You are on page 1of 59
Advanced Product Quality Planning and Control Plan red Oa Second Edition ADVANCED PRODUCT QUALITY PLANNING (APQP) AND CONTROL PLAN Reference Manual Second Edition Issued June 1994, Second Printing February 1995 (new cover only), Second Edition, July 2008 Copyright © 1994, © 1985, © 2008 Chrysler Corporation, Ford Motor Company, and General Motors Corporation ISBN: 978-1-60534-137-8 FOREWORD Second Edition Effective November 1, 2008, APQP and Control Plan Second Edition replaces APQP and Control Plan First Edition unless otherwise specified by your customer. APQP and Control Plan Second Edition includes: © incorporation of the customer focused process approach © updated terminology and concepts consistent with ISO/TS 16949 and other Chrysler, Ford and General Motors core tool manuals appropriate references to customer specifies provided without the full text ‘This manual continues to provide general guidelines for ensuring that Advanced Product Quality Planning is. implemented in accordance with the requirements of the customer. It does not give specific instructions on how to arrive at each APQP or Control Plan entry, a task best left to each organization. While these guidelines are intended to cover most situations normally occurring either in the easly planning, design phase, or process analysis, there will be questions that arise. These questions should be directed to your authorized customer representative. ‘The Supplier Quality Requirements Task Force gratefully acknowledges the contributions of the following individuals and their respective companies that participated in the revision process. Bryan Book, Chrysler LLC, Chair Russ Hopkins, Ford Motor Company William Fick, General Motors Corporation Robert Minkler, Delphi Corporation Craig Williams, Eaton Corporation This document is copyrighted by Chrysler LLC, Ford and General Motors, all rights reserved, 2008. Additional copies can be ordered from ALAG at www.aiag.org. Organizations purchasing APQP Second Edition have permission to copy any forms and/or checklists contained herein. July 2008 iii D TABLE OF CONTENTS FOREWORD. ‘TABLE OF CONTENTS. IntRopucTion 1 FUNDAMENTALS OF PRODUCT QUALITY PLANNING. 3 Organize the Team. 3 Define the Scope. 3 Team-to-Team 4 Training. 4 Customer and Organization Involvement. sn 4 Simultaneous Engineering 4 Control Plans ae 4 Concern Resolution. 5 Product Quality Timing Plan 5 Plans Relative o the Timing Chart 5 CHAPTER I PLAN AND DEFINE PROGRAM. 7 INTRODUCTION. 9 1.1 Voice ofthe Customer. nn 9 1.2 Business Plan and Marketing Strategy....... vs cose iW 1.3 Produc/Process Benchmark Data ul 14 Product Process Assumptions 2 1.5 Product Reliability Studies. : — 22 > 116 Customer Inputs : — — 2 17 Design Goals 2 18 Reliability and Quality Goals.....ese : Soom cod? ‘1.9 Preliminary Bill of Material. vnsonnsansensvnssens vs sensonnvansenve o soe dD 1.10 Preliminary Process Flow Chart. B 1.11 Preliminary Identification of Special Product and Process Characteristics. 13 1.12 Product Assurance Plan ve on DB LIB Management Stpport oss 3 ee ny 7 CHAPTER 2 PRODUCT DESIGN AND DEVELOPMENT IntRopucTion. uv 2.1 Design Failure Mode and Effects Analysis (DFMEA) 18 2.2 Design for Manufacturability and A8seMbW .rrunsnnsnnvnnvnnininnnnninnnnnnnnen 2.3 Design Verification eee . 19 24 Design Reviews : 19 2.5 Prototype Build - Control Pla... 20 26 Engineering Drawings (Ineluding Math Data)...ssscscnsonsvssnnnnncnensnnnvnn 20 27 Engineering Specifications 21 2.8 Material Specifications. M A 2 2.9 Drawing and Specification Changes... Sanne 21 2.10 New Equipment, Tooling and Facilities Requirements... ears 21 2.11 Special Product and Process Characteristics. . son 21 2.12 Gages/Testing Equipment Requirements co — 2 2.13 Team Feasibility Commitment and Management Support 2 CHAPTER 3 PROCESS DESIGN AND DEVELOPMENT, IntRopuction, se 25 5.2 Prdhe-rocets Qual Stem Reon 26 Ly Process Flow Char 26 13. Flor Plan ent. 26 1S Charactosice Marie 7 1s Procss Pate Mod Ei ais PFE) 2 14 Pre Launch Conra Pla 7 51s Pree actions = 28 3D aseremon Stone fossa 28 310 Preiminon Prces Capi, Sac Pia, 8 1.1 Manageme Spt. Be (CHAPTER 4 PRODUCT AND FROCESS VALIDATION sv ananenseenevenen _ vmnooucrins 2 “1 Signe’ Prodiction in Se {2 Mearremon Sons Aras. 4 4G Prclminary Process Capi Si oH 14 Production Par appr S as 45 Prod Vliet Tesing 3 4 PoctarngEsatation = as 413 Pract Con Pi os ‘15 Quali Plowing Si-O ond anagoment Sopa. as (CHAPTER $ FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION ovnorwsnennmnnmnenaen3T Inmg9ueTeN = Th Reduced Fran ~ 38 5:2 improved Catone Sutin oO {improved Deter ond Serie. 54 Bene Une of aon Laue Paces (CHAPTER 6 CONTROL PLAN METHODOLOGY Iermooucron. (6! Connel Fan Cas Deri, 2 Proc daha APPENDIX A PRODUCT QUALITY PLANNING CHECKLISTS seen [APPENDIX B_ANALYTICAL TECHNIQUES Cus 4,2 Measurement Systems Analysis “The specified monitoring and measuring devices and methods should be used t check the conrl plan identified characteristics to engineering {peciication and be subjected to measurement syst evaluation during or por fo the significant production run. Refer to the Chyler, Ford, and Gener Motors Measurement Systeme Analysis (MSA) reference mani. 43 Preliminary Process Capability Study The preliminary process capability study should be performed on Glartrisies ieitiied in the contol plan TBs study provides fssessment of the reainese ofthe proces fr production. Refer to the Chrysler, Ford, and General Motos Production Part Approval