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APQPPPAPAPQPAPerspectiveon8-DandPFMEAandControlPlanDuringAPQPandAfterwardsWhatisAPQP?•APQPisa"define

d"processforaproductdevelopmentsystemforFord,Daimler-Chrysler,GMandtheirsuppliers.•APQPisanattempttoprovideacommonpat

handsynchronizationofproductdevelopmentactivities.•APQPisanattempttoensurecommunicationbothwithinacompanyandbetweenacompanyanditscustomerMarketin

g&CommunicationsBenefitsofAPQP•Ensuresearlyplanningtakesplace.•Directsresourcestothecustomer.•Identifiesrequiredchangesearlyintheproces

s.•Providesqualityproductontimeandatlowestcost.•Enablescross-functionalinputsandoutputs.•AddressespotentialproblemsearlyM

arketing&CommunicationsCustomerandSupplierInvolvement•Customermayinitiateplanningprocess.•Supplierhastheobligationtoestablishcross-functionalteam

tomanageprocess.•Suppliershouldexpectthesameperformancefromtheirsubcontractors.Marketing&CommunicationsDetermineCustomerRe

quirements•Print•PurchaseRequestorRequestforQuotation.•StatementofWork(SOW)•Customervisitsanddiscussions.•Productchecklists.Marketing&Co

mmunicationsTraining•Customerneedsandexpectations.•Workingasateam.•RequirementsofAPQP•FMEA•APQP•PPAPMarketing&CommunicationsAPQPFivePhaseP

rocessPlanningProductDesignandDevelopmentProcessDesignandDevelopmentProductandProcessValidationProductionFeedbackAssessmentandCorrectiveActionPil

otLaunchConceptInitiation/ApprovalProgramApprovalPrototypePlanningLinksBetweentheToolsContractReviewProgramPlanDFMEATeamFeasibilityCo

mmitmentProduceProcessFlowDiagramsConductProcessFMEADevelopControlPlanWorkInstructionDevelopmentProductandProcessValidationEnsureContinuousImpro

vementPhaseIPhaseIIPhaseIIPhaseIIIPhaseIIIPhaseIIIPhaseIIIPhaseIVPhaseVDetermineCustomerExpectationsandPl

anforQualityIdentifyKeyCharacteristicsDetermineRiskandFeasibilityAssociateCharacteristicswithProcessStepsandIdentifyKeyC

haracteristicsExposeSourcesofVariationandFinalizeKeyCharacteristicsDetermineMethodstoImproveProcessandControlVariationImplementC

ontrolPlanandStandardizetheProcessEnsureCustomerExpectationsareMetExerciseManagementOversightTheTargetandTheGoalMarketing&Communicat

ionsLinkBetweentheDocumentsProcessFlowOperationNumberProduct/ProcessCharacteristicIncomingSourcesofVariationPFMEAControlPlanVariat

ionClassWorkInstructionsProcessFlowDiagrams•Updatedafterproductiontrialrun.•Needtoindicatespecialcharacte

risticsgeneratedateachstep.•CompletedAlongwithControlPlan(APQPProcess).•Generallycontainssameinformationasprocess

traveler.Marketing&CommunicationsProcessFlowDiagramExampleMarketing&CommunicationsAPQPLinkstoPFMEAWorkInstructionsPFMEAChang

eindetectionChangeinoccurenceChangeinseverityControlPlanDesignChangeOtherActionororororProcessFMEA•Mu

stfollowflowoftheprocessflowdiagram.•MustincludeALLprocessspecialcharacteristics(asaminimum).Marketing&CommunicationsHowaPFMEAWorks•Wheredoesthedataf

orthePFMEAcomefrom?•WhattypesofpeopleareapartofthePFMEAteam?•Whattypesofactivitiesshouldwespendalotoftimeon?PFMEAs/ControlPlansand8

-DsDuringAPQP•PFMEAsshouldbedrivenbyrealdata,including8-Ds(internalandexternal),warrantyandreturnedpartanalysis•PFMEAsshouldbecompletedbyprocessex

pertsandshouldbeadriverofthecontrolplansandworkinstructions•Workinstructions(Postcontrollog,processparameterlogs,preventivemaintenance,etc

