通用APQP项目评审英文版-课件.ppt

1、1Supplier Program Review Meeting#1GM1927-15APQP Kick-off Meeting Advanced Product Quality Planning2Supplier Program Review Meeting#1Purpose:Communicate the process that will be used to provide program updates for APQP Deliverables.Confirm APQP communication Channels between Supplier and GM.Ensure th

2、at GM requirements are understood.Understand current program status to ensure conformance to GM Timing.Provide a formal process to raise open issues for resolution.Form joint focus on future steps.3 Background -APQP -Global APQP Development APQP Project Plan Overview APQP Kick-off Meeting-SQ Require

3、ments-Program Timing-Review Checklists-Identify Open Issues SummaryAgendaAdvanced Product Quality PlanningWorldwide PurchasingNovember 2000General Motors CorporationGM4Background Definition:Advanced Product Quality Planning-APQPStructured method defines and establishes steps necessary to ensure prod

4、uct meets customer requirementsRequired for all new partsResponsibility of the supplierPurpose&Structure:Communicates the requirements necessary to develop a product quality planTop Management support by the supplier is key to the success of the any APQP processRequires an environment of trust and c

5、ooperation between all parties APQP5QS-9000 APQP DirectionEstablishment of an Advanced Product Quality PlanQS-9000 section 4.2.3.1 requires the establishment of an advanced product quality planAIAG APQP Manual is referenced as the document that should be used Detail of specific deliverables was not

6、clearly defined Separate “unique”Regional&Divisional requirements developedBackground 6GM Global APQP GM-1927 is the General Motors Common Global APQP Manual GMs common directionfor the development andimplementation of an APQP planGlobal APQP Development Advanced Product Quality PlanningWorldwide Pu

7、rchasingNovember 2000General Motors CorporationGM7Common Global APQP Process for GM WorldwideGM-1927 replaces all regional and divisional APQP reference manualsGM-1927 harmonized and standardized the multiple regional and divisional APQP manuals Aligns with the 5 phases within the AIAG APQP manual a

8、nd provides the detail required to implement an APQP plan Aligns with GMs 4 Phase Program Timing and DeliverablesGlobal APQP Development 8GM 1927 Documents and FormsOrdering:Ordering information for all documents and manuals listed or referenced throughout this manual(GM 1927)is contained on page II

9、Electronic Copies:This manual and all documents that are part of this manual(this includes any document with a GM 1927 number)can be found through the internet at the GMSupplyPower websiteThe address is ,then follow these steps:Log in Select Quality Power Select Library Select Supplier Quality Selec

10、t APQP Manual&DocumentsGlobal APQP Development 9START OF PRODUCTION RUN RATE(GP-9)PRODUCTION PARTAPPROVAL(PPAP)PROTOTYPE SAMPLEAPPROVAL(GP-11)PRE-PRODUCTION MEETINGADVANCED PRODUCT QUALITY PLANNING (APQP)SOURCING DECISION POTENTIAL SUPPLIERASSESSMENTADVANCE PLANNING&PREVENTIONWWP SUPPLIER QUALITY IM

11、PROVEMENT PROCESSLIFE OF PARTTIME LINE EARLY PRODUCTION CONTAINMENT(GP-12)GLOBAL SOURCING IMPROVEMENT MEETING QUALITY WORKSHOP LEVEL II CONTROLLED SHIPPINGLEVEL I CONTROLLED SHIPPING SUPPLIER QUALITY PROCESSES&MEASURES(GP-5)PERFORMANCE MONITORING CONTINUOUS IMPROVEMENT(GP-8)PROBLEM RESOLUTIONGM Glob

12、al APQPA P Q P P ro ject P lan4 P has eP has e 0P has e 1P has e 2P has e 3G M P re-so u rcin gP la n a n d D e fin eP ro d u ct D e sig n a n d D e ve lo p m e n tA IA GP ro ce ss D e sig n a n d D e ve lo p m e n tP ro d u ct a n d P ro ce ss V a lid a tio nF e e d b a ck,A sse ssm e n t a n d C o

13、 rre ctive A ctio nV D PP re-s ourc ing-96-92-88-84-80-76-72-68-64-60-56-52-48-44-40-36-32-28-24-20-16-12-8-404812162024G e n e ric A lp h aB e taP ro toF E1 F E2 F E3P P A PP ilo tS S FA P Q P T a skP ro g ram R e view sPR-1PR-2 PR-3 PR-4 1 K ey S tak eholders M tgP R-1o-o2 Tec hnic al R eview sP R

