質(zhì)量先期策劃APQP-教材課件

中國(guó)國(guó)際管理科學(xué)研究院

上海一卿企業(yè)管理顧問有限公司實(shí)事求是中國(guó)國(guó)際管理科學(xué)研究院

上海一卿企業(yè)管理顧問有限公司實(shí)事求ISO/TS16949系列培訓(xùn)教材之一APQP-產(chǎn)品質(zhì)量先期策劃ISO/TS16949系列APQP-產(chǎn)品質(zhì)量先期策劃產(chǎn)品質(zhì)量先期策劃

ADVANCED

PRODUCTQUALITYPLANNING產(chǎn)品質(zhì)量先期策劃

ADVANCEDPRODUCTQUA項(xiàng)目計(jì)劃產(chǎn)品設(shè)計(jì)先期產(chǎn)品質(zhì)量策劃過程設(shè)計(jì)產(chǎn)品確認(rèn)持續(xù)改進(jìn)項(xiàng)目計(jì)劃產(chǎn)品設(shè)計(jì)先期產(chǎn)品質(zhì)量策劃過程設(shè)計(jì)產(chǎn)品確認(rèn)持續(xù)改進(jìn)Introduction,導(dǎo)言產(chǎn)品開發(fā)成本時(shí)間質(zhì)量Introduction,導(dǎo)言產(chǎn)品開發(fā)成本時(shí)間質(zhì)量質(zhì)量先期策劃APQP_教材課件Customer-SpecificRequirements

顧客的特殊要求Yourcustomermighthavespecificrequirements.Beawareofwhattheyarepriortostarting.Inaddition,thecustomermighthavespecificformatsorformsyoumustuse.Ifso,youwillneedtogettheirwrittenapprovaltouseanalternateformat. 顧客可能有特殊要求，開始APQP之前應(yīng)首先了解這些特殊要求。此外，顧客可能有特定的表單或格式。在此情況下，只有經(jīng)過顧客的書面批準(zhǔn)方可使用其他格式。Customer-SpecificRequirementsContents,內(nèi)容Introduction,導(dǎo)言O(shè)rganizationalActivities,組織活動(dòng)TimingChart,五階段具體要求Overview,概要Tools,工具LinkingofTools/Documents,工具/文件之間的關(guān)系Contents,內(nèi)容Introduction,導(dǎo)言什么是質(zhì)量？Introduction,導(dǎo)言什么是質(zhì)量？Introduction,導(dǎo)言Introduction,導(dǎo)言WhatisQuality? 什么是質(zhì)量？qualitymeansthattheproductorservicemeetstheneedsandwantsofthecustomer 質(zhì)量系指產(chǎn)品或服務(wù)能滿足顧客的需求qualitymeansminimizingwastebyreducingvariation 質(zhì)量系指通過減少變差，最大限度地減少浪費(fèi)Introduction,導(dǎo)言WhatisQual質(zhì)量策劃與質(zhì)量改進(jìn)Introduction,導(dǎo)言質(zhì)量策劃與質(zhì)量改進(jìn)Introduction,導(dǎo)言APQPencouragesSimultaneousEngineeringviadevelopmentprocesses(i.e.,useofcross-functionalteams)APQP鼓勵(lì)開發(fā)過程中采用同步技術(shù)

(即運(yùn)用跨部門小組)andconcentrationonDefectPrevention并且強(qiáng)調(diào)預(yù)防缺陷Introduction,導(dǎo)言APQPencouragesSimultaneousEHowdoesAPQPaccomplishthis? APQP如何實(shí)現(xiàn)這一目標(biāo)？itdirectscompanyresourcestosatisfythecustomer

引導(dǎo)公司資源集中用來滿足顧客要求promotesearlyidentificationofproblems 有助于及早發(fā)現(xiàn)問題anticipateschangestoavoidlatechanges 預(yù)先作出更改，以免晚期更改producesthehighestqualityatthelowestcost 以最低的成本，生產(chǎn)最優(yōu)質(zhì)的產(chǎn)品APQPprovidesalogicalsequenceofstepstofollow APQP提供了一套可供遵循的前后連貫的工作步驟Introduction,導(dǎo)言HowdoesAPQPaccomplishthis?SummaryofAPQP,APQP概要Organizethecross-functionalteamanddefinethescope 組織跨部門小組，確定工作范圍Developatimingchart(projectplan) 編制時(shí)間表(項(xiàng)目計(jì)劃)Identifythetoolsandresponsibilitiesneededtocarryouttheactivitiesineachphase,確定完成每一階段任務(wù)所需采用的工具和應(yīng)履行的責(zé)任Revise/adaptasnecessary,必要時(shí)進(jìn)行修改Implementandassesstheplan

執(zhí)行和評(píng)價(jià)該計(jì)劃Introduction,導(dǎo)言SummaryofAPQP,APQP概要IntroduAPQPisaccomplishedthroughtheexecutionofYOURownProductDevelopmentProcedure.通過實(shí)施貴公司的產(chǎn)品開發(fā)程序來實(shí)現(xiàn)APQP。Introduction,導(dǎo)言APQPisaccomplishedthroughtResponsibilities,責(zé)任-----公司負(fù)有的責(zé)任performallapplicablepartsofAPQP 執(zhí)行APQP所有適用的部分thefollowingchartshowswhatisexpected 下圖表明了需要進(jìn)行的工作Introduction,導(dǎo)言Responsibilities,責(zé)任-----公司負(fù)有的

Definethescope,確定范圍 X X XPlananddefine,計(jì)劃和確定項(xiàng)目 XProductdesign/dev,產(chǎn)品設(shè)計(jì)/開發(fā) XFeasibility,可行性 X X XProcessdesign/dev,過程設(shè)計(jì)/開發(fā) X X XProduct/processval.,產(chǎn)品/過程驗(yàn)證 X X XFeedback/CorrAction,反饋/修正措施 X X XControlPlans,控制計(jì)劃 X X XIntroduction,導(dǎo)言Mfg.Only