.)implementthecontrolplanintheprocess•WhenthereisaqualityproblemthereisanopportunitytoimprovethecontrolplanandtheworkinstructionsAPQPLinkstoC

ontrolPlanFirst/LastPieceMistakeProofingControlPlanP/MChecklistQualityChecklistControlPlans•Includesproductandp

rocessspecialcharacteristics.•IncludesSPCrequirements.•FollowsflowofprocessflowchartandPFMEA.•Mayrequirecustomerappr

oval.Marketing&CommunicationsTypesofControlPlans•Prototypebuildcontrolplan(s)•Pre-launchcontrolplan•P

roductioncontrolplanMarketing&CommunicationsPrototypeBuildControlPlan•Adescriptionofthedimensionalmeasurements.•Mater

ialtests–Functionalteststhatwilloccurduringprototypebuild.Marketing&CommunicationsPre-launchControlPlan•Descriptionofdimensionalmeasuremen

ts,materials,andfunctionaltests.•Addsadditionalproductandprocesscontrols.•Purposeistocontainpotentialnonconformitiesutilizing:–Morefrequentinspectio

nsand/ortests.–Morein-processandfinslinspectionand/orcheckpoints.–Statisticalevaluations.–Increasedaudits.Marketing&Co

mmunicationsProductionControlPlan•Up-datepre-launchcontrolplan.•Add:–Samplingplans–Controlmethod–SPC,inspection,attr

ibutedataandmistakeproofing.–Reactionplan•Nonconformancesclearlyidentified,quarantinedanddispositionmade.

•Requirescustomerapprovalunlessotherwisespecified.Marketing&CommunicationsControlPlanUse•Initial:Todocumentandcomm

unicateinitialprocesscontrol.•Next:Guidanceincontrollingprocessesandtoensureproductquality.•LastAlivingdocumentreflectingcurrentmethodsof

controlandmeasurementsystemsused.Marketing&CommunicationsMultipleMolds,Tools,DiesandPatterns•Completedimensio

nallayerrequiredfromonepartfromeachcavityasaminimum.•Suppliermustidentifyspecificcavityforeachpartsubmitted.Marketing&Comm

unicationsPartSubmissionStatus•Nevershipproductionpartsbeforereceivingcustomerapproval.•Suppliermustensurethatf

utureproductioncontinuestomeetcustomerrequirements.•Noproductionpartscanbeshippeduntilapprovalisreceived.Marketing&Communicati

onsAutomotiveDocumentationDevelopmentDevelopProcessFlowListingCheckforCustomerRequirementsEnterEvery“Major”Processf

romFlowListingintoFMEAFormGivecarefulconsiderationtowhatyouconsidera“Major”processDevelopFMEAElementforEveryP

rocessUsetheappropriateRPNnumbersandconsiderationsofotherappropriateinformation/datatodetermineCritica

lcharacteristicsDeveloptheControlPlanwithCriticalCharacteristicsDevelopcontrolmechanismsappropriateforCriticalcharacteristics.Givecarefulconsider

ationtodefiningControlPlanstagesPrototypePre-launchProductionMarketing&CommunicationsMarketing&Communications•Pr

ovidesProofofCapability•MadeupofDocumentsfromAPQPMarketing&CommunicationsPPAPPurpose•Ensurethatcustomerdesignrecordandspecificationrequirementsare

understood.•EnsurethattheprocesshasthepotentialforproducingproductmeetingthoserequirementsMarketing&CommunicationsPPAPScope•Prod

uctionparts-generally300pieces.•Includesinternalandexternalsourcesforinformation.•Submissionrequiredpriortofirstproductionshipment.Mar

keting&CommunicationsBaseDocumentation•Criticalcharacteristicsmatrix.•Processflowdiagram.•DesignFMEA(supplie

dbycustomer).•ProcessFMEA.•Controlplan.Marketing&CommunicationsGeneral•Supplierisresponsibleformeetingallapplicablespecifications.•Donotsubmitpart

sanddocumentationresultsiftheyareoutsidespecification.•Takecorrectiveactiontomeetalldesignrecordrequirements.•Contactcustomerifunabletomee

tallrequirements•Complywithcustomerdevelopedmaterialspecificationsand/orapprovedsourcelist.Marketing&CommunicationsGeneral•Suppliersar

erequiredtocompleteandmaintaincopiesofalldocumentationidentifiedin“requirementsforapproval”regardlessofsubmissionlevel.•RecordsofPPAParetoberetai

nedforthelifeofthepartplusonecalendaryear.Marketing&CommunicationsElementsofaPPAP•Partsubmissionwarrant•Subcontra

