A V Manivannan Principal Consultant & Trainer CSR

Transcription

1 & P P A P A V Manivannan Principal Consultant & Trainer CSR

2 A new product development & approval process A most practical workshop 2

3 Sri Padhmam Consultancy & Training S O P for the Workshop on APQP & PPAP ( as per IATF : 2016 ) with a focus on CSR Target participants : Engineers & above Type of Program :- Technical Management Behavioral Min. Max. Hours No. of Participants Mixed Group : Yes No Program Objectives To familiarize the participants to apply the concepts & Practices of Advanced Product Quality Planning & Control Plan ( APQP ) 2 nd edition Production Part Approval Process ( PPAP ) 4 th Edition. To provide the skill sets on new product development through APQP & PPAP methodologies. Also to familiarize on linkages to IATF 16949:2016 requirements. Performance Indicators Performance during the team presentations Final Test Marks Exercise marks during the Program Program feed-back Short-term Long-term Usage of APQP, PPAP & Control Plan Methodology Better focus on Customer requirements Enhanced skill index Process Methodology : Class Room discussions Team Exercises ( 20 exercises ) Group Presentations Best practices on APQP & PPAP Structure : Ice Breaking The whole course to cover all the phases with exercises Evaluation during the sessions Quiz Final Test & Evaluation Verbal Feed Back Written Feed Back Deliverables Origin of APQP Basic concepts & Principles Linkages to IATF 16949:2016 Techniques of APQP process - Quality Function Deployment ( QFD ) - Error proofing & PDCA cycle - Process Flow for Lean management - Characteristics matrix - M E O S T for product validation - Quality plan - Gantt chart - Quality planning sign-off of APQP : Linkage to PPAP Successful PPAP through structured APQP Process Five Phases of APQP with exercises Control plan - Creation & management PPAP How to interpret & Implement? Situations Analysis on PPAP

4 APQP Importance APQP & Control Plan IATF : 2016 & 3 Product Design & Development Clause 8 Clause 8.3 ( inputs & outputs ) # Elements of APQP IATF Clause reference 1 Design FMEA Process FMEA Design Changes Control plan A glimpse 4 3

5 Advanced Product Quality Planning Phase CFT formation & Scope definition Plan & Define Product design & development Process design & development Product & Process validation Feed-back, assessment & corrective action 5

6 CFT formation & Scope definition 7 Prof. Yoji Akao 1980s Introduced QFD technique Quality Function Deployment [ Q F D ] 6

7 + Acoustic window CFT formation & Scope definition 8 Bench marking 1 Harvard business review case study Bench marking Quality Function Deployment [ Q F D ] 7

8 10 Voice of Customers ( V O C ) CFT formation & Scope definition Internal factors Mfg. Feasibility Customer Inputs Success of Designers Competence an NPD Marketing Priorities process QMS strength Field Conditions Top Management Focus External factors Success factors 8

9 CFT formation & Scope definition 11 Prof. Kano Japan Needs & Expectations of the Customer 9

10 Plan & define 17 Bath tub curve 1.7 Design goals 10

11 Refer Page # 18 to 21 In the workbook 11

12 Plan & define Anticipated manufacturing process! Source(s) to prepare Preliminary Process Flow Chart ( PFC ) 12

13 Plan & define Design goals ( section 1.7 ) Product Assurance Plan Design Requirements Product assurance plan 13

14 Plan & define APQP Meeting Involve your Top Management! Inform the Status! Gain support! 1.13 Management support 14

15 USE CFT Customer inputs Lessons learnt 25 Product D & D Data & information Boundary diagram Parameter diagram Interface matrix 2.1 Design FMEA 15

16 User friendly designs Product D & D Cost & Manufacturing Efforts Design for Manufacturability & Assembly ( DFA & DFM ) 16

17 Product D & D # Focus during DFMA analysis What will be ideal? 1 No.of parts Less More 2 Common parts Less More 3 Assembly adjustments Less More 4 Self-fastening parts Less More 5 Setting related activities Less More Team based exercise : 07 6 Self-locating parts Less More 7 Masters for setting Less More 8 Standard parts Less More 9 Handling of parts Less More 10 Re-orientation while assembly Less More Answers 25 Template 2.2 Design for Manufacturability & Assembly ( DFA & DFM ) 17

18 Product D & D D F A & D F M immediate outputs? 25 Child part drawings Sub-system drawings System level drawing 2.2 Design for Manufacturability & Assembly ( DFA & DFM ) 18

19 Product D & D Customer Requirements 26 5 phased APQP approach Design Outputs 1. Design Review 2. Documents Review 3. Tests 2.3 Design verification 19

20 # Statement True False Evln 1 Proto samples are not produced, when the customer is not particular about them 2 Pre-launch samples are produced to prove the new product s concept 3 Proto samples shall be produced, even when sufficient real-time facilities are not present 4 Proto-type control plans must have all the process related information also 5 At times, even a single unit shall be produced as a proto-type sample 6 The first control plan during the APQP journey is Prototype control plan Team based exercise : 08 7 It is mandatory, that the proto-type control plan to be approved by the Customer Product D & D 27 8 Prototype samples shall be used for Road-proving purpose also, always 9 The input for Prototype control plans is only Design FMEA, not Process FMEA 10 Generally, Proto samples are verified 100 % Prototype control plans must cover performance test related information, as applicable Outputs derived immediately after Proto build are Packaging requirements & Process parameters 2.5 Prototype Control Plan 20

21 Specifications Documents / Lists Activities Hard wares Specifications Documents / Lists Activities Hard wares Product D & D # Description # Description 1 Proto-type samples 11 List out 2 Engineering specification 3 Proto build 4 DFA & DFM Team based exercise : 09 5 Special Characteristics 6 DFMEA & related documents 7 Material specifications 8 Design review 9 Engineering drawings 10 DVP & R Key activities & the outputs 21

