Professional Documents
Culture Documents
01 Apqp
01 Apqp
01 Apqp
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eselSyst
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Mannur,Tami
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Subcontractor Development
Training Program
*APQP *PPAP *CP *PFMEA*SPC
Mars Consultants
F5, Giri Apartment, #26A, Arcot Road,
Virugambakkam, Chennai – 600092
srini@marsconsultants.com
94440 84652, 94440 04929, 044-42072732
Objective
PROACTIVE APPROACH
Training
Teamwork
Logical methodology
Sound techniques
Documentation
Communication
Feedback
Mars Consultants Advanced Product Quality Planning
Stages of APQP
1. Voice of Customer P
H
2. Business Plan & Marketing Strategy
A
3. Product / Process Benchmark Data
S
4. Product / Process Assumptions E
5. Product Reliability Studies
6. Customer Inputs
I
a. Market Research
Ø Customer Complaints
P
Ø Data / information from internal / external H
customers A
Ø Customer Interviews
S
b. Historical Warranty and Quality Information
E
Ø Things Gone Right / Things gone Wrong (TGR/TGW)
Ø Supplier and internal Quality Reports
Ø Customer Returns and Rejections I
c. Team Experience
Mars Consultants Advanced Product Quality Planning
PLAN & DEFINE PROGRAM - Inputs
P
2. Business Plan / Marketing Strategy
H
A
Ø Framework for Quality Plan
Ø May place Constraints viz. Timing, Cost, Investment
S
Ø Target Customers E
P
4. Product / Process Assumptions
H
Ø Certain features
A
Ø Process Concepts
S
Ø Tolerances
E
1. Design Goals P
2. Reliability & Quality Goals H
3. Preliminary Bill of materials A
4. Preliminary Process Flow Chart S
5. Preliminary Listing of special Product / process E
Characteristics
6. Product Assurance Plan
I
7. Management Support
Mars Consultants Advanced Product Quality Planning
PRODUCT DESIGN AND DEVELOPMENT
P
1. New Equipment, Tooling and Facilities H
requirement
A
2. Gages / Testing Equipment Requirement
S
3. Team Feasibility Commitment
E
4. Management Support
II
II
1. Packaging Standards
2. Product / Process Quality System Review P
3. Process Flow Chart H
4. Floor Plan Layout
5. Characteristics Matrix
A
6. PFMEA S
7. Pre-launch Control Plan
8. Process Instructions
E
9. Measurement System Analysis Plan
10. Preliminary Process Capability Study Plan III
11. Packaging Specifications
12. Management Support
Mars Consultants Advanced Product Quality Planning
PROCESS DESIGN AND DEVELOPMENT
1. Packaging Standards
P
• Follow Customer Specific Packaging standards H
• Ensure Product Integrity at point of use A
S
E
II
III
5. Characteristics Matrix
• Recommended analytical technique for displaying the
P
relationship between the PROCESS PARAMETERS and H
MANUFACTURING STATIONS
A
Operation Nos
Dimension
No
Description Specification
10 20 30 40
S
1 ID X C X E
2 Face X C L
8. Process Instructions P
• Understandable process instruction H
• Sufficient detail for all operating personnel who
have direct responsibility for the process
A
• Shall include parameters such as machine speed, S
feed, cycle time etc E
• Accessible to operators and incharges
III
8. Process Instructions
• Instruction shall be developed from following P
sources H
- PFMEA - Control Plan - Drawings A
- Material Specification, Visual Standards
- Process Floor Chart, Floor Plan Layout S
- Characteristics Matrix E
- Packaging Standards
- Process Parameters
- Expertise and knowledge of operators III
- Handling Requirements
Mars Consultants Advanced Product Quality Planning
PRODUCT & PROCESS VALIDATION
1. Reduced Variation P
2. Customer Satisfaction H
3. Delivery & Service
A
S
E
1. Reduced Variation P
• Control Charts H
• Analysis and Corrective action to reduce A
variation
S
• Reduction or Elimination of common cause
results in cost reduction E
• Value Analysis
V
2. Customer Satisfaction P
• Repeated Business H
• Further Development
A
3. Delivery & Service
S
• On-Time Delivery with right quantity E
?
… Clarifications / Comments