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    AIAG – Advanced Product Quality Planning 2nd Edition

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    AIAG – Advanced Product Quality Planning 2nd Edition

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    1K views115 pages

    AIAG - Apqp

    Uploaded by

    Mariana Herrera
    AIAG – Advanced Product Quality Planning 2nd Edition

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 115
    Advanced Product Quality Planning and Control Plan alee ad PS TofTTe ello) ADVANCED PRODUCT QUALITY PLANNING (APQP) AND CONTROL PLAN Reference Manual Second Edition leevad June 1864, Saco Pinting Fatcuary 1005 ‘Conynghte 1008, CChye Corporation, For Motor Compa hy 2008 FOREWORD Second Edition Effie November 1, 2008, APQP and Control Pan Second Eton replaces APQP anf Catol Pan Fist Eaion uns oerwise specified by you customer, -APOPand Consol Plan Second ation ints: incorporation of the custome foeed proces SFproHch 1 update terminology and concept consent with ISOS 16949 and other Chyler, oe an (General Motor cor tol mals + appre references fo come specifics provided witout the fl text ‘This manual otis to provide goer guidelius for ensuring tht Advanced Product Quality Panning ‘implemented in ocordance withthe requirements of the eutomer. Tt dos nat give speciation on hw toarve at each APOP or Cone! Plan entry, task best Te to cach organization, While thse iene are intended o cover mat sinatons normally occuring either nth ely planing, sign paseo proces ali, thre willbe questions Out ase. These qestons shold be dred our thorized coor reprsennive, ‘The Suplier Quality Requirements Task Fore grateful setaowledges the cntibutions ofthe flowing India andthe respective companies that pated in the revision proces. [yan Book, Chrysler LC Car [Rss Hopins, Ford Motor Comgeay ‘Willan Fick General Motos Copration Rotert Miner, Dep Coporation rag Willams, Eston Corporation ‘his document copped ty Chyler LLC, Ford and General Motos iaht reseed, 2008. ‘Actonal copies cn be ordered fom AIAG a s.in.os- Orgnzationsprchsiag ABQP Second sion have pemision 1 opy any Torn nde checklists contained herein. Saty 2008 TABLE OF CONTENTS. Funnies auc Qi PLING ———— ‘Orgone he Tao ‘fh or {ison nd Oran roe Sle ping Proc ay Ting Pi Pls ale Tong Ch. (CHAPTER PLAN AND DEFINE PROGRAM x ooemo 1S Pte eta Sear = - 16 Catone pet a 12 Deion Goo. = {shat andi Goi 19 raininary Bf atria ‘ior Proce oe Ch 1 Peli lion fil Md Pr hin 1.12 Pade rane Pl 11d Managment Spot (CHAPTER 2 PRODUCT DESIGN AND DEVELOPMENT meme 1 Deion Faire i od cna BFAD) 22 Deion or Neca and Arey 25 bain Vertes 24 Deon Rees 2S preps Bul Coma Pim 26 Egg Dring cating Mh Daa) $10 Epon Pag nd Pats Raguremens. 2.1 Special Pract nd Prcear Charter 212 Gefen Epon Repronent 115 Team Fahy Comin ant Monogoet Sippr (CHAPTER 3 PROCESS DESIGN AND DEVELOPMENT. Tr Pasty Seda nd Span ae 432 ProiuexProcess Quality Sem Revie. 26 54 Ror Plan Loe. fe 3S Ohowcurnes ari 2 3 rie ae nd ii ns Fe) 2 50 Measromen Som ai Pon ae ‘Latvia Proc Coty Std ln 2 11 NaagentSpot 4 “1 Signi acto on » a ileaowenen Stems Ani anes ue ‘Ty PrtminayPrecar Coby Sia a Be Le Pratcton Prt dppron nn & 15 Prnbctin Pataon Tesg. 3s 46 Pacing Ean B 15 Prd Cnr la. a 3 58 Quan Pam Sgw Of and agement Spar 8 (CHAPTER S FEEDEACK, ASSESSMENT AND CORRECTIVE ACTION wenn? 5:3 igroed Car Saigon 53 apron Denery and Serve 5S ef Une of eran agrees (2) Cena Pan Col Deion - a (62 Proves Ana. 36 APPENDIX A PRODUCT QUALITY PLANNING CHECKLISTS. APPENDIX ANALYTICAL TECHNIQUES. Assen Bald Yvon Anat a Con dBc Diagram. = (Cherries Hom - 50 ‘Baten of permet (B08) 31 Desig far Mama and sey 32 Desig Preon Plan an apr (VP. ote Misia Pasig’ Barron 32 ‘Duty Paton Deplmen (BPB) 2 APPENDDS E FRODUCT QUALITY PLANNING SUMMARY AND APPROVALS. PRODUCT QUALITY PLANNING CYCLE Feedback Assessment ‘and Corrective Action| Plan and Define Product and Process Validation Product Design and Development Process Design ‘and Development Introduction Introduction “The purpose of this mara eo commit to orgsnizatons (ternal td eer) and sapples, common Pradict Quit Panag and Conta ian gidtines developed july by Chyler Ford and General Motors. This manual provides pudelines designed to produce a product ‘uly pln, bic ll supp the development of x predot or service thet il suey the caster (ee Sesion 18). The flowing terms, ted in hie eon sre aed to drei the supply chin The le "organization refers othe unt w which these guidlines apply. The tem spl” replicas th em subcontractor tat vas sed in he Fist on, Some ofthe expected beets in sing ths pudelines ar ‘A rection in the complet af product quality planaing for the ‘means for organizations to ely commuicsle product quality Pmsing requirement sop. ‘This ference man conisns guidlines hat supp the requirements decribed ia ISO/TS 1649. and applicable easomerspecific ‘equement All ms in dis manual are rovided as examples only {Te prpse i to ait th organizations prot quay plsming tam in developing te appropiate comminiation forme suppor acti csiomer requirements, needs, and expectations. ‘The: Praduct Quality Plaming Cycle shown onthe cing page is a phic depiction of «typical program. The various phases ae equrced to rpreent planed timing to exerte the fn Adserbe. The purpose of the Product Qusly Planing Cycle so ‘enpsi Upton planing. The fst tte quarters ofthe cele are devoted to ‘toa product quality planing tru podscupracesvldaton. “The at of inplemenution. The urd quate ste stage where the Importance of evaluating the ouput serves te Factions to determine It eatomers ae satsed, and to supper the past of contin Depicting product quay planing a ele illustrat the never-ending prt of continual ngroverent tht cat ony be achieved by taking he fxperince in one program and ppying hat acquired koowiedge fe ext program, Introduction PRODUCT QUALITY PLANNING RESPONSIBILITY MATRIX The mati shown blow depicts he Product Quality Hanning Functions {or te types of organs. ts oasis rgmiations in defining the soope of thei planing responsi. Predict Quality Planing en the nxt page The mate doesnot dpit site llleent yen of rodet qual planing eatnshis tat eulé ‘xs among organza, supps and castomes Design Responsible Define the Spe x Plan an Define Chater 1. x Product Design an Development x Chapier20 easily Seton 2.13 x ‘Process Design al Develoennt x apie 3.0 Chapier.0 Feedback, Assessment and Coretive x ‘Astion Chapter 0 Contol Plan Methodology Chaper60 |X. += Refer to Section 1 “Scope” of ISOVTS 16049, *Manatactaring ‘Only "efor te Fundamenal of Service Organization Le eat Treat, warehow Introduction Fundamentals of Product Quality Planning Organize the Team Define the Scope Product Qualiy Planing Is a structed method of defining and sstblshing the seps ncesary 1 asus that a pout satisfies the slower. The geal of prodot sia panniny ist. fite main with everyone invlve o asure dll euied steps fe completed on ine, Ellostve roduc quay planing depends on 8 empua's tp matagenent commitnent 19 the eer requied.it Schlevng customer stisttion. Some ofthe beefs of prouet uaiy Planning oe To det esures ost the castor + Topromot eal ideation ofeqired change. ‘+ To provide a qaltyproucton ie atthe lest at ‘Te wor practices, tools and anal techniques described i this ‘mana ar iste i npc sequence to make te) 1 follow. Each Product Qualiy Plat unique The actual timing and sequence of ‘teeiton i depen on cartons nee and expects andor oer Sractial ler. The earlier a work practice, fol, andlor aoaies! {ecnique can be plemented in he Prot Quality Flaming Cel, the beter ‘The organi’ fit step in prodct quality planing isto essign woces one the APOP projec In adton eres Fnctinal tart hold be elise to assests prod qual panna. The feu shold nce repretatves om mule funtion: such 28 ‘reinceing, manufacrng, eral ono, purus, gual man ‘sours, sles, ld service, supers and cstomer a props. Its impo for the organizations prod quality planing tam in te clit sage of the product program wo identify easier neds, ‘xpecatons, and reqement Ata mutimun, the team must meet 1 Selest prec team lender responsible for oversing the planing proces (it sme cass i ay be advantageous 0 fut the team FEadr dig the planning yee) 4+ Define th roles and responses ofeach area epesete. ety the casomers- interes eer + Define eusomerresutements, (Use QFD if spl, as referenced in appendix) Select the disciplines individ, andor spp tat must be added tothe tam, and thee not eis Team-to-Team Introduction + Understand customer expettions i, desig, number ft + Asst the feasibly of the proposed den, performance ‘urements nd manafactring proces. 