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REVISION RECORD SHEET

TITLE : PROCEDURE FOR


REV.NO 00 ADVANCED PRODUCT QUALITY PLANNING AND DEVELOPMENT OF PRODUCTS DESC. OF AMENDMENT DATE OF AMENDMENT FIRST ISSUE AS PER QS 9000 :1995 REQUIREMENTS.

PR.NO : QP-02-01 PAGE NO : 1 OF 9 ISSUE NO : 01 REV NO : B DATE : 03.07.1997 REASON FOR AMENDMENT QS 9000 ; 1995 UPDATION

DISTRIBUTED TO :
SL.NO DESIGNATION NAME & SIGNATURE OF THE RECEIVER

PREPARED BY:

APPROVED & REVIEWED AND RELEASE CONTROLLED BY:

QUALITY ASSURANCE PROCEDURE


TITLE : PROCEDURE FOR
PURPOSE :
ADVANCED PRODUCT QUALITY PLANNING AND DEVELOPMENT OF PRODUCTS

PR.NO : PAGE NO : ISSUE NO : REV NO : DATE :

QP-02-01 2 OF 9 01 B 03.07.1997

To establish a procedure for a structured system of upfront product quality planning, to ensure that the requirements for quality of the customersare met and to assure that the product satisfies the customer, emphasising defect prevention. This procedure is applicable for all products developed & manufactured by the company except MAP & STU product range.

SCOPE

RESPONSIBILITY: Cross Functional Team - ( Leader - GM(O) for LS & AGM - STB resp.) (As referred in -QM-01) PROCEDURE : FEASIBILITY REVIEW Review of Engg. Drg., Engg. Specs., & Matl. Specs: Whenever an enquiry is forwarded by marketing Deptt. Feasibility Review shall be done.The CFT reviews the customer drgs for any special characteristics, adequate information for a dimensional layout of the individual parts and the datum/references are clearly defined & identified so that appropriate functional gages and equipment can de designed for ongoing controls. Dimensional evaluation is evaluated to assure feasibility and compatibility with industry manufacturing and measuring standards. CFT reviews for any specifications that has a controlling factor on functional performance of the product. Material specifications is to be reviewed for special characteristics relating to physical properties, performance, environmental, handling, and storage requirements. The purpose of the above review is to take control of the vital parameters and subsequently identify in the control plan so as to take control during the manufacturing processes. + When the product is found to be not feasible due to any resource requirements (equipment , tooling , manpower, etc.) the CFT shall declare as not feasible mentioning the particular requirements under which it would be feasible and the same communicated to marketing deptt. The CFT shall also identify & communicate the actions and the lead time, if any, under which the specifications could be met using alternative method for sample/ prototype development. Marketing in turn shall consider the requirements while quoting & shall communicate to the customer about the same. The review shall be evident on the form no.DC-PE-04 /Lfor Leaf Spring & DC-PE- 71/S for STB. On receipt of copy of contract review from marketing dept. by Engg. Dept., he shall verify whether the contract received is for only sample development & submission, or a bulk order along with sample, pilot batch production &

QUALITY ASSURANCE PROCEDURE

PR.NO : QP-02-01 PAGE NO : 3 OF 9 ISSUE NO : 01

TITLE : PROCEDURE FOR

ADVANCED PRODUCT QUALITY PLANNING AND DEVELOPMENT OF PRODUCTS

REV NO DATE

: B : 03.07.1997

regular supply. Accordingly, the time line chart for Advanced Product Quality Planning shall be prepared. APQP procedure is documented as per the requirements and guideline from the AIAG published Advanced Product Quality Planning & Control Plan sanctioned by GM, Ford & Chrysler. If any clarifications are to be sought from the customer during the development stage, it shall be obtained by Engg. Dept. through marketing. 02. Advanced product quality planning shall be activated, as soon as a contract is reviewed and accepted and the intimation is provided to the Engg. Dept. 03. The advanced product quality planning shall be planned by the Cross Functional Team chaired by CFT-Leader. The Engg. Dept. shall float an Internal Office Memo to the CFT members regarding the date, time & venue for the planning activity. 04. The Cross Functional Team - I shall constitute the following members: (For Management Support) a) Vice President b) GM - Operations c) GM - Commercial d) DGM - OEM - Marketing e) AGM - QA for LS & Dy.M-QA for STB f) AGM- STB & Proj. ( For Stabiliser Bar) g) Any other invitees as felt necessary. 05. The Details of the product quality planning shall be as follows : The CFT as defined in Chap. No. -QM-01 shall develop a timing plan and chart out listing all the tasks, assignments and any other events considering the complexity of the product and the expectations of the customers. The timing plan shall bear the document no. DC-PE-73.The timing plan shall be developed and phased in such a manner that the timing meets or surpasses the customers requirement. The timing plan shall indicate the start & completion of the respective tasks and have provision for status reporting to record the actual status of the progress. The CFT should agree on all the actions decided for the timely completion of the product. 06. The timing plan by default shall constitute the following task/events for which the time shall be phased, assigning the responsibility for the start and completion. In addition to this, as per the requirements of the contract, the same shall be added in the time line chart, sequentially. (Each task is described

