An advanced product quality planning is a framework of procedures and techniques used to develop products in industry, particularly in the automotive industry. APQP is a structure process aim at ensuring customer satisfaction with new products or processes.
The APQP is a process develop at the end of 1980 by a Committee form by Ford, GM and Chrysler. This tool is used today by these three companies, their suppliers and some subsidiaries. The APQP is a guide in the development process and also is a standard way to share results between suppliers and automotive companies.
Advanced product quality planning is a structure process to define important key features for compliance with regulatory requirements and achieve customer satisfaction. APQP includes methods and controls (i.e., measures, tests) that will be use in the design and production of a product or of a specific family of products (i.e., parts, materials).
Quality planning incorporates the concepts of prevention of the defect and of continuous improvement according to put in contrast to the detection of the defect.
Its purpose is to produce a plan of the quality of the product that support the development of a product or keep it to meet customer. This process focuses on the development, industrialization and new product launch. During these phases 23 issues are monitor, these shall be finish until mass-production start.
Some topics that are monitor are: robustness of design, testing, design and compliance with the specifications, design of the production processes, standard of inspection quality, process capability, production capacity, packing of product, product testing and training of operators, among others.
Advanced product quality planning process: consists of four phases and five important activities together with the assessment in the process of regeneration and the corrective action as shown:
Phase 1:
This stage is design to ensure that the needs and expectations of customers are clearly understood. The entrance of this phase is equip by the revision of agreement for full of service suppliers. The outputs include:
Providers can consider this phase of APQP equivalent to design and planning and the design of the development enter into Qs-9000.
Phase 2:
This area includes a thorough review of the requirements for the design of product (engineering) and concludes with a sign-off on the reliability of the design.
Outlets per head of the design activity.
Outputs of the advanced product quality planning team.
Phase 3:
This phase ensures that the customer's expectations and the requirements of the design are carefully incorporate in the manufacturing process. Outputs:
Phase 4:
This phase ensures that the customer's expectations and the requirements of the design are carefully incorporate in the manufacturing process. Outputs:
Phase 5:
Outputs:
For the successful development of the APQP is use a series of tools which help a better development of this tool which should be mention in a general way giving their definition.
Is a set of statistical tools that allow us to monitor the behavior of a process over time with the aim of achieving a production within standard and with the lowest possible variation.
I a tool use to determine the variation of instruments of measurement and the person making the measurement in order to reduce the variability of the same.
Analysis of the mode of failure and effect of the failure potential (FMEA or FMEA): is a group of structure activities, which help to identify potential failure modes, identify and prioritize actions, document processes.
A control plan is a written description of the system design to control the parts of the process. This system has been design to ensure all the outputs of the process are in "control state".
(PPAP) production part approval process: Is the evidence that the supplier is able to detect and monitor changes in the process, which could put at risk the quality and supply of parts to customer. And with this evidence is obtain approval by the client with the signing of the PSW (Part Submission Warrant).
Importance of the APQP in the development of new products in the automotive industry.
The importance of APQP in new product development is to produce a plan of the quality of the product that support the development of a product or keep it and that meets the customer to review the entries and run outs, including FMEA, DFMA, design verification, design, material and engineering specifications reviews.
What is APQP?
The APQP is a process develop at the end of 1980 by a Committee form by Ford, GM and Chrysler. This tool is used today by these three companies, their suppliers and some subsidiaries. The APQP is a guide in the development process and also is a standard way to share results between suppliers and automotive companies.
Advanced product quality planning is a structure process to define important key features for compliance with regulatory requirements and achieve customer satisfaction. APQP includes methods and controls (i.e., measures, tests) that will be use in the design and production of a product or of a specific family of products (i.e., parts, materials).
Quality planning incorporates the concepts of prevention of the defect and of continuous improvement according to put in contrast to the detection of the defect.
