A P Q P P P A P
APQPA V ManivannanPrincipal Consultant & Trainer&PPAPCSR
A new product development & approval processA most practicalworkshop2
Type of Program :-Sri Padhmam Consultancy & TrainingS O P for the Workshop onAPQP & PPAP ( as per IATF 16949 : 2016 ) with a focus on CSR 91 94428 ioralTarget participants : Engineers & abovewww.sripadhmam.comProgram ObjectivesTo familiarize the participants to apply theconcepts & Practices of Advanced Product QualityPlanning & Control Plan ( APQP ) 2nd edition –Production Part Approval Process( PPAP )th4 Edition.Also to familiarize on linkages to IATF 16949:2016requirements.Hours1826No. of Participants1020YesNoDeliverablesMethodology : Origin of APQP Class Room discussions Basic concepts & Principles Team Exercises ( 20 exercises ) Linkages to IATF 16949:2016 Group Presentations Techniques of APQP process- Quality Function Deployment ( QFD )- Error proofing & PDCA cycleStructure : Ice Breaking The whole course to cover all thePerformance IndicatorsMax.Mixed Group :Process Best practices on APQP & PPAPTo provide the skill sets on new n.phases with exercises- Process Flow for Lean management- Characteristics matrix- M E O S T for product validation- Quality plan Evaluation during the sessions- Gantt chart Performance during the team presentations Quiz- Quality planning sign-off Final Test Marks Exercise marks during the Program Program feed-back Final Test & Evaluation Phase 4 of APQP : Linkage to PPAP Verbal Feed Back Successful PPAP through structured APQP Process Written Feed Back Five Phases of APQP – with exercisesShort-termLong-term Control plan - Creation & managementUsage of APQP, PPAP & Control Plan Methodology PPAP – How to interpret & Implement ?Better focus on Customer requirements Situations Analysis on PPAPEnhanced skill index
APQP – ImportanceAPQP &Control PlanIATF 16949 : 2016Clause 8Phase 2 & 3Product Design & DevelopmentClause 8.3( inputs & outputs )#Elements of APQPIATF Clause reference1Design FMEA8.3.5.12Process FMEA8.3.5.23Design Changes8.3.64Control plan8.5.1.13A glimpse4An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Advanced Product Quality Planning543210 CFT formation & Scope definitionPlan & Define0Product design & developmentProcess design & developmentProduct & Process validationPhase “0”Feed-back, assessment & corrective action5An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Phase 0CFT formation & Scope definitionPhase 1Phase 2Phase 3Phase 47Phase 5 Prof. Yoji AkaoAPQP 1980s Introduced QFD techniqueQuality Function Deployment [ Q F D ]6An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
CFT formation & Scope definitionPhase 0Phase 18Phase 2 AcousticwindowPhase 3Phase 4Phase 5APQPBench marking 1Harvard business reviewcase study7.5Bench marking 2Quality Function Deployment [ Q F D ]7An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
CFT formation & Scope definitionPhase 0Internal factorsPhase 110Phase 2Voice of Customers(VOC)Mfg. FeasibilityCustomer InputsDesigners’CompetencePhase 3Phase 4Phase 5APQPMarketing PrioritiesSuccess ofan NPDprocessQMS strengthTop ManagementFocusField ConditionsExternal factorsSuccess factors8An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Phase 0CFT formation & Scope definitionPhase 111Phase 2Phase 3Phase 4Prof. KanoJapanAPQPPhase 5Needs & Expectations of the Customer9An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Plan & definePhase 0Phase 117Phase 2Phase 3Phase 4APQPPhase 5Bath tub curve1.7Design goals10An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Refer Page #18 to 21In the workbook11
Plan & definePhase 0Anticipatedmanufacturing process !Phase 1Phase 2Phase 3Source(s) to preparePhase 4APQPPhase 5221.10Preliminary Process Flow Chart ( PFC )12An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Plan & definePhase 0Phase 1Design goalsPhase 2( section 1.7 )Phase 3Phase 4Phase 5APQPProduct AssurancePlanDesign Requirements231.12Product assurance plan13An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Plan & definePhase 0Phase 1Phase 2Phase 3APQP MeetingPhase 4Phase 5APQP Involve your Top Management ! Inform the Status ! Gain support !1.13Management support14An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Phase 0Product D & DUSECFT25Phase 1Customer inputsPhase 2Lessons learntPhase 3Data & informationPhase 4Phase x2.1Design FMEA15An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Product D & D“User friendly designs”Phase 0Phase 1Phase 2Phase 3Phase 4APQPPhase 5Cost & Manufacturing Efforts252.2DesignforManufacturability & Assembly ( DFA & DFM )16An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Product D & DPhase 0#Phase 1Focus during DFMA analysis25What will be ideal ?1No.of partsLessMorePhase 22Common partsLessMorePhase 33Assembly adjustmentsLessMore4Self-fastening partsLessMore5Setting related activitiesLessMore6Team basedexercise : 07Self-locatingpartsLessMore7Masters for settingLessMore8Standard partsLessMore9Handling of partsLessMore10Re-orientation while assemblyLessMorePhase 4APQPPhase 52.2DesignAnswersforTemplateManufacturability & Assembly ( DFA & DFM )17An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Product D & DPhase 0Phase 1D F A & D F M immediate outputs ?Phase 225Phase 3Phase 4APQPPhase 5Child partdrawingsSub-systemdrawings2.2DesignforSystem leveldrawingManufacturability & Assembly ( DFA & DFM )18An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Product D & DPhase 0Phase 1Phase 226CustomerRequirementsPhase 3Phase 45 phasedPhase 5DesignAPQPAPQP approach1. Design ReviewOutputs2. Documents Review2.33. TestsDesign verification19An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Phase 0#Product D & DStatementTrue1Proto samples are not produced, when the customer is not particular about them2Pre-launch samples are produced to prove the new product’s concept3Proto samples shall be produced, even when sufficient real-time facilities are notpresentPhase 34Proto-type control plans must have all the ‘process’ related information alsoPhase 45At times, even a single unit shall be produced as a proto-type sample6The first control plan during the APQP journey is Prototype control planPhase 1Phase 2Phase 57basedexercise08 by the CustomerIt is mandatory, thatTeamthe proto-typecontrolplan to be :approved8Prototype samples shall be used for Road-proving purpose also, always9The input for Prototype control plans is only Design FMEA, not Process FMEAFalseEvln27APQP10 Generally, Proto samples are verified 100 %Prototype control plans must cover performance test related information, as11 applicableOutputs derived immediately after Proto build are Packaging requirements & Process12 parameters2.5Prototype Control Plan20An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Phase 3Phase 4APQPPhase 5Proto-type samples112Engineering specification123Proto build134DFA & DFM145Special CharacteristicsTeambased exercise : 09156DFMEA & related documents167Material specifications178Design review189Engineering drawings1910DVP & R2031Hard waresList out12.0DescriptionActivities#Documents /ListsPhase 2Hard waresDescriptionActivities#Documents /ListsPhase 1SpecificationsPhase 0SpecificationsProduct D & DKey activities & the outputs21An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Phase 0Phase 1Process D & DJRQMS32QMSContractPhase 2Phase 3Phase 4APQPPhase 5Joint Review on QMS3.2Product / process Quality system review22An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Process D & DPhase 0Phase 133Purpose ?Phase 2To decide what comes Where in the Shop Floor !Phase 3Phase 4Phase 5Focus ?Material TravelAPQPMaterial HandlingIATF 16949 Clause #8.3.5.2 ( e )Health & SafetySpace utilization3.4Floor plan layouts23An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Process D & DPhase 0Dim#Phase 1Phase 2DescriptionToleranceOperation #1020XC1ID 22.520 micronsPhase 32Facing5 micronsXPhase 43Boring 67 dia25 micronsX4Chamfering0.5 x 455OD turning 4518 micronsPhase 53040XCCLXXAPQPX : Characteristics created / changed by this operation. To match PFDC Characteristics at an operation is used for ClampingL : Characteristics at an operation used for LocationInputsProcess FMEA !!!343.5Characteristics matrix24An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Process D & DPhase 0USECFT35Phase 1Customer inputsPhase 2Lessons learntPhase 3Data & informationPhase 4Phase 5DesignFMEAAPQPPFDCharacteristicsmatrixBetter to focus on Productdesign solutions !!!3.6Process FMEA25An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Process