QUALITY ASSURANCE PROCEDURE


TITLE : PROCEDURE FOR
ADVANCED PRODUCT QUALITY PLANNING AND DEVELOPMENT OF PRODUCTS

PR.NO : QP-02-01 PAGE NO : 4 OF 9 ISSUE NO : 01 REV NO : B DATE : 03.07.1997

below for its proper understanding and implementation) . 07. Any Resource requirement identified in the tasks mentioned below, resource requirement shall be filled in for the same & appropriate Management Approval sought to provide the same. PHASE - 1 This phase shall consider the inputs received from the customer such as Engg. drawings, specifications, standards, test procedures, etc., and the feasibility report which was created earlier during the proposal period. The tasks: Bill of Material (BOM): CFT has to establish a bill of material for the product/process so that sources can be identified for planning procurement activities or sub-contracting activities or evaluation. The BOM shall be documented in doc.no. DC-PE-X 22 XX XXX for LS & DC-PE-72/S indicating the Product/model with Rev. no, Customer, P.O. no. with Rev.no., list of materials with Part no. (with Rev.no.), unit quantity and the source of supply. The Bill of Material shall be approved by Respective Engg. Head. Requirement Of New Equipment,Gages,Test Equipment, Tooling and Facilities : CFT shall identify the requirements of new gages/testing equipment/equipment/tooling/facilities, if any, and these are to be identified in the timing plan ensuring its capability and timely delivery. In case any requirements are identified, form no DC-PE-75 which is self explanatory, shall be duly filled in. Any new equipment/gage/test equipment of capital nature ,to be procured, shall be sent to AGM(Projects) on the resource request form FM-01-03 duly approved by ED, if the identified equipment is not budgeted in the business plan of the year. AGM(Projects) after approval shall float enquiries / raise purchase order for the resource identified. ED / VP / GM(Comm) / AGM(Projects) shall be the approving authority of the PO. AGM (Projects) then shall keep track of progress at the machine manufacturers end. He shall be the authority to correspond/ communicate with the equipment supplier. Once the machine is received it shall be the responsibilty of Projects deptt. to get the machine installed & Commissioned. The progress shall be monitored by GM(O) for LS & AGM - STB to assure completion to surpass planned production tryout. Identification of Special Product & Process Characteristics: Special product and process characteristics are to be identified by CFT during this phase. Special characteristics are those characteristics that may affect safe vehicle operation/govt. safety regulations and /fit or function. Sometimes customer would have identified some special product characteristics. Special Characteristics if specified by the customer, shall be designated by

QUALITY ASSURANCE PROCEDURE


TITLE : PROCEDURE FOR ADVANCED PRODUCT QUALITY
PLANNING AND DEVELOPMENT OF PRODUCT

PR.NO :QP-02-01 PAGE NO : 5 OF 9 ISSUE NO : 01 REV NO : B DATE : 03.07.1997

symbols designated by the customer.

