產(chǎn)品質(zhì)量先期策劃與控制計劃AdvancedProductQualityPlanningandControlPlan,北京逖埃斯管理顧問有限公司BeijingTISmanagementconsultantltd.,第二版Secondedition2008.11.1實施,黃建平JackyHuang,1,APQP-產(chǎn)品質(zhì)量先期策劃,產(chǎn)品質(zhì)量先期策劃是一種結構化的方法，用來確定和制定確保某產(chǎn)品使顧客滿意所需的步驟。產(chǎn)品質(zhì)量先期策劃的目標使促進與所涉及的每一個人的聯(lián)系，以確保所要求的步驟按時完成。ProductQualityPlanningisastructuredmethodofdefiningandestablishingthestepsnecessarytoassurethataproductsatisfiesthecustomer.Thegoalofproductqualityplanningistofacilitatecommunicationwitheveryoneinvolvedtoassurethatallrequiredstepsarecompletedontime.,2,產(chǎn)品質(zhì)量策劃循環(huán),反饋評審和糾正措施,產(chǎn)品和過程確認,計劃和規(guī)定,過程設計和開發(fā),產(chǎn)品和過程開發(fā),持續(xù)改進,技術和概念開發(fā),產(chǎn)品/過程開發(fā)和樣件驗證,確定產(chǎn)品和確認工具,計劃,措施,實施,研究,3,ProductQualityplanningcycle,Feedbackassessmentandcorrectiveaction,ProductandprocessValidation,Plananddefine,Processdesignanddevelopment,Productdesignanddevelopment,ContinualImprovement,Technologyandconceptdevelopment,Product/processDevelopmentandPrototypeVerification,ConfirmationProductandValidationProcess,Plan,Action,Do,Check,4,前言Foreword,APQP與CP第二版包括：融入了顧客關注的過程方法；按ISO/TS16949及克萊斯勒、福特、通用汽車公司核心工具手冊更新了概念及術語；適當?shù)貐⒖剂祟櫩鸵??？巳R斯勒汽車公司福特汽車公司通用汽車公司德爾福公司伊頓公司,APQPandcontrolsecondeditionincludes:Incorporationofthecustomerfocusedprocessapproach,UpdatedterminologyandconceptsconsistentwithISO/TS16949andotherChrysler,FordandGeneralMotorscoretoolmanuals,Appropriatereferencestocustomersspecificsprovidedwithoutthefulltext.ChryslerLLCFordMotorCompanyGeneralmotorscorporationDelphiCorporationEatonCorporation,5,前言Foreword,使用APQP具有如下預期收益：對顧客和供方減少產(chǎn)品質(zhì)量策劃的復雜性；便于組織與供方就產(chǎn)品質(zhì)量策劃要求進行溝通。,SomeoftheexpectedbenefitsinuseAPQPare:Areductioninthecomplexityofproductqualityplanningforthecustomersandorganizations.Ameansfororganizationstoeasilycommunicateproductqualityplanningrequirementstosuppliers.,6,目錄Tableofcontents,產(chǎn)品質(zhì)量先期策劃的基本原則第一章計劃和確定項目第二章產(chǎn)品設計和開發(fā)第三章過程設計和開發(fā)第四章產(chǎn)品和過程的確認第五章反饋、評審和糾正措施第六章控制計劃方法論,FundamentalsofProductqualityplanningChapter1PlananddefineprogramChapter2ProductdesignanddevelopmentChapter3ProcessdesignanddevelopmentChapter4ProductandprocessvalidationChapter5Feedback,AssessmentandcorrectiveactionChapter6Controlplanmethodology,7,產(chǎn)品質(zhì)量先期策劃的基本原則Fundamentalsofproductqualityplanning,組織小組確定范圍小組間的聯(lián)系培訓顧客和組織的參與同步工程控制計劃問題的解決產(chǎn)品質(zhì)量的