AdvancedProductQualityPlanningandControlPlan產(chǎn)品質(zhì)量先期策劃及控制計劃1WhatisAPQP?什么是產(chǎn)品質(zhì)量先期策劃APQP？ProductQualityPlanningisastructuredmethodofdefiningandestablishingthestepsnecessarytoassurethataproductsatisfiesthecustomer.產(chǎn)品質(zhì)量先期策劃是：一種定義并建立保證產(chǎn)品滿足顧客要求的步聚的結(jié)構(gòu)化方法WhatisthegoalofAPQP?什么是APQP的目標(biāo)？Thegoalofproductqualityplanningistofacilitatecommunicationwitheveryoneinvolvedtoassurethatallrequiredstepsarecompletedontime.產(chǎn)品質(zhì)量先期策劃的目標(biāo)是：加強相關(guān)人員之間的溝通以確保所有要求的步聚按時完成。APQP2WhatisthebenefitsofProductQualityPlanning?什么是產(chǎn)品質(zhì)量策劃的益處？Todirectresourcestosatisfythecustomer.向著使顧客滿意的方向引導(dǎo)資源Topromoteearlyidentificationofrequiredchanges.促進(jìn)及早識別需要進(jìn)行的更改Toavoidlatechanges.避免事后更改Toprovideaqualityproductontimeatthelowestcost.以最低的成本及時提供高質(zhì)量的產(chǎn)品APQP3ProductQualityPlanningCycle產(chǎn)品質(zhì)量策劃循環(huán)APQP4ThepurposeoftheProductQualityPlanningCycleistoemphasize:產(chǎn)品質(zhì)量策劃循環(huán)的目的是強調(diào)：Up-frontplanning:Thefirstthreequartersofthecyclearedevotedtoup-frontproductqualityplanningthroughproduct/processvalidation.策劃：前四分之三循環(huán)含蓋產(chǎn)品質(zhì)量策劃到產(chǎn)品/過程確認(rèn)Theactofimplementation:Thefourthquarteristhestagewheretheimportanceofevaluatingtheoutputservestwofunctions:todetermineifcustomersaresatisfied,andtosupportthepursuitofcontinualimprovement.措施的實施：第四階段對結(jié)果進(jìn)行評價的重要性體現(xiàn)在兩方面：是否達(dá)到顧客滿意及對持續(xù)改進(jìn)的追求。APQP5KeytoEffectiveProductQualityPlanning有效的產(chǎn)品質(zhì)量策劃其關(guān)鍵在于：－Supportfromthetopmanagementfor－來自于最高管理者的支持 concludingeachphaseofproductqualityplanning 質(zhì)量策劃每一階段的總結(jié)

Note:theteamshouldinformtopmanagementaboutthecurrentstatus oftheprojectinordertokeepuptheinterestandunderpintop managementcommitmentandsupport.Theinformationshouldbein writtenform solvingproblemareasandconcerns 參與問題的解決

APQP7 finalassessmentoftheproductqualityplanningprocess (signing-off) 產(chǎn)品質(zhì)量策劃過程的最終評價(總結(jié)認(rèn)定appendixF)－TeamandCommunicationSkill－團(tuán)隊技巧及溝通技巧

Note:Teamskillmeanstoworkinateamratherthanthinking“great, somebodyelsedoesit”.Communicationskillmeanstheabilitytopasson informationcomprehensivelyandwithoutlossofinformation.APQP8ResponsibilityMatrix職責(zé)矩陣APQP9ProductQualityPlanningTimingChart

APQP10Thetimingchartshowstheidealprocedureofproductqualityplanning.Theindividualphasesareshownastimebarsandtherespectivestartingpointsareshownasverticallines(conceptinitiation/approval,programapproval,prototype,pilot,launch)

