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Process Training - Supplier
APQP – Advanced Product Quality Planning– Supplier Quality
Revised: January 5, 2015
Revision Number: 1Polaris CONFIDENTIAL
2
Welcome
Welcome!Polaris CONFIDENTIAL
Welcome to the Advanced Product Quality Planning (APQP) Polaris Supplier
Training Module.
This module will allow you to better understand the requirements, expectations
and process for delivering new products and/or parts to your customer with
great success through the use of APQP.
3
Agenda
APQP: Polaris Internal Training Module
Learning Objectives
The Process Flow – the When and How
The What, When, Who of APQP
Training Content
Tools and References
Demo / Example
Learning Objectives Recap
FAQ
Thank you!
Polaris CONFIDENTIAL
4
Learning Objectives
Focus on the objectives and ask questions throughout!!
At the end of this training, participants will be able to:
• Understand the overall process of APQP and when you are required to utilize
the APQP process.
• The importance of a standardized method for APQP
• Guidelines for APQP
• How to use the APQP process.
Polaris CONFIDENTIAL
Critical Process Steps:
This will be your guide in the presentation to give you an understanding of APQP
topic and its benefits to you.
Process Usage:
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
5
Process Overview
APQP is integrated with PDP (Polaris Development Process)Polaris CONFIDENTIAL
P
P
A
P
Supplier
QualificationPDP
EOL
Safe Launch
Supplier Performance
Product
Assurance
ControlMonitoring Improvement
APQPQuality Event
Resolution
Supplier On-
Boarding
The Quality Lifecycle Management process is a
process to ensure product quality assurance.
………….Serial
Production…….………MaturityVolume Ramp….SOP PPAP…..APQP……
SupplierSelection
What is APQP?
Advanced Product Quality Planning is a structured method of
defining and establishing the steps necessary to assure that a
product satisfies the customer’s needs and that failure
modes are identified and mitigated early in development
process
Hard to Find
Easy to Fix
Failures
Easy to
Find
Hard to Fix
Failures
Guiding Principles
The AIAG Advanced Product Quality
Planning (APQP) and Control Plan
Reference Manual [available at aiag.org] provides
the general guidelines for ensuring that
APQP is implemented in accordance with
the requirements of the customer.
The APQP spreadsheet used by Polaris
includes the corresponding page number
referencing each of the APQP steps for
quick orientation
Why do APQP?
Advanced – start early, with concepts, drive
collaboration from onset
Product – focus on the product and the
customer needs/requirements
Quality – Get it right the first time, efficiently and
every time, build quality in from concept
Planning – Collaboration will drive a robust plan
and a superior product launch
Who has responsibility within APQP?
Project Lead SQE – Assigns key dates (gates) and measures progress of
entire program
SQE’s – Facilitate APQP activities with suppliers, help to pull in PII resources,
coordinate joint activities, keep project on task, support the supplier
Plant Quality – Support suppliers, SQE’s, design engineers, etc through the
course of APQP. Play pivotal role in customer needs and PPAP approval.
Engineering – Execute assigned APQP activities, participate in design
reviews, FMEA reviews, etc and support supplier for DFM activities
Purchasing – Assist in APQP activities, support entire team and collaborate as
necessary to ensure tasks are completed on time and accurately
Supplier – Execute APQP activities, on time, thoroughly to
prepare for a successful launch
Execute to the plan
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
10
Narrow full BOM to critical few parts with greatest risk to program
What Parts get APQP?
BOM Parts
New/Revised Parts
Group 1, Group 2 Risk Parts
Critical Parts
APQP
Parts
Identify parts that
are Safety- or
Performance-Critical
All Group 1 Risk Parts + Group 2
Parts that have new/problem
supplier or historically problem
part
Highest risk critical parts
Parts follow detailed
supplier selection
process. Risk
communicated through
heat map
Part status managed
and communicated
through APQP
Plan/Report Card
Sourced
Product
Risk
Analysis
Project-
Level Heat
Map
Part Risk Management Funnel
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
11
Sourced Product Risk Analysis Heat Maps APQP Plan
Supplier Risk Management Framework
Maintain throughout program
Gate 1 CSR Gate 2 SOP
Maintain throughout program
APQP Level Selection
Level M is for manually selecting requirements
based on project, part and/or supplier need
Levels 1 – 3 are minimum APQP requirements
as determined by Polaris, other value added
APQP steps may be selected by the
Supplier/Polaris cross functional teams
Level M –Manual
• 63 Total Potential APQP Steps to Select
Level 1 – Low Risk
• 21 Mandatory APQP Steps Selected
Level 2 –Medium Risk
• 29 Mandatory APQP Steps Selected
Level 3 –High Risk
• 39 Mandatory APQP Steps Selected
0.0
2.0
4.0
6.0
8.0
10.0
0.0 5.0 10.0Co
mm
od
ity
Ris
k
PII Impact
Risk Assessment
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
How the Key Dates are Selected
Key dates are selected based off of PDP gate milestones and key
build dates and assigned by the lead PII SQE
Gate 2
V (Validation) Build
PDP Design Review
PI (Production Intent) Build
PV (Process Verification) Build
Gate 3
SOP
All dates between milestone dates are to be agreed upon by Polaris
and Supplier and must meet key Gate dates.