1+ eats cots, timing, ane consis tht must be considered 1+ Decenine ssistanc quired fom the cater 4+ Heoitydocumenaion process o method “Te organization's reduc quality planing eam mist exabich ines of communication with ether easter and oyanizatin teams. Tis may incude regular mesings with oor teams. The exe of tanta ‘onc fs dependent upon the mame of sues requ salto, “The success of Product Qusiy Plan ie dependent upon an efetve esiningpopram th commanicaes afl the requirements and fovlopen silo fll some needs and expections ‘Customer and Organization Involvement The primary casomer may inte the quality planning press wih rganiation. However, te organization asa option ro establish a ‘one fonction! team to manage th product ality planning proces ‘Onnizatione mas expect the sae prZortance fo th splits Simultaneous Engineering _ Control Plans Simutancous Engineering is «process whee cos fnctins tame fe fr common goa. Ic replaces the sequent sere of phases ‘ere resale ae tied othe ex ars Tor exetion. The purpose jn to expedite the ineoduetin of gully prodoxs sooner The Crgnzation's pret qulty planing ten rsrires hatter ‘Seas pla and execute activites tt support te comaon gol ot oa. ‘Cool plans sre writen despa ofthe systems fir conn pcs ‘sd proeses,Seprste coo plans covertiree dite phases: 1 Prototype = A. description of the dimensional neasuements end atrial nd performance tet that wil oer dng Prototype Oil Concern Resolution Introduction relaunch - A description of the dimensional memsurements and tater and performance tess that wil sccuraler Potty ahd ‘ere fl rodcton, Prodvcton - A compecensive. documentation cf producpocess harsctersics, proces coals, tes, and measurement stems tha il cur ring mass production, During the planning proces, the tem will enoumer produc design andr processing eancens These concerns soul be documented on & taux ith aegned responsibil, and ining. Disciplined. problem Solving methods ne tesommendel in lieu siutions. Anata tecniques deserted in Append Ib should be sod asappropit, Product Quality Timing Plan Plans Relative to the Ti Chart The rganizaton’s product cualty planing team's fit order of business folowing organizational activites shoul be the development of & Tining Plan The typeof produ, complesiy and customer ‘pettons should be conidered in selecting the tning cements tat fist be panned an care All earn nembers shoud wees with each ven, aon and ming. A welhaganized ining chat should ist {aks asignmens, ndloroter event (The Cc! Ph Metiod may be apprise reference Append B). Als, the cart provides the Planning fem with conser fora for xing progress and seting ‘pesting agendas. To lie status reporting, each event must havea art and s "compen" date with fhe acta! oi of progres recoded. fete stats reporting supports program monitoring with 3 ous on identifying ioms tn requis spl snenon, “The sicsis of any program depends on meatng isomer nee an petition ns tnely manera cos tat represents value THe Product Quay Paras Timing Chart below and te Prodct Quality Planing Cycle desciied previously reque a plsning tex 1 ancetate is efons on problem prevention. Profle prevention fiver by. Simultaneous Expiccing performed by product ad ‘munuctning engoeedng clvides Working concen. Planing teams must be pepued © modify profoet qual plans to met faster expectations The orzaizations pauc! quali planing team is responsbie for ssrng Wat ining teed or exceeds he Introduction PRODUCT QUALITY PLANNING TIMING CHART Ropes — Petey me ante + [roe nd Proce Vemion Fescheck Asoreman and Carecive An Chapter 4 Plan and Define Chapter | Plan and Define Program Chapter + Plan and Define PRODUCT QUALITY PLANNING TIMING CHART t rote nt Process Vasbon Fesdback Asses and Corectve Aston ourpurs: Design Goals Reliability and Quality Goals Preliminary Bill of Material Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan ‘Management Support Chapter 4 Plan and Define Introduction ‘This caper describes how customer neds and expecatons are linked 1 lanaing and ining aqui program. The goal fey product rogram fs mecing ester needs while providing compete Yalue. The tal pote product quality planing pres to exsuetatcstomer needs {id expections ae clearly understood ‘The laputs and outpats applicable tothe planning process may vay coortng to the Prost devslopment proces, and casomer needs and petitions. Some revommeniations cused inthis cular sre 4 Voice ofthe Customer ©. Market Research nating OEM Vehicle Build Timing and OEM ‘Volme Expositions) © Winrice! Waray and Quality Iafrmaton Team Experience “Business PlanyMarksting Srtegy 1+ ProdesProces Benchmark Data 4+ ProdeevProcess Assumptions © Customer inputs ‘OUTPUTS (Become inputs for Chapter 2) ‘+ Design Goals + Roliaitiy an Quality Goal 4+ Preliminary Pree Flow Chart “+ Pretminry ising of Speci! Produc and Process Claratrises Product surance Plan 4+ Manzgement Support Gacating program timing and panning for ‘esorees and tffg te support equed capaci) ‘41.4 Voice of the Customer ‘The "Vols ofthe Customer encompasses complins recommendation, dae an information obeined fom intel andr eral comers Some metho for gabersg this inormation appea i the Tllowies parsers Chapter 4 Plan and Dofine 4.4.4 Market Research “The onaizaton's pout quay planning team my need to obin make esearch dita and infomation feflecting te Vo ofthe Cusine. ‘Te flowing souces can sist in entlying cistomer concems and wens end tanning those concers. ito) product and process ‘Sharer + Custocerierviews Customer questionnaires and surveys Market ts and pstoning ports New product unity and ret sties ‘+ Compeitve product quliy sues + Best Practices 1 Lesons Letmed 1.4.2 Historical Warranty and Quality Information A ls of strc estore consers and want should be prepared 2 tise the. potential for recronce ring the dia, manufrs, Tnstalon snd se ofthe produc Thee sould be considered an tension of he eer design requements and iclde in he analysis oF | Eisner acts “Many of te folowing tems can asi the team in entihng customer ances and wnt nd pring appropriate resolu + Lessons Leamed “+ Copa inonors + Soper plant intra unity reports 4+ Problem resltion reports 4 Casomer plant ret aeetons eld eta prodoct nalgsis 4.4.3 Team Experience ‘The eam may use any source of any infomation as aprotinin tbe flowing + Input fn higher system level or past Quality Fureton Deplyeent (QED) paces in commentary and analysis: magazine