产品质量先期策划(APQP) - AIAG Manual.pdf
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1、ADVANCED PRODUCT QUALITY PLANNING (APQP) AND CONTROL PLAN Reference Manual Issued June 1994, Second Printing February 1995 (new cover only) Copyright 1994, 1995 Chrysler Corporation, Ford Motor Company, and General Motors Corporation FOREWORD This Reference Manual and Reporting Format were developed
2、 by the Advanced Product Quality Planning (APQP) and the Control Plan teams that were sanctioned by Chrysler, Ford, General Motors Supplier Quality Requirements Task Force. The Task Force charter is to standardize the reference manuals, procedures, reporting formats, and technical nomenclature used
3、by Chrysler, Ford, and General Motors in their respective supplier quality systems. Accordingly, this manual and format, approved and endorsed by Chrysler, Ford and General Motors, should be used by suppliers implementing APQP techniques into their design/manufacturing processes. In the past, Chrysl
4、er, Ford, and General Motors each had their own guidelines and formats for ensuring supplier APQP compliance. Differences between these guidelines and formats resulted in additional demands on supplier resources. To improve upon this situation, Chrysler, Ford and General Motors agreed to develop and
5、 distribute this Manual. The work group responsible for this Manual was led by Mike Mazur of Ford Motor Company. This manual provides general guidelines for preparing plans and checklists for ensuring that Advanced Product Quality Planning is in actuality carried out at the supplier. It does not giv
6、e specific instructions on how to arrive at each APQP or Control Plan entry, a task best left to each component review team. While these guidelines are intended to cover all situations normally occurring either in the early planning, design phase, or process analysis, there will be questions that ar
7、ise. These questions should be directed to your customers Supplier Quality activity. If you are uncertain as to how to contact the appropriate activity, contact your buyer in your customers Purchasing office. The Task Force gratefully acknowledges: the leadership and commitment of Vice Presidents Th
8、omas T. Stallkamp at Chrysler, Norman F. Ehlers at Ford, and G. Richard Wagoner, Jr. of General Motors; the assistance of the AIAG in the development, production, and distribution of this manual; and the guidance of Task Force Principals Russell Jacobs (Chrysler), Radley Smith (Ford), and Dan Reid (
9、General Motors). This procedure is copyrighted by Chrysler, Ford and General Motors, all rights reserved, 1994. Additional copies can be ordered from AIAG 810-358-3003. Suppliers of the Automotive Industry have permission to copy any forms and/or checklists. June 1994 i ii ACKNOWLEDGEMENT This docum
10、ent, which includes a reference manual and reporting format, represents the consensus of the members of the Advanced Product Quality Planning and Control Plan teams sanctioned by the Chrysler, Ford, General Motors Supplier Quality Requirements Task Force. Team members, whose names appear below, wish
11、 to acknowledge the many contributions made by individuals from within their respective organizations, individuals without whose support and assistance this document would not have been possible. Advanced Product Quality Planning Team Members ChryslerFordGeneral Motors Robert RoushMichael A. MazurR.
12、 Dan Reid Andy KucharskiRoderick A. MunroDavid L. Kraush Suppliers Paul AnglinITT Automotive Brenda DusekHarvard Industries Charles R. DykstraInverness Casting Donald GeisFederal Mogul Corporation Al WaltonUnited Technologies Control Plan Team Members Frederick N. BazFord Brenda DusekHarvard Industr
13、ies Rebecca FrenchGeneral Motors Gary HoytChrysler Mary Ann RaymondRobert Bosch Corporation Additional Assistance Bea AndersonChrysler ? iii Table of Contents Introduction1 Product Quality Planning Responsibility Matrix2 Fundamentals of Product Quality Planning3 Product Quality Planning Timing Chart
14、5 1.0Plan and Define Program6 1.1Voice of the Customer7 1.1.1Market Research8 1.1.2Historical Warranty and Quality Information8 1.1.3Team Experience8 1.2Business Plan/Marketing Strategy9 1.3Product/Process Benchmark Data9 1.4Product/Process Assumptions9 1.5Product Reliability Studies9 1.6Customer In
15、puts9 1.7Design Goals10 1.8Reliability And Quality Goals10 1.9Preliminary Bill of Material10 1.10Preliminary Process Flow Chart10 1.11Preliminary Listing of Special Product and Process Characteristics10 1.12Product Assurance Plan11 1.13Management Support11 2.0Product Design and Development12 2.1Desi
16、gn Failure Mode and Effects Analysis (DFMEA)14 2.2Design for Manufacturability and Assembly14 2.3Design Verification15 2.4Design Reviews15 2.5Prototype Build Control Plan15 2.6Engineering Drawings (Including Math Data)16 2.7Engineering Specifications16 2.8Material Specifications16 2.9Drawing and Spe
17、cification Changes16 2.10New Equipment, Tooling and Facilities Requirements17 2.11Special Product and Process Characteristics17 2.12Gages/Testing Equipment Requirements17 2.13Team Feasibility Commitment and Management Support17 3.0Process Design and Development18 3.1Packaging Standards20 3.2Product/
18、Process Quality System Review20 3.3Process Flow Chart20 3.4Floor Plan Layout20 TABLE OF CONTENTS Page No. ? Page No. iv 3.5Characteristics Matrix20 3.6Process Failure Mode and Effects Analysis (PFMEA)21 3.7Pre-Launch Control Plan21 3.8Process Instructions21 3.9Measurement Systems Analysis Plan22 3.1
19、0Preliminary Process Capability Study Plan22 3.11Packaging Specifications22 3.12Management Support22 4.0Product and Process Validation24 4.1Production Trial Run25 4.2Measurement Systems Evaluation26 4.3Preliminary Process Capability Study26 4.4Production Part Approval26 4.5Production Validation Test
20、ing26 4.6Packaging Evaluation27 4.7Production Control Plan27 4.8Quality Planning Sign-Off and Management Support27 5.0Feedback, Assessment and Corrective Action28 5.1Reduced Variation29 5.2Customer Satisfaction30 5.3Delivery and Service30 6.0Control Plan Methodology31 6.1Table of Contents32 6.2Overv
21、iew33 6.3Control Plan Column Descriptions37 6.4Process Analysis46 6.5Supplements47 ? v Table of Contents Page No. Appendix A Product Quality Planning Checklists63 A-1Design FMEA Checklist64 A-2Design Information Checklist65 A-3New Equipment, Tooling and Test Equipment Checklist69 A-4Product/Process
22、Quality Checklist71 A-5Floor Plan Checklist75 A-6Process Flow Chart Checklist77 A-7Process FMEA Checklist78 A-8Control Plan Checklist79 Appendix B Analytical Techniques81 Assembly Build Variation Analysis81 Benchmarking81 Cause and Effect Diagram81 Characteristics Matrix81 Critical Path Method82 Des
23、ign of Experiments (DOE)82 Design for Manufacturability and Assembly82 Design Verification Plan and Report (DVP reference Appendix B.) Also, the chart provides the planning team with a consistent format for tracking progress and setting meeting agendas. To facilitate status reporting, each event mus
24、t have a “start” and a “completion” date with the actual point of progress recorded. Effective status reporting supports program monitoring with a focus on identifying items that require special attention. PLANS RELATIVE TO THE TIMING CHART The success of any program depends on meeting customer need
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