1、12/7/2022APQP 2nd Edition and PPAP 4th Edition 1APQP 2nd Edition and PPAP 4th Edition WORKSHOPPlexus International(Rich Roberts)12/7/2022APQP 2nd Edition and PPAP 4th Edition 2ENVIRONMENT(On site)Mobile PhonesToilets Coffee Breaks Lunch12/7/2022APQP 2nd Edition and PPAP 4th Edition 3First:In your te
2、am,brainstorm some reasons why planning is necessary.Place on flip chart and be prepared to discuss.Second:If planning is so necessary,what gets in the way of planning?Team Exercise:5 min12/7/2022APQP 2nd Edition and PPAP 4th Edition 4First:In your team,brainstorm some reasons why planning is necess
3、ary.Place on flip chart and be prepared to discuss.Identify ways to improveMeans of tracking and checkingContingency planningWorst case planningWithout a planSecond:If planning is so necessary,what gets in the way of planning?Lack of disciplineTime management issuesUnclear prioritiesUnclear responsi
4、bilitiesLack of accountabilityExercise:5 min12/7/2022APQP 2nd Edition and PPAP 4th Edition 5What is Quality Planning?Write a couple bullet points of what quality planning is in your participants manuals.Individual Exercise:2 min12/7/2022APQP 2nd Edition and PPAP 4th Edition 6What is Quality Planning
5、?Quality Planning=A structured and systematic process of defining,establishing and specifying goals and objectives to deliver products and services that meet customer expectations and needs while ensuring the planned-for quality levels.The process enables identification of improvement opportunities
6、throughout the design,development,pre-production and production stages.12/7/2022APQP 2nd Edition and PPAP 4th Edition PM Page 37Quality Planning CycleUpfront planning:The first(3)quarters of the cycle are devoted to up-front product quality planning through product/process validation.The act of impl
7、ementation:The 4th quarter is the stage where the importance of evaluating the output serves(2)functions;to determine if customers are satisfied and to support the pursuit of continual improvement.The quality planning cycle is a never-ending cycle in the pursuit of continuous improvement.This can on
8、ly be achieved by taking the experience in one program and applying that acquired knowledge to the next program.12/7/20228312345PDCA Cycle(Also known as the Deming Management Cycle)APQP 2nd Edition and PPAP 4th Edition PM Page 412/7/20229What is Advanced Quality Planning(APQP)?Quality planning and m
9、oreTotal integration of quality tools with management functionsMulti-disciplinary team approach to quality planningTool to enable suppliers to not only meet but exceed customer requirementsWhat is a multi-disciplinary team?Who should be on the team?ActivityA team made up of a variety of functions wi
10、thin the organization,that have a role within the planning processAPQP 2nd Edition and PPAP 4th Edition PM Page 512/7/202210What is Advanced Quality Planning(APQP)?Quality planning and moreTotal integration of quality tools with management functionsMulti-disciplinary team approach to quality plannin
11、gTool to enable suppliers to not only meet but exceed customer requirementsWhat is a multi-disciplinary team?EngineersWho should be on the team?A team made up of a variety of functions within the organization,that have a role within the planning processQuality team member(s)Production team membersMa
12、nagement team membersPurchasing groupMaintenance and Tooling representativesAPQP 2nd Edition and PPAP 4th Edition PM Page 512/7/2022APQP 2nd Edition and PPAP 4th Edition 11InputsOutputsInputsOutputs12/7/202212*DesignResponsible*ManufacturingOnlyService Supplier(i.e.Heat Treat,Warehousing,Transportat
13、ion)Define the ScopeXXXPlan and defineSection 1.0XProduct Design and DevelopmentSection 2.0XFeasibilitySection 2.13XXXProcess Design and DevelopmentSection 3.0XXXProduct and Process ValidationSection 4.0XXXFeedback,Assessment and Corrective ActionSection 5.0XXXControl Plan MethodologySection 6.0XXXP
14、roduct Quality PlanningResponsibility Matrix7.2.2.27.37.3APQP 2nd Edition and PPAP 4th Edition PM Page 6The quality matrix for(3)types of suppliers.This matrix does not depict all the different types of product quality planning relationships that exist among suppliers,subcontractors and customer.Man
15、ufacturing and Service Suppliers can take exclusion to ISO/TS clause 7.3 part design,not process design.Processes are designed by the organization.Fundamentals of Product Quality PlanningnProduct Quality Planning is a structured method of defining and establishing the steps necessary to assure that
16、a product satisfies thencustomer.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 companys top management commitment to the effort required in achieving c
17、ustomer satisfaction.Some of the benefits of product quality planning are:n 12/7/202213To direct resources to satisfy the customerTo promote early identification of required changesTo avoid late changesTo provide a quality product on time at the lowest costThe work practices,tools,and analytical tec
