APQP PROCESS MAP - 2º Edition

PRODUCT QUALITY PLANNING TIMING CHART

Concept Program Concept

Prototype Pilot Launch
Initiation/Approval Approval Initiation/Approval

PLANNING PLANNING

PRODUCT DESIGN AND DEVELOPMENT

PROCESS DESIGN AND DEVELOPMENT

PRODUCT AND PROCESS VALIDATION

PRODUCTION

FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

PROCESS
PLANNING PRODUCT DESIGN AND DEVELOPMENT PROCESS DESIGN AND DEVELOPMENT PRODUCT AND PROCESS VALIDATION
PRODUCT AND PROCESS VALIDATION

INPUTS OUTPUTS INPUTS OUTPUTS INPUTS OUTPUTS INPUTS OUTPUTS

INPUTS OUTPUTS

2.1 DESIGN FAILURE MODE

1.1 VOICE OF THE DESIGN FAILURE MODE AND 3.1 PACKAGING STANDARDS SIGNIFICANT
1.7 DESIGN GOALS DESIGN GOALS AND EFFECTS ANALYSIS 5.1 REDUCED VARIATION
CUSTOMER EFFECTS ANALYSIS (DFMEA) AND SPECIFICATIONS PACKAGING STANDARDS 4.1 SIGNIFICANT PRODUCTION RUN
(DFMEA)
AND SPECIFICATIONS PRODUCTION RUN

1.8 RELIABILITY AND RELIABILITY AND QUALITY APPENDIX A- 1 (DESIGN APPENDIX A- 1 (DESIGN 3.2 PRODUCT/PROCESS MEASUREMENT SYSTEM 5.2 IMPROVED CUSTOMER
1.1.1 MARKET RESEARCH
QUALITY GOALS GOALS FMEA CHECKLIST) QUALITY SYSTEM REVIEW PRODUCT/PROCESS 4.2 MEASUREMENT ANALYSIS SATISFACTION
FMEA CHECKLIST)
QUALITY SYSTEM REVIEW SYSTEM ANALYSIS

1.1.2 HISTORICAL WARRANTY 1.9 PRELIMINARY BILL OF PRELIMINARY BILL OF 2.2 DESIGN FOR DESIGN FOR PRELIMINARY PROCESS 5.3 IMPROVED DELIVERY
MANUFACTURABILITY AND MANUFACTURABILITY AND APPENDIX A- 4 AND SERVICE
AND QUALITY INFORMATION MATERIAL MATERIAL APPENDIX A- 4 4.3 PRELIMINARY PROCESS CAPABILITY STUDY
ASSEMBLY ASSEMBLY (PRODUCT/PROCESS QUALITY
(PRODUCT/PROCESS QUALITY CHECKLIST) CAPABILITY STUDY
CHECKLIST)
5.4 EFFECTIVE USE OF LESSONS
1.10 PRELIMINARY PRELIMINARY PROCESS
1.1.3 TEAM EXPERIENCE 2.3 DESIGN VERIFICATION DESIGN VERIFICATION
3.1 PACKAGING STANDARDS PRODUCTION PART LEARNED/BEST PRACTICES
PROCESS FLOW CHART FLOW CHART AND SPECIFICATIONS PACKAGING STANDARDS 4.4 PRODUCTION PART APPROVAL(PPAP)
AND SPECIFICATIONS APPROVAL(PPAP)

1.11 PRELIMINARY LISTIMG OF PRELIMINARY LISTIMG OF

1.2 BUSINESS PRODUCTION VALIDATION
SPECIAL PRODUCT AND SPECIAL PRODUCT AND 2.4 DESIGN REVIEWS
PLAN/MARKETING STRATEGY DESIGN REVIEWS 3.3 PROCESS FLOW CHART 4.5 PRODUCTION TEST
PROCESS CHARACTERISTICS PROCESS CHARACTERISTICS
PROCESS FLOW CHART
VALIDATION TEST

1.4 PRODUCT/PROCESS 1.12 PRODUCT PRODUCT ASSURANCE 2.5 PROTOTYPE BUILD - PROTOTYPE BUILD - APPENDIX A- 6 (PROCESS PACKAGING EVALUATION
BENCHMARK DATA ASSURANCE PLAN PLAN CONTROL PLAN APPENDIX A- 6 (PROCESS 4.6 PACKAGING
CONTROL PLAN FLOW CHART CHECKLIST)
FLOW CHART CHECKLIST) EVALUATION

1.5 PRODUCT RELIABILITY 1.13 MANAGEMENT APPENDIX A- 8 (CONTROL APPENDIX A- 8 (CONTROL PRODUCTION CONTROL
MANAGEMENT SUPPORT 3.4 FLOOR PLAN LAYOUT
STUDIES SUPPORT PLAN CHECK LIST) PLAN CHECK LIST) 4.7 PRODUCTION PLAN
FLOOR PLAN LAYOUT
CONTROL PLAN

1.6 CUSTOMER INPUTS 2.6 ENGINEERING APPENDIX A- 5 (FLOOR APPENDIX A- 8 (CONTROL

DRAWINGS ENGINEERING DRAWINGS APPENDIX A- 5 (FLOOR
PLAN CHECKLIST) APPENDIX A- 8 (CONTROL PLAN CHECKLIST)
PLAN CHECKLIST) PLAN CHECKLIST)