Process (PPAP) maval and Chiylr, Ford, and Generel Motos Sista Process {Control (SPC) reference manual for deals concerning the preliminary 4 Chapter 4 Product and Process Validation process captiity study Unique eguremenss Refer to customer-specfic requirements for 44 Production Part Approval PPAPs purpose isto provide the evidence tall customer engineering design record snd apecificaton regiment are properly understood by the ‘cegeization and tht te manufactring process has the potential to produce Product consistently meting these reyuitemens dung an” sctal Production run atte quoted prodbeton rate. Refer tothe Chrysler, Ford, bd General Motoes reduction Part Approval Press (PPAP) manu 445 Production Validation Testing Production validation testing refers to cagineerig tests that valat that products made fom prodacion tools and processes meet customer ngincerng standards inelodng appearance requirements 486 Packaging Evaluation All test shipments (hen required) and test methods must assess the protetion ofthe product from normal transportation damage and adverse ivitonmentalfctors. Customer specified packaping does not preclude the ‘rzaization's produ’ quality planning team iovolvemeat in evaluating te tffetivenes ofthe packaging. 4.7 Production Control Plan “The production contol plan is ¢ writen description ofthe systems for ontoling production pre and process, The production conral plan is & Tving document and shoal be updated to reflect the ain o deletion of ontus based on experience guned by producing pars. (Approval ofthe futoried customer representative may be requred) The production onto plan is logic extension ofthe prelautch contol pln. Mass production provides the organization the opportunity t evaluate output Feview the control plan snd make appropriate changes, Chapter 6 and ‘Append A-8 present Contol Plan Methodology and s checklist 0 verily completeness 4.8 Quality Planning Sign-Off and Management Support “The eranzatn's prot gait plnning tam shoul pero a review atthe manufacturing location(s) and coordinate 2 formal sigo-ff. The oduct quality sign-off indiests to management that the spproprite APQP 3s Chapter 4 Product and Process Validation acivtes have been completed. The sign-off occurs prior to fist product ‘shipment and inca review ofthe Following: 1 Process Flow Chars. Verify hat process flow chars exist and ae being falowed, + Contol Plans. Verify dat contol plans exist, are available and are followed allies forall affsed persons 4 Process Instructions. Verify tat these documents contain all the special chinatises speeifed in the contol plan and that all PEMEA Teoommendations ave been addressed) Compare. the process Insitutions, PEMEA and pres low ehart othe cont plan 4 Monitoring and Measuring Devices. Where special gages, Sxtures, cquipment or devices are required per the contol plan, verify gage ‘epoaaly and vproducbiity (GRBR) and pope usage. (Refer ote Chrysler, Ford, and General Motors Measurement Systems Analysis (MSA) reference manu or more formation.) ‘+ Demonstration of Required Capacity. Using production processes, ‘uipment, nd personnel, ‘Upon completion of the sign-off, «review with management should be scheduled to inform management of ke program statis and gn ‘apport with ary open sees, The Prodot Quality Planning Summary and Approval por shown in Appendix E i an example ofthe documenstion required support an effective quay planning sign-of 36 } Feedback, Assessment and Corrective Action Chapter 5 Feedback, Assessment and Corrective Action a Chapter 5 Feedback, Assessment and Corrective Action PRODUCT QUALITY PLANNING TIMING CHART Planing Panning g Produc Design ard Dov + + Proce Design and Development [prt ana Procession Foodbock Asossarent and Crresve Acton OUTPUTS: + Reduced Variation + Improved Customer Satisfaction + Improved Delivery and Service + Effective Use of Lessons Learn / Best Practices 38 es a ng tenenanancnnmenei Chapter 5 Introduction Feedback, Assessment and Corrective Action (Quy pinning doesnot end with process validation and insallition. Is the component manafectarng stage where outpt canbe evaluated wha all ‘speciel and common causes of variation are present. This is alo the ie 10 ruse the effeccveness of the product quality planing eff. The production contol plan i the basis for eslating producto sevice at his Sage, Variable aad strbute data most be evaluated Appropiseectins fs desrbod in the Chrysler, Ford, and General Motors Staistial Process Conta (SPC) reference ranal must be takes. Orginizations that flly implement an effective APQP proces willbe ina beter postion to met ‘customer requirements eluding any special eharaceristis specified by the “The inputs end outputs applicable to the process step inthis chapter are as follow INPUTS (Derived from the outputs of Chapter 4) Significant Prodvetion Ran Measurement Sytens Evaluation Preliminary Process Capability Study Production Part Approval Production Validation Testing Packaging Evaluation Production Cone Plan Quality Planing Sign-Offané Management Support ovrrurs Reduced Variation Improved Customer Satistation Improved Delivery an: Effeive ue of Lesions LearediBest Pracies 3, gts) 5.1 Reduced Variation ‘Contol chars and other saistical techniques should be used as tools to ‘enti processvarntion, Analysis and corectve actions shouldbe used 10 rede variation, Continual improvemeet quite artetion not only to the ‘syeia eases of variation bul understanding common causes and seeking ‘ays fo reduce