1. 1 ADVANCED PRODUCT QUALITY PLANNING Prepared By: Mr. Prashant S. Kshirsagar (Sr.Manager-QA dept.)

2. -: ADVANCED PRODUCT QUALITY PLANNING :-

3. -: Content :- Types of Core Tools History of APQP Definition of APQP Various Organizational Road blocks Importance of APQP PDSA cycle in APQP APQP various Stages Input/Outputs of APQP in every Stages/Phases Benefits of APQP Some examples for APQP

4. -: What are the Core tools for IATF 16949 compliance? :- Core Tools. Tools that have the Greatest Impact on Product and Process Success are called the Core Tools. 1. 2. 3. 4. 5.

5. -: History of APQP :- Chrysler, Ford and General Motors Product Quality Planning and Control Plan guidelines developed jointly by Chrysler, Ford and General Motors. Ford Motor Company Ford Motor Company published the first Advanced Quality Planning handbook for suppliers in the early 1980’s.

6. Advanced Product Quality Planning (APQP) is a Structured Methodology to define and establish all necessary steps to standardized & meet all quality requirements to satisfies the customer Structured collaboration involving Engineering, Manufacturing, Material Control, Purchasing, Quality, Sales and Management -: What is APQP?:-

7. -:Organizational Road Blocks :-

9. -:Goals of APQP:-  Plan before Acting  Anticipate and Prevent issues  Validate/ Confirm before moving forward  Facilitate/ Expedite communication

10. -: Why do we need APQP?:-  Achieve cost and budgeted targets  Optimization of Cost  Improve profit  Minimal or No Quality problem  Defect free products  Increase Yields  Mitigate & Minimal launch Quality risks  Shorten Lead Times  On-time delivery  Continual improvement  Enhance customer satisfaction failure There are plenty of possibilities for failure, especially when new products are being launched. E.g. Car wheel tyre QualityPerformance APQP is used to assure Quality and Performance through Planning. It focus on Utilization of Tools and Methods for Mitigating the risks associated with change in the New Product or Process. It helped to Develop appropriate Prevention & Detection controls for new products

11. -: APQP House:-

12. -: What are the stages/phases of APQP?:- 80% of APQP process: Planning & Prevention 20% of APQP process: Validation & Evidence

13. -: What is the importance of PDSA cycle in APQP?:-  What are we trying to accomplish ?  How will we know that change is an improvement?  What changes can we test that results in an improvement?

14. -: :- -: When to Apply Advanced Product Quality Planning (APQP):- APQP is used in 2 ways: 1. New Product Introduction (NPI):- APQP supplements product development processes by adding a focus on risk as a substitute for failure. This allows the team to take action on the risk instead of having to wait for failure to occur in testing or worse, in the hands of the customer. APQP utilizes risk based tools that focus on all aspects of product and process design, service, process quality control, packaging and continuous improvement. Each application of APQP may be unique to a previous application because of the percentage of new content, changes to current off-the-shelf technology or past failure history. 2. Product or Process Change (Post Release):- APQP follows a product or process change outside of Product Development and assures the risk of change is managed successfully by preventing problems created by the change.

15. -: How to plan? :-

16. -: APQP Timing Chart:-

17. Outcome of Various Process Stages of APQP PFMEA Control Plan Launch Containment Plan Ram Up Plan PPAP Approval -: Different stages/phases of APQP:- Preliminary SC/CC Review Engineering Release DFMEA DV Test Equip & Facilities Review Gage & Fixture Review Control Plan Feasibility Dimensional & Appearance Approval Packaging Approval Doc, Process & SC/CC Review Engineering Release Process Flow/Floor Plan PFMEA & Control Plan Process / Operator Instructions Production Tooling Complete PPAP Submission Team Feasibility

18. -: Different stages/phases of APQP:- Pre-Planning  Phase 0: Pre-Planning APQP begins with assumptions, concepts and past knowledge. Bookshelf knowledge and standard work practices are listed as well as where significant change is expected. This section compiles the inputs into Section 1 – Plan and Define.  Aspects of Pre-Planning include:  Scope of the project  Product and Process Assumptions  Past Failure  Team size, structure and experience  Methods for issue resolution  Space and resources required  Timing of the project

20. -: Different stages/phases of APQP:- Plan and Define  Phase 1: Plan and Define Section 1 links customer expectations, wants, needs and desires to requirements. Plan Development will assure the output of this section is satisfactory product quality. Resource planning, process and product assumptions are made. A list of preliminary special characteristics and design/reliability goals are also established. The Cross Functional Team (CFT) in APQP evolves and changes as the process progresses. Preliminary details required to begin Product Quality Planning are collected by a CFT prior to project kick-off. This process is typically short and does not involve any product or process design effort. The CFT adds members as certain disciplines are required. Each CFT discipline communicates with their colleagues on items which can impact quality, cost or delivery, either positively or negatively.

21. Plan and Define -: APQP phase 1: Plan and Define :- Inputs & Outputs of Phase 1 Voice of the Customer °Market Research °Historical Warranty and Quality Information °Team Experience Business Plan and Marketing Strategy Product/Process Benchmark Data Product/Process Assumptions Product Reliability Studies Customer Inputs Service Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support Phase 1 Phase 1: Inputs Phase 1: Outputs (= Phase 2: Inputs)

22. Objective of Plan and Define -: APQP phase 1: Objective of Plan and Define phase:- - To plan & Define Advanced product quality planning (APQP) for the program. - To ensure that the supplier clearly understands customer needs and expectations in order to plan and define a quality program. - The supplier is responsible for completing, using and updating the planning documents throughout the program.

