APQP-Bilingual Rev 2 2010

APQP
Vision Technology International Limited
APQP Reference Manual should be read, understood and

adhered to (as appropriate) by every supplier to the Big-3 , ( )APQP
APQP
Benefits
To direct resources to satisfy the client
To promote early identification of required changes
To avoid late changes To provide a quality product on time at the lowest costs Not only quality dept. But also subcontractors and clients
Organize team ()

Form the team

The first step: Form Cross Functional Team
Define the Scope

Select team leader Define roles and responsibilities Identify customer (internal and ext.) Define customers req. (e.g. QFD) QFD Select the disciplines, individuals ,and/or suppliers that must be added to the team, and those not required. ,, ;
7
Understand customer expectation, i.e. design, number of tests.,. Assess the feasibility of proposed design, performance requirements and manufacturing process Identify costs, timing and any constraints Determine assistance from customer Identify documentation process or method
Timing Chart
The first order of CFT is: development of timing chart : Consideration: type of product, complexity and customer expectation . Members should agree with.
Simultaneous Engineering
Simultaneous Engineering:
Cross functional Team strive for common goal Replaces the sequential series of phases where results are transmitted to the next area for execution
GOAL: Expedite the introduction of quality products sooner :

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APQP

Planning
Product Design & Dev. Process Design & Dev.

Product &Process Validation Production
Feedback Assessment And Corrective Action

.
Concept Initiation / Approval
Program Approval
Prototype
Pilot
Launch
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Design Resp. Define the Scope Plan and Define (sec. 1) Product Design and Development (sec. 2) Feasibility2.132.13 Process Design and Development (sec. 3) Product and Process Validation (sec. 4) Feedback, Assessment and Corrective Action (sec. 5) X X X X X X
Manufacturing Resp. X
X X X
X
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Plan and Define Programme 1. 0

Determine customer needs and expectations in order to plan and define the quality system. ,
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Plan and Define Program 1.0

Input Voice of Customer Customer Business plan/Marketing strategy/ Product/process benchmark data / Product/process assumptions / Product reliability studies Customer input
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1.1 VOC
Source of info.: - Market Reserach - Warranty and Quality Info. - Team Expererience
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1.1.1 MARKET RESEARCH

Customer interviews Customer questionnaires and surveys Market test and positioning report New product quality and reliability Competitive product quality studies Best Practices Lessons Learned
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1.1.2 HISTORICAL WARRANTY AND QUALITY INFORMATION
Best Practices Lessons Learned Warranty reports Capability indicators Supplier plant internal quality reports
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1.1.2 HISTORICAL WARRANTY AND QUALITY INFORMATION
Problem resolution reports Customer plant returns and rejections Field return product analysis
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1.1.3 TEAM EXPERIENCE

QFD projects Media commentary and analysis: magazine and newspaper reports, : Customer letters and suggestions Best Practice Lessons Learned Dealer comments
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1.1.3 TEAM EXPERIENCE

Fleet Operators comments Field service reports Internal evaluations using surrogate customers Road Trips Management comments or direction Problems and issues reported form internal customers Government requirements and regulations Contract review
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1.2 BUSINESSS PLAN/MARKETING SYRATEGY /

Customer business plan may place constraints (timing, cost, investment, product positioning, research and development (R&D) resources). ( (R&D) ) The marketing strategy will define the target customer, the key sales points, and key competitors.
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1.3
PRODUCT/PROCESS BENCHMARK DATA
/
Establishing product/process performance targets. / Successful benchmarking is: : Identify the appropriate benchmarks Understand the reason for the gap Develop a plan to close the gap
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1.4 PRODCUT/PROCESS ASSUMPTIONS /

Assumptions that the product has certain features, design, or process concepts include: , : Technical innovations Advanced materials Reliability assessments New technology
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1.5 PRODUCT RELIABILITY STUDIES

Data considers frequency of repair or replacement of components.
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1.6 CUSTOMER INPUTS