these soures of variation. Proposals sould be developed Tnsloing cots, ining and aniipated imrovrment fr cusome eve “The reduction or elimination of commen cause may provide tbe ditional benefit of lower costs, Organizations shouldbe using tools such as value fnalyss and redoction of variation to improve quality and reduce eos, Refer othe Chrysler, For, and General Motors Statistical Process Control » Chaptor 5 Feedback, Assessment and Corrective Action Chapter 6 Control Pian Methodology (SFO) referee manual for details on ongsiem capability, special and common cases of vaition ) 5.2 Improved Customer Satisfaction Detsled plansing activites and demonstated process capbilty of # product or service are important components to customer stsacton. However, the product or service stil ba to perform in the customer vironment. This product usage stge requires organization patipation. Th this stage much ean be lard bythe ergmization and easton The effectiveness of the product quality planing efor can so be evaluated st this sage } ‘The orgasztion and customer become parers in making the changes acessaryf correct ny efcletclas and improve customer ststcton 5.3 Improved Delivery and Service The delivery and service stge of quality planing continues che crzanization and customer parterehip in solving problems and contin improvement. The customers replacement pars and sevice operations ‘ust else meet requremeats for quality, cost, and delivery. The goal Tis ime quliy, Hostever, where proiems or deficiencies ceca in the field i ic essential that te crgnieation and custome form sn effective rersip to comet the problem and sais the end-user custome. Chapter 6 Control Plan Methodology The experience gained inthis stage provides the customer and organization write the necessary Inowledge to reduce proces, inventor, std quality Costs and tc provide the right component or system for the next prodit —— 5.4 Effective Use of Lessons Leamed/Best Practices A Lesspns Lesmed or Best Practices porfolio is beneficial for capturing, retaining and applying Knowledge. put to Lessons Lesmed and Best Practices canbe obtained trough a variety of methods including: ‘+ Review of Things Gon Righy Things Gone Wrong (TOR'TGW) + Data fom waranty and other performance met + Comostive ation plane + "Read-acrse” wit sia products and processes + DEMEA and PFMEA studies 0 4 Chapter 6 page intentionally left blank Controt Pian Methodology Chapter 6 Introduction Control Pian Methodology “The purpose ofthis contro plan methodcogy isto aid inthe manafactie of quality peogucte according to customer requirements. 1 does this by providing 1 snared approach for the design, selection and Inplemttation of value-added consol methods forthe tot) system, Cento! pans provide a writen summary desertion o he systems used in tmnimzing process and product variation. The intent ofthe eonrl plan form displayed in thi chyper is to provide an example of how this information can be documented. An aerate format may be useé a8 Jong ‘i cootins the same information, a8 ¢munimum. ‘The contol plan does fot replace the information contained in detailed operazor instructions. This, ‘methodology is applicable toa wide range of manufacturing proceses and {eshnologies. The congl plan isan integral part of an overall quality process end isto be utiiaed as a ving document. Therefore this chapter ‘Should be wed in conjunction wih other related documents ‘An important pase of th process for quality planing iste development ‘fa contol plan. A cont plan eo writen description of the sytem for outllng pts sod pocese A single consol lan may apply to a group for family of products that are produced bythe same process atthe sume Source. Drawings a visual standards as necessary, may be atached tothe extol pan for lusteton purposes. Tn suppor of &conzl plan, operator tnd process monitoring instructions shouldbe defined and used contin. In effet, the contol plan describes the acons that ae request each pase of the process including reccving, i-proces, out-going, ani Pode requirement fo assure that ll process cutpts will be ina sate of, fontol During regular production rans, the contol plan provides the process monitoring and contol methods at wil be used 0 consol ‘harasses, Sine posees are expected fo be continually updated end Improved, the contol plan celeste # salegy Gat is responsive t these chnging proces conditions. “The conto plan is maintained and sed throughout the produc life eyle Em inthe prodact life eyle i primary purpose is to document and ‘omni te intl plan for process contr. Subsequent, it guides manufacturing in how to contol the process and ensure product quality Uttimotely, the contol plan remains « Living document reflecting the current methods of cote), and measurement systems used. The coool Plan is updated es measurement systems and contre methods are eveluated nd improved Chapter 6 Controt Plan Methodology Chapter § Controt Plan Methodology r T For process conto! and improvement tobe effective, a base understanding ofthe process must be obtined. A mul-deiglined team i tablished to ® | velop the cong) plan by wing all he svllabe Infermation fo gain 2 better understanding ofthe process, suc a: ‘+ Proces Flow Diagram ‘+ Systen/DesiavProess Flare Moe and Pec Analysis @ Special Characteristics ‘Lessons Leamed fiom Similar Pact + Team's Koowledge ofthe Prossss + Design Reviews ‘+ Optinizason Metods (e, QED, DOE, et.) | |] | ‘The benefits of developing and implementing a control plan