APQP与PPAP概述(英文版)课件

书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难04 五月 2024APQP与与PPAP概述概述(英英文版文版)书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难APQPA Perspective on 8-D and PFMEA and Control Plan During APQP and Afterwards书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难What is APQP?APQP is a defined process for a product development system for Ford,Daimler-Chrysler,GM and their suppliers.APQP is an attempt to provide a common path and synchronization of product development activities.APQP is an attempt to ensure communication both within a company and between a company and its customer书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Benefits of APQPEnsures early planning takes place.Directs resources to the customer.Identifies required changes early in the process.Provides quality product on time and at lowest cost.Enables cross-functional inputs and outputs.Addresses potential problems early书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Customer and Supplier InvolvementCustomer may initiate planning process.Supplier has the obligation to establish cross-functional team to manage process.Supplier should expect the same performance from their subcontractors.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Determine Customer RequirementsPrintPurchase Request or Request for Quotation.Statement of Work(SOW)Customer visits and discussions.Product checklists.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难TrainingCustomer needs and expectations.Working as a team.Requirements of APQPFMEAAPQPPPAP书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难APQP Five Phase ProcessPlanningProduct Design and DevelopmentProcess Design and DevelopmentProduct and Process ValidationProductionFeedback Assessment and Corrective ActionPilotLaunchConcept Initiation/ApprovalProgram ApprovalPrototypePlanning书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Links Between the ToolsContract Review Program PlanDFMEATeam Feasibility CommitmentProduce Process Flow DiagramsConduct Process FMEADevelop Control PlanWork Instruction DevelopmentProduct and Process ValidationEnsure Continuous ImprovementPhase IPhase IIPhase IIPhase IIIPhase IIIPhase IIIPhase IIIPhase IVPhase VDetermine Customer Expectations and Plan for QualityIdentify Key Characteristics Determine Risk and FeasibilityAssociate Characteristics with Process Steps and Identify Key CharacteristicsExpose Sources of Variation and Finalize Key CharacteristicsDetermine Methods to Improve Process and Control VariationImplement Control Plan and Standardize the ProcessEnsure Customer Expectations are MetExercise Management Oversight书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难The Target and The Goal书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Link Between the Documents书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Process Flow DiagramsUpdated after production trial run.Need to indicate special characteristics generated at each step.Completed Along with Control Plan(APQP Process).Generally contains same information as process traveler.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Process Flow Diagram Example书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难APQP Links to PFMEA书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Process FMEAMust follow flow of the process flow diagram.Must include ALL process special characteristics(as a minimum).书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难How a PFMEA WorksWhere does the data for the PFMEA come from?What types of people are a part of the PFMEA team?What types of activities should we spend a lot of time on?书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难PFMEAs/Control Plans and 8-Ds During APQPPFMEAs should be driven by real data,including 8-Ds(internal and external),warranty and returned part analysisPFMEAs should be completed by process experts and should be a driver of the control plans and work instructionsWork instructions(Post control log,process parameter logs,preventive maintenance,etc.)implement the control plan in the processWhen there is a quality problem there is an opportunity to improve the control plan and the work instructions书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难APQP Links to Control Plan书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Control PlansIncludes product and process special characteristics.Includes SPC requirements.Follows flow of process flow chart and PFMEA.May require customer approval.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Types of Control PlansPrototype build control plan(s)Pre-launch control planProduction control plan书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Prototype Build Control PlanA description of the dimensional measurements.Material testsFunctional tests that will occur during prototype build.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Pre-launch Control PlanDescription of dimensional measurements,materials,and functional tests.Adds additional product and process controls.Purpose is to contain potential nonconformities utilizing:More frequent inspections and/or tests.More in-process and finsl inspection and/or check points.Statistical evaluations.Increased audits.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Production Control PlanUp-date pre-launch control plan.Add:Sampling plansControl methodSPC,inspection,attribute data and mistake proofing.Reaction planNonconformances clearly identified,quarantined and disposition made.Requires customer approval unless otherwise specified.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Control Plan UseInitial:To document and communicate initial process control.Next:Guidance in controlling processes and to ensure product quality.Last A living document reflecting current methods of control and measurement systems used.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Multiple Molds,Tools,Dies and PatternsComplete dimensional layer required from one part from each cavity as a minimum.Supplier must identify specific cavity for each part submitted.