1、中国国际管理科学研究院 上海一卿企业管理顾问有限公司,ISO/TS16949系列 培训教材之一,APQP-产品质量先期策划,产品质量先期策划 ADVANCED PRODUCT QUALITY PLANNING,Introduction, 导 言,产品开发,成本,时间,质量,Customer-Specific Requirements 顾客的特殊要求,Your customer might have specific requirements. Be aware of what they are prior to starting. In addition, the customer might
2、 have specific formats or forms you must use. If so, you will need to get their written approval to use an alternate format. 顾客可能有特殊要求，开始APQP之前应首先了解这些特殊要求。此外，顾客可能有特定的表单或格式。在此情况下，只有经过顾客的书面批准方可使用其他格式。,Contents,内容,Introduction, 导言 Organizational Activities, 组织活动 Timing Chart, 五阶段具体要求 Overview, 概要 Tools
3、, 工具 Linking of Tools/Documents, 工具/文件之间的关系,什么是质量？,Introduction, 导 言,Introduction, 导 言,What is Quality?什么是质量？ quality means that the product or service meets the needs and wants of the customer质量系指产品或服务能满足顾客的需求 quality means minimizing waste by reducing variation质量系指通过减少变差，最大限度地减少浪费,质量策划 与 质量改进,Intr
4、oduction, 导 言,APQP encourages Simultaneous Engineering via development processes(i.e., use of cross-functional teams) APQP鼓励开发过程中采用 同步技术 (即运用跨部门小组)and concentration on Defect Prevention 并且强调 预防缺陷,Introduction, 导 言,How does APQP accomplish this?APQP如何实现这一目标？ it directs company resources to satisfy th
5、e customer引导公司资源集中用来满足顾客要求 promotes early identification of problems有助于及早发现问题 anticipates changes to avoid late changes预先作出更改，以免晚期更改 produces the highest quality at the lowest cost以最低的成本，生产最优质的产品 APQP provides a logical sequence of steps to followAPQP提供了一套可供遵循的前后连贯的工作步骤,Introduction, 导 言,Summary of
6、APQP, APQP概要 Organize the cross-functional team and define the scope组织跨部门小组，确定工作范围 Develop a timing chart (project plan)编制时间表(项目计划) Identify the tools and responsibilities needed to carry out the activities in each phase, 确定完成每一阶段任务所需采用的工具和应履行的责任 Revise/adapt as necessary, 必要时进行修改 Implement and asse
7、ss the plan执行和评价该计划,Introduction, 导 言,APQP is accomplished through the execution of YOUR own Product Development Procedure. 通过实施贵公司的产品开发程序来实现APQP。,Introduction, 导 言,Responsibilities, 责任-公司负有的责任 perform all applicable parts of APQP执行APQP所有适用的部分 the following chart shows what is expected下图表明了需要进行的工作,I
8、ntroduction, 导 言,Define the scope, 确定范围 X X X Plan and define, 计划和确定项目 X Product design/dev, 产品设计/开发 X Feasibility, 可行性 X X X Process design/dev, 过程设计/开发 X X X Product/process val., 产品/过程验证 X X X Feedback/Corr Action, 反馈/修正措施 X X X Control Plans, 控制计划 X X X,Introduction, 导 言,Mfg. Only 制造,Design Resp
9、. 设计责任,Services 服务,Organizational Activities 组织活动,Necessary for Any APQP Program 对任何实施APQP的项目 都是不可或缺的,Who Initiates APQP?谁发起APQP活动？ you do!发起人就是你 you are responsible for the planning and implementation of the activities你负责策划和开展APQP活动,Organizational Activities 组织活动,Organize a Cross-Functional Team组建跨
10、部门小组 May include but is not limited to:可能包括，但不局限于： - engineering，工程 - manufacturing，制造 - quality，质量 - purchasing，采购 - sales，销售 - customers，顾客 - field service，现场服务 - subcontractors，分包商 - material control，材料控制,Organizational Activities 组织活动,Assess the training needs of team members and take action!评估小