18、hniques described in the manual are listed in logical sequence to make it easy to follow.Each Product Quality plan is unique.The actual timing and sequence of execution is dependent on customer needs and expectations and/or other practical matters.The earlier a work practice,tool and/or analytical t
19、echnique can be implemented in the APQP cycle,the better.APQP 2nd Edition and PPAP 4th Edition PM Page 812/7/2022APQP 2nd Edition and PPAP 4th Edition 14Product Quality Timing Plan The organizations product quality planning teams first order of business following organizational activities should be
20、the development of a Timing Plan.12/7/2022APQP 2nd Edition and PPAP 4th Edition 15Fundamentals of Product Quality Planning nOrganize the Team(Multidisplinary Team:TS 7.3.1.1)nDefine the Scope(pg 3 APQP AIAG manual)nTeam-to-Team(Customer teams/Supplier Teams)nTraining(What is needed,who needs trainin
21、g)nCustomer and Organization Involvement nSimultaneous Engineering nControl Plans(pg.31)nConcern Resolution(8D/5 Why/East/West /A3)nSteps of the Planning processn1.Organize the Teamn The organizations first step is to assign a process owner.In n addition,a cross functional team should be established
22、 to assuren effective product quality planning.The team should include n representatives from multiple functions such as engineering,n manufacturing,material control,purchasing,quality human n resources,sales,field service,suppliers and customers,as n appropriate.nDefine the Scopen It is important f
23、or the organizations product quality planning n team in the earliest stages of the product program to identify n customer needs,expectations,and requirements.n 12/7/202216Fundamentals of Product Quality Planning APQP 2nd Edition and PPAP 4th Edition PM Page 9nSteps of the Planning process (continued
24、)n2.Define the Scopen It is important for the organizations product quality planning n team in the earliest stages of the product program to identify n customer needs,expectations,and requirements.At a minimum,n the team must meet to:nSelect a project leadernDefine roles and responsibilitiesnIdentif
25、y the customers,internal and externalnDefine customer requirements(Use QFD if applicable)nSelect the disciplines,individuals,and/or suppliers that must be added to the team,and those not requirednUnderstand customer expectationsnAccess the feasibility of the proposed design,performance requirements
26、and manufacturing processesnIdentify costs,timing,and constraints that must be considerednDetermine assistance required from the customernIdentify documentation process or methodn n 12/7/202217Fundamentals of Product Quality Planning APQP 2nd Edition and PPAP 4th Edition PM Page 9nSteps of the Plann
27、ing process (continued)nTeam to Teamn The organizations product quality planning team must establishn lines of communication with other customers and organization n teams.The extent of team to team contact is dependent uponn the number of issues requiring resolution.nTraining:n The success of a Prod
28、uct Quality Plan is dependent upon an n effective training program that communicates all the n requirements and development skills to fulfill customer needs n and expectations.n 12/7/202218Fundamentals of Product Quality Planning APQP 2nd Edition and PPAP 4th Edition PM Page 10nSteps of the Planning
29、 process (continued)n5.Customer and Organization Involvement n The primary customer may initiate the quality planning process with an organization.n However,the organization has an obligation to establish a cross functional team ton manage the product quality planning process.Organizations must expe
30、ct the same n performance from their suppliers.n6.Simultaneous Engineering:n Simultaneous engineering is a process where cross functional teams strive for a n common goal.It replaces sequential series of phases where results are transmitted n to the next area for execution.The purpose is to expedite
31、 the introduction of n quality products sooner.The organizations product quality planning team assuresn that other areas/teams plan and execute activities that support the common n goal or goals.n 12/7/202219Fundamentals of Product Quality Planning APQP 2nd Edition and PPAP 4th Edition PM Page 9 and
32、 Page 11nSteps of the Planning process (continued)n7.Control plans:n Control plans are written descriptions of the systems for controlling parts and n processes.Separate control plans cover(3)distinct phases.nPrototype A description of dimensional measurements and material and n performance tests th
33、at will occur during Prototype build.n Pre-launch-A description of dimensional measurements and material and n performance tests that will occur after Prototype build and before full n Productionn Production A comprehensive documentation of product/process n characteristics,process controls,tests,an
