APQP (Pankaj Nalwa)

Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)

By: Pankaj Nalwa


APQP, but for what?

Purpose of APQP is to produce a product quality plan which will support

development of a product or service that will satisfy the customer.

In simple words, APQP is intended to ensure that the supplier / manufacturer meets

all of the customer's requirements on time.

How to achieve this purpose?

By :

Up-front quality planning

Evaluating the output to determine if customer are satisfied & support continual

improvement.

APQP, but for what?

Purpose of APQP is to produce a product quality plan which will support

development of a product or service that will satisfy the customer.

In simple words, APQP is intended to ensure that the supplier / manufacturer meets

all of the customer's requirements on time.

How to achieve this purpose?

By :

Up-front quality planning

Evaluating the output to determine if customer are satisfied & support continual

improvement.

By: Pankaj Nalwa


Product Quality Planning Cycle

By: Pankaj Nalwa


The purpose of Product Quality Planning Cycle is to emphasize:

Up-front planning.The first three quarters of the cycle are devoted to up-front product quality planningthrough product / process validation.

The act of implementation.The fourth quarter is the stage where importance of evaluating the output serves twofunctions: to determine customer satisfaction and to support the pursuit of continualimprovement.

The purpose of Product Quality Planning Cycle is to emphasize:

Up-front planning.The first three quarters of the cycle are devoted to up-front product quality planningthrough product / process validation.

The act of implementation.The fourth quarter is the stage where importance of evaluating the output serves twofunctions: to determine customer satisfaction and to support the pursuit of continualimprovement.

By: Pankaj Nalwa


PQP usually doesn’t work effectively in organizations.

By: Pankaj Nalwa


PDCA

Plan

DoAct

Always

AlwaysSometimes

CheckSometimes

By: Pankaj Nalwa


If quality is to become a business strategy, top management mustunderstand quality as a planning strategy and provide leadership forcarrying out this strategy.

By: Pankaj Nalwa


Advanced product Quality Planning (APQP) is a structuredapproach to the design and development of new products andmanufacturing processes, designed to ensure that:

Suppliers understand the requirements of clients, end users andconsumers.

The proposed product or process design satisfies thoserequirements.

The supplier has the ability to consistently meet the clientsrequirements for quality, cost and delivery.

Advanced product Quality Planning (APQP) is a structuredapproach to the design and development of new products andmanufacturing processes, designed to ensure that:

Suppliers understand the requirements of clients, end users andconsumers.

The proposed product or process design satisfies thoserequirements.

The supplier has the ability to consistently meet the clientsrequirements for quality, cost and delivery.

By: Pankaj Nalwa


Roadblocks for APQP.

Lack of commitment from Top Management.

Lack of discipline.

Undefined priorities.

Undefined responsibilities.

Lack of accountability.

Personal egos and lack of team spirit.

Unclear approach.

Lack of resources.

Lack of knowledge.

Roadblocks for APQP.

Lack of commitment from Top Management.

Lack of discipline.

Undefined priorities.

Undefined responsibilities.

Lack of accountability.

Personal egos and lack of team spirit.

Unclear approach.

Lack of resources.

Lack of knowledge.

By: Pankaj Nalwa


The APQP process includes five main functions:

Planning of APQP elements.

Execution of APQP elements.

Monitoring the “Quality-of-Event” of the execution of the elements, as well as thetiming, by the team in-between FPDS milestones.

Issues Resolution

Status Reporting

The APQP process includes five main functions:

Planning of APQP elements.

Execution of APQP elements.

Monitoring the “Quality-of-Event” of the execution of the elements, as well as thetiming, by the team in-between FPDS milestones.

Issues Resolution

Status Reporting

By: Pankaj Nalwa


Prepare forAPQP

Plan and DefineProgram

ProductDesign and

Development

Product &Process

Validation

ProcessDesign and

Development

Feedback,Assessment &

Corrective Action

Process Flow for APQP

• Organize the Team

• Define the Scope

• Establish Team-to-TeamCommunication

• Provide Core ToolsTraining

• Involve Customersand Suppliers

• ImplementSimultaneousEngineering

• Develop ControlPlan Format

• Decide on ConcernResolution

• Develop ProductQuality Timing Plan










By: Pankaj Nalwa


Phase 1: Planning and defining the program

This phase is meant to determine customer needs and expectations. Purpose of thisphase is to ensure that the customer’s needs and expectations are fully understoodbefore proceeding with the “design & development of the product” or “manufacturingprocess associated with product”.

