2. Hendra Hendrasmara – Industrial Battery Development Dept.
APQP
2
• Memahami proses APQP
• Mengidentifikasi input dan output 5 phase APQP
• Memahami APQP sebagi methodology dalam
“new Product Development”
3. 30 Sep 2014 – by Hendra Hendrasmara
Hendra Hendrasmara – Industrial Battery Development Dept.
3
4. Advanced Product Quality Planning
APQP (Advanced Product Quality Planning)
adalah metode yang terstruktur mendefinisikan dan
menetapkan langkah-langkah yang dibutuhkan
untuk menjamin produk yang akan dihasilkan
memenuhi atau sesuai dengan keinginan
Customer.
Hendra Hendrasmara – Industrial Battery Development Dept.
4
5. Advanced Product Quality Planning
Apa itu Advanced ?
Hendra Hendrasmara – Industrial Battery Development Dept.
5
Control Plan
FMEA
SPC MSA
PPAP
Team Planning 5W 2H + Core Tools Implementation
6. Advanced Product Quality Planning
APQP dijelaskan dalam AIAG (Automotive Industry Action
Group) 810-358-3003.
Organisasi ini didirikan oleh visioner dari tiga produsen
otomotif Amerika Utara terbesar - Chrysler, Ford, dan
General Motors.
Keanggotaan AIAG telah berkembang dengan masuknya
perusahaan-perusahaan Jepang seperti Toyota, Honda dan
Nissan, dan part suppliers serta services providers mereka.
Hendra Hendrasmara – Industrial Battery Development Dept.
6
7. Advanced Product Quality Planning
Hendra Hendrasmara – Industrial Battery Development Dept.
7
Tujuan dari product quality planning adalah untuk
memfasilitasi komunikasi dengan semua orang
yang terlibat untuk memastikan bahwa langkah-langkah
yang diperlukan semua selesai tepat
waktu.
Perencanaan kualitas produk yang efektif
tergantung pada komitmen manajemen puncak
perusahaan untuk upaya yang diperlukan dalam
mencapai kepuasan pelanggan.
8. APQP mengatur tahap-tahap perencanaan product (dan
proses manufaktur), mulai dari tahap konsep sampai
produksi massal.
Beberapa manfaat dari Product Quality Plan adalah:
• Mengatur Sumber Daya dalam upaya memenuhi
kepuasan Customer (persyaratan customer)
• Menghasilkan identifikasi awal terhadap kemungkinan
perubahan
• Menghindari adanya perubahan yang terlambat
• Menyediakan produk yang berkualitas tepat waktu dan
dengan cost yang serendah mungkin.
Hendra Hendrasmara – Industrial Battery Development Dept.
8
Advanced Product Quality Planning
9. APQP dalam ISO/TS 16949
Hendra Hendrasmara – Industrial Battery Development Dept.
9
Phase Description Kalusul ISO/TS 16949
Phase 1 Plan define Program 7.3.1, 7.3.2, 7.3.2.1
Phase 2 Product Design and Development
7.3.2.1, 7.3.2.3, 7.3.3, 7.3.3.1,
7.3.4, 7.3.4.1
Phase 3 Process Design and Development 7.3.2.2, 7.3.3.2, 8.2.3.1
Phase 4 Product and Process Validation 7.3.5, 7.3.6.3
Phase 5
Feedback Assessment and
Corrective Action
8.2.3.1
10. ORGANIZE THE TEAM
Tahap awal yang harus dibvangun oleh pemasok adalah
penetapan penanggung jawab untuk cross functional team.
Product Quality Planning yang efektif membutuhkan
keterlibatan seluruh perwakilan yang mencakup
engineering, manufacturing, material control, procurement,
quality, sales, pelayanan lapangan, serta subkontraktor dan
pelanggan yang terkait.
Hendra Hendrasmara – Industrial Battery Development Dept.
10
Dasar-dasar APQP
11. DEFINE THE SCOPE
Hal ini penting untuk Product Quality Planning Team dalam
tahap awal perencanaan produk untuk mengidentifikasi
kebutuhan, harapan dan persyaratan pelanggan.
Hendra Hendrasmara – Industrial Battery Development Dept.
11
Dasar-dasar APQP
• Pilih pemimpin tim proyek yang bertanggung jawab untuk mengawasi proses
perencanaan.
• Tentukan peran dan tanggung jawab masing-masing area yang diwakili.