APQPAPQPAPQPAPQPAPQPAPQP11OrganizationofAPQPReferenceManualAPQP手冊的組織結(jié)構(gòu)APQPPlanandDefineProgramSection1.0ProductDesignandDevelopmentSection2.0ProcessDesignandDevelopmentSection3.0ProductandProcessValidationSection4.0Feedback,AssessmentandCorrectiveActionSection5.0ControlPlanMethodologySection6.0OrganizetheteamDefinethescopeTeam-to-teamTrainingindevelopmenttechniquesCustomerandsupplierinvolvementSimultaneousEngineeringConcernresolutionMonitoringwithtimingplansystemsAPQP12OrganizingtheTeam組織小組Theresponsibilityforproductqualityplanningmustbeassignedtoacross-functionalteam.TheteamshouldcompriserepresentativesofthefunctionsDevelopment,Production,MaterialTesting,Purchasing,Quality,Sales,CustomerService,aswellassubcontractorsandcustomers.Team-to-TeamCo-operation小組之間的合作Theteammustestablishcommunicationchannelstoothercustomerandsupplierteams.Thismayincluderegularmeetingswithotherteams.APQP13TraininginDevelopmentTechniques開發(fā)技術(shù)的培訓(xùn)Thesuccessoftheproductcontrolplandependsonaneffectivetrainingprogramwhichwillconveyalldefinedrequirementsanddevelopmenttechniquesnecessaryforthefulfillmentofcustomerrequirementsandexpectations.CustomerandSupplierInvolvement顧客及供方的參與Ifnecessary,thecustomerandsubcontractormustbeinvolvedintheplanningprocess.Thesuppliershallrequestacross-functionalteamfromtheirsubcontractors.APQP14DefiningtheScopeoftheTeam:給小組界定范圍selectaprojectteamleader（itmaybeadvantageoustorotatetheteamleaderduringtheplanningcycle)選一個小組長（輪流做樁較好）definetherolesandresponsibilitiesofeacharearepresented定義各方代表的角色和職責(zé)identifythecustomers-internalandexternal明確誰是內(nèi)部的及外部的顧客definingcustomerrequirements(useQFD,ifapplicable)定義顧客要求(如適用，使用QFD)APQP15definethedisciplines,individualsand/orsubcontractorsthatmustbeaddedtotheteam,andthosenotrequired明確部門，各人及哪些供方必須加到小組中來，哪些不必understandcustomerexpectations搞清顧客的期望assessthefeasibility,performancerequirements,manufacturingprocess評價可行性，性能要求，制造過程identificationofcostsinvolved,timingandconstraints明確成本，時間及其他方面的限制determinationofassistancerequiredfromthecustomer明確需顧客提供的邦助有哪些identificationofdocumentationprocessormethod明確報告/記錄的過程和方法APQP16SimultaneousEngineering同步工程Itisaprocesswherecrossfunctionalteamsstriveforacommongoal.各多功能小組為共同的目標(biāo)努力Itreplacethesequentialseriesofphaseswhereresultsaretransmittedtothenextareaforexecution.代替按階段排序Thepurposeistoexpeditetheintroductionofqualityproductssooner.其目的是加速高質(zhì)量產(chǎn)品的引入

DesignforManufacturabilityandAssemblyisaSimultaneousEngineeringprocessdesignedtooptimizetherelationshipbetweendesignfunction,manufacturability,andeaseofassembly.APQP17ConcernResolution問題的解決Duringtheplanningprocesstheteamwillhitondesignand/orprocessrelatedconcerns.Theseconcernsshouldbedocumentedinatablewithallocationoftheresponsibilitiesanddeadlinesfortheirresolution.Indifficultsituationsselectedmethodsforconcernresolutionmustbeemployed.AnalyticaltechniqueslistedinAppendixBofAPQPmanual:AssemblyBuildVariationAnalysis;Benchmarking;CauseandEffectDiagram;CharacteristicsMatrix;CriticalPathMethod;DesignofExperiments(DOE);DesignforManufacturabilityandAssembly;DesignVerificationPlanandReport(DVP&R);DimensionalControlPlan(DCP)orDynamicControlPlan;MistakeProofing(POKA-YOKE);ProcessFlowCharting;QualityFunctionDeployment(QFD);SystemFailureModeandEffectsAnalysis(SFMEA)APQP18MethodforConcern-Resolution解決問題的方法1.Recognizetheproblem,focusonitanddescribeitcomplains,defects,variations,scrap,audits,listofproblems2.Collectdatamultipledefectchart,qualitycontrolchart,dataprocessing3.EvaluatedataHistogram,pareto,processFMEA4.CauseandeffectsanalysisIshikawadiagram,problemanalysis,valueengineering,8Dreport,DOE5.WorkoutproblemresolutionproposalsBrainstorming,DOE,flowdiagram,visualizingproblemonpinwallAPQP196.AssessproblemresolutionproposalsDecisiontree,cost-benefit-analysis,riskanalysis,nominalgroupmethod7.Decision8.Informthoseinvolvedandimplementsolutionactionplan,definitionoftargets,determinemeasurables9.Checkoutcometrenddiagram,pareto,audits10.RECOGNITIONAPQP20MonitoringwithTimingPlanSystems用時間計劃表來監(jiān)控ThefirstorderofAPQPteamfollowingorganizationalactivitiesshouldbethedevelopmentofaTimingPlan.APQP小組的組織工作完成后的第一個任務(wù)應(yīng)該是制定一個時間計劃表。Awell-organizedtimingchartshouldlisttasks,assignments,othereventsandtiming.(TheCriticalPathMethodmaybeappropriate)一個完善的時間表應(yīng)羅列出任務(wù)，負(fù)責(zé)人，和/或其他事件及時間。Tofacilitatestatusreporting,eacheventmusthavea“start”anda“completion”datewiththeactualpointofprogressrecorded.為輔助對完成狀態(tài)進(jìn)行報告，每一事件必須有“開始”和“完成”日期并記錄實際進(jìn)展?fàn)顩rAPQP21AttentionPlease注意！Planningteamsmustbepreparedtomodifyproductqualityplanstomeetcustomerexpectations.策劃小組必須準(zhǔn)備好對產(chǎn)品質(zhì)量計劃進(jìn)行修改以滿足顧客的期望TheProductQualityPlanningTeamisresponsibleforassuringthattimingmeetsorexceedsthecustomertimingplan.產(chǎn)品質(zhì)量先期策劃小組負(fù)責(zé)確保滿足或超出顧客時間計劃的要求。APQP22Section1.0PlanandDefineProgram階段1.0定義及確定項目Taskofthissection此階段的任務(wù):DeterminationofcustomerneedsandexpectationsFocussingallworkonthecustomer(finaluser,consumer)Translatingcustomerinputrequirementsintooutputrequirements(orbriefingspecificationintoofferspecification)Definingdevelopment,reliabilityandqualitygoalsAPQP23InputVoiceofthecustomerMarketresearchHistoricalwarrantyandqualityinformationTeamexperienceBusinessplan/customermarketingstrategyProduct/processbenchmarkdataProduct/processassumptionsProductreliabilitystudiesCustomerinputsOutputDesigngoalsReliabilityandqualitygoalsPreliminarybillofmaterialPreliminaryprocessflowchartPreliminarylistingofspecialproductandprocesscharacteristicsProductassuranceplan(outputrequirements)PlanandDefineProgramSection1.0APQP24