11、组成员的培训需求，并采取相应措施。,Organizational Activities 组织活动,CROSS FUNCTIONAL TEAM Responsibility责任 Approva赞成l Support支持 Inform通知 Consult商量,Organizational Activities 组织活动,Define the Scope (you must.)确定范围(必须要.) have a project team leader任命一名项目小组组长 have defined roles and responsibilities of team members确定小组成员的作用和
12、责任 identify and understand the customers and their expectations确认和了解顾客及其期望 assess feasibility of program评估项目可行性,Organizational Activities 组织活动,Define the Scope (continued)确定范围(续) identify the costs, timing, and constraints确定成本、时间安排和限制条件 determine what assistance might be required from the customer确定
13、需要从顾客那里得到哪些帮助 identify documentation process确定文件编制过程,Organizational Activities 组织活动,Establish Lines of Communication建立沟通渠道 with other teams in the company与公司内部其它小组之间 with customer teams与顾客小组之间 might include regular meetings可包括定期会议,Organizational Activities 组织活动,Timing Chart 时间表,Each Program Will Hav
14、e a Unique Timing Chart 每个项目都应有单独的时间表,Timing Chart, 时间表,After the organizational activities, begin to develop a timing chart组织工作完成后，应制订时间表 activities，活动 events，事项 responsibilities，责任 timing, including sequences of activities时间安排，包括活动顺序,The 5-Phase model to be described in this training can be used a
15、s a starting point培训中介绍的5阶段模型可作为一个起点 some of the useful tools will be described in this training培训中将介绍一些实用工具 the list of tools is not meant to be all-inclusive工具清单并非详细无遗,Timing Chart, 时间表,* Your customer might use different terminology. 顾客可能使用其它术语,APQP 5-phase modelAPQP 5阶段模型,Timing Chart, 时间表,Note
16、the phases of the timing chart:注意时间表上的各个阶段 1. Plan and define the program, 计划和确定项目 2. Design and develop the product, 产品设计和开发 3. Design and develop the process, 过程设计和开发 4. Validate the product and process, 产品和过程确认 5. Feedback and Corrective Action, 反馈和纠正措施 Each phase contains several activities and
17、suggested helpful tools每个阶段都包括若干活动内容和推荐的实用工具。,Timing Chart, 时间表,Phase 1，第一阶段,Plan and Define Program计划 和确定项目,Timing Chart， 时间表,顾客需求,设计目标,设计文件,工艺文件,作业指导书,开发：保证转换的充分性和完备性,超越顾客期望 性能达到设计目标 产品特性符合规范 达到工艺文件要求 严格遵循作业指导书,Phase 1, Plan and Define Program 第一阶段, 计划和确定项目,Purpose目的 determine market and customer
18、needs and translate them into an initial product and process design; capture lessons learned确定市场和顾客需求，并体现在初步产品和过程设计中；汲取以往的经验和教训。 develop a plan for assuring that design goals and reliability goals, as defined and required by the customer, are built into the design制订计划，确保设计能够实现顾客确定的和要求达到的设计目标与可靠性目标 g
19、ain management commitment取得管理层的支持,List of Inputs (may vary according to product, process, or customer needs):输入清单(不同产品、过程或顾客需要，可所有不同)： Voice of the Customer 顾客之声Customer needs: contact your Sales Dept., Product Engineering, Application Engineering, etc., whichever are applicable顾客需求：与销售部、产品设计部、应用工程部
20、等了解顾客需 求的部门取得联系 Marketing needs: consult your Marketing group市场需求：请市场开发小组提供咨询意见 Business Plan/Marketing Strategy: consult your business unit, operational director, customer management (might be confidential) 业务计划/市场开发战略：请业务部门、经营主管、顾客管理部门提供咨询意见(可能需保密),Phase 1, Plan and Define Program 第一阶段, 计划和确定项目,Li