制造DesignResp.設(shè)計(jì)責(zé)任Services服務(wù)Introduction,導(dǎo)言Mfg.OnlyDeOrganizationalActivities

組織活動(dòng)NecessaryforAny

APQPProgram對(duì)任何實(shí)施APQP的項(xiàng)目都是不可或缺的OrganizationalActivities

組織活動(dòng)WhoInitiatesAPQP? 誰發(fā)起APQP活動(dòng)？youdo! 發(fā)起人就是你youareresponsiblefortheplanningandimplementationoftheactivities 你負(fù)責(zé)策劃和開展APQP活動(dòng)OrganizationalActivities

組織活動(dòng)WhoInitiatesAPQP?OrganizatioOrganizeaCross-FunctionalTeam 組建跨部門小組Mayincludebutisnotlimitedto: 可能包括，但不局限于：-engineering，工程 -manufacturing，制造-quality，質(zhì)量 -purchasing，采購(gòu)-sales，銷售 -customers，顧客-fieldservice，現(xiàn)場(chǎng)服務(wù) -subcontractors，分包商-materialcontrol，材料控制OrganizationalActivities

組織活動(dòng)OrganizeaCross-FunctionalTeAssessthetrainingneedsofteammembersandtakeaction! 評(píng)估小組成員的培訓(xùn)需求，并采取相應(yīng)措施。OrganizationalActivities

組織活動(dòng)AssessthetrainingneedsoftCROSSFUNCTIONALTEAM

Responsibility責(zé)任Approva贊成lSupport支持Inform通知Consult商量OrganizationalActivities

組織活動(dòng)CROSSFUNCTIONALTEAMOrganizaDefinetheScope(youmust...) 確定范圍(必須要...)haveaprojectteamleader 任命一名項(xiàng)目小組組長(zhǎng)havedefinedrolesandresponsibilitiesofteammembers 確定小組成員的作用和責(zé)任identifyandunderstandthecustomersandtheirexpectations 確認(rèn)和了解顧客及其期望assessfeasibilityofprogram 評(píng)估項(xiàng)目可行性O(shè)rganizationalActivities

組織活動(dòng)DefinetheScope(youmust...)DefinetheScope(continued) 確定范圍(續(xù))identifythecosts,timing,andconstraints 確定成本、時(shí)間安排和限制條件determinewhatassistancemightberequiredfromthecustomer 確定需要從顧客那里得到哪些幫助identifydocumentationprocess 確定文件編制過程OrganizationalActivities

組織活動(dòng)DefinetheScope(continued)OrEstablishLinesofCommunication 建立溝通渠道withotherteamsinthecompany 與公司內(nèi)部其它小組之間withcustomerteams 與顧客小組之間mightincluderegularmeetings 可包括定期會(huì)議OrganizationalActivities

組織活動(dòng)EstablishLinesofCommunicatiTimingChart

時(shí)間表EachProgramWillHaveaUniqueTimingChart每個(gè)項(xiàng)目都應(yīng)有單獨(dú)的時(shí)間表TimingChart

時(shí)間表EachProgramWTimingChart,時(shí)間表Aftertheorganizationalactivities,begintodevelopatimingchart 組織工作完成后，應(yīng)制訂時(shí)間表activities，活動(dòng)events，事項(xiàng)responsibilities，責(zé)任timing,includingsequencesofactivities 時(shí)間安排，包括活動(dòng)順序TimingChart,時(shí)間表AftertheorgThe5-Phasemodeltobedescribedinthistrainingcanbeusedasastartingpoint 培訓(xùn)中介紹的5階段模型可作為一個(gè)起點(diǎn)someoftheusefultoolswillbedescribedinthistraining 培訓(xùn)中將介紹一些實(shí)用工具thelistoftoolsisnotmeanttobeall-inclusive 工具清單并非詳細(xì)無遺TimingChart,時(shí)間表The5-Phasemodeltobedescri*Yourcustomermightusedifferentterminology.顧客可能使用其它術(shù)語(yǔ)APQP5-phasemodelAPQP5階段模型PlanningProductDesign&DevelopmentProcessDesign&DevelopmentProduction

FeedbackAssessmentandCorrectiveActionPrototypePilotLaunchProgramApprovalConceptInitiationProduct&ProcessValidationTimingChart,時(shí)間表*YourcustomermightusediffNotethephasesofthetimingchart:注意時(shí)間表上的各個(gè)階段1.Plananddefinetheprogram,計(jì)劃和確定項(xiàng)目2.Design

and

develop

the

product,產(chǎn)品設(shè)計(jì)和開發(fā)3.Design

and

develop

the

process,過程設(shè)計(jì)和開發(fā)4.Validate

the

product

and

process,產(chǎn)品和過程確認(rèn)5.Feedback

and

Corrective

Action,反饋和糾正措施Eachphasecontainsseveralactivitiesandsuggestedhelpfultools 每個(gè)階段都包括若干活動(dòng)內(nèi)容和推薦的實(shí)用工具。TimingChart,時(shí)間表Notethephasesofthetiming

Phase1，第一階段PlanandDefineProgram計(jì)劃和確定項(xiàng)目

TimingChart，時(shí)間表Planning策劃ProductDesign&Development產(chǎn)品設(shè)計(jì)和開發(fā)ProcessDesign&Development過程設(shè)計(jì)和開發(fā)Product&ProcessValidation產(chǎn)品和過程的確認(rèn)Production生產(chǎn)

