APQP

Advanced Product
Quality Planning
According to AIAGs (QS9000) APQP Manual

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 1, Printed 10/12/98

About This Course....

This course is not meant to be an
exercise in Sit and Listen.
If you have a question, speak up and
we can discuss your question or
comments.
Timing is approximate.
Breaks are scheduled to be long
enough for you to stay aware of What
Is Happening.
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 2, Printed 10/12/98

What Is APQP?
APQP is defined process for a product
development system for Ford, GM, Chrysler
and their suppliers.
APQP is an attempt to provide a common
path and synchronization of product
development activities.
APQP is an attempt to ensure communication
both within a company and between a
company and their customer.

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 3, Printed 10/12/98

What is the AIAGs APQP Reference Manual?

It Is General Information
It Does Not Address Specific
Manufacturer Information or
Requirements
It is NOT Auditable
It Does Attempt To Give Guidance
It Does NOT Address Any Specific
Industry or Manufacturer
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 4, Printed 10/12/98

Basics
Do NOT try to write a procedure just like
the APQP reference manual.
Look at what YOU are doing and relate
it to the APQP process described by the
reference manual.
Be ready to explain Equivalencies Where and How and What your system
does which fulfills APQP timeline
elements.
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 5, Printed 10/12/98

The Target & Goal

Continuous Improvement

Production

Pre-Launch

Prototype

LSL

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

USL

Advanced Product Quality Planning

Slide 6, Printed 10/12/98

Advanced Product Quality Planning

Concept
Initiation - Program
Approval Approval
Prototype
Planning
Design & Development

Planning

Pilot
Product
Process

Launch

Validation Product - Process

Production
Feedback Assessment & Corrective Action
Plan &
Define
Program

Product
Process Product &
Design & Design & Process
Dev.
Dev.
Validation
Verification Verification

AIAG APQP & Ctrl Plan Reference Guide, Page 5

A structured method of defining the steps (process) necessary to assure that a

product satisfies the customer

The goal of APQP is to facilitate communication with everyone involved to

ensure that all required steps are completed on time.
Effective APQP depends upon top management commitment and support to
assure that customer satisfaction is achieved

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 7, Printed 10/12/98

Fords Concept to Customer (CTC)

Initiated in 1984. Technically obsolete.

Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 8, Printed 10/12/98

Simplicity
Do not make your system overly
complex
Dont try to copy the APQP manual, just
Meet the intent with your system

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 9, Printed 10/12/98

A Simple APQP Sequence

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Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

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Customer

Sales

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Quality Assurance

Purchasing

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Program Manager

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Production

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Materials

Manufacturing Engineering

Design Engineering

Responsibility

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Market Research Information

Quality History Review
Engineering Research Data
Advanced Quality Planning Schedule
Preliminary Product/Process Design
Feasibility Analysis
Design FMEA
Process FMEA
Prototype Build and Verification
Significant Characteristics
Final Product and Process Design
Measurement and Test Equipment Needs & Costs
Process Control Plan
Process Flow Chart
Audit and QA Work Instructions
Order Production Tooling, Gages, Test Equipment
Select & Rate Suppliers
Train Quality Personnel
Supplier PSW Review & Sign-Off
Set-Up & De-Bug Production and Inspection Equipment
Preliminary Capability Studies For Production Processes
Process Optimization (Design Of Experiments)
Process Review (PFMEA Walk Through)
Product Training
Work Instructions (Manufacturing)
Measurment and Test Equipment Verification
Packaging
Part Sample Warrant
A = Assistance
I = Input
R = Responsibility
F = Sachs - Florence
T = Sachs - Troy

Advanced Product Quality Planning

Slide 10, Printed 10/12/98

QS 9000
APQP Involves:
4.1 Management Responsibility
4.2 Quality System
4.3 Contract Review
4.4 Design Control
4.5 Document and Data Control
4.9 Process Control
4.10 Receiving (Incoming)
4.11 Inspection, Measuring and Test Equipment
4.12 Inspection and Test Status
4.13 Control of Nonconforming Product
4.14 Corrective Action
4.15 Handling, Storage, Packaging and Delivery
4.16 Quality Records
4.18 Training
4.19 Servicing
4.20 Statistical Techniques
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 11, Printed 10/12/98

A Word About Design

If you design it in, its there to stay!

You will constantly be waiting for the next problem to surface!

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 12, Printed 10/12/98

PPAP
Sub-Set

APQP Launch Binders

PPAP Submission

The End Product of APQP!

Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 13, Printed 10/12/98

Typical Automotive Trilogy Development

APQP Timeline
Process Flow Diagram
(Includes ALL Processes)

Process FMEA
(On ALL Processes)

Critical Characteristics
& Failure Effects Issues

Process Control Plan

Some Elements may
be Included On

(Critical Processes from FMEA)

Critical Characteristics
& Characteristic Control Issues

Design FMEA
(On Intended Use)
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 14, Printed 10/12/98

Automotive Documentation Development

Develop Process
Flow Listing

Check for Customer

Requirements.

Enter Every
Major Process
from Flow Listing
into FMEA Form

Give careful consideration

to what you consider a
Major process.

Develop FMEA(s)
Element for Every
Process

Give careful consideration

to defining Control Plan
stages:
Prototype
Pre-launch
Production

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Develop the
Control Plan with
Critical
characteristics

Use the appropriate RPN

numbers and
considerations of other
appropriate information /
data to determine Critical
Characteristics.

Develop control
mechanisms appropriate
for Critical
characteristics.

Advanced Product Quality Planning

Slide 15, Printed 10/12/98

APQP Design & Process Controls

Design Reviews
Design Verification
Design Validation
Process Validation
Design FMEA
Process FMEA
Prototype Validation

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 16, Printed 10/12/98

Product Quality Planning Responsibility Matrix

APQP Phases
Define the Scope
Plan and Define (Section 1.0)
Product Design and Development (Section 2.0)
Feasibility (Section 2.13)
Process Design & Development (Section 3.0)
Product and Process Validation (Section 4.0)
Feedback, Assessment and Corrective Action (Section 5.0)
Control Plan Methodology (Section 6.0)

Design
X
X
X
X
X
X
X

Manufacturing
X

Service Supplier
X

X
X
X
X

X
X
X
X

AIAG APQP & Ctrl Plan Reference Guide, Page 2

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 17, Printed 10/12/98

Product Quality Planning Checklists

Design FMEA
Design Information
New Equipment, Tooling and Test Equipment
Product/Process Quality
Flow Plan
Process Flow Chart
Process FMEA
Control Plan
Check Lists for these line items are in the
AIAGs APQP & Control Plan reference manual
contained as a group - Appendix A starting on
page 63. Use them!

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 18, Printed 10/12/98

Benefits of APQP
Ensures early planning takes place
Directs resources to the customer
Identifies required changes early in the
process
Provides quality product on time and at
lowest cost
Enables cross-functional inputs and outputs
Addresses potential problems early in
Design
Manufacturing
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 19, Printed 10/12/98

Each APQP is Unique

Because of product and program differences
Timing and sequence are dependent upon
customer needs and expectations
Product complexity
Stamping
Sub-assembly

New
Modification

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 20, Printed 10/12/98

Progressive Fundamentals
Organize a Cross-Functional TEAM
Define the scope
Team-to-team communications
Training
Simultaneous (concurrent) engineering
Control Plan Phases
KEY**

Prototype
Pre-Launch
Production

Concern resolution
Includes analytical techniques
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 21, Printed 10/12/98

QS 9000 Elements to Consider

4.6
4.10
4.11
What else do you think???

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 22, Printed 10/12/98

Team Organization
Cross-functional
Engineering (Typically the leader)
Quality Assurance
Purchasing
Manufacturing Engineering
Material Control
Sales/Marketing
Etc.