21、st of Inputs (may vary according to product, process, or customer needs):输入清单(不同产品、过程或顾客需要，可所有不同)： Benchmarking Data (internal and external): e.g. competitive analysis, cost information, reliability, process equipment benchmarks基准评测(内部和外部)：如竞争力分析、成本信息、可靠性、生产设备基准评测等 Product/Process Assumptions: consu
22、lt design and manufacturing standards产品/过程设想：查阅设计和制造标准,Phase 1, Plan and Define Program 第一阶段, 计划和确定项目,List of Inputs (may vary according to product, process, or customer needs):输入清单(不同产品、过程或顾客需要，可所有不同)： Lessons learned: systems are being developed to share lessons learned with divisional personnel经验
23、教训：建立一套系统，使大家能够共享经验教训 Product Reliability Studies: as defined and required by the customer产品可靠性研究：根据顾客意见和要求进行 Customer Inputs: other information they can provide顾客输入：他们可提供的其它信息,Phase 1, Plan and Define Program 第一阶段, 计划和确定项目,List of Outputs (may vary according to product, process, or customer needs):
24、输出清单(不同的产品，过程或顾客需求可有所不同) Design Goals: measurable characteristics and attributes with target values where applicable设计目标：可测量的产品特性和属性，可能的情况下提出量化指标 Reliability Goals: performance over the life of the product under normal conditions可靠性目标：产品在正常使用条件下寿命周期内的性能 Quality Goals: measured as Ppk, Cpk, first tim
25、e quality, ppm, DPTV, scrap reduction质量目标：可用Ppk、Cpk、初次检验质量、ppm、DPTV和废品降低率等指标确定,Phase 1, Plan and Define Program 第一阶段, 计划和确定项目,List of Outputs (may vary according to product, process, or customer needs):输出清单(不同的产品，过程或顾客需求可有所不同) Preliminary Bill of Materials初步材料清单 Preliminary Process Flowchart初步过程流程图
26、Preliminary KPCs, KCCs: must be documented on the control plan, and, maybe also on the process flow diagram (depending on the customer)初步KPC、KCC清单：必须列入控制计划，有些顾客要求列入过程流程图,Phase 1, Plan and Define Program 第一阶段, 计划和确定项目,List of Outputs (may vary according to product, process, or customer needs):输出清单(不同
27、的产品，过程或顾客需求可有所不同) Product Assurance Plan产品保证计划 Management Support: demonstrate that planning requirements are met, and concerns are scheduled for resolution 管理支持：表明策划要求已经达到，而且问题的解决已有计划,Phase 1, Plan and Define Program 第一阶段, 计划和确定项目,a plan to assure that the design goals are met确保设计目标得以实现 might inclu
28、de 可以包括： Reliability, durability apportionment可靠性、耐用性指标分解 Function/quality deployment功能/质量展开 Risk and roadblock assessment风险和困难评估 Failure modes analysis and action plan失效模式分析和措施实施计划,Phase 1, Plan and Define Program 第一阶段, 计划和确定项目,Product Assurance Plan，产品保证计划,Phase 2，第二阶段,Timing Chart， 时间表,Product De
29、sign and Development产品设计和开发,Purpose目的 develop the design into near final form使设计接近定型 verify the design to make sure it meets all requirements对设计进行验证，以保证达到全部要求 assess production and quality assurance needs对生产和质量保证需求进行评估,Phase 2, Product Design & Development 第二阶段,产品设计和开发,List of Outputs by Design Grou
30、p (may vary according to product, process, or customer needs)由设计部门完成的结果(具体内容可根据产品类型、过程和顾客需求确定) Design Failure Mode and Effects Analysis设计失效模式及后果分析 Design for Manufacturability设计的制造工艺性 Design Verification and Prototype Build设计验证和样件制造,Phase 2, Product Design & Development 第二阶段,产品设计和开发,List of Outputs
