Apqp+english+version[1]

Section:

Project management for product realisation

4

Manuals for the core tools of the automobile industry:

Topic: QS9000 Manual: VDA Volume:

Advance Quality planning

APQP VDA4, VDA4.3

Approval Process PPAP VDA2

Risk analysis FMEA VDA4.2

Statistics SPC VDA3.1-3.3

Spec. characteristics

APQP / FMEA VDA1

Capability of test equipment

MSA VDA5

4.1.Overview of manuals

What for do I need it:

“Guideline for support at launch of new products“

With and without product development

4.2.Field of application

Why do I need it? • It makes complex processes transparent and reproducible• It helps to prevent redundant activities• It offers a continous check in a project • It exonerates at product liabilities • It is a recommended demand of Daimler/Chrysler, Ford and General Motors (Opel)


Why do I need it?


Are you sure that our

calculation was

correct??

Reasons of customer•In order to provide means which satisfy the customer

•In order to identify necessary modifications as early as possible

•In order to prevent late modifications

•In order to produce a quality product timely with lowest costs


PLAN GoalsObjectiveSupplement InformationStandardsKey persons Structure

PreparationMeetingsReviewClosing

DO

Action plan

CHECK

Plan conducted?“Customer” happy?

AC

T

Negative differencesor corrective action planor correction

Positive differencesStoppOvertake benefitsImprove

PLAN

PRODUCT deve./engi.

PROCESS development/engineering

PRODUCT & PROCESS validation

Feedback, appraisal, corrections

Concept Release Prototype Pre-series Series

4.3.Phase model

PLAN

PRODUCT deve./engi.




INPUT OUTPUT

4.3.Phase model

PLAN

PRODUCT deve./engi.




XDropped if nodevelopment responsibility

4.3.Phase model

When does it start?

Customer

Contractreview

Offer

Order

InquiryNew Product

APQP

Definition according to QS9000:“If the supplier may compile or change specifications for the customer.“

Definition according to VDA6.1:“If the supplier bears the written development responsibility.“

Supplement according to TS 16949:“Development then exists when the supplier specifies products in cooperation with the customer.“

4.4.Development

IdeaCustomerSupplier

SpecificationCompiled

by supplier(Cooperation with customer

or also in subcontract)

Compiled by customer

4.4.Development

Support of managementCapacities and means have to available; development order placed in writing.

4.5.Basic prerequisites

Overlapping team:Employees of quality management, development department, production, logistics, purchase, distribution, field consulting, sub-suppliers and customers.


Define the volume! •Define a team leader who keeps track of the planning process.•Defining of roles and responsibilities of each co-operating sector. •Define internal and external customers (interface matrix)•Choose which methods, persons and sub-suppliers are needed in the team and which not.•Understanding of customer expectations •Inspection of doability of provided design, reliability features and manufacturing process. •Costs, time and requirements have to be considered. •Determine if support by customer is needed. •Determine documentation process or method.


Communication


SIMULTANEOUS ENGINEERING:

ACTIVITY „A“

ACTIVITY „B“

ACTIVITY „C“

Total period


PLAN

PRODUCT deve./engi.




The voice of the customer:ComplaintsRecommendationsCustomer satisfaction analysesInternal customer informationMarket surveysWarranties / liabilitiesQuality analysesExperiences of the team

4.6.Phase 1

Defaults of the business plan:Market strategiesTimingInvestmentsBudgetCustomer areasTurnoversCompetition

4.6.Phase 1

Product and process benchmarking:Ascertain „best in class“Define and understand deficiencies Compile a plan in order to fill the gapRepeat analysis

4.6.Phase 1

Product and process assumptions:Design conceptsInnovationsNew techniquesModern materials

4.6.Phase 1

Product reliability analysis:RepairSpare part marketEndurance tests

4.6.Phase 1

Customer information:Information of next user (customer and end customer)Needs and expectationsInspections and tests of customerCustomer satisfaction bar

4.6.Phase 1

Development targets:

Customer expectationsMeasurable

values

4.6.Phase 1

Reliability and quality targets:

•Customer expectations•Benchmark analysis•Reports, statistics•Repairs

Reliability targets:•probabilities•confidence limits

Quality targets:•targets of continual improvement•e.g.: PPM. Reduction of rejects, error margins

4.6.Phase 1

Preliminary process flow plan:

•Material list•Product assumption•Process assumption

4.6.Phase 1

Preliminary listing of specific features:Definition:“Features which have effect on safety and/or fulfilment of legal restraints resp. are functional important.“

•Given by customer.•Ascertained by supplier (at design responsibility).