Participation appropriate for phase being conducted

Resources - Team defines Needs
*Should* involve customer or subcontractor
participation (not always feasible)
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 23, Printed 10/12/98

Define Scope
Select team members and functions
Define roles and responsibilities
Identify external customer needs, expectations and
requirements
Identify internal customer needs, expectations and
requirements
Complete preliminary feasibility study
Identify costs, timing and constraints
Identify documentation process and method
Develop program plan (if project is a go)

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 24, Printed 10/12/98

Team-to-Team Communication

Manage using the APQP process

Understanding of How We Work As A Team
Should have a Focus Person & Distributed Minutes
Customer teams
Internal teams
Supplier teams
Sub-Teams
Subcontractors should be encouraged to embrace
APQP and QS 9000

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 25, Printed 10/12/98

Materials

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Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

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Customer

Sales

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Quality Assurance

Purchasing

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Production

Simple Responsibilities Matrix Example

Program Manager

Design Engineering

Manufacturing Engineering

Responsibility

Element
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Market Research Information

Quality History Review
Engineering Research Data
Advanced Quality Planning Schedule
Preliminary Product/Process Design
Feasibility Analysis
Design FMEA
Process FMEA
A
Prototype Build and Verification
A
Significant Characteristics
I
Final Product and Process Design
Measurement and Test Equipment Needs & Costs
A
Process Control Plan
I
Process Flow Chart
Audit and QA Work Instructions
Order Production Tooling, Gages, Test Equipment
Select & Rate Suppliers
Train Quality Personnel
Supplier PSW Review & Sign-Off
Set-Up & De-Bug Production and Inspection Equipment
Preliminary Capability Studies For Production Processes
Process Optimization (Design Of Experiments)
I
Process Review (PFMEA Walk Through)
Product Training
I
Work Instructions (Manufacturing)
I
Measurment and Test Equipment Verification
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Packaging
A
Part Sample Warrant
A = Assistance
I = Input
R = Responsibility
F = Site 1
Advanced Product Quality Planning
Slide 26, Printed 10/12/98
T = Site 2

Training
Customer needs and expectations
Working as a Team
Group process skills
Development skills
Requirements of APQP
FMEA
APQP
PPAP
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 27, Printed 10/12/98

Recommended Statistical Courses

Basic Business

Advanced
Business

Office, Staff, &

Management

Selected Staff, &

Management

Statistical
Process Control
Production Floor,
Production Staff &
Management,
All of Quality
& Engineering

Measurement
System Analysis

Design of
Experiment

Production Staff &

Management,
All of Quality
& Engineering

Specific Production
Staff,
Quality Engineers&
QA Manager
& Product
Engineering

*Your APQP Team should attend as many classes as time will allow
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 28, Printed 10/12/98

Customer and Supplier Involvement

Customer may initiate the planning
process
Supplier has the obligation to establish
cross-functional team to manage
process
Supplier should expect the same
performance from their subcontractors

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 29, Printed 10/12/98

Simultaneous (Concurrent) Engineering

Requires cross-functional team participation
Replaces prior system of sequential phases
and pass-off (old method)
APQP team ensures that other functions and
teams plan and execute support activities

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 30, Printed 10/12/98

Customer Requirements
Ways to Determine Customer Requirements

Print
Purchase Request or Request for Quotation
QFD - Quality Function Deployment
Service Engineers
Verbal Communications
Development Engineers
Product Check List

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 31, Printed 10/12/98

Base Documentation
Critical Characteristics Matrix
Process Flow Diagram
Design FMEA
Process FMEA
Control Plan

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 32, Printed 10/12/98

Chicken or Egg
Which is First? Second? Third?
Control Plan?
Process Flow Diagram?
Design FMEA?
Process FMEA?
Process Documentation (Work Instructions)?

Why Does it Matter?

Relationship to Product Planning

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 33, Printed 10/12/98

Typical Automotive Trilogy Development

APQP Timeline
Process Flow Diagram
(Includes ALL Processes)

Process FMEA
(On ALL Processes)

Critical Characteristics
& Failure Effects Issues

Process Control Plan

Some Elements may
be Included On

(Critical Processes from FMEA)

Critical Characteristics
& Characteristic Control Issues

Design FMEA
(On Intended Use)
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 34, Printed 10/12/98

The Links
Each Flow Chart element must have a
matching FMEA element. As a trilogy,
remember - the links must all match.
The trilogy documents must precisely
link to your process documentation
(work instructions or however your company
addresses this issue)

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 35, Printed 10/12/98

One Document? Or More?

Manufacturing Entity
Receiving

Machine
or Cell 2

Machine or
Cell 1

Machine
or Cell 3

Pack
& Ship

Internal or
External
Customer

Segmented = By machine or cell

Device, Technology or Family = a flow of a technology or a device

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Receiving
Pack
& Ship

Slide 36, Printed 10/12/98

The Control Plan

A Control Plan is a written description of systems for parts and processes

Process Dominated
Prototype *A Design Output
Used During Prototype Build
Dimensional Measurements
Material and Performance Tests

Pre-Launch
Update After Prototype and Before Production

Production
Comprehensive
Process Controls
Test and Measurement Systems Used
Reaction Plan
Sampling Plans
SPC Requirements

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 37, Printed 10/12/98

QS9000:1996 - FMEAs
4.2.3 - Quality Planning

Process Failure Mode and Effects

Analysis (Process FMEAs)
Process FMEAs shall consider all special
characteristics. Efforts shall be taken to improve
the process to achieve defect prevention rather
than defect detection. Certain customers have
FMEA review and approval requirements that shall
be met prior to production part approval (see
customer specific pages). Refer to the Potential
Failure Mode and Effects Analysis reference
manual.
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 38, Printed 10/12/98

QS9000:1996 - Control Plans

4.2.3 - Quality Planning

The Control Plan

Suppliers shall develop Control Plans at the system,
subsystem, component and/or material level, as appropriate
for the product supplied.
The Control Plan requirement encompasses processes
producing bulk material (e.g., steel, plastic resin, paint) as
well as those producing parts.
The output of the advanced quality planing process, beyond
the development of robust processes, is a Control Plan.
Control Plans may be based on existing plans (for mature
products and capable processes). New plans are required
when products or processes differ significantly from those in
current production.
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 39, Printed 10/12/98

QS9000:1996 - Control Plans

4.2.3 - Quality Planning

The Control Plan (continued)

The Control Plan shall cover three distinct phases as appropriate:

Prototype - a description of the dimensional measurements and
material and performance tests that will occur during Prototype build.
NOTE: Prototype control plans may not be required from all suppliers.
Pre-launch - a description of the dimensional measurements and
material and performance tests that will occur after Prototype and
before full Production.
Production - a comprehensive documentation of product/process
characteristics, process controls, tests, and measurement systems that
will occur during mass production.
Suppliers shall establish cross-functional teams to develop Control Plans for
approval by the appropriate customer engineering and quality personnel
unless this approval requirement is waived by the customer. In some cases,
the customer will establish a cross-functional team to develop the Control
Plan.

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 40, Printed 10/12/98

Semiconductor Supplement
Quality Planning - 4.2.3.S
During the advanced quality planning processes, the supplier shall
include all processes from the incoming material through shipping
and warehousing
Failure Mode and Effects Analysis and Control Plan documents
shall include these processes.

The Intent:
The supplier shall *consider* all processes. But - does it mean that
all process shall be included in the FMEA and Control Plan?

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 41, Printed 10/12/98

APQP Manual : 1995

6.2 Overview
A control plan is a written description of the
system for controlling parts and processes
In effect, the Control Plan describes the actions
that are required at each phase of the process
including receiving, in-process, out-going, and
periodic requirements to assure that all process
outputs will be in a state of control

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 42, Printed 10/12/98

FMEA Manual : 1995

Process Potential FMEA
Is ...a summary of engineers/teams thoughts
(including an analysis of items that could go wrong
based upon experience and past concerns) as a
process is developed.
A process FMEA should begin with a flow chart/
risk assessment of the general process. This flow
chart should identify the product/c characteristics
associated with each operation.

