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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.
Sometimes
Act
PDCA
Do
Always
Check
Sometimes
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.
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.
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
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
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
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
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
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
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
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
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
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
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
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.
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
Select Measures
No
and
Preliminary Analysis
Process Maps FMEA Customer requirements
Calibration Requirements
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
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
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
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
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
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