14、-1o-o3 R is k A s s es s m entP R-1,2,3T R o-o4 S upplier P rogram R eview soooo5 Tim ing C harts/O pen Is s uesP R-1,2,3,4oooooooooo6 F eas ibility LettersP R-1,2,3,4ooo7 F low C hart P R-1,2,4oo-oo-o8 D F M E AP R-1,2,4ooo9 D es ign R eviewP R-2,3oo10 G age R eviewP R-2,3,4o-o11 G P-11 P R-2,3o-o1

15、2 P F M E A S trategyP R-1,2,3,4oo-ooo-oo13 C ontrol P lanP R-1,2,3,4oo-oo-oo14 G P-12 P R-4o-o15 P P A P P R-4 o-o16 R un R ate(G P-9)P R-1,4oo o-o17 Les s ons LearnedP R-1,2,3,4ooooooPlac omplete/s tac onc ept des ign gage approv al,KCDS f inal Plain itia l-in itia l-in itia l-GD&T prototy pe f in

16、al prototy pe f inal prototy pe Complete(Platf orm in itia l-TRK ick-o ff in itia l-planUpdate Ris kSQ Global APQPCombination of the Best Processes Experience10Manual ContentsPrefaceTable of Contents RASIC Explanation of PMIs (Process Model Integration)PMIs for 17 Tasks/Deliverables Appendices Gloss

17、ary Global APQP The 17 Tasks are the Key for Success!Advanced Product Quality PlanningWorldwide PurchasingNovember 2000General Motors CorporationGM11APQP“At a Glance”Shows the linkage of the 17 deliverables to:GMs 4 phase timing GMs Sourcing Process AIAG APQP 5 phases within the APQP planning proces

18、s The focus of the APQP Project Plan is on timing of each deliverable Levels of completeness for specific deliverables is clearly identified The required completion of items is tied to the specific GM build eventAPQP Project PlanAPQP Project Plan4 PhasePhase 0Phase 1Phase 2Phase 3GM Pre-sourcingPlan

19、 and DefineProduct Design and DevelopmentAIAGProcess Design and DevelopmentProduct and Process ValidationFeedback,Assessment and Corrective ActionVDPPre-sourcing-96-92-88-84-80-76-72-68-64-60-56-52-48-44-40-36-32-28-24-20-16-12-8-404812162024Generic AlphaBetaProtoFE1 FE2 FE3PPAPPilotSSFAPQP TaskProg

20、ram ReviewsPR-1PR-2 PR-3 PR-4 1 Key Stakeholders MtgPR-1o-o2 Technical ReviewsPR-1o-o3 Risk AssessmentPR-1,2,3TR o-o4 Supplier Program Reviewsoooo5 Timing Charts/Open IssuesPR-1,2,3,4oooooooooo6 Feasibility LettersPR-1,2,3,4ooo7 Flow Chart PR-1,2,4oo-oo-o8 DFMEAPR-1,2,4ooo9 Design ReviewPR-2,3oo10 G

21、age ReviewPR-2,3,4o-o11 GP-11 PR-2,3o-o12 PFMEA StrategyPR-1,2,3,4oo-ooo-oo13 Control PlanPR-1,2,3,4oo-oo-oo14 GP-12 PR-4o-o15 PPAP PR-4 o-o16 Run Rate(GP-9)PR-1,4oo o-o17 Lessons LearnedPR-1,2,3,4ooooooPlacomplete/staconcept design gage approval,KCDS final Plainitial-initial-initial-GD&T prototype

22、final prototype final prototype Complete(Platform initial-TRKick-off initial-planUpdate RiskSQ Global APQP12APQP Project PlanAPQP Project PlanGM GVDP GenericAPQP Task Gate ReviewsSourcingActivitiesGR-1GR-2 GR-3 GR-4 1Commodity Sourcing Strategy MtgGR-1o-oo2 Technical ReviewsGR-1o-oo3Risk Assessment/

23、SourcingGR-1,3TRooo4Supplier Gate Reviews5Timing Charts/Open IssuesGR-1,2,3,4ooooooooooooooooooooooooooo6Feasibility/Assessment LettersGR-1,2,3,4oooo7 Flow Chart GR-1,2,4oooooo8 DFMEAGR-1,2,4ooooooo9 Design ReviewsGR-2,3oooo10Gage,Tooling and Equipment ReviewsGR-1,2,3,4ooooo11 GP-11 GR-2,3oooo12 PFM