By: Pankaj Nalwa


Prepare forAPQP


ProductDesign and

Development

Product &Process

Validation

ProcessDesign and

Development


Corrective Action











• Voice of theCustomer

• BusinessPlan/MarketingStrategy

• Product/ProcessBenchmark Data

• Product/ProcessAssumptions

• Product ReliabilityStudies

• Customer Inputs

INPU

T• Organize the Team














• Customer Inputs

By: Pankaj Nalwa


Prepare forAPQP


ProductDesign and

Development

Product &Process

Validation

ProcessDesign and

Development


Corrective Action
















• Customer Inputs

INPU

T• Design Goals

• Reliability andQuality Goals

• Preliminary Billof Material

• PreliminaryProcess FlowChart

• PreliminaryListing of SpecialProduct andProcessCharacteristics

• ProductAssurance Plan

• ManagementSupport

OU

TPU

T















• Customer Inputs

• Design Goals


• Preliminary Billof Material

• PreliminaryProcess FlowChart

• PreliminaryListing of SpecialProduct andProcessCharacteristics

• ProductAssurance Plan


By: Pankaj Nalwa


Phase 2: Product design and development

In this phase, design features and characteristics are developed into near final form.

This phase focuses on developing the design of the product or service, and onensuring that it is feasible and will meet the customer’s expectations.

By: Pankaj Nalwa


Prepare forAPQP


ProductDesign and

Development

Product &Process

Validation

ProcessDesign and

Development


Corrective Action
















• Customer Inputs

INPU

T• Design Goals


• Preliminary Bill ofMaterial

• Preliminary ProcessFlow Chart

• Preliminary Listingof Special Productand ProcessCharacteristics

• Product AssurancePlan


OU

TPU

T

• Design Failure Modeand Effects Analysis(DFMEA)

• Design forManufacturability andAssembly

• Design Verification

• Design Reviews

• Prototype Build –Control Plan

• Engineering Drawings(Including Math Data)

• EngineeringSpecifications

• Material Specifications

• Drawing andSpecification Changes

• New Equipment, Toolingand FacilitiesRequirements

• Special Product andProcess Characteristics

• Gages/TestingEquipment Requirements

• Team FeasibilityCommitment andManagement Support

INPU

T

OU

TPU

T















• Customer Inputs

• Design Goals










• Design Reviews


• Engineering Drawings(Including Math Data)








By: Pankaj Nalwa


Phase 3: Process design and development

This phase concentrates on developing a manufacturing system and related controlplans to achieve quality products.

This phase focuses on creating a process that will ensure the design that wasdeveloped in the previous phase at the same quality level, quantity and cost, and atthe same time assuring that any other customer requirements and expectations willbe met.

Activities of this phase make sure that the product represents a value to customer.

Phase 3: Process design and development

This phase concentrates on developing a manufacturing system and related controlplans to achieve quality products.

This phase focuses on creating a process that will ensure the design that wasdeveloped in the previous phase at the same quality level, quantity and cost, and atthe same time assuring that any other customer requirements and expectations willbe met.

Activities of this phase make sure that the product represents a value to customer.

By: Pankaj Nalwa


Prepare forAPQP


ProductDesign and

Development

Product &Process

Validation

ProcessDesign and

Development


Corrective Action
















• Customer Inputs

INPU

T• Design Goals







OU

TPU

T




• Design Reviews


• Engineering Drawings








INPU

T

OU

TPU

T

• PackagingStandards

• Product/ProcessQuality SystemReview

• Process Flow Chart

• Floor Plan Layout

• CharacteristicsMatrix

• Process FailureMode and EffectsAnalysis (PFMEA)

• Pre-Launch ControlPlan

• Process Instructions

• MeasurementSystems AnalysisPlan

• PreliminaryProcess CapabilityStudy Plan

• PackagingSpecifications


INPU

T

OU

TPU

T















• Customer Inputs

• Design Goals










• Design Reviews










• PackagingStandards

• Product/ProcessQuality SystemReview



• CharacteristicsMatrix

• Process FailureMode and EffectsAnalysis (PFMEA)



• MeasurementSystems AnalysisPlan

• PreliminaryProcess CapabilityStudy Plan



By: Pankaj Nalwa


Phase 4: Product and process validation

This phase concentrates on validating the manufacturing process through evaluationof production trial run and all the activities related to it.

This phase focuses on methods and techniques for determining that the long-termproduction process is capable of meeting all the requirements that have beenresearched and documented through the previous phases.