• Mengidentifikasi pelanggan - internal dan eksternal.
• Tentukan kebutuhan pelanggan.
• Pilih ahli-ahli, individu, dan / atau subkontraktor yang harus ditambahkan ke tim.
• Memahami harapan pelanggan, yaitu, desain, sistem pengujian.
• Menilai kelayakan desain yang diusulkan, persyaratan kinerja dan proses manufaktur.
• Mengidentifikasi biaya, waktu, dan kendala yang harus diperhatikan.
• Tentukan bantuan yang diperlukan dari pelanggan.
• Mengidentifikasi proses dokumentasi atau metode.
12. Team-to-Team
Product Quality Planning Team harus membangun jalur
komunikasi dengan tim pelanggan dan tim pemasok lainnya.
Ini mungkin termasuk pertemuan rutin dengan tim lain.
Tingkat kontak tim-to-tim tergantung pada sejumlah isu yang
membutuhkan kesepakatan.
Hendra Hendrasmara – Industrial Battery Development Dept.
12
Dasar-dasar APQP
13. Training
Keberhasilan Product Quality Plan tergantung pada program
pelatihan yang efektif untuk mengkomunikasikan semua
persyaratan dan pengembangan keahlian untuk memenuhi
kebutuhan dan harapan pelanggan.
Hendra Hendrasmara – Industrial Battery Development Dept.
13
Dasar-dasar APQP
14. Customer and Organization Involved
Pelanggan utama dapat memulai proses perencanaan
kualitas dengan pemasok. Namun, pemasok memiliki
kewajiban untuk membentuk tim lintas fungsional untuk
mengelola proses Product Quality Planning.
Pemasok harus mengharapkan kinerja yang sama dari
subkontraktor mereka.
Hendra Hendrasmara – Industrial Battery Development Dept.
14
Dasar-dasar APQP
15. Simultaneous Engineering
Simultaneous Engineering adalah proses di mana cross
functional team berusaha untuk mencapai tujuan bersama.
Tujuannya adalah untuk mempercepat pengenalan produk-produk
berkualitas lebih cepat. Product Quality Planning
team menjamin bahwa area lain / tim lain merencanakan
dan melaksanakan kegiatan yang mendukung tujuan
bersama.
Hendra Hendrasmara – Industrial Battery Development Dept.
15
Dasar-dasar APQP
16. Control Plans
Control Plans adalah deskripsi yang tertulis untuk
mengendalikan part dan proses.
Terbagi dalam 3 phase :
• Prototype
Penjelasan mengenai pengukuran dimensi dan material, test performance yang akan
terjadi selama pembuatan Prototype.
• Pre-launch
Penjelasan mengenai pengukuran dimensi dan material, test performance yang akan
terjadi setelah Prototype dan sebelum mass Production.
• Production
Sebuah dokumentasi lengkap dari karakteristik produk / proses, kontrol proses, tes, dan
sistem pengukuran yang akan terjadi selama produksi massal.
Hendra Hendrasmara – Industrial Battery Development Dept.
16
Dasar-dasar APQP
17. Concern Resolution
Permasalahan-permasalahan yang terjadi selama proses
perencanaan harus didokumentasikan dalam matrik
penanggungjawab dan target waktu. Meminta rekomendasi
dari ahli sangat disarankan untuk masalah yang sulit.
Hendra Hendrasmara – Industrial Battery Development Dept.
17
Dasar-dasar APQP
18. Keberhasilan program apapun tergantung pada pemenuhan
kebutuhan dan harapan pelanggan pada waktu yang tepat
dengan biaya yang sesuai.
Hendra Hendrasmara – Industrial Battery Development Dept.
18
Dasar-dasar APQP
Product Quality Timing Plan
Plans Relative to the Timing Chart
Suksesnya sebuah program bergantung kepada kepuasan
pelanggan terutama waktu dan cost.
Tim perencana harus memastikan product qulity planning
bisa disesuaikan dengan harapan pelanggan
19. PRODUCT QUALITY PLANNING TIMING CHART
Pilot Launch
Hendra Hendrasmara – Industrial Battery Development Dept.
19
PLAN AND
DEFINE
PROGRAM
PRODUCT
DESIGN AND
DEVELOPMENT
VERIFICATION
PROCESS
DESIGN AND
DEVELOPMENT
VERIFICATION
PRODUCT
AND PROCESS
VALIDATION
FEEDBACK
ASSESSMENT AND
CORRECTIVE ACTION
Concept
Initiation/Approval
Program
Approval Prototype
PLANNING PLANNING
PRODUCT DESIGN AND DEV.