進度計劃與進度圖有關的計劃,OrganizetheteamDefinethescopeTeam-to-teamTrainingCustomerandorganizationInvolvementSimultaneousengineeringControlplanConcernresolutionProductqualitytimingplanPlansrelativetothetimingchart,8,設計責任僅限制造服務組織如熱處理貯存、運輸?shù)鹊却_定范圍xxx計劃和定義x產(chǎn)品設計和開發(fā)x可行性xxx過程設計和開發(fā)xxx產(chǎn)品和過程確認xxx反饋評定和糾正xxx措施xxx控制計劃方法論xxx,產(chǎn)品質(zhì)量策劃責任矩陣圖Productqualityplanningresponsibilitymatrix,9,產(chǎn)品質(zhì)量策劃責任矩陣圖Productqualityplanningresponsibilitymatrix,10,ISO/TS16949:2009中的相關要求RequirementsofISO/TS16949:2009,注：有些顧客將項目管理或產(chǎn)品質(zhì)量先期策劃作為一種產(chǎn)品實現(xiàn)方法，產(chǎn)品質(zhì)量先期策劃與缺陷探測不同，包括防錯和持續(xù)改進的概念，并是基于多方論證的方法。NOTESomecustomersrefertoprojectmanagementoradvancedproductqualityplanningasameanstoachieveproductrealization.Advancedproductqualityplanningembodiestheconceptsoferrorpreventionandcontinualimprovementascontrastedwitherrordetectionandisbasedonamultidisciplinaryapproach.,11,策劃,產(chǎn)品設計和開發(fā),過程設計和開發(fā),產(chǎn)品與過程確認,生產(chǎn),反饋、評定和糾正措施,策劃,計劃和定義階段,產(chǎn)品設計開發(fā)與驗證,過程設計開發(fā)與驗證,產(chǎn)品與過程確認,反饋、評定和糾正措施,產(chǎn)品質(zhì)量策劃時間進度圖,12,planning,Productdesignanddevelopment,Processdesignanddevelopment,ProductandprocessValidation,Production,FeedbackAssessmentandcorrectionaction,Planning,Plananddefineprogram,Productdesignanddevelopmentverification,Processdesignanddevelopmentverification,Productandprocessvalidation,Feedbackassessmentandcorrectionaction,Productqualityplanningtimingchart,13,APQP與防錯APQPanderrorproofing,1、設計文件Designdocuments2、潛在失效模式及后果分析FMEA；3、控制計劃ControlPlan4、作業(yè)指導書Workinstructions5、生產(chǎn)件批準程序PPAP6、防錯Errorproofing,風險risk,APQP進程APQPprocess,14,實施APQP的時機implementationAPQPoccasion,新產(chǎn)品Newproduct更改的產(chǎn)品Changedproduct,15,顧客滿意,APQP,APQP-計劃和確定項目,反饋，評價和糾正措施,產(chǎn)品設計和開發(fā),計劃和確定項目,過程設計和開發(fā),產(chǎn)品和過程確認,16,第一階段計劃和確定項目Chapter1Plananddefine,輸入：1.1顧客呼聲-市場研究（包括OEM車型開發(fā)時間及期望的市場容量）-保修記錄和質(zhì)量信息小組經(jīng)驗1.2業(yè)務計劃/營銷戰(zhàn)略1.3產(chǎn)品/過程基準數(shù)據(jù)1.4產(chǎn)品/過程設想1.5產(chǎn)品可靠性研究1.6顧客輸入,Inputs:1.1Voiceofthecustomer-Marketresearch-Historicalwarrantyandqualityinformation-Teamexperience1.2Businessplanandmarketingstrategy1.3Product/Processbenchmarkdata1.4Product/processassumptions1.5Productreliabilitystudies1.6Customerinputs,17,第一階段計劃和確定項目Chapter1Plananddefine,輸出：1.7設計目標1.8可靠性和質(zhì)量目標1.9初始材料清單1.10初始過程流程圖1.11產(chǎn)品和過程特殊特性的初始清單1.12產(chǎn)品保證計劃1.13管理