APQP常識(shí).ppt

1 精準(zhǔn) 激情 團(tuán)隊(duì)APQPTRAINING 2 APQPAwareness常識(shí) AdvancedProductQualityPlanning產(chǎn)品質(zhì)量先期策劃 3 Expectations期望 APQPTRAININGNANCHANG 4 WhydoweneedAPQP 為何需要APQP TodelivertothecustomertheneworthechangedParts 目的是在向顧客交付新的或已變更的零件時(shí)能夠符合如下三條 intherighttime恰當(dāng)?shù)臅r(shí)間intherightnumber正確的數(shù)量intherightquality合格的質(zhì)量 5 Purposeoftoday sSession今日培訓(xùn)之目的 YouwillgetanoverviewoftheAPQPprocess 掌握APQP流程的概述 TheprinciplesoftheAPQPelementswillbeoutlined 概述APQP各要素的原則 DetailsofeachAPQPelementarenotoutlined 不包括APQP要素的詳細(xì)描述 6 DefinitionofAPQP定義 APQPisastructuredmethodfordefiningandsettingtheactionsnecessarytoensurethataproductmeetscustomerrequirements particularlywithregardtoquality APQP是一種結(jié)構(gòu)化的方法 用來確定和制定確保某產(chǎn)品滿足顧客要求 尤指質(zhì)量方面 所需的措施 7 TheBenefitofAPQP益處 ThebenefitoftheAPQPstatusreportistolaydownacommon standardisedapproachforthetransmissionofprogrammestatusinordertofacilitatecommunicationsbetweencustomersandsuppliers APQP現(xiàn)狀報(bào)告的好處是為變速箱程序狀態(tài)規(guī)定一個(gè)一般的 標(biāo)準(zhǔn)化的方法 以促進(jìn)顧客和供方的聯(lián)系 8 HowQS 9000wasdevelopedQS 9000是如何制定的 1988summerconferenceoftheASQCAutomotiveDivisionASQC 美國質(zhì)量控制學(xué)會(huì) 汽車分部1988夏季會(huì)議OEMVPsdecidetosetupanOEMSupplierQualityRequirementsTaskForceOEM 整車廠 的副總們決定建立整車廠供方質(zhì)量要求特別工作組Aim harmonisationofquality relatedmanualsandformats目的 協(xié)調(diào)質(zhì)量相關(guān)手冊及表格ResultsofharmonisationareQS 9000andtherelatedmanuals 7 Pack 1993 2ndedition January1996 協(xié)調(diào)的結(jié)果便是制定了QS 9000及相關(guān)手冊 7 套 1993 第二版 1996 1 ASQC AmericanSocietyforQualityControlOEM OriginalEquipmentManufacturer autobuilders VP VicePresident 9 The 7 Packconsistsof 7 套包括 QualitySystemRequirementsQS9000質(zhì)量體系要求QualitySystemAssessmentQSA質(zhì)量體系評(píng)估ProductionPartApprovalProcessPPAP生產(chǎn)件批準(zhǔn)程序AdvancedProductQualityPlanning ControlPlansAPQP產(chǎn)品質(zhì)量先期策劃和控制計(jì)劃FundamentalStatisticalProcessControlSPC基本統(tǒng)計(jì)過程控制PotentialFailureModesandEffectsAnalysisFMEA潛在失效模式及后果分析MeasurementSystemAnalysisMSA測量系統(tǒng)分析 10 APQPManual手冊 11 ISO TS16949 QS9000 Chrysler Ford GM otherautomakers standards fromFrance Spain Japan etc werebroughttogetherinISO TS16949 InternationalStandardOrganisation TechnicalSpecification inordertocreateaglobalstandard 集合QS9000 Chrysler Ford GM 和其它汽車制造商的標(biāo)準(zhǔn) 法國 西班牙 日本等 共同制定ISO TS16949 國際標(biāo)準(zhǔn)化組織 技術(shù)規(guī)范 以建立一個(gè)全球化的標(biāo)準(zhǔn) 12 Whichstandardapplies 采用何種標(biāo)準(zhǔn) GETRAGrelationswithsuppliers