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APQPPPAPAPQPAPerspectiveon8-DandPFMEAandControlPlanDuringAPQPandAfterwardsWhatisAPQP?•APQPisa"defined"processforaproductdevelopm

entsystemforFord,Daimler-Chrysler,GMandtheirsuppliers.•APQPisanattempttoprovideacommonpathandsynchroni

zationofproductdevelopmentactivities.•APQPisanattempttoensurecommunicationbothwithinacompanyandbetweenacompanyandits

customerMarketing&CommunicationsBenefitsofAPQP•Ensuresearlyplanningtakesplace.•Directsresourcestothecustomer.•Id

entifiesrequiredchangesearlyintheprocess.•Providesqualityproductontimeandatlowestcost.•Enablescross-functi

onalinputsandoutputs.•AddressespotentialproblemsearlyMarketing&CommunicationsCustomerandSupplierInvolvement•Customermayinitiateplann

ingprocess.•Supplierhastheobligationtoestablishcross-functionalteamtomanageprocess.•Suppliershouldexpectthesameperformancefromtheir

subcontractors.Marketing&CommunicationsDetermineCustomerRequirements•Print•PurchaseRequestorRequestforQuotation.

•StatementofWork(SOW)•Customervisitsanddiscussions.•Productchecklists.Marketing&CommunicationsTraining•Customerneedsandexpectations.•W

orkingasateam.•RequirementsofAPQP•FMEA•APQP•PPAPMarketing&CommunicationsAPQPFivePhaseProcessPlanningProductDesignandDevelopmen

tProcessDesignandDevelopmentProductandProcessValidationProductionFeedbackAssessmentandCorrectiveActionPilo

tLaunchConceptInitiation/ApprovalProgramApprovalPrototypePlanningLinksBetweentheToolsContractReviewProgramPla

nDFMEATeamFeasibilityCommitmentProduceProcessFlowDiagramsConductProcessFMEADevelopControlPlanWorkInstruc

tionDevelopmentProductandProcessValidationEnsureContinuousImprovementPhaseIPhaseIIPhaseIIPhaseIIIPhaseIIIPhaseIIIPhaseIIIPhaseIVPhaseVDetermine

CustomerExpectationsandPlanforQualityIdentifyKeyCharacteristicsDetermineRiskandFeasibilityAssociateChara

cteristicswithProcessStepsandIdentifyKeyCharacteristicsExposeSourcesofVariationandFinalizeKeyCharacteristicsDetermineMethodstoImproveP

rocessandControlVariationImplementControlPlanandStandardizetheProcessEnsureCustomerExpectationsareMetExer

ciseManagementOversightTheTargetandTheGoalMarketing&CommunicationsLinkBetweentheDocumentsProcessFlowOperationNumberProduct/Pro

cessCharacteristicIncomingSourcesofVariationPFMEAControlPlanVariationClassWorkInstructionsProcessFlowDiagrams•Updatedafterprod

uctiontrialrun.•Needtoindicatespecialcharacteristicsgeneratedateachstep.•CompletedAlongwithControlPlan(

APQPProcess).•Generallycontainssameinformationasprocesstraveler.Marketing&CommunicationsProcessFlowDiagramExampleMarketing&

CommunicationsAPQPLinkstoPFMEAWorkInstructionsPFMEAChangeindetectionChangeinoccurenceChangeinseverityControlPlanDesignChangeOtherAc

tionororororProcessFMEA•Mustfollowflowoftheprocessflowdiagram.•MustincludeALLprocessspecialcharacteristics(asaminimum).Marketing&CommunicationsHowaPF

MEAWorks•WheredoesthedataforthePFMEAcomefrom?•WhattypesofpeopleareapartofthePFMEAteam?•Whattypesofactivitiesshouldwespendal

otoftimeon?PFMEAs/ControlPlansand8-DsDuringAPQP•PFMEAsshouldbedrivenbyrealdata,including8-Ds(internalandexternal),warrantyandr

eturnedpartanalysis•PFMEAsshouldbecompletedbyprocessexpertsandshouldbeadriverofthecontrolplansandworkinstructions•Workinstructions(Postcontrol

log,processparameterlogs,preventivemaintenance,etc.)implementthecontrolplanintheprocess•Whenthereisaqualityproblemthereisanopportunitytoimprovethe

controlplanandtheworkinstructionsAPQPLinkstoControlPlanFirst/LastPieceMistakeProofingControlPlanP/MChecklistQualityChecklistControl

