apqp advance product quality...

APQP – Advance Product Quality Planning

Krzysztof Dybioch – Bridgestone Poznań Quality Engineer

21-05-2014 Poznań

Agenda

1. History of Quality Systems

2. Quality system core tools

2.1. QS-9000

2.2. FMEA

2.3. PPAP

2.4. SPC

2.5. MSA

2.6. APQP

1. History of Quality Systems

• 1959 – USA Ministry of Defense „Quality programme reqirements” • 1968 – NATO and AQAP-1 • 1978 – GB Ministry of Defense and DEF/STAN 05-8 • 1979 - British Standards Institute issue first trade standard BS 5750 • 1987 – International Standard Organisation (ISO) issue ISO 9000 • 1993 – PN-EN 29000-29004 standards • 1994 – update to ISO 9000:1994 • 1994 – „big three” Ford/Chrysler/GM issue QS-9000 • 1999 – IATF/AIAG – ISO/TS 16949 • 1999 – new standards, more process oriented ISO 9000:2000 • 2002 – Second edition of ISO/TS 16949:2002 • 2008 – Update ISO 9001:2008 • 2009 – ISO/TS 16949:2009 also includes ISO 9001:2008 requirements

2. Quality system core tools

• QS 9000 Quality System Requirements (3rd edition October 1998)

• FMEA – Potential Failure Mode and Effects Analysis (4th edition June 2008)

• PPAP - Production Part Approval Process (4th edition March 2006)

• SPC – Statistical Process Control (2nd edition July 2005) • MSA – Measurement System Analysis (4th edition July

2010) • QSA – Quality System Assessment (2nd edition March

1998) • APQP – Advanced Product Quality Planing (2nd edition July

2008)

2.1. QS 9000

QS-9000 (Quality System Requirements) which basis on ISO 9001 from 1994 but enruched with the requirements of automotive industry

2.1. QS-9000

The minimum seven documents one will need for the QS-9000 program are:

• QS-9000 Quality System Requirements • Advanced Product Quality Planning and Control Plan

(APQP) • Failure Mode and Effects Analysis (FMEA) • Measurement Systems Analysis • Statistical Process Control • Production Part Approval Process (PPAP) manual • Quality System Assessment (QSA) manual

2.2. FMEA – Failure Mode and Effects Analysis

FMEA is a tool used to systematically analyze component or process failures and identify the resultant effects on system operations. To be reliable such analysis has to be done by CFT comprising members of different departments (QA, TS, Prod, MNT, Planning, etc.)

2.2. FMEA – Failure Mode and Effects Analysis

2.3. PPAP - Production Part Approval Process PPAP is a confirmation from supplier. It usually contains

such elements:

• Design Records

• Authorized Engineering Change Documents

• Engineering Approval

• DFMEA

• Process Flow Diagram

• PFMEA

• Control Plan

• Measurement System Analysis Studies (MSA)

• Dimensional Results

• Records of Material / Performance Tests

• Initial Sample Inspection Report

• Initial Process Studies

• Qualified Laboratory Documentation

• Appearance Approval Report

• Sample Production Parts

• Master Sample

• Checking Aids

• Customer-Specific Requirements

• Part Submission Warrant (PSW)

2.3. PPAP - Production Part Approval Process

2.4. SPC – Statistical Process Control

SPC is a quality methods to monitor and control process stability with statistical tools like: • Average • Standard deviation • process capability index CPK • Process capability CP • Process performence index PPK • Statistical control cards like X-R

2.4. SPC – Statistical Process Control cont.

• Cpk

• X-R

2.5. MSA

MSA is a method of exsperiment to check measurement system capability:

• Variations

• Repeatability

• Reproducibility

• Ndc

2.5. MSA

Part Number Gage Name Appraiser A Part Number Gage Name Appraiser A

Part Name Gage Number Appraiser B Part Name Gage Number Appraiser B

Characteristic Gage Type Appraiser C Characteristic Gage Type Appraiser C

Characteristic Classif ication Trials Parts Appraisers Date Performed Characteristic Classif ication Trials Parts Appraisers Date Performed

APPRAISER/ PART AVERAGE Measurement Unit Analysis

TRIAL # 1 2 3 4 5 6 7 8 9 10 Repeatability - Equipment Variation (EV)