If Special Characteristics are not specified by the customer, CFT shall identify as relevant to the applicable processes and/or product based on PFMEA findings and past experience. Resp. Engg. Dept. shall maintain a list of identified special product/process characteristics in the form DC-PE-68/L & 69/L for LS and DC-PE-68/S for STB indicating the symbol to be used during the manufacturing process. A copy of the list shall be made available to the concerned functional dept. heads to be included in the control plan,work instructions, process drgs., as appropriate. In case need arises to use our specified symbols equivalent to that of the customer specified one, prior approval shall be obtained from customer by resp. Engg. Dept. Refer section - III of QS 9000 : 1995 for customer specific requirements of Special characteristics ( for the three Bigs). PHASE - 2 PROCESS DESIGN & DEVELOPMENT The Tasks: Packaging Standards & Specifications: Packaging specifications shall be decided by the CFT in this phase so as to ensure the product integrity at point of use. If customer have specified packaging standards, the same shall be specified in the packaging instructions available with the despatch dept. Product/Process Quality System Review: The CFT has to review the organisations Quality System Documentation for inclusion of any additional controls or any procedural changes require to produce the product. Form no DC-PE-76 which is self explanatory shall be used as an aid to review the quality system documentation. MR shall assist in this activity and take appropriate action for timely completion Process Flow Chart: CFT shall prepare the proposed or current process flow. The purpose of this flow chart is to analyse the sources of variations of machines, materials, methods, and manpower from the beginning to the end of a manufacturing or assembly process. Form no DC-PE-77 shall be used as an aid for the evaluation of the flow chart. The flow chart shall be approved by AGM - QA for LS & Dy.M-Engg.for STB The flow chart shall assist in the development of Process FMEAs and control plan. Floor Plan Layout: CFT shall develop & review floor plan to determine the acceptability of inspection points, acceptability of visual aids, interim repair stations, and storage areas to contain defective material. All material flow should be keyed to the process flow chart and control plan.

QUALITY ASSURANCE PROCEDURE


TITLE : PROCEDURE FOR
PLANNING ADVANCED PRODUCT QUALITY

PR.NO :QP-02-01 PAGE NO : 6 OF 9 ISSUE NO : 01 REV NO : B DATE : 03.07.1997

CFT shall use form no DC-PE-78 as aid for the evaluation. Floor plan shall be approved by Resp. Engg. Heads. Process Failure Mode and Effects Analysis : Process FMEA shall be

conducted by the CFT for all the special characteristics identified. The details for the conduction of PFMEA is as described in the procedure QP-02-02. Form no DC-PE-79 shall be used as an aid for the evaluation of FMEA. Prototype & Prelaunch Control Plan : If the customer calls for a prototype control plan the same shall be developed during this phase by the CFT. Prelaunch control plans are a description of the dimensional measurements and material and functional tests that will occur after prototype and before full production. The prelaunch control plan should include additional product/process controls to be implemented until the production process is validated. The purpose of the prelaunch control plan is to control potential nonconformances during or prior to initial production runs. The controls may be more frequent inspection, more in-process and final check points, statistical evaluation and increased audits. Form no.DC-PE-80 shall be used as an aid for the evaluation of the control plans. The Control Plans shall be approved by Engg. & Quality Heads.. Process Instruction: The CFT shall review existing & develop, if reqd., process instructions that provide sufficient detail for all operating personnel who have direct responsibility for the operation of the processes. These instructions should be developed from the following resources: FMEAs Control Plans Engg. Drgs., performance specs., matl. specs., visual stds., & Industry stds. Process Flow chart Floor plan layout Packaging standards Process parameters Producer expertise and knowledge of the process & products Handling requirements The process instructions should be displayed and include set up parameters and be accessible to the operators. The process work instruction shall be approved by GM (O) for LS & AGM(STB)

QUALITY ASSURANCE PROCEDURE


TITLE : PROCEDURE FOR ADVANCED PRODUCT QUALITY
PLANNING AND DEVELOPMENT OF PRODUCT.

PR.NO :QP-02-01 PAGE NO : 7 OF 9 ISSUE NO : 01 REV NO : B DATE : 03.07.1997

for STB. Prototype development : Prototype of the product shall be developed by the resp. Engg Dept. along with production & QA, for the quantity as specified in the P.O. In case of requirement/ purchase of any high valued equipment for making the sample ,CFT shall decide whether to make a hand made sample, if feasible. In such cases once the PO is received after sample acceptance,necessary equipment

identified shall be purchased before Pre-Launch. Resp. Engg. Dept. & QA Dept. jointly shall carryout 100% inspection or as specified on the samples developed, and prepare inspection report. The acceptance of samples shall be as per the acceptance limits mentioned in the prototype control plan.Once the samples are accepted, the resp. Engg. Dept. shall inform marketing either to despatch the sample or request the customer to do inspection at our premises as per contract provisions, for approval. Measurement Systems Analysis Plan & Evaluation: To list out gages/instruments identified in the control plans and mention in the timing plan. The details are as described in the procedure QP-11-01. Preliminary Process Capability Study Plan & Study : To list out the characteristics identified in the control plan and mention in the timing plan. The details are as described in the procedure QP-09-05 & QP-20-01. Production Trial Run: The production trial run must be conducted using production tooling, equipment, environment (including production operators), facility and cycle time. The validation of the effectiveness of the manufacturing process begins with the production trial run. The minimum quantity for a production trial run is usually set by the customer but can be exceeded by the CFT. Output of the production trial run is used for: PpK study MSA Process Review Final Feasibility Production Validation Testing PPAP Packaging Evaluation Quality Planning sign off Production Part Approval Process: To validate the products made from production tools and processes to meet engineering standards. For details refer procedure QP-21-01.