include: ual The contol plan methodology rdoes wast nd improves the quality of| 1 | products dung design, manufacturing, an atembly. This sructured Aiscpline provides a hough evaluation ofthe produt and process. Contol plans identity process characterises sna ‘methods fo the sures of vacation (input variable), which cause variation ‘im podact characteristics out visible), ‘Customer Satstcton: Con plans fous rescues on process end prods rel shracteriscs that are important tothe custome. The proper al ® | resources on these major items help to reduce costs without sacrificing swat eer Communication ‘Asalivingdocament the contol plan identifies and communicates changes inthe product process characterises, contol method, and charcteritie CONTROL PLAN k f H g Cmte ae 7 ' Chapter 6 Control Pian Methodology Chapter 6 Control Plan Methodology T 6.1 Control Plan Column | 3 lz | 9 3 Descriptions | of e PLE ) PROTOTYPE, Inde the appropri cagoy fad PRELAUNCH, ae E i 5 + Prottype-A desrption fhe dimensions mesures = i is i PRODUCTION ‘material and performance tests occuring during Prototype RAG | oat aa i + ProLamsh- A dtripn oft desir . EE) LE j ‘easteent mtr a pertomance xs tht wil FORE | se ! {ca afer Preloe and bere normal rosin It i | + Poin. Aces dementon RGB lage i rotucieces chee ove contol xd E een | Feaourment ye ocaing uring nr predation. Tea | [oy connor rLaN NUMBER | Exerte coro! pln document under wed for waking if ae | j tpl, Fre control apes eter page lage { Geo) le 3) PART NUMBERLATEST | Ener te numer ofthe system, subsystem o compose being i ese (CHANGE LEVEL conirlled. When applicable, ener he nest engineering change He | Iovel anor nse ate om the dain spestenon. Be | ee 4) PARTNAME/DESCRIPTION | Enter the name and description of he produclproces being Z contol 3 Jol £33 & __ - x 1 5) ORGANIZATIONPLANT | Ene the name ofthe conpary end the appropriate 2 Svuonplandeprent eprint con en. 2h] i @ JC Ze 6) ORGANIZATION CODE _| Enter the identicaion number (For example: DUNS, Customer Sil a | | (SUPPLIER CODE) Split Code as requested by te customer. i ae | - i a 7) KEY OONTACTIPHONE AND | Ente: the ume, phone ne and oer eons! inoraton, q Onipe conTACT tegen of he pay conta! esponibl fre conto plan i | INFORMATION a LE a 8) CORE TEAM Enter the name(s), telephone number(s), and other contact ag ; intenaon eo of he nde) reponse fr ate 23 preparing the control plan to the latest revision. It is recommended # alk) | 222 ld | Tialalof te team member? names, ove numbers, sa lesions 4 ie I ash | ‘be ioclded on an atached sibation ist. | a 3 oxoatarvesant | cot escent at pet iE lf i ede APPROVALIDATE ‘cepmnization(ifroguited- see appropriate customerspecifc i ae Hie | requirement) Gu be 2 L L : Chapter 6 Control Pian Methodology Chapter 6 Control Plan Methodology 12) CUSTOMER ENGINEERING APPROVAL/DATE ‘QUALITY (ifreuied- se appropiate estoneespeifieequremen’). ‘APPROVALIDATE ik! | 12) CUSTOMER ‘bai the respoasibe customer soplier quality epeenttive approval 1) OTHER ‘APPROVALDDATE 15) PARTIPROCESS, NUMBER 16) PROCESS NAME OPERATION DESCRIPTION 17) MACHINE, DEVICE, 1G, TOOLS FOR MANUFACTURING the processing equipent, manufacturing, 2 appropri, aor oO (CHARACTERISTICS (tudes ters 18, 19 and 20) 1) NUMBER CONTROL PLAN pT Cneace Tessie prreor can ‘AGojoPOMEN URId [OUD NOWWoUISsv19 ousREaLovavED “Ivioads (12 ssaooua (2 sonaoxa (st gusideyo ‘ABojopoUoN eld JOxUOD ® ® comms yrengnontay tunoubua moma) cme] © taco © NYid TOULNOD gueideyg Chapter 6 Control Plan Methodology Chapter 6 Control Pian Methodology | [ merHops (INCLUDES ITEMS 22-25) | A systematic plan using procedures and other tools to control Pl) " fpmoee Hol bb 72) PRODUCTIPROCESS Specifiontclennce may be biel evan ||OE cone ERG L if i EE IN! MEASUREMENT ER EGE i Ei H bE OB IB 28) SAMPLE SIZE! FREQUENCY 25) CONTROL METHOD Oo © =) ‘@ SRT feraluation oF he contol method Control Pian Methodology Chapter 6 Control Pian Methodology Chapter 6 [Pomona QD ___ cbs pamcmentoy uo] © corey emamosar tiny mswal oe @ ® coma norma somo sa @ compa] Oren @ smn peagroaie mac] eam ® ote NY1d TOULNOD g ¢ Pe g 8 z° z 9 i —— g 3 = g g > ABojopowneW weld jonu0D Control Plan Methodology Chapter 6 Control Pian Methodology Chaptor 6 = | o (SESC=- a anf oo 5 aol S52} scence) a | tl | Mi 2 aa = rear & & - ntmenoea)_ enone pre 2 eae Z io | a ae ae Nv14 70MLNOD ‘Supplement B pupegesnioe| weenat| spat a ‘en Saag tne Nyta 1081No9 emotes nes ogo red agama are an 2 pmb Be pn mem ps ns tomer rend ea msapaysnintor ou poe joarapor ee wana mops ten nan momma set Sen a tae evo epee enaaeo n= er on at 9 eats PT, sue ana pao o a ee a fsa [aE TT - B SF aaa TORTI Ream RT s . a a ae g ie] SS 25 ee ome | | 8 ES ——— 7 » OL ATOR CN aT 3 g 3 a fauevenr ToCLNG BoM FROCEEE Tian eee ea ‘CONTROL PLAN a co ae an NE snc pT SST g ome [ee | 7 = I. =| omen ao Bz Sei ts | tt [5 Tner [ mene | | SS ee erp me] ee] 5 featton | tm | anon immo Pee | 8 C : L ABojOpOWREW wea JoAUED Control Plan Methodology ‘Supplement F ae Chapter § Control Pian Methodology fnwsemevncl more | wit] yok Se . emma] | menor | . gas —[-[- = oe = a f= |= See [=| [lee] Sa 2 " wa chapter 6 9 ge =a [RMCNMENT CLMATE DONNIE PROCESS. Ce ites sc ep Intl dpe se oma el 1 Ty stomntts npc rss srs pre che wahoo tn + Pr cri ecb rin yl paces nyse paca oundeug ‘9 wawalddng ‘AB ojopoWeIN Weld JOAIUOD Hawuewejddng ‘ABojopouneW UeId JoxIUOD Control Plan Methodology Chapter 6 Control Plan Methodology Chapter 6 “sg pam ea ey sei Sip eee tO “ges onpoge be 9 0 I Trae eso Kg paral | I