24、EAGR-1,2,3,4ooooooo13 Control PlanGR-1,2,3,4oooooo14 GP-12 GR-3,4ooo15 PPAP GR-4oo16 Run Rate(GP-9)GR-1,2,3,4ooooooo17 Lessons LearnedGR-1,2,3,4oooooAIAG APQPPilot/Pre-LaunchPrototypeLaunch/Feedback,Assessment and Corrective ActionProductionProduct Design and DevelopmentPlanningProcess Design and De

25、velopmentProduct and Process ValidationGage Concept ApprovalGage Design ApprovalGage Approval/R&R,Tool CompletionKCDS WorkshopProductionPlanInitial-TRInitial-TRInitial-TR Initial-TRGD&T GP-12&ProductionExit(Platform Discretion)Initial-TRInitial-TRPlanUpdate RiskProd Concept-TR Conduct RunRateStructu

26、reVehicleIntegrationVehicleValidation VehicleMVBsSOPMVBnsAlphaBetaGamma/ProtoPre-Pilot/Pilot 1Pilot/Pilot 2FE1FE2FE3SSFCapacity AnalysisLetter 2Letter 3Letter 4Update DFMEARPN Reduction ExecuteExecutePrototype/RPN BaselinePrototypeProduction/RPN ReductionRPN ReductionPrototypeExecuteCapacity Analysi

27、s13APQP Project Plan4 PhasePhase 0Phase 1Phase 2Phase 3GM Pre-sourcingPlan and DefineProduct Design and DevelopmentAIAGProcess Design and DevelopmentProduct and Process ValidationFeedback,Assessment and Corrective ActionVDPPre-sourcing-96-92-88-84-80-76-72-68-64-60-56-52-48-44-40-36-32-28-24-20-16-1

28、2-8-404812162024Generic AlphaBetaProtoFE1 FE2 FE3PPAPPilotSSFAPQP TaskProgram ReviewsPR-1PR-2 PR-3 PR-4 1 Key Stakeholders MtgPR-1o-o2 Technical ReviewsPR-1o-o3 Risk AssessmentPR-1,2,3TR o-o4 Supplier Program Reviewsoooo5 Timing Charts/Open IssuesPR-1,2,3,4oooooooooo6 Feasibility LettersPR-1,2,3,4oo

29、o7 Flow Chart PR-1,2,4oo-oo-o8 DFMEAPR-1,2,4ooo9 Design ReviewPR-2,3oo10 Gage ReviewPR-2,3,4o-o11 GP-11 PR-2,3o-o12 PFMEA StrategyPR-1,2,3,4oo-ooo-oo13 Control PlanPR-1,2,3,4oo-oo-oo14 GP-12 PR-4o-o15 PPAP PR-4 o-o16 Run Rate(GP-9)PR-1,4oo o-o17 Lessons LearnedPR-1,2,3,4ooooooPlacomplete/staconcept

30、design gage approval,KCDS final Plainitial-initial-initial-GD&T prototype final prototype final prototype Complete(Platform initial-TRKick-off initial-planUpdate RiskStartHereTask 4APQP Project PlanSupplier ActivitiesSupplier Program Reviews14Task 4)Supplier Program ReviewsFour Major Program Reviews

31、:Purpose:Ensure Suppliers Quality Plan is Progressing to Meet GM Program Timing Provide a Formal Process to Raise Issues for Resolution Pre-Production Meeting(APQP Kickoff)Beta Prototype Build Review Gamma Prototype Build Review Pilot(Final PPAP Submission)ReviewMeeting Responsibility:Pre-Production

32、 Meeting is Scheduled by SQE Meetings 2,3,4 are Scheduled by SupplierTODAYOverview154)Supplier Program Reviews APQP Major/Open Issues List APQP Timing Chart Updates Progress of Tooling/Fixtures/Gages Supplier Manufacturing Assessment Letters(3 letters)Lessons Learned Design Issues RPN Reduction Plan

33、s AIAG New Equipment Checklist(A-3)AIAG Process Flow Checklist(A-6)AIAG PFMEA Checklist(A-7)AIAG Control Plan Checklist(A-8)GP-12 PlanSQEs will Review Documents at MeetingsMeeting Subjects Include:Suppliers need to be prepared for each meeting with supporting documentsSupplier Program Reviews 2,3,4T

34、ask 6165)Timing Charts/Open IssuesSQE Responsibility:Purpose:Ensure Program Deliverables are Executed on Schedule Review the APQP Timing Chart and APQP Issues List Identify and Communicate Key Timing and Program Issues with GM ManagementSupplier Responsibility:Create and maintain an APQP Timing Char