Next users of the product can provide valuable information relating to their needs and expectations. In addition, the next product users may have already conducted some or all of the aforementioned reviews and studies. ,
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Plan and Define Program 1.0

Output Design goals Reliability and quality goals Preliminary bill of material Preliminary process flow chart Preliminary listing of special product & process characters Product assurance plan Management Support
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1.7 DESIGN GOALS

Translation of the Voice of the Customer into tentative and measurable design objectives. The Voice of the Customer also includes regulatory requirements such as materials composition reporting and polymeric part marking. ,
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1.8 RELIABILITY AND QUALITY GOALS
Reliability goals - established based on customer wants and expectations and reliability benchmarks.
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1.8 RELIABILITY AND QUALITY GOALS
Quality goals targets based on continual improvement. Examples: . : parts per million (PPM)/ defect levels scrap reduction
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1.9 PRELIMINARY BILL OF MATERIAL
Based on product/process assumptions and include early subcontractor list. /
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1.10 PRELIMINARY PROCESS FLOW CHART
Development from the preliminary bill of material and

product/process assumptions. /
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1.11 Special product & process characters
Listing developed from: : Product assumption Reliability goals Identification of SC from anticipated manufacturing process Similar part FMEAs FMEAs
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: ( ) (S/C)
( ) SPC ()
/ - <F/F>
SC
- <D>
<P>
( ) ( )
/ <S/C>
( ) / -CC
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1.12 PRODUCT ASSURANCE PLAN
Translates design goals into design requirement

Outlining of program requirement
Identification of reliability Assessment of new technology, materials, environment, packaging, manufacturing requirements, other factor that may place the program at risk. Use of Failure Mode Analysis Development of preliminary engineering standards requirements
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1.13 MANAGEMENT SUPPORT

Management should be updated management at the conclusion of product quality planning phase to Reinforce their commitment and support program timing and planning for resources and staffing
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2.0 Product Design & Development
Planning

Product Design & Dev. Process Design & Dev. Product &Process Validation

Production

.
Program Approval
Prototype
Pilot
Launch
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To assure a comprehensive and critical review of engineering requirements and other related technical information to assure that voice of customer can be met.
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Output Design Dept. DFMEA Design for manufacturing & assembly Design verification Design Review Prototype build Eng. drawings, spec. & material spec. Drawing & spec. changes
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Output Quality Planning Team

New equipment, tooling and facilities requirements Special product and process characteristics Gage/testing equipment requirements / Team feasibility commitment & management support
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2.1 DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA)
A disciplined analytical technique that assesses the probability of failure as well as the effect of such failure. Refer to Potential Failure Mode and Effect Analysis reference manual The Design FMEA Checking in Appendix A-1 FMEAA-1
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2.2 DESIGN FOR MANUGFACTURABILITY AND ASSEMBLY

A Simultaneous Engineering process designed to optimize the relationship between design function, manufacturability, and ease of assembly.
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Item should be considered by the Product Quality Planning Team::

Design, concept, function, and sensitivity to manufacturing variation Manufacturing and/or assembly process / Dimensional tolerances Performance requirements Number of components Process adjustments Material handling
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2.2 DESIGN FOR MANUGFACTURABILITY AND ASSEMBLY
2.3 DESIGN VERIFICATION
Verifies that the product design meets the customer requirements
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2.4 DESIGN REVIEWS
Regularly scheduled meetings led to prevent problems and misunderstandings.
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2.5 PROTOTYPE BUILD CONTROL PLAN
A description of the dimensional measurements and material and functional tests that will occur during prototype build. Control Plan Checklist is provided in both Appendix A-8 A-8
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2.6 ENGINEERING DRAWINGS
Engineering drawings from customer may include special (government regulatory and safety) characteristics that must be shown on the control plan. () Drawings should be reviewed by planning team to determine which characteristics affect fit, function, durability and/or governmental regulatory safety requirements. /
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2.7 ENGINEERING SPECIFICATIONS
Should determine which characteristics affect functional, durability, and appearance requirements.
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2.8 MATERIAL SPECIFICATIONS
Should be reviewed for Special Characteristics
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2.9 DRAWING AND SPECIFICATION CHANGES
Ensure that the changes are promptly communicated and properly documented
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2.10 NEW EQUIPMENT, TOOLING AND FACILITIES REQUIREMENTS
New equipment and facilities requirements may come from: : The DFMEA DFMEA Product Assurance Design Reviews
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2.10 NEW EQUIPMENT, TOOLING AND FACILITIES REQUIREMENTS
Team should address these requirements by adding the items to the Timing Chart Team should ensure that the new equipment and tooling is capable and delivered on time New Equipment, Tooling and Test Equipment Checklist in Appendix A-3A-3
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2.11 SPECIAL PRODUCT AND PROCESS CHARACTERISTICS
The organizations product quality team should build on this listing and reaching consensus through the evaluation of the technical information. ,
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2.12 GAGES/TESTING EQUIPMENT REQUIREMENTS /