者支持,Outputs:1.7Designgoals1.8Reliabilityandqualitygoals1.9Preliminarybillofmaterial1.10Preliminaryprocessflowchart1.11preliminaryidentificationofspecialproductandprocesscharacteristics1.12Productassuranceplan1.13Managementsupport,18,初始過程流程圖PreliminaryProcessFlowChart,19,過程流程圖示例,20,APQP,APQP-產(chǎn)品設計和開發(fā),顧客滿意,反饋，評價和糾正措施,產(chǎn)品設計和開發(fā),計劃和確定項目,過程設計和開發(fā),產(chǎn)品和過程確認,Plananddefineprogram,Productdesignanddevelopmentverification,Processdesignanddevelopmentverification,Productandprocessvalidation,Feedbackassessmentandcorrectionaction,CustomerSatisfaction,21,第二階段產(chǎn)品設計和開發(fā)Chapter2Productdesignanddevelopment,設計輸出：2.1設計潛在失效模式及后果分析2.2可制造性和裝配性設計2.3設計驗證2.4設計評審2.5樣件制造2.6工程圖樣（包括數(shù)學數(shù)據(jù)）2.7工程規(guī)范2.8材料規(guī)范2.9圖樣和規(guī)范的更改,Designoutputs2.1Designfailuremodeandeffectsanalysis(DFMEA)2.2DesignforManufacturabilityandassembly2.3Designverification2.4Designreviews2.5Prototypebuildcontrolplan2.6EngineeringDrawings(includemathdata)2.7Engineeringspecifications2.8Materialspecifications2.9Drawingandspecificationchanges,22,第二階段產(chǎn)品設計和開發(fā)Chapter2Productdesignanddevelopment,APQP輸出：2.10新設備、工裝和設施的要求2.11產(chǎn)品和過程特殊特性2.12量具/試驗設備要求2.13小組可行性承諾和管理者支持,APQPoutputs:2.10Newequipment,toolingandfacilitiesrequirements2.11Specialproductandprocesscharacteristics2.12Gages/testingequipmentrequirements2.13Teamfeasibilitycommitment&managementsupport,23,APQP-DFMEA實例,24,APQP-產(chǎn)品特性標識,如顧客無特別說明，則建議使用下列產(chǎn)品特性符號：,25,APQP,APQP-過程設計和開發(fā),顧客滿意,反饋，評價和糾正措施,產(chǎn)品設計和開發(fā),計劃和確定項目,過程設計和開發(fā),產(chǎn)品和過程確認,26,第三階段過程設計和開發(fā)Chapter3Processdesignanddevelopment,輸出：3.1包裝標準和規(guī)范3.2產(chǎn)品/過程質(zhì)量體系評審3.3過程流程圖3.4場地平面布置圖3.5特性矩陣圖3.6過程潛在失效模式及后果分析3.7試生產(chǎn)控制計劃3.8過程指導書3.9測量系統(tǒng)分析計劃3.10初始過程能力研究計劃3.11管理者支持,Outputs:3.1PackagingstandardsandSpecifications3.2Product/processqualitysystemreview3.3Processflowchart3.4Floorplanlayout3.5Characteristicsmatrix3.6Processfailuremodeandeffectsanalysis(PFMEA)3.7Pre-launchcontrolplan3.8Processinstructions3.9Measurementmanagementsystemanalysis3.10Preliminaryprocesscapabilitystudyplan3.11Managementsupport,27,APQP-PFMEA,28,MSA計劃,-線性-準確度-重復性-再現(xiàn)性-目視標準-行業(yè)水準-過程流程圖-場地平面布置-特性矩陣-包裝標準,29,測量的準確度,30,APQP,APQP-產(chǎn)品和過程確認,顧客滿意,反饋，評價和糾正措施,產(chǎn)品設計和開發(fā),計劃和確定項目,過程設計和開發(fā),產(chǎn)品和過程確認,31,第四階段產(chǎn)品和過程的確認Chapter4Productandprocessvalidation,輸出：4.1有效