階段1.0定義及確定項目

輸入：l·1顧客的呼聲1·1·1市場調(diào)研1·1·2保修記錄和質(zhì)量信息l·l·3小組經(jīng)驗1．2業(yè)務(wù)計劃／營銷策略1．3產(chǎn)品／過程指標(biāo)l．4產(chǎn)品／過程設(shè)想1．5產(chǎn)品可靠性研究1．6顧客輸入

輸出：1．7設(shè)計目標(biāo)1．8可靠性和質(zhì)量目標(biāo)l．9初始材料清單l．10初始過程流程圖1．11初始特殊產(chǎn)品特性及特殊過程特性清單l·12產(chǎn)品保證計劃l·13管理者支持25261.1The‘VoiceoftheCustomer’The‘VoiceoftheCustomer’encompassescomplaint,recommendations,dataandinformationobtainedfrominternaland/orexternalcustomers.1.1.1Marketresearch:Thefollowingsourcescanassistinidentifyingcustomerconcerns/wantsandtranslatingthoseconcernsintoproductandprocesscharacteristics:CustomerinterviewsCustomerquestionnairesandsurveysMarkettestandpositioningreportsNewproductqualityandreliabilitystudiesCompetitiveproductqualitystudiesThingsGoneRight(TGR)reportsAPQP27l·1顧客的呼聲