FeedbackAssessmentandCorrectiveAction反饋評(píng)估和改進(jìn)措施Prototype制作樣件Pilot試生產(chǎn)Launch投入生產(chǎn)ProgramApproval批準(zhǔn)項(xiàng)目ConceptInitiation提出概念Phase1，第一階段PlanandTimingCh顧客需求設(shè)計(jì)目標(biāo)設(shè)計(jì)文件工藝文件作業(yè)指導(dǎo)書開發(fā)：保證轉(zhuǎn)換的充分性和完備性超越顧客期望性能達(dá)到設(shè)計(jì)目標(biāo)產(chǎn)品特性符合規(guī)范達(dá)到工藝文件要求嚴(yán)格遵循作業(yè)指導(dǎo)書顧客需求設(shè)計(jì)目標(biāo)設(shè)計(jì)文件工藝文件作業(yè)指導(dǎo)書開發(fā)：保證轉(zhuǎn)換的充Phase1,PlanandDefineProgram

第一階段,計(jì)劃和確定項(xiàng)目Purpose 目的determinemarketandcustomerneedsandtranslatethemintoaninitialproductandprocessdesign;capturelessonslearned 確定市場(chǎng)和顧客需求，并體現(xiàn)在初步產(chǎn)品和過程設(shè)計(jì)中；汲取以往的經(jīng)驗(yàn)和教訓(xùn)。developaplanforassuringthatdesigngoalsandreliabilitygoals,asdefinedandrequiredbythecustomer,arebuiltintothedesign 制訂計(jì)劃，確保設(shè)計(jì)能夠?qū)崿F(xiàn)顧客確定的和要求達(dá)到的設(shè)計(jì)目標(biāo)與可靠性目標(biāo)gainmanagementcommitment取得管理層的支持Phase1,PlanandDefineProgListofInputs(mayvaryaccordingtoproduct,process,orcustomerneeds):

輸入清單(不同產(chǎn)品、過程或顧客需要，可所有不同)：VoiceoftheCustomer 顧客之聲Customerneeds:contactyourSalesDept.,ProductEngineering,ApplicationEngineering,etc.,whicheverareapplicable顧客需求：與銷售部、產(chǎn)品設(shè)計(jì)部、應(yīng)用工程部等了解顧客需求的部門取得聯(lián)系Marketingneeds:consultyourMarketinggroup市場(chǎng)需求：請(qǐng)市場(chǎng)開發(fā)小組提供咨詢意見BusinessPlan/MarketingStrategy:consultyourbusinessunit,operationaldirector,customermanagement(mightbeconfidential) 業(yè)務(wù)計(jì)劃/市場(chǎng)開發(fā)戰(zhàn)略：請(qǐng)業(yè)務(wù)部門、經(jīng)營(yíng)主管、顧客管理部門提供咨詢意見(可能需保密)Phase1,PlanandDefineProgram

第一階段,計(jì)劃和確定項(xiàng)目ListofInputs(mayvaryaccorListofInputs(mayvaryaccordingtoproduct,process,orcustomerneeds):

輸入清單(不同產(chǎn)品、過程或顧客需要，可所有不同)：BenchmarkingData(internalandexternal):petitiveanalysis,costinformation,reliability,processequipmentbenchmarks基準(zhǔn)評(píng)測(cè)(內(nèi)部和外部)：如競(jìng)爭(zhēng)力分析、成本信息、可靠性、生產(chǎn)設(shè)備基準(zhǔn)評(píng)測(cè)等Product/ProcessAssumptions:consultdesignandmanufacturingstandards 產(chǎn)品/過程設(shè)想：查閱設(shè)計(jì)和制造標(biāo)準(zhǔn)Phase1,PlanandDefineProgram

第一階段,計(jì)劃和確定項(xiàng)目ListofInputs(mayvaryaccorListofInputs(mayvaryaccordingtoproduct,process,orcustomerneeds):

輸入清單(不同產(chǎn)品、過程或顧客需要，可所有不同)：Lessonslearned:systemsarebeingdevelopedtosharelessonslearnedwithdivisionalpersonnel 經(jīng)驗(yàn)教訓(xùn)：建立一套系統(tǒng)，使大家能夠共享經(jīng)驗(yàn)教訓(xùn)ProductReliabilityStudies:asdefinedandrequiredbythecustomer 產(chǎn)品可靠性研究：根據(jù)顧客意見和要求進(jìn)行CustomerInputs:otherinformationtheycanprovide 顧客輸入：他們可提供的其它信息Phase1,PlanandDefineProgram

第一階段,計(jì)劃和確定項(xiàng)目ListofInputs(mayvaryaccorListofOutputs(mayvaryaccordingtoproduct,process,orcustomerneeds):

輸出清單(不同的產(chǎn)品，過程或顧客需求可有所不同)DesignGoals:measurablecharacteristicsandattributeswithtargetvalueswhereapplicable 設(shè)計(jì)目標(biāo)：可測(cè)量的產(chǎn)品特性和屬性，可能的情況下提出量化指標(biāo)ReliabilityGoals:performanceoverthelifeoftheproductundernormalconditions 可靠性目標(biāo)：產(chǎn)品在正常使用條件下壽命周期內(nèi)的性能QualityGoals:measuredasPpk,Cpk,firsttimequality,ppm,DPTV,scrapreduction 質(zhì)量目標(biāo)：可用Ppk、Cpk、初次檢驗(yàn)質(zhì)量、ppm、DPTV和廢品降低率等指標(biāo)確定Phase1,PlanandDefineProgram

第一階段,計(jì)劃和確定項(xiàng)目ListofOutputs(mayvaryaccoListofOutputs(mayvaryaccordingtoproduct,process,orcustomerneeds):

輸出清單(不同的產(chǎn)品，過程或顧客需求可有所不同)PreliminaryBillofMaterials 初步材料清單PreliminaryProcessFlowchart 初步過程流程圖PreliminaryKPCs,KCCs:mustbedocumentedonthecontrolplan,and,maybealsoontheprocessflowdiagram(dependingonthecustomer) 初步KPC、KCC清單：必須列入控制計(jì)劃，有些顧客要求列入過程流程圖Phase1,PlanandDefineProgram

