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    APQP (v1) _ 1994

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    nelson.hsiao.tw
    This Reference Manual and Reporting Format were developed by the Advanced Product Quality Planning (APQP) and the Control Plan teams that were sanctioned by Chrysler, Ford, General Motors Supplier Quality Requirements Task Force.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    APQP (v1) _ 1994

    Uploaded by

    nelson.hsiao.tw
    0 views127 pages
    This Reference Manual and Reporting Format were developed by the Advanced Product Quality Planning (APQP) and the Control Plan teams that were sanctioned by Chrysler, Ford, General Motors Supplier Quality Requirements Task Force.

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    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    This Reference Manual and Reporting Format were developed by the Advanced Product Quality Planning (APQP) and the Control Plan teams that were sanctioned by Chrysler, Ford, General Motors Supplier Quality Requirements Task Force.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    0 views127 pages

    APQP (v1) _ 1994

    Uploaded by

    nelson.hsiao.tw
    This Reference Manual and Reporting Format were developed by the Advanced Product Quality Planning (APQP) and the Control Plan teams that were sanctioned by Chrysler, Ford, General Motors Supplier Quality Requirements Task Force.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 127

    Table of Contents

    TABLE OF CONTENTS

    Advanced Product Quality Planning and Control Plan / APQP


    Foreword
    Acknowledgement
    Product Quality Planning Cycle
    Page No.
    Introduction 1
    Product Quality Planning Responsibility Matrix 2
    Fundamentals of Product Quality Planning 3
    Product Quality Planning Timing Chart 5

    1.0 Plan and Define Program 6


    1.1 Voice of the Customer 7
    1.1.1 Market Research 8
    1.1.2 Historical Warranty and Quality Information 8
    1.1.3 Team Experience 8
    1.2 Business Plan/Marketing Strategy 9
    1.3 Product/Process Benchmark Data 9
    1.4 Product/Process Assumptions 9
    1.5 Product Reliability Studies 9
    1.6 Customer Inputs 9
    1.7 Design Goals 10
    1.8 Reliability And Quality Goals 10
    1.9 Preliminar y Bill of Material 10
    1.10 Preliminar y Process Flow Chart 10
    1.11 Preliminar y Listing of Special Product and Process Characteristics 10
    1.12 Product Assurance Plan 11
    1.13 Management Support 11

    2.0 Product Design and Development 12


    2.1 Design Failure Mode and Effects Analysis (DFMEA) 14
    2.2 Design for Manufacturability and Assembly 14
    2.3 Design Verification 15
    2.4 Design Reviews 15
    2.5 Prototype Build - Control Plan 15
    2.6 Engineering Drawings (Including Math Data) 16
    2.7 Engineering Specifications 16
    2.8 Material Specifications 16
    2.9 Drawing and Specification Changes 16
    2.10 New Equipment, Tooling and Facilities Requirements 17
    2.11 Special Product and Process Characteristics 17
    2.12 Gages/Testing Equipment Requirements 17
    2.13 Team Feasibility Commitment and Management Support 17

    3.0 Process Design and Development 18


    3.1 Packaging Standards 20
    3.2 Product/Process Quality System Review 20
    3.3 Process Flow Chart 20
    3.4 Floor Plan Layout 20

    iii
    Page No.
    3.5 Characteristics Matrix 20
    3.6 Process Failure Mode and Effects Analysis (PFMEA) 21
    3.7 Pre-Launch Control Plan 21
    3.8 Process Instructions 21
    3.9 Measurement Systems Analysis Plan 22
    3.10 Preliminar y Process Capability Study Plan 22
    3.11 Packaging Specifications 22
    3.12 Management Support 22

    4.0 Product and Process Validation 24


    4.1 Production Trial Run 25
    4.2 Measurement Systems Evaluation 26
    4.3 Preliminar y Process Capability Study 26
    4.4 Production Part Approval 26
    4.5 Production Validation Testing 26
    4.6 Packaging Evaluation 27
    4.7 Production Control Plan 27
    4.8 Quality Planning Sign-Off and Management Support 27

    5.0 Feedback, Assessment and Corrective Action 28


    5.1 Reduced Variation 29
    5.2 Customer Satisfaction 30
    5.3 Deliver y and Ser vice 30

    6.0 Control Plan Methodology 31


    6.1 Table of Contents 32
    6.2 Over view 33
    6.3 Control Plan Column Descriptions 37
    6.4 Process Analysis 46
    6.5 Supplements 47

    iv
    Table of Contents

    Page No.
    Appendix A - Product Quality Planning Checklists 63
    A-1 Design FMEA Checklist 64
    A-2 Design Information Checklist 65
    A-3 New Equipment, Tooling and Test Equipment Checklist 69
    A-4 Product/Process Quality Checklist 71
    A-5 Floor Plan Checklist 75
    A-6 Process Flow Chart Checklist 77
    A-7 Process FMEA Checklist 78
    A-8 Control Plan Checklist 79

    Appendix B - Analytical Techniques 81


    Assembly Build Variation Analysis 81
    Benchmarking 81
    Cause and Effect Diagram 81
    Characteristics Matrix 81
    Critical Path Method 82
    Design of Experiments (DOE) 82
    Design for Manufacturability and Assembly 82
    Design Verification Plan and Report (DVP&R) 83
    Dimensional Control Plan (DCP) 83
    Dynamic Control Plan (DCP) 83
    Mistake Proofing (Poka-Yoke) 84
    Process Flow Charting 84
    Quality Function Deployment (QFD) 84
    System Failure Mode and Effects Analysis (SFMEA) 85

    Appendix C - Special Characteristics Symbols 87

    Appendix D - Reference Material 89

    Appendix E - Team Feasibility Commitment 91

    Appendix F - Product Quality Planning Summary and Sign-off 93

    Appendix G - Ford's Powertrain Dynamic Control Planning 95

    Appendix H - Glossary 103

    Appendix I - Acronyms 107

    Appendix J - Bibliography 109

    Appendix K - Alphabetic Index 111

    Appendix L - Forms 113

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