“顧客的呼聲”包括來自內(nèi)部和／或外部顧客的抱怨、建議、資料和信息。以下各段提供了收集這種信息的一些方法。1·1·1市場調(diào)研產(chǎn)品質(zhì)量策劃小組可能需要獲取反映顧客時聲的市場調(diào)研資料和信息。以下來源有助于識別顧客關(guān)注的事項／需求，并將這些關(guān)注事項轉(zhuǎn)變?yōu)楫a(chǎn)品和過程特性：對顧客的采訪；顧客意見征詢與調(diào)查；市場調(diào)查和預(yù)測報告；新產(chǎn)品質(zhì)量和可靠性研究；競爭產(chǎn)品質(zhì)量的研究；運行情況良好（TGR）報告。281.1.2Historicalwarrantyandqualityinformation:Thelistofhistoricalcustomerconcerns/wantsshouldbepreparedtassessthepotentialforrecurrenceduringthedesign,manufacture,installationanduseoftheproduct.Ascertainingcustomerconcernscanbesupportedby:ThingsGoneWrong(TGW)reportsWarrantyreportsSupplierplantinternalqualityreportsCustomerplantreturnsandrejectionsFieldreturnsandproductanalysisAPQPAPQP291·1·2保修記錄和質(zhì)量信息為廠評定在產(chǎn)品的設(shè)計、制造、安裝和使用當(dāng)中再發(fā)生不合格的可能性，應(yīng)制定一份以往顧客所關(guān)注問題儒要的清單，這些應(yīng)作為其它設(shè)計要求的擴(kuò)展來考慮并且應(yīng)包括在對顧客需要的分析中。以下項目中的許多內(nèi)容有助于小組識別顧客關(guān)注問題／需要，并優(yōu)選出適當(dāng)?shù)慕鉀Q方案：運行情況不良（TGW）報告；保修報告；能力指數(shù)；供方工廠內(nèi)部質(zhì)量報告；問題解決報告；顧客工廠退貨和廢品；現(xiàn)場退貨產(chǎn)品分析。301.1.3TeamExperience:MediacommentaryandanalysisInputfrompastQualityFunctionDeploymentprojectsGovernmentrequirementsandregulationsRoadtripsManagementcommentsordirection.APQPAPQP31l·l·3小組經(jīng)驗小組適當(dāng)時可利用包括如下內(nèi)容的任何信息來源：來自更高層體系或過去質(zhì)量功能開發(fā)（QFD）項目的輸入；媒介的評論和分析：雜志和報刊報告等；顧客的信件和建議；運行情況良好（TGR）／運行情況不良（TGW）報告；銷售商意見；車隊負(fù)責(zé)人的意見；現(xiàn)場服務(wù)報告；利用指定的顧客代理所作的內(nèi)部評價；道路行駛體驗；管理者的意見或指示；由內(nèi)部顧客報告的問題和議題；政府的要求和法規(guī)；合同評審。321.2BusinessPlan/CustomerMarketingStrategyThecustomerbusinessplanandmarketingstrategywillsettheframeworkfortheproductionqualityplan.Thebusinessplanmayplacethefollowingconstraintsontheteam:TimingCostInvestmentProductpositioningResearchanddevelopment(R&Dresources)Themarketingstrategywilldefinethetargetcustomer,thekeysalespoints,andkeycompetitors.APQPAPQP331．2業(yè)務(wù)計劃／營銷策略顧客業(yè)務(wù)計劃和營銷策略將成為產(chǎn)品質(zhì)量計劃的設(shè)定框架。業(yè)務(wù)計劃可將限制性要求施加給小組（諸如進(jìn)度、成本、投資、產(chǎn)品定位、研究與開發(fā)（R＆D）資源）而影響其執(zhí)行方向。營銷策略將確定目標(biāo)顧客、主要的銷售網(wǎng)點和主要的競爭者。341.3Product/processBenchmarkDataTheuseofBenchmarkingwillprovideinputtoestablishingproduct/processperformancetargets.Onemethodtosuccessfulbenchmarkingis:IdentifytheappropriatebenchmarksUnderstandthereasonforthegagbetweenyourcurrentstatusandthebenchmarkDevelopaplantoeitherclosethegap,matchthebenchmark,orexceedthebenchmark1.4Product/processAssumptionsTherewillbeassumptionsthattheproducthascertainfeatures,design,orprocessconcepts.Theseincludetechnicalinnovations,advancematerials,reliabilityassessments,andnewtechnology.Allshouldbeutilizedasinputs.APQP351．3產(chǎn)品／過程指標(biāo)基準(zhǔn)確定（參見附錄B）將成為建立產(chǎn)品／過程能力目標(biāo)提供輸入。研究和開發(fā)也可提供基準(zhǔn)和概念。成功的基準(zhǔn)確定方法為；識別合適的基準(zhǔn)；了解你目前狀況和基準(zhǔn)之間產(chǎn)生差距的原因；制定一縮小差距、符合基準(zhǔn)或超過基準(zhǔn)的計劃。l．4產(chǎn)品／過程設(shè)想