INPUTS: product assumptions, customer information, FMEA of similar parts

4.6.Phase 1

PLAN

PRODUCT deve./engi.




Design FMEA:“Methodical analysis of all possible potential errors of a

design,their effect and importance on the customer as well as

planningand operating of activities for risk reduction.“

4.7.Phase 2

Design for manufacturing and assembly:

PRODUCTMANUFACTURING

ASSEMBLY

4.7.Phase 2

The activities of phase 1 have to lead to this that the design result fulfils the design defaults

4.7.Phase 2

Design defaults(requirement specification,

inputs phase 1)

Design result(CAD, drawing,

specification etc.)

4.7.Phase 2

Regularly Design Reviews:Meetings in order to determine if the given plan isobserved:

• Consider design/function• Reliability and confidence targets• Components, sub-systems and systems• Computer simulations, Benchmark• DFMEA• Checking of producibility and assembly • DOE methods• Test errors

4.7.Phase 2

“Control plans are written descriptions of systems which serve for this to dominate parts and processes.“

It differs in:

•Prototype – A description of dimensional measurements, material and performance tests which are carried out during prototype phase.•Pre-series – A description of dimensional measurements, material and performance tests which are carried out after prototype phase but before series. •Series – A comprehensive documentation of product/process features, process control inspections and measuring systems which are carried out during mass production.

4.7.Phase 2

Manufacturing of the prototype has to lead to this that…

• the product fulfils the specification resp. provides required data.

• specific product and process features have been considered.

• data and information are used in order to define preliminary process parameters and packaging standards.

• all doubts, deviations and influences are reported to the customer.

4.7.Phase 2

Preparation of engineering drawing

•Legal demands•Safety features•Determination of features for „fit & function“•Tolerated dimensions•Documented inspection of the drawing

4.7.Phase 2

Preparation of engineering drawing

Test equipment available for all features?Dimensions producible?CAD data compatible to customer?

4.7.Phase 2

Preparation of technical specifications(can be included in engineering drawing!)

Functional requirementsReliability requirementsFeatures dependent on appearance

(Kind of inspection, volume, frequentness and carrying out are defined in standards, specifications, test instructions and control plans, etc.)

4.7.Phase 2

Preparation of material specification(can be included in engineering drawing!)

Have to be tested with reference to:Specific featuresPhysical characteristicsPerformanceEnvironment (disposal)HandlingStocking (conservation)

4.7.Phase 2

New equipment, tools and facilities

Tools = Formative means of productionEquipment = Constructive auxiliary means of productionFacility = New areas, assembly line and plant extensions

•Include into schedule•Tools and equipment have to be process-capable•Delivered and provided in time

4.7.Phase 2

Discussion which specific features are determined(basis is the preliminary determination of phase 1)

•Find accordance (involve customers)•Consult attachment C of QS 9000 (determinations of features)•Include into control plan•Consider customer release procedure•Consider documentation requirements•Use auxiliary means APQP forms

4.7.Phase 2

Determination of requirements on all test equipment and teachings.

=> include into schedule and monitoring!

4.7.Phase 2

Team doability declaration:The APQP team confirms in writing that thesuggested design…1. can be manufactured2. can be assembled (if claimed) 3. can be verified positively 4. can be packaged5. can be delivered... in satisfying quality and quantity as well as

according to given costs.

Attention! Please use form „Team Feasibility Commitment“

4.7.Phase 2

PLAN

PRODUCT deve./engi.




Packaging standars are given by customer and have to be worked into the own QM-system.