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 43, Printed 10/12/98

Concern Resolution
Design or Process concerns
Responsibility matrix
Disciplined problem solving methods
Use analytical techniques (*as appropriate)
(See AIAGs APQP & Control Plan reference manual page 4 and appendix B, page 81)

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 44, Printed 10/12/98

Product Quality Planning Timing Chart

Concept
Initiation - Program
Approval Approval
Prototype
Planning
Design & Development

Planning

Pilot
Product
Process

Launch

Validation Product - Process

Production
Feedback Assessment & Corrective Action
Plan &
Define
Program

Product
Process Product &
Design & Design & Process
Dev.
Dev.
Validation
Verification Verification
AIAG APQP & Ctrl Plan Reference Guide, Page 5

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 45, Printed 10/12/98

Timing Plan
Depends upon
Product complexity
Customer expectations

Team plan for

Training
Event
Action

Do NOT Under Estimate the

Importance of Timing!

Framework for tracking

Basis for status reporting
Prepare a timing chart using available project or similar
software

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 46, Printed 10/12/98

Timing Plan Contents

Identify individual tasks
Track resources by task
Establishes dependencies between tasks
Determine critical path
Track specific tasks or groups of tasks
Status reports
ID
1

Task Name
Visit 1

Dur
5d

Start
4/28/97

Finish
5/2/97

April

May

June

July

August

September

Apr

May

Jun

Jul

Aug

Sep

Plant Tour and Gather Information

2d

4/28/97

4/29/97

100%

Meet with Teams

2d

4/28/97

4/29/97

100%

Feasibility Determination

2d

5/1/97

5/2/97

Initial Project Plan Developed

1d

5/2/97

5/2/97

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

100%

Advanced Product Quality Planning

Slide 47, Printed 10/12/98

Project Plan Elements

Mission
Scope
Objectives
How to measure

Consider this a laundry list for an

index.

Requirements
Definitions and specifications
Market analysis
Feasibility

Time
Resources
Plant space
Etc.

Each item does not, however, have

to reside in one book.
You should have (at least) an index
of the project plan with the
location and owner (responsibility)
of each element clearly identified.

Timeline
Control system
Team
Cost Estimate
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 48, Printed 10/12/98

Project Plan Definitions

Mission - Goal, customer and approach
Scope - What will and will not be included (with
consideration to available technology)

Objectives - Technical, profit, performance, quality, etc.

Requirements - Deliverables
Definition and specification - Criteria it must meet
Market analysis - Expected annual production volume,
length of run, start (delivery) target date, target price (Japan),
key sales points, key competitors, etc.

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 49, Printed 10/12/98

Project Plan Definitions (continued)

Preliminary Feasibility - Degree to which current tooling and

equipment can be used
Timeline - Major milestones and detail task schedule
Control system - Answers questions such as:
How will progress be measured?
Who will receive reports?
How are changes handled?
What limits are there on authority, responsibility, and
accountability?

Team - Who, from where and who is the team leader?

Beware of Turf Wars!

Cost estimate - Estimate with assumptions. Often all information is

not available.

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 50, Printed 10/12/98

Project Plan Summary Sheet

Broad
Project #

Title

Customer

Model/Year

Part #

Date

Project Mission
Project Scope
Project Objectives
Contractural Requirements
Product Definition & Spec.
Current Capability
Timeline
Control System
Team Definition

Specific

Prelim. Cost Estimate

Project vs D&D (Design & Development)

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 51, Printed 10/12/98

Analytical Techniques

Assembly Build Variation Analysis

Benchmarking
Cause & Effect Diagram
Characteristics Matrix
Critical Path Method
Design of Experiments (DOE)
Design for Manufacturability & Assembly (DFM & DFA)
Design Verification Plan & Report (DVP&R - Chrysler & Ford)
Dimensional (Dynamic) Control Plan (DCP)
Mistake Proofing (Poka-Yoke)
Process Flow Charting
Quality Function Deployment (QFD)
System Failure Mode & Effects Analysis (SFMEA)
See AIAGs APQP & Control Plan reference manual appendix B, pages 81 thru 85

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 52, Printed 10/12/98

APQP Phases

Phase 1: Plan & Define Program

Phase 2: Product Design & Development Verification
Phase 3: Process Design & Development Verification
Phase 4: Product & Process Validation
Phase 5: Feedback Assessment & Corrective Action

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 53, Printed 10/12/98

APQP Phase 1:
Plan and Define Program
Concept
Initiation - Program
Approval Approval
Planning

Planning
Design & Development

Product
Process

Validation Product - Process

Production
Feedback Assessment & Corrective Action
Plan &
Define
Program
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 54, Printed 10/12/98

Phase 1 Inputs

Voice of the Customer

Business Plan and Marketing Strategy
Product/Process Benchmark Data
Product/Process Assumptions
Product Reliability Studies
Customer Inputs
Service

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 55, Printed 10/12/98

Voice of the Customer

Market research
Historical warranty and quality information
Team experience
Complaints
Recommendations
Data and/or other information

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 56, Printed 10/12/98

Voice of the Customer

External and
Internal
Customers

Stated, Real and

Perceived
Needs

Cultural Needs

Unintended
Uses

Functional
Needs vs.
Technical
Features

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 57, Printed 10/12/98

Market Research

Customer
interviews
Customer
questionnaires
and surveys
Marketing test
and positioning
reports
New product
quality and
reliability studies
Competitive
product quality
studies
Things Gone
Right reports

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Things Gone Right

The following is a list of vehicle features. Please read the entire list and place
an X next to those features of your new vehicle that you Particularly Like.

Room & Comfort

Interior Appearance
Front Room
Seat Appearance
Front Seat Comfort
Instrument Panel
Entry & Exit from Front
Door Panels
Cargo Capacity
Carpeting
Cargo loading, unloading
Exterior Appearance
Front View
Side View
Rear View
Paint
Moldings

Advanced Product Quality Planning

Handling
Handling on Highway
Handling in City, Parking
Visibility in Rear
Steering
Brakes

Slide 58, Printed 10/12/98

Historical Warranty and Quality Information

Things Gone Wrong

Things gone
Tell us about any troubles you have had with the vehicle. Mark a X in each
Wrong reports
box next to any item you have had trouble with.
Warranty reports
Exterior Paint
Capability
Paint mist or soray over body finish
Chipped paint
indicators
Color difference between body panels
Scratched paint
Uneven color on one body panel
Sags, runs in paint
Supplier plant
Paint ot tape stripes coming off, missing
Dirt in paint
internal quality
Rust, corrosion
Body paint on moldings, ornaments
Other paint troubles. Please describe.
reports
Problem
Steering & Handling
resolution reports
Steering noisy
Steering requires high or uneven effort
Customer plant
Constant pull to one side
returns and
Vehicle vibrates at speeds
Below 45 MPH
Above 45 MPH
Steering wheel spokes not correctly positioned when front wheels streight
rejections
Other steering and handling problems. Please describe.
Field return
product analysis

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 59, Printed 10/12/98

Team Experience
Input from higher system level or past
QFD projects
Media commentary and analysis
Customer letters and suggestions
Things gone Right/Wrong reports
Dealer comments
Fleet operator comments

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 60, Printed 10/12/98

Team Experience (continued)

Field service reports
Problems and issues reported from Internal
customers
Internal evaluations using surrogate customers
Road trips (e.g.: Struts)
Management comments and/or direction
Government requirements and/or regulations
Contract review

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 61, Printed 10/12/98

Business Plan - Marketing Strategy

Framework for quality plan

May place constraints on timing, cost, investment, positioning,
R&D resources
Strategy defines target customer, key sales points, key
competitors
SWAT
Strengths
Weaknesses
Opportunities
Threats