設(shè)想產(chǎn)品具有某些特性、某種設(shè)計和工藝過程概念，它們包括技術(shù)革新、先進(jìn)的材料、可靠性評定和新技術(shù)。所有這些都應(yīng)用作輸入。361.5ProductReliabilityStudies.Thistypeofdataconsidersfrequencyofrepairofreplacementofcomponentswithindesignatedperiodsoftimeandtheresultsoflongtermreliability/durabilitytests.1.6CustomerInputsTheendusersoftheproductcanprovideviableinformationrelatingtotheirneedandexpectations.Thisinputshouldbeusedbythecustomerand/orsuppliertodevelopagreeduponmeasuresofcustomersatisfaction.1.7DesignGoalsDesigngoalsareatranslationofthe“VoiceoftheCustomer”intotentativeandmeasurabledesignobjectivesAPQP371．5產(chǎn)品可靠性研究這一類型的數(shù)據(jù)考慮了在一規(guī)定時間內(nèi)零件修理和更換的頻率，以及長期可靠性／耐久性試驗的結(jié)果。1．6顧客輸入產(chǎn)品的后續(xù)顧客可提供與他們的需要和期望有關(guān)的有價值信息，此外，后續(xù)產(chǎn)品顧客可能已進(jìn)行部分或全部前面已提到的評審和研究。顧客和/或供方應(yīng)使用這些輸入以開發(fā)統(tǒng)一的衡量顧客滿意的方法。1．7設(shè)計目標(biāo)設(shè)計目標(biāo)就是將顧客的呼聲轉(zhuǎn)化為初步并具體的設(shè)計任務(wù)。設(shè)計目標(biāo)的正確選擇確保顧客的呼聲不會消失在隨后的設(shè)計活動中。381.8ReliabilityandQualityGoalsReliabilitygoalsareestablishedbasedoncustomerwantsandexpectations,programobjectives,andreliabilitybenchmarks.Someexamples:nonsafetyrelateddefectsservicefriendlinessQualitygoalsaretargetsbasedoncontinualimprovement.Someexamples: ppmvalues defectlevelsreductionofscrap1.9PreliminaryBillofMaterialTheteamshouldestablishapreliminarybillofmaterialbasedonproduct/processassumptionsandincludeanearlysubcontractorlist.APQPAPQP391．8可靠性和質(zhì)量目標(biāo)可靠性目標(biāo)是在顧客需要和期望、項目目標(biāo)及可靠性基準(zhǔn)的基礎(chǔ)上制定的。顧客需要和期望可以是無安全問題和可維修性。有些可靠性基準(zhǔn)可以是競爭者產(chǎn)品的可靠性、顧客的報告或在一設(shè)定時間內(nèi)修理的頻率?？偟目煽啃阅繕?biāo)可用概率和置信度表示。質(zhì)量目標(biāo)是基于持續(xù)改進(jìn)的目標(biāo)，諸如（PPM）零件／百萬缺陷水平或廢品降低率。l．9初始材料清單小組在產(chǎn)品／過程設(shè)想的基礎(chǔ)上應(yīng)制定一份初始材料清單，并包括早期分承包方名單。為了識別初始特定產(chǎn)品／過程特性，有必要事先選定合適的設(shè)計和制造過程。401.10PreliminaryProcessFlowChartTheanticipatedmanufacturingprocessshouldbedescribedusingaprocessflowchartdevelopedfromthepreliminarybillofmaterialandproduct/processassumptions.1.11PreliminaryListingofSpecialProductandProcessCharacteristicsSpecialproductandprocesscharacteristicsareidentifiedbythecustomerinadditiontothoseselectedbythesupplierthroughknowledgeoftheproductandprocess.Theteamshouldassurethatapreliminarylistofspecialproductsandprocesscharacteristicsresultingfromtheanalysisoftheinputpertainingtocustomerneedsandexpectationsisdeveloped.Thislistingcanbedevelopedfromthefollowingitems:ProductassumptionsbasedontheanalysisofcustomerneedsandexpectationsIdentificationofreliabilitygoals/requirementsAPQP411．8可靠性和質(zhì)量目標(biāo)可靠性目標(biāo)是在顧客需要和期望、項目目標(biāo)及可靠性基準(zhǔn)的基礎(chǔ)上制定的。顧客需要和期望可以是無安全問題和可維修性。有些可靠性基準(zhǔn)可以是競爭者產(chǎn)品的可靠性、顧客的報告或在一設(shè)定時間內(nèi)修理的頻率?？偟目煽啃阅繕?biāo)可用概率和置信度表示。質(zhì)量目標(biāo)是基于持續(xù)改進(jìn)的目標(biāo)，諸如（PPM）零件／百萬缺陷水平或廢品降低率。l．9初始材料清單除了由供方根據(jù)產(chǎn)品和過程經(jīng)驗中選擇外，特殊的產(chǎn)品和過程特性均由顧客確定。在這一階段，小組應(yīng)確保制定出通過對有關(guān)顧客需要和期望的輸入的分析而得出的特殊產(chǎn)品和過程特性的初始明細(xì)表。這一明細(xì)表的制定基于（但不限于）以下方面：基于顧客需要和期望分析的產(chǎn)品設(shè)想；可靠性目標(biāo)／要求的確定；從預(yù)期的制造過程中確定的特殊過程特性；類似零件的失效模式及后果分析（FMFA）。42IdentificationofspecialprocesscharacteristicsfromtheanticipatedmanufacturingprocessSimilarpartFMEAsNote:Specialcharacteristiccanaffectthesafefunctioningofthevehicleandcompliancewithgovernmentregulationssuchasflammability,occupantprotection,steeringcontrol,braking,emissions,noise,EMCetc.Duringtheproductdesignanddevelopmentphase,thelistshouldberefined,reviewed,andconsensusreached.Theoutputisrequiredtobedocumentedintheprototypecontrolplan.Duringprocessdesignanddevelopment,thelistshouldbeconvertedintoamatrixwhichdisplaystherelationshipbetweentheprocessparametersandthemanufacturingstationsandthisdocumentedintheproductioncontrolplan.1.12ProductAssurancePlanTheProductAssurancePlantranslatesdesigngoalsintodesignrequirements.TheamountofeffortdevotedtotheProductAssuranceAPQP43Planbytheteamdependsoncustomerneeds,expectations,andrequirements.TheProductAssurancePlancanbedevelopedinanyformatandshouldinclude,butisnotlimited,tothefollowingactions:

OutliningofprogramrequirementsIdentificationofreliability,durability,apportionment/allocationgoalsand/orrequirementsAssessmentofnewtechnology,materials,application,environment,packaging,service,andmanufacturingrequirementsoranyotherfactorthatmayplacetheprogramatriskDevelopmentofFailureModeAnalysisDevelopmentofpreliminaryengineeringstandardsrequirementsTheProductAss.PlanisanimportantpartoftheProductQualityPlan.1.13ManagementSupportAPQP44l·12產(chǎn)品保證計劃產(chǎn)品保證計劃將設(shè)計目標(biāo)轉(zhuǎn)化為設(shè)計要求。產(chǎn)品質(zhì)量策劃小組在產(chǎn)品保證計劃上所作的努力的程度取決于顧客的需要、期望和要求。本手冊對制定產(chǎn)品保證計劃的方法不作規(guī)定，產(chǎn)品保證計劃可采用任何清晰易懂的格式，它可包括（但不限于）以下措施：概述項目要求；可靠性、耐久性和分配目標(biāo)和／或要求的確定；新技術(shù)、復(fù)雜性、材料、應(yīng)用、環(huán)境、包裝、服務(wù)和制造要求或其它任何會給項目帶來風(fēng)險的因素的評定；進(jìn)行失效模式分析（FMA）（參見附錄H）；制定初始工程標(biāo)準(zhǔn)要求。

產(chǎn)品保證計劃是產(chǎn)品質(zhì)量計劃的重要組成部分。l·13管理者支持

產(chǎn)品質(zhì)量策劃小組成功的關(guān)鍵之一是高層管理者對此工作的興趣、承諾和支持，小組在每一產(chǎn)品質(zhì)量策劃階段結(jié)束時應(yīng)將新情況報告給管理者以保持其興趣，并進(jìn)一步促進(jìn)他們的承諾和支持。在小組的要求下，可以更頻繁地報告新情況和／或要求幫助，這種新情況報告是正式的，留有提問和解答的機(jī)會。45Section2.0ProductDesignandDevelopment階段2.0產(chǎn)品設(shè)計及開發(fā)Taskofthissection:此階段的任務(wù)AcomprehensiveandcriticalreviewofengineeringrequirementandotherrelatedtechnicalinformationPreliminaryfeasibilityanalysistoassessthepotentialproblems,anddevelopmentoftherespectivecontrolplanforprototypeVerifythattheproductorservicemeetstheobjectivesofthecustomer(designverification)APQP46InputDesigngoalsReliabilityandqualitygoalsPreliminarybillofmaterialPreliminaryprocessflowchartPreliminarylistingofspecialproductandprocesscharacteristicsProductassuranceplanOutputDesignFMEADesignverificationDesignreviewsPrototypebuild-controlplanEngineeringdrawingsEngineeringspecificationsMaterialspecificationsNewequipment,toolingandfacilitiesrequirementsSpecialproductandprocesscharacteristicsGages/testequipmentrequirementsTeamfeasibilitycommitmentandmanagementsupportProductDesignandDevelopmentSection2.0APQP47