第一階段,計(jì)劃和確定項(xiàng)目ListofOutputs(mayvaryaccoListofOutputs(mayvaryaccordingtoproduct,process,orcustomerneeds):

輸出清單(不同的產(chǎn)品，過程或顧客需求可有所不同)ProductAssurancePlan 產(chǎn)品保證計(jì)劃ManagementSupport:demonstratethatplanningrequirementsaremet,andconcernsarescheduledforresolution 管理支持：表明策劃要求已經(jīng)達(dá)到，而且問題的解決已有計(jì)劃Phase1,PlanandDefineProgram

第一階段,計(jì)劃和確定項(xiàng)目ListofOutputs(mayvaryaccoaplantoassurethatthedesigngoalsaremet 確保設(shè)計(jì)目標(biāo)得以實(shí)現(xiàn)mightinclude 可以包括：Reliability,durabilityapportionment

可靠性、耐用性指標(biāo)分解Function/qualitydeployment

功能/質(zhì)量展開Riskandroadblockassessment

風(fēng)險(xiǎn)和困難評(píng)估Failuremodesanalysisandactionplan

失效模式分析和措施實(shí)施計(jì)劃Phase1,PlanandDefineProgram

第一階段,計(jì)劃和確定項(xiàng)目ProductAssurancePlan，產(chǎn)品保證計(jì)劃工具aplantoassurethatthedesi

Phase2，第二階段TimingChart，時(shí)間表Planning策劃ProductDesign&Development產(chǎn)品設(shè)計(jì)和開發(fā)ProcessDesign&Development過程設(shè)計(jì)和開發(fā)Product&ProcessValidation產(chǎn)品和過程的確認(rèn)Production生產(chǎn)

FeedbackAssessmentandCorrectiveAction反饋評(píng)估和改進(jìn)措施Prototype制作樣件Pilot試生產(chǎn)Launch投入生產(chǎn)ProgramApproval批準(zhǔn)項(xiàng)目ConceptInitiation提出概念ProductDesignandDevelopment產(chǎn)品設(shè)計(jì)和開發(fā)Phase2，第二階段TimingChart，時(shí)間表

Purpose 目的developthedesignintonearfinalform 使設(shè)計(jì)接近定型verifythedesigntomakesureitmeetsallrequirements 對(duì)設(shè)計(jì)進(jìn)行驗(yàn)證，以保證達(dá)到全部要求assessproductionandqualityassuranceneeds 對(duì)生產(chǎn)和質(zhì)量保證需求進(jìn)行評(píng)估Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)PurposePhase2,ProductDesiListofOutputsbyDesignGroup(mayvaryaccordingtoproduct,process,orcustomerneeds)由設(shè)計(jì)部門完成的結(jié)果(具體內(nèi)容可根據(jù)產(chǎn)品類型、過程和顧客需求確定)DesignFailureModeandEffectsAnalysis 設(shè)計(jì)失效模式及后果分析DesignforManufacturability 設(shè)計(jì)的制造工藝性DesignVerificationandPrototypeBuild 設(shè)計(jì)驗(yàn)證和樣件制造Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)ListofOutputsbyDesignGrouListofOutputsbyDesignGroup(mayvaryaccordingtoproduct,process,orcustomerneeds)由設(shè)計(jì)部門完成的結(jié)果(具體內(nèi)容可根據(jù)產(chǎn)品類型、過程和顧客需求確定)DesignVerificationandPrototypeBuild 設(shè)計(jì)驗(yàn)證和樣件制造DesignReviews 設(shè)計(jì)審查EngineeringDrawingsandChanges 工程圖紙及其更改EngineeringandMaterialSpecifications 技術(shù)要求和材料規(guī)格Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)ListofOutputsbyDesignGrouListofOutputsbyQualityPlanningTeam 由質(zhì)量策劃小組完成的結(jié)果NewEquipment,Tooling,FacilitiesReqmts 對(duì)新設(shè)備、新工具、新設(shè)施的要求KPCs,KCCs KPC、KCC清單PrototypeBuildControlPlan 樣件制造控制計(jì)劃Gages/TestingEquipmentReqmts 對(duì)檢測(cè)儀表/試驗(yàn)設(shè)備的要求FeasibilityReview/Commitment 可行性審查/承諾Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)ListofOutputsbyQualityPlaDesignFMEA

設(shè)計(jì)FMEAlistingoffailuremodesinherenttotheproductdesign 列出產(chǎn)品設(shè)計(jì)中固有的失效模式listoftheeffectsandcausesoffailure 列出失效的后果和產(chǎn)生原因correctiveactionprioritizedby 按如下各項(xiàng)排序改進(jìn)措施severityofeffect，后果的嚴(yán)重程度likelihoodofoccurrence，發(fā)生的可能性abilitytodetectfailure，探測(cè)失效的能力Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)工具DesignFMEAPhase2,ProductDDesignVerification

設(shè)計(jì)驗(yàn)證verificationmeanscheckingadesigntomakesureitmeetsalltherequirements 設(shè)計(jì)驗(yàn)證是指對(duì)設(shè)計(jì)進(jìn)行檢查，以確保其符合所有要求differsfromvalidation

與確認(rèn)的區(qū)別：validationusesproductionpartsinarealisticenvironment(QS9000requiresvalidationintheactualenvironment) 確認(rèn)是指將生產(chǎn)部件在實(shí)際環(huán)境中使用(QS9000要求在實(shí)際環(huán)境中進(jìn)行確認(rèn))verificationisoftenjustapaper/computercheck

驗(yàn)證通常僅指案頭/計(jì)算機(jī)檢查Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)工具DesignVerificationPhase2,PDesignReviews