ee SE mong ssocnipapan pes jean] eee nrecd | —taminpaseeey trea ponbeu uonay weumog | vn| on |sea| onsen Supplement J sie] oraud ong_| uosieg ASIMOSHO NVTd TOMLNOD ‘Supplement ! es panne] np aro nena 9 aT seen Oh eon Nya TOuLNOD a eee Cheptrs Contrel Pan Methodlogy ‘SUPPLEMENT K 1D Supplement K ee ; _ E E Ley ae i if je if i3| sealer 5 eo Og | iy i } oo | a 4 tt ae fe A iE f a3 . | SLSITMD3HD ONINNV 1d ALITWND LONGOYd Vv XIGN3ddV sisipyoat}g Buyuuelg Aen Yonporg wspuaddy ‘ABojopOWNEW Weld 1Os1UOD J uewerddns trvnoudo) eaivmiawoos iMiod Viva gamdeua SS | EREGE AG28E2 tela eeithe qegces 2faees : ggiage ies ke B7ase bFeges fiigtee PRRs? ESSEGE eet Be beg ee to aap Ay 0) pepo You 3H 8 309 2 249, #58 ‘Qupregs ah JO 350 9, ‘At DESIGN FMEA CHECKLIST s}S|PJ9EYD ey} Jo esoding Question na] Comment Action Required Ea Sa aoa Sema Besse aaa - Desi he FEA way Scat | iste east Sime eT oa "ple or MCA spat nt ple ve tes crc Te Stose sapien amnesty 19 Sere have teen cet sd ead? ay wy xipueddy sieipooug Bujuuetg ApEn YonPosd wnipueddy SsIppesyo Buyuuelg AWeND npord e 5 ‘2 DESIGN INFORMATION CHECKLIST cutee ornate eee cme ra] a] comer acin utes [my beSnn | HH oer = te as Bria ea For usnTCaTSy aT lesen bcm come) fives ae capa ae RT Se eactal ons maha Syren aT 1 tceapanen store oxy ened “a Spool Corer as OPT z i 2 a ‘°° z vxipueddy A-2 DESIGN INFORMATION CHECKLIST Question ver] No [twa] Comment Action Required ie tetas pce caneig an etn epi ny | 7 EA ROS TS {panuquog) ys1pj2249 UoReWOjU] UBISEQ Z-y sys1pyoaug Buuuelg Ay/enp onpoug [A-2 DESIGN INFORMATION CHECKLIST ‘Comment Action Requited Porson { responsbie | ° ‘A-2 DESIGN INFORMATION CHECKLIST ‘Comment! Action Required Person Responsible | Ove Date Ba Brae, Rag ere xipueddy S80 ZV (panunuod) ys1p}9249 UoReUOJU) Ut qstpje0up 6ujuuelg Alten Yonpold S80 ZW (penuuog) s1pjoey9 uonewuoyuy siysous Buwueg |A-3 NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST ( ‘Comment Action Roaulred ‘Question tarieaaign eae ; Hota : ‘its petra i Tre an buen res HIG I Het es aman mans 7 sraner Sa cara Dan ROTATE {lng ae i preteen capably uty cone [te ot ero arte fe ncaa FN eS ‘A NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST > uestion a fes| No ‘Comment / Action Raqui [Person ‘Due eee [reno |wal comment atoneures | nara | ba | feet aetna ‘Buyjoo, quowdinba MeN e-¥ aby Ee capa ee fresneperenepad “ fetish er pe RT (Penuquos) sipjoeyg wowdinba 1801 put wetpusddy ‘sysipyooug Buyuuejd Ayend onpold vy mipueddy ‘ss1py90U9 BulUUeld Aend YonpOLd ‘yxpueddy ‘A-4 PRODUCTIPROCESS QUALITY CHECKLIST ee ‘Comment Action Required ‘Question Ine soar (vies ar approved por cst apetie 08 openers se ete? [eden ote yedt ns cost syaipypouy Buyuuerg Aen onpold ‘A-4 PRODUCTIPROCESS QUALITY CHECKLIST ‘wxipusddy ‘Comment Action Required Apa aoe a aT oni (penujuoa) ysip04D Aiyeng sseoosgnonpord HY Tike et (REO ‘Sisippp9y9 BujuUeLg Arend nposd ‘A-4 PRODUCTIPROCESS QUALITY CHECKLIST con —— ma | een Bae ‘Question [ves] Nowa] Comment/ Action Reaui reels | eo Fra ere orm [eprom creer tio eam — cacao SSitigaed marae onto ca, 2 [tami tndeangerenn none (penuguos) 3s1pj90U9 Ailend SseD01dnONPOLd HY ‘A-4 PRODUCTIPROCESS QUALITY CHECKLIST ueston yes] No[ Na] Comment’ Acton Required [ERS TN a 2s [fetaroremry react ope | oR aaa NT : [enna sate Te Paes marr spe Fra fresno angen gen i go? 26 [nswean apron! tasty ponte? | » here ee yore ea TS aT Pepses by (panujuos) 8149049 AyreND sse20sG;oNPold FW wmipueddy systpy20up Bujuuelg AyrEND MPO vy xipueddy ‘Sys1pypoup Bujuueig Aen onpotg ey A-S FLOOR PLAN CHECKLIST Jv+s] Nowa] Commont/ Action Required Responelbie Person] Due Siac co para feist sore DaIST owt [nome nosey para [onosmng ecnng mo? a oe ‘AG PROCESS FLOW CHART CHECKLIST ‘Question yes] No[wal Comment Action Required Parson Responsibie Bue |_oate |e fe how attra ha 7 [ibe tow rtyee poate cn he arte pond PEAT © [rotreentnieenal etre Jr elu eprops aussi Ihouacies caring upper pode wat \yxpueddy sisippoug Gujuuerg AajeM oNPOAd wxipueddy Sisip90u9 Buyuuelg AyeMD rnPoAd AT PROCESS FMEA CHECKLIST vmpueddy [ ‘uction ee] wo ]wa] Comment’ Acton Required ne Ts SSE EK FRET 1 [score pot eciart eti (aed oa ee omar 2 _ ear me aoe 8 Aujent) onpod pata aera ect I - sfimtaenercstomenrsroea| | 3 es é Prepay: — zg & 3 > ‘oe eo z A-8 CONTROL PLAN CHECKLIST 3 : Ses _ 2 ‘Question yee] no|wia] Comment Action Required Ll > Paar TS spore | bate besa his tesa a sa percares a + fneicres eee eestor 2 feet ese 11 forpnainsessie wbarnee [—[itetteasiromary var ug plan a Poison Dat ‘is1p}00uD BujuuErE Ayend onpoLg ‘Appendix B Analytical Techniques APPENDIX B ANALYTICAL TECHNIQUES D Appendix B Analytical Techniques ‘Assembly Build Variation Analysis ‘Benchmarking Cause and Effect Diagram ‘An assembly build variation analysis isan analysis that simulates he buildup of an assembly and examines tolerance acomultion, sass aranetrs, sensitivity, and "what i invention, Benchmarking is systematic approach to identifying standards fr comparison. It provides. input to the erablisment of measrabe performance targets, aswell seas for product design and process desis. 