31、by Design Group (may vary according to product, process, or customer needs)由设计部门完成的结果(具体内容可根据产品类型、过程和顾客需求确定) Design Verification and Prototype Build设计验证和样件制造 Design Reviews设计审查 Engineering Drawings and Changes工程图纸及其更改 Engineering and Material Specifications技术要求和材料规格,Phase 2, Product Design & Develop
32、ment 第二阶段,产品设计和开发,List of Outputs by Quality Planning Team由质量策划小组完成的结果 New Equipment, Tooling, Facilities Reqmts对新设备、新工具、新设施的要求 KPCs, KCCsKPC、KCC清单 Prototype Build Control Plan样件制造控制计划 Gages/Testing Equipment Reqmts对检测仪表/试验设备的要求 Feasibility Review/Commitment可行性审查/承诺,Phase 2, Product Design & Develop
33、ment 第二阶段,产品设计和开发,Design FMEA设计FMEA listing of failure modes inherent to the product design列出产品设计中固有的失效模式 list of the effects and causes of failure列出失效的后果和产生原因 corrective action prioritized by按如下各项排序改进措施 severity of effect， 后果的严重程度 likelihood of occurrence， 发生的可能性 ability to detect failure， 探测失效的能力,
34、Phase 2, Product Design & Development 第二阶段,产品设计和开发,工 具,Design Verification设计验证 verification means checking a design to make sure it meets all the requirements设计验证是指对设计进行检查，以确保其符合所有要求 differs from validation与确认的区别： validation uses production parts in a realistic environment (QS9000 requires validatio
35、n in the actual environment)确认是指将生产部件在实际环境中使用(QS9000要求在实际环境中进行确认) verification is often just a paper/computer check验证通常仅指案头/计算机检查,Phase 2, Product Design & Development 第二阶段,产品设计和开发,工 具,Design Reviews设计评审 a review of the design by a cross-functional team to check (among others)由跨部门小组对下列内容进行评审 design
36、requirements，设计要求 failure modes，失效模式 predicted reliability，可靠性预测 design standards used and DFM efforts采用的设计标准和DFM措施 test plans and test results，试验计划和结果 verification studies，验证研究,Phase 2, Product Design & Development 第二阶段,产品设计和开发,工 具,KPCs (key product characteristics)，KPC(关键产品特性) a product characteri
37、stic for which reasonably anticipated variation is likely to affect customer satisfaction, safety, or compliance with regulations 是一种产品特性，当其在合理范围内出现变差时，会引起顾客不满，影响安全性或违反某些法规 can be identified by the customer or the cross-functional team 可由顾客或跨部门小组确定 KCCs (key control characteristics)，KCC(主要控制特性) a pr
38、ocess characteristic that must be controlled in order to reduce the variation in a KPC 为减少KPC的变差，必须加以控制的过程特性,Phase 2, Product Design & Development 第二阶段,产品设计和开发,工 具,Prototype Control Plan，样件控制计划 includes dimensional measurements and functional tests on prototype builds包括尺寸测量和样件功能试验 to verify the prot
39、otype product对样件产品进行验证 to verify the process if production-intent tooling is used如果使用将来生产用的工装，则对过程进行验证 a good way to find and fix real problems prior to production tooling being made 是一种在生产工具制造之前及时发现和解决实际问题的好办法,Phase 2, Product Design & Development 第二阶段,产品设计和开发,工 具,Feasibility Review/Commitment-make
40、 sure Manufacturing is part of this review可行性评审/承诺 - 确保产品制造也在评审之列 can quality be met?能达到质量要求吗？ is there sufficient capacity?有足够的过程能力吗？ can it be done on schedule?能按预定计划完成吗？ are costs within reason?成本是否适中？,Phase 2, Product Design & Development 第二阶段,产品设计和开发,工 具,Feasibility must be assessed even if the