Old vs. New

How deep and how far to go

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 62, Printed 10/12/98

Product - Process Benchmark Data

A requirement of QS 9000 para. 4.1

Provides inputs to establish performance targets
Must address key process(es)
Must be measurable
Methods for successful benchmarking:
Identify appropriate benchmark(s)
Find reason for gap between your status and benchmark
Develop a plan for closing gap, meeting or exceeding
benchmark

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 63, Printed 10/12/98

Product - Process Assumptions

Assumptions
Features
Design
Process concepts
Technical innovations
Advanced materials
Reliability assessments
New technology

Document assumptions as part of project plan

Utilize as inputs to plan
Consider alternate paths in case assumptions do not play out

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 64, Printed 10/12/98

Product Reliability Studies

Frequency of repairs or replacements within
designated time period(s)
Repair or Throw-away?
LRU Level (Line Replaceability Unit)

Long range reliability and/or durability tests

Studies can be VERY costly and lengthy
EDCTP (Environmental Design Criteria Test Plan)
Failures
Market
Share

Durability

MTBR = Mean Time Between Replacement

Cayman Systems 1998 - Revision Q 980812
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MTBO = Mean Time Between Overhaul

MTBF = Mean Time Between Failures

Advanced Product Quality Planning

Slide 65, Printed 10/12/98

Customer Inputs
Next users provide information about
needs and expectations
Possibility of previous conducted
reviews and studies
Used to develop measure of customer
satisfaction

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 66, Printed 10/12/98

Phase 1 Project Review

Project #
Model/Year

Title
Part #

Customer
Date

Our advanced quality planning team has considered the following questions in Phase 1
of our APQP process. The documents provided have been used as a basis for analyzing
the ability to meet all specified requirements. All 'NO' answers are supported with attached
comments identifying our concerns and/or proposed changes to enable us to meet
specified requirements.
Yes
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

No

Checklist Item
Has historical data and experience concerning customer needs been considered?
Has full consideration been given to the overall business plan and marketing strategy?
Have product/process benchmark data been considered?
Have the product/process assumptions been identified and challanged?
Have product reliability studies been conducted?
Have there ben appropriate customer inputs into the process?
Do the design goals reflect the data generated?
Do the quality and reliability goals reflect appropriate standards?
Is the preliminary bill of materials sufficiently thorough?
Does the preliminary process flow chart relate to the primary BOM and
product/process assumptions?
Are all special product and process characteristics lited?
Does the produxct assurance plan include and outline of program requirements, goals,
factors that may place the program at risk, FMEA, and preliminary enginering
standards requirements?

Feasible
Feasible
Not Feasible

Product can be produced as specified with no revisions.

Changes recommended (See attached)
Design revision required to produce product within specified requirements

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

This form is Slide

on course
disk 10/12/98
67, Printed

MIS

Materials

Maintenance

HR

Production

Sales

Laboratory

Quality

Engineering

Purchasing

Phase 1: Plan and Define Program

Management

Phase 1 Responsibility Matrix

Output
Design Goals
Reliability and Quality Goals
Preliminary BOM
Preliminary process flow chart
Preliminary list of special product and
process characteristics.
Product assurance plan
Management Support

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

This form is on course disk

Slide 68, Printed 10/12/98

APQP Phase 2:
Product Design and Development
Program
Approval
Prototype
Planning

Planning
Design & Development

Product
Process

Validation Product - Process

Production
Feedback Assessment & Corrective Action
Product
Design &
Dev.
Verification
Cayman Systems 1998 - Revision Q 980812
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Advanced Product Quality Planning

Slide 69, Printed 10/12/98

Outputs by Design Responsible Activity

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

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 70, Printed 10/12/98

Additional Outputs by Design Responsible Activity

Updated special characteristics list

Prototype parts build
Make - Buy decisions
Parts inspection
Assembly of prototype(s)
Preferably manufacturing, not model shop

Inspection layout
Prototype validation testing

Redesign as required and design review

Update DFMEA (and System Level FMEA if appropriate)
Feasibility report

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 71, Printed 10/12/98

FMEAs

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 72, Printed 10/12/98

DFMEA
Disciplined analytical tool
Assess probability of failure
Effect of failure

Must be continually updated

Causes changes and/or additions to previously
selected special product and/or process
characteristics
If you do not have design control, you MUST (should)
have customer DFMEA
Check list (AIAG APQP Manual Appendix A-1)

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 73, Printed 10/12/98

Design, concept,
function and
sensitivity
(tolerancing) to
manufacturing
variation
Manufacturing
and/or assembly
process
Dimensional
tolerances

DFM and DFA

Performance
requirements
Number of
components
(complexity)
Process
adjustments
Material
handling

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 74, Printed 10/12/98

Design Verification
Inspection methods
Testing methods
Ensure that all design outputs meet
design input requirements
Alternate calculations
CAD/math data
Review design stage documents before release

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 75, Printed 10/12/98

Design Reviews - Evaluations

Design/functional requirement(s) and considerations

Formal reliability and confidence goals
Component/subsystem/system duty cycles
Computer simulation and bench test results
DFMEA(s)
Review of the DFM and DFA
Design of experiments (DOE) and assembly build
variation results
Test failures
Design verification progress
Max/Min builds
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 76, Printed 10/12/98

Design Review Tracking

Track verification progress using a
design verification plan and report (DVP&R
- Ford & Chrysler)

Product/process validation of
components

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 77, Printed 10/12/98

Process Flow Diagram Example

Process Flow Diagram

Inspect

Store

Move

Step

Fabrication

Part Number:
Part Description:
Prepared By:

Date: 4/5/93
Rev. : C

Approved By:

QA Manager
Operations Manager
Senior Advisor
QA Engineer

Operation Description
Item #Key Product Characteristic
Item #

Key Control Characteristic

Move "OK" Vinyl Material

From Storage Area and
Load Into Press.

1.0

Material Specs

1.0

Material Certification Tag

Auto Injection Mold Cover

In Tool #

2.0

Tearstrip In Cover

2.1
2.2

Tool Setup
Machine Setup

3.0

Hole Diameter In Cover

2.1
2.2

Tool Setup
Machine Setup

4.0

Flange Thickness In Cover

2.1
2.2

Tool Setup
Machine Setup

5.0

Pressure Control Protrusions

Height

2.1
2.2

Tool Setup
Machine Setup

6.0

Pressure Control Protrusions

Filled Out

2.1
2.2

Tool Setup
Machine Setup

7.0

Cover - Flash Free

8.0

Cover Filled Out

9.0

Free Of Foreign Material

2.1
2.2
2.1
2.2
2.2

Tool Setup
Machine Setup
Tool Setup
Machine Setup
Machine Setup

Visually Inspect Cover

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 78, Printed 10/12/98

PFMEA Example
Process Failure Mode And Effects Analysis
Process:

Low - High

Outside Suppliers Affected:

Engineer:

Primary Process Responsibility:

Model Year/Vehicle(s):

Part Number:

Other Div. Or People Involved:

Scheduled Production Released:

PFMEA Date:

Quality Assurance Manager

Quality Assurance Engineer

Take TPPE
Material Held In

Storage Area

Fragmented Container

Insufficient Supplier Control

Unpredictable Deployment

Improper Handling
Misidentified Material

Material Certification

18

10

90

Actions
Taken

RPN

Recommended
Actions And Status

Detection

Current Controls

Severity

Potential Cause Of Failure

RPN

Wrong Material

SIR
Container

Potential Effects Of Failure

Detection

Potential Failure
Mode

Severity

Process Function

Senior Advisor

Occured

Operations Manager

Part Name
Operation
Number

Rev.