GETRAG與供方間關(guān)系 APQPedition2withminoradjustments 使用第二版APQP 作輕微調(diào)整GETRAGrelationswithFord GETRAG與Ford間 APQPedition2withPNDslinkedtoFPDS 使用第二版APQP 并建立項(xiàng)目要求日期與福特產(chǎn)品開發(fā)系統(tǒng)的鏈接GFT srelationswithothercustomers GETRAG與其它顧客間 Thecustomerinformsusoftheirpreferredreportformat 由顧客將他們所選擇的報(bào)告格式通知我們 PND ProgramNeedDateFPDS FordProductDevelopmentSystem 13 Thebeginning開始 TheprocessleadingtotheAPQPstatusreportbeginsassoonasasupplierhasbeenselected 只要選定了供應(yīng)商 就應(yīng)開始著手產(chǎn)生APQP狀態(tài)報(bào)告的過程 ESTA EarlySourcingTargetAgreement 早期貨源目標(biāo)合同 14 FormheadingI表格標(biāo)題I 15 FormheadingII表格標(biāo)題II 16 Riskassessment風(fēng)險(xiǎn)評(píng)估 The4elementsofriskassessment 風(fēng)險(xiǎn)評(píng)估的四要素 Qualityhistory質(zhì)量事件記錄TGWsetc 運(yùn)行情況不良等Supplierprofile供方概評(píng)InaccordancewithSTA SIM SupplierPerformanceAudit 800 1200points 依據(jù)STA SIM 審核供方表現(xiàn) 800 1200分 Designprofile設(shè)計(jì)概況Newdesignsorprocesses 新設(shè)計(jì)還是新過程 Targetrequirements目標(biāo)要求Degreeofdifficulty costs time難度 成本 時(shí)間 TGW ThingsGoneWrongSIM SupplierImprovementMatrix 17 Riskassessment風(fēng)險(xiǎn)評(píng)估 18 Adjustments調(diào)整 Ifoneormoreofthepointslistedintheriskassessmentapply thecustomercanrequireallAPQPelementstobecompleted Iftheprogrammeisclassifiedaslowrisk thesuppliermay byagreementwiththecustomer omitcertainelements 如涉及風(fēng)險(xiǎn)評(píng)估列表中的單項(xiàng)或多項(xiàng) 顧客可要求完成全部的APQP要素 如果該項(xiàng)目確定為低風(fēng)險(xiǎn)類別 供方可通過與顧客協(xié)商 刪除某些要素 GFTrequiresitssupplierstodealwithallpoints GFT要求其供方完成風(fēng)險(xiǎn)列表中的全部項(xiàng) 19 FormheadingIII表格標(biāo)題III 20 FormheadingIV表格標(biāo)題IV 21 TheAPQPTeam supplier 供方 APQP小組 22 TheAPQPTeam supplier 供方 APQP小組 23 FormheadingV表格標(biāo)題V 24 P I S T P I P C P I S T PercentageofInspectionPointsSatisfyingTolerances P I S T 符合規(guī)定公差的檢測次數(shù)百分比 Percentageofinspectionpointslyingwithinthetolerances許公差范圍內(nèi)的檢測次數(shù)百分比P I P C PercentageofIndicesthatareProcessCapable P I P C 過程能力指數(shù)百分比 PercentageofallCCs SCs MajorCharacteristicswithPpkvaluesdemonstratingpreliminaryprocesscapability 所有關(guān)鍵特性和重要特性百分比 表明初始過程能力的Ppk值的主要特性 25 P I S T P I P C 26 The23elementsofAPQPIAPQPI的23要素 27 Definition 定義Specificdocuments activitiesanddisciplinesthathavetobefulfilledinordertosupportthecustomerprogramme 為支持顧客程序而必須履行的特定文件 措施和原則 19areindustrystandard 其中19項(xiàng)為行業(yè)標(biāo)準(zhǔn)4areGETRAG Ford specific 下列4項(xiàng)為GETRAG Ford專用標(biāo)準(zhǔn)PSWPartDeliveryatMRD SourcingDecisionMRD日期前PSW零件交付 