In Generally Manufacturing Industry, maybe you will recognize with therminology of APQP or Advance Product Quality Planning. In Indonesia, [on my understanding] that all of Automotive Company already had applicated APQP Program. But actually, APQP is not only for Automotive Industry. APQP also suitable for Electronics Industry, Metal Industry, etc.
Introduction
As Etimology, APQP consist of words : Advance(Kelanjutan) – Product (Produk) – Quality (Kualitas) – Planning (Perencanaan).
And as Epistimology, APQP is defined as a framework of procedures and techniques used to develop products in industry, particularly the automotive industry. APQP is a ‘defined’ process for a product development system for General Motors, Ford, Chrysler and their suppliers.
Product Quality Planning is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer. The goal of product quality planning is to facilitate communication with everyone involved to assure that all required steps are completed on time.
The classic reason that will be asked to you if you presented APQP in your company is “What is the benifits for our Company?”. Some of the benifits of APQP are :
1. To direct resources to satisfy the customer.
2. To promote early identification of required changes.
3. To provide a quality product on time at the lowest cost.
4. To avoid late changes.
The Fundamentals of APQP
Just for your notification that the actual timing and sequence of execution is dependent on customer needs and expectations and or the other practical matters. It’s more better if the earlier a work practice, tool and or analytical technique can be implemented in the Product Quality Planning Cycle.
Organize the Team
Team coordination and solid team is one of sucess key factors of APQP implementation. The first step in Product Quality Planning is to assign responsibility to a cross functional team. Effective product quality planning requires the involvement of more than just the quality department. In the apllication time, the initial team should include representatives from engineering, manufacturing, supply chain management, quality control, sales, field service, subcontractors and customer [If Needed].
Communication Team to Team
The Team must establish lines of communication with other customer and supplier teams.
Simultaneous Engineering
This is a process where cross functional teams strive for a common goal. It replaces the sequential series of phases where results are transmitted to the next area for execution.
Define the Scope
Scope of APQP have to be defined before starting process. It is important for the Product Quality Planning Team in the earliest stage of the product program to identify customer needs, expectations and requirements.
At a minimum, the team must :
a. Select a project team leader responsible for overseeing the planning process.
b. Define the roles and responsibilities of each area represented.
c. Identify the customers (internal and external).
d. Define customer requirements (It is recommended to use Quality Function Deployment - QFD). e. Select the disciplines, individuals and or subcontractors that must be added to the team and those not required.
f. Understand customer expectations, for example : design, number of tests.
g. Assess the feasibility of the proposed design, performance requirements and manufacturing process.
h. Identify costs, timing, and constraints that must be considered.
i. Determine assistance required from the customer.
j. Identify documentation process or method.
Training
The success of a Product Quality Plan is dependent upon an effective training program that communicates all the requirements and development skills to fulfill customer needs and expectations.
Customer and Supplier Involvement
The primary customer may initiate the quality planning process with a supplier.
Control Plans
Control Plans are written descriptions of the systems for controlling parts and processes. Separate Control Plans cover three distinct phases :
1. Prototype - A description of the dimensional measurements and material and performance tests that will occur during Prototype build.
2. Pre-launch - A description of the dimensional measurements and material and performance tests that will occur after Prototype and before full Production.
3. Production - A comprehensive documentation of product/process characteristics, process controls, tests, and measurement systems that will occur during mass production.
Concern Resolution
During the planning process, the team will encounter product design and or processing concerns. These concerns should be documented on a matrix with assigned responsibility and timing.
Note : Disciplined problem-solving methods are recommended in difficult situations.
Product Quality Timing Plan
The Team’s first order of business following organizational activities should be the development of a Timing Plan. The type of product, complexity and customer expectations should be considered in selecting the timing elements that must be planned and charted.
Note : A well-organized timing chart should list tasks, assignments, and or the other events.