and newspie eps, o Chapter 1 Plan and Define Comore eter and suggestions Best Prats Lesson are Dealer comments lest Operator's comments Fil sevice repo ‘mera evaluations wing suropte customers + Management comments or reton Problems an ists report fom neal customers + Government equirements and regulations contact review 1.2 Business Plan and Marketing Strategy 1.3 Product/Process Benchmark Data ‘The customer business plan and marketing strategy wil st he fework fate prt qty plan, The busines lan may pe cams (e Timing, Sn investment product posioning,veseach and development (RAD) resources) on he tem that alt the dreon taken The Imukeing strategy wil Gta he age custome, they sles points, ad ey competitor. “The ue of benchmarking (referenced in Appendix B) wil provide inp to subbing rodvcdproces perfomance target. "Research and Sevelopment ay also provide henchman and once ieas. One method to suc bonthaing i Teeny the appropriate benchmarks Understand te reson forthe gap between your caret status andthe tenchmar ‘+ Devel plant close the gap, mach the benehnark, o exceed the Chapter 4 1.4 ProductProcess ‘Assumptions Plan and Define “There wil be ssupuows dat th product has ceri ees, design &| process cngezs These cud tecnial insviton advanced mater, Felbiliy assesimen, and aew technology. AI shuld be tized as inp. 1.5 Product Reliability Studies 1.6 Customer Inputs This type of data considers fequency of repair or replacment of| components within designated periods of tine ed the ests of Tonge rely durabiy es “The nex wers ofthe product cn provide ata infomation relating to thc needs sn expectations In addon, the next pod ors may av tlrady conducted sme o all ofthe aforementioned eviews and ses, ‘These opts sould be wed by the earomer andor rrinton Wo develop seen upon meanres of ester aici Design goals re a wasn ofthe Voce of the Catone ino measurable sian objeatvs. The proper selecion of design pals asses tht the ‘Voice of he Customer sot ost in sibooqer esignactiviy. The Voie ‘tthe Customer lg icudes regulatory queens such as mesial ‘composition epoting and payor part mating 41.8 Reliability and Quality Goals ‘Relay goal ae erable ated on customer warts an expectations, program objectives, an relly benchmarks. An example of case ‘vans and expecatins coud neue no safe) falas, Some reliably Tenchmarks sould be competior product reli, waranty a, ot frequency of rpc over se time period. Quality als shoul be based ‘mets Soc spars per il, problem level, or rap edt. 41.9 Preliminary Bill of Material ‘The team shold sabish # pretiminay bil of material ted on [roduclprocesetunpions sod include a ptetlsplir lt In onder {© iden the polminary special producdprocesssharuceriss it necessary 10 have selected the aproprat design and anafcting proces. Chapter 1 Plan and Define 1.10 Preliminary Process Flow Chart ‘The stepted manuferring proces should be dese using a procsss flow chu developed fom’ the. preliminary lof mater and productos asin 4.44 Preliminary Identification of Special Product and Process Characteristics ‘Special rout and proces characteristic re ati by te customer ia dion to those selected by the organization trough Knowledge of the ‘odit and process Examples of inpat to Henin of special ‘Sharer inl: + Product sumptions baied on the alysis of castomer needs and cetpecatos. 4+ Mention of inbiliy goals ans requirements + Meniction of special process chactristics fom the antipated searutatring proces 1 Sila prt FMEAS 1.42 Product Assurance Plan The Product Asturnce Plan transits design goals ito. design requirements and is faced on comer needs and expectations. Tht mania! does aot require» specie mao! for repuring a Pret ‘Asuance Plan, The Product Awtranos Plan can be Gevloped in ay format undersbd by the organization and shoal inet 4+ Outining of program requirements + Mention felilty, duabilty, and apporionnen allocation goals andor requirements + Assesment of new techalogs, complexity, maeals, splcaton, croroament packasing, serie, and manufactrng elements, o ary ‘ther actor tat nay pace he program a isk. + Useofilure Mose and Efcs Analysis (FMEA). + Development of pliminy engnerng requirement Chapter 4 Pl and Define 1.43 Management Support ‘One ofthe keys tothe sucous of Advanced Product Quilty Planing ithe ines commionnt and suppot of upper management. Putcipaton by ‘anagcinet in pros qoaliy planing mings swat ensuing he ces ofthe program, Management shoud be updated at he conelsion of ‘rory product quality pinning pase to reinforce thee comment and ‘ppt Updates andlor requ for assance ean ocr more equ ‘sequired A primary goal of Advanced Product ality Panning © ‘maintain management supper by demonstrating. tat all planing ‘equiement ve teen met and cancers documenta and sehouled fo ‘esalution cdg program miog and planing for resources and Salling Wo suport egued capi. Chapter 2 Product Design and Development Chapter 2 Product Design and Development CChaptor 2 Product Design and Levelopment PRODUCT QUALITY PLANNING TIMING CHART neaion topo ‘rogram Tope Penne lee Laan Pama anna g Product Deion ars Dew Process Design ae Developme ae DESIGN OUTPUTS. + Design Failure Mode and Effects Analysis (OF MEA) + Design For Manufacturability and Assembly = Design Veritation = Design Reviews ‘+ Prototype Build - Control Plan ‘+ Engineering Drawings (Including Math Data) + Engineering Specifications + Material Specifications. + Drawing and Specification Changes APQP OUTPUTS. ‘+ New Equipment, Tooling and Facilities Requirements, ‘+ Special Product and Process Characteristics + Gages/Testing Equipment Requirements ‘+ Team Feasibility Commitment & Management Support Chapter 2 Introduction Product Design and Development “This chapter discses the cements ofthe pling faces during which dksign fenures and characterises are developed ite see fal for. All Seige factors should be comidered by the eganzaon inthe Advanced Product Quliy Planing process even ifthe design is owned by the stoner or sare. The steps inlade rsatype bal to wey tht the Proctor service mess te objectives ofthe Voce a the Cutomer. Fesile design mast permit mesg producon vane st schedules, and be consistent wih the ably to meet engineering requtemens, along it ely relay, investment cost, wel, uit eas and ining objotves Atowgh feasibly sties nd contol plans re primarily bared oo ‘unering dewings and spectfeation eqemets,talable nfneaton a be derived rm the alc wool deserbed in tis chapter to fur ‘ein ad pine the characters that may ned speil product and proces contol In tis hope, he Pret Quality Phnning Process designed to are 3 Felted tcclaieal infomation. At this stage of Be pce, preliminary ‘aii analyse wil be msde oases the poten robioms tht could occur during manuictring The inp nd utp applicable to his chapter areas lows INPUTS (Derived from the outputs of Chapter 1) + Design Goats ‘Reliab and Quality Goals ‘Preliminary Bil of Mati ‘+ Preminary Process Flow Chart + Prominry Listing f Spoil Product nd Process Characteristics + Product Assrance Plan DESIGN OUTPUTS (Become inputs for Chapter 3) Design Faire Mode and Effects Analysis (DFMEA) + Design for Mansfacrabilty and Asserly Design Veietion ‘Prope Build -Cootol Plan ‘+ Enginsing Drawings lasing Math Dutt) + Enplneing Specifications + Mei Specifications + Drawing and Spcieuton Changes ” Chapter 2 Product Design and Development APOP OUTPUTS (Becomes Inputs for Chapter3) ‘+ New Equipment, Tooling and Faliies Requrenents Spi! Product and Process Chaacteisies + Gages Testing Equipment Requirenents ‘Team