貨源決定CustomerInputRequirements顧客輸入要求SubcontractorAPQPStatus分承包方APQP狀態(tài)Craftsmanship精致工藝 The23elementsofAPQPIIAPQPII的23要素 28 Definition 定義Specificdocuments activitiesanddisciplinesthathavetobefulfilledinordertosupportthecustomerprogramme 為支持顧客程序而必須履行的特定文件 措施和原則 19areindustrystandard 其中19項(xiàng)為行業(yè)標(biāo)準(zhǔn)4areGETRAG Ford specific 下列4項(xiàng)為GETRAG Ford專用標(biāo)準(zhǔn)PSWPartDeliveryatMRD SourcingDecisionMRD日期前PSW零件交付 貨源決定CustomerInputRequirements顧客輸入要求SubcontractorAPQPStatus分承包方APQP狀態(tài)Craftsmanship精致工藝 The23elementsofAPQPIIAPQPII的23要素 29 ProgramNeedDates PND s 項(xiàng)目要求日期 30 DefinitionofPND ProgramNeedDates 定義 The ProgramNeedDate isthelastpossibledateatwhichanelementcanbecompletedwithoutadverselyaffectingtheprogramqualityorschedule 項(xiàng)目要求日期 指的是完成某要素的最后可能期限 在此期限內(nèi) 不會(huì)對(duì)項(xiàng)目質(zhì)量或進(jìn)度產(chǎn)生不利影響 31 CalculatingPNDsatFORDFORD如何計(jì)算PNDs PNDs ProgramNeedDates arelinkedtoFPDS Gateways PNDs鏈接了FPDS 關(guān)鍵點(diǎn) 32 SupplierTimingDates 供方進(jìn)度日期 33 1 SourcingDecision貨源決定 Formalcustomercommitmenttoworkwiththesupplier 與供方合作的正式顧客方承諾Iswithinthecustomer ssphereofresponsibilityandmustbeinitiatedbycustomer spurchasingdepartment 屬于顧客的職責(zé)范圍 且需由顧客方的采購部門啟動(dòng) IsdocumentedbymeansofESTA EarlySourcingTargetAgreement 書面記錄在ESTA中 早期貨源目標(biāo)合同 Preliminaryworkshouldbecompletedat ESTAisdueat 初期工作應(yīng)在階段完成 ESTA應(yīng)在階段完成 34 2 CustomerInputRequirements顧客輸入要求 CustomerinputrequiredtolaunchAPQP APQP投產(chǎn)所需的顧客輸入Designgoals設(shè)計(jì)目標(biāo)Reliabilityandqualitygoals可靠性和質(zhì)量目標(biāo)Costtargets成本指標(biāo)Programmetiming項(xiàng)目進(jìn)度Timeframefromto時(shí)間節(jié)點(diǎn)是從到階段 35 3 Craftsmanship 精致工藝 Assessmentoftheproduct squalityimpressionwithregardto 從下列項(xiàng)目評(píng)估產(chǎn)品質(zhì)量印象 appearance外觀feel觸感noise噪聲smell氣味Timeframefrom KO to J1 時(shí)間節(jié)點(diǎn)從 KO 到 J1 階段 36 3 4 DesignFMEA設(shè)計(jì)FMEA Systematicapproachtoensurethatpotentialdesignfailuremodesandtheircauseshavebeenconsideredandaddressed 是一種系統(tǒng)方法 用以保證考慮并記錄了潛在設(shè)計(jì)失效模式及其原因 Preparationfromtoandelaborationupto 從到是準(zhǔn)備階段 細(xì)節(jié)要到階段 37 3 4 DesignFMEA設(shè)計(jì)FMEA 38 3 4 DesignFMEA設(shè)計(jì)FMEA 39 FocusElementRating焦點(diǎn)要素評(píng)定 0 fewerthan50 ofexpectationsfulfilled完成不到期望的50 1 morethan50 butnotallexpectationsfulfilled完成期望的50 100 不包括100 2 allexpectationsfulfilled necessaryinordertocompletetheelementbyPND完成所有期望 需要在項(xiàng)目要求日期前完成要素3 allexpectationsfulfilled andothersbesides完成所有期望 包括其它的 40 4 5 DesignReview s 設(shè)計(jì)評(píng)審 