34、d measurement systems thatn will occur during mass production.n8.Concern Resolution:n During the planning process,the team will encounter product design and/or n processing concerns.These concerns should be documented on a matrix with n assigned responsibility and timing.Disciplined problem-solving
35、methods aren recommended in difficult situations.Analytical techniques described in Appendix Bn should be used as appropriate.n .n 12/7/202220Fundamentals of Product Quality Planning APQP 2nd Edition and PPAP 4th Edition PM Page 11nThe organizations product quality planning teams first order of busi
36、ness following nOrganizational activities should be the development of a Timing Plan.nThe product,complexity and customer expectations should be considered in selecting the timing elements that must be planned and charted.All team members should agree with each event,action and timing.A well-organiz
37、ed timing chart should list task,assignments,and/or other events,utilizing tools like Microsoft Project.nThe chart provides the planning team with a consistent format for tracking progress and setting meeting agendas.To facilitate status reporting,each event must have a“start”and a“completion”date w
38、ith the actual point of progress recorded.Effective status reporting supports program monitoring with a focus on identifying items that require special attention.12/7/202221Product Quality Timing Plan APQP 2nd Edition and PPAP 4th Edition PM Page 1212/7/202222PRODUCT QUALITY PLANNING TIMING CHARTCON
39、CEPTINITIATION/APPROVAL PROGRAM APPROVAL PROTOTYPE PILOT LAUNCHPLANNINGPRODUCTIONProduction INPUTS|Production OUTPUTSPlanning INPUTS|Planning OUTPUTSProduct Design&Dev.INPUTS|Product Design&Dev.OUTPUTSProcess Design&Dev.INPUTS|Process Design&Dev.OUTPUTSProduct&ProcessValidation INPUTS|Product&Proces
40、sValidation OUTPUTSPLANNINGPRODUCT DESIGN AND DEV.PROCESS DESIGN AND DEVELOPMENTPRODUCT&PROCESS VALIDATIONFEEDBACK ASSESSMENT AND CORRECTIVE ACTION5APQP 2nd Edition and PPAP 4th Edition PM Page 13The success of APQP depends on meeting customer needs and expectations in a timely manner at a cost that
41、 represents value to the customer.The planning teams efforts should focus on problem prevention.Problem prevention is driven by“Simultaneous Engineering”.The APQP team is responsible for meeting or exceeding the customers timing plan.12/7/202223Advanced Product Quality PlanningTASKJulAugSepOctNovDec
42、JanFebMarAprMayJunJulAugSepPlan and defineSection 1.0 Product Design&DevelopmentSection 2.0 FeasibilitySection 2.13 Process Design&DevelopmentSection 3.0 Product&Process ValidationSection 4.0 Feedback,Assessment&Corrective ActionSection 5.0 Gantt Chart ExampleAPQP 2nd Edition and PPAP 4th Edition PM
43、 Page 1412/7/202224 ProductionPl anni ngC Cononc cepteptI I ni tini ti a ati on/ti on/A Appppr ro ov valalP Pr ro og gr ramamA Appppr ro ov valalP Pr ro ot to ot ty yp pe eP Pi l oti l otL LaunchaunchA Appppr ro ov valalFeedback Assessment and Corrective ActionProduct and Process ValidationProcess D
44、esign and DevelopmentProduct Design and Dev.Planning Plan and DefineAPQP 2nd Edition and PPAP 4th Edition PM Page 14 and Page 16Outputs:(Become Inputs for Phase 2)Design GoalsReliability and Quality GoalsPreliminary BOMPreliminary Process Flow ChartPreliminary Listing of Special Product and Process
45、CharacteristicsProduct Assurance PlanManagement Support(Including program timing,planning for resources and staffing to support required capacity)Inputs:Voice of the CustomerMarket ResearchHistorical Warranty and Quality InfoTeam ExperienceBusiness Plan/Marketing StrategyProduct Process Benchmark Da
46、taProduct/Process AssumptionsProduct Reliability StudiesCustomer Input12/7/2022APQP 2nd Edition and PPAP 4th Edition 25Phases of a Process Based SystemnIdentify Inputs(what is the need,defined as requirements at the characteristic level?)nCustomer RequirementsnOrganizational RequirementsnGovernmenta
47、l RegulationsnDemonstrate how inputs are transformed into outputsnIdentify Outputs(was the need fulfilled all of the requirements were met?)In a process based system,we have inputs(customer requesting something),with a series of events/actions that led to outputs(customers request fulfilled).A trans
48、formation occurs.12/7/202226 ProductionPl anni ngC Cononc cepteptI I ni tini ti a ati on/ti on/A Appppr ro ov valalP Pr ro og gr ramamA Appppr ro ov valalP Pr ro ot to ot ty yp pe eP Pi l oti l otL LaunchaunchA Appppr ro ov valalFeedback Assessment and Corrective ActionProduct and Process Validation
49、Process Design and DevelopmentProduct Design and Dev.Planning Plan and Define(Review)APQP 2nd Edition and PPAP 4th Edition PM Page 14 and Page 16Outputs:(Become Inputs for Phase 2)Design GoalsReliability and Quality GoalsPreliminary BOMPreliminary Process Flow ChartPreliminary Listing of Special Pro
50、duct and Process CharacteristicsProduct Assurance PlanManagement Support(Including program timing,planning for resources and staffing to support required capacity)Inputs:Voice of the CustomerMarket ResearchHistorical Warranty and Quality InfoTeam ExperienceBusiness Plan/Marketing StrategyProduct Pro