的生產(chǎn)4.2測量系統(tǒng)分析4.3初始過程能力研究4.4生產(chǎn)件批準4.5生產(chǎn)確認試驗4.6包裝評價4.7生產(chǎn)控制計劃4.8質(zhì)量策劃認定和管理者支持,Outputs:4.1Significantproductionrun4.2Measurementsystemanalysis4.3Preliminaryprocesscapabilitystudy4.4Productionpartapproval4.5Productionvalidationtesting4.6Packagingevaluation4.7Productioncontrolplan4.8Qualityplanningsign-offandmanagementsupport,32,APQP,APQP-反饋、評定和糾正措施,顧客滿意,反饋，評價和糾正措施,產(chǎn)品設計和開發(fā),計劃和確定項目,過程設計和開發(fā),產(chǎn)品和過程確認,33,第五階段反饋評審和糾正措施Chapter5Feedback,assessmentandcorrectiveaction,輸出：5.1減少變差5.2改善顧客滿意5.3改善交付和服務5.4有效應用經(jīng)驗總結/最佳實踐,Outputs:5.1Reducedvariation5.2Improvedcustomersatisfaction5.3Improveddeliveryandservice5.4Effectiveuseoflessonslearned/bestpractices,34,Outofcontrol不受控，存在特殊原因,Incontrol受控，沒有能力符合規(guī)范但普通原因造成變差大,OntargetReducingvariation減少普通原因變差，達到目標,Continuedvariationreduction持續(xù)的減少變差,APQP,APQP-反饋、評定和糾正措施,35,APQP,APQP-反饋、評定和糾正措施,反饋，評價和糾正措施,產(chǎn)品設計和開發(fā),計劃和確定項目,過程設計和開發(fā),產(chǎn)品和過程確認,顧客滿意,APQP,所有顧客關注的問題都已圓滿得到關閉,不斷傾聽和解決顧客新的呼聲,36,第六章控制計劃方法論Chapter5Controlplanmethodology,制訂并實施控制計劃的益處包括：質(zhì)量：控制計劃方法論減少了浪費并提高了設計、制造和裝配中的產(chǎn)品質(zhì)量。這一結構性的方法為產(chǎn)品和過程提供了一完整的評價。控制計劃識別過程特性并幫助識別導致產(chǎn)品特性變差（輸出變量）的過程特性的變差源（輸出變量）。,Thebenefitsofdevelopingandimplementingacontrolplaninclude：Quality:Thecontrolplanmethodologyreduceswasteandimprovesthequalityofproductsduringdesign,manufacturing,andassembly.Thisstructureddisciplineprovidesathoroughevaluationoftheproductandprocess.Controlplansidentifyprocesscharacteristicsandidentifythecontrolmethodsforthesourcesofvariation(inputvariables),whichcausevariationinproductcharacteristics(outputvariables).,37,第六章控制計劃方法論Chapter5Controlplanmethodology,顧客滿意度：控制計劃聚集于將資源用于與對顧客來說重要的特性有關的過程和產(chǎn)品。將資源正確地分配在這些重要的項目上有助于在不影響質(zhì)量的情況下降低成本。交流：作為一個動態(tài)文件，控制計劃明確地傳達了產(chǎn)品/過程特性、控制方法和特性測量中的變化。,CustomerSatisfaction:Controlplansfocusresourcesonprocessesandproductsrelatedtocharacteristicsthatareimportanttothecustomer.Theproperallocationofresourcesonthesemajoritemshelpstoreducecostswithoutsacrificingquality.Communication:Asalivingdocumentthecontrolplanidentifiesandcommunicateschangesintheproduct/processcharacteristics,controlmethod,andcharacteristicmeasurement.,38,控制計劃,39,控制計劃-案例,40,Controlplan,41,Controlplanensample,42,有效生產(chǎn)運行輸出中引入生產(chǎn)節(jié)拍展示,樣品生產(chǎn)件,標準樣品(按要求)包裝評估的測試發(fā)運,有原先的可行時更新為有要求時質(zhì)量策劃認定及管理者支持應在制造