Regularmeetingsinordertoensuretimelysolutionofconcernsduringdevelopmentandimplementationandtopreventmisunderstandings 是一種定期會(huì)議 用以保證在制定 執(zhí)行和防止誤解階段所產(chǎn)生問題的及時(shí)解決 Mostimportantexpectation 重大期望事項(xiàng)Projectplanningmeeting 項(xiàng)目策劃會(huì)議Timeframefromto時(shí)間節(jié)點(diǎn)從到階段 41 5 6 DesignVerificationPlan設(shè)計(jì)驗(yàn)證計(jì)劃 TheDesignVerificationPlanisthebasisfortheEngineeringSignOff ESO Listsallthemeasurescarriedoutforthepurposesofverification 設(shè)計(jì)驗(yàn)證計(jì)劃是工程簽發(fā) ESO 的基礎(chǔ) 列舉所有用于驗(yàn)證目的所完成的測量 calculations simulations tests 計(jì)算 模擬和試驗(yàn) Preparationfromto 從到為準(zhǔn)備階段 Elaborationandreportingby 到節(jié)點(diǎn)為詳盡描述和報(bào)告階段 42 5 6 DesignVerificationPlan設(shè)計(jì)驗(yàn)證計(jì)劃 43 5 6 DesignVerificationPlan設(shè)計(jì)驗(yàn)證計(jì)劃 44 5 6 DesignVerificationPlan設(shè)計(jì)驗(yàn)證計(jì)劃 45 5 6 DesignVerificationPlan設(shè)計(jì)驗(yàn)證計(jì)劃 46 6 7 Subcontr APQPStatus分承包方APQP狀態(tài) Summarisesthesubcontractors APQPstatus 概述分承包方APQP狀態(tài) APQPprocesshastobecarriedoutwith highimpact suppliers 高風(fēng)險(xiǎn) 供應(yīng)商必須執(zhí)行APQP程序 Thelistof highimpact suppliersistobeagreedwiththecustomer 高風(fēng)險(xiǎn) 供方清單要和顧客意見一致 Timeframefromtowith maintenance upto 時(shí)間節(jié)點(diǎn)從到 維護(hù) 要到 47 6 7 Subcontr APQPStatus分承包方APQP狀態(tài) 48 7 8 Facilities Tools Gages設(shè)備 工裝和量具 Facilities toolsandgagesarethoseadditional new refurbishedandrelocatedresourcesrequiredtomanufacturetheproducttothequalitylevelandinthequantitiesspecifiedbythecustomer 設(shè)備 工裝和量具指的是用于制造符合顧客關(guān)于質(zhì)量等級(jí)和數(shù)量規(guī)定的產(chǎn)品所需的附加的 新的 整修的或重新安置的那些資源 Theyinclude forexample capabilitystudiesattools machineryandmeasuringequipmentsupplierspremises 包括諸如在工具 機(jī)械和測量設(shè)備供應(yīng)商前提上的能力研究 Timeframefromto with maintenance upto 49 8 9 PrototypeBuildCont Plan樣件制造控制計(jì)劃 ThePrototypeBuildControlPlanspecifiesthedimensionstobemeasuredandthefunctionalandmaterialtestsfortheprototypestobedelivered particularlyforCP 樣件制造控制計(jì)劃規(guī)定的是要交付的樣件 特別是CP階段 的尺寸測量和功能與材料試驗(yàn) Timeframefromto with maintenance upto 50 8 9 PrototypeBuildCont Plan樣件制造控制計(jì)劃 51 8 9 PrototypeBuildCont Plan樣件制造控制計(jì)劃 52 9 10 PrototypeBuilds樣件制造 Prototypepartsareallthosepartsdeliveredbefore1PP 樣件是指在1PP前交付的零件 ThepartshavetobedeliveredattheMRDdatesandthecustomer sconsentmustbeobtainedforanyvariationsintheirspecifications 零件必須在MRD前交付 規(guī)范中如有任何變更必須得到顧客的同意 Timeframefromtowith maintenance upto 53 10 11 Drawings Specific 圖樣及規(guī)范 Includesalltechnicaldrawings CADdata materialspecificationsandengineeringspecifications 