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Advanced Product Quality Planning and Control Plan APQP Second Edition

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
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