17. ประโยชน์ของ APQP
• Teamwork เด่น
• ขันตอนดี
• ไม่มีเซอร์ไพรส์
• ใช ้ลดความเสียง
• หลีกเลียงปัญหา
• ลูกค ้าพอใจ
• ฉับไวตรงเวลา
• พาลดต ้นทุน
Fail to plan is planning to fail !!!
18. Phases For APQP
Plan and define program
Product Design and Development
Process Design and Development
Product and Process Validation
Feedback, Assessment and Corrective Action
18
20. Fundamental Steps for APQP Process
Organize The Team
Define the Scope
Team to Team
Training
Customer & Supplier Involvement
Simultaneous Engineering
Control Plans
Timing Plan & Monitoring
สิงไหนสําคัญทีสุด
21. Core Team
Supporters
• Sale
• Purchase
• Store
• HR
• Safety
• Supplier
• Customer
• Specialist
• Engineering
• Production
• QA - QC
• Maintenance
• Tooling
APQP Team • Cross Functional Team
• Multidisciplinary Approach
30. APQP Timing Chart
Plan & Define
Programme
Product Design &
Development
Verification
Product & Process
Validation
Feedback Assessment
& Corrective Action
•Reliability &
Quality
Goals
•Pre PFC
•Pre SC of
Product &
Process
•Management
Support
•DFMEA
•Drawing
•Eng Spec
•Material
Spec
•Prototype CP
•Management
Support
•PFC + SC
•Floor Plant
•PFMEA
•Ppk Plan
•Pre Launch CP
•MSA Plan
•Packing Std.
•Training Plan
•Management
Support
•Training Record
•Production Trial
•MSA Result
•Ppk Result
•Validation Test
•Production CP
•PPAP
•Sign Off
•Management
Support
•Customer
Satisfaction
•QCD
•Reduction
Variation
•Lesson Learned
•Management
Support
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
31. APQP : Phase 1 Plan and Define Program
• Business Plan
• Benchmarking Data
• Voice of Customer
• Voice of Process
• Team Experience
• Lesson Learned
• Reliability & Quality Goals
• Preliminary Process Flow Chart
• Preliminary SC of Product &
Process
• Quality Assurance Plan
• Management Support
Input Output
57. How to actions ?
Defect S O D RPN Priority
Scratch 2 8 8 128
Burr 6 3 6 108
Crack 8 1 9 72
0
50
100
150
Scratch Burr Crack
RPN
58. How to actions ?
Defect S O D RPN Priority
Scratch 3 7 7 196
Burr 7 3 7 196
Crack 7 7 3 196
0
50
100
150
Scratch Burr Crack
RPN
59. Alternative method : วิธีการทีเป็นทางเลือกอืนๆ
• Method A : S x O x D (เอาค่า SOD คูณกันทังสาม
ตัว)
• Method B : S x O (เอาค่า S คูณกับค่า O แค่สองตัว)
• Method C : S : O : D (เรียงตัวเลขค่า SOD ตามลําดับ)
• Method D : S : D (เรียงตัวเลขเฉพาะค่า S กับค่า D)
FMEA Improvement Guidance
• Reduce S by product design & development (DFMEA)
• Reduce probability of O process control (4M1E)
• Improve D automatic detection system (error proofing)
Defect S O D
RPN + Alternative Method
S x O x D S:O:D S:D
Scratch 3 7 7 147 377 37
Burr 7 3 7 147 737 77
Crack 7 7 3 147 773 73
66. 66
Reference from
Process Flow Chart
Ref. from Drawing
& FMEA
Ref. from
FMEA
Ref. from Drawing &
Experience
or DOE Result
Ref. from FMEA
Ref. from
Drawing
79. MSA Study – Attribute Gages (Effectiveness Index)
80. MSA Study - Attribute Gage (Kappa)
พนักงาน B ผลรวม
NG G
พนักงาน A NG 18
(12.6)
6
(11.4)
24
G 3
(8.4)
13
(7.6)
16
ผลรวม 21 19 40
Kappa A B C
A - 0.545 0.592
B 0.545 - 0.648
C 0.592 0.648 -
ค่าอ้างอิง ผลรวม
NG G
พนักงาน A NG 14
(9.6)
10
(14.4)
24
G 2
(6.4)
14
(9.6)
16
ผลรวม 16 24 40
Kappa Standard
A 0.423
81. Process Capability Study
23.423.122.822.522.221.921.6
LSL USL
LSL 21.5
Target *
USL 23.5
Sample Mean 22.5308
Sample N 125
StDev (Within) 0.184908
StDev (O v erall) 0.188657
Process Data
C p 1.80
C PL 1.86
C PU 1.75
C pk 1.75
Pp 1.77
PPL 1.82
PPU 1.71
Ppk 1.71
C pm *
O v erall C apability
Potential (Within) C apability
PPM < LSL 0.00
PPM > USL 0.00
PPM Total 0.00
O bserv ed Performance
PPM < LSL 0.01
PPM > USL 0.08
PPM Total 0.09
Exp. Within Performance
PPM < LSL 0.02
PPM > USL 0.14
PPM Total 0.16
Exp. O v erall Performance
Within
Overall
Process Capability of Daimeter
OK ?
PHASE 4 : OUTPUTS
87. Benefits of Control Plan
Control Plan
Controlled
Variations (5M)
Waste
Cost of Poor
Satisfaction
for
88. Control Plan Input
Process Flow Chart (PFC)
Process FMEA
Drawing (SC)
Engineering Specification
VOC Claim, Complaint
VOP Experience from Similar Product
Team Experience
92. ส่งมอบ PPAP File เพือขออนุมัติการผลิตจริง
92
PSW: Part Submission Warrant
Sample Parts
Dimension Check / Performance Test
Material Performance Test
Engineering Drawing / Design Record
Engineering Change Documents
Check Fixtures / Aids
Process Flow Chart
FMEA
Control Plan
Process Capability Study (Ppk, Cpk)
Measurement System Analysis
Lab Accreditation & Scope