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Advanced Product Quality Planning (APQP)

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP) APQP, but for what?


Purpose of APQP is to produce a product quality plan which will support development of a product or service that will satisfy the customer. In simple words, APQP is intended to ensure that the supplier / manufacturer meets all of the customer's requirements on time.

How to achieve this purpose?


By : Up-front quality planning Evaluating the output to determine if customer are satisfied & support continual improvement.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP) Product Quality Planning Cycle

By: Pankaj Nalwa

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 planning through product / process validation.

The act of implementation.

The fourth quarter is the stage where importance of evaluating the output serves two functions: to determine customer satisfaction and to support the pursuit of continual improvement.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)

PQP usually doesnt work effectively in organizations.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Plan
Always

Sometimes

Act

PDCA

Do

Always

Check
Sometimes

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)

If quality is to become a business strategy, top management must understand quality as a planning strategy and provide leadership for carrying out this strategy.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)

Advanced product Quality Planning (APQP) is a structured approach to the design and development of new products and manufacturing processes, designed to ensure that: Suppliers understand the requirements of clients, end users and consumers. The proposed product or process design satisfies those requirements. The supplier has the ability to consistently meet the clients requirements for quality, cost and delivery.

By: Pankaj Nalwa

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.

By: Pankaj Nalwa

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 the timing, by the team in-between FPDS milestones. Issues Resolution Status Reporting

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Process Flow for APQP
Prepare for APQP Plan and Define Program Product Design and Development Process Design and Development Product & Process Validation Feedback, Assessment & Corrective Action

Organize the Team Define the Scope Establish Team-toTeam 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

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)

Phase 1: Planning and defining the program


This phase is meant to determine customer needs and expectations. Purpose of this phase is to ensure that the customers needs and expectations are fully understood before proceeding with the design & development of the product or manufacturing process associated with product.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Process Flow for APQP
Prepare for APQP Plan and Define Program Product Design and Development Process Design and Development Product & Process Validation Feedback, Assessment & Corrective Action

Organize the Team Define the Scope Establish Team-toTeam 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

INPUT

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Process Flow for APQP
Prepare for APQP Plan and Define Program
OUTPUT

Product Design and Development

Process Design and Development

Product & Process Validation

Feedback, Assessment & Corrective Action

Organize the Team Define the Scope Establish Team-toTeam 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

INPUT

Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)

Phase 2: Product design and development


In 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 on ensuring that it is feasible and will meet the customers expectations.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Process Flow for APQP
Prepare for APQP Plan and Define Program
OUTPUT

Product Design and Development


INPUT OUTPUT

Process Design and Development

Product & Process Validation

Feedback, Assessment & Corrective Action

INPUT

Organize the Team Define the Scope Establish Team-toTeam 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 and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing 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 (Including Math Data) 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 and Management Support

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)

Phase 3: Process design and development


This phase concentrates on developing a manufacturing system and related control plans to achieve quality products. This phase focuses on creating a process that will ensure the design that was developed in the previous phase at the same quality level, quantity and cost, and at the same time assuring that any other customer requirements and expectations will be met. Activities of this phase make sure that the product represents a value to customer.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Process Flow for APQP
Prepare for APQP Plan and Define Program
OUTPUT

Product Design and Development


OUTPUT INPUT

Process Design and Development


INPUT OUTPUT

Product & Process Validation

Feedback, Assessment & Corrective Action

INPUT

Organize the Team Define the Scope Establish Team-toTeam 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 and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing 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 and 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

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)

Phase 4: Product and process validation


This phase concentrates on validating the manufacturing process through evaluation of production trial run and all the activities related to it. This phase focuses on methods and techniques for determining that the long-term production process is capable of meeting all the requirements that have been researched and documented through the previous phases.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Process Flow for APQP
Prepare for APQP Plan and Define Program
OUTPUT

Product Design and Development


OUTPUT INPUT

Process Design and Development


OUTPUT INPUT INPUT

Product & Process Validation


OUTPUT

Feedback, Assessment & Corrective Action

INPUT

Organize the Team Define the Scope Establish Team-toTeam 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 and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing 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 and 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

