APQP

P2

2006
Ershadi


Very Late (20% OR MORE)
Late (LESS THAN 20%)
On time

New design
Design of product
Design of Process
Feedbacks during
Prototype Build
Try out
Changes
concepts
and specifications
and technology
mass production

Resp.

Ershadi

APQP

Rahmani

Zanjani

Fakharian

Timing Plan

Business
Plan

VOCT

Market
Research

%10

%75

Bench mark

Pars Tire

Iranian Comp

12

60000 gr

59000 gr

1250000

1200000

2.1 % over STD

1.7 % Over STD

Macro
Targets

ISIRI
/

ISIRI
( )
10


Very Late (20% OR MORE)
Late (LESS THAN 20%)
On time

11

Design of product
Design of Process
Feedbacks during
Prototype Build
Try out
Changes
and specifications
and technology
mass production

12

Product
Over View

13

HOQ

14

15

Final Product
Special Char.

FBD

16

DFMEA

17

DFMEA

18

DFMEA

19

Design
Calculation

14

12

1.2
0.8
0.6

20

Design
Alternatives

21

Prototype
CP

22


Very Late (20% OR MORE)
Late (LESS THAN 20%)
On time

23

Design of Process
Feedbacks during
Prototype Build
Try out
Changes
and technology
mass production

24

Product Design
Verification

25

Product Design
Verification

26

Production
of samples

27

0.8

1.1 +/- .1

(
)

Lab
Results

28

100

1000

10000

20000

40000

100

1000

10000

20000

12

40000

Lab
Results

2100

29

12 Layers

8 Layers

2900

2500

2860

2700

2870

2650

2920

2570

2790

2710

2800

2660

2730

2580

Statistical
Analysis

( )

30


Very Late (20% OR MORE)
Late (LESS THAN 20%)
On time

2007-01

31

Design of Process
Feedbacks during
Try out
Changes
and technology
mass production

32

Design of Process
Feedbacks during
Try out
Changes
and technology
mass production

10000

( )
10

1.6 :

33

Flow Process
Chart

34

ProductProcess Matrix

35

Process
FMEA

36

Process
FMEA

37

Process
FMEA
Potential Failure Mode And Effect Analysis
(PFMEA)
Process
Product

Tire Building

Tires made in 2007

Core team

Page

FMEA Date (Rev)

2006/06

Of

(2006/12)2

Mr. Mohammadi Kar

RPN

Beta ray
Thickness
control

160

Rec.
Action

Responsible
and target
date

Action Results
Action Taken

O D

RPN

Current
Process Control

Detection

Potential
Cause

Mr. Ershadi

Occurrence

Potential
Effects

Class

Potential
Failure Mode

Severity

Requirements

Key Date

Tires with 8 Layers Carcass

Model Year / Vehicle

Process

Process Head

Calende
ring
Lower
Thickness

Appropriate
Thickness

Separation of
layers

10

Less Rubber

Identification of
appropriate curing
curve for 8 layers
design by
Thermocouple test

38

Pre
launch CP

39


Very Late (20% OR MORE)
Late (LESS THAN 20%)
On time

2007-01

40

Feedbacks during
Try out
Changes
mass production

41

One day
production run

42

Cpk of Ply
thickness

Layer Thickness
1.00
1.02
1.00
1.02
1.04
1.02
1.02
1.00
1.02
1.04
1.04
1.02
1.00
1.04
1.00
1.02
1.00
1.04

43

Verification of
process

= 8

Not yet
calculated

44

1.6

CPK

Target missed
but still > 1.33

1.44

1.6 CPK

Target met

12%

10%

Target met

11000

10000

 APQP

45