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APQPPPAPAPQPAPerspectiveon8-DandPFMEAandControlPlanDuringAPQPandAfterwardsWhatisAPQP?•APQPisa"defined"processforaproductdevelopmentsystemforFord,Daim

ler-Chrysler,GMandtheirsuppliers.•APQPisanattempttoprovideacommonpathandsynchronizationofproductdevelopmen

tactivities.•APQPisanattempttoensurecommunicationbothwithinacompanyandbetweenacompanyanditscustomerMarketing&CommunicationsBenefitsofAPQP•Ens

uresearlyplanningtakesplace.•Directsresourcestothecustomer.•Identifiesrequiredchangesearlyintheprocess.•Providesqualityproductontimeandatlowestcost.•

Enablescross-functionalinputsandoutputs.•AddressespotentialproblemsearlyMarketing&CommunicationsCustomerandSupplierInvolvement•

Customermayinitiateplanningprocess.•Supplierhastheobligationtoestablishcross-functionalteamtomanageprocess.•Suppliershouldexpectthesameperforman

cefromtheirsubcontractors.Marketing&CommunicationsDetermineCustomerRequirements•Print•PurchaseRequestorRequestforQuotation.•

StatementofWork(SOW)•Customervisitsanddiscussions.•Productchecklists.Marketing&CommunicationsTraining•Customerneedsandex

pectations.•Workingasateam.•RequirementsofAPQP•FMEA•APQP•PPAPMarketing&CommunicationsAPQPFivePhaseProcessPla

nningProductDesignandDevelopmentProcessDesignandDevelopmentProductandProcessValidationProductionFeedbackAssessmentandCorrectiveActionPilotLaun

chConceptInitiation/ApprovalProgramApprovalPrototypePlanningLinksBetweentheToolsContractReviewProgramPlanDFMEATeamFeasibilityCommitmentProduceP

rocessFlowDiagramsConductProcessFMEADevelopControlPlanWorkInstructionDevelopmentProductandProcessValidationEnsureContinuousImpro

vementPhaseIPhaseIIPhaseIIPhaseIIIPhaseIIIPhaseIIIPhaseIIIPhaseIVPhaseVDetermineCustomerExpectationsand

PlanforQualityIdentifyKeyCharacteristicsDetermineRiskandFeasibilityAssociateCharacteristicswithProcessStepsandIdentifyKeyCharacteristicsEx

poseSourcesofVariationandFinalizeKeyCharacteristicsDetermineMethodstoImproveProcessandControlVariationImplementControlPlanandStandardizethePr

ocessEnsureCustomerExpectationsareMetExerciseManagementOversightTheTargetandTheGoalMarketing&CommunicationsLi

nkBetweentheDocumentsProcessFlowOperationNumberProduct/ProcessCharacteristicIncomingSourcesofVariationPFMEAControlPlanVariatio

nClassWorkInstructionsProcessFlowDiagrams•Updatedafterproductiontrialrun.•Needtoindicatespecialcharacteristicsgeneratedateachstep.•CompletedAlongwit

hControlPlan(APQPProcess).•Generallycontainssameinformationasprocesstraveler.Marketing&CommunicationsProcessFlowDiagramExampleMarketing&Communication

sAPQPLinkstoPFMEAWorkInstructionsPFMEAChangeindetectionChangeinoccurenceChangeinseverityControlPlanDesignChangeOtherActionorororor

ProcessFMEA•Mustfollowflowoftheprocessflowdiagram.•MustincludeALLprocessspecialcharacteristics(asaminimum).Marketing&Communicat

ionsHowaPFMEAWorks•WheredoesthedataforthePFMEAcomefrom?•WhattypesofpeopleareapartofthePFMEAteam?•Whattypesofactivitiesshouldwespendaloto

ftimeon?PFMEAs/ControlPlansand8-DsDuringAPQP•PFMEAsshouldbedrivenbyrealdata,including8-Ds(internalandexternal),wa

rrantyandreturnedpartanalysis•PFMEAsshouldbecompletedbyprocessexpertsandshouldbeadriverofthecontrolplansandworki

nstructions•Workinstructions(Postcontrollog,processparameterlogs,preventivemaintenance,etc.)implementthecontrolplaninthepr

ocess•WhenthereisaqualityproblemthereisanopportunitytoimprovethecontrolplanandtheworkinstructionsAPQPLinkstoControl

