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Advanced Product Quality Planning and Control Plan APQP Second Edition

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TABLE OF CONTENTS

FOREWORD . и;

TABLE OF CONTENTS V

1NTRODUCTIOK j

Fundamentals of Product Quality Planning 3

Organize the Team J

Define the Scope 3

Team-to-Team 4

Training 4

Customer and Organization Involvement 4

Simultaneous Engineering 4

Control Plans ,..,4

Concern Resolution 5

Product Quality Timing Plan J

Plans Relative to the Timing Chart 5

CHAPTER I PLAN AND DEFINE PROGRAM 7

Introduction 9

l.J Voice of the Customer 9

1.2 Business Plan and Marketing Strategy J ]

1.3 Product/Process Benchmark Data / J

1.4 Product/Process Assumptions 12

1.5 Product Reliability Studies 12

1.6 Customer Inputs . 12

1.7 Design Goals 12

1.8 Reliability and Quality Goals 12

1.9 Preliminary Bill of Material 12

1.10 Preliminary Process Flow Chart /3

1.11 Preliminary’ Identification of Special Product and Process Characteristics 13

1.12 Product Assurance Plan , 13

1.13 Management Support 14

CHAPTER 2 PRODUCT DESIGN AND DEVELOPMENT 15

Introduction 17

2.1 Design Failure Mode and Effects Analysis (DFMEA) ] 8

2.2 Design for Manufacturability and Assembly 18

2.3 Design Verification 19

2.4 Design Reviews 19

2.5 Prototype Build - Control Plan 20

2.6 Engineering Drawings (Including Math Data) 20

2.7 Engineering Specifications 21

2.8 Material Specifications 21

2.9 Drawing and Specification Changes , 21

2.10 New Equipment, Tooling and Facilities Requirements 21

2.11 Special Product and Process Characteristics 21

2.12 Gages/Testing Equipment Requirements 22

2.13 Team Feasibility Commitment and Management Support 22

CHAPTER 3 PROCESS DESIGN AND DEVELOPMENT 23

Introduction 25

3.1 Packaging Standards and Specifications 26

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5.5 Process- Funs Chan

5.5 Floor Plan Layout

5.5 Characteristic'- Maino

5.5 Process Failure Mode and Effects Analysis; tPFMi

5. Г Pre-Launch Control Plan

3.8 Process instructions

3.9 Measurement Systems Analysis Plan 28

3.10 Preliminary' Process Capability Study Plan 29

3.11 Management Support 29

CHAPTER 4 PRODUCT AND PROCESS VALIDATION 31

Introduction 33

4.1 Significant Production Run 34

4.2 Measurement Systems Analysis 34

4.3 Preliminary Process Capability? Study 34

4.4 Production Part Approval 35

4.5 Production Validation Testing 35

4.6 Packaging Evaluation 35

4.7 Production Control Plan 35

4.8 Quality Planning Sign-Off and Management Support 35

CHAPTER 5 FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION 37

Introduction 39

5.1 Reduced Variation 39

5.2 Improved Customer Satisfaction 40

5.3 Improved Delivery1 and Service 40

5.4 Effective Use of Lessons Learned/Best Practices 40

CHAPTER 6 CONTROL PLAN METHODOLOGY ...41

INTRODUCTION 43

6.1 Control Plan Column Descriptions 47

6.2 Process Analysis 56

APPENDIX A PRODUCT QUALITY PLANNING CHECKLISTS 71

APPENDIX B ANALYTICAL TECHNIQUES 88

Assembly Build Variation Analysis 89

Benchmarking 89

Cause and Effect Diagram 89

Characteristics Matrix 90

Critical Path Method. 91

Design of Experiments (DOE) 91

Design for Manufacturability and Assembly 92

Design Verification Plan and Report (DVP&R) 92

Mistake Proofing/Error-Proofing 92

Process Flow Charting 93

Quality Function Deployment (QFD) 93

APPENDIX C REFERENCE MATERIAL 95

APPENDIX D TEAM FEASIBILITY COMMITMENT.., ,97

APPENDIX E PRODUCT QUALITY PLANNING SUMMARY AND APPROVALS................ „99

APPENDIX F GLOSSARY 102

APPENDIX G INDEX - .105