1e can alo provide ideas for improving business proceses and Work procedures. Product end process benchmarking should include the identification of world clas or bestinelass bored on customer end intel ol performance measures and research into how ths performance wes 'chioved. Benchmarking should provide » stepping stone for developing new designs and processes that exceed the capabilities ofthe beneknark The "cause and effect” diagram is an sonic! tol to indicate the selationship between an ‘effect and all posible "coues”ifluncing i This is sometimes refered to as fshbone diagram, Ishikawa capa, Or feather diagram, 9 —————— ‘Analytical Techniques ‘Appendix i Eqvonent eros Temper ‘Sere Figure 1 Cause and Effect Diagram ro ncase and ef se, igre 1 xarizes he pe of pees input it TES minay grouping we. Pepe Maeal, Equipment, Metis Trassem Zovvonmsnt and asomer Reqiemens st eee process is he key 10 success development of : Tae tela oft source of aati an appre coal tos teristics Matrix + a wracteristics matrix is a display of the relationship berween process H A dans maicing Saioa. A ehod of evelping De : aati mh nfo munber the deosions andor fxs om he { ‘part print and each manufacturing operation. All manufacturing operations 225 Eon appear tre the fp ond he prose prance we Used se enon clun, ie ntetanifcusing lon sr ee npr he ol of chester bcs Repl ‘St matin size, the upstream relationships of characteristics are evident ‘ie mat show low = |. | (C= Characteristic ten operation used for clamping 1L Characteristic at an operation used for locating x= Characteristic crested or changed by this operation should match the process lw diagram form Critical Path Method ‘The esto path method can be a Pert or Gantt Chart that shows the honological sequence of tasks that require the pestest expected fine 19 accomplish, It ean prove valuable infomation ast: + Ineclatonsips + Early Forecast of Problems ‘+ entiation of Resporsiilsy ‘+ Resource entation, Allostion and Leveling Design of Experiments (DOE) A design experiment is atest or sequence of tests where potential infuentil process variables re systematically changed acconding fo a prescribed design maui, The response of interest iv evalsted under the various conditions to: (1) identify the inhuentl variables among te oes ‘ested, @) quantity the effects acoss the range represented by the levels of the ‘aribles, 3) gina beter understanding ofthe nature ofthe cal system at work in the prooess, and (4) compare the effect and interactions. ‘Application eal inthe producvrocese development eycle can teu in (improved process yields, 2) reduced variability around « nominal or ‘agt vlc, (3) reduced development ime ad (8) duced overl eos, — ‘Appendix B Analytical Techniques Design for Manufacturability and Assembly ‘Dosen for Maafactiiy and Asserby ia SilineousEngneing ares Gaigmd t optimce the ratonhp betwee design fancon, Mfncbliy,sbd eae of assembly. The enhancement of designs [or cup and utara ap npr sp. Pt represeaves ‘Sou be ented eur the eign proces oreviw component Yau snd" provde input on specie swsembly 20d manaficting ‘furments, Specific dinesorl erase shuld be determined based SARS e pct. This wll ait in ening he equipment equed Ad ny proves changes ness Design Verification Plan and Report (OVP&R) - ‘The Design Verification Plan and Report (DVP&R) is a method to plan and Gecument testing, avin” ough each pase. of produc eocess ‘Cccopment font ices o ongoing rebaement An etleive DVP&R sabes sone woking document at is eniering personel in he foiowing ae: le “+ Facilites the development ofa logial esting sequence by requiring the Fesponsible areas to thoroughly pln te tests needed to assure ta he Component or sytem mse all engineering requirements. | Asus profi laity nee ese ven tees | Highlights sation where customer ting requires an accertd test pla, l ‘Serves as working oo for esponsibl area(s) by iu © Summarizing functional, durability, and reliability testing segue an vl in oe Soviet Tr ease free. 1+ Providing the ability to ensily prepare test stats end progress reports fr design reviews Detailed instructions can be obtained ftom the appropriate Chrysler end Ford Quay or Enginerng aes, Mistake Proofing/Error- Proofing ‘intake proofing is tshaique to idonfy ers afer they occur. Mistake oun should bo wad ae tocheique to contol eptidve tasks of etions nd prevent nor conformances from being pass on to the subsequent peraton and ultimately fhe easomer. Eror-poofing is a technique used {0 ident potential proces eos and either design them ou ofthe produ Appendix 8 Process Flow Charting Quality Function Depk (FD) Analytical Techniques or proces, or eliminate the posibiity tit the ror cou produce a pocen possibility tat the ld produce non Poses fow charg isa vs speach to desctng and devening seul te von aise ih sa Communica abd tay for plain. Seveopran scine a ‘manufacturing processes. a “ Since one goal of quality as i sacace is (0 eliminate non-confomities and improve the eficienty of manufacturing and aesebly processes, advanced ‘Product quality plans should include illisrations of the controls and ‘spuresinvalved. These process fow chars shoulé be used to detly improvements and to locale significant of eral product and proces characeristis tat wil be adresse in coat plans be veloped ae, loyment QED is systematic poste for tanlting caster regu iio tecnica nd operational tems, playing snd docunentog he tasted ‘somtnni fom_QHD otto gta fo a roves the mechanism to tel selected esto enhance compa advantages. : " pane Depending pon he ei ro Be equ of QED maybe wed as 4 srwcure forthe quality planning proces. In particule, QFD Posse | Product Planning tansates customer quirements ino counter contol sharscterisies or design requirements. QFD. provides a means of Sowerng genet ue Suen it pes fal eb a ‘Process control characteristics. nn ALASPECTS OF QED. The wo dimensions of QFD ae: Cua Deployment