Post on 31-Dec-2015
AdvancedProductQuality
PlanningADVANCED PRODUCT QUALITY PLANNING
INSTRUCTIONAL PRESENTATION – MIKE RIZUTORev 6.1
Lack of collaboration is a major risk Late engagement is a risk
How much is new? How much time? How many resources?
Design Collaboration Process Collaboration
Rev 6.1
= AdvancedLet’s start early,
with the concepts and collaboration
= ProductThis is what the
customer is requesting
= QualityLet’s get it right the first time, efficiently
and every time = Planning
Through Collaboration we’ll
create a robust plan
Structured collaboration involving Engineering, Manufacturing, Material Control, Purchasing, Quality, Sales and Management from both Polaris and the Supplier
INPUT!
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Advanced Product Quality Planning is a structured method of defining and
establishing the steps necessary to assure that a product satisfies the customer
Sometimes Referred to as Moving the MountainRev 6.1
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.
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The APQP/PDP Spreadsheet acts as
both a workbook and project tracker
Relevant product information is entered
Cross functional teams are established
Individual tasks are selected and assigned
Time lines are managed by date, responsibility, and
percent of completion
Documentation relative to the project
is stored
Overall APQP/PDP performance/progress
is reported
Here is where progress is
recorded and stored
The Spreadsheet
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Risk is determined by several factors:•Time to resource•New product•New supplier•Design risks• Safety critical•Technically complex• Supplier assessment score• Supplier performance (history)
The Polaris Risk Assessment considers the factors and selects whether the
APQP/PDP workbook will be level 1, 2 or 3
Each level will have a minimum number of APQP steps assigned
required to be completed by both Polaris and the Supplier
There are 63 possible steps to select on the APQP/PDP spreadsheet. These steps are selected by all or part of both
cross functional teams. Based on project risk, Polaris has 3 levels of APQP/PDP with
minimum required steps preselected.
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Level 1 – Low Risk
• 21 Mandatory APQP Steps SelectedLevel 2 –
Medium Risk
• 28 Mandatory APQP Steps SelectedLevel 3 –
High Risk
• 39 Mandatory APQP Steps Selected
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.00.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
Risk Assessment
PII Impact
Com
mod
ity R
isk
These are minimum APQP requirements as determined by Polaris, other value added APQP steps may be selected by the Supplier/Polaris cross functional teams
When saving APQP/PDP workbooks please use the naming convention of:project name_supplier_part number
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• 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
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• 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”
PDP Status Tab of Workbook
Provides a Snapshot of
PDP Progress by the Supplier
Populated from APQP Spreadsheet
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Data Derived from the Supplier PDP Status is Used to
Report Overall PDP Project Status
Across Multiple Suppliers
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SQE’s issue the APQP/PDP Workbook to our Suppliers. When the Supplier utilizes the Workbook Project PDP reporting is automatically reported by Supplier and by
Project to our Management Group.
RECAP• The APQP Spreadsheet acts as both a workbook and project tracker
• Relevant product information is entered
• Cross functional teams are established
• Individual tasks are selected and assigned
• Time lines are managed by date, responsibility, and percent of completion
• Documentation relative to the project is stored
• Overall APQP performance/progress is reported
Rev 6.1