 minutes to:1. Design a fixture to safely hold a MP3 / IPOD and a sound system interface.2. Identify any special customer characteristics or concerns3. Identify the material specifications4. Identify any special tooling and equipment
Inputs to Prototype Control Plan CONTROL PLAN SUMMARY Pre-Launch Production x PrototypeControl Plan Number Reference Key Contact/Phone Date (Orig.) Rev. Date (Revised)Part Number/Latest Change Level Part Name/Description Supplier/Plant Core TeamCustomer MACHINE, CHARACTERISTIC METHODS PART/ PROCESS NAME/ DEVICE, SPECIALPROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE CONTROL REACTION CORRECTIVENUMBER DESCRIPTION FOR MFG. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. METHOD PLAN ACTION TOLERANCE TECHNIQUE Error proofing Other LSL TARGET USL#1 #1 #2 #3 #4 #5 #6 #7 #8 #9 #10 Outputs & Expectations: 1 – Assure product meets specification 2 – Ensure attention to process/product characteristics 3 – Establish preliminary process/product characteristics 4 – Communicate to the customer
3.0 Process Design and Development Prototype Pilot Objectives Inputs Develop comprehensive and The outputs of Section 2.0 effective manufacturing process Ensure process capability to meet customer requirements Outputs Packaging StandardsProcess Design and Development 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 Process Preliminary Process Capability Study Plan Design and Packaging Specifications Development Management Support
Breakout – Quality PlanningNext Steps Continue with the process design and development. Your team (4 to 6 people) has 10 minutes to: 1. Develop a process flow. 2. Identify critical manufacturing parameters to measure and control 3. Identify 3 potential failures with this product
Inputs to Pre-launch Control Plan CONTROL PLAN SUMMARY x Pre-Launch Production PrototypeControl Plan Number Reference Key Contact/Phone Date (Orig.) Rev. Date (Revised)Part Number/Latest Change Level Part Name/Description Supplier/Plant Core TeamCustomer MACHINE, CHARACTERISTIC METHODS PART/ PROCESS NAME/ DEVICE, SPECIALPROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE CONTROL REACTION CORRECTIVENUMBER DESCRIPTION FOR MFG. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. METHOD PLAN ACTION TOLERANCE TECHNIQUE Error proofing Other LSL TARGET USL#1 #1 #2 #3 #4 #5 #6 #7 #8 #9 #10 Outputs & Expectations: 1 – Communication for process control 2 – Input to pre-launch control plan 3 – Product quality & customer satisfaction 4 – Identified opportunities for improvement
4.0 Product and Process ValidationPrototype Pilot Launch Objectives Inputs Validate the product The outputs of Validate the manufacturing process Section 3.0 Validate the control plan Ensure product meets customer requirements Identify concerns Product and Process Validation Outputs Production Trial Run Measurement Systems Evaluation Preliminary Process Capability Study Production Part Approval Production Validation Testing Packaging Evaluation Production Control Plan Product Quality Planning Sign-Off and Management Support and Process Validation
5.0 Feedback, Assessment and Corrective Action Pilot Launch Inputs Objectives The outputs of Section 5.0 Evaluate all variation (variable and attribute data) Planning Evaluate effectiveness of product quality planning Use control plan and corrective action Outputs Reduced Variation Production Customer Satisfaction Delivery and ServiceFeedback Assessment and Corrective Action Feedback Assessment and Corrective Action
Summary:The AIAG APQP ModelWhat is APQP? APQP is a process, not just an event Integration of quality tools with management functions Status Reporting and Program Management Multi-disciplinary team approach to quality planning Satisfies requirement of TS, with linkage to several ISO/TS 16949:2002 elements Tool for continuous improvement
Summary: The 5 Phases of APQP1.Plan and Define the Program 1.2.Product Design and Development 2.3.Process Design and Development4.Product and Process Validation 3.5.Feedback, Assessment and 4. Corrective Action 5.
New Product Development and Launch Process New Process Concept Development Initiation/Approval Project Program Ramp to Start First Silicon Production Approval Volume APQP Planning Planning Product Design and Development Process Design and Development and Validation Product and Application Validation Production Feedback Assessment and Corrective ActionAPQP andISO/TS Applicable ISO/TS 16949 Requirements16949:2002 Design & Dev. Planning 7.3 (Product) Production & Service Provision 7.5 16949:2002 ISO/TS Design & Dev. Planning 7.3 (Process) Monitoring & Measurement of Processes 22.214.171.124 7.1 Planning of Product Realization Monitoring & Measurement of Product 7.2 Customer- 8.2.4 Related Processes Production Part Approval - 126.96.36.199 Feedback Assessment - 8 Continual Improvement - 8.5
Retention/Submission Requirements Table I.4.1 – AIAG PPAP Reference Guide 3 ed. All listed items may not necessarily apply to every customer part from every supplier, Consult design record and customer to determine which items or records apply Submission Level Requirement Level 1 Level 2 Level 3 Level 4 Level 5 1. Design/Development Records R S S • R -for proprietary components/details R R R • R -for all other components/details AIAG PPAP: R S S • R 2. Engineering Change Documents, if any R S S • R 3. TI Engineering Final Approval R R S • R 4. Design FMEA (or Risk Assessment) R R S • R Contents 5. 6. 7. Process Flow Diagrams Process FMEA (or Risk Assessment) Dimensional Results R R R R R S S S S • • • R R R and 8. 9. 10. Material, Performance Test Results Initial Process Study Measurement System Analysis Studies R R R S R R S S S • • • R R R Submission 11. 12. 13. Qualified Laboratory Documentation Control Plan Part submission Warrant (PSW) R R S S R S S S S • • S R R R levels 14. Appearance Approval Report, (AAR) S S S • R if applicable 15. Bulk Material Requirements Checklist R R R • R (for bulk material PPAP only) 16. Sample Product R S S • R 17. Master Sample (See I.2.2.17) R R R • RNote: the PPAP form and 18. Checking Aids R R R • Rdescriptions of each requirement 19. Records of Compliance With Customer-Specific Requirements R R S • Ris from the AIAG reference S = The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items at appropriate locations, including manufacturing.manual for PPAP, Third Edition R = The supplier shall retain at appropriate locations, including manufacturing, and make readily available to the customer representative upon request. • = The supplier shall retain at appropriate locations, and submit to customer upon request. Training/Graphics/APQP/R-S Requirement Table.doc