668: APQP - Efficient Project Management with Control Plan

SAP Best Practices IM&C Package (China)

SAP Best Practices

Scenario Overview – 1

Purpose The scenario shows the full project management cycle following the

APQP standard.

Benefits Standardizes the development process by using templates Increase customer satisfaction Deliver quality products on time with the lowest possible costs Reduce nonconformity costs by recognizing necessary changes early Improve communication and decision making processes with internal

and external partners by using Web-based access Increase the transparency of projects by full integration between

project, documents and cFolders which enables direct access to all project-related documents

Integration of control plan and PLM backend system help the supplier raise the project management efficiency as well as quality management in future production

Purpose and Benefits:

Scenario Overview – 2

Project Manager Quality Manger Engineer

SAP Applications Required:

Company Roles Involved in Process Flows:

Key Process Flows Covered:

Project creation based on the APQP template using cProjects Roles and authorization definition for different parties in

cProjects Project Resource Planning Document uploading Checklist maintenance Checklist Items status maintenance Q-Gate: Initiating Phase Approval Project Evaluation Control Plan Collaboration via cFolders Q-Gate: Phase and project completion approval

SAP ECC 6.0 EhP3

Scenario Overview – 3

Detailed Process Description:

APQP - Efficient Project Management with Control Plan

The OEM requests a new product development from the supplier

The supplier creates the project by copying the APQP template. Changes are made to the project structure based on the OEM’s specific requirement. Resources are later assigned to the project, and the project is scheduled

For the first phase - Concept Design, a Q-Gate is defined. After creating the related template documents for the project, and changing the task status, the project manager creates an approval

The Quality Manager grants the approval, then the engineers start to create the control plan for the project

After the control plan is created, it is downloaded as a pdf file. The control plan is also transferred to the SAP ERP system, and an inspection plan in the SAP ERP system is generated automatically

The project manager transfers the related data during the project to cFolders, and the project is completed

Process Flow Diagram E

ng

ine

er

Ev

en

t

MRP = Material Requirements Planning, PPV = Purchase Price Variance

Confirm status for Checklist

Items

Create a collaboration

folder with the OEM

Create Project base on APQP

template

Complete Project

Maintain Checklist

Generate Object (Export Insp. Plan to

SAP ERP)

Roles and Authorization

Definition

Project Resource

Scheduling

Upload document to

project

Maintain Task Status

Create Control Plan

Pro

jec

t M

an

ag

er

Create Collaboration

Qu

ali

ty

Ma

na

ge

r

Q-Gate: Phase Approval

Project Evaluation

Print and Download

Control Plan

Maintain Designing FMEA Task

and Checklist

APQP - Efficient Project Management with Control Plan

Define type of APQP

Review/ Approval

Review/Approval

ReviewPre-ProductionRelease

ReviewSOP Release

1) Concept

Phase

RFQ / Businesscase

Development Plan

Regulations (Laws, Standards, Objectives)

Continuous Improvement

2) Product Design

Design FMEA

PreliminaryBill of Materials

Specification

Design collaboration

Control Plan(Prototype)

3) ProcessDesign

Process FMEA

Routing creation

Process flow diagram

Statistical processControl (SPC)

Control plan(Model)

4) Validation

Planning and production under real-life conditions

Control plan forseries production and inspection plan

Process audit

Production partapproval process

5) Product Launch

Quality Inspections during Production

Requalificationtests

Processoptimization

Advanced Product Quality Planning Phase Approach

A guideline for APQP is included in QS9000, which contains the general requirements on how the supplier should handle a new product development project to meet the customer requirements by planning the product and process quality in advance.

In this scenario, the basic requirements from the APQP manual are included in a project template, for preparing plans and checklists, to ensure that Advanced Product Quality Planning is actually carried out at the supplier.

APQP (Advanced Product Quality Planning) is a mandatory new product development process for suppliers in many Industries, in order to fulfill the requirements from QS9000.

To use APQP, OEM and Supplier have the following requirements:

Need a standard template for an APQP project

Different roles and authorization defined for the different parties involved

Detailed processing for the control plan

Transparency to the OEM

With the traditional SAP system, it is difficult to fulfill all the requirements and standards defined for APQP. But we can meet the requirements by using cProject as following:

A business scenario for APQP project management starts by creating a project following the APQP standard. Roles and authorization should be defined for different parties. Interactive operations between the QM, PM, and engineer at the supplier side are then processed.

A practical control plan should be created during the procedure, and be seamlessly linked to the quality execution system.