41、 customer owns the design 即使是顾客提供的设计，也必须对可行性进行评估,Phase 3，第三阶段,Timing Chart， 时间表,Process Design and Development过程设计和开发,Purpose目的 develop an effective manufacturing system and related control plans建立有效的加工制造系统，并制订有关的控制计划,Phase 3, Process Design & Development 第三阶段, 过程设计和开发,List of Outputs (may vary acco
42、rding to product, process, or customer needs)输出列表(根据产品类型、过程和顾客需求而定) Packaging Standards, 包装标准 Process Flowchart, 过程流程图 Floor Plan Layout, 场地平面布置图 Characteristics Matrix, 特性矩阵 Process Failure Mode and Effects Analysis过程失效模式及后果分析 Pre-Launch Control Plan, 试生产控制计划,Phase 3, Process Design & Development 第
43、三阶段, 过程设计和开发,List of Outputs (may vary according to product, process, or customer needs)输出列表(根据产品类型、过程和顾客需求而定) Process Instructions，作业指导书 Measurement Systems Analysis Plan，测量系统分析计划 Preliminary Process Capability Plan，初始过程能力研究计划 Packaging Specifications，包装规范 Product/Process Quality System Review，产品/过
44、程质量体系评审 Management Support， 管理支持,Phase 3, Process Design & Development 第三阶段, 过程设计和开发,Process Flowchart，过程流程图 lists all steps in making the product列出产品制造的所有步骤 from receiving to shipping从来料验收到成品装运 includes different types of activities包括不同的作业类型 fabricate/assemble，制造/装配 move，搬运 store，存放 inspect，检验,Phas
45、e 3, Process Design & Development 第三阶段, 过程设计和开发,工 具,过程流程图,建议的最终格式,Phase 3, Process Design & Development 第三阶段, 过程设计和开发,工 具,过程流程图,建议的最终格式,场地平面布置图,确定检验和试验点的可接受性 控制图的位置 目视辅具 缺陷材料的储存区 关键材料的流程和控制计划,关键术语和基本概念,Characteristics Matrix (Recommended but not required)特性矩阵(推荐但不要求) allows us to prioritize which ch
46、aracteristics are important to control使我们能够优先控制那些重要的特性,Phase 3, Process Design & Development 第三阶段, 过程设计和开发,工 具,Process FMEA，过程FMEA listing of failure modes caused by the process not meeting requirements列出因过程不符合要求所产生的失效模式 list of the effects and causes of failure列出失效的后果和产生原因 corrective action priorit
47、ized by按下列各项改进措施的优先顺序 severity of effect，后果的严重程度 likelihood of occurrence，发生的可能性 ability to detect failure，检测失效的能力,Phase 3, Process Design & Development 第三阶段, 过程设计和开发,工 具,Pre-Launch Control Plan试生产控制计划 includes dimensional measurements, attributes, and functional tests on early production parts包括对早期
48、生产的部件进行尺寸检验、特性和功能试验 to check the process prior to full production在正式生产之前检查过程 also includes additional controls to be in place until the process is validated也包括在过程确认之前所采取的附加控制措施,Phase 3, Process Design & Development 第三阶段, 过程设计和开发,工 具,Measurement Systems Analysis Plan测量系统分析计划 to assure that gages and
49、measurement procedures are capable of detecting changes in process output确保测量系统具有探测过程输出变化的能力 can also be used to check inspection gages and procedures for sorting conforming vs. nonconforming product用于判别产品合格，不合格的测量系统也可进行MSA,Phase 3, Process Design & Development 第三阶段, 过程设计和开发,工 具,Preliminary Process Capability Study Plan初始过程能力研究计划 an assessment of the the ability of the process to meet specifications评估过程能否达到技术要求 measures the process variation检测过程变差 based on a significant production run on production equipment以在正式生产装备上进行的有效的生产为基础,