PROCESS DESIGN AND DEVELOPMENT
PRODUCT AND PROCESS VALIDATION
PRODUCTION
FEEDBACK ASSESSMENT AND CORRECTIVE ACTION
Problem
Time
20. Concept
Initiation / Approval
Program
Approval
PLANNING
Hendra Hendrasmara – Industrial Battery Development Dept.
20
PLAN AND
DEFINE
PROGRAM
1.0 PLAN AND DEFINE PROGRAM
INPUTS OUTPUTS
• 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
Tujuan :
Menentukan kebutuhan pelanggan
Menentukan dan merencanakan
Program quality
• Voice of the Customer
• Market Research
• Historical Warranty and Quality Information
• Team Experience
• Business Plan/Marketing Strategy
• Product/Process Benchmark Data
• Product/Process Assumptions
• Product Reliability Studies
• Customer Inputs
21. Program
Approval Prototype
PRODUCT DESIGN AND DEV.
Hendra Hendrasmara – Industrial Battery Development Dept.
21
PRODUCT
DESIGN AND
DEVELOPMENT
VERIFICATION
2.0 PRODUCT DESIGN AND DEVELOPMENT
INPUTS OUTPUTS
• Design Failure Mode and Effects
Analysis (DFMEA)
• Design for Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build – Control Plan
• Engineering Drawings (Including
Math Data)
• Engineering Specifications
• Material Specifications
• Drawing and Specification Changes
• New Equipment, Tooling and
Facilities Requirements
• Special Product and Process
Characteristics
• Gages/Testing Equipment
Requirements
• Team Feasibility Commitment and
Management Support
• 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
Tujuan :
Develop design features and characteristic
Review engineering requirement
Menilai masalah manufactur yang mungkin terjadi
22. Prototype
Pilot
PROCESS DESIGN AND DEVELOPMENT
Hendra Hendrasmara – Industrial Battery Development Dept.
22
PROCESS
DESIGN AND
DEVELOPMENT
VERIFICATION
3.0 PROCESS DESIGN AND DEVELOPMENT
INPUTS OUTPUTS
• Packaging Standards
• Product/Process Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process Failure Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control Plan
• Process Instructions
• Measurement Systems Analysis
Plan
• Preliminary Process Capability
Study Plan
• Packaging Specifications
• Management Support
• Design Failure Mode
and Effects Analysis
(DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering Drawings
(Including Math Data)
• Engineering Specifications
• Material Specifications
• Drawing and Specification
Changes
• New Equipment, Tooling
and Facilities Requirements
• Special Product and
Process Characteristics
• Gages/Testing Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
Tujuan :
Mengembangkan proses manufactur
yang komprehensif dan efektif
Pastikan kapabilitas proses untuk
memenuhi kebutuhan pelanggan
23. Pilot Launch
Hendra Hendrasmara – Industrial Battery Development Dept.
23
PRODUCT
AND PROCESS
VALIDATION
Prototype
PRODUCT AND PROCESS VALIDATION
4.0 PRODUCT AND PROCESS VALIDATION
Tujuan :
Validasi produk
Validasi control plan
Pastikan produk sesuai kebutuhan pelanggan
Identifikasi masalah
INPUTS OUTPUTS
• Production Trial Run
• Measurement Systems
Evaluation
• Preliminary Process
Capability Study
• Production Part
Approval
• Production Validation
Testing
• Packaging Evaluation
• Production Control
Plan
• Quality Planning Sign-
Off and Management
Support
• Packaging Standards
• Product/Process Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process Failure Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control Plan
• Process Instructions
• Measurement Systems Analysis
Plan
• Preliminary Process Capability
Study Plan
• Packaging Specifications
• Management Support
24. 5.0 FEEDBACK ASSESMENT AND CORRECTIVE ACTION
Pilot Launch
INPUTS OUTPUTS
Hendra Hendrasmara – Industrial Battery Development Dept.