設(shè)計(jì)評(píng)審areviewofthedesignbyacross-functionalteamtocheck(amongothers) 由跨部門小組對(duì)下列內(nèi)容進(jìn)行評(píng)審designrequirements，設(shè)計(jì)要求failuremodes，失效模式predictedreliability，可靠性預(yù)測(cè)designstandardsusedandDFMefforts采用的設(shè)計(jì)標(biāo)準(zhǔn)和DFM措施testplansandtestresults，試驗(yàn)計(jì)劃和結(jié)果verificationstudies，驗(yàn)證研究Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)工具DesignReviewsPhase2,ProducKPCs(keyproductcharacteristics)，KPC(關(guān)鍵產(chǎn)品特性)aproductcharacteristicforwhichreasonablyanticipatedvariationislikelytoaffectcustomersatisfaction,safety,orcompliancewithregulations 是一種產(chǎn)品特性，當(dāng)其在合理范圍內(nèi)出現(xiàn)變差時(shí)，會(huì)引起顧客不滿，影響安全性或違反某些法規(guī)canbeidentifiedbythecustomerorthecross-functionalteam 可由顧客或跨部門小組確定KCCs(keycontrolcharacteristics)，KCC(主要控制特性)aprocesscharacteristicthatmustbecontrolledinordertoreducethevariationinaKPC 為減少KPC的變差，必須加以控制的過程特性Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)工具KPCs(keyproductcharacteristPrototypeControlPlan，樣件控制計(jì)劃includesdimensionalmeasurementsandfunctionaltestsonprototypebuilds包括尺寸測(cè)量和樣件功能試驗(yàn)toverifytheprototypeproduct對(duì)樣件產(chǎn)品進(jìn)行驗(yàn)證toverifytheprocessifproduction-intenttoolingisused如果使用將來生產(chǎn)用的工裝，則對(duì)過程進(jìn)行驗(yàn)證agoodwaytofindandfixrealproblemspriortoproductiontoolingbeingmade

是一種在生產(chǎn)工具制造之前及時(shí)發(fā)現(xiàn)和解決實(shí)際問題的好辦法Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)工具PrototypeControlPlan，樣件控制計(jì)劃FeasibilityReview/Commitment--makesureManufacturingispartofthisreview

可行性評(píng)審/承諾--確保產(chǎn)品制造也在評(píng)審之列canqualitybemet? 能達(dá)到質(zhì)量要求嗎？istheresufficientcapacity? 有足夠的過程能力嗎？canitbedoneonschedule? 能按預(yù)定計(jì)劃完成嗎？arecostswithinreason? 成本是否適中？Phase2,ProductDesign&Development

第二階段,產(chǎn)品設(shè)計(jì)和開發(fā)工具Feasibilitymustbeassessedevenifthecustomerownsthedesign 即使是顧客提供的設(shè)計(jì)，也必須對(duì)可行性進(jìn)行評(píng)估FeasibilityReview/Commitment-

Phase3，第三階段TimingChart，時(shí)間表Planning策劃ProductDesign&Development產(chǎn)品設(shè)計(jì)和開發(fā)ProcessDesign&Development過程設(shè)計(jì)和開發(fā)Product&ProcessValidation產(chǎn)品和過程的確認(rèn)Production生產(chǎn)

FeedbackAssessmentandCorrectiveAction反饋評(píng)估和改進(jìn)措施Prototype制作樣件Pilot試生產(chǎn)Launch投入生產(chǎn)ProgramApproval批準(zhǔn)項(xiàng)目ConceptInitiation提出概念ProcessDesignandDevelopment過程設(shè)計(jì)和開發(fā)Phase3，第三階段TimingChart，時(shí)間表Purpose 目的developaneffectivemanufacturingsystemandrelatedcontrolplans 建立有效的加工制造系統(tǒng)，并制訂有關(guān)的控制計(jì)劃Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)PurposePhase3,ProcessDesigListofOutputs(mayvaryaccordingtoproduct,process,orcustomerneeds)

輸出列表(根據(jù)產(chǎn)品類型、過程和顧客需求而定)PackagingStandards, 包裝標(biāo)準(zhǔn)ProcessFlowchart,過程流程圖FloorPlanLayout,場(chǎng)地平面布置圖CharacteristicsMatrix, 特性矩陣ProcessFailureModeandEffectsAnalysis過程失效模式及后果分析Pre-LaunchControlPlan,試生產(chǎn)控制計(jì)劃Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)ListofOutputs(mayvaryaccoListofOutputs(mayvaryaccordingtoproduct,process,orcustomerneeds)

輸出列表(根據(jù)產(chǎn)品類型、過程和顧客需求而定)ProcessInstructions，作業(yè)指導(dǎo)書MeasurementSystemsAnalysisPlan，測(cè)量系統(tǒng)分析計(jì)劃PreliminaryProcessCapabilityPlan，初始過程能力研究計(jì)劃PackagingSpecifications，包裝規(guī)范Product/ProcessQualitySystemReview，產(chǎn)品/過程質(zhì)量體系評(píng)審ManagementSupport， 管理支持Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)ListofOutputs(mayvaryaccoProcessFlowchart，過程流程圖listsallstepsinmakingtheproduct列出產(chǎn)品制造的所有步驟fromreceivingtoshipping從來料驗(yàn)收到成品裝運(yùn)includesdifferenttypesofactivities包括不同的作業(yè)類型fabricate/assemble，制造/裝配move，搬運(yùn)store，存放