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Part Submission StatusNever ship production parts before receiving customer approval.Supplier must ensure that future production continues to meet customer requirements.No production parts can be shipped until approval is received.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Automotive Documentation DevelopmentDevelop Process Flow ListingCheck for Customer RequirementsEnter Every “Major”Process from Flow Listing into FMEA Form Give careful consideration to what you consider a“Major”processDevelop FMEA Element for Every ProcessUse the appropriate RPN numbers and considerations of other appropriate information/data to determine Critical characteristicsDevelop the Control Plan with Critical CharacteristicsDevelop control mechanisms appropriate for Critical characteristics.Give careful consideration to defining Control Plan stagesPrototype Pre-launch Production书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Provides Proof of CapabilityMade up of Documents from APQP 书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难PPAP PurposeEnsure that customer design record and specification requirements are understood.Ensure that the process has the potential for producing product meeting those requirements书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难PPAP ScopeProduction parts-generally 300 pieces.Includes internal and external sources for information.Submission required prior to first production shipment.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难 Base DocumentationCritical characteristics matrix.Process flow diagram.Design FMEA(supplied by customer).Process FMEA.Control plan.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难GeneralSupplier is responsible for meeting all applicable specifications.Do not submit parts and documentation results if they are outside specification.Take corrective action to meet all design record requirements.Contact customer if unable to meet all requirementsComply with customer developed material specifications and/or approved source list.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难GeneralSuppliers are required to complete and maintain copies of all documentation identified in“requirements for approval”regardless of submission level.Records of PPAP are to be retained for the life of the part plus one calendar year.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Elements of a PPAPPart submission warrantSubcontractor warrantsDesign record(customer/design documentation)Sample/Master sample(Master sample retained by supplier)Dimensional analysisTest dataFlow diagramControl planPFMEAMeasurement Systems Analysis(GR&R)Capability studies书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Parts Submission WarrantUpon satisfactory completion of all required measurements and tests,enter all required information on the warrant.A separate is required for each part number.Responsible supplier official verifiesMeasurements and tests conform to customer requirementsRequired documentation is available for proper submission level.Signs warrant and provided date,title and telephone number.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Part WeightDetermine part weight without packaging or shipping material.Report weight in kilograms to three decimal places.Weight determinationWeigh 10 parts randomly selected and report the average weight.For parts less than 0.100 kilogram,weigh 10 parts together and report the average weight.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Master SampleRetain same as PPAP,orUntil new master sample is produced for the purpose of a customer approval.Identify master sample by:Part numberDrawing level or revision levelCustomer approval date书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Preliminary Process Capability StudiesCharacteristics identified in the control plan.Usually 100 pieces minimum.May be 30 if run is less.Ppk 1.67 is acceptable unless otherwise specified.Ppk 1.67 requires action plan unless otherwise specified.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Production Trial RunProduction tooling,equipment,environment,facilities and cycle time.Process Instructions and control plans.Minimum quantity set by the customer.Generally 300 parts.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Production Trial Run Product Used ForPreliminary process capability studies.MSA(if not completed earlier)Final Feasibility.Process review.Production Validation Testing.PPAPPackaging evaluationFirst time capabilityQuality planning sign-off书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Measurement System Analysis(MSA)Complete studies as defined in the MSA plan.Minimum are those identified in the control plan.Subjected to evaluation prior to or during production trial.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Packaging EvaluationPackaging must conform to specifications developed by customer or supplier.Assess protection of product.Customer specified packaging must be evaluated by team.Pilot or production trial run parts usually used in evaluation.书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Floor Plan LayoutDetermine acceptability of inspection and test points.Control chart locationsVisual aidesInterim repair stationsNonconforming material storageKeyed to material flow and control plan书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Review and Sign-OffProcess instructions in place and followed!Flow charts in place and followed!GR&R plans exist and are followedPublish final feasibility reportObtain formal sign-offSchedule and conduct management reviewObtain management commitment to assist in open issues书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Quality Problemsyesnonoyesnoyesnoyes书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难Cause unknownUse PFMEANote:When a customer problem occurs,follow customer prescribed methodology书山有路勤为径，书山有路勤为径，学海无涯苦作舟学海无涯苦作舟书到用时方恨少，书到用时方恨少，事非经过不知难事非经过不知难When to use 8-DWhen the cause is unknownWhen you need to get input from several partiesWhen customers dictate useNote:We use voting techniques,X to Y variable testing,and IS/IS Not to determine the root cause.However,you still may not know what the root cause is?