D & DPhase 037Phase 1Phase 2Phase 3Clause # 10.2.4 – Error proofing ( EP )Phase 4Shall have a documented process to identifyPhase 5Method to identify EP shall be documented in P FMEATest frequency shall be in the control planAPQPChallenge parts for EPEP failures shall have a reaction planEP failures testing records3.7Pre-launch Control plan26An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Phase 0Phase 1Phase 2Phase 3Phase 4Phase 5Process D & DStandard Operating Procedures [ S O Ps ]#DescriptionInput1PFD & Floor plan layouts2Design FMEA3Process FMEA4Set-up Instructions & First piece approval instructions5Design & Quality goals6Characteristics matrix7Capability norms ( 1.33 or 1.67 ) & MSA acceptance criteria8Process & Product parameters identified by the APQP team9Handling requirementsOutputNo linkTeam based exercise : 12APQP38 10 Operators’ knowledge on the process11Details from the equipment manufacturers12Packaging requirements13Current controls ( P & D ) identified in the FMEAs14Customer’s inputs relevant to the manufacturing stages3.8Process instructions27An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Phase 0Process D & DMSA & Capability Studies : Reference documents ?Phase 139Phase 2Pre-Launch Control PlanPhase 3Phase 4Phase 5APQPTiming Plan ( for period )JRQMS3.9 &3.10An intellectual property from Sri Padhmam Consultancy & TrainingMSA Plan & Preliminary process capability planoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com28
Product & process validationPhase 0Phase 1Phase 2Phase 3Phase 4APQPPhase 54.1Significant Production Run29An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Product & process validationPhase 0Phase 142Phase 2Understood by theorganizationPhase 3Phase 4Phase 5Organization to demonstrate through PPAP .APQPof the manufacturing processes Its potentiality .in meeting the requirements Its consistency .Actual production run4.1Quoted productionrateSignificant Production Run30An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Phase 0Product & process validation#StatementTruePhase 11PPAP run must use the Pre-launch Control planPhase 22If Customer specified Packaging are used, APQP team need not evaluate the packaging3Number of units to be produced during PPAP run may also be specified by the Customer4PPAP run must be produced as consecutive unitsPhase 45Quality planning sign-off must be done prior to PPAP lot despatch to the customerPhase 56Additional controls ( such as robust statistical evaluation ) must be identified during PPAP run7MSA studies must be completed during the PPAP time8Master samples mean ‘First-off’ samples also9Production Control plan ( PCP ) must include controls on the Special characteristics alsoPhase 3APQP46FalseEvlnTeam based exercise : 1410IATF 16949:2016 – Clause 8.1.5.5 is dealing with the PCP11PCPs & the Reaction plans are the same12Both D & P FMEAs will provide inputs to the PCPs13Bulk materials means components such as Fasteners14Customer Engineering design record must cover all the Technical requirements in it31An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Product & process validationRun at ratePhase 0Phase 1ChecklistsHow to perform ?Phase 2 After PPAPPhase 3 1000 parts generallyPhase 4 Run at full speedPhase 5 Focus on FPY%Click for hyperlink Use audit checklists Identify all bottlenecksAPQP Focus on Process capability47Snap allowed ! Ensure MSA results Use PFMEA and PCP for audits4.1Significant Production Run32An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Product & Process validationPhase 0Phase 1Phase 2Phase 3APQP MeetingPhase 4Phase 5APQP Involve your Top Management ! Inform the Status ! Gain support !4.8Management support33An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Snaps allowed !S34
Best practice # 1Snaps allowed !Supplier PPAP approval – a TVS model35
Tricky Part of PPAP ?53PPass Through CharacteristicsPBlack Box ItemsAROHS & MD systemsPPart Weight CriteriaChecked & Marked Prints36An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Marked Prints53An engineering drawing – modified, signed and dated by the customer engineerP73.00PAP37An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