The OEM should also have the possibility to check the working procedures and related documentation through a certain system.

Business Background

Supplier

Project Manager Quality Manager Engineer

OEM

New Product Development

Request

Supplier - cProjects

APQP Project

Create Project basedOn APQP template

Resources Planning

Create Project basedOn APQP template

Project Scheduling

Q-Gate Setting

Resources Planning

Project Scheduling

Q-Gate Setting

APQPtemplate

Upload Documents

Concept Design

Maintain Task Status

Upload Documents

Copy/Maintain Checklistand confirm Status

Maintain Task Status Project Evaluation

Q-Gate:Phase Approval

Create/Download/PrintControl Plan

Export Inspection PlanTo R/3Create Collaboration

Complete Project

Copy/Maintain Checklistand confirm Status

Project Evaluation

Q-Gate:Phase Approval

Create/Download/PrintControl Plan

cFolders

APQP Project Folders

Export Inspection PlanTo R/3

Product Design

Concept Design

Design FMEABOM

Control Plan

Monitor

Product Design

Process Design

Validation

Product Launch

Design FMEA, BOM, Control Plan, Process Flow, Diagram, Process FMEA, PPAP Design

Process Design

Validation

Product Launch

Create Collaboration

Complete Project

Information Synchronization Solution for OEM and Supplier in SAP BP

cProjects is used to control the project, especially the pre-BOM phase

The template is pre-defined in SAP Best Practices for IM&C

Project Template in c-Project

Control Plan created in cProjects can be downloaded as a pdf file

Control Plan created in cProjects can be transferred to the SAP ERP system

An Inspection Plan in the SAP ERP system can be automatically generated based on the Control Plan

Control Plan in pdf Format

cFolders is linked with cProjects

Related information during the project can be published to the cFolders

The OEM has the possibility to monitor the project remotely

cFolders Linked to the cProjects

Legend

Symbol Description Usage Comments

Band: Identifies a user role, such as Accounts Payable Clerk or Sales Representative. This band can also identify an organization unit or group, rather than a specific role.

The other process flow symbols in this table go into these rows. You have as many rows as required to cover all of the roles in the scenario.

Role band contains tasks common to that role.

External Events: Contains events that start or end the scenario, or influence the course of events in the scenario.

Flow line (solid): Line indicates the normal sequence of steps and direction of flow in the scenario.Flow line (dashed): Line indicates flow to infrequently-used or conditional tasks in a scenario. Line can also lead to documents involved in the process flow.

Connects two tasks in a scenario process or a non-step event

Business Activity / Event: Identifies an action that either leads into or out of the scenario, or an outside Process that happens during the scenario

Does not correspond to a task step in the document

Unit Process: Identifies a task that is covered in a step-by-step manner in the scenario

Corresponds to a task step in the document

Process Reference: If the scenario references another scenario in total, put the scenario number and name here.

Corresponds to a task step in the document

Sub-Process Reference: If the scenario references another scenario in part, put the scenario number, name, and the step numbers from that scenario here

Corresponds to a task step in the document

Process Decision: Identifies a decision / branching point, signifying a choice to be made by the end user. Lines represent different choices emerging from different parts of the diamond.

Does not usually correspond to a task step in the document; Reflects a choice to be made after step execution

Symbol Description Usage Comments

To next / From last Diagram: Leads to the next / previous page of the Diagram

Flow chart continues on the next / previous page

Hardcopy / Document: Identifies a printed document, report, or form

Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines

Financial Actuals: Indicates a financial posting document

Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines

Budget Planning: Indicates a budget planning document

Does not correspond to a task step in a document; instead, it is used to reflect a document generated by a task step; this shape does not have any outgoing flow lines

Manual Process: Covers a task that is manually done

Does not generally correspond to a task step in a document; instead, it is used to reflect a task that is manually performed, such as unloading a truck in the warehouse, which affects the process flow.

Existing Version / Data: This block covers data that feeds in from an external process

Does not generally correspond to a task step in a document; instead, this shape reflects data coming from an external source; this step does not have any incoming flow lines

System Pass / Fail Decision: This block covers an automatic decision made by the software

Does not generally correspond to a task step in the document; instead it is used to reflect an automatic decision by the system that is made after a step has been executed.

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Ext

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Business Activity /

Event

Unit Process

Process Reference

Sub-Process

Reference

Process

Decision

Diagram Connection

Hardcopy / Document

Financial Actuals

Budget Planning

Manual Proces

s

Existing Version /

Data

System Pass/F

ail Decisio

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