包括所有的技術(shù)圖樣 CAD數(shù)據(jù) 材料規(guī)范和工程規(guī)范 Alsoincludesthespecificationsforthevalidationteststhatserveasabasisfordeveloping Pre LaunchControlPlans 也包括作為 試生產(chǎn)控制計(jì)劃 制定基準(zhǔn)的確認(rèn)試驗(yàn)規(guī)范 TimeframefromtoFERwith maintenance upto 54 11 12 TeamFeasibilityCom 小組可行性承諾 Across functionalteammustassessthefeasibilityoftheprojectwithregardtodesign productionandcosts 橫向職能小組應(yīng)評(píng)估關(guān)于設(shè)計(jì) 生產(chǎn)和成本項(xiàng)目的可行性 TimeframefromtoFERwith maintenance upto 55 11 12 TeamFeasibilityCommitment小組可行性承諾 56 12 13 Man ProcessFlowCh 制造過程流程圖 Theflowchartforthemanufacturingprocessisagraphicrepresentationofthemanufacturingsequence 制造過程流程圖是一種展示制造順序的圖表 ItistheinputfortheProcessFMEAandtheDCP DynamicControlPlanning Process 是PFMEA和DCP 動(dòng)態(tài)控制策劃 過程的輸入 TimeframefromtoFER 57 12 13 Man ProcessFlowCh 制造過程流程圖 58 12 13 Man ProcessFlowCh 制造過程流程圖 59 13 14 ProcessFMEA Systematicapproachtoensurethatpotentialprocess relatedfailuremodesandtheircauseshavebeenaddressedandresolved 是一種系統(tǒng)方法 用以保證已記錄并解決潛在過程相關(guān)的失效模式及其原因 PartoftheDCPProcess 屬DCP過程的一部分 PreparationfromtoFERandelaborationupto 從到FER是準(zhǔn)備階段 細(xì)節(jié)要到階段 60 13 14 ProcessFMEA 61 13 14 ProcessFMEA 62 13 14 ProcessFMEA 63 13 14 ProcessFMEA 64 14 15 MSA測量系統(tǒng)分析 MeasurementSystemAnalysisstudiesthevariationinmeasuringsystemsinordertoensuretheircapability 測量系統(tǒng)分析研究測量系統(tǒng)的變量 以確保其性能 TheexactprocedureisdescribedinthetechicalguidelineGFT 3002 derivedfromMSAvolumeofthe 7 Pack 在GFT 3002技術(shù)導(dǎo)則中描述了具體流程 源自 7 套中的MSA卷 Timeframefromtowith maintenance upto 65 14 15 MSA測量系統(tǒng)分析 66 15 16 Pre LaunchCont Plan試生產(chǎn)控制計(jì)劃 ThePre LaunchControlPlandescribesthemeasurementsandmaterialandfunctionalteststhatarecarriedoutafterthePrototypeBuildbutbeforethelaunchoffullproduction 試生產(chǎn)控制計(jì)劃是對(duì)樣件制造后批量生產(chǎn)前進(jìn)行的尺寸測量和材料 功能試驗(yàn)的描述 PartoftheDCPProcess 屬DCP過程的一部分 TimeframefromFERtowith maintenance upto 67 15 16 Pre LaunchCont Plan試生產(chǎn)控制計(jì)劃 68 15 16 Pre LaunchCont Plan試生產(chǎn)控制計(jì)劃 69 15 16 Pre LaunchCont Plan試生產(chǎn)控制計(jì)劃 70 15 16 Pre LaunchCont Plan試生產(chǎn)控制計(jì)劃 71 16 17 OperatorProcessInst 操作過程指導(dǎo)書 Theprocessinstructionsconsistoftheprocessdescriptionsandtheoperatinginstructions 過程指導(dǎo)書包括過程描述和操作指導(dǎo) Theoperatinginstructionssetoutindetailwhatoperatorshavetodoinordertomanufacturetheproducttotheappropriatequality 操作指導(dǎo)書詳述操作工的具體操作 以確保制造質(zhì)量合格的產(chǎn)品 PartoftheDCPProcess 屬DCP過程的一部分 Timeframefromto 72 16 17 