Feasbily Commitment and Management Support 2A Design Failure Mode and Effects Analysis (DFMEA) ‘The DEMEA is 2 sliipliad andy! technique tht assesses the probability of flue as well the effect of sich fae. A DMEA isa living document continually wpded as caster nee and expectons ‘eur, The DFMEA isan fporant int the APCD procs ta sy Ince previously sled product and process carats. The Crysler, Ford and Genwral Motor Poteial Falure Mode and Ess ‘Aalsis (FMEA) reference manual provides guidance fr the preparion (ofa DIMEA. The Design FMEA Chectist m Appensx Act should also be reviewed fo Sue tat the appropriate design hurts have been 2.2 Design for Manufacturability and Assembly ‘Desig for Manufctursilty and Auebly is Simataneos Engineering proces delgned to optimize the relatoship between design funtion, ‘Manuficturablity, and exe of asembly, The scope ofeustomer noe nd petitions defied in Chaptr Iwill determine the extent of the ‘orgnimions proce gual Paorng team involvement in ths acy This runual doee not isade oe refer oa formal mead of preparing * Design for Manfatrsiiy and Assembly Plan Ata inmumthe et sted here shuld be considered by the organization's pod quality Planing teas “+ Design concept, fnction, and sestvity to manaictring variation + imensonlwlrances 1+ Peformance rqurenects + Number of components + Process ajstments = Mati anding Chapter 2 Product Design and Development ‘The stove list may be augmented based onthe opaiaion"s produ ‘uly planning eam Knowledge, experience, the progbcUprocss, [verment regulon, and vervice oqo. 2.3 Design Verification 2.4 Design Reviews Design vrgetion verifies thatthe product design ness the customer ‘eulements derived fam the ete eves in Chase ‘Design reviews te rogusly Scheduled cigs led by the organization lige coginceing avi and mast inclode ther atte areas. The ‘lsign review it an. effecive. method wo. previt problems snd Imisundemaning; it lo provider = mechanism to monitor progres, ‘porto management an bain omer approval as eqs. Design reviews ste a sves of veriaon actives ut re more han an engiauring ispocion. AL a ltimum, design reviews shuld neue crahation of ‘+ Design Functional equiement()conieations 4+ Foal elibilty and eondence goats + Componenvesbeysemiystem dy yes + Compute simulation and bench stress + DEMEN) + Review of the Design or Maufacubiiyand Assembly effort ‘+ Design of Experiments (DOE) nd assem til varatio els (Refer so Appendix) + Tet fates ‘Design verittion progress ‘Ansar fnesion of design reviews isthe tacking of design veritcaion ‘ogres. The onsnizaion should ack design wifeaion. progress ough the use of plan and repo format, refered to as Design ‘Veriton Pn and Report (DVPaR) hy some customers. The pla ad ‘report ir aol method ose + Design veritetion + Prods and proces validation of cmponens and ascents through he pplication of compechensie et plan ad repo "he osaiztion’s oduct quality planning tam is noted to the items Ted “The tum should consider and eas apropsit, the analy cal tecniques listed in Appendin 8 Chapter 2 Product Design and Development 2.5 Prototype Build - Control Pi Prootype contol plans area descipon ofthe dimens nal measurements hd ae ao tonal este tt wl oot ring poate tal. The ‘renin’ rot quality plang tam sold enue tat = rte ‘Sot! plon prepared Carol plan mehadaony i debs in Chop {5°A Control Plan Checkin x provided pbk Seria 6 and Appendix AS {0 it in the propertion of te pote conte plan ‘The manuf of pottype prs provides an excelent opportnity for the team an th customer to eval how well he prods or sorvoe Inet the Voie ofthe Cstomer objectives. Is he organization's product ‘qi planing. team's reeponsiity to review petohpes for De folowing Assure thatthe produto servioe mess specificton sd report daa 3+ equi sure that parca ateton has been given to special produst and ‘poces huncterss. ‘Use data. and experience oeublih prliouy proves parameters and ackasng requirement Communicate any concems, devinions, andor cat impact 10 the 2.6 Engineering Drawings (including Math Data). Customer dsigns do not prude the organization's product quity Planning ean’ responsi to review engineering. ravings in the following manner.” Engineering drovings may inelnde special (goverment egulatory snd sfety) characters tha: must shown on the contol plan When customer engineering drawings are aonexiset tbe antoling dings should be rvewed bythe cum 9 datrmine whch ‘rset fi, finer, dural adr governed ello Sate regulon. Drawings sould be viewed to determine if thei sufe:infomaton| fia dnarsiond Inyo of the india pars Canrel or dtm | ‘rficesflatrs shold be clenty identified 80 at ponte neon ages and equpment cn be dignd fr ongoing couls.Dinensions Should be clued to sie feasibly and compat wit industy Inanufcting and measuring standards If appropri the tear should ‘ste that math it compte withthe customers sem for effcive Chapter 2 Product Design and Development 2.7 Eny eering Specifications ‘A dete review and undersnding ofthe controling specfetons wil ielp the orpninon’s prodict quality soning town to ‘deny the finctiona) darby and appenance Tegument of the subject ‘component or asembly. Sample size, equa, and wsceptance era of | ‘hese prantors ae generally defied inthe i-proces test secon of the Engineering Specfeation. Otherwise the sample sis ad resueaey ae ‘be dormine by the aguizaton an Tse in the compan I eer ‘ce th eratzation should determine which characte fect mectig funciona; duably andappesrance requirements, 2.8 Material Specifications In adon to drawings and_ performance spefitions,_ mates specications should be reviewed for spec characrstr relating 10 ‘yscalproperies,pelrmance, eveonmentl, hang and storage Fequrements These churctersc shuld nls be ince fn te ened pan 2.9 Drawing and Specification Changes Where clawing and specication changes are req, the team must ‘sie tae the changes are promptly commiiewed. and. propery ocsmenad to al feted ares 2.10 New Equipment, Tooling and Facilities Requirements “The DFMEA, Product Assure Plan anor design reviews may ieniy new equpmet and facies incofing mesg apc requirements THe ‘ganzaton’s product quay paolng team shld adds. these reatremens by adding the net he Timing Char The team should ‘sre tht ther isa proces to determin tne eopment nd linge ‘apie and deer on tine. Facliies poor shld be monitored fo ‘sure completion rir to planned production cout. Refer tb the New Equipment, Tooling and Test Equpmene Chests in Appendix A, 2.11 Special Product and Process Characteristics Tn the Plan and Defi Progam stage (Chapter 1), the team Identiod srelminary spell product and proces characters. The rgnization roduc quality planing team shuld build on ths Hsing. and reach onrenartrowgh the ealation of he technical information. The ‘ranization oad eer to the apron casos reireents a Chapter 2 Product Design and Development for sditioal ews on the use of special product and_ process ‘hance, The comin ito be documented on the appropiate foniol plan. The Contra Plan Special Chuacterises and Data Point Coordinates fms referenced la Chapter 6, Supplements K and L, ate ‘ecammended methods to docunect and upte specl characteristics. The ‘rganiatin cn ie ay frm tat mews the dosumertaon requirements Refer casomerspecfe requremants or unite appovalrequremcns 2.42 Gages/Testing Equipment Requirements 2.13 Team Feasibility ‘Gngestesting equipment requirments may alo be idee at his tme The. organization's product quaity planning. tam shoulda. these rouiement oth Thing Char. Progress shuld be