The Timing Chart
The Phases of APQP
1. Plan and Define Program [Where do we want to go?]
2. Product Design and Development Verification [Can we design one?]
3. Process Design and Development Verification [Can we make one?]
4. Product and Process Validation [Proof of Phases 2 and 3]
5. Launch, Feedback, Assessment and Corrective Action [Production, Continuous Improvement, Prevent Recurrence]
The Activities of APQP
On APQP, there are five major activities :
1. Planning.
2. Product Design and Development.
3. Process Design and Development.
4. Product and Process Validation.
5. Production.
Target and Goal
The APQP Process
Phase 1st of APQP – Plan adn Define Program
Input of Phase 1st
Voice of the Customer
The “Voice of the Customer” encompasses complaints, recommendations, data and information obtained from internal and or external customers. Several methods for this are:
Market Research
The Team may need to obtain market research data and information reflecting the Voice of the Customer. The following sources can assist in identifying customer concerns or wants and translating those concerns into product and process characteristics. The Sources of Market Researche are :
1. Customer interviews.
2. Customer questionnaires and surveys.
3. Market test and positioning reports.
4. New product quality and reliability studies.
5. Competitive product quality studies.
6. Things Gone Right (TGR) reports.
Historical Warranty and Quality Information
A list of historical customer concerns or wants should be prepared to assess the potential for recurrence during the design, manufacture, installation and use of the product. These should be considered as an extension of the other design requirements and included in the analysis of customer needs. The Assisting Items are :
a. Things Gone Wrong (TGW) reports.
b. Warranty reports.
c. Capability indicators.
d. Supplier plant internal quality reports.
e. Problem resolution reports.
f. Customer plant returns and rejections.
g. Field return product analysis.
Team Experience
The Team may use any source of any information as appropriate, including :
1. Input from higher system level or past QFD projects.
2. Media commentary and analysis (magazine and newspaper reports, etc.)
3. Customer letters and suggestions.
4. TGR or TGW reports.
5. Dealer comments.
6. Fleet Operator’s comments.
7. Field service reports.
8. Internal evaluations using surrogate customers.
9. Road trips.
10. Management comments or direction.
11. Problems and issues reported from internal customers.
12. Government requirements and regulations.
13. Contract review.
Business Plan or Marketing Strategy
The customer business plan and marketing strategy will set the framework for the product quality plan. The business plan may place constraints (e.g., timing, cost, investment, product positioning, R and D resources) on the team that affect the direction taken. The marketing strategy will define the target customer, the key sales points, and key competitors.
Product or Process Benchmark Data
The use of Benchmarking will provide input to establishing product or process performance targets. One method to successful benchmarking is:
a. Identify the appropriate benchmarks.
b. Understand the reason for the gap between your current status and the benchmark.
c. Develop a plan to either close the gap, match the benchmark, or exceed the benchmark.
Product or Process Assumptions
There will be assumptions that the product has certain features, design, or process concepts. These include technical innovations, advanced materials, reliability assessments, and new technology. All should be utilized as inputs.
Product Reliability Studies
This type of data considers frequency of repair or replacement of components within designated periods of time and the results of long-term reliability/durability tests.
Customer Inputs
The 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. These inputs should be used by the customer and or supplier to develop agreed upon measures of customer satisfaction.
Output of Phase 1st
Design Goals
Design goals are a translation of the Voice of the Customer into tentative and measurable design objectives. The proper selection of Design Goals assures that the Voice of the Customer is not lost in subsequent design activity.
Reliability and Quality Goals
Reliability goals are established based on customer wants and expectations, program objectives and reliability benchmarks. Overall reliability goals should be expressed in terms of probability and confidence limits.
Quality goals are targets based on continual improvement. Some examples are parts per million, defect levels, or scrap reduction.
Preliminary Bill of Material
The Team should establish a preliminary bill of material based on product/process assumptions and include an early subcontractor list. In order to identify the preliminary special product/process characteristics it is necessary to have selected the appropriate design and manufacturing process.
Preliminary Process Flow Chart
The anticipated manufacturing process should be described using a process flow chart developed from the preliminary bill of material and product/process assumptions.
Preliminary Listing of Special Product and Process Characteristics
Special product and process characteristics are identified by the customer in addition to those selected by the supplier through knowledge of the product and process.