Plans•Includesproductandprocessspecialcharacteristics.•IncludesSPCrequirements.•FollowsflowofprocessflowchartandPFMEA.•Mayrequirecustomerapproval.Mar

keting&CommunicationsTypesofControlPlans•Prototypebuildcontrolplan(s)•Pre-launchcontrolplan•Productioncontr

olplanMarketing&CommunicationsPrototypeBuildControlPlan•Adescriptionofthedimensionalmeasurements.•Materialtests–F

unctionalteststhatwilloccurduringprototypebuild.Marketing&CommunicationsPre-launchControlPlan•Descriptionofdimensionalmeasurements,

materials,andfunctionaltests.•Addsadditionalproductandprocesscontrols.•Purposeistocontainpotentialnonconformitiesutil

izing:–Morefrequentinspectionsand/ortests.–Morein-processandfinslinspectionand/orcheckpoints.–Statisticalevaluations.–Increasedaudits.Marketing&

CommunicationsProductionControlPlan•Up-datepre-launchcontrolplan.•Add:–Samplingplans–Controlmethod–SPC,inspection,attributedataa

ndmistakeproofing.–Reactionplan•Nonconformancesclearlyidentified,quarantinedanddispositionmade.•Requirescustomerapprovalunlessotherwisespecified.Mar

keting&CommunicationsControlPlanUse•Initial:Todocumentandcommunicateinitialprocesscontrol.•Next:Guidanceincontrollingproce

ssesandtoensureproductquality.•LastAlivingdocumentreflectingcurrentmethodsofcontrolandmeasurementsystemsused.Marketing&CommunicationsMult

ipleMolds,Tools,DiesandPatterns•Completedimensionallayerrequiredfromonepartfromeachcavityasaminimum.•Suppliermustiden

tifyspecificcavityforeachpartsubmitted.Marketing&CommunicationsPartSubmissionStatus•Nevershipproductionpartsbeforereceivi

ngcustomerapproval.•Suppliermustensurethatfutureproductioncontinuestomeetcustomerrequirements.•Noproductionpartscanbe

shippeduntilapprovalisreceived.Marketing&CommunicationsAutomotiveDocumentationDevelopmentDevelopProcessFlow

ListingCheckforCustomerRequirementsEnterEvery“Major”ProcessfromFlowListingintoFMEAFormGivecarefulconsiderationtowhatyouconsidera“Ma

jor”processDevelopFMEAElementforEveryProcessUsetheappropriateRPNnumbersandconsiderationsofotherappropriateinformation/datatodetermineCriticalch

aracteristicsDeveloptheControlPlanwithCriticalCharacteristicsDevelopcontrolmechanismsappropriateforCriticalcharacteris

tics.GivecarefulconsiderationtodefiningControlPlanstagesPrototypePre-launchProductionMarketing&CommunicationsMarketing&Communic

ations•ProvidesProofofCapability•MadeupofDocumentsfromAPQPMarketing&CommunicationsPPAPPurpose•Ensurethatcu

stomerdesignrecordandspecificationrequirementsareunderstood.•Ensurethattheprocesshasthepotentialforproducingproduc

tmeetingthoserequirementsMarketing&CommunicationsPPAPScope•Productionparts-generally300pieces.•Includesinte

rnalandexternalsourcesforinformation.•Submissionrequiredpriortofirstproductionshipment.Marketing&CommunicationsBaseDocumentation•Criticalch

aracteristicsmatrix.•Processflowdiagram.•DesignFMEA(suppliedbycustomer).•ProcessFMEA.•Controlplan.Marketing&

CommunicationsGeneral•Supplierisresponsibleformeetingallapplicablespecifications.•Donotsubmitpartsanddocumentationresultsiftheyareoutsidespeci

fication.•Takecorrectiveactiontomeetalldesignrecordrequirements.•Contactcustomerifunabletomeetallrequirements•Complywithcustomerdevelopedmat

erialspecificationsand/orapprovedsourcelist.Marketing&CommunicationsGeneral•Suppliersarerequiredtocompleteandmaintaincopiesofalldocumentationidentifi

edin“requirementsforapproval”regardlessofsubmissionlevel.•RecordsofPPAParetoberetainedforthelifeofthepartplusonecalendaryear

