ADVANCE PRODUCT QUALITY PLANNING

by : Wahyu Epifanto

APQP| WHAT IS IT?

A structured methodology for the design and development of new and modified products from concept through to production It provides a set of detailed requirements to be undertaken at each stage in the APQP system It involves the utilization of various techniques to be employed to identify and resolve problems before going into full production

APQP| WHAT IS IT?

The goal is to facilitate communication with everyone involved to assure that all required steps are completed on time. Effective planning depends on a companys top management commitment to achieving customer satisfaction.

APQP Timing Chart

Concept Initiation/Approval Program Approval Prototype Pilot Launch

Planning Product Design & Dev. Process Design & Development Product & Process Validation

Planning

Production Feedback Assessment and Corrective Action Product Design & Development Verification Process Design & Development Verification Product & Process Validation Feedback Assessment & Corrective action

Plan & Define Program

APQP
PHASE 1 1 PHASE PHASE 2
Planning Product Design & Dev.

PLANNING
Concept Initiation/Approval Program Approval Prototype Pilot Launch

Planning

PHASE 3 PHASE 4

Process Design & Development Product & Process Validation Production Feedback Assessment and Corrective Action

PHASE 5

Plan & Define Program

Product Design & Development Verification

Process Design & Developmen t Verification

Product & Process Validation

Feedback Assessment & Corrective action

PHASE 1 |PLANNING
Phase 1 Inputs
Voice of the costumer
Market Research Historical Warranty and Quality Information Team Experience PLANNING Design Goals Reliability & Quality Goals

Phase 1 Outputs

Preliminary Process Flow Chart

Preliminary Listing of special Product & Process Characteristics Product Assurance Plan Management Support

Business Plan/MKT Strategy Product/process Assumptions Product Reliability Studies Cuctomer Inputs

APQP
PHASE 1 PHASE 2 PHASE 3 PHASE 4 PHASE 5 APQP Phase 2: Product Design & Dev.
Concept Initiation/Approval Program Approval Prototype Pilot Launch

Planning Product Design & Dev. Process Design & Development Product & Process Validation

Planning

Production Feedback Assessment and Corrective Action Plan & Define Program Product Design & Development Verification Process Design & Developmen t Verification Product & Process Validation Feedback Assessment & Corrective action

PHASE 2 |PRODUCT DESIGN & DEVELOPMENT

Phase 2 Inputs
Design Goals
Reliability & Quality Goals Preliminary Bill of Material Preliminary Listing of Special Product & Process Characteristic Product Assurance Plan

Phase 2 Outputs
Design FMEA

Design for Manufactturability and assembly

Design Verification

PRODUCT & DESIGN DEVELOPMENT

Design Reviews
Prototype CP Engineering Drawings Engineering Spesifications Material Spesifications Drawing & Spec. Changes

Management Support

PHASE 2 |PROCESS DESIGN & DEVELOPMENT

Phase 2 Inputs
Design Goals
Reliability & Quality Goals Preliminary Bill of Material Preliminary Listing of Special Product & Process Characteristic Product Assurance Plan New equipment, Tooling and Facilities Requirement

Phase 2 Outputs

PROCESS DESIGN & DEVELOPMENT

Special Product and Process Characterictics Gages/Testing Equipment Requirements Team Feasibility Commitment and Management Support

Management Support

APQP
APQP Phase 3: Process Design & Validation PHASE 1 PHASE 2 PHASE PHASE 33 PHASE 4 PHASE 5
Concept Initiation/Approval Program Approval Prototype Pilot Launch

Planning Product Design & Dev. Process Design & Development Product & Process Validation

Planning

Production Feedback Assessment and Corrective Action Product Design & Development Verification Process Design & Developmen t Verification Product & Process Validation Feedback Assessment & Corrective action

Plan & Define Program

PHASE 3 |PROCESS DESIGN & DEVELOPMENT

Phase 3 Inputs
Phase 2 Design Outputs

Phase 3 Outputs
Packaging Standards & Specs.
Prod/Proc. Quality System Review Process Flow Chart Floor Plan Layout

Process Design & Development

Characteristics Matrix
PFMEA Pre-launch CP Process Instructions

MSA Plan

Phase 2 APQP Outputs

Preliminary Process Capability Study Plan Management Support (including operator staffing & training plan)

APQP
APQP Phase 4: Product & Process Validation PHASE 1 PHASE 2 PHASE 3 PHASE PHASE 44
Feedback Assessment and Corrective Action Product Design & Development Verification Concept Initiation/Approval Program Approval Prototype Pilot Launch

Planning Product Design & Dev. Process Design & Development

Planning

Product & Process Validation

Production

PHASE 5

Plan & Define Program

Process Design & Developmen t Verification

Product & Process Validation

Feedback Assessment & Corrective action

PHASE 4 |Product & Process Validation

Phase 4 Inputs
Packaging Standards & Specs.

Phase 4 Outputs
Significant production Run Measurement Systems Evaluations

Prod/Proc. Quality System Review

Process Flow Chart Floor Plan Layout Characterictics Matrix PFMeA Pre Launch CP Process Instructions MSA Plan Preliminary process Capability Study Plan Management support (including operator staffing & training plan)

Product and Process Validation

Preliminary Process Capability Study PPAP Production Validation Testing Packaging Evaluation Production CP Quality Planning Sign off and management Support

APQP
PHASE 1 PHASE 2 PHASE 3 PHASE 4 PHASE PHASE 55
Plan & Define Program

Feedback Assessment & Corrective Action

Concept Initiation/Approval Program Approval Prototype Pilot Launch

Planning
Product Design & Dev. Process Design & Development

Planning

Product & Process Validation Production Feedback Assessment and Corrective Action Product Design & Development Verification Process Design & Developme nt Verification Product & Process Validation Feedback Assessmen t& Corrective action

PHASE 5|Feedback Assessment & Corrective Action

Phase 5 Inputs
Significant Production Run
Measurement Systems Evaluation Preliminary Process Capability Study PPAP Production Validation Testing Feedback Assessment & Corrective Action Reduced Variation Improved Customer Satisfication Improved Delivery and Service Effective Use of Lessons Learned/Best Practices

Phase 5 Outputs

Packaging Evaluation
Production CP Quality Planning Sign-off and ManagementnSuport

QUALITY MANAGEMENT SYSTEM

Continual improvement of the quality management system

5
Management Responsibility

Customers 6
Resource management

Customers 8
Measurement, analysis and improvement Satisfaction

Requirements

Input

7
Product Realisation

Product

Output