At this stage, the team should assure that a preliminary list of special product and process characteristics resulting from the analysis of the inputs pertaining to customer needs and expectations is developed.
This listing could be developed from but is not limited to the following :
1. Product assumptions based on the analysis of customer needs and expectations.
2. Identification of reliability goals/requirements.
3. Identification of special process characteristics from the anticipated manufacturing process.
4. Similar part FMEAs.
Product Assurance Plan
This Plan translates design goals into design requirements. The Plan can be developed in any understandable format and should include, but is not limited to the following actions :
a. Outlining of program requirements.
b. Identification of reliability, durability, and apportionment/allocation goals and/or requirements.
c. Assessment of new technology, complexity, materials, application, environment, packaging, service, and manufacturing requirements, or any other factor that may place the program at risk.
d. Development of Failure Mode Analysis (FMA).
e. Development of preliminary engineering standards requirements.
Note : The Product Assurance Plan is an important part of the Product Quality Plan.
Management Support
One of the keys to the Team’s success is the interest, commitment and support of upper management. Participation by management in product quality planning meetings is vital to ensuring the success of the program.
Phase 2nd of APQP – Product Design and Development Verification
Output of Phase 2nd
Design Failure Mode and Effect Analysis
A DFMEA is a living document continually updated as customer needs and expectations require.
DFMA is a Simultaneous Engineering process designed to optimize the relationship between design function, manufacturability, and ease of assembly.
At a minimum, the Team should consider :
1. Design, concept, function, and sensitivity to manufacturing variation.
2. Manufacturing and/or assembly process.
3. Dimensional tolerances.
4. Performance requirements.
5. Number of components.
6. Process adjustments.
7. Material handling.
Note : The Team’s knowledge, experience, the product or process, government regulations, and service requirements may require other factors to be considered.
Design Verification
Design Verification verifies that the product design meets the customer requirements derived form activities described in Phase 1.
Design Reviews
The Design Review is an effective method to prevent problems and misunderstandings; it also provides a mechanism to monitor progress and report to management.
Design Reviews are a series of verification activities that are more than an engineering inspection.
At a minimum, Design Reviews should include evaluation of :
a. Design or Functional requirement(s) considerations.
b. Formal reliability and confidence goals.
c. Component/subsystem/system duty cycles.
d. Computer simulation and bench test results.
e. DFMEA(s).
At a minimum, Design Reviews should include evaluation of :
1. Review of the Design for Manufacturability and Assembly effort.
2. Design of Experiments (DOE) and assembly build variation results.
3. Test failures.
4. Design Verification progress.
A major function of Design Reviews is the tracking of design verification progress. The company should track the progress through the use of a plan and report format, referred to as Design Verification Plan and Report (DVP and R). The plan and report is a formal method to assure :
a. Design verification.
b. Product and process validation of components and assemblies through the application of a comprehensive test plan and report.
Prototype Build Control Plan
Prototype Control Plans are a description of the dimensional measurements and material and functional tests that will occur during prototype build. The Team should ensure that a prototype control plan is prepared.
The manufacture of prototype parts provides an excellent opportunity for the team and the customer to evaluate how well the product or service meets Voice of the Customer objectives. All prototypes should be reviewed to :
1. Assure that the product or service meets specification and report data as required.
2. Ensure that particular attention has been given to special product and process characteristics.
3. Use data and experience to establish preliminary process parameters and packaging requirements.
4. Communicate any concerns, deviations, and/or cost impact to the customer.
Engineering Drawings including Math Data
Engineering drawings may include special (governmental regulatory and safety) characteristics that must be shown on the control plan.
Drawings should be reviewed to determine if there is sufficient information for a dimensional layout of the individual parts.
Control or datum surfaces or locators should be clearly identified so that appropriate functional gages and equipment can be designed for ongoingcontrols.
Dimensions should be evaluated to assure feasibility and compatibility with industry manufacturing and measuring standards.
Note : If appropriate, the team should assure that math data is compatible with the customer’s system for effective communications.