Accelerated Learning Process Matching Exercise56PPPAP : Accelerated LearningMatch the following in a MOST Logical way !PRightAnswersRef.CriteriaRef.CriteriaAAppearance items1Stability First & then Performance targetBInitial process Studies2NABL certificationCCustomer wants 2.0 as Ppk target3Take as 3, if Customer has not specified itDQualified Laboratory Documentation4Re run the PPAP before bulk ProductionEInitial process study results are not satisfactoryFDefault PPAP level6Randomly selected 10 parts’ average weight in 4decimals, written in KgsGPPAP target date is advanced by the Customers now7Master samples & Limit SamplesHNew Vernier and an Air gauge introduced now8Inform your Customer before taking any actionsIPart weight in PSW9Amend the Timing Plan and speed-up related actionsJTool has not been used for 16 months, after the PPAP approval10Quality Goal and include in the JRQMS ( QMS Contract )ATeam based exercise: 185PConduct MSA study and include them in Checking aid list38An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
SituationAnalysisTeam based exercise : 20PP Please study the situations carefully and decide your action(s).A You may have certain ( logically acceptable ! ) assumptions and conclude. Must justify your conclusionsP Let us have a healthy discussion to enhance our PPAP understanding PPAP submission level is 2Issue the A 3sheet The Quality system review & agreement ( JRQMS ) must be kept in mind39An intellectual property from Sri Padhmam Consultancy & Trainingoffice@sripadhmam.com 91 94428 92185www.sripadhmam.com
# 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 inf
akuntansi musyarakah (sak no 106) Ayat tentang Musyarakah (Q.S. 39; 29) لًََّز ãَ åِاَ óِ îَخظَْ ó Þَْ ë Þٍجُزَِ ß ا äًَّ àَط لًَّجُرَ íَ åَ îظُِ Ûاَش
Collectively make tawbah to Allāh S so that you may acquire falāḥ [of this world and the Hereafter]. (24:31) The one who repents also becomes the beloved of Allāh S, Âَْ Èِﺑاﻮَّﺘﻟاَّﺐُّ ßُِ çﻪَّٰﻠﻟانَّاِ Verily, Allāh S loves those who are most repenting. (2:22
reintroduction of grammar schools on a national level, mandated from a central government level, or indeed any other ‘blueprint’ for a national school system, did not fit within this focus on independence and autonomy. Nevertheless, sizable factions of the Conservative party continued to call for the reintroduction of grammar
bribery risks associated with the conduct of their business. The supplier must undertake a regular anti-bribery risk assessment in order to identify and mitigate the bribery risks associated with the conduct of its business. The supplier must ensure that all risks identified are managed and mitigated by the application of its anti-bribery controls. Due diligence The purpose of due diligence is .
Buku Saku Keperawatan Onkologi. Jakarta: EGC Pugalendhi, P. dan S. Manoharan. 2010. Chemopreventive Potential of Genistein and Daidzein in Combination during 7,12-Dimethylbenz (α)anthracene (DMBA) induced Mammary Carcinogenesis in Spray-Dawley Rats. Pakistan Journal of Biological Sciences. 13 (6): 279-286 Purwanto, Djoko Agus dan Achmad Toto Purnomo. 1999. Penetapan Kadar Metil Pada Hasil .
circuits containing the most basic of components -- resistors and batteries -- to show the difference between the two configurations. We’ll then explore what happens in series and parallel circuits when you combine different types of components, such as capacitors and inductors. Covered in this Tutorial What series and parallel circuit configurations look like How passive components act in .
The Civil Engineering Standard Method of Measurement thjrd edjfion .(CES.MM3), has been approved by the sponsors—the Institution of Civil Engineers-jand the Federation of Civil Engineering Contractors—for use in works of civil engineering-construction. This third edition supersedes the second edition published in 1985. Reference to CESMM3 in the Appendix to the Form of Tender, as provided .
Oracle Communications Operations Monitor may be used to record media from a particular user for later playback for further quality analysis. The recorded media may include audio, video, text, image, messages, and even T.38 fax transmissions. In-Depth, Root-Cause Analysis Oracle Communications Operations Monitor enables users to drill down from the