1. A 1 EV = R x K1 Trials K1 % EV = 100 (EV/TV)

2, 2 = 2 0,8862 =

3, 3 = 3 0,5908 =

4, AVE xa= Reproducibility - Appraiser Variation (AV)

5, R ra= AV = {(xDIFF x K2)2 - (EV2/nr)}1/2

% AV = 100 (AV/TV)

6. B 1 = =

7, 2 = 2 3 =

8, 3 0,7071 0,5231 n = number of parts

9, AVE xb= Repeatability & Reproducibility (R & R) r = number of trials

10, R rb= R & R = {(EV2 + AV2)}1/2Parts K3 % R&R = 100 (R&R/TV)

11. C 1 = 2 0,7071 =

12, 2 = 3 0,5231 =

13, 3 Part Variation (PV) 4 0,4467

14, AVE xc= PV = RP x K3 5 0,4030 % PV = 100 (PV/TV)

15, R rc= = 6 0,3742 =

16. PART X= = 7 0,3534 =

AVE ( Xp ) Rp= Total Variation (TV) 8 0,3375 ndc =

17, (ra + rb + rc) / (# OF APPRAISERS) = R= TV = {(R&R)2+PV2}1/29 0,3249 =

18, (Max x - Min x) = xDIFF= = 10 0,3146 =

19, R x D4* = UCLR= = =

20, R x D3* = LCLR=

Attention:

* D4 =3.27 for 2 trials and 2.58 for 3 trials; D3 = 0 for up to 7 trials. UCLR represents the limit of individual R's. Circle those that are - All calculations are based upon predicting 5.15 sigma (99.0% of the area under the normal distribution curve).

beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or dis-- K1, K2, K3 are obtained from MSA Reference Manual (Fourth Edition, First Printing, June 2010)

card values and re-average and recompute R and the limiting value from the remaining observations. - For information on the theory & constans used in the form see MSA Reference Manual (Fourth Edition).

Notes:

Specif ication

Appraisers

K2

% Total Variation (TV )

1.41 x (PV/R&R)

GAGE REPEATABILITY AND REPRODUCIBILITYData Collection Sheet (according to MSA 4'th ed.)

GAGE REPEATABILITY AND REPRODUCIBILITYReport (according to MSA 4'th ed.)

2.6. APQP

APQP is NOT a tool.

It is an idea of quality management and defines action need to be taken before mass production realization

2.6.1. APQP - content

APQP says to You what to do before even contract signing with customer, it contains:

• Knowleadge about technology • Customer specyfic requirements • Technical and financial requirements to start production • Construction • Nonconforming product risk analysis • SPC – methods of quality, process and measurment devices control • Instructions, control plans • Delivery • Maintenance • Personel qualifications • Client approval process • Serial or mass production realization

2.6.2. APQP - purpose

• The aim of APQP is to meet as fast as possible customer requirements by stable process. It is very important not only from business poinf of view but in automotiv it can influence helth and lives of clients

2.6.3. APQP – rules and sequensce of realization

time

Process planning

Planning

Construction design

Part and process

validation

Action evaluation and corrective action

Tools

Planning

Serial production

PPAP

PSW

Project analysis Product project

Process projects Project acceptance

Serial production

Client inquiry Start of production

2.6.4. APQP - Management principles

• Project leader • Teamwork • The use of quality tools • Close cooperation with client • Documentation • Monitoring of various stages • PPAP documentation and client approvals • Require certificates from suppliers • Continous improovement

2.6.5. APQP - Teamwork

QS-9000 and ISO/TS16949 requires work in CFT !!!

• FMEA Control Plans

• Floor Layout Projects

• QPRs and countermeasures

2.6.6. APQP - Tools

Calculations:

• Control sheets, SPC, Six Sigma

• Pareto

• Histogram

2.6.7. APQP – Tools cont.

Teamwork techniques

Brainstorm JIT Ishikawa


Concept work

Risk analysis Flow chart


Concept work

5S Radar


Concept work

Poka-Yoke Experiments 8D


Concept work

Benchmarking Business Plan

and many more …

Thank You for Your attention