Gages/testing equipment requirements may also be identified. / Add these requirement to the Timing Chart
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2.13 TEAM FEASIBILITY COMMITMENT AND MANAGEMENT SUPPORT
The Product Quality Planning Team must assess the feasibility of the proposes design. Customer design ownership does not preclude the organizations obligation
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Team must be satisfied that the proposed design can manufactured assembled tested packaged delivered in sufficient quantity at an acceptable cost to the customer on schedule
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The Design Information Checklist in Appendix A-2 allows the team to review its efforts A-2 Team Feasibility commitment form shown in Appendix E E
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3.0 Process Design & Development
Planning


Production

.
Program Approval
Prototype
Pilot
Launch
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Develop a manufacturing system and its related control plans to assure that customer requirements, needs and expectations are met.
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Output
Package standards Product/process quality system review
/
Workplace Organization
TOOLS
Process flow chart Floor plan layout Characteristics Matrix Process FMEA
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PULL CARDS
T R
A S
T O
E L S
G L O
S V E
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Output
Pre-launch control plan Process instructions Measurement system analysis plan
Preliminary process capability study plan
Packaging specifications Management support

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Flow Manufacturing
Our integrated line is balanced to meet customer demand.
Now that we do quick changeovers, we can run every part every day.
Machining Coating Our people are flexible, and WIP is down due to single piece flow. Welding Pressing
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Quality Two-point Inspection I checked it, but let me know if there are any problems. Il check it out before I do the next operation. Error Proofing Jig The part won go on unless it oriented properly
jamming pin CONTROL WARNING The light goes on if the machine fails.
Material Movement Pull System ADDRESS 0017-0010-002R
KIT
Make what we need when we need it
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3.1 PACKAGING STANDARDS AND SPECIFICATIONS
Packaging design should ensure product integrity at point of use.
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3.2 PRODUCT/PROCESS QUALITY SYSTEM REVIEW/ REVIEW

Team should review the manufacturing site(s) Quality management system Any additional controls and/or procedural changes required to produced the product should be updated, documented and included in the manufacturing control plan. / Checklist provided in Appendix A-4 A-4
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3.3 PROCESS FLOW CHART

Process flow used to analyze sources of variations of machines, material, methods, and manpower The flow chart assists the organizations product quality planning team to focus on process when conducting the PFMEA and DFMEA PFMEADFMEA, . The Process Flow Chart Checklist in Appendix A-6 can be used A-6
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3.4 FLOOR PLAN LAYOUT
The floor plan should be developed and reviewed to determine