Packaging specifications are developed by supplier and have to be worked into the own QM-system. Thereby it has to be considered how far packaging has effect on product quality (drop test, conservation, etc.)

4.8.Phase 3

Inspection of QM-system

•Inspection and practice of any modifications into the QM-manual•Involvement of process and work instructions•Regeneration of necessary documents and forms

4.8.Phase 3

Matrix of features

Appropriation of features (product and process)to a process.

•The more product features are influenced by a process the more important is the control on this process!

4.8.Phase 3

Process FMEA:“Methodical analysis of all possible potential errors of all processes, their effect and importance on the customer as

wellas planning and operating of activities for risk reduction.“

Basis:Process flow plan

4.8.Phase 3

Differences to series control plan:

• Higher frequented inspections• More in-process and final inspections• Statistical analyses• Stronger audits (product and process)

Comment: With pre-series SAMPLES are meant.

4.8.Phase 3

Information at machines:• Name of process (relevant to process flow chart) • Name of part and number• Revision status• Tools, equipment and test equipment information• Material and disposal instructions• Demands on specific features• SPC requirements• Necessary norms / standards• Inspection and test instructions• Reaction plans• Visual auxiliary means• Tool change intervals and facility instructions

4.8.Phase 3

A measuring process contains diversifications

Every ascertained measured value consists of •every real value and•measurement error.

Measurement error is caused by•diversification influences of measuring equipment and•diversification influences of the inspector or the measuring method.

Measurement error consists ofa systematic error and a random error.

Measurement System AnalysisMeasurement System Analysis(MSA)(MSA)

4.8.Phase 3

Statistical Process ControlStatistical Process Control(SPC)(SPC)

Analysing of proceedings with the target to dominate the process.Determination of preliminary process capability on real fabrication conditions.Determination of continous process capability on real fabrication conditions.

4.8.Phase 3

PLAN

PRODUCT deve./engi.




PRODUCTION ATTEMPTPRODUCTION ATTEMPTProduction attempt should be carried out as possible on close-to-production conditions :•Tool•Equipment•Environment•Material•Staff•Plant areas

4.8.Phase 4

PRODUCTION ATTEMPTPRODUCTION ATTEMPTThe quantity to manufacture has to be clarified with the customer. Targets of pilot production are:•Preliminary process capability studies•Evaluation of capability of measuring equipment•Process inspection•Production validation•Production parts release•Inspection of packaging•„Sign Off“

4.8.Phase 4

All in control plan listed measuring equipment is taken a inspection of capability of measuring equipment according to method MSA of QS 9000.Only test equipment for fabrication is allowed to put in which does not exceed demonstrably a maximum R&R value of 30%.

Measurement System AnalysisMeasurement System Analysis(MSA)(MSA)

4.8.Phase 4

Only at features given by customer or own determination.Arrange procedure with customer:

1. Take parts2. Measure parts3. Determine standard deviation4. Determine PPK values

Results of preliminary process capabilityResults of preliminary process capability(SPC)(SPC)

4.8.Phase 4

Production part approval processProduction part approval process(PPAP)(PPAP)

•Ensure that the supplier understands all customer requirements and can translate these in processes and products which meet customer requirements

Comment:On the subject of PPAP, a separate course can be attended!

4.8.Phase 4

Inspection of packaging

•Stock test•Conditioning•Drop test•Road trial

4.8.Phase 4

DEFINITION:

“A comprehensive documentation of product/process features, process control inspections and measuringsystems which are carried out during mass production.“

4.8.Phase 4

DEFINITION:

The quality planning team should ensure that all process flows and control plans are realised. It is recommended to carry out and document the “sign off“ in the production plant.

4.8.Phase 4

The „Sign off“ should enclose the following points:

1. Control plans should exist and be available at any time at locations which need these for realisation of contents.

2. It should be checked that all process instructions considered the specified specific features which are mentioned in the control plan. Recommendations of process FMEA should have been realised.

3. With special test equipment or in control plan mentioned test equipment, a successful inspection of capability of test equipment should be present.

4.8.Phase 4

PLAN

PRODUCT deve./engi.




Documents

Apqp+english+version[1]