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

ample(Mastersampleretainedbysupplier)•Dimensionalanalysis•Testdata•Flowdiagram•Controlplan•PFMEA•MeasurementSystemsAnalysis(GR&R)•Capabil

itystudiesMarketing&CommunicationsPartsSubmissionWarrant•Uponsatisfactorycompletionofallrequiredmeasurementsandtests,enterallrequir

edinformationonthewarrant.•Aseparateisrequiredforeachpartnumber.•Responsiblesupplierofficialverifies–Measurementsandtestsconformtocustomerr

equirements–Requireddocumentationisavailableforpropersubmissionlevel.–Signswarrantandprovideddate,titleandtelephonenumber.Marketing&Co

mmunicationsMarketing&CommunicationsPartWeight•Determinepartweightwithoutpackagingorshippingmaterial.•Reportweightinkilogramst

othreedecimalplaces.•Weightdetermination–Weigh10partsrandomlyselectedandreporttheaverageweight.–Forpartslessthan0.100kilogram,weig

h10partstogetherandreporttheaverageweight.Marketing&CommunicationsMasterSample•RetainsameasPPAP,or•Untilnewmastersampleisproducedforthepurposeofacus

tomerapproval.•Identifymastersampleby:–Partnumber–Drawinglevelorrevisionlevel–CustomerapprovaldateMarketing&CommunicationsPrelimina

ryProcessCapabilityStudies•Characteristicsidentifiedinthecontrolplan.•Usually100piecesminimum.•Maybe30ifrunisless.•Ppk>1.67isacceptableunlessotherwi

sespecified.•Ppk<1.67requiresactionplanunlessotherwisespecified.Marketing&CommunicationsProductionTrialRun•Productiontooling,eq

uipment,environment,facilitiesandcycletime.•ProcessInstructionsandcontrolplans.•Minimumquantitysetbythecustomer.•Gener

ally300parts.Marketing&CommunicationsProductionTrialRunProductUsedFor•Preliminaryprocesscapabilitystudies.•MSA(ifnotcompletedearlier)•F

inalFeasibility.•Processreview.•ProductionValidationTesting.•PPAP•Packagingevaluation•Firsttimecapability•Qualityp

lanningsign-offMarketing&CommunicationsMeasurementSystemAnalysis(MSA)•CompletestudiesasdefinedintheMSAplan.•Minimumarethosei

dentifiedinthecontrolplan.•Subjectedtoevaluationpriortoorduringproductiontrial.Marketing&CommunicationsPacka

gingEvaluation•Packagingmustconformtospecificationsdevelopedbycustomerorsupplier.•Assessprotectionofproduct.•

Customerspecifiedpackagingmustbeevaluatedbyteam.•Pilotorproductiontrialrunpartsusuallyusedinevaluation.Marketing&CommunicationsFloorPlanLayou

t•Determineacceptabilityofinspectionandtestpoints.•Controlchartlocations•Visualaides•Interimrepairst

ations•Nonconformingmaterialstorage•KeyedtomaterialflowandcontrolplanMarketing&CommunicationsReviewandSign-Off•Proces

sinstructionsinplaceandfollowed!•Flowchartsinplaceandfollowed!•GR&Rplansexistandarefollowed•Publishfinalfeasibilityreport•Obtainformalsign

-off•Scheduleandconductmanagementreview•ObtainmanagementcommitmenttoassistinopenissuesMarketing&CommunicationsQualityProblemsUpda

teControlPlanandPlantWorkInstructionsCorrectiveActionRevisitPFMEACauseknown?Causeknown?ConductD.O.E.Causeknown?ConductDisc

iplinedProblemSolvingCustomerProblemQualityProblemOccursyesnonoyesnoyesnoyesCauseunknown•UsePFMEANote

:Whenacustomerproblemoccurs,followcustomerprescribedmethodologyWhentouse8-D•Whenthecauseisunknown•Whenyouneedtogetinputfromseve

ralparties•WhencustomersdictateuseNote:Weusevotingtechniques,XtoYvariabletesting,andIS/ISNottodetermineth

erootcause.However,youstillmaynotknowwhattherootcauseis?UpdatethePFMEA&ControlPlansProcessFlowPFMEAControlPlanWorkInstructionScrap,Rew

orkDataWarranty&AssemblyPlantDataAfterthe8-Discompleted,thePMEAandthecontrolplanshouldberevisedandupdatedasapplicable