Acceptability of inspection points Control chart location Applicability of visual aids Interim repair stations Storage areas to contain defective material
Floor Plan Checklist in Appendix A-5 can be used. A-5
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-optimize the material travel, handling and value-added use of the floor space , -facilitate the synchronous flow of materials through the process
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3.5 CHARACTERISTICS MATRIX
A recommended analytical technique for displaying the relationship between process parameters and manufacturing stations.
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3.6 PROCESS FAILUTE MODE AND EFFECTS ANALYSIS
A PFMEA should be conducted during product quality planning and before beginning production. PFMEA The process FMEA Checklist in Appendix A-7 can be used. A-7FMEA
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3.7 PRE-LAUNCH CONTROL PLAN
A description of the dimensional measurements and material and functional tests that will occur after prototype and before full production. Control Plan Checklist in Appendix A-8 can be used. A-8
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3.8 PROCESS INSTRUCTIONS
Instructions should be developed from the following sources: : FMEAs Control plan(s) Engineering drawings, performance specifications, material specifications, visual standards and industry standards
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3.8 PROCESS INSTRUCTIONS
Process flow chart Floor plan layout Characteristics matrix Packaging standards Process parameters Organization expertise and knowledge of the processes and products Handling requirements Operators of the Process
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3.9 MEASUREMENT SYSTEMS ANALYSIS PLAN
A plan to accomplish the required measurement systems analysis is developed.
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3.10 PRELIMINARY PROCESS CAPABILITY STUDY PLAN
The characteristics identified in the control plan will serve as the basis for the preliminary process capability study plan.
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3.11 MANAGEMENT SUPPORT
The organizations product quality team should update management at the conclusion of product quality planning phase to Reinforce their commitment and support
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4.0 Product and Process validation
Planning

Production

. /

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To validate control plan and flow chart are being followed and the products meet customer requirements
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Output
Significant production run Measurement system evaluation Preliminary process capability study Production part approval Production validation testing Packaging evaluation Production control plan Quality planning sign-off and management support
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4.1 SIGNIFICANT PRODUCTION RUN
Using production tooling, equipment, production environment, facility, production gage and production rate. (Refer to the Chrysler, Ford, and General Motors Production Part Approval Process (PPAP) manual or the appropriate customer-specific requirements for additional details ) (PPAP )
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Output of the significant production run (product) is used for: (): Preliminary process capability study Measurement systems evaluation Production rate demonstration Process review Production validation testing 81
Production part approval Packaging evaluation First time capability (FTC) (FTC) Quality planning sign-off
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Sample production parts Master sample (as required) ()
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4.2 MEASUREMENT SYSTEM EVALUATION
Measurement devices and methods should be subjected to measurement system evaluation during or prior to the significant production run. ,
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4.3 PRELIMINARY PROCESS CAPABILITY STUDY
Should be performed on characteristics identified in the control plan. Refer to the Production Part Approval Process reference manual
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4.4 PRODUCTION PART APPROVAL
All customer engineering design record and specification requirements are properly understood by the organization The manufacturing process has the potential to produce product consistently meeting these requirements during and actual production run at the quoted production rate.
Refer to Production Part Approval Process reference manual.

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4.5 PRODUCTION VALIDATION TESTING
Refers to engineering tests that validate that products made from production tools and processes meet engineering standards.
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4.6 PACKAGING EVALUATION
Assess the protection of the product from normal transportation damage and adverse environmental factors.
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4.7 PRODUDTION CONTROL PLAN
A written description of the system for controlling parts and processes. Appendix A-8 present Control Plan Methodology and a checklist to verify completeness.A-8
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4.8 QUALITY PLANNING SIGN-OFF AND MANAGEMENT SUPPORT
Team performs its review at the manufacturing location(s) and coordinates a formal sign-off. The sign-off occurs prior to first product shipment and includes a review of the following: :
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4.8 QUALITY PLANNING SIGN-OFF AND MANAGEMENT SUPPORT
Process flow chart Control plan Process instruction Monitoring and measuring devices Demonstration of required capacity
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4.8
QUALITY PLANNING SIGN-OFF AND MANAGEMENT SUPPORT
Upon the completion of the sign-off, a review with management should be scheduled to inform management of the program status and gain their support with any open issues. The Product Quality Planning Summary and Sign-off report shown in Appendix F is an example. F
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5.0 Feedback, Assessment & Corrective Action
Planning