Occured

Approvals:

1 - 10

Responsible
Activity

Required With Each

Shipment
Release Verification

Out Of Spec
Material
Contaminated

Fragmented Container

Supplier Material
Visual Inspection

63

Fragmented Container

Engineering Change

Release Verification

10

70

Unpredictable Deployment

Supplier Change

Fragmentation

Untrained LTO

10

50

10

30

Unpredictable Deployment

Material
Change
2

Move To

Unreleased

Periodic Audit Of

Open Boxes

Fragmented Container

Material
Composition

Supplier Process Control

Unpredictable Deployment

Green "OK" Tag

Customer Notification

Approved

Untrained Personnel

Storage

Check For Green "OK"

Tag At Press
Trace Card
Check List
Training

Hold In Approved
Storage Until

Contamination

Fragmentation

Open Containers

Process Problems

Housekeeping

Needed

Area Maintenance

Boxes Kept In Sealed

Storage Area Until
Needed
Boxes Lined With
Plastic
Liner On Pallets
Inside Storage
P. M. Facility

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 79, Printed 10/12/98

Prototype Build Control Plan

A description of the dimensional
measurements
Material tests
Functional tests that will occur during prototype
build
Depending upon product complexity, several
prototype builds may be necessary and may
require updates to the control plan

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 80, Printed 10/12/98

Standard Control Plan Example

Control Plan Number

Key Contact / Phone

Date (Orig.)

Part No./ Latest Change No.

Core Team

Customer Engineering Approval/Date

Part Name/Description

Supplier/Plant Apoproval/Date

Customer Quality Approval/Date

Other Approval/date (If Req'd)

Other Approval/date (If Req'd)

Supplier/Plant

Supplier Code

Characteristics
Process Name/
Part/
Process
Operation
Number
Description

Machine,
Device,
Jig, Tools
for Mfg.

Cayman Systems 1998 - Revision Q 980812

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No.

Product

Process

Date (Rev.)

Methods
Special
Char.
Class

Product/
Process
Spec/
Tolerance

Evaluation
Measurement
Technique
Size

Advanced Product Quality Planning

Frequency

Control
Method

Reaction
Plan

This form is onSlide

course
81,disk
Printed 10/12/98

Fords Dimensional Control Plan (DCP)

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 82, Printed 10/12/98

Control Plan Example (GM)

Process Control Plan
Supplier Name:
Supplier Rep.:

Supplier Code:
Telephone:

Title:

Part Number:
Part Description:

Date: 4/5/93

Key Product Control Characteristics

Engineering Change Letter:

Process Plan Effective Date: 4/5/93

Process Capability
Process Performance
(Short Term Capability)
(Long Term Capability)
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
[15]
Item Key Product Key Control Operation
Gage
Attr./ Last R&R % Gage Process
% Process
Cpk or Dev Process % ProcessCpk or Dev Type Of
Characteristic/CharacteristicsDescription Operation Variable
Date
R&R Capability
Capability
From
Perform. Perform
From
Control
Spec
Date
Target/Nom. Date
Target/Nom. Method

1.0

Vinyl Material
Spec

2.0

Tear Strip
(Cover)
1 = 0.41mm
.+/- 0.11mm

Gage Study

Auto
Injection
Mold
Cover
In TL#

2-7 = 0.685mm
.+/- 0.135mm
[7]
2.1
2.2
3.0

[1]
[2]
[3]
[4]
[5]
[6]
[7]

[1]
[2]
[3]
[4]
[5]
[6]
[7]

Tool Setup
Machine
Setup
Hole Diameter
(Cover)
4.60mm
.+/- 0.25mm

Auto
Injection
Mold Cover
TL#

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

[1]
[2]
[3]
[4]
[5]
[6]

[1]
[2]
[3]
[4]
[5]
[6]

Advanced Product Quality Planning

Controls
[16]
Freq. Of
Inspect.

Check
Every
Vendor
Box
Cert(s).
X bar and Start Of
R Charts Each Run
And Each
SQC
Shift
Database

Verify To
Spec
Sheet
X bar and 5 Pieces
R Charts Every 6
Months
SQC
Database

[17]
[18]
Operator
Process
Set-Up
Audit
Gage
Method
Instruction
and
(Proced. #) Frequency
Green "OK"
Release,
Each Box
3.607

3.609

This form is on course disk

Slide 83, Printed 10/12/98

Prototype Build
Make -buy decisions
Part inspections
Assemble prototypes
Perform layout inspection
Validation testing (Who will do testing?)
Redesign as required
Update DFMEA and SFMEA if required

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 84, Printed 10/12/98

Customer or Supplier Engineering Drawings

(including math data)
Review for special and/or critical characteristics
Review controlling drawings when engineering drawings
are nonexistent
Review drawings for:
Dimensions for form, fit, function, durability, government S&R
Control or datum surfaces/locators for function gages and
equipment
Feasibility/compatibility with industry standards

Compatibility of math data with two-way communications

(Written waivers acceptable)

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 85, Printed 10/12/98

Customer or Supplier Engineering Specifications

Review and understand controlling specifications
Identify functional, durability and appearance
requirements
Should define:
Sample size
Frequency
Acceptance criteria

Otherwise, determined by supplier and included in

control plan

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 86, Printed 10/12/98

Material Specifications
Review material specifications for
special characteristics
Physical properties
Performance
Environmental
Handling
Storage

Include in Control Plan

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 87, Printed 10/12/98

Drawing and Specifications Changes

Change control requirement applies
Ensure proper communication
QS 9000 Element 4.5 Document and data
Control applies (requires a Change Control system)

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 88, Printed 10/12/98

APQP Team Outputs

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

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 89, Printed 10/12/98

New Equipment, Tooling and Facilities Requirements

Preliminary identification of new equipment, tooling
and facilities
Address these items on the timing chart
Address capability requirements
Establish delivery times

Complete check list in AIAG APQP & Control Plan reference manual
Appendix A-3

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 90, Printed 10/12/98

Special Product and Process

Characteristics List
Upgrade preliminary list started in Phase 1 from
information gathered through review and
development of design features
Additional sources
DFMEA
SFMEA if applicable
PFMEA
Previous history

These may overlap

Must be on control plans for prototype, pre-launch

and production
Listing should be a team consensus

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 91, Printed 10/12/98

Gage and Testing Equipment Requirements

Preliminary identification of inspection, test and
measurement equipment
Requirements on timing chart
Complete in time to conduct measurement
systems analysis
Equipment builder
Pilot build
Production trial run

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 92, Printed 10/12/98

Team Feasibility, Commitment and Management Support

Team feasibility commitment

Complete program review check list, including:
Design feasibility
Can be manufactured, assembled, tested and packaged
Can be delivered in the right quantities on schedule at acceptable cost
Review design information check list in AIAG APQP Reference manual Appendix A-2 as part of
feasibility inputs

Open issues that require resolution with assigned responsibility and

timing.
Management Support
Report project status to management
Recommend continue or drop project depending on feasibility
Cover open issues and concerns
Management support as required

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 93, Printed 10/12/98

Subcontractor Pilot Build

Supplier participated, if appropriate
Sample quantity required
Check that it is according to:
Work instructions
Control plan

Where to be produced

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 94, Printed 10/12/98

Supplier Pilot Sample Build

Parts availability
Tooling and equipment availability
Measurement equipment availability

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 95, Printed 10/12/98

MIS

Materials

Maintenance

HR

Production

Sales

Laboratory

Quality

Engineering

Purchasing

Phase 2: Product Design and Development

Management

Phase 2 Responsibility Matrix

Output
DFMEA
DFM / DFA
Design Verification
Design Reviews
Prototype Build
Engineering Drawings (inc. math data)
Engineering Specifications
Material Specifications
Drawing / Specification Changes
New Equipment, Tooling, Facilities Requirements
Special Product & Process Characteristics
Prototype Control Plan
Gages / Testing Equipment Requirements
Team Feasibility Committment
Management Support
Subcontractor Built
Supplier Build
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

This form is on course disk

Advanced Product Quality Planning

Slide 96, Printed 10/12/98

Phase 2 Project Review

Project #
Model/Year

Title
Part #

Customer
Date

Our advanced quality planning team has considered the following questions in Phase 2
of our APQP process. The documents provided have been used as a basis for analyzing
the ability to meet all specified requirements. All 'NO' answers are supported with attached
comments identifying our concerns and/or proposed changes to enable us to meet
specified requirements.
Yes
1.
2.
3.
4.
5.
6.
6a
6b
6c
7.
8.
8a
8b

No

Checklist Item
Is the product adequately defined (application requiremetns, etc.) to enable
feasibility evaluation?
Can engineering performance specifications be met as written?
Can product be manufactured to tolerances specified on the drawing?
Can product be manufactured with Cpks which meet requirements?
Is there adequate capacity to produce product?
Can the product be manufactured without incurring any unusual:
Costs for tooling?
Costs for capital equipment?
Alturnate manufacturing methods?
Is Statistical Process Control required on the product?
Where Statistical Process Control is used on similar product?
Are the processes in control and stable?
Are Cpks greater than 1.33?