Key Dates are selected by Polaris – Activity Dates selected by team
Supplier APQP Kickoff
The Kickoff meeting is one of the most important events
for a supplier working on APQP.
Objectives of Kickoff:
• Establish Part List
• Establish Core Team
• Communicate key dates and JOINTLY select activity dates
• Agree upon a review / submittal cadence
• Determine escalation path if project goes off track
Kickoff meeting is critical to project success
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
Fulfilling the Requirements
Be thorough in your document review before submitting
Add completion percentage to cover sheet: when 1.0 is
entered, SQE will review that element and sign off or send
back comments/feedback
Add non-data intensive elements to the workbook tabs
For data intensive elements, add cover sheet to tab and
send actual documents to SQE via Email
How to use the APQP spreadsheet
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
How to use the APQP spreadsheet
How to use the APQP spreadsheet
How to use the APQP spreadsheet
How to use the APQP spreadsheet
• The tabs at the bottom of the workbook are hyperlinked to the steps on the APQP sheet
• Information on APQP and sometimes sample forms are located on these tabs
• The tabs should also be used to convey information related to the selected step
Rev 6.1
How to use the APQP spreadsheet
• The tabs at the bottom of the workbook are hyperlinked to the steps on the APQP sheet• Information on APQP and sometimes sample forms are located on these tabs• The tabs should also be used to convey information related to the selected step• Marked up drawings for 2.2 DFM&A, completed 2.13 MFC, completed Packaging Approval Form
are a few examples of items which should be attached to the workbook• Larger items such as PFMEAs and Control Plans we ask that upon completion the first page of the
document be placed on the corresponding tab and the full copy sent to the SQE for review
One of the many advantages of APQP is PPAP related documents, which have to be submitted before the PPAP due date, can
be preapproved by Polaris ahead of time by obtaining a GOLD square
The Polaris SQE is saying, “This document is ready for PPAP submission”
How to use the APQP spreadsheet
PDP Status Tab of Workbook
Provides a Snapshot of PDP Progress by the
Supplier
Populated from APQP Spreadsheet
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
SOP - PPAP
One core outcome of APQP is a first pass of the PPAP
Collaboration between Supplier and Polaris should aid in this successful PPAP approval
Submit early if possible
The primary outcome is successful production launch
Success = PV builds with no major quality spills, SOP builds with no quality spills, fulfilled safe launch period, no line down situations, no field actions
APQP Successful SOP
APQP Tracking goals and metrics in place; PDP deliverables defined24
How is APQP Tracked?
APQP Report Card
1. Queries existing APQP workbooks that are populated by the supplier quality team
2. Tracks APQP completion % vs. plan; along with Critical task completion
3. Automatically color codes data points based on % off plan.
4. Table on left side displays supplier level detail
5. Part-level detail is available through a link to supplier’s APQP workbook
High Level Part Risk Identified
pre G2
Heat Map to drive APQP
Level (H/M/L)
SQE Project Leader assigns
key dates
APQP Project Kicked off with
Supplier
Supplier and SQE collaborate
to submit and approve key
elements
Project SOPEnd APQP with Phase 5 review
Project Completion - Phase 5 Review
Lessons Learned
Variation Reduction Plans
KPC Improvement / Monitor Plans
26
As a Polaris Supplier, you should understand:
• Understand the overall process of APQP and when you are required to utilize the APQP process.
• The importance of a standardized method for APQP
• Guidelines for APQP
• How to use the APQP process.
Learning Objectives Recap
Are you comfortable with the APQP process?Polaris CONFIDENTIAL
27
Thank you!
Thank You!Polaris CONFIDENTIAL
Thank you for taking the time to complete the APQP Polaris Training Module.
Questions? Please contact your key Supplier Quality or Development Engineer!
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