inspect，檢驗(yàn)Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)工具ProcessFlowchart，過程流程圖Phase過程流程圖建議的最終格式moldpart注塑零部件fab加工move搬運(yùn)store存放insp檢驗(yàn)step步驟oper.descr.作業(yè)說明item#編號(hào)KPCitem#編號(hào)KCCinspectpartforflash檢驗(yàn)零件有無飛邊storepartincontainer將零部件放入周轉(zhuǎn)箱內(nèi)carrypartstoassyarea將零部件送往裝配區(qū)1noflash無飛邊pressure壓力11234Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)工具過程流程圖建議的最終格式moldpartfabmovest過程流程圖建議的最終格式moldpart注塑零部件fab加工move搬運(yùn)store存放insp檢驗(yàn)step步驟oper.descr.作業(yè)說明item#編號(hào)KPCitem#編號(hào)KCCinspectpartforflash檢驗(yàn)零件有無飛邊storepartincontainer將零部件放入周轉(zhuǎn)箱內(nèi)carrypartstoassyarea將零部件送往裝配區(qū)1noflash無飛邊pressure壓力11234過程流程圖建議的最終格式moldpartfabmovest場(chǎng)地平面布置圖確定檢驗(yàn)和試驗(yàn)點(diǎn)的可接受性控制圖的位置目視輔具缺陷材料的儲(chǔ)存區(qū)關(guān)鍵材料的流程和控制計(jì)劃關(guān)鍵術(shù)語(yǔ)和基本概念場(chǎng)地平面布置圖關(guān)鍵術(shù)語(yǔ)和基本概念CharacteristicsMatrix(Recommendedbutnotrequired)

特性矩陣(推薦但不要求)allowsustoprioritizewhichcharacteristicsareimportanttocontrol 使我們能夠優(yōu)先控制那些重要的特性ProcessSteps加工步驟Characteristics特性lookforrelationships尋找相互關(guān)系Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)工具CharacteristicsMatrix(RecommProcessFMEA，過程FMEAlistingoffailuremodescausedbytheprocessnotmeetingrequirements 列出因過程不符合要求所產(chǎn)生的失效模式listoftheeffectsandcausesoffailure 列出失效的后果和產(chǎn)生原因correctiveactionprioritizedby 按下列各項(xiàng)改進(jìn)措施的優(yōu)先順序severityofeffect，后果的嚴(yán)重程度likelihoodofoccurrence，發(fā)生的可能性abilitytodetectfailure，檢測(cè)失效的能力Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)工具ProcessFMEA，過程FMEAPhase3,PPre-LaunchControlPlan

試生產(chǎn)控制計(jì)劃includesdimensionalmeasurements,attributes,andfunctionaltestsonearlyproductionparts 包括對(duì)早期生產(chǎn)的部件進(jìn)行尺寸檢驗(yàn)、特性和功能 試驗(yàn)tochecktheprocesspriortofullproduction 在正式生產(chǎn)之前檢查過程alsoincludesadditionalcontrolstobeinplaceuntiltheprocessisvalidated 也包括在過程確認(rèn)之前所采取的附加控制措施Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)工具Pre-LaunchControlPlanPhaseMeasurementSystemsAnalysisPlan

測(cè)量系統(tǒng)分析計(jì)劃toassurethatgagesandmeasurementproceduresarecapableofdetectingchangesinprocessoutput 確保測(cè)量系統(tǒng)具有探測(cè)過程輸出變化的能力canalsobeusedtocheckinspectiongagesandproceduresforsortingconformingvs.nonconformingproduct 用于判別產(chǎn)品合格，不合格的測(cè)量系統(tǒng)也可進(jìn)行MSAPhase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)工具M(jìn)easurementSystemsAnalysisPPreliminaryProcessCapabilityStudyPlan

初始過程能力研究計(jì)劃anassessmentofthetheabilityoftheprocesstomeetspecifications 評(píng)估過程能否達(dá)到技術(shù)要求measurestheprocessvariation 檢測(cè)過程變差basedonasignificantproductionrunonproductionequipment 以在正式生產(chǎn)裝備上進(jìn)行的有效的生產(chǎn)為基礎(chǔ)Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)工具PreliminaryProcessCapabilityPackagingSpecifications

包裝規(guī)范individualpackagingmustassurethattheproductcharacteristics,attributes,etc.donotchangeduringpacking,transit,andunpacking 每個(gè)包裝均必須保證產(chǎn)品特性、屬性等在包裝、運(yùn) 輸和開包過程中不會(huì)改變Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)工具PackagingSpecificationsPhaseProduct/ProcessQualitySystemsReview

產(chǎn)品/過程質(zhì)量體系評(píng)審areviewoftheproceduresandothercomponentsofthequalitysystemtomakesurethecustomerdoesnotreceivenonconformingparts 對(duì)質(zhì)量體系的過程控制和其它要素進(jìn)行檢查、以免向客 戶提供不符合要求的產(chǎn)品basedonsimilarprocesses,teamexperience,andcustomerinput 建立在類似的過程、小組經(jīng)驗(yàn)和顧客輸入的基礎(chǔ)上Phase3,ProcessDesign&Development

第三階段,過程設(shè)計(jì)和開發(fā)工具Product/ProcessQualitySystem

Phase4，第四階段TimingChart，時(shí)間表Planning策劃ProductDesign&Development產(chǎn)品設(shè)計(jì)和開發(fā)ProcessDesign&Development過程設(shè)計(jì)和開發(fā)Product&ProcessValidation產(chǎn)品和過程的確認(rèn)Production生產(chǎn)

FeedbackAssessmentandCorrectiveAction反饋評(píng)估和改進(jìn)措施Prototype制作樣件Pilot試生產(chǎn)Launch投入生產(chǎn)ProgramApproval批準(zhǔn)項(xiàng)目ConceptInitiation提出概念ProductandProcessValidation產(chǎn)品和過程確認(rèn)Phase4，第四階段TimingChart，時(shí)間表Purpose 目的productiontrialrun 生產(chǎn)試運(yùn)行validatethemanufacturingprocess 對(duì)制造過程進(jìn)行確認(rèn)developacontrolplanforproduction 制訂生產(chǎn)控制計(jì)劃Phase4,Product&ProcessValidation