Phase 4: Product and process validation

This phase concentrates on validating the manufacturing process through evaluationof production trial run and all the activities related to it.

This phase focuses on methods and techniques for determining that the long-termproduction process is capable of meeting all the requirements that have beenresearched and documented through the previous phases.

By: Pankaj Nalwa


Prepare forAPQP


ProductDesign and

Development

Product &Process

Validation

ProcessDesign and

Development


Corrective Action
















• Customer Inputs

INPU

T• Design Goals







OU

TPU

T




• Design Reviews










INPU

T

OU

TPU

T

• Packaging Standards

• Product/ProcessQuality System Review



• Characteristics Matrix

• Process Failure Modeand Effects Analysis(PFMEA)



• MeasurementSystems Analysis Plan

• Preliminary ProcessCapability Study Plan


• Management Support

INPU

T

OU

TPU

T

• Production TrialRun

• MeasurementSystemsEvaluation

• PreliminaryProcess CapabilityStudy

• Production PartApproval

• ProductionValidation Testing

• PackagingEvaluation

• ProductionControl Plan

• Quality PlanningSign-Off andManagementSupport

INPU

T

OU

TPU

T















• Customer Inputs

• Design Goals










• Design Reviews











• Product/ProcessQuality System Review







• MeasurementSystems Analysis Plan




• Production TrialRun

• MeasurementSystemsEvaluation

• PreliminaryProcess CapabilityStudy


• ProductionValidation Testing

• PackagingEvaluation

• ProductionControl Plan

• Quality PlanningSign-Off andManagementSupport

By: Pankaj Nalwa


Phase 5: Feedback, assessment and corrective action.

At this point, output is evaluated for all special and common cause variation. This isalso the time to evaluate the effectiveness of the quality planning effort itself.

In this phase, variation can be studied and reduced over the time.

Results of organization’s continuous improvement philosophy will be most visible.

Phase 5: Feedback, assessment and corrective action.

At this point, output is evaluated for all special and common cause variation. This isalso the time to evaluate the effectiveness of the quality planning effort itself.

In this phase, variation can be studied and reduced over the time.

Results of organization’s continuous improvement philosophy will be most visible.

By: Pankaj Nalwa


Prepare forAPQP


ProductDesign and

Development

Product &Process

Validation

ProcessDesign and

Development


Corrective Action
















• Customer Inputs

INPU

T• Design Goals







OU

TPU

T




• Design Reviews










INPU

T

OU

TPU

T


• Product/Process QualitySystem Review







• Measurement SystemsAnalysis Plan




INPU

T

OU

TPU

T

• Production Trial Run

• MeasurementSystems Evaluation

• Preliminary ProcessCapability Study


• Production ValidationTesting

• Packaging Evaluation

• Production ControlPlan

• Quality PlanningSign-Off andManagement Support

INPU

T

OU

TPU

T

• Reduced Variation

• CustomerSatisfaction

• Delivery andService

OU

TPU

T

INPU

T















• Customer Inputs

• Design Goals










• Design Reviews











• Product/Process QualitySystem Review







• Measurement SystemsAnalysis Plan




• Production Trial Run

• MeasurementSystems Evaluation

• Preliminary ProcessCapability Study


• Production ValidationTesting

• Packaging Evaluation

• Production ControlPlan

• Quality PlanningSign-Off andManagement Support

By: Pankaj Nalwa


An important phase of APQP is the development of “Control Plan”.

What is a Control Plan?

It is a written description of the system for controlling parts and processes. Controlplan describes the actions that are required at each phase of the process includingreceiving, in-process, out-going and periodic requirements to assure that all processoutputs will be in state of control.

When to generate this document and for how long to use it?

Control plan is maintained and used throughout the product life cycle. Early inproduct life cycle, its primary purpose is to document and communicate the initialplan for process control. Subsequently, it guides manufacturing in how to control theprocess and ensure product quality.

The control plan remains a living document, reflecting the current methods of control,and measurement systems used. It is updated as measurement systems and controlmethods are evaluated and improved.

An important phase of APQP is the development of “Control Plan”.

What is a Control Plan?

It is a written description of the system for controlling parts and processes. Controlplan describes the actions that are required at each phase of the process includingreceiving, in-process, out-going and periodic requirements to assure that all processoutputs will be in state of control.

When to generate this document and for how long to use it?