Feasible
Feasible
Not Feasible

Product can be produced as specified with no revisions.

Changes recommended (See attached)
Design revision required to produce product within specified requirements

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

This form is on course disk

Advanced Product Quality Planning

Slide 97, Printed 10/12/98

APQP Phase 3:
Process Design and Development
Prototype
Planning
Design & Development

Pilot

Planning

Product
Process

Validation Product - Process

Production
Feedback Assessment & Corrective Action
Process
Design &
Dev.
Verification

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 98, Printed 10/12/98

Typical Design Responsibility Outputs

DFMCA
DFM/DFA
DV
Design Reviews
Prototype Build
Engineering Drawings
Engineering Specifications
Material Specifications
Drawing and Specification Changes

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 99, Printed 10/12/98

Typical APQP Team Outputs

New Equipment
Facilities
Etc.

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 100, Printed 10/12/98

Process Design and Development Outputs

Packaging standards
Product and process quality system review
Process flow chart
Floor plan layout
Characteristics matrix
PFMEA
Pre-launch control plan
Process instructions
Measurement systems analysis plan
Preliminary process capability study plan (Typically 100 Parts)
Management support
Additional Outputs

Update tooling, equipment and facilities list

Update process flow chart
Update PFMEA
Quote in-house gages, tooling and equipment
Order gages, tooling and equipment
Delivery of gages in time for MSA plan
Delivery of equipment

Must consider approval at equipment subcontractor, in-house installation, debugging and process potential studies (runoff)

Subcontractor pilot build

Supplier pilot build
Salable units?

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 101, Printed 10/12/98

Packaging Standards
From customer
Developed during prototype or prelaunch runs

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 102, Printed 10/12/98

Product and Process Quality System Review

Team must review existing quality systems manual to
ensure that changes resulting from APQP (if any) are
reflected
Must comply with QS 9000
Changes must be reflected in control plan

Reference AIAG APQP Reference manual Appendix A-4 check list

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 103, Printed 10/12/98

Process Flow Chart

Update process flow chart

(Example in AIAG APQP Reference manual Appendix A-6)

Describes current or proposed process flow

Used to analyze sources of variation
Helps analyze total process
Needed for process FMEA, characteristics matrix and control
plan

Reference AIAG APQP Reference manual Appendix A-6 check list

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 104, Printed 10/12/98

Process Flow Diagram Example

Process Flow Diagram

Inspect

Store

Move

Step

Fabrication

Part Number:
Part Description:
Prepared By:

Date: 4/5/93
Rev. : C

Approved By:

QA Manager
Operations Manager
Senior Advisor
QA Engineer

Operation Description
Item #Key Product Characteristic
Item #

Key Control Characteristic

Move "OK" Vinyl Material

From Storage Area and
Load Into Press.

1.0

Material Specs

1.0

Material Certification Tag

Auto Injection Mold Cover

In Tool #

2.0

Tearstrip In Cover

2.1
2.2

Tool Setup
Machine Setup

3.0

Hole Diameter In Cover

2.1
2.2

Tool Setup
Machine Setup

4.0

Flange Thickness In Cover

2.1
2.2

Tool Setup
Machine Setup

5.0

Pressure Control Protrusions

Height

2.1
2.2

Tool Setup
Machine Setup

6.0

Pressure Control Protrusions

Filled Out

2.1
2.2

Tool Setup
Machine Setup

7.0

Cover - Flash Free

8.0

Cover Filled Out

9.0

Free Of Foreign Material

2.1
2.2
2.1
2.2
2.2

Tool Setup
Machine Setup
Tool Setup
Machine Setup
Machine Setup

Visually Inspect Cover

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 105, Printed 10/12/98

Floor Plan Layout

Determine acceptability of inspection and test points

Control chart location(s)
Visual aides
Interim repair stations
(rework)
Nonconforming material storage
Keyed to material flow and control plan
Reference AIAG APQP Reference manual Appendix A-5

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 106, Printed 10/12/98

Characteristics Matrix
Displays relationship between:
Process parameter
Manufacturing stations

Reference AIAG APQP Reference manual Appendix B, page 82

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 107, Printed 10/12/98

Process FMEA
To the extent possible, potential failure modes
have been considered and addressed
May be started after design FMEA in Phase 2
Needs to be updated regularly
Must be done prior to committing new tools and
equipment
Living document
Typically started too late!

Reference AIAG APQP Reference manual Appendix A-7

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 108, Printed 10/12/98

Automotive Process FMEA

Process Failure Mode And Effects Analysis
Process:

Low - High

Outside Suppliers Affected:

Engineer:

Primary Process Responsibility:

Model Year/Vehicle(s):

Part Number:

Other Div. Or People Involved:

Scheduled Production Released:

PFMEA Date:

Quality Assurance Manager

Quality Assurance Engineer

Take TPPE
Material Held In

Storage Area

Fragmented Container

Insufficient Supplier Control

Unpredictable Deployment

Improper Handling
Misidentified Material

Material Certification

18

10

90

Actions
Taken

RPN

Recommended
Actions And Status

Detection

Current Controls

Severity

Potential Cause Of Failure

RPN

Wrong Material

SIR
Container

Potential Effects Of Failure

Detection

Potential Failure
Mode

Severity

Process Function

Senior Advisor

Occured

Operations Manager

Part Name
Operation
Number

Rev.

Occured

Approvals:

1 - 10

Responsible
Activity

Required With Each

Shipment
Release Verification

Out Of Spec
Material
Contaminated

Fragmented Container

Supplier Material
Visual Inspection

63

Fragmented Container

Engineering Change

Release Verification

10

70

Unpredictable Deployment

Supplier Change

Fragmentation

Untrained LTO

10

50

10

30

Unpredictable Deployment

Material
Change
2

Move To

Unreleased

Periodic Audit Of

Open Boxes

Fragmented Container

Material
Composition

Supplier Process Control

Unpredictable Deployment

Green "OK" Tag

Customer Notification

Approved

Untrained Personnel

Storage

Check For Green "OK"

Tag At Press
Trace Card
Check List
Training

Hold In Approved
Storage Until

Contamination

Fragmentation

Open Containers

Process Problems

Housekeeping

Needed

Area Maintenance

Boxes Kept In Sealed

Storage Area Until
Needed
Boxes Lined With
Plastic
Liner On Pallets
Inside Storage
P. M. Facility

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 109, Printed 10/12/98

Pre-launch Control Plan

Description of dimensional measurements, materials
and functional tests
Adds additional product and/or process controls
Purpose is to contain potential nonconformities
utilizing:
More frequent inspections and/or tests
More in-process and final inspection and/or check points
Statistical evaluations
Increased audits
Reference AIAG APQP Reference manual Appendix A-8 check list

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 110, Printed 10/12/98

Automotive Control Plan

Control Plan Number

Key Contact / Phone

Date (Orig.)