階段2.0產(chǎn)品設(shè)計及開發(fā)由設(shè)計負(fù)責(zé)部門的輸出：

設(shè)計失效模式及后果分析（DFMEA）可制造性和裝配設(shè)計設(shè)計驗證設(shè)計評審樣件制造工程圖樣（包括數(shù)學(xué)數(shù)據(jù)工程規(guī)范材料規(guī)范圖樣和規(guī)范的更改由產(chǎn)品質(zhì)量先期策劃小組的輸出：新設(shè)備

工裝和設(shè)施要求特殊產(chǎn)品和過程特性樣件制造-控制計劃量具／試驗設(shè)備要求小組可行性承諾和管理者支持

48492.1DesignFailureModeandEffectsAnalysisThedesignFMEAisadisciplinedanalyticaltechniquethatassessestheprobabilityoffailureaswellastheeffectofsuchfailure.TheDesignFMEAChecklistinappendixA-1shouldalsobereviewedtoassurethattheappropriatedesigncharacteristicshavebeenconsidered.2.2DesignforManufacturabilityandAssemblyDesignforManufacturabilityandAssemblyisaSimultaneousEngineeringprocessdesignedtooptimizetherelationshipbetweendesignfunction,manufacturability,andeaseofassembly.Ataminimum,theitemslistedhereshouldbeconsideredbytheProductQualityPlanningTeam:Design,concept,function,andsensitivitytomanufacturingvariationManufacturingand/orassembleprocessAPQP502．1設(shè)計失效模式和后果分析DFMEA是一種評定失效可能性及其失效影響的分析技術(shù)，DFMEA的一種形式為系統(tǒng)失效模式及后果分析（SFMEA），DFMEA是一種動態(tài)文件，隨顧客需要和期望不斷更新，DFMEA的制定為小組提供了評審以前選擇的產(chǎn)品和過程特性和作出必要補充、改變和刪減的機(jī)會?？巳R斯勒、福特和通用汽車公司的潛在失效模式及后果分析參考手冊應(yīng)作為一種可接受的DFMEA的方法，還應(yīng)評審附錄A一1中的設(shè)計FMEA清單，以保證已考慮合適的設(shè)計特性。2．2可制造性和裝配設(shè)計可制造性和裝配設(shè)計是一種同步技術(shù)過程，用來優(yōu)化設(shè)計功能、可制造性和易于裝配之間的關(guān)系。第一章中所確定的顧客需要和期望范圍將決定供方產(chǎn)品質(zhì)量策劃小組進(jìn)行此活動的程度。本手冊不包括或涉及制定可制造性和裝配設(shè)計計劃的正式方法。產(chǎn)品質(zhì)量策劃小組至少要考慮以下所列的項目：設(shè)計、概念、功能和對制造變差的敏感性；制造和／或裝配過程；尺寸公差；性能要求；部件數(shù)；過程調(diào)整；材料搬運。

產(chǎn)品質(zhì)量策劃小組的知識、經(jīng)驗、產(chǎn)品／過程、政府法規(guī)和服務(wù)要求有可能需要考慮其它因素。51DimensionaltolerancesPerformancerequirementsNumberofcomponentsProcessadjustmentsMaterialHandling2.3DesignVerificationDesignverificationverifiesthattheproductdesignmeetsthecustomerrequirementsderivedfromtheactivitiesdescribedinsection1.0.2.4DesignReviewsDesignreviewsareregularlyscheduledmeetingledbythesupplier’sdesignengineeringactivityandmustincludeotheraffectedareas.Designreviewsareaseriesofverificationactivitiesthataremorethananengineeringinspection.APQPAPQP52AtaminimumDesignReviewsshouldincludeevaluationof:Design/functionalrequirementsFormalreliabilityandconfidencegoalsComputersimulationandbenchtestresultsDesignFMEAsReviewoftheDesignForManufacturabilityandAssemblyeffortApplicationofDesignofExperiments(DOE)andassemblybuildvariationresultsTestfailureDesignVerificationprogressAPQPAPQP532．3設(shè)計驗證設(shè)計驗證檢驗產(chǎn)品設(shè)計是否滿足第一章所述活動的顧客要求。2．4設(shè)計評審設(shè)計評審是以供方設(shè)計技術(shù)活動為主并且應(yīng)包括其它被影響領(lǐng)域的定期安排的會議。設(shè)計評審為防止問題和誤解的有效方法，而且還是監(jiān)測進(jìn)展雙向管理者報告的途徑。設(shè)計評審不只是技術(shù)檢驗，而是一系列的驗證活動。至少設(shè)計評審應(yīng)包括以下方面的評價：設(shè)計／功能要求的考慮；正式的可靠性和置信度目標(biāo)；部件／子系統(tǒng)／系統(tǒng)工作循環(huán)；計算機(jī)模擬和臺架試驗結(jié)果；設(shè)計失效模式及后果分析（DFMEA）；可制造性和裝配設(shè)計的評審；試驗設(shè)計（DOE）和裝配產(chǎn)生的變差結(jié)果（參見附錄B）；破壞性試驗；設(shè)計驗證進(jìn)展；