Engineering Specifications
A detailed review and understanding of the controlling specifications will help the Team to identify the functional, durability and appearance requirements of the subject component or assembly. Sample size, frequency, and acceptance criteriaof these parameters are generally defined in the in-process test section of the Engineering Specification.
Material Specifications
Material specifications should be reviewed for Special Characteristics relating to physical properties, performance, environmental, handling, and storage requirements.
Drawing and Specification Changes
Where drawing and specification changes are required, the team must ensure that the changes are promptly communicated and properly documented to all affected areas.
Phase 3rd of APQP – Process Design and Development Verification
Phase 4th of APQP – Product and Process Validation
Phase 5th of APQP – Launch, Feedback, Assessment and Corrective Action
Control Plan Methodology - Advanced Product Quality Planning (APQP)
Phase 1st
1. Determining customer needs, requirements and expectations using tools such as quality function deployment (QFD).
2. Review the entire quality planning process to enable the implementation of a quality program.
3. How to define and set the inputs and the outputs.
Phase 2nd
Review the inputs and execute the outputs, which include FMEA, DFMA, design verification, design reviews, material and engineering specifications.
Phase 3rd
a. Addressing features for developing manufacturing systems and related control plans.
b. These tasks are dependent on the successful completion of phases 1 and 2.
c. Execute the outputs.
Phase 4th
1. Validation of the selected manufacturing process and its control mechanism through production run evaluation outlining mandatory production conditions and requirements.
2. Identifying the required outputs.
Phase 5th
a. Focuses on reduced variation and continuous improvement.
b. Identifying outputs and links to customer expectations and future product program.
Additional Materials
Understand customer needs
This is done using voice of customer techniques to determine customer needs and using quality function deployment (QFD) to organize those needs and translate them into product characteristics or requirements.
Proactive feedback and corrective action
The advance quality planning process provides feedback from other similar projects with the objective of developing counter-measures on the current project. Other mechanisms with verification and validation, design reviews, analysis of customer feedback and warranty data also satisfy this objective.
Design within process capabilities
This objective assumes that the company has brought processes under statistical control, has determined its process capability and has communicated it process capability to its development personnel.
Note: Once this is done, development personnel need to formally determine that critical or special characteristics are within the enterprise’s process capability or initiate action to improve the process or acquire more capable equipment.
Analyze and mitigate failure modes
This is done using techniques such as failure modes and effects analysis or anticipatory failure determination.
Verification and validation
Design verification is testing to assure that the design outputs meet design input requirements. Design verification may include activities such as: design reviews, performing alternate calculations, understanding tests and demonstrations, and review of design documents before release.
Validation is the process of ensuring that the product conforms to defined user needs, requirements, and or specifications under defined operating conditions.
Design validation is performed on the final product design with parts that meet design intent.
Production validation is performed on the final product design with parts that meet design intent produced production processes intended for normal production.
Design reviews
Design reviews are formal reviews conducted during the development of a product to assure that the requirements, concept, product or process satisfies the requirements of that stage of development, the issues are understood, the risks are being managed, and there is a good business case for development. Typical design reviews include:
1. Requirements review,
2. Concept or preliminary design review,
3. Final design review, and
4. A production readiness or launch review.
Control special or critical characteristics
Special or critical characteristics are identified through quality function deployment (QFD) or other similar structured method. Once these characteristics are understood, and there is an assessment that the process is capable of meeting these characteristics (and their tolerances), the process must be controlled.
A control plan is prepared to indicate how this will be achieved. Control plans provide a written description of systems used in minimizing product and process variation including equipment, equipment set-up, processing, tooling, fixtures, material, preventive maintenance and methods.
The Elements
The APQP process has seven major elements :
a. Understanding the needs of the customer.
b. Proactive feedback and corrective action.
c. Designing within the process capabilities.
d. Analyzing and mitigating failure modes.
e. Verification and validation.
f. Design reviews.
g. Control special or critical characteristics.
Reference : Training Module of Sachbudi Abbas Ras, S.T., M.T.
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