Part No./ Latest Change No.

Core Team

Customer Engineering Approval/Date

Part Name/Description

Supplier/Plant Apoproval/Date

Customer Quality Approval/Date

Other Approval/date (If Req'd)

Other Approval/date (If Req'd)

Supplier/Plant

Supplier Code

Characteristics
Process Name/
Part/
Process
Operation
Number
Description

Machine,
Device,
Jig, Tools
for Mfg.

Cayman Systems 1998 - Revision Q 980812

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No.

Product

Process

Date (Rev.)

Methods
Special
Char.
Class

Product/
Process
Spec/
Tolerance

Evaluation
Measurement
Technique
Size

Advanced Product Quality Planning

Frequency

Control
Method

Reaction
Plan

Slide 111, Printed 10/12/98

Process Instructions

Work instructions for operating personnel

Sources:
FMEAs
Control plans
Engineering drawings and specifications
Material specifications
Visual standards
Industry standards
Process flow chart
Floor plan layout
Characteristic matrix
Packaging standards
Process parameters
Producer expertise
Handling requirements
Operators of process
Accessible operators
Include set-up parameters
Reference QS 9000 Element 4.9 Process Control

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 112, Printed 10/12/98

Measurement Systems Analysis Plan Ensures Gage:

Linearity
Accuracy
Repeatability
Reproducibility
Correlation for duplicate gages
Gages may be needed prior to gage sign-off at subcontractor plant or any inhouse pilot runs

Material

Inspector
Sample
Collection

Methods
Test Method

Training

Sample
Preparation

Workmanship

Parallax

Practice
Samples

Reproducibility

Ergonomics
Standards

Measurement
Discrimination

Vibration
Bias

Repeatability

Calibration

Linearity

Instrument
Cayman Systems 1998 - Revision Q 980812
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Temperature
Lighting
Humidity

Environment

These are some of the variables in a

measurement system. What others can
you think of?

Advanced Product Quality Planning

Slide 113, Printed 10/12/98

Measurement Precision

Indicates
Poor
Precision

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 114, Printed 10/12/98

Measurement Bias & Repeatability

Precise

Imprecise

Accurate

Inaccurate

Bias

You can correct for Bias

You can NOT correct for Imprecision
Cayman Systems 1998 - Revision Q 980812
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Advanced Product Quality Planning

Slide 115, Printed 10/12/98

Preliminary Process Capability Study Plan

Must include characteristics identified in control
plan
Few characteristics for simple component
Many characteristics for complex product with
many parts

Reference AIAG Fundamental SPC Reference Manual

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 116, Printed 10/12/98

Packaging Specifications

For individual products

Customer packaging
Generic standards where appropriate
Must ensure delivery quality
Compatible with all material handling
equipment used

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 117, Printed 10/12/98

Additional Phase 3 Outputs

Updated equipment, tools and facility lists

Updated process flow chart, PFMEA and control plan
Quotes for in-house tooling, equipment and gages
Selection of potential new subcontractors
Quote and delivery of gages in time for MSA plan
Equipment build and runoffs
Generation of a subcontractor pilot build
Generation of a supplier pilot build

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 118, Printed 10/12/98

Updated Tool, Equipment and Facilities Lists

Information from PFMEA and other sources
Address on timing chart
Address capability requirements

Reference AIAG APQP Reference manual Appendix A-3 check list

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 119, Printed 10/12/98

Quoting In-House Tooling, Equipment and Gages

Delivery timing for pilot build or production trial run

Include capability requirements
Include trial run/runoff/prove-out requirements
Gage delivery for MSA plan and runoff

Reference AIAG APQP Reference manual Appendix A-3

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 120, Printed 10/12/98

Selecting Potential New Subcontractors

Responsible for planning, tracking and
follow-up for subcontracted work
Provide technical resources for tool and
gage design, fabrication and full
dimensional inspection

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 121, Printed 10/12/98

Subcontractor Pilot Sample Build

Supplier participation, if appropriate
Build sample quantity required
Machine trial runs
Pilot run(s)

In accordance with appropriate work

instructions
In accordance with control plan
Production tooling and equipment, if possible

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 122, Printed 10/12/98

Supplier Pilot Build

Provide for customer participation, if
specified
have process instructions in place
Have control plan in place
Provide required quantity
Complete MSA
Generate required documentation as
planned
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 123, Printed 10/12/98

Project Review III

Include in control plan
Manufacturing locations quality system
manual should be reviewed
Procedures and control plans to be
updated to reflect changes
Last chance to eliminate problems
before ramp-up

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 124, Printed 10/12/98

MIS

Materials

Maintenance

HR

Production

Sales

Laboratory

Quality

Engineering

Purchasing

Phase 3: Process Design & Development

Management

Phase 3 Responsibility Matrix

Output
Packaging Standards
Product/Process Quality System Review
Process Flow Chart
Floor Plan Layout
Characteristics Matrix
PFMEA
Pre-Launch Control Plan
Process Instructions
Measurement Systems Analysis Plan
Preliminary Process Capability Study Plan
Packaging Specifications
Management Support

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

This form is on course disk

Advanced Product Quality Planning

Slide 125, Printed 10/12/98

Phase 3 Project Review

Project #
Model/Year

Title
Part #

Customer
Date

Our advanced quality planning team has considered the following questions in Phase 3
of our APQP process. The documents provided have been used as a basis for analyzing
the ability to meet all specified requirements. All 'NO' answers are supported with attached
comments identifying our concerns and/or proposed changes to enable us to meet
specified requirements.

Yes
1.
2.
3.
4.

5.
6.
7.
8.
9.
10.
11.

No

Checklist Item
Does packaging design ensure product integrity at point of use and meet customer specs?
Is the product process quality checklist completed for the system review?
Does the process flow chart indicate any problems with the process?
Does the floor plan checklist indicate any problems with the aceptability of inspection
points, control chart locations, applicability of visual aids, interim repair stations, and
storage area to contain defective materials?
Is a characteristics matrix appropriate and has one been constructed?
Does the process FMEA check list indicate any problems and is there a system for
periodic review of the PFMEA?
Does the control plan check list indicate that all dimensional requirements, material, and
functional tests that will occur after the prototype, and before full production, are included?
Are clear process instructions in appropriate detail and are they cross-referenced to all
appropriate sources?
Does the measurement systems analysis plan include responsibility to ensure gage linearity,
accuracy, repeatrability, reproducability, and correlation for duplicate gages?
Has the preliminary process capability study plan been completed?
Do the packaging specifications resulting from the packaging design assure that product
performance and characteristics will remain unchanged during packing, transit, unpacking,
and will it have compatability with all material handling equipment, including robots?

Feasible
Feasible
Not Feasible

Product can be produced as specified with no revisions.