monitored o ase that rege ining is met Commitment and Management Support “The organization's product quality lansing eam rst sees he feasibility cof the proposed design a hs time. Cstomer design oweemip does at Presloe the rzaizaton' obligation oases design fab. The team "BUS bested tt the propesod desgh canbe manufcured assonbled, fered, pacaged. and delivered in sient quantity on schedle at at cepiable cont to the cantare." ‘The Design Infoeaion Checklist ‘Ronen A2 allows th eam o review i flor i is section nd ke ‘Srevahton of effectiveness This check wl also serve sta tsi for the apn ace discussed in he Team Feabity Commitment, Append 1D. The team consensus thatthe proposed design is feasible sould be Aocumened slong ity al ope sae hat eis reclton and presented to management for hele suppor The Tex Fesilty Comalanest fom Sowa in Appendie D is an example ofthe type of writen record tesormended Chapter 3 Process Design and Development Chapter 3 Process Design and Development Chapters Process Design and Development PRODUCT QUALITY PLANNING TIMING CHART concent nnn Roper, Korot roe ast sch Produt Design ard Dev. Feedback Aasseement an Caectve Acton ourputs: + Packaging Standards and «+ Pre-Launch Control Plan Specifications PreLaunch Control Pl + ProductProcess Quality System ie caeaenaer ear Review + Measurement Systems Analysis + Process Flow Chart i + Proiminary Process Capabi + Floor Plan Layout re aity + Characteristios Matrix + Process Failure Mode and Effects Analysis (PFMEA) ‘+ Management Support Chapter 3 Introduction Process Design and Development ‘This chapter discusses the major fetes of developing = manafictring system and its elated conto plan achieve quality products. The asks to te scompished a this step ofthe prodoet qual plaming process Spend upon the succesful emplton ofthe pir stages coma in the {it two setons This next sep designed t ens the comprehensive evelopment of an effstve manofctrng sytem. The manalctrng ‘yaterm mst sre hat customer reqement, needs ad expectations ae ‘mc. The puts and ouput splat te proces Sip in his chapter ae ‘follows INPUTS (Derived from the outputs of Chapter 2) “+ Design Fale Mode nd ects Analysis (DFMEA) “+ Design for Manufacurbiy and Assembly ‘+ Design Veritcaon + Protrype Build -Contl Pan ‘+ Enginsig Drawings (tung Math Dat) 4 ngnceringSpeiions “+ Mati Speciemons ‘+ Drawing and Spciteation Changes + New Buipment, Tooting nd Facilites Requirements + Speci Product and Process Charaterisies + GapesTestng Equipment Requirements + Team Fesilty Commitment and Management Supeot ‘OUTPUTS (Become inputs fr Chapter 4) 1+ Polagng Standards & Specifications + ProtucuProcess Quality System Review + Proce Flow Chart, + Coaacteriies Matic Proves Fire Mode nd fc Analysis (PEMEA) ‘+ PreLaunch Control Plan isang rror-Profing Devices) + Measurement ystems Analysis Plan 1 Prsliminary Poses Capabity Sly Pn 4 Management Suppor (inluing oper sing antraning pln) as Chapter 3 Process Design and Development 3.1 Packaging Standards and Specifications The cuxomer will ususly have peckaging requirments tht should be ‘incorporated into any packaging specications forthe oduct. IF one are ‘provided, the packaging design should encre product tegriy point of {se The erganizatin’s product quali planing tear should ensre that {nda product packaging (clung incre patins Isdesigned and developed" Customer packaging sendards "or generic packaging ‘oquirements abou be wed when appropriate Tn all ass te packaging ‘sign sould as tht the pode pertormance apd chrterindcs il romain unchanged during packing, ans tnd npocting. The peckaping ‘Soald ve compaabily wih al denied mateal ending equpment including robo, 3.2 ProductiProcess Quality ‘System Review The ongniition’s produ qualiy planning teu should review the manufectring site(s) Qualty Manageteat Stem. Any onl contols Sndlor procedural changer required to podice the prodot sould be ‘piste docameatod ond incaed inthe mamuactrng cont pla, Ths [an opportunity for the erganiaton's product quay pling team to improve te existing quality” system based on euomer input, cam ‘expertise and previous exprenee The ProductProces Quy Choskist povided in Appendix At can be wed bythe organizations prot quality lng tae to vey completes 3.3 Process Flow Chart ‘The procs flow chars a schematic rpescmtoe of the curent roposed presto. can Be sued to male soars of variations of ‘athine, materials, methods and manpower bor the egianing o el of 2‘ mufctvig or asenly proces Is wed to mplasize te pact of Sues of variation on te process. The ow cat belo analyze he [roces rather than invite step nthe process. The flow char ass {he organization's produ quaiy planing team to fens on the proces ‘hee eonducirg the PPMEA and designing the Cond Plat The Process Flow Chart Checklist in Appendix A-6 can be used by the organization's ‘product quay planing eam to verify completes ‘The Moar plan should be developed and reviened to dteoine the scp of Important contol eas, suchas ispecon plas, coal ‘hat Featon, appleby of vital as, interim repair stations, and Chapter 3 Process Design and Development storage aes to contain non-conforming mate. All css ow should be keyed to the process flow chat and contol lar The Foo Pn Checklist in Append A-S can be ued by the onpiation's product ‘yay planing eam to very comptes. The flo plan layout shoud {eetloped in such manne optimize the mate rave! Rading and ‘alae use of flor pac and shoud fiat the fyetronous ow of | ‘mais thre he oes. 3.5 Characteristics Matrix (A characterise matin 8 resomumended aalyfal technique for ‘spaying the eonship between proces parameters and manfatring Stations See Analytica Technigues in Appendix for farther deta. 3.6 Process Failure Mode and Effects Analysis (PFMEA) |APPMEA should be conducted during podut quality lansing and before belong production. Te is «disciplined review and walysis of «new oF reve proces ane condsted 1 antipat, eave or moelar peal Process problems for new or revised product prov. For futher [Efagnon on th resin aod tenance of PFMEAs refer to Chrys, Ford apd General Mots Pottal Fale Mode and Efects Anaysis (EMEA) reference mani. The Process FMEA Checks in Append A? fn he ted bythe oration’ prouet quali plang team wo Ye 37 Pre-Launch Control Plan relaunch contol plan ar esrigion ofthe dimensional measurements ‘tnd meri ad Snooth wil oecar ar peta andoere Fal] prodcin, Tae prelaunch cael an abou cde anal roducdrocess coals o be implemented unl the peduton proces is “aldsted. ‘The porpose of te pre-nnch coro plan ro conan poten en-onfomiisdrng or prio oi eodueon vas Examples of hancement inthe pesiuoet conta pan are 4+ More eauet inspection 1 More n-roces nfl check pints + Rout stil evans “+ Enhanced its ‘+ Ldesieaon of nor protiag devices For fe information onthe crenon ad mnenaee of contol pins refer to Chapter 6 The Conta! Plan Chee in Agpendix A can be n Chapter 3 Process Design and Development Sede retin pric amy pleming am 1 vey fompleeness 3.8 Process Instructions ‘he rpanization’s product quality plaming tam should ene that process inructons provide suet understanding and tal or all PSone! whe have dec espoasbiltyfrthe operaton ofthe presse. ‘These inseucons shoud be developed rom the flowing source Conon) ‘+ Enpincring drawings, performance speciaions, materi spelcatons, visual standard pd dusty Standards + Proves flow hart 4 oor lan yout + Charis mati. 1+ Packaging Sanda nd Specifications 1 Poot yarameters ‘+ Orpstznton experi and knowledge of he proces sd procs Hanan equlemens 1 Opecators