PlanFirst/LastPieceMistakeProofingControlPlanP/MChecklistQualityChecklistControlPlans•Includesproductandprocessspecialcharacteristics.•I

ncludesSPCrequirements.•FollowsflowofprocessflowchartandPFMEA.•Mayrequirecustomerapproval.Marketing&CommunicationsTypesofControlPlans•P

rototypebuildcontrolplan(s)•Pre-launchcontrolplan•ProductioncontrolplanMarketing&CommunicationsPrototypeBu

ildControlPlan•Adescriptionofthedimensionalmeasurements.•Materialtests–Functionalteststhatwilloccurduringprototypebuild.Marketing&Communica

tionsPre-launchControlPlan•Descriptionofdimensionalmeasurements,materials,andfunctionaltests.•Addsadditionalproductandprocesscon

trols.•Purposeistocontainpotentialnonconformitiesutilizing:–Morefrequentinspectionsand/ortests.–Morein-processandfinslinspectionand/orcheckpoints.–

Statisticalevaluations.–Increasedaudits.Marketing&CommunicationsProductionControlPlan•Up-datepre-launchcontrolpl

an.•Add:–Samplingplans–Controlmethod–SPC,inspection,attributedataandmistakeproofing.–Reactionplan•Nonconform

ancesclearlyidentified,quarantinedanddispositionmade.•Requirescustomerapprovalunlessotherwisespecified.Marketing&CommunicationsCo

ntrolPlanUse•Initial:Todocumentandcommunicateinitialprocesscontrol.•Next:Guidanceincontrollingprocessesandtoensureproductquality.•LastAlivingdocument

reflectingcurrentmethodsofcontrolandmeasurementsystemsused.Marketing&CommunicationsMultipleMolds,Tools,DiesandPatterns•Completedimensionall

ayerrequiredfromonepartfromeachcavityasaminimum.•Suppliermustidentifyspecificcavityforeachpartsubmitted.Marketing&CommunicationsPartSubmissionSta

tus•Nevershipproductionpartsbeforereceivingcustomerapproval.•Suppliermustensurethatfutureproductioncontinuestomeetcustomerrequirements.•Noprod

uctionpartscanbeshippeduntilapprovalisreceived.Marketing&CommunicationsAutomotiveDocumentationDevelopmentDevelopProcessFlowLi

stingCheckforCustomerRequirementsEnterEvery“Major”ProcessfromFlowListingintoFMEAFormGivecarefulconsiderationtowhatyo

uconsidera“Major”processDevelopFMEAElementforEveryProcessUsetheappropriateRPNnumbersandconsiderationsofotherapp

ropriateinformation/datatodetermineCriticalcharacteristicsDeveloptheControlPlanwithCriticalCharacteristicsDevelop

controlmechanismsappropriateforCriticalcharacteristics.GivecarefulconsiderationtodefiningControlPlanstagesPrototy

pePre-launchProductionMarketing&CommunicationsMarketing&Communications•ProvidesProofofCapability•MadeupofDocumentsfromAPQPMarketing&Communicat

ionsPPAPPurpose•Ensurethatcustomerdesignrecordandspecificationrequirementsareunderstood.•Ensurethattheprocesshasthepotentialforproducingproductmeeti

ngthoserequirementsMarketing&CommunicationsPPAPScope•Productionparts-generally300pieces.•Includesinternalandexternalsourcesfo

rinformation.•Submissionrequiredpriortofirstproductionshipment.Marketing&CommunicationsBaseDocumentation•Criticalcharacte

risticsmatrix.•Processflowdiagram.•DesignFMEA(suppliedbycustomer).•ProcessFMEA.•Controlplan.Marketing&CommunicationsGeneral•Supplierisr

esponsibleformeetingallapplicablespecifications.•Donotsubmitpartsanddocumentationresultsiftheyareoutsidespecification.•Takecorrectiveactiontome

etalldesignrecordrequirements.•Contactcustomerifunabletomeetallrequirements•Complywithcustomerdevelopedmaterialspec

ificationsand/orapprovedsourcelist.Marketing&CommunicationsGeneral•Suppliersarerequiredtocompleteandmaintaincopiesofalldocumentationidentifiedin“requ

irementsforapproval”regardlessofsubmissionlevel.•RecordsofPPAParetoberetainedforthelifeofthepartplusonecal

endaryear.Marketing&CommunicationsElementsofaPPAP•Partsubmissionwarrant•Subcontractorwarrants•Designrecord(customer/designdocumentation)•Sample/Maste