Tension of Casomer Rue it rf Design Requirements. a Function Deployment: Translation of Design Requirement into appropriate Pan, Process aod Production Regimens B. BENEFITS OF QFD. lncreses the assurance of meeting the customer reuirements Reduces numer of changes det nseasedengnering sfessome egies enesing wdesang entities potentially con ne design requirements. ‘Appendix B Analytical Techniques Focuses various company stvties on customer oriented objectives. Reduces product development eyle tine + Reduces cost of engineering, manuetring, and service 4+ Improves quay of product and services. €| od Reference Material Appendix ¢ APPENDIX C REFERENCE MATERIAL Appendix Reference Material ‘The following anual can be obtained fom ATAG at wu ago ‘Measurement Systems Analysis (MSA) Reference Manual ‘Thisisareference manual that dseribes common methods of evaluating measurement sytem variation and ives general guidance in the application of ecriqaes Potential Failure Mode and Effects Analysis (FMEA) Reference Manual “This isa eference masta potent Faure Mode and Etfects Analy vidance inthe aplication of twohniqus (FMEA) and gives geeral Production Part Approval Process (PPAP) “This requirements document covers generic requirments fr prodetion par approval forall production and servi commodiies Statistical Process Control (SPC) Reference Manual This reference man! that provides a unified reference for tatsial process contol and gives general suidance inthe aplication of techniqes Appendix D APPENDIX D Team Feasibility Commitment TEAM FEASIBILITY COMMITMENT ‘Appendix D ‘Team Feasibility Commitment ‘TEAM FEASIBILITY COMMITMENT TT = eaueaea ———- Ferwenomiatis — ‘Appendix E Product Quality Planning Summary and Approvals APPENDIX E PRODUCT QUALITY PLANNING SUMMARY AND APPROVALS ‘Appendix E PRODUCT QUALITY PLANNING SUMMARY AND APPROVALS Product Quality Planning Summary and Approvals = + smuacsoumen shangae Tape EATOSERTTEGATE _ eo ‘Appendix E Product Quality Planning Summary and Approvals PRODUCT QUALITY PLANNING SUMMARY AND APPROVAL - INSTRUCTIONS SECTION ' Under *roquie,” foreach tem indicat he numberof characteristics equ Under “acceptable,” fr each tem indicate te quantity that was accepted ps Cy Ford, and General Motos Production Pat Approval Prose mantal or ustomet requirements ‘Unser "pending." for each tem, indicate the quantity not accepted. Attach action pl for cach tem 2 Indiete if conto plan hasbeen approved bythe customer (i equ) by crtng yes orn, yes, indicate dat approved. Ifo atch action plan "samples incate the quantity of samples ingpeted foreach item, ‘Under "harcternies per sample” for each item india the numberof characteristics inspected on each sample fr esc category, ‘Unser "acepabl," for each ite indicts te quantity of characteristics acceptable on all samples. ‘Under pending” foreach iter indicate he quantity of characterises ot accepted. tach ction plan for each ter. rule)” foreach item indicate the mamber of chsractrisics require "acceptable" fr each tem indcte the quant acceptable per Chrys, Ford and eneral Motors Measurement Systems Analysis Reference Manuel, Under "pending." foreach tern, indicate quantity not accepted. tach ction plan foreach 5 Under "required, for ech item nde the quantity required ‘Under "socepable” foreach tem, indicate the quantity accepted pending,” for each time, indicat quantity not seepted. Attach ation pan for each 6 Under “required,” for each item indicate yes ono oindicte item is equ Under eecepibie,” foreach tam iat sor uo to inate acceptance ‘Under “pening,” ifanswer under "acceptable" isn tach action plan, 7 ach eam member should sign form and indicate te and dt of iat, 101 ‘Appendix F APPENDIX F GLOSSARY oa Glossary Appendix F Glossary Glossary Apportionment: Referred to inthis manual asa par of Relailiy Enginering. Synonymous with he tem Reliability Apportionment, which the arigntent of elailiypouls fom system to subsystem in such away ta the whole system wil have the rquied flail? ‘eachmark Data: The results of an investigation to determine how competitrs edie bestn-lass companies achived thei lve of performance Dillof Materia; Totals ofl component and material required to manufacture the product (Characterises Matrix: An analytical technique for delaying the reationship between process parnmeters and manufacturing stations, Design Failure Mode and Effects Anlysis (DFMEA) An snalyticalecique used by design ‘esponsbl organization as means 1 assure, to the extent possible that pte ire ‘modes an their associated causesmechanisms have been considered and ees See carte eiton of FMEA. Design for Manufacturablity and Assembly: A simultaneous engineering process designed to optimize ‘he celaionship between design function, manufutuably, and este of assembly CCheclist: A mistake proofing checklist designed to. ‘were considered in establishing design requirements, Design Informs sure that al important items ‘Design Reviews: Milestone checkpins review progres ofthe design process a prctive proces. as ) Validation: Confirmation tizoush objective evidence, thatthe requirement for a specific intended use or aplication have been Tulle. Testing o ensure tat product conforms 0 defined user needs andor requirements, Design vilidtion follows sucessful design, ‘efication and is normaly performed onthe Gal product under defined operating onions, Multple validations may be performed if there are diferent intended ee, (Design) Verifeation: Conftion tough objective evidence, that