APQP Advance Product Quality...
Transcript of APQP Advance Product Quality...
APQP – Advance Product Quality Planning
Krzysztof Dybioch – Bridgestone Poznań Quality Engineer
21-05-2014 Poznań
Agenda
1. History of Quality Systems
2. Quality system core tools
2.1. QS-9000
2.2. FMEA
2.3. PPAP
2.4. SPC
2.5. MSA
2.6. APQP
1. History of Quality Systems
• 1959 – USA Ministry of Defense „Quality programme reqirements” • 1968 – NATO and AQAP-1 • 1978 – GB Ministry of Defense and DEF/STAN 05-8 • 1979 - British Standards Institute issue first trade standard BS 5750 • 1987 – International Standard Organisation (ISO) issue ISO 9000 • 1993 – PN-EN 29000-29004 standards • 1994 – update to ISO 9000:1994 • 1994 – „big three” Ford/Chrysler/GM issue QS-9000 • 1999 – IATF/AIAG – ISO/TS 16949 • 1999 – new standards, more process oriented ISO 9000:2000 • 2002 – Second edition of ISO/TS 16949:2002 • 2008 – Update ISO 9001:2008 • 2009 – ISO/TS 16949:2009 also includes ISO 9001:2008 requirements
2. Quality system core tools
• QS 9000 Quality System Requirements (3rd edition October 1998)
• FMEA – Potential Failure Mode and Effects Analysis (4th edition June 2008)
• PPAP - Production Part Approval Process (4th edition March 2006)
• SPC – Statistical Process Control (2nd edition July 2005) • MSA – Measurement System Analysis (4th edition July
2010) • QSA – Quality System Assessment (2nd edition March
1998) • APQP – Advanced Product Quality Planing (2nd edition July
2008)
2.1. QS 9000
QS-9000 (Quality System Requirements) which basis on ISO 9001 from 1994 but enruched with the requirements of automotive industry
2.1. QS-9000
The minimum seven documents one will need for the QS-9000 program are:
• QS-9000 Quality System Requirements • Advanced Product Quality Planning and Control Plan
(APQP) • Failure Mode and Effects Analysis (FMEA) • Measurement Systems Analysis • Statistical Process Control • Production Part Approval Process (PPAP) manual • Quality System Assessment (QSA) manual
2.2. FMEA – Failure Mode and Effects Analysis
FMEA is a tool used to systematically analyze component or process failures and identify the resultant effects on system operations. To be reliable such analysis has to be done by CFT comprising members of different departments (QA, TS, Prod, MNT, Planning, etc.)
2.2. FMEA – Failure Mode and Effects Analysis
2.3. PPAP - Production Part Approval Process PPAP is a confirmation from supplier. It usually contains
such elements:
• Design Records
• Authorized Engineering Change Documents
• Engineering Approval
• DFMEA
• Process Flow Diagram
• PFMEA
• Control Plan
• Measurement System Analysis Studies (MSA)
• Dimensional Results
• Records of Material / Performance Tests
• Initial Sample Inspection Report
• Initial Process Studies
• Qualified Laboratory Documentation
• Appearance Approval Report
• Sample Production Parts
• Master Sample
• Checking Aids
• Customer-Specific Requirements
• Part Submission Warrant (PSW)
2.3. PPAP - Production Part Approval Process
2.4. SPC – Statistical Process Control
SPC is a quality methods to monitor and control process stability with statistical tools like: • Average • Standard deviation • process capability index CPK • Process capability CP • Process performence index PPK • Statistical control cards like X-R