ctorwarrants•Designrecord(customer/designdocumentation)•Sample/Mastersample(Mastersampleretainedbysupplier)•Dimensionalanalysis•Tes

tdata•Flowdiagram•Controlplan•PFMEA•MeasurementSystemsAnalysis(GR&R)•CapabilitystudiesMarketing&CommunicationsPartsSubmissionWarrant•Uponsatisfactor

ycompletionofallrequiredmeasurementsandtests,enterallrequiredinformationonthewarrant.•Aseparateisrequiredforeachpart

number.•Responsiblesupplierofficialverifies–Measurementsandtestsconformtocustomerrequirements–Requireddocumentationisavail

ableforpropersubmissionlevel.–Signswarrantandprovideddate,titleandtelephonenumber.Marketing&CommunicationsMarketing&Com

municationsPartWeight•Determinepartweightwithoutpackagingorshippingmaterial.•Reportweightinkilogramstothreedecimalplaces.•Weightdeterminati

on–Weigh10partsrandomlyselectedandreporttheaverageweight.–Forpartslessthan0.100kilogram,weigh10partstogetherandreportthea

verageweight.Marketing&CommunicationsMasterSample•RetainsameasPPAP,or•Untilnewmastersampleisproducedforthepurposeofacustomerapproval.•Ide

ntifymastersampleby:–Partnumber–Drawinglevelorrevisionlevel–CustomerapprovaldateMarketing&CommunicationsPreliminaryProcessCapabil

ityStudies•Characteristicsidentifiedinthecontrolplan.•Usually100piecesminimum.•Maybe30ifrunisless.•Ppk>

1.67isacceptableunlessotherwisespecified.•Ppk<1.67requiresactionplanunlessotherwisespecified.Marketing&Communication

sProductionTrialRun•Productiontooling,equipment,environment,facilitiesandcycletime.•ProcessInstructionsandcontrolplans.•Minimumqua

ntitysetbythecustomer.•Generally300parts.Marketing&CommunicationsProductionTrialRunProductUsedFor•Preliminaryprocesscapabilitystudies.•MSA(if

notcompletedearlier)•FinalFeasibility.•Processreview.•ProductionValidationTesting.•PPAP•Packagingevaluation•Firsttimecapability•Qualityplanningsig

n-offMarketing&CommunicationsMeasurementSystemAnalysis(MSA)•CompletestudiesasdefinedintheMSAplan.•Minimumarethoseidenti

fiedinthecontrolplan.•Subjectedtoevaluationpriortoorduringproductiontrial.Marketing&CommunicationsPackagingEvaluation•Packagingmustconformtos

pecificationsdevelopedbycustomerorsupplier.•Assessprotectionofproduct.•Customerspecifiedpackagingmustbeevalu

atedbyteam.•Pilotorproductiontrialrunpartsusuallyusedinevaluation.Marketing&CommunicationsFloorPlanLayout•Determineacc

eptabilityofinspectionandtestpoints.•Controlchartlocations•Visualaides•Interimrepairstations•Nonconformingmaterialstorage•Keyedtomaterialflowandcontr

olplanMarketing&CommunicationsReviewandSign-Off•Processinstructionsinplaceandfollowed!•Flowchartsinplaceandfollowed!•GR&Rplansexistandarefollowe

d•Publishfinalfeasibilityreport•Obtainformalsign-off•Scheduleandconductmanagementreview•ObtainmanagementcommitmenttoassistinopenissuesMarketing&Commu

nicationsQualityProblemsUpdateControlPlanandPlantWorkInstructionsCorrectiveActionRevisitPFMEACauseknown?Causeknown?ConductD.O.E.Causek

nown?ConductDisciplinedProblemSolvingCustomerProblemQualityProblemOccursyesnonoyesnoyesnoyesCauseunk

nown•UsePFMEANote:Whenacustomerproblemoccurs,followcustomerprescribedmethodologyWhentouse8-D•Whenthe

causeisunknown•Whenyouneedtogetinputfromseveralparties•WhencustomersdictateuseNote:Weusevotingtechniques,XtoYvariabletesting,andIS/ISN

ottodeterminetherootcause.However,youstillmaynotknowwhattherootcauseis?UpdatethePFMEA&ControlPlansProcessFlowPFMEAControlPlanW

orkInstructionScrap,ReworkDataWarranty&AssemblyPlantDataAfterthe8-Discompleted,thePMEAandthecontrolplanshouldberevisedandupdatedasapplicable