specified requirements have been fale, Testing to ensure that all design outputs meet requirements may include sctviies such + Design Review ‘Performing AltemateCaleslations ‘+ Understanding Tests and Demonstrations ‘Review of Design Stage Documents Before Release Dorabitty: The probly that an tem wil continue to fneton at customer expectation level a the ‘sf fe without requiring ovechau! or rebuild ue to wert. Failure Modes Effects Analysis (FMEA): See cureneton of FMEA Feasibility: A determination tht a proces, esi, procedure, or pln can be sucesflly accomplished inthe require timeframe, Packaging: A unit ha provides protection and containment of iema pus cas of handing by mal os mechanical mesne. Pass-through Characteristics: Carctrstcs manufactured within the supplier process and used inthe ‘organization's process witbou modiiation a further validaon, 103 ‘Appendix F Glossary preliminary Bill of Material: An int! Bill of Matera completed priors design and print lease. ‘reiminary Process Flom Chart: An carly depiction ofthe anticipated manufcurng process fos produc. process Fallare Mode and Esfects Analysis (PEMA): An analytic! eehigue used by 8 manufacturing responsible engineefeam as a means to assire ta, tothe extent possible, tential fare modes and ter ascosntod causes mechani hve been considered and cessed, Sev curt edn of FMEA, product Assrance Plan: A part ofthe Product Quality Plan. Its prevention oriented managemea! oo “hat aldesses produ! desig, process sign, and whee appliable sofware design, ty Planning Approval: A review an vorifctin by the organization’ product quality panning Team that ll planned conls and processes ae bein followed. cr Relabilty: The probability that an tem wil continue to funtion at customer expectation levels a measurement point under epciied envionment and duty eyele conditions. Reliability Apportionment: See Apporionment. fant Production Run: Product made ving ll production tools, processes, equipment, xvironment ity, and eel ine ‘Simulation: The patice of diese syster, tating some o al of the behavior of one systers with ifr, pica Characteristics; Product and process characteristics designated by the eastome,ineing verona eglaory and safety, andor selected by te organization trough knowledge ‘ofthe produet snd proces. Subsystem: A major prt of sytem which tel asthe charctersties ofa system, usally consisting ‘of several component of processes, system: A combination of several components, processes or pees of equipment integrated 0 perform » specie funcion, ‘Team Feasiblty Commitment: A commitment by te organization's product quality planning team that the design canbe manufctre, assembled, etd, packaged, ad shipped in sufcient ‘qanity at an secepable cost, and on schedule. riming Plan; A pan that ists sks eesignments, events, and ming required to provide produc that meets customer needs and expectations Voice ofthe Customer: Customer feedheck bot positive and negative including likes, ilies, probleme and suggestions. ‘Appendix inde APPENDIX G INDEX 0s ‘Appendix @ Index assembly bit variaton 19,98 B benching. - 18 Siler STR TH, hoe sins planing say 3 ce coe anette 9,90, hese at 36 35,27, 38 3, 90,91, 103 ono reslao. S a la 2) 17,20 3,28 26 27,28, 29,52, Sa 3h 35,9638, 4,45, 47,49, 3,68, 53,101 tel pa tod. eee foster npu 3.12 tate eons = 3) 12 38 39,40, 45 ‘tomer 123,9,1119 Cosas Si 31 > ein he coe a elves rn nnn 56,33, 40 ‘esi Fale Mode od iis Analg (DEMEA) 16.17, 18,25 108 clei fv macy ad ese 16,17, 18, 19, 25,92, 103 desig gels. 5.9,12,1817 ‘design formato checks ‘03 Sesign of experiment 19,56,91, ‘esign reponse. 2108 hat rev 1617, 19,21, 25,4, 5,92, 109 eign vex, 46.1719, 25,103 (esp veixton pan reper 1.92 (doving wd pecan changes 16 17, 21,25 sity. eee 130,21, 92, 103 E coining dings. 16, 17,20, 28.28 ipneeing specter new 1 ITIS F faites regen. 16, 18,21,28 Fale Mode snd bcs Aub MEA) 213,18 feasiiy 3h 82,2, 25,108,108 fore 425, 26,28,38, @ ngeteting elpent eutenests.. 16 1, 2,28 Index strc waranty ad quay formation... 10 menage support 9, 1416 16, 228,293, 33, 3 meufcting ony 2 Toke eee sia ronkesng ety n ‘tel evens Parerece ‘teint tes nasil. 28,25, 28, 33 ‘Reset yer ean non 32,33 38 ‘mse rooting 52103 nyse sign is pe. 16 ° cxgze he tea, 3 , rclagieg specification 6 Frclaging santa 8 as Finn elie the ening ha 5 ean contol pl Was Tas ray til of steal 59,1217, 18 Freimnary kt of pein proc an proces 9,17 Frsetrty proces ape Pah 2 romney procs apoity suly 23,35 28,3, 33 3439 peace owe cat 8,9, 13,17, 104 rvs cpg 24,28, 25 3 3, 36,38, 40,53 Proves Fale Me ed tots Aaa (PPMEA) . 25,27, 3, 45,104 woes ow chat 815,38 35,385, 28,38, 368,98, 108 proces insti 24, 25,28,38,36 roduc amurence plan. 895,10, 21, 1 ruc guy panning oe sai 3,8 Fofot qa png srry 101 Protect gai sino 38 prota quit ng pi 3 roduc ably ses. ria roducproces sumptions 8 [rectrecar bench ae 3.1L Srodctprosts diy check. 26 Fradctfoces qty sytem ew 24,25 26,33 Frotacon pat sppoval 2, 32,35 34, 35,3801 rotation vba ing 32,38 34 35,39 pao. te a7 20,27,87 Appendix G type alco as 2 cpaty to depeynet 10.93 spay png ett aly pang a Sas moe ain Sabi inion s seh 2,31 1,1, 19,20,38,39, 4098 Sut otc ah 2,334 38 Sapa it Smaon inion ‘mula glee aia 92, 13 or Index spel roi ad proce ches. 20,21, 25, news r tm ey cane Me testing quipenest requirements. 18,22,25 tiieg ar men SH 3i aaa ‘ring ‘ y vation 12,6, 19,32, 34,35 39,103 acon. i, 18, 26,38, 39,43, 48,51, 56 5,50 vole fie cone 9110, 12,17,20 ” wenn. 9,10,12,40

You might also like