Production

. /

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Evaluate the effectiveness of APQP process, reduce variation and enhance customer satisfaction by employing statistical technique
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Output
Employee Environment & Involvement
Employee Information Center
Reduced Variation Customer Satisfaction Delivery and Service Effective use of Lessons Learned/Best Practice /
Business Objectives Scrap Uptime On Time Delivery Goal Jan. Apr. Jul. Dec.
Goal
Jan. Apr. Jul. Dec.
Goal
Our improvement Teams efforts have helped us meet our goals.
Jan. Apr. Jul. Dec.
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5.1
REDUCED VARIATION
Statistical techniques should be used as tools to identify process variation Analysis and corrective actions should be used to reduce variation.
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5.2
CUSTOMER SATISFACTION
The product or service must perform in the customer environment. The organization and customer must be partners in making the changes necessary to correct deficiencies to improve customer satisfaction.
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5.3
DELIVERY AND SERVICE
Experience gained provides the customer and organization with the necessary knowledge to reduce process, inventory, and quality costs and to provide the right component or system for the next product.
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5.4 EFFECTIVE USE OF LESSONS LEARNED/BEST PRACTICES /

A lessons Learned or Best Practices portfolio is beneficial for capturing, retaining and applying knowledge, Input to Lessons Learned and Best Practices can be obtained through a variety of methods including: Review of Things Gone Rights/Things Gone Wrong (TGR/TGW) Data from warranty and other performance metrics Corrective action plans Red-across with similar products and processes DFMEA and PFMEA
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5.4 EFFECTIVE USE OF LESSONS LEARNED/BEST PRACTICES /

/ : (TGR/ TGW) DFMEA & PFMEA
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APQP PPAP
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APQP

Vision Technology International Limited

Vision Technology International Limited

Vision Technology International Limited

APQP Reference Manual should be read, understood and

Vision Technology International Limited

To promote early identification of required changes

Vision Technology International Limited

Form the team

Vision Technology International Limited

Define the Scope

Vision Technology International Limited

Vision Technology International Limited

Vision Technology International Limited

GOAL: Expedite the introduction of quality products sooner :

Vision Technology International Limited

Product Design & Dev. Process Design & Dev.

Product &Process Validation Production

Feedback Assessment And Corrective Action

Concept Initiation / Approval

Vision Technology International Limited

Vision Technology International Limited

Plan and Define Programme 1. 0

Vision Technology International Limited

Plan and Define Program 1.0

Vision Technology International Limited

Vision Technology International Limited

Vision Technology International Limited

1.1.1 MARKET RESEARCH

Vision Technology International Limited

1.1.2 HISTORICAL WARRANTY AND QUALITY INFORMATION

Vision Technology International Limited

1.1.2 HISTORICAL WARRANTY AND QUALITY INFORMATION

Vision Technology International Limited

1.1.3 TEAM EXPERIENCE

Vision Technology International Limited

1.1.3 TEAM EXPERIENCE

1.2 BUSINESSS PLAN/MARKETING SYRATEGY /

Vision Technology International Limited

PRODUCT/PROCESS BENCHMARK DATA

Vision Technology International Limited

1.4 PRODCUT/PROCESS ASSUMPTIONS /

Vision Technology International Limited

1.5 PRODUCT RELIABILITY STUDIES

Vision Technology International Limited

1.6 CUSTOMER INPUTS

Vision Technology International Limited

Plan and Define Program 1.0

Vision Technology International Limited

1.7 DESIGN GOALS

Vision Technology International Limited

1.8 RELIABILITY AND QUALITY GOALS

Vision Technology International Limited

1.8 RELIABILITY AND QUALITY GOALS

Vision Technology International Limited

1.9 PRELIMINARY BILL OF MATERIAL

Based on product/process assumptions and include early subcontractor list. /

Vision Technology International Limited

1.10 PRELIMINARY PROCESS FLOW CHART

Development from the preliminary bill of material and

Vision Technology International Limited

1.11 Special product & process characters

Vision Technology International Limited