Changes recommended (See attached)
Design revision required to produce product within specified requirements

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

This form is on course disk

Advanced Product Quality Planning

Slide 126, Printed 10/12/98

APQP Phase 4:
Product and Process Validation
Planning
Design & Development

Planning

Pilot
Product
Launch

Process

Validation Product - Process

Production
Feedback Assessment & Corrective Action
Product &
Process
Validation

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 127, Printed 10/12/98

Phase 4 Outputs

Production trial run

Measurement system evaluation (complete)
Preliminary process capability study
Production part approval
Production validation testing
Packaging evaluation
Production control plan
Quality planning sign-off and management support

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 128, Printed 10/12/98

Production Trial Run

Production tooling, equipment,
environment, facilities and cycle time
Process instructions and control plans
Minimum quantity set by customer
(Can be increased by team)

Generally 300 parts

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 129, Printed 10/12/98

Production Trial Run Product Used For:

Preliminary process capability studies

MSA (if not completed earlier)
Final feasibility
Process review
Production validation testing
PPAP
Packaging evaluation
First time capability
Quality planning sign-off
Design changes (if required)

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 130, Printed 10/12/98

Measurement Systems Analysis (MSA)

Complete studies as defined in the MSA
plan
Minimum are those identified in the
control plan
Subjected to evaluation prior to or
during production trial

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 131, Printed 10/12/98

Preliminary Process Capability Studies

Characteristics identified in the control plan

Usually 100 pieces minimum
May be 30 if run is less
Ppk 1.67 is acceptable unless otherwise specified
Ppk 1.67 requires action plan unless otherwise
specified

Reference AIAG Fundamental SPC Reference Manual

1.0 at spec limit
+-3 sigma = 1.67
Allows flop within spec limit

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 132, Printed 10/12/98

PPAP Scope

Production parts - generally 300 pieces

Service subcontractors - fulfill requirements
Bulk material
Includes internal and external sources for
information
Submission required prior to first production
shipment
Section II When submission is required for
guidance
Cayman Systems 1998 - Revision Q 980812
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Advanced Product Quality Planning

Slide 133, Printed 10/12/98

Production Part Approval Process (PPAP)

Production Part Approval Process

Parts produced at production site using:
Production tooling
Production gages
Process
Operators
Environment
Process settings

Feeds
Speeds
Cycle times
Pressures
Temperatures

Intent is to validate (prove) that products made using production equipment meet
engineering requirements
If submission level is not known, contact customer
Default level is 3
Customer approval is required prior to quantity production

Reference AIAG Production Part Approval Process reference manual

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 134, Printed 10/12/98

Production Validation Testing

Engineering tests validate products manufactured
with:
Production tools
Production processes
Production operators

Performed under end-use operating conditions

Multiple validations for multiple intended uses

Reference QS 9000 Element 4.4.8

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 135, Printed 10/12/98

Packaging Evaluation
Packaging must conform to specifications
developed by customer or supplier
Assess protection of product
Customer specified packaging must be
evaluated by team
Pilot or production trial run parts usually
used in evaluation

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 136, Printed 10/12/98

Production Control Plan

Update pre-launch control plan (living document)
Add:
Sampling plans
Control method
SPC, inspection, attribute data and mistake-proofing
Reaction plan

Nonconformances clearly identified, quarantined and

disposition made
Requires customer approval unless otherwise
specified

Reference AIAG APQP Reference manual Appendix A-8, B and G

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 137, Printed 10/12/98

Review and Sign-Off

Process instructions in place and followed

Flow charts in place and followed
GR&R plans exist and are followed
Publish final feasibility report
Obtain formal sigh-off
Schedule and conduct management review
Obtain management commitment to assist in
open issues

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 138, Printed 10/12/98

Phase 4 Project Review

Project #
Model/Year

Title
Part #

Customer
Date

Our advanced quality planning team has considered the following questions in Phase 4
of our APQP process. The documents provided have been used as a basis for analyzing
the ability to meet all specified requirements. All 'NO' answers are supported with attached
comments identifying our concerns and/or proposed changes to enable us to meet
specified requirements.

Yes
1.
2.
3.
4.
5.
6.
7.

No

Checklist Item
Has the production trial run been conducted and does it indicate the need for any change?
Does the evaluation of the measurement systems indicate any need to modify the
control plan characteristics?
Does the preliminary process capability study indicate any potential problems?
Has the production part been approved?
Has the production validation testing indicated any problems?
Has rthe evaluation of the packaging of test shipments, where feasible, and test methods
indicated any difficulty?
Has the control plan methodology check list indicated any problems with that document?

Feasible
Feasible
Not Feasible

Product can be produced as specified with no revisions.

Changes recommended (See attached)
Design revision required to produce product within specified requirements

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

This form is on course disk

Slide 139, Printed 10/12/98

MIS

Materials

Maintenance

HR

Production

Sales

Laboratory

Quality

Engineering

Purchasing

Phase 4: Product and Process Validation

Management

Phase 4 Responsibility Matrix

Output
Production Trial Run
Measurement Systems Evaluation
Preliminary Process Capability Study
Production Part Approval
Production Validation Testing
Packaging Evaluation
Production Control Plan
Quality Planning Sign-Off
Management Support

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

This form is on course disk

Slide 140, Printed 10/12/98

APQP Phase 5:
Feedback, Assessment and Corrective Action
Planning

Planning
Design & Development

Product
Process

Launch

Validation Product - Process

Production
Feedback Assessment & Corrective Action
Feedback
Assessment &
Corrective Action

The results of continuing production are evaluated for common

or special causes of variation during this phase to ensure that
the products satisfy customer satisfaction requirements
The effectiveness of the quality process should be evaluated
during this process step
Includes continual improvement efforts
Includes delivery and service performance

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 141, Printed 10/12/98

Continuing Production

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 142, Printed 10/12/98

Phase 5 Outputs
Reduced variation
Customer satisfaction
Delivery and service

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 143, Printed 10/12/98

Reducing Variation
Identify process variation
take corrective action to reduce
variation
Develop proposal for customer review
Gain customer decision to implement,
negotiate or change design

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 144, Printed 10/12/98

Customer Satisfaction
Product or service must perform in
customers environment
Supplier must participate
Supplier and customer must be partners

Reference QS 9000 Element 4.1.6

Cayman Systems 1998 - Revision Q 980812

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Advanced Product Quality Planning

Slide 145, Printed 10/12/98

Customer Satisfaction Metrics

Warranty
Labour claims
Concerns reports
Nonconforming material reports

Corrective actions
On time delivery
Tech calls
Customer rating
Returns
PPM
Response time

On-site representative
Market share
Cost control (total cost)

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 146, Printed 10/12/98

Delivery and Service

Continues the supplier - customer partnership
in problem solving and continuous
improvement
Replacement parts and services are
important
Leads to possible price reduction from:
Inventory cost reduction
Process cost reduction
Cost of quality reduction
Reference QS 9000 Element 4.15
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 147, Printed 10/12/98

MIS

Materials

Maintenance

HR

Production

Sales

Laboratory

Quality

Engineering

Purchasing

Phase 5: Feedback, Assessment and Corrective Action

Management

Phase 5 Responsibility Matrix

Output
Reduced Variation
Customer Satisfaction
Delivery and Service

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

This form is on course disk

Slide 148, Printed 10/12/98

Phase 5 Project Review

Project #
Model/Year

Title
Part #

Customer
Date

Our advanced quality planning team has considered the following questions in Phase 5
of our APQP process. The documents provided have been used as a basis for analyzing
the ability to meet all specified requirements. All 'NO' answers are supported with attached
comments identifying our concerns and/or proposed changes to enable us to meet
specified requirements.

Yes
1.
2.
3.

No

Checklist Item
Has a system for reducing future variation been developed and is it in place?
Is there a system for ensuring continuing customer satisfaction?
Is there a process in place for monitoring delivery and service so that it continues
to met customer needs?

Feasible
Feasible
Not Feasible

Product can be produced as specified with no revisions.

Changes recommended (See attached)
Design revision required to produce product within specified requirements

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Team Member/Title/Date

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

This form is on course disk

Slide 149, Printed 10/12/98

Control Plan Methodology

Aids in the manufacturing of products according to
customer requirements
Provide structured approaches
Contain a written summary of the system used in
minimizing process and product variation
Forms provided in the AIAG handbook are examples
of how to document
Alternate formats can be used if they contain
necessary information
Must be maintained and used throughout the product
life cycle
Cayman Systems 1998 - Revision Q 980812
(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 150, Printed 10/12/98

Control Plan Use

Initial: To document and communicate
initial process control
Next: Guidance in controlling processes
and to ensure product quality
Last: A living document reflecting
current methods of control and
measurement systems used

Cayman Systems 1998 - Revision Q 980812

(513) 777-3394 www.qs9000.com

Advanced Product Quality Planning

Slide 151, Printed 10/12/98