QUALITY ASSURANCE PROCEDURE


TITLE : PROCEDURE FOR ADVANCED PRODUCT QUALITY
PLANNING AND DEVELOPMENT OF PRODUCT.

PR.NO :QP-02-01 PAGE NO : 8 OF 9 ISSUE NO : 01 REV NO : B DATE : 03.07.1997

Production Validation Testing : Production validation testing refers to engineering tests that validate the products made from production tools and processes meet engineering standards. This shall be evident by test reports. Packaging Evaluation: Assess the product from normal transportation damage and adverse environmental effects. This shall be in the form of approved drawings. Production Control Plan: Production control plan is a written description of the systems for controlling parts and processes. The production control plan is a living document and should be updated to reflect the addition deletion of controls

based on the experience gained by producing parts. This shall be the responsibility of the CFT. Form no. DC-PE-80 shall be used as an aid to assist in the evaluation. All Functional heads shall then modify or amend all the process instructions, component drawings, sequence of operations, process sheets, operation sheets, tooling drawings etc., as may be applicable,for induction in regular production and the results of all inspection reports of sample & pilot batch shall be available with the CFT. Copy of these changes on an internal note shall be sent to Mktg. head. He shall ensure distribution of customer supplied documents,if any, in appropriate form to all concerned. CFT shall evolve control plans,duly approved by QA head, for the regular production considering modification in equipment / process during development stage & including requirements of FMEA. Control Plans review shall be reviewed on the guide lines of APQP manual and release for implementation. He shall update the master list of gauges, jigs fixtures for newly inducted items. Engg & Development department shall handover copy of Drwaings of jigs, fixtures,toolings to Q. A./Tool Room incharge at the time of handover to production.CFT shall confirm their acceptance for induction of new product into production. This shall also be referred as SIGN OFF activity. The meaning of SIGN OFF is that the newly inducted product is adequately supported by documents, equipments & toolings & can be inducted into regular production smoothly. Quality Planning Sign OFF: The CFT shall ensure that all control plans and process flow charts are being followed. CFT shall co - ordinate a formal sign off. The sign off shall be reported on form no. DC-PE-81. PHASE - 3 ( The Follow up Phase) Feedback, Assessment and Corrective Action The Tasks: CFT shall follow up for continuous improvement techniques and seek ways to

QUALITY ASSURANCE PROCEDURE


TITLE : PROCEDURE FOR ADVANCED PRODUCT QUALITY
PLANNING AND DEVELOPMENT OF PRODUCT.

PR.NO :QP-02-01 PAGE NO : 9 OF 9 ISSUE NO : 01 REV NO : B DATE : 03.07.1997

reduce the source of variations. Ensure that the product performs satisfactorily at the Customers end and prompt attention to the customer needs. Once the product is inducted into regular production, at any stage, due to change in customer need, - change of production equipment, change of lay out, amendments in drawings, specifications & control plans may be necessary. Change control is as described in procedure QP-05-01 shall apply and same shall be the responsibility of Engg. department. Also any new documents introduced by customer shall be obtained, reviewed, consolidated if necessary and distributed to all concerned by Engg. Incharge. Along with incorporating modifications in equipment tooling / equipment as applicable. Q. A. incharge shall incorporate appropriate changes in control plans as applicable. Customer initiated change as described in Procedure NoQP-03-01 shall be

acknowledged by Engg. incharge within one week after receipt of same. The changes made as preventive actions shall be part of continuous improvement activity. After incorporating all these changes, each time Engg department shall produce sample and ensure that quality requirements are met as per acceptance standards if contractually needed obtain customer approval. Engg. department shall be responsible for maintaining appropriate records of change implemented and new part approval, while Q. A. department shall maintain record of effective date of changes implemented and communicate to customer through marketing. DEVELOPMENT THROUGH VALUE ENGINEERING PROCESS

Sometimes during the process of production , by the virtue of the experience , Engg. may develop a suggestion through value engineering(manufacturing) & communicated to the customer through a copy of the drawing & simultaneously feasibilty review conducted. On approval by the customer & the release of P.O. for the sample APQP procedure described above shall be applicable. APQP & CP MANUAL FMEA MANUAL SPC MANUAL MSA MANUAL PPAP MANUAL

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