othe process ‘The procs insrctons fr sada opting posed shouldbe posted nd Should sce sup parameter uch a! machine pas, fn, eee times, and tooling, and shoud be acesbe to the opertrs and ‘uperisrs. Adina information for pros nstucton preparation ay 3.9 Measurement Systems Analysis Plan “The organs prodst quality planing tam soot ensure th plan to aceplch the gue! mestorenent sts anys deveope, Inculig chocking ads. This plan should Inciae, at mina a Iaboratory scope appropri fer the ogued ese and tx he reorient ey, ep, Ford, and Genta Motors Messiroment Systema Analy (MSA) relerence natal 2s Process Design and Development Study Plan “The organization's profuct quali’ plsaing ter should entre the evelopment of preliminary procs espa plan. The chases ‘Med ta the carl plan will eves the bass fr the prelininary proces capably study plan. Reference the Chyse, Ford, and Gene Motors Production Put Approval Proess(PPAP) mal and Chyler, Ferd, and’ Genet Motors Shisies! Proc Cental (SPC) reference anal for farther dent, 3.14 Management Support “The expnizatin's product quality planing eam shoul schedule a formal review designed to Flore managenent commitment the concsion of | teeing upper managment inermed swell a gaining asian oaset In esluton of any open sss, Management pport incoder te entiation of te planing and providing the resove=s and stafing cet the requ capac, 2» Chapter 3 Process Design and Development Chapter 4 Product and Process Validation Chapter 4 Product and Process Validation Chapter 4 Product and Process Validation PRODUCT QUALITY PLANNING TIMING CHART Invaton Aro ‘room| Repro) Prete re Laan Prost Design ana Dev Feedback Asresenan and Conectve Aton outputs: + Significant Production Run + Measurement Systems Evaluation ‘+ Proliminary Process Capability Study ‘+ Production Part Approval + Production Validation Testing + Packaging Evaluation + Production Control Plan + Quality Planning Sign-Off and Management Support 2 Chapter 4 Introduction Product and Process Validation ‘This chalerascunes the major feanees of validating the manufacurng process though an evaluation of sigifeantprodaion run. During gic production run, the organization's product uly planing ta ‘ould valle tut te contol plan and proces flow chart are being followed and the prods mont cusiomer requirments, Addison soocers sould be eae for investigation and resolution peor 10 ‘aul produson rns ‘The inputs and eutputs applicable othe proces steps in his chap ares flows INPUTS (Derived from the outputs of Chapter 3) + Petaping Sundar &Specteations + ProducuProcess Quality Sytem Review + Proce Flow Chart, + oor Pian Layout ‘+ Process Fllre Mode and Eos Analysis (PFMEA) + PresLavach Control Pan Poca estos 4 Measrement Systems Analysis Pm Polini Process Capailty Sty Plan + Management Support OUTPUTS (ecome fps for Chapter 5) ‘+ Sigufeet Producson Run 4 Measurement Systems Evaluation Preliminary Process Cpaility Stay ‘Production Pat Approval Production Valin Tsing + Packaging Evaluation + Production Control Plan ‘+ Quay Planing Sigr-Of and Management Sapport Chapter 4 Product and Process Validation 44 Significant Production Run ‘The signiiest production un mart be conde sing production toting, rogsstion equipment, production etvircamext (ising roducon persis) Gc, production gages ad production rat. The valdaton of | the effectiveness ofthe manafictring process begins withthe sigan ‘duction rn (rf ote Chyler, Ford nd Genes: Mtr Prodcion Part Approval Poces(PPAP) maria the sppropise exsiomerspecie requirement or ats! dts). The mini gua fra sana ‘roducton ron usualy st bythe cstamer, but ean be exceeded by the ‘rzniatin’s product goal planing team, Ouspr of the sieican ‘odeton rn (peut is used fr: “+ Preliminary proces capbity study 4+ Measurement systems analysis “+ Production rte demonstration + Proves review “+ Prodvtonvatdation esting + Production par aproal ‘+ Packaging evaluation lime expat (FTC) + Quy planing se oft ate production pas “+ Mase sample (as equied) 4.2 Measurement Systems Analysis ‘The speiid monitoring and measuring devices und metods shoud be sed to check the contol plan identiied chreteritics to eginering “pecifeaton and be soja o easement sem easton ring ot ror othe spins prduion ro.” Relr to te Chyler, Ford, aad ‘General Mours Mensuremeat Stems Anlsis (MSA) efence mantel 4.3 Preliminary Process Capability Study The proiminary process cagbiily stay shold be permed ov cratersies eatied in the coool plan. The Sy provides an Ssstesment ofthe readines ofthe procest fr production Refer tothe CChyser For, ard Genera Motors Production Pat Apeoval Process (PAP) mantal spd Chelr, Ford, and General Motor Statistical Process {Contol (SPC) reference manual for deals conceming the preliminary CChaptor 4 Product and Process Validation process capably study, Refer to eustomerspecific requirement for gue requirement 4.4 Production Part Approval [PAP purpose isto provide the evidence tat all estomer engincerog| ‘design seo end epeteation requirements ate pope undrsiond by te ‘ranization and tht he manus procs as the potato produce predic comistnly mecing tise roqurenent dung. an acted Proucton rans the gute production rae, Reto the Crtr, Feed, Ed General Motors Proton Part Approval Proce (PPAP) mam 4.5 Production Validation Testing Production validation testing refs to eninsrng tes that valde that ‘rode mae fom. prodition toolr and procezes mest casioner ‘Shginoeing standards needing appearance equremens- 4.6 Packaging Evaluation ‘AL st shies (when required) and test methods must asess the Protection of the produc from normal taneporion timage sn averse ‘Sivonen fst Customerspeifed packaging dct not precalethe naniatin's product uit plaming eum veers in evalting the ‘Hfotiveness ofthe phase. 4.7 Production Control Plan “The production consol pln is» writen description of the systems foe anolingprdston pas an proces. The production coma la is 8 living document and shouldbe uplsed reflect the ation or deletion of| tsntols bua oa experience ald by pring pars. (Approval ofthe thornsd ster represemtve may be regres) The adic nil plan isn Tog! exersion ofthe prelanch coal plan. Mass rodston provides the organization the oppor) fo evalua ou, Feview the con! plas and make appropri changes, Chapter 6 ad ‘Kopondi A pesent Control Plan Methodology’ ad's checklist er completeness. 4.8 Quality Planning Sign-Off and Management Support “The organization’ product gaaiy planing tam should perf areview se manafctring locaton) and corte fora signoff The prodct quality sigma indents to management tae appropiate APOP Chapter 4 Product and Process Validation sctvites have been competed. The sgt cir prio 9 int produt ‘Shipment and nce a eview ofthe flowing ‘+ Process Flow Chats. Veiy tht proces Dow cart exis andar being + Contol Pans. Verify that contol plans exit, are avalible and ae followed tall ime oral feted operations. ‘+ Proc Instructions. Verify that these documents contain ll the speci hrecterines specified in the contol plan ane dat ll PENEA Tecommentntions hive been addressed) Compare the proces Srrctions PEMA and proces ow chart 0 he coml plan, + Montrng and Measuring Devices. Whee special pages, Gxtares est ‘sument or devices re reuied per the contd plan, very age repent and reprodacbity (GREK) apd proper usage (Ref othe Cheyne, Ford, and Genel Mots Meastemen. Systems. Analysis (9484) race mal for mre information) ‘+ Demonsration of ‘Requiréd Capacity. Using puction process, cupment and peroneal Upon completion of the sigeofl, a review with