第四階段,產(chǎn)品和過程確認(rèn)PurposePhase4,Product&ProListofOutputs

輸出清單ProductionTrialRun(InternalPilotRun)，生產(chǎn)試運(yùn)行(內(nèi)部試生產(chǎn))MeasurementSystemsEvaluation，測(cè)量系統(tǒng)評(píng)價(jià)PreliminaryProcessCapabilityStudy，初始過程能力研究ProductionValidationTesting，生產(chǎn)確認(rèn)試驗(yàn)PackagingEvaluation， 包裝評(píng)價(jià)ProductionControlPlan，生產(chǎn)控制計(jì)劃ProductionPartApproval，生產(chǎn)件批準(zhǔn)Phase4,Product&ProcessValidation

第四階段,產(chǎn)品和過程確認(rèn)ListofOutputsPhase4,ProduProductionTrialRun，生產(chǎn)試運(yùn)行mustcompletetotalmanufacturingsystemrelease 整個(gè)制造系統(tǒng)都必須全部開通performedunderproductionconditions,incl.cycletime,environment,operators 在生產(chǎn)條件下運(yùn)行，包括周期時(shí)間、環(huán)境和操作人員等makepartsforpreliminaryprocesscapabilityandproductionvalidationtest 制造的零部件用于初始過程能力研究和生產(chǎn)確認(rèn)試驗(yàn)assurecontainmentisinplaceifpartsaretobeshipped 如果零部件要裝運(yùn)，應(yīng)確保有相應(yīng)的限控手段Phase4,Product&ProcessValidation

第四階段,產(chǎn)品和過程確認(rèn)工具ProductionTrialRun，生產(chǎn)試運(yùn)行PhaProductionValidationTest

生產(chǎn)確認(rèn)試驗(yàn)referstoengineeringteststhatvalidatetheproductsmadefromproductiontoolsandprocessesmeetengineeringstandards 系指確認(rèn)由生產(chǎn)工具和過程制造的產(chǎn)品是否符合設(shè)計(jì)標(biāo)準(zhǔn)的工程試驗(yàn)Phase4,Product&ProcessValidation

第四階段,產(chǎn)品和過程確認(rèn)工具ProductionValidationTestPhaProductionControlPlan

生產(chǎn)控制計(jì)劃systemsforcontrollingpartsandprocesses 控制零部件和過程的系統(tǒng)includesreceivinginspection,manufacturingprocesses,assembly,packaging,etc.asapplicable 包括原材料驗(yàn)收、制造過程、裝配和包裝等項(xiàng)內(nèi)容usedfortheproductionrun 用于生產(chǎn)運(yùn)行DOESNOTreplacewrittenprocessinstructionsorprocedures

不能取代書面的制造過程指令或程序Phase4,Product&ProcessValidation

第四階段,產(chǎn)品和過程確認(rèn)工具ProductionControlPlanPhaseProductionPartApproval(PPAP)

生產(chǎn)件批準(zhǔn)(PPAP)warrant，保證書drawings,checkingaids，零部件圖紙、檢驗(yàn)輔具sampleparts,mastersample，樣件、標(biāo)準(zhǔn)樣件listofKPCs,KCCs，KPC、KCC清單dimensionalandappearanceevaluation 尺寸和外觀評(píng)價(jià)materialtests，材料試驗(yàn)FMEAs，失效模式及后果分析controlplan,gages,processflowchart 控制計(jì)劃、檢測(cè)儀表、過程圖processcapabilityresults，過程能力研究結(jié)果Phase4,Product&ProcessValidation

第四階段,產(chǎn)品和過程確認(rèn)工具ProductionPartApproval(PPAP

Phase5，第五階段TimingChart，時(shí)間表Planning策劃ProductDesign&Development產(chǎn)品設(shè)計(jì)和開發(fā)ProcessDesign&Development過程設(shè)計(jì)和開發(fā)Product&ProcessValidation產(chǎn)品和過程的確認(rèn)Production生產(chǎn)

FeedbackAssessmentandCorrectiveAction反饋評(píng)估和改進(jìn)措施Prototype制作樣件Pilot試生產(chǎn)Launch投入生產(chǎn)ProgramApproval批準(zhǔn)項(xiàng)目ConceptInitiation提出概念Feedback,Assessment,CorrectiveAction反饋，評(píng)定，糾正措施Phase5，第五階段TimingChart，時(shí)間表

Purpose

目的monitortheprocessandcustomerfeedback 監(jiān)測(cè)過程，聽取顧客反饋意見improvetheprocess 改進(jìn)過程installmethodstoworkwiththecustomertocorrectandsolveproblems 與顧客合作，共同建立糾正和解決問題的方法Phase5,Feedback,Assess.,CorrectiveAction

第五階段,反饋，評(píng)定，糾正措施PurposePhase5,Feedback,AsOutputs

輸出ReducedVariation 減少變差CustomerSatisfaction 顧客滿意DeliveryandService 交付和服務(wù)Phase5,Feedback,Assess.,CorrectiveAction

第五階段,反饋，評(píng)定，糾正措施OutputsPhase5,Feedback,AssReduceVariation 減少偏差SPC SPC(統(tǒng)計(jì)過程控制)StatisticalEngineering/ProblemSolving 統(tǒng)計(jì)工程/問題的解決RobustDesign 穩(wěn)健性設(shè)計(jì)Errorproofing 差錯(cuò)預(yù)防DesignofExperiments 實(shí)驗(yàn)設(shè)計(jì)Phase5,Feedback,Assess.,CorrectiveAction

第五階段,反饋，評(píng)定，糾正措施工具ReduceVariationPhase5,FeedCustomerSatisfaction 顧客滿意theproductorservicemustworkinthecustomer’senvironment 產(chǎn)品或服務(wù)必須適合顧客的實(shí)際使用環(huán)境suppliermustworkwiththecustomertocorrectproblemsandcorrectdeficiencies 供貨商必須與顧客合作，共同解決所出現(xiàn)的問題，并彌補(bǔ)產(chǎn)品缺陷Phase5,Feedback,Assess.,CorrectiveAction