By: Pankaj Nalwa

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 is also 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 organizations continuous improvement philosophy will be most visible.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Process Flow for APQP
Prepare for APQP Plan and Define Program
OUTPUT

Product Design and Development


OUTPUT INPUT

Process Design and Development


OUTPUT INPUT INPUT

Product & Process Validation


OUTPUT

Feedback, Assessment & Corrective Action


INPUT OUTPUT

INPUT

Organize the Team Define the Scope Establish Team-toTeam 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 and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing 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 and 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 Customer Satisfaction Delivery and Service

By: Pankaj Nalwa

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. Control plan describes the actions that are required at each phase of the process including receiving, in-process, out-going and periodic requirements to assure that all process outputs 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 in product life cycle, its primary purpose is to document and communicate the initial plan for process control. Subsequently, it guides manufacturing in how to control the process 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 control methods are evaluated and improved.

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)

Cross Functional Team (CFT) is required to develop Control Plan by utilizing all available 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 Teams knowledge of process Design review Optimization methods

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Define Process

Select Measures

Collect & Interpret Data

Is Process Stable? Yes No

No

Investigate & Fix Special Causes

Improve Process Capability

Is Process Capable? Yes Develop Control Plan

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Monitor variables for out of control conditions

Develop alarm recording strategy

and

Finalize process sampling plan

Document control plan for each key variable

Identify Opportunities for Mistake Proofing

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Measurement System
Measurement System Analysis

Preliminary Analysis
Process Maps FMEA Customer requirements

Calibration Requirements

Short Term Capability

Sampling & Testing Plans

Control Plan
SPC Plans Long Term Capability DOE's Operating Windows Maintenance Schedules Reaction plans Trouble shooting Aids Training Materials SOP's

Improvement Activities

Procedures

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


PHASE I (Planning & Defining the program)
Wk 1 Wk 2 Wk 3 Wk 4 Wk 5 Wk 6

Voice of customer Historical data (Internal & External) Bench mark data (Product & Process) Assumptions (Product & Process) Customer design inputs Design goals Reliability & quality goals Preliminary bill of material Preliminary process flow diagram Preliminary list of special characteristics Management review & support

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


PHASE II (Product design & development)
Wk Wk Wk Wk Wk Wk

Block diagram Design FMEA Engineering drawing (for Prototype) Engineering specifications (for Prototype) Material specifications (for Prototype) Final bill of material Design verification Design review Changes in drawing & specifications Make or buy decision Supplier selection & allocation

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


PHASE II (Product design & development)
Wk Wk Wk Wk Wk Wk

Preparation of inspection standards for BOP Procurement of BOP Prototype control plan Identification of new equipment, tooling, gauges, test facilities Acquisition of new equipment, tooling, gauges & test facilities Prototype samples Prototype approval from customer Changes in drawing & specifications Team feasibility & commitment Final drawing & specifications Management review & support

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


PHASE III (Process design & development)
Wk Wk Wk Wk Wk Wk

Final process flow diagram Floor plan layout Final special characteristics (Product & Process) Process FMEA Prelaunch control plan Process control standards / Work instructions M.S.A. plan Preliminary process capability study plan Packaging standards & specifications Quality system review (Product & Process) Management review & support

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


PHASE IV (Product & process validation)
Wk Wk Wk Wk Wk Wk

Material for trial production (Pilot lot) Trial production run (Pilot lot) Measurement system analysis Process capability study Process validation testing Packaging evaluation PPAP documents compilation & submission Customer approval Release : Production control plan Quality planning & summary sign off Initial supply control initiation Management review & support Regular production

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


PHASE V (Feedback assessment & corrective action)
Wk Wk Wk Wk Wk Wk

Reduction of variation Continual improvement Delivery of regular product

By: Pankaj Nalwa

Advanced Product Quality Planning (APQP)


Notes:

By: Pankaj Nalwa

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