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Apqp & Ppap PDF
Apqp & Ppap PDF
ADVANCED
PRODUCT QUALITY PLANNING
&
PRODUCTION PART APPROVAL PROCESS
Presented by: ANURAG SRIVASTAVA
Objective of Session
To provide
To explain
Basic To facilitate
APQP & PPAP
understanding Value added
methodology
of APQP & APQP & PPAP
in detail
PPAP process
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New Product Development
Customer
Core focused
Engineering QUALITY
ENGINEERING
Two
Aspects
To To ensure
understand that all the
the customer requirements
requirements are met
Systematic
approach
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What is Advanced Product Quality Planning
Provides specialized
tools to offer the
opportunity to get
ahead of problems
and solve them
before the problems
affect the customer
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Benefits…
“..Designed to be a ‘before-the-event’
action, not an ‘after-the-fact’ exercise”
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Phase-1: Define the Scope
A process Cross
owner for Functional
APQP Team
•Representatives from
Organize •Engineering,
the •Manufacturing,
•Quality,
Team •Materials,
•Sales,
•Service,
•Suppliers and
•Customers, as
appropriate
Preparatory Step
Define Scope:
Team must meet to decide
- Project Team Leader
- to over see the planning process
- Rotating team members
permissible
- Their Roles and Responsibilities,
- Customers (Internal / External),
- Customer Requirements,
- Additional Members, when required
- Feasibility Assessment ,
- Cost , Timings, Constraints etc.
- Customer Assistance, when required
- Documentation process or method
- Review Frequency
- Periodic
- Gate
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Fundamentals of Product Quality Planning
(New Addition)
Consider
Critical Path Customer
Method (CPM) may Requirements
be appropriate. while deciding
Timings
Chart to have
Shall list tasks, “Start” and
Assignments “Completion”
and/or other dates with
events
Timing actual point of
progress
Plan
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Actual
Planned Planned Ready Status Actual
# Activity Supplier Resp. Completion- Follow-up / Comments / References
Start-Date Due Date Start-Date
(YYYY-MM-DD) (YYYY-MM-DD) (YYYY-MM-DD)
Date
20% 40% 60% 80% 100% Status (YYYY-MM-DD)
1 Project Team
8 Special characteristics
15 Process flowchart
16 Process FMEA
17 Control Plan
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Five Phases of APQP 3
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Concept
Initiation / ApprovalProgramme Prototype Pilot Launch
Approval
PLANNING
PLANNING
PRODUCTION
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Product Quality Planning Responsibility Matrix
(New Addition) Design Manufacturing Service Org.
Responsible Only i.e. H/T,
W. House,
X – Means “Required” Transport etc
Define the Scope X X X
Phase I
Plan & Define Program X Not Reqd. Not Reqd.
Product Design &
Development X Not Reqd. Not Reqd.
Phase II
Feasibility Section X X X
Process Design &
Phase III Development X X X
Product & Process
Phase IV
Validation X X X
Feedback, Assessment &
Phase V Corrective Action X X X
Control Plan Methodology
X X X
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Objective
• To understand customer requirements (Needs &
Expectations)
• To establish design intent
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Phase I : Plan and Define
Inputs of Phase I Outputs of Phase I
Plan & Define Inputs of Phase II & V
Program
Phase I
•Design Goals
•Customer Requirements
•Voice of Customer •Reliability & Quality Goals
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Plan and Define - Inputs
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MARKET RESEARCH
Team obtains data and information reflecting the voice of customer to
identify concerns, wants for translating into product process
characteristics. Can be in the form of
• Customer interviews
• Customer questionnaire and surveys
• Market test and positioning reports
• New product quality and reliability studies
• Competitive product quality studies
• Things Gone Right (TGR) reports
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Plan and Define – Inputs (Cont’d.)
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TEAM EXPERIENCE
The team may use other source of information such as:
• Input from higher system level or past Quality Function Deployment (QFD) projects
• Media commentary and analysis: magazine and newspaper reports, etc.
• Customer letters and suggestions
• TGR / TGW reports
• Dealer comments
• Fleet Operator’s comments
• Field service reports
• Internal evaluations using surrogate customers
• Road trips
• Management comments or direction
• Problems and issues reported from internal customers
• Government requirements and regulations
• Contract review
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Plan and Define – Inputs (Cont’d.)
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Plan and Define – Inputs
CUSTOMER INPUTS
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DESIGN GOALS
A translation of the voice of customer into tentative and measurable
design objectives. Assures that voice of customer is not lost
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Design Goals Example
Stop Fast
Long Life
Low Vibration
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Plan and Define – Output (Cont’d.)