rsample(Mastersampleretainedbysupplier)•Dimensionalanalysis•Testdata•Flowdiagram•Controlplan•PFMEA•MeasurementSystemsAnalysis(GR&R)•Capabilitystud

iesMarketing&CommunicationsPartsSubmissionWarrant•Uponsatisfactorycompletionofallrequiredmeasurementsandtests,enterallrequiredinformat

iononthewarrant.•Aseparateisrequiredforeachpartnumber.•Responsiblesupplierofficialverifies–Measurementsand

testsconformtocustomerrequirements–Requireddocumentationisavailableforpropersubmissionlevel.–Signswarrantandpr

ovideddate,titleandtelephonenumber.Marketing&CommunicationsMarketing&CommunicationsPartWeight•Determinepartweightwithout

packagingorshippingmaterial.•Reportweightinkilogramstothreedecimalplaces.•Weightdetermination–Weigh10partsrandomlyselectedandreporttheaverage

weight.–Forpartslessthan0.100kilogram,weigh10partstogetherandreporttheaverageweight.Marketing&CommunicationsMasterSample•RetainsameasPPAP,

or•Untilnewmastersampleisproducedforthepurposeofacustomerapproval.•Identifymastersampleby:–Partnumber–Drawinglevelorrev

isionlevel–CustomerapprovaldateMarketing&CommunicationsPreliminaryProcessCapabilityStudies•Characteristicsidentifiedinthecontrolplan.•Usually

100piecesminimum.•Maybe30ifrunisless.•Ppk>1.67isacceptableunlessotherwisespecified.•Ppk<1.67requiresactionpl

anunlessotherwisespecified.Marketing&CommunicationsProductionTrialRun•Productiontooling,equipment,environment,facilitiesa

ndcycletime.•ProcessInstructionsandcontrolplans.•Minimumquantitysetbythecustomer.•Generally300parts.Mar

keting&CommunicationsProductionTrialRunProductUsedFor•Preliminaryprocesscapabilitystudies.•MSA(ifnotcompletedearlier)•

FinalFeasibility.•Processreview.•ProductionValidationTesting.•PPAP•Packagingevaluation•Firsttimecapability•Qualityplanningsign-

offMarketing&CommunicationsMeasurementSystemAnalysis(MSA)•CompletestudiesasdefinedintheMSAplan.•Minimumarethoseidentifiedinthecontrolplan.•Subjecte

dtoevaluationpriortoorduringproductiontrial.Marketing&CommunicationsPackagingEvaluation•Packagingmustconformtos

pecificationsdevelopedbycustomerorsupplier.•Assessprotectionofproduct.•Customerspecifiedpackagingmustbeevaluatedbyteam.•Pilot

orproductiontrialrunpartsusuallyusedinevaluation.Marketing&CommunicationsFloorPlanLayout•Determineacceptabilityofinspectionandtestpoints.•Cont

rolchartlocations•Visualaides•Interimrepairstations•Nonconformingmaterialstorage•KeyedtomaterialflowandcontrolplanMarketing&Comm

unicationsReviewandSign-Off•Processinstructionsinplaceandfollowed!•Flowchartsinplaceandfollowed!•GR&Rplansexistandarefollowed•Publishfinalfeasi

bilityreport•Obtainformalsign-off•Scheduleandconductmanagementreview•ObtainmanagementcommitmenttoassistinopenissuesMarketin

g&CommunicationsQualityProblemsUpdateControlPlanandPlantWorkInstructionsCorrectiveActionRevisitPFMEACausekn

own?Causeknown?ConductD.O.E.Causeknown?ConductDisciplinedProblemSolvingCustomerProblemQualityProblemOccursy

esnonoyesnoyesnoyesCauseunknown•UsePFMEANote:Whenacustomerproblemoccurs,followcustomerprescribedmethodologyWhentouse8-D•When

thecauseisunknown•Whenyouneedtogetinputfromseveralparties•WhencustomersdictateuseNote:Weusevotingtechniques

,XtoYvariabletesting,andIS/ISNottodeterminetherootcause.However,youstillmaynotknowwhattherootcauseis?UpdatethePFMEA&ControlPlansProcessFlo

wPFMEAControlPlanWorkInstructionScrap,ReworkDataWarranty&AssemblyPlantDataAfterthe8-Discompleted,thePMEAand

thecontrolplanshouldberevisedandupdatedasapplicable