OperatorProcessInst 操作過程指導(dǎo)書 73 16 17 OperatorProcessInst 操作過程指導(dǎo)書 74 17 18 PackagingSpecific 包裝規(guī)范 Thesupplierofaproductmustensurethatappropriatepackagingforshipmentisdevelopedandthatitmeetsthecustomer srequirements 產(chǎn)品供方應(yīng)確保其制定的包裝規(guī)范適于運(yùn)輸及顧客要求 ThepackagingmustbeapprovedbythecustomerinaccordancewithEU1121 按EU1121標(biāo)準(zhǔn) 包裝需經(jīng)顧客批準(zhǔn) Timeframefromto 75 17 18 PackagingSpecific 包裝規(guī)范 PackagingGuidelineGFT 1750Version 00EDate 2005 03 17 76 18 19 ProductionTrialRun生產(chǎn)試運(yùn)行 ThepurposeoftheProductionTrialRunistovalidatetheproductionprocessusingproductiontooling equipment environment includingproductionpersonnel facilitiesandcycletimes Aday soutput 試生產(chǎn)的目的是對(duì)使用生產(chǎn)工裝 設(shè)備 環(huán)境 包括生產(chǎn)操作者 設(shè)施和循環(huán)時(shí)間 每天的輸出 的生產(chǎn)過程進(jìn)行確認(rèn) TheresultsareusedforthePSW 其結(jié)果用于PSW Timeframefromtowith maintenance upto J1 77 19 20 ProductionControlPlan生產(chǎn)控制計(jì)劃 TheProductionControlPlandescribesthemeasurementsandmaterialandfunctionalteststhatcomeintooperationoncefullproductionislaunched ItisbasedonthePre LaunchControlPlan PartoftheDCPProcess 生產(chǎn)控制計(jì)劃描述的是批量生產(chǎn)一旦開始即進(jìn)行的尺寸測量和材料及功能試驗(yàn) 它以試生產(chǎn)控制計(jì)劃為基礎(chǔ) 是DCP過程的一部分 Timeframefromto1PPwithcontinuous maintenance 78 19 20 ProductionControlPlan生產(chǎn)控制計(jì)劃 79 19 20 ProductionControlPlan生產(chǎn)控制計(jì)劃 80 19 20 ProductionControlPlan生產(chǎn)控制計(jì)劃 81 19 20 ProductionControlPlan生產(chǎn)控制計(jì)劃 82 19 20 ProductionControlPlan生產(chǎn)控制計(jì)劃 83 20 21 Pre ProcessCapability初始過程能力 ThePreliminaryProcessCapabilityStudyisastatisticalassessmentoftheprocess sabilitytoproducetheproductinaccordancewiththespecifications 初始過程能力研究是指對(duì)過程能力的一種統(tǒng)計(jì)評(píng)估 以生產(chǎn)符合規(guī)范的產(chǎn)品 ThepreciseprocedureissetoutinthePPAPvolumeofthe 7 Pack 7 套中的PPAP卷對(duì)此程序有詳盡闡述 Timeframefromto 84 20 21 Pre ProcessCapability初始過程能力 85 21 22 ProductionValidationTest 生產(chǎn)確認(rèn)試驗(yàn) Thesearetheengineeringtestscarriedouttoconfirmthatproductsmanufacturedwithproductiontoolsandprocessesmeetthespecifications 是指確認(rèn)由正式生產(chǎn)工裝和過程制造出來的產(chǎn)品是否滿足規(guī)范要求的工程試驗(yàn) ThevalidationtestsareapreconditionforthePSW 確認(rèn)試驗(yàn)是PSW的前提 Timeframefromto 86 22 23 ProductionPartApproval生產(chǎn)件批準(zhǔn) ThePartSubmissionWarrant PSW isthefinalsign off whichtestifiesthattheProductionPartApprovalProcesshasbeenfollowedandthatthesupplierisabletoprovidetherequiredvolumesofpartsofthespecifiedqualityinordertoguaranteethecustomer ss