Purpose
Its purpose is to produce a plan of the quality of the product that support the development of a product or keep it to meet customer. This process focuses on the development, industrialization and new product launch. During these phases 23 issues are monitor, these shall be finish until mass-production start.
Some topics that are monitor are: robustness of design, testing, design and compliance with the specifications, design of the production processes, standard of inspection quality, process capability, production capacity, packing of product, product testing and training of operators, among others.
Phases that make up the APQP.
Advanced product quality planning process: consists of four phases and five important activities together with the assessment in the process of regeneration and the corrective action as shown:
Phase 1:
Planning and defining the program.
This stage is design to ensure that the needs and expectations of customers are clearly understood. The entrance of this phase is equip by the revision of agreement for full of service suppliers. The outputs include:
- The design goals
- Reliability goals
- Account of the preliminary material
- Preliminary process flow sheet
- Preliminary listing of the special product and process characteristics
- Product assurance plan
- Management support
Providers can consider this phase of APQP equivalent to design and planning and the design of the development enter into Qs-9000.
Phase 2:
Design and product development.
This area includes a thorough review of the requirements for the design of product (engineering) and concludes with a sign-off on the reliability of the design.
Outlets per head of the design activity.
- Mode of failure of the design and analysis of the effects.
- The design for manufacture and Assembly.
- A design verification.
- Design reviews.
- The prototype build-control plan.
- Engineering (including math data) plans
- Engineering specifications
- The drawings and specification changes.
Outputs of the advanced product quality planning team.
- New equipment, tooling, and facilities requirements
- Consensus on product key/critical and characteristics of the process
- Gages/testing equipment requirements
- Commission of the viability of the team and management support
Phase 3:
Design and development of the process
This phase ensures that the customer's expectations and the requirements of the design are carefully incorporate in the manufacturing process. Outputs:
- Packaging standards
- Review of system of quality of Product/process
- The floor plan available
- Process flow sheet
- Features matrix
- Process FMEA (analysis of the mode of failure and effect)
- Pre-Lance the control plan
- Process instructions
- The analysis of the measurement system
- Preliminary plan of the study of the processing capabilities
- Packaging specifications
- Management support
Phase 4:
Validation of the production process
This phase ensures that the customer's expectations and the requirements of the design are carefully incorporate in the manufacturing process. Outputs:
- Packaging standards
- Review of system of quality of product/process
- The floor plan available
- Process flow sheet
- Features matrix
- Process FMEA (analysis of the mode of failure and effect)
- Pre-Lance the control plan
- Process instructions
- The analysis of the measurement system
- Preliminary plan of the study of the processing capabilities
- Packaging specifications
- Management support
Phase 5:
Launch of the product and continuous improvement
Outputs:
- Reduce variation
- Customer satisfaction
- Documentation and service
Tools used in the development of APQP.
For the successful development of the APQP is use a series of tools which help a better development of this tool which should be mention in a general way giving their definition.
Statistical process control:
Is a set of statistical tools that allow us to monitor the behavior of a process over time with the aim of achieving a production within standard and with the lowest possible variation.
Measurement systems analysis:
I a tool use to determine the variation of instruments of measurement and the person making the measurement in order to reduce the variability of the same.
Analysis of the mode of failure and effect of the failure potential (FMEA or FMEA): is a group of structure activities, which help to identify potential failure modes, identify and prioritize actions, document processes.
Control plan:
A control plan is a written description of the system design to control the parts of the process. This system has been design to ensure all the outputs of the process are in "control state".
(PPAP) production part approval process: Is the evidence that the supplier is able to detect and monitor changes in the process, which could put at risk the quality and supply of parts to customer. And with this evidence is obtain approval by the client with the signing of the PSW (Part Submission Warrant).
Importance of the APQP in the development of new products in the automotive industry.
The importance of APQP in new product development is to produce a plan of the quality of the product that support the development of a product or keep it and that meets the customer to review the entries and run outs, including FMEA, DFMA, design verification, design, material and engineering specifications reviews.
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