2.7 ENGINEERING 3.5 CHARACTERISTICS 4.5 QUALITY PLANNING SIGN-

ENGINEERING
MATRIX 4.5 QUALITY PLANNING SIGN- OFF AND MANAGEMENT
SPECIFICATIONS SPECIFICATIONS CHARACTERISTICS MATRIX
OFF AND MANAGEMENT SUPPORT
SUPPORT

3.6 PROCESS FAILURE MODE

2.8 MATERIAL MATERIAL AND EFFECTS PRODUCT QUALITY PLANNING
PROCESS FAILURE MODE AND
SPECIFICATIONS SPECIFICATIONS ANALYSIS(PFMEA) SUMMARY AND APPROVALS
EFFECTS ANALYSIS(PFMEA)

2.9 DRAWING DRAWING SPECIFICATION

SPECIFICATION CHANGES APPENDIX A- 7 (PROCESS
CHANGES APPENDIX A- 7 (PROCESS
FMEA CHECKLIST)
FMEA CHECKLIST)

2.10 NEW EQUIPMENT 2.10 NEW EQUIPMENT

TOOLING AND FACILITIES 3.7 PRE-LAUNCH
TOOLING AND FACILITIES PRE-LAUNCH CONTROL
REQUIREMENTS REQUIREMENTS CONTROL PLAN
PLAN

APPENDIX A- 3 (NEW APPENDIX A- 3 (NEW

EQUIPMENT, TOOLING AND EQUIPMENT, TOOLING AND APPENDIX A- 8 (CONTROL
TEST EQUIPMENT CHECKLIST) TEST EQUIPMENT CHECKLIST) APPENDIX A- 8 (CONTROL
PLAN CHECKLIST)
PLAN CHECKLIST)

2.11 SPECIAL PRODUCT AND SPECIAL PRODUCT AND 3.8 PROCESS

PROCESS CHARACTERISTICS PROCESS CHARACTERISTICS INSTRUCTIONS PROCESS INSTRUCTIONS

2.12 GAGES/TESTING GAGES/TESTING EQUIPMENTS 3.9 MEASUREMENT

EQUIPMENTS REQUIREMENTS REQUIREMENTS SYSTEM ANALYSIS PLAN MEASUREMENT SYSTEM
ANALYSIS PLAN

2.13 TEAM FEASIBILITY TEAM FEASIBILITY 3.10 PRELIMINARY PROCESS

COMMITMENT AND COMMITMENT AND PRELIMINARY PROCESS
MANAGEMENT SUPPORT
CAPABILITY STUDY PLAN
MANAGEMENT SUPPORT CAPABILITY STUDY PLAN

APPENDIX A- 2 (THE DEIGN APPENDIX A- 2 (THE DEIGN 3.11 MANAGEMENT

INFORMATION CHECKLIST) INFORMATION CHECKLIST) SUPPORT MANAGEMENT SUPPORT

APPENDIX
PRODUCT QUALITY PLANNING CHECKLISTS (APPENDIX A) ANALYTICAL TECHNIQUES (APPENDIX B) REFERENCE MATERIAL (APPENDIX C) TEAM FEASIBILITY COMMITMENT (APPENDIX D) PRODUCT QUALITY PLANNING SUMMARY AND APPROVALS (APPENDIX E)

PRODUCT QUALITY
APPENDIX A- 3 (NEW TEAM FEASIBILITY
PLANNING SUMMARY AND
APPENDIX A- 1 (DESIGN APPENDIX A- 2 (THE DEIGN EQUIPMENT, TOOLING AND ASSEMBLY BUIT VARIATION APPENDIX A- 2 (THE DEIGN CAUSE AND EFFECT MEASUREMENT SYSTEM POTENTIAL FAILURE MONDE PRODUCTION PART COMMITMENT
APPROVALS
FMEA CHECKLIST) INFORMATION CHECKLIST) TEST EQUIPMENT ANALYSIS INFORMATION CHECKLIST) DIAGRAM ANALYSIS (MSA) AND EFFECT ANALYSIS (FMEA) APPROVAL PROCESS (PPAP)
CHECKLIST)

APPENDIX A- 4 DESIGN OF EXPERIMENTS STATISTICAL PROCESS

APPENDIX A- 5 (FLOOR APPENDIX A- 6 (PROCESS CHARACTERISTIC MATRIX CRITICAL PATH METHOD
(PRODUCT/PROCESS (DOE) CONTROL (SPC)
PLAN CHECKLIST) FLOW CHART CHECKLIST)
QUALITY CHECKLIST)

DESIGN FOR MISTAKE PROOFING/ERROR

DESIGN VERIFICATION PLAN
APPENDIX A- 7 (PROCESS APPENDIX A- 8 (CONTROL MANUFACTURING AND PROOFING
AND REPORT (DVP&R)
FMEA CHECKLIST) PLAN CHECKLIST) ASSEMBLY

QUALITY FLOW CHARTING

PROCESS FLOW CHARTING
(QFD)

Reference: Advanced Product Quality Planning (APQP) and Control Plan - Second Edition
Elaborated by: Guilherme Bruno