22 J R Q M S Q M S Contract Process D & D 32 Joint Review on QMS 3.2 Product / process Quality system review 22

23 Process D & D Purpose? Focus? 33 To decide what comes Where in the Shop Floor! Material Travel Material Handling Health & Safety IATF Clause # ( e ) 3.4 Space utilization Floor plan layouts 23

24 Dim # Description Tolerance Operation # ID microns X C X 2 Facing 5 microns X C C 3 Boring 67 dia 25 microns X L 4 Chamfering 0.5 x 45 X 5 OD turning microns X Process D & D X : Characteristics created / changed by this operation. To match PFD C Characteristics at an operation is used for Clamping L : Characteristics at an operation used for Location Inputs 34 Process FMEA!!! 3.5 Characteristics matrix 24

25 USE CFT Customer inputs Lessons learnt 35 Process D & D Data & information Design FMEA PFD Characteristics matrix Better to focus on Product design solutions!!! 3.6 Process FMEA 25

26 Process D & D 37 Clause # Error proofing ( EP ) Shall have a documented process to identify Method to identify EP shall be documented in P FMEA Test frequency shall be in the control plan Challenge parts for EP EP failures shall have a reaction plan EP failures testing records 3.7 Pre-launch Control plan 26

27 38 Standard Operating Procedures [ S O Ps ] Process D & D # Description Input Output No link 1 PFD & Floor plan layouts 2 Design FMEA 3 Process FMEA 4 Set-up Instructions & First piece approval instructions 5 Design & Quality goals 6 Characteristics matrix 7 Capability norms ( 1.33 or 1.67 ) & MSA acceptance criteria 8 Process & Product parameters identified by the APQP team 9 Handling requirements 10 Operators knowledge on the process 11 Details from the equipment manufacturers 12 Packaging requirements 13 Current controls ( P & D ) identified in the FMEAs 14 Customer s inputs relevant to the manufacturing stages 3.8 Team based exercise : 12 Process instructions 27

28 MSA & Capability Studies : Reference documents? Process D & D 39 Pre-Launch Control Plan Timing Plan ( for period ) J R Q M S 3.9 & 3.10 MSA Plan & Preliminary process capability plan 28

29 Product & process validation 4.1 Significant Production Run 29

30 Product & process validation Understood by the organization Organization to demonstrate through PPAP. 42 of the manufacturing processes Its potentiality... in meeting the requirements Its consistency. 4.1 Actual production run Significant Production Run Quoted production rate 30

31 Product & process validation # Statement True False Evln 1 PPAP run must use the Pre-launch Control plan 2 If Customer specified Packaging are used, APQP team need not evaluate the packaging 3 Number of units to be produced during PPAP run may also be specified by the Customer 4 PPAP run must be produced as consecutive units 5 Quality planning sign-off must be done prior to PPAP lot despatch to the customer Team based exercise : 14 6 Additional controls ( such as robust statistical evaluation ) must be identified during PPAP run 7 MSA studies must be completed during the PPAP time 8 Master samples mean First-off samples also 46 9 Production Control plan ( PCP ) must include controls on the Special characteristics also 10 IATF 16949:2016 Clause is dealing with the PCP 11 PCPs & the Reaction plans are the same 12 Both D & P FMEAs will provide inputs to the PCPs 13 Bulk materials means components such as Fasteners 14 Customer Engineering design record must cover all the Technical requirements in it 31

32 47 Run at rate How to perform? After PPAP 1000 parts generally Run at full speed Focus on FPY% Use audit checklists Identify all bottlenecks Focus on Process capability Ensure MSA results Use PFMEA and PCP for audits 4.1 Product & process validation Checklists Click for hyperlink Snap allowed! Significant Production Run 32

33 Product & Process validation APQP Meeting Involve your Top Management! Inform the Status! Gain support! 4.8 Management support 33

34 Snaps allowed! S 34

35 Best practice # 1 Snaps allowed! Supplier PPAP approval a TVS model 35

36 Tricky Part of PPAP? Pass Through Characteristics Black Box Items ROHS & MD systems 53 P P A P Part Weight Criteria Checked & Marked Prints 36

37 Marked Prints 53 An engineering drawing modified, signed and dated by the customer engineer P P A P 37

38 Accelerated Learning Process Matching Exercise 56 P PPAP : Accelerated Learning Match the following in a MOST Logical way! Ref. Criteria Ref. Criteria A Appearance items 1 Stability First & then Performance target B Initial process Studies 2 NABL certification C Customer wants 2.0 as Ppk target 3 Take as 3, if Customer has not specified it D Qualified Laboratory Documentation 4 Re run the PPAP before bulk Production Team based exercise : 18 E Initial process study results are not satisfactory 5 Conduct MSA study and include them in Checking aid list F Default PPAP level 6 Randomly selected 10 parts average weight in 4 decimals, written in Kgs G PPAP target date is advanced by the Customers now 7 Master samples & Limit Samples P Right Answers A P H New Vernier and an Air gauge introduced now 8 Inform your Customer before taking any actions I Part weight in PSW 9 Amend the Timing Plan and speed-up related actions J Tool has not been used for 16 months, after the PPAP approval 10 Quality Goal and include in the JRQMS ( QMS Contract ) 38

39 Situation Analysis Team based exercise : 20 P P Please study the situations carefully and decide your action(s). You may have certain ( logically acceptable! ) assumptions and conclude. A Must justify your conclusions Let us have a healthy discussion to enhance our PPAP understanding PPAP submission level is 2 The Quality system review & agreement ( JRQMS ) must be kept in mind Issue the A 3 sheet 39 P