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Management Commitment & Support
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Phase II
Product Design and Development :
Objective
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Design Verification
• Verifies that product design meets the customer requirements
Design Review
• Regularly scheduled meeting led by design engineering activities
and must include other affected area
• An effective method to prevent problems, misunderstandings and
provide mechanism to monitor progress
• Design reviews are a series of verification activities that are more
than an engineering inspection
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Product Design and Development - Outputs
Engineering Drawings
• Customer design do not preclude the responsibility to review the
following in the engineering drawings
Special characteristics (Governmental, Regulatory and Safety)that must
be shown on the control plan
In case customer drawings do not exist, review which characteristic affect
fit function durability and/or governmental, regulatory and safety
requirements
Drawing should be reviewed to determine
adequacy of informations for dimensional layout of the individual part
control / datum services / locators clearly identified
dimensional evaluation to assure feasibility and compatibility with
manufacturing and measuring standards
In case of math data, it has two way communication compatibility
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Engineering Specifications
• Specification review helps to identify functional durability and
appearance requirements
• Sample size frequency and acceptance criteria generally
identified in the specifications otherwise establish in the control
plan
• Determine which characteristics affect or control the results that
fulfill functional durability and appearance requirements
Material Specifications
• Material specifications should be reviewed for special
characteristics relating to physical properties, performance,
environmental, handling and storage requirements
• These characteristics should be included in control plan
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Product Design and Development - Outputs
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Phase III
Process Design and Development : Objective
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Process Design and Development:
Inputs of Phase III Outputs of Phase III
Process Design & Inputs of Phase IV & V
Development Phase III
Outputs of
•DFMEA PhaseII Packaging Standards (Customer
•Design for Manufacturing & Assembly Defined)
•Design Verification Process Flow Chart
•Design Reviews
•Prototype Build-Control Plan
Floor Plan Layout
•Engineering Drawing Characteristics Matrix (Optional)
•Engineering Specification PFMEA
•Materials Specification
Pre-launch Control Plan
•Drawings & Specification Changes
•New Equipment, Tooling & Facilities Work Instructions / Work Standards
Requirement Measurement System Analysis Plan
•Special Product & Process Characteristic Capability Study Plan
•Gage / Testing Equipment Requirements
•Team Feasibility Commitment Packaging/Transportation Specifica-
& Management Support tions etc..
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Packaging Standard
• Incorporate customer packaging standard into packaging
specifications for the product. If not provided packaging design
should ensure product integrity at point of use
Product / Process Quality System Review
• Team should review the quality system. Additional controls /
procedural changes should be updated. Also an opportunity to
improve the existing quality system based on customer input,
team expertise, previous experience
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Process Design and Development -
Outputs
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Process Design and Development -
Outputs
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Process Design and Development -
Outputs
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Process Design and Development -
Outputs
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Process Design and Development -
Outputs
Packaging Specifications
• Ensure that individual product packaging (including interior
partitions) is designed and developed. Customer
packaging standards or generic packaging requirements
should be used when appropriate. In all cases the
packaging design must assure that the product
performance and characteristics will remain unchanged
during packing, transit and unpacking. The packaging
should have compatibility with all material handling
equipment including robots
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Phase IV
Product and Process Validation
Objective
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Product and Process Validation: Phase IV
Inputs of Phase IV Outputs of Phase IV
Product & Process
Inputs of Phase V
Validation Phase IV
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Product and Process Validation –
Phase IV
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Product and Process Validation –
Phase IV
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Product and Process Validation
What is APQP Sign-off
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Feedback, Assessment & Corrective Action : Phase V
Objective:
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Applicability
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Applicability
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Section 1 - General
1.1 Submission of PPAP
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Note : Items from 2.2.1 to 2.2.18 may not necessarily apply to every
customer part number from every organization e.g. Appearance
& color requirements; plastic parts may have Polymeric part
marking requirements
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Section 2 - PPAP Requirements
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Indicate Date of design record; change level and any authorized Engineering change
document, drawing date on auxiliary documents
Tracing to be included when optical comparator is necessary for inspection
Identify one of the parts measured as the master sample and retain the same
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When an external / commercial Lab. is used, test results to be on Lab. letter head or
normal Lab Report Format containing name of Lab which performed the tests, date of
testing and the standards used to run the test
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Section 2 - PPAP Requirements
2.2.13 Appearance Approval Report (AAR)
Prepare separate Appearance Approval Report for each part or series of part for
appearance item
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Section 2 - PPAP Requirements
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Note: Organizations are responsible for notifying the authorized customer representative of
any changes to part design and/or the manufacturing process
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Section 3 - Customer Notification &
Submission Requirements
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Section 3 - Customer Notification &
Submission Requirements
Submission Requirement Clarifications
1. A new part or product (i.e. Submission is required for a new product (initial release) or a
a specific part, material, or previously approved product that has a new or revised
color not previously product / part number (e.g., suffix) assigned to it. A new part /
supplied to the customer) product or material added to a family may use appropriate
PPAP documentation from a previously approved part within
the same product family.
2. Correction of a Submission is required to correct any discrepancies on a
discrepancy on a previously submitted part.
previously submitted part. A “discrepancy” can be related to:
The product performance against the customer
requirements
Dimensional or capability issues
Supplier issues
Approval of a part replacing an interim approval
Testing, including material, performance, or engineering
validation issues
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Section 3 - Customer Notification &
Submission Requirements
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Section – 5 Parts Submission
Status
5.1 General
Upon approval of Submission, assure that all customer requirements are met in future,
i.e. after Product Approval Process
NOTE 1: Supplier approval considered as Customer Approval for Self Certified items /
supplier combination unless specifically advised
5.2 Customer PPAP Status
5.2.1 Approved
Indicates all customer requirements and specifications are met
Supplier has authority of shipping as per schedule / order
5.2.2 Interim Approval
Authorize shipment for production requirements on a limited time or piece quantity basis
only granted when
• Root cause of non-conformity preventing approval clearly identified and
• Approval from customer obtained on interim approval with action plans
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