matagement should be ‘hoduled fs lafacn management of the pogram sits and in thie “apport ith any open ster. The Prados Quality Planing Samay sr “Approval report shown i Appendix Fi an example ef the documentation ‘eed support anofective aly planing sig. Chapter 5 Feedback, Assessment and Cerrective Action Chapter 5 Feedback, Assessment and Corrective Action Chapter 5 Feedback, Assessment and Corrective Action PRODUCT QUALITY PLANNING TIMING CHART cee natonproa Reprod — Pretty Poe tae, + + t Proc na Process Valiston Feschock Ascent and Corecve Aion ourputs: + Reduced Variation + Improved Customer Satisfaction + Improved Delivery and Service ‘+ Effective Use of Lessons Lear / Best Practices * Chapter 5 Feedback, Assessment and Corrective Action, Introduction ali planning des aa end with roes vaidtion ad istallaton. is ‘he component nanufscasing sage where op canbe evaluated ben all ‘speci and otumon ents of vrintion se present This also the inet ‘lute the effectiveness of the product qual, pling effort The ‘rodocton conta plan th ats for evaiting praetor services this Sage, Vasale and attibte da mist be evant. Appropeae actions fs descrbed inte Chrysler, For, and Gene! Motor Sac Proce {Conol (SPC) reference manta mst be ten. Organs hat fly implemen an effective APOP procs Wil bein a beter poston fo meet omer egurerets inlay spel churetrsis spose by the ‘The agus and oupus apical to the process epi this chapter are as falows: INPUTS (Derived from the outputs of Chapter 1 SigitcanePadution Run ‘+ Measurement Systems valuation 1+ Proiminary Pres Capability Sty ‘+ Produsion Pat Approval 1+ Production Vain Testing + Packaging Evaluation “+ Production Contol Plan + Quay Planing Sigs-OF and Managemest Support ovreurs + Reseed Varaton + Improved Customer Sutsaction + Improved Dative and Service fective te of Lesions Leumed Best Prctios ‘5:4 Reduced Variation ‘Conol chars and other sisi! technigues should e usd a als to deny proces variation, Analysis and caectve acs should be wed 0 edue variation Comal improvement requis ation fot oly tthe Special causes of variation but understanding common eases and Seking ‘nay to rede these sures of tariaon- Proposal be developed Inciding cos, timing, spac provement fr caste vie “The edtonoelininsion fa comin aus nay provide the ations! ‘bnefi of lower east Orgazatons sould be wing ols such as valve smalls and eduction of variation to iprove quali ané rece cost Referto the Chyler, Ford and General Motor Statstal Process Cond » Chapter 5 Feedback, Assessment and Corrective Action (SPC) reference masa fr details on longserm capsity, special and onion eas of variation, 5.2 Improved Customer Satisfaction ‘Deisild plaming activites and demonsated proces capeiliy of = frodict or save are Inport componen 19 catomer snsicton, Flowever the pode of service sll as to pevorn in he custome: ‘nvronment This produc nage sage rogues organisation parteipatn In this sage mach car be lewd by the oypanizatin nd ease. The electives fhe product culty panning ers canals be evaiated a ‘hiss. ‘The cranizution and cusomer become purer: in making the changes neces fo coret ay deficiencies and a prove case sais, 5.3 Improved Delivery and Service The delivery and sevice stage of usliy planing colons the orgniton and saromer parnentip in solving pels ad coin Imroverent” The cutamers replacment pars ad Service operations fue alse mst requirements for quality cost, and defveny. The pol is fist tne quali, However, whee problems or deficits ocr inthe field i erential that the opeizton sn custome Tor an efectve parr to comet he problem an su the ead customer The experience gana in this stage provides the customer and organization withthe necessary knowledge tb reduce proses, inv=nory, and culty ‘stand to provide thee component or system fr he ex product 5.4 Effective Use of Lessons LearnediBest Practices A Lessons Learned o Best Prasioesportolio ix benical foe eating, Tetsning and spying knowledge Lap to Lesions Lead and Best Practices canbe obtained trough variety of methods inuding Revie of Things Ge RghtTings Gone Wrong (TR/TGW) ata rom waranty and ber performance mete Camrestive ation plans "Rend acre with smi product ad processes DEMEA and PEMEA sues 0 Chapter 6 Control Plan Methodology Chapter 6 Control Plan Methodology Chapter 6 Control Plan Methodology ‘This page itentionall let bl Chapter 6 Introduction Control Plen Methodology “The purpose ofthis onl plan mathadlogy i to ac nthe manfacie| of ality produ acording to customer equrment. It does tis by froviding “a stuctued. approach forthe dergnslecton and Implementation of valve-added convo! mods forthe taal sem. (Conrolpans provide writen summary desertion ofthe systems se in ‘minimizing proces and product vaio. The itn’ ofthe contol pan form dapayed inthis chapter te to provide an etmple of how tht Information can be documestes. An aerate forms ny be sed len {st cmt the same information, ss 2 misma. Te cool pln does ‘ot replace the information sonsnod in deal operate nstuctons, Th ‘methodology i applabe wo a wide range of manicurng processes and {ealsologles. The contol plan i an inegrl par of an veal! ality procera sf be wind ae ving document. "Theefoe tis taper ‘Shoo be sed in conjnction with ther raed docu [An important phe of he proce or quality planing isthe development ‘contol plan A contol plans writen descrip of he system for fentoling pts and process. A single cout pan may apt oa woup fr family of pret hat reproduced by the tame ross atthe same ‘Source. Drawings and visual standards, as necessary, ny be atch othe onto plan frustration purposes. Th suppor a's oo plan, operator fd protese monitoring instructions shold be defined nd se cata le effet, the conrol plan describes the actions tat are require at enh Biase of the process inching reniving, inproces oun, and Perio reqtrements i sre hat al process opus wil be state of | foniel. Dising regular producson rus, the conml plan provides the process monitoring and convol methods tht wil be use to coat harass, Since process are expected tobe conn upe snd Improve, the contol plan refets» sateny ta rpnsive to hee The contol plan sited and used duoughout th product ie eee Early in the product ie cele is primary purpose sto document and communi the inl plan for proces cool, Sutequenly i ies Imansfctring in hos to contol the proces and ensure podace aly. Uitimatly, te coaol plan remains a Ivlag document, telecine the fst meth of contol and messrenent systems sed. The cont Plan i updated ac measirement sytem and ent metho re evans improved e Control Plan Methodology Chapter 6 QD season t NY1d TONLNOD Chapter 6 ati: Control Pian Methodology For proces controls improvement o be efective, abasic understanding ofthe procs must be obtained. A mulasepined team is estas ‘develop the col plan by ulizing al the vailable aforatin to gai 2 beser understanding the proces, sch a Proce Flow Diag + Systen/Design Process Fire Mode a Efets Alysia 1 Spcil Characerisice + Lessons Learned fom Similar Pans ‘Teams Knowloige of the Process + Design Reviews ‘+ Optimization Metbods(e4, FD, DOE, ee.) ‘The bereits of developing and ipleneating acon an incase ‘The con plan methodology retusa waste and improves the quality of product during design, manufcturing, end esembly. This sutured {Iscitine provides a thorough evaluation ofthe proc and proces. Control plane enify proces chaste and Wen th conc methods er the sources of variation ing varie), wich cause variation ‘in prodet characterises utp vrbles). Cont pls focus resources