23. Product Design and Development -: APQP phase 2: Product Design and Development :- Product Design and Development  Phase 2: Product Design and Development The focus in Phase 2 is on product design and development. Geometry, design features, details, tolerances and refinement of special characteristics are all reviewed in a formal Design Review. Design verification through prototypes and testing are also part of this section. Tools Tools: Tools which typically provide great benefit in this section are DFM/A, Design Failure Mode and Effects Analysis (DFMEA) and Design Verification Plan and Report (DVP&R).DFM/ADesign Failure Mode and Effects Analysis (DFMEA)Design Verification Plan and Report (DVP&R)

24. Product Design and Development -: APQP phase 2: Product Design and Development :- Inputs & Outputs of Phase 2 Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan Management Support Phase 2 Outputs by Design Responsible Activity Outputs by Advanced Product Quality Planning Team Design FMEA DFM and DFA Design for Manufacturability Design for Assembly Design Verification Design Reviews Prototype Build Control Plan Engineering Drawings (including Math data) Engineering Specifications Material Specifications Drawing and Specification Changes New equipment, tooling and facilities requirements Special product and process characteristics Gage and testing equipment requirements Team feasibility commitment and management support Subcontractor build Supplier build Phase 1 Outputs (Phase 2 Inputs) Phase 2 Outputs (Phase 3 Inputs)

25. Objective of Product Design and Development -: APQP phase 2:- Objective of Product Design and Development :- - Identify the product's potential failure modes, assess the probability of the failure modes occurring, review the effects of such failures and formulate action plans to improve the product designs to prevent or counteract the failures and their effects.

26. -: APQP phase 3: Process Design and Development :- Process Design and Development :-  Phase 3: Process Design and Development :- This Phase explores manufacturing techniques and measurement methods that will be used to bring the design engineer’s vision into reality. - Tools: Process Flow Charts, Process Failure Mode and Effects Analysis (PFMEA) and Control Plan Methodology are examples of tools used in this section.Process Failure Mode and Effects Analysis (PFMEA)Control Plan Methodology

27. -: APQP phase 3: Process Design and Development :- Inputs & Outputs of Phase 3 Outputs by Design Responsible Activity Outputs by Advanced Product Quality Planning Team Design FMEA DFM and DFA Design for Manufacturability Design for Assembly Design Verification Design Reviews Prototype Build Control Plan Engineering Drawings (including Math data) Engineering Specifications Material Specifications Drawing and Specification Changes New equipment, tooling and facilities requirements Special product and process characteristics Gage and testing equipment requirements Team feasibility commitment and management support Subcontractor build Supplier build Phase 3 Phase 3 Outputs (Phase 4 Inputs) Packaging Standards Product / Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Phase 2 Outputs (Phase 3 Inputs) Phase 2 Design Activity Outputs Phase 2 APQP Team Outputs

28. Objective of -: APQP phase 3: Objective of Process Design and Development :- - Develop a process flow diagram and process map of layout of the manufacturing area. - Develop comprehensive and effective manufacturing system to ensure the manufacturing systems meets customer requirements.

29. -: APQP phase 4: Product and Process Validation:- Productand Process Validation Phase 4: Product and Process Validation Validation of the process quality and volume capabilities is the focus of Section 4. Statistical Process Control (SPC), Measurement Systems Analysis (MSA) and Process Capability Studies are introduced in this section. Product Part Approval Process (PPAP) is ready for submission and production begins upon approval.Process Capability Studies Juran Trilogy diagram:-

30. -: APQP phase 4: Product and Process Validation:- Production Trial Run Measurement Systems Evaluation Preliminary Process Capability Study Production Part Approval (PPAP) Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-off Phase 4 Packaging Standards Product / Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Phase 3 Outputs (Phase 4 Inputs) Phase 4 Outputs (Phase 5 Inputs) Inputs & Outputs of Phase 4

31. Objective of -: APQP phase 4: Objective of Product and Process Validation:- - Validate the manufacturing processes & the product, and to ensure that customer's requirement will be meet. The supplier shall develop a PPAP document package and submit to the customer for approvals. The supplier should communicate with customer to determine PPAP submission level requirements.

32. -: APQP phase 5: Feedback Assessment and Corrective Action:- Phase 5: Feedback Assessment and Corrective Action Section 5 explores learning's from the ongoing manufacturing process, RPN reduction, corrective actions (both internal and external), Eight Disciplines of Problem Solving (8D) and the capture of information pertinent for future use.Eight Disciplines of Problem Solving (8D)

33. -: APQP phase 5: Feedback Assessment and Corrective Action:- Reduced Variation Customer Satisfaction Delivery and Service Phase 5 Production Trial Run Measurement Systems Evaluation Preliminary Process Capability Study Production Part Approval (PPAP) Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-off Phase 5 Outputs Phase 4 Outputs (Phase 5 Inputs)

34. Objective of -: APQP phase 5: Objective of Feedback Assessment and Corrective Action :- The objective of this phase is to assess the effectiveness of APQP for the program and to incorporate the changes or practices in upcoming program planning to improve the system.

35. -: APQP Complete House structure :- NPI NPI: New Product Introduction

36. Directing/ Aiming resources by defining the vital few items from the trivial many Promote early identification of change Intentional & Incidental Avoid late changes (post release) by anticipating failure and preventing it On-time quality product at lowest cost Multiple options for mitigating the risk when found earlier Higher capability of verification and validation of a change Improved collaboration between Design of the Product and Process Improved Design for Manufacturing and Assembly (DFM/A)Design for Manufacturing and Assembly (DFM/A) Lower cost solutions selected earlier in the process Advancement of Tribal Knowledge and standard work creation and utilization -: What are the benefits of APQP?:-

37. -: Example of APQP :-