35、t and Open Issues List Maintain Detail behind Each High Level APQP Chart Review Timing Chart and Issues List at All Program Reviews Identify and Communicate Any Changes to SQE Identify and Communicate Key Timing and Program Issues with SQE176)Manufacturing Assessment LettersManufacturing Assessments

36、:Design-can the Design be Manufactured to Conform to all GM Performance Requirements?Prototype-using the Intended Production Process,will all Parts Conform to GM Requirements?Process Capability-will the Production Process Provide Parts that Conform to GM Requirements?Supplier Responsibility:Evaluate

37、 Feasibility during 3 stages of program development Submit Letters Signed by the Manufacturing Plant ManagerPurpose:Supplier Evaluates Manufacturability of the Part 18ABC Company123 Part LaneAnywhere,Michigan 48000(313)777-7777July 12,1997GM Supplier Quality EngineerGM Release EngineerGeneral Motors

38、 CorporationSUPPLIER MANUFACTURING ASSESSMENT OF DESIGNAs required by General Motors,ABC Company held a manufacturing review of the Model Year design on date.The review has led us to the following position:(Select one)Manufacturing is confident the design is manufacturable to GM requiredquality leve

39、ls,within PPAP design specifications,and within PPAPcapability requirements.Manufacturing is making a commitment toachieve zero defects as specified in the GM Supplier Quality Statement ofRequirements.There are no concerns to report.Manufacturing has minor concerns about the design which have beenre

40、ported to the design community and are described below.We areconfident that the design will be modified to accommodate our issues andbe manufacturable to GM required quality levels,within PPAP designspecifications,and within PPAP capability requirements.Manufacturingis making a commitment to achieve

41、 zero defects as specified in the GM SupplierQuality Statement of Requirements.Manufacturing has major concerns about the design and we are not confident that we canproduce this part at required quality levels.These concerns are described below.Design Is Manufacturable to GM Required Quality LevelsM

42、anufacturing is making a commitment to achieve zerodefects.Minor concerns about the design.Confident that designwill be modified.manufacturableto Required Quality Levelscommitment to achieve zerodefects.Major concerns about design,not confident part can be produced at GM Required Quality Levels6)Man

43、ufacturing Assessment Letters197)Flow ChartSQE Responsibility:Purpose:Provide a Logical Pictorial Representation of the Process Flow that can be used as the Foundation for PFMEAs.Control Plans,Work Station Layouts,etc.Review Process Flow Charts at Sourcing(if available),at Prototype,at Production Pa

44、rt Approval and Regular Production Ensure that the Production Version is linked to the PFMEA and Control Plan Ensure that the Flow Chart Includes Inspection and ReworkSupplier Responsibility:Create Preliminary Process Flow Chart using a Similar Process Create and Maintain the Flow Chart through Prot

45、otype and into Production Ensure the Flow Chart is Linked to the PFMEA and Control Plan Communicate any Changes to the SQE208)Design Failure Mode and Effects AnalysisPurpose:Support the Design Process in Reducing the Risk of FailureSQE Responsibility:Confirm that a DFMEA has been Completed Ensure th

46、at Supplier has a DFMEA for input to PFMEA Lessons Learned Checklist to Design OwnerSupplier Responsibility:GM Design Responsible Suppliers must participate in DFMEA Reviews with Product Engineer Share Knowledge and Experience on Similar Designs Recommend Action Plans for Severity,Occurrence,Detecti

47、on Targets Supplier Design Responsible Lead Cross-functional Team to Develop and Improve FMEA Schedule Review Meetings with GM Product Engineer Develop Action Plans for Severity,Occurrence,Detection Targets Maintain DFMEA for PPAP Submission219)Design ReviewsPurpose:Ensure that the Design has been a

48、dequately Defined to Build Tools and GaugesSQE Responsibility:Participate in KCDS Workshop and GD&T Reviews Participate in Design Reviews addressing changes in Manufacturing Process/Quality/Timing/RiskSupplier Responsibility:Participate in KCDS Workshop and GD&T&Design Reviews Participate in Definin

49、g Measurable KPCs Participate in Defining Appearance Specifications Satisfy all Performance and Material Testing Requirements Ensure that the Manufacturing Process can achieve Tolerances on a Continuing BasisQuality of the Design Directly Impacts Process Design and Process Quality2210)Gage,Tooling&E

50、quipment ReviewsPurpose:Ensure that the Manufacturing process is being designed,built and certified to produce parts with quality at rate according to GM program requirementsSQE Responsibility:Confirm that Gage,Tooling and Equipment Timing is on Schedule to Support Program Requirements Confirm that