Control plan is maintained and used throughout the product life cycle. Early inproduct life cycle, its primary purpose is to document and communicate the initialplan for process control. Subsequently, it guides manufacturing in how to control theprocess and ensure product quality.

The control plan remains a living document, reflecting the current methods of control,and measurement systems used. It is updated as measurement systems and controlmethods are evaluated and improved.

By: Pankaj Nalwa


Cross Functional Team (CFT) is required to develop Control Plan by utilizing allavailable information to gain better understanding of process, like:

• Process flow diagram• Design / Process failure mode and effect analysis (FMEA)• Special characteristics• History of similar parts• Team’s knowledge of process• Design review• Optimization methods

Cross Functional Team (CFT) is required to develop Control Plan by utilizing allavailable information to gain better understanding of process, like:

• Process flow diagram• Design / Process failure mode and effect analysis (FMEA)• Special characteristics• History of similar parts• Team’s knowledge of process• Design review• Optimization methods

By: Pankaj Nalwa


Collect &Interpret Data

SelectMeasures

IsProcessStable?

Investigate &Fix Special

Causes

No

DefineProcess

Develop ControlPlan

IsProcess

Capable?

ImproveProcess

Capability

IsProcessStable?

Investigate &Fix Special

Causes

No

Yes

No

Yes

By: Pankaj Nalwa


Monitor variables for out ofcontrol conditions

Develop alarm andrecording strategy

Finalize process samplingplanFinalize process samplingplan

Document control plan foreach key variable

Identify Opportunities forMistake Proofing

By: Pankaj Nalwa


Control Plan

PreliminaryAnalysis

MeasurementSystem

ProcessMaps

FMEA

MeasurementSystem Analysis

CalibrationRequirements

Sampling & Testing PlansCustomer requirements

Short TermCapability

Control Plan

ProceduresImprovementActivities

SPC Plans

OperatingWindows

DOE's

Maintenance Schedules

Training Materials

SOP's

Long TermCapability

Reaction plans

Trouble shooting Aids

By: Pankaj Nalwa


PHASE – I (Planning & Defining the program)Wk1

Wk2

Wk3

Wk4

Wk5

Wk6

Voice of customer

Historical data (Internal & External)

Bench mark data (Product & Process)

Assumptions (Product & Process)

Customer design inputsCustomer design inputs

Design goals

Reliability & quality goals

Preliminary bill of material

Preliminary process flow diagram

Preliminary list of special characteristics

Management review & support

By: Pankaj Nalwa


PHASE – II (Product design & development)Wk Wk Wk Wk Wk Wk

Block diagram

Design FMEA

Engineering drawing (for Prototype)

Engineering specifications (for Prototype)

Material specifications (for Prototype)Material specifications (for Prototype)

Final bill of material

Design verification

Design review

Changes in drawing & specifications

Make or buy decision

Supplier selection & allocation

By: Pankaj Nalwa


PHASE – II (Product design & development)Wk Wk Wk Wk Wk Wk

Preparation of inspection standards for BOP

Procurement of BOP

Prototype control plan

Identification of new equipment, tooling,gauges, test facilities

Acquisition of new equipment, tooling,gauges & test facilitiesAcquisition of new equipment, tooling,gauges & test facilities

Prototype samples

Prototype approval from customer

Changes in drawing & specifications

Team feasibility & commitment

Final drawing & specifications


By: Pankaj Nalwa


PHASE – III (Process design & development)Wk Wk Wk Wk Wk Wk

Final process flow diagram

Floor plan layout

Final special characteristics (Product &Process)

Process FMEA

Prelaunch control planPrelaunch control plan

Process control standards / Workinstructions

M.S.A. plan

Preliminary process capability study plan

Packaging standards & specifications

Quality system review (Product &Process)


By: Pankaj Nalwa


PHASE – IV (Product & process validation)Wk Wk Wk Wk Wk Wk

Material for trial production (Pilot lot)

Trial production run (Pilot lot)

Measurement system analysis

Process capability study

Process validation testing

Packaging evaluationPackaging evaluation

PPAP documents compilation & submission

Customer approval

Release : Production control plan

Quality planning & summary sign off

Initial supply control initiation


Regular production

By: Pankaj Nalwa


PHASE – V (Feedback assessment & corrective action)Wk Wk Wk Wk Wk Wk

Reduction of variation

Continual improvement

Delivery of regular product

By: Pankaj Nalwa


Notes:

By: Pankaj Nalwa

APQP (Pankaj Nalwa)

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Transcript of APQP (Pankaj Nalwa)