24
PLANNING
PRODUCTION
FEEDBACK ASSESSMENT AND CORRECTIVE ACTION
FEEDBACK
ASSESSMENT AND
CORRECTIVE ACTION
• Production Trial Run
• Measurement Systems
Evaluation
• Preliminary Process
Capability Study
• Production Part
Approval
• Production Validation
Testing
• Packaging Evaluation
• Production Control
Plan
• Quality Planning Sign-
Off and Management
Support
• Reduced Variation
• Customer Satisfaction
• Delivery and Service
Tujuan :
Mengevaluasi semua variasi (data variabel dan data attribut)
Mengevaluasi efektivitas Product quality planning
Penggunaan Control Plan dan Corrective action
25. APQP PROCESS FLOW
Hendra Hendrasmara – Industrial Battery Development Dept.
25
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
26. Hendra Hendrasmara – Industrial Battery Development Dept.
26
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
APQP PROCESS FLOW
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
27. INPUT
Hendra Hendrasmara – Industrial Battery Development Dept.
27
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
APQP PROCESS FLOW
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
28. Hendra Hendrasmara – Industrial Battery Development Dept.
28
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
INPUT
OUTPUT
APQP PROCESS FLOW
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
29. Hendra Hendrasmara – Industrial Battery Development Dept.
29
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Material
Specifications
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
INPUT
INPUT
OUTPUT
OUTPUT
APQP PROCESS FLOW
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
30. Hendra Hendrasmara – Industrial Battery Development Dept.
30
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Material
Specifications
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Packaging
Standards
• Product/Process
Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Support
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
APQP PROCESS FLOW
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
31. APQP PROCESS FLOW
Hendra Hendrasmara – Industrial Battery Development Dept.
31
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Material
Specifications
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Packaging
Standards
• Product/Process
Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Support
• Production Trial
Run
• Measurement
Systems
Evaluation
• Preliminary
Process Capability
Study
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
INPUT
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
32. APQP PROCESS FLOW
Hendra Hendrasmara – Industrial Battery Development Dept.
32
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Material
Specifications
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Packaging
Standards
• Product/Process
Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Support
• Production Trial
Run
• Measurement
Systems
Evaluation
• Preliminary
Process Capability
Study
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
INPUT
INPUT
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
33. Hendra Hendrasmara – Industrial Battery Development Dept.
33
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Material
Specifications
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Packaging
Standards
• Product/Process
Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Supportc
• Production Trial
Run
• Measurement
Systems
Evaluation
• Preliminary
Process Capability
Study
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
INPUT
INPUT
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
FMEA
APQP PROCESS FLOW
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
34. APQP PROCESS FLOW
Hendra Hendrasmara – Industrial Battery Development Dept.
34
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Material
Specifications
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Packaging
Standards
• Product/Process
Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Support
• Production Trial
Run
• Measurement
Systems
Evaluation
• Preliminary
Process Capability
Study
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
INPUT
INPUT
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
FMEA
APQP
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
35. APQP PROCESS FLOW
Hendra Hendrasmara – Industrial Battery Development Dept.
35
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Material
Specifications
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Packaging
Standards
• Product/Process
Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Support
• Production Trial
Run
• Measurement
Systems
Evaluation
• Preliminary
Process Capability
Study
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
INPUT
INPUT
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
FMEA
APQP
SPC
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
36. APQP PROCESS FLOW
Hendra Hendrasmara – Industrial Battery Development Dept.
36
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Material
Specifications
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Packaging
Standards
• Product/Process
Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Support
• Production Trial
Run
• Measurement
Systems
Evaluation
• Preliminary
Process Capability
Study
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
INPUT
INPUT
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
FMEA
APQP
MSA
SPC
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
37. APQP PROCESS FLOW
Hendra Hendrasmara – Industrial Battery Development Dept.
37
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• 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
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Material
Specifications
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Packaging
Standards
• Product/Process
Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Support
• Production Trial
Run
• Measurement
Systems
Evaluation
• Preliminary
Process Capability
Study
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
INPUT
INPUT
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
FMEA
APQP
MSA
SPC
PPAP
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Product and
Process
Validation
Process Design
and
Development
Feedback,
Assessment and
Corrective Action
38. ANALYTICAL TECHNIQUES
Hendra Hendrasmara – Industrial Battery Development Dept.
38
1. Assembly Build Variation Analysis
2. Benchmarking
3. Cause and Effect Diagram
4. Characteristics Matrix
5. Critical Path Method
6. Design of Experioments (DoE)
7. Design for Manufacturability and Assembly
8. Design Verification Plan and Report (DVP&R)
9. Mistake Proofing / ErrorProofing
10. Process Flow Charting
11. Quality Function Deployment (QFD)