第五階段,反饋，評(píng)定，糾正措施工具CustomerSatisfactionPhase5,DeliveryandService(ifpartofcontract) 發(fā)貨和服務(wù)(如果合同中有規(guī)定的話)thesupplierandcustomermustdevelopasystemforservicinganddeliveringreplacementparts 供貨商和顧客必須建立一個(gè)提供服務(wù)和發(fā)運(yùn)更換件的系統(tǒng)thisisagoodopportunitytorecordandactoncommentsandcomplaintsfromtheultimatecustomer 是記錄最終顧客的意見和投訴，并據(jù)此采取行動(dòng)的極好機(jī)會(huì)Phase5,Feedback,Assess.,CorrectiveAction

第五階段,反饋，評(píng)定，糾正措施工具DeliveryandService(ifpart質(zhì)量先期策劃APQP_教材課件質(zhì)量先期策劃APQP_教材課件質(zhì)量先期策劃APQP_教材課件中國(guó)國(guó)際管理科學(xué)研究院

上海一卿企業(yè)管理顧問有限公司實(shí)事求是中國(guó)國(guó)際管理科學(xué)研究院

上海一卿企業(yè)管理顧問有限公司實(shí)事求ISO/TS16949系列培訓(xùn)教材之一APQP-產(chǎn)品質(zhì)量先期策劃ISO/TS16949系列APQP-產(chǎn)品質(zhì)量先期策劃產(chǎn)品質(zhì)量先期策劃

ADVANCED

PRODUCTQUALITYPLANNING產(chǎn)品質(zhì)量先期策劃

ADVANCEDPRODUCTQUA項(xiàng)目計(jì)劃產(chǎn)品設(shè)計(jì)先期產(chǎn)品質(zhì)量策劃過程設(shè)計(jì)產(chǎn)品確認(rèn)持續(xù)改進(jìn)項(xiàng)目計(jì)劃產(chǎn)品設(shè)計(jì)先期產(chǎn)品質(zhì)量策劃過程設(shè)計(jì)產(chǎn)品確認(rèn)持續(xù)改進(jìn)Introduction,導(dǎo)言產(chǎn)品開發(fā)成本時(shí)間質(zhì)量Introduction,導(dǎo)言產(chǎn)品開發(fā)成本時(shí)間質(zhì)量質(zhì)量先期策劃APQP_教材課件Customer-SpecificRequirements

顧客的特殊要求Yourcustomermighthavespecificrequirements.Beawareofwhattheyarepriortostarting.Inaddition,thecustomermighthavespecificformatsorformsyoumustuse.Ifso,youwillneedtogettheirwrittenapprovaltouseanalternateformat. 顧客可能有特殊要求，開始APQP之前應(yīng)首先了解這些特殊要求。此外，顧客可能有特定的表單或格式。在此情況下，只有經(jīng)過顧客的書面批準(zhǔn)方可使用其他格式。Customer-SpecificRequirementsContents,內(nèi)容Introduction,導(dǎo)言O(shè)rganizationalActivities,組織活動(dòng)TimingChart,五階段具體要求Overview,概要Tools,工具LinkingofTools/Documents,工具/文件之間的關(guān)系Contents,內(nèi)容Introduction,導(dǎo)言什么是質(zhì)量？Introduction,導(dǎo)言什么是質(zhì)量？Introduction,導(dǎo)言Introduction,導(dǎo)言WhatisQuality? 什么是質(zhì)量？qualitymeansthattheproductorservicemeetstheneedsandwantsofthecustomer 質(zhì)量系指產(chǎn)品或服務(wù)能滿足顧客的需求qualitymeansminimizingwastebyreducingvariation 質(zhì)量系指通過減少變差，最大限度地減少浪費(fèi)Introduction,導(dǎo)言WhatisQual質(zhì)量策劃與質(zhì)量改進(jìn)Introduction,導(dǎo)言質(zhì)量策劃與質(zhì)量改進(jìn)Introduction,導(dǎo)言APQPencouragesSimultaneousEngineeringviadevelopmentprocesses(i.e.,useofcross-functionalteams)APQP鼓勵(lì)開發(fā)過程中采用同步技術(shù)

(即運(yùn)用跨部門小組)andconcentrationonDefectPrevention并且強(qiáng)調(diào)預(yù)防缺陷Introduction,導(dǎo)言APQPencouragesSimultaneousEHowdoesAPQPaccomplishthis? APQP如何實(shí)現(xiàn)這一目標(biāo)？itdirectscompanyresourcestosatisfythecustomer

引導(dǎo)公司資源集中用來滿足顧客要求promotesearlyidentificationofproblems 有助于及早發(fā)現(xiàn)問題anticipateschangestoavoidlatechanges 預(yù)先作出更改，以免晚期更改producesthehighestqualityatthelowestcost 以最低的成本，生產(chǎn)最優(yōu)質(zhì)的產(chǎn)品APQPprovidesalogicalsequenceofstepstofollow APQP提供了一套可供遵循的前后連貫的工作步驟Introduction,導(dǎo)言HowdoesAPQPaccomplishthis?SummaryofAPQP,APQP概要Organizethecross-functionalteamanddefinethescope 組織跨部門小組，確定工作范圍Developatimingchart(projectplan) 編制時(shí)間表(項(xiàng)目計(jì)劃)Identifythetoolsandresponsibilitiesneededtocarryouttheactivitiesineachphase,確定完成每一階段任務(wù)所需采用的工具和應(yīng)履行的責(zé)任Revise/adaptasnecessary,必要時(shí)進(jìn)行修改Implementandassesstheplan

執(zhí)行和評(píng)價(jià)該計(jì)劃Introduction,導(dǎo)言SummaryofAPQP,APQP概要IntroduAPQPisaccomplishedthroughtheexecutionofYOURownProductDevelopmentProcedure.通過實(shí)施貴公司的產(chǎn)品開發(fā)程序來實(shí)現(xiàn)APQP。Introduction,導(dǎo)言