2.4. SPC – Statistical Process Control cont.
• Cpk
• X-R
2.5. MSA
MSA is a method of exsperiment to check measurement system capability:
• Variations
• Repeatability
• Reproducibility
• Ndc
2.5. MSA
Part Number Gage Name Appraiser A Part Number Gage Name Appraiser A
Part Name Gage Number Appraiser B Part Name Gage Number Appraiser B
Characteristic Gage Type Appraiser C Characteristic Gage Type Appraiser C
Characteristic Classif ication Trials Parts Appraisers Date Performed Characteristic Classif ication Trials Parts Appraisers Date Performed
APPRAISER/ PART AVERAGE Measurement Unit Analysis
TRIAL # 1 2 3 4 5 6 7 8 9 10 Repeatability - Equipment Variation (EV)
1. A 1 EV = R x K1 Trials K1 % EV = 100 (EV/TV)
2, 2 = 2 0,8862 =
3, 3 = 3 0,5908 =
4, AVE xa= Reproducibility - Appraiser Variation (AV)
5, R ra= AV = {(xDIFF x K2)2 - (EV2/nr)}1/2
% AV = 100 (AV/TV)
6. B 1 = =
7, 2 = 2 3 =
8, 3 0,7071 0,5231 n = number of parts
9, AVE xb= Repeatability & Reproducibility (R & R) r = number of trials
10, R rb= R & R = {(EV2 + AV2)}1/2Parts K3 % R&R = 100 (R&R/TV)
11. C 1 = 2 0,7071 =
12, 2 = 3 0,5231 =
13, 3 Part Variation (PV) 4 0,4467
14, AVE xc= PV = RP x K3 5 0,4030 % PV = 100 (PV/TV)
15, R rc= = 6 0,3742 =
16. PART X= = 7 0,3534 =
AVE ( Xp ) Rp= Total Variation (TV) 8 0,3375 ndc =
17, (ra + rb + rc) / (# OF APPRAISERS) = R= TV = {(R&R)2+PV2}1/29 0,3249 =
18, (Max x - Min x) = xDIFF= = 10 0,3146 =
19, R x D4* = UCLR= = =
20, R x D3* = LCLR=
Attention:
* D4 =3.27 for 2 trials and 2.58 for 3 trials; D3 = 0 for up to 7 trials. UCLR represents the limit of individual R's. Circle those that are - All calculations are based upon predicting 5.15 sigma (99.0% of the area under the normal distribution curve).
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or dis-- K1, K2, K3 are obtained from MSA Reference Manual (Fourth Edition, First Printing, June 2010)
card values and re-average and recompute R and the limiting value from the remaining observations. - For information on the theory & constans used in the form see MSA Reference Manual (Fourth Edition).
Notes:
Specif ication
Appraisers
K2
% Total Variation (TV )
1.41 x (PV/R&R)
GAGE REPEATABILITY AND REPRODUCIBILITYData Collection Sheet (according to MSA 4'th ed.)
GAGE REPEATABILITY AND REPRODUCIBILITYReport (according to MSA 4'th ed.)
2.6. APQP
APQP is NOT a tool.
It is an idea of quality management and defines action need to be taken before mass production realization
2.6.1. APQP - content
APQP says to You what to do before even contract signing with customer, it contains:
• Knowleadge about technology • Customer specyfic requirements • Technical and financial requirements to start production • Construction • Nonconforming product risk analysis • SPC – methods of quality, process and measurment devices control • Instructions, control plans • Delivery • Maintenance • Personel qualifications • Client approval process • Serial or mass production realization
2.6.2. APQP - purpose
• The aim of APQP is to meet as fast as possible customer requirements by stable process. It is very important not only from business poinf of view but in automotiv it can influence helth and lives of clients
2.6.3. APQP – rules and sequensce of realization
time
Process planning
Planning
Construction design
Part and process
validation
Action evaluation and corrective action
Tools
Planning
Serial production
PPAP
PSW
Project analysis Product project
Process projects Project acceptance
Serial production
Client inquiry Start of production
2.6.4. APQP - Management principles
• Project leader • Teamwork • The use of quality tools • Close cooperation with client • Documentation • Monitoring of various stages • PPAP documentation and client approvals • Require certificates from suppliers • Continous improovement
2.6.5. APQP - Teamwork
QS-9000 and ISO/TS16949 requires work in CFT !!!
• FMEA Control Plans
• Floor Layout Projects
• QPRs and countermeasures
2.6.6. APQP - Tools
Calculations:
• Control sheets, SPC, Six Sigma
• Pareto
• Histogram
2.6.7. APQP – Tools cont.
Teamwork techniques
Brainstorm JIT Ishikawa
2.6.8. APQP – Tools cont.
Concept work
Risk analysis Flow chart
2.6.9. APQP – Tools cont.
Concept work
5S Radar
2.6.10. APQP – Tools cont.
Concept work
Poka-Yoke Experiments 8D
2.6.11. APQP – Tools cont.
Concept work
Benchmarking Business Plan
and many more …
Thank You for Your attention