om processes and produc related to ‘raters that ar imporut tothe easomer. The rope locaton of| sources on these major tems helps to reduce costs witout sacifcing ‘aly. [Av living document the cont pla identifies and communicate changes ‘nthe roduetprocess characteristics, contol need, and characterise 6 Control Plan Methodology Chapter 6 e Qromadsvanasaenst © sus QD season: Nv1d TOMLNOD Chaptor 6 Control Plan Methodology 641 Control Plan Column Descriptions 1) PROTOTYPE, Inde pyro ay. FRopocion, ‘+ Proiaiype- A desertion ofthe dimensional measurements ‘materi nd performance este occuring during Proatype car + ProLauach- A desc of he dimensional ‘measurement, mari nd performance ts that Will ‘ceuaterProttype and before nme! educton 1+ Preston A comprehensive documento of product proces characteris, process contol ets ad ‘easement systems oecuting during mal production 3) PARTNUMDERLATEST | Enterthe number fhe ssem, suspen o component being CHANGE LEVEL. fentoled, When aplicable ener he test enti chaise tovl endl ese date rom th raving peli, 4) PARTNAMBDDESCRIPTION. | Bier th nme and description ofthe produccess being 5) ORGANIZATION LAN” | nur ne a company ad pone Shauna en pa. @ oRawazaTiN cone |x be atone cae DO, Gamer turret cone, Sip Cissy ce “KEY CONTACDPHONE AND | Ener th ane, tlephone sunber and other cont infomation, orner contact ‘ses emal fhe primary contac responsible forthe cont pan, INFORMATION. 8) CORETEAM Enter th names), lepine sume), and othe eonaet information, eg email ofthe individu) response for repring the contro plano the test revision. is ecommended Taal of thea member names, pone nmi, and lotions belated on a atace dstrbaton it 9) ORGANIZATIONPLANT | Obtain he apoosible manvfactrng pant spor of he APPROVALDATE twnmizaton (i reqired- te appropriate cutimepeciie reguremet) ° Control Plan Methodology Chapter 6 Seas parawesty mio] 2 esnato] Pravcerate sanity ugveneavetio| D scromamimind eae yore —u wwv1a-10uuNo9 Chaptor 6 Control Plan Methodology 10) DATE (ORIG) ater the date dt the original cone plan was compl 1) DATE (REV) tere deo the test contra pln ups. 12) CUSTOMER ‘Oban the responsible customer enginesing approval ifrequred = see ENGINEERING spprprnte easter specie eqiremen)- APPROVALIDATE, 13) cusTOMER ‘Oban the responsible customer supplier quali representative approve ‘QUALITY (freuited se appropriate eastomerspeifereurenen) [APPROVALIDATE. | 14) OTHER ‘Oban anyother agred upon approval Freie) | [APPROVALIDATE: 15) PARTIPROCESS “This tem numbers usualy feed from the Proces Flow Chur. If ‘NUMBER rile part mamters exit (assem) it the nde! pr nambers and ter processes acorn. 16) PROCESS NAME ‘Allstepa in the manufacturing of syst, sobsystem, oF component ae (clues items 18,19 and 20) (OPERATION ‘esrted na process flow diagram. Ide the procesloperation name DESCRIPTION from the ow ingredients ati ena mre. I) MACHINE, DEVICE, | For ath operation tat s desea identity the procesing quent, 1G, TOOLS FOR ‘eg. tmchine device jo ober ol for manfatrn, appropri MANUFACTURING ‘CHARACTERISTICS [A distinguishing fare, dimension o propery fa pees ort opt (roduc) on which varuble or wou data can beled, Us ital ‘i whee applieable 1) NUMBER ‘Assign a eos eflence number wall applicable docanents such, but ‘ot miedo, process flow diagram, numbered lo pit, FMEAS, and ‘ravings oF her visa saad, required. Opiond example work ‘Sheets und explanation of thse work shart are loadin Supplements K fant, ” Control Plan Methodology Chapter 6 em os © enraecses os ay Qownciyresiseente ® come aan ta @ © ae Q_ sexsem) © semsayenna] Sa] ST Ny1d T0LNOo 8 Chapter 6 19) PRODUCT 20) PROCESS 21) SPECIAL CHARACTERISTIC CLASSIFICATION Product Caractere athe fears or popes of apart component or ‘hich proces conta se oul tacked drag oral opens ‘Ure the appropriate clasifiation as required bythe carne se the Control Plan Methodology ‘sembly tht re deveribe on dang oe pia engioorng infomation, The Cove Teun sould deni the pei produce harass that re compilation of important Frost Christi ftom all sores. Al pecil characterises mt be Hired om he contr Plan I alton, the organization may Ist ther Produ Characters for Process Characeriis are the proces variables (pat viiabas) hat have @ use and effect reltionship wih he identi Product Characters. A Process Caraceriic can oly be measured atthe time Koger. The Core Tear shoud deny Process Characteristics fr which aan mst be roll o minimize product vriaton. Tere could beone or more Process Characters ied for enchProdt Characters Ta sre Drocestes one Process Characters may lfc several rot ‘spproprintecacomer specific requrmens) to designate the peo pela | ‘rarer or ths Geld cn be left lank fer ter wndesgntod Steracteses Customers may use unig ynbos ois important ‘orate, such as those tat affect customer safety compince wi ‘epultons, anton, t,o apperaes. 5 Control Plan Methodology Chapter 6 w w wees peraway a © cox werawnsiy ima mses DQ worsen Nya TOuLNOD ia} Saray 6 Chapter 6 Controt Plan Methodology "METHODS (INCLUDES ITEMS 2225) ‘Acostemat plan wing procedures and ote tol ental 2) PRODUCTPROCESS ‘SPECIFICATION’ TOLERANCE, ‘Specfctionstolennce may be obsined fom various reincering document sch but not ited ndings, ‘Sign reviws, mater standard, computed desion ‘, anufctring andor assebly Tequremeats 23) EVALUATION’ MEASUREMENT, ‘TECHNIQUE “This column dein the mensurement sytem being wed. “This could inlae ages, furs, ols, andor tt, ‘equlpmenteqled te measure the prvpcessnanutactrng ‘qulpment A measurement systems arlis sould be done tserure contra of ontering snd messing devices pear o rep on mestiement system For example, an analysis of the Linearity, reproduc repeat, tabi end accursey ofthe measurement tem soul be peered. Improvemeats tthe measurement systems should be mace sccordngly_ Refer the Chrysler, Ford, nd General Motors Measurement Syste Analysis (MSA) efrence manta for nal etal 24) SAMPLE SIZE/ FREQUENCY ‘When smpine rogue st the corresponding sample size snd regen. 25) CONTROL METHOD ‘This sone ofthe eta elements oan effetve conto plan ‘This com ona = re denen of how the operation willbe controle including procedure aaners where plicable. The contol mabod lized soul be based on ‘Hote analysis ofthe proces. The conta med is ‘eternity the pe of proces ae the sk ered tiring quality planing (ex FMA). Operations may be ntl by, bar ar ot ited o, steal process convo, Inspection, atubute dita, mistake proofing. ontemated non | atomated), and sampling, plans. The cont plan descriptions ‘ould reflect the planning and salepy beng plemented ‘he manufeuring proces If elaborate conol procedures are ‘sd the plan wl plealy reference the ocedure document by apecif dentifiestinn name andor ume. Refer othe ‘amples orhow tpl proses re courolled ‘The method of conta shold be continual evaluated for | Mletvenes of process contol For example, sigifcant | Stange inthe proces r process capability sou Tad tan | Saletion ofthe control metho. 8 Control Plan Methodology Chapter 6 rad Ta = ®, Qowuatinesenate e ay QD nonsennss tn Ny1d T0NLNOO Chapter 6 Control Plan Methodology 26) REACTION PLAN The ecto pla specifies he cores ations| secssary avid producing nonforing roel or aerating oof coat. The actions ‘ould normaly be the spotty of the people ‘ln tthe proces, the opera, jbseter, of Supervise, and be clay esate in the plan Provision shouldbe made fo decuentng aeons ‘ake, Ina cases, supa and nonconteming prods ‘st beclery et snd qucrane, and

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