54設(shè)計評審的重要功能是跟蹤設(shè)計驗證進(jìn)展。供方應(yīng)通過使用計劃和報告格式，即由克萊斯勒和福特汽車公司制定的設(shè)計驗證計劃和報告（DVP＆R）來跟蹤設(shè)計驗證進(jìn)展。計劃和報告是保證以下方面的正式方法：設(shè)計驗證；通過采用綜合的試驗計劃和報告對部件和總成的產(chǎn)品和過程確認(rèn)。產(chǎn)品質(zhì)量策劃小組不只限于所列項目，適當(dāng)時小組應(yīng)考慮并使用附錄B中所列的分析技術(shù)。552.5PrototypeBuild-ControlPlanPrototypecontrolplansareadescriptionofthedimensionalmeasurementsandmaterialandfunctionalteststhatwilloccurduringprototypebuild.Allprototypesshouldshouldbereviewedwithrespecttothefollowingaspects:Assurethattheproductorservicemeetsspecificationandreportdataasrequired.Ensurethatparticularattentionhasbeengiventospecialproductsandprocesscharacteristics.Usedataandexperiencetoestablishpreliminaryprocessparametersandpackagingrequirements.Communicateanyconcerns,deviationsand/orcostimpacttothecustomer.APQP562．5樣件制造——控制計劃樣件控制計劃是對樣件制造過程中的尺寸測量和材料與功能試驗的描述，產(chǎn)品質(zhì)量策劃小組要確保制定樣件控制計劃?？刂朴媱澐椒ㄕ撘姷诹滤?。附錄A－8和第六章中的控制計劃檢查清單可幫助制定樣件控制計劃。樣件的制造為小組和顧客提供了一個極好的機(jī)會來評價產(chǎn)品或服務(wù)滿足顧客愿望的程度。產(chǎn)品質(zhì)量策劃小組負(fù)責(zé)的所有樣件都應(yīng)被評審以便：保證產(chǎn)品或服務(wù)符合所要求的規(guī)范和報告數(shù)據(jù)；保證已對特殊產(chǎn)品和過程特性給予了特別的注意；使用數(shù)據(jù)和經(jīng)驗以制定初始過程參數(shù)和包裝要求；將關(guān)注問題、變差和／或費用影響傳達(dá)給顧客。572.6EngineeringDrawingsCustomerdesignsdonotprecludetheplanningteam’sresponsibilitytoreviewengineeringdrawings.Theteamshouldreviewengineeringdrawingsinordertodeterminewhichcharacteristicsaffectfit,function,durabilityand/orgovernmentalregulatorysafetyrequirements.Drawingshouldbereviewedtodetermineifthereissufficientinformationforadimensionallayoutoftheindividualpart.Controlordatumsurfaces/locatorsshouldbeclearlyidentified.Theteamshouldassurethatmathdataiscompatiblewiththecustomerssystem.2.7EngineeringSpecificationThesuppliershoulddeterminewhichcharacteristicsaffectorcontroltheresultsthatfulfilmeetingfunctional,durability,andappearancerequirements.Thesizeandfrequencyofsamples,unlessspecified,aretobedeterminedbythesupplierhimself.APQP582．6工程圖樣（包括數(shù)學(xué)數(shù)據(jù)）顧客設(shè)計不排除策劃小組以如下方式評審技術(shù)圖樣的職責(zé)。工程圖樣可包括應(yīng)在控制計劃上出現(xiàn)的特殊（政府法規(guī)和安全性）特性。如沒有顧客工程圖樣，應(yīng)由策劃小組評審控制圖樣以決定哪些特性影響配合、功能、耐久性和／或政府法規(guī)中的安全要求。應(yīng)對工程圖樣進(jìn)行評審來確定是否具有足夠的數(shù)據(jù)以對每個零件進(jìn)行全尺寸檢驗。應(yīng)能清楚地標(biāo)識控制或基準(zhǔn)平面／定位面，以便能為現(xiàn)行的控制過程設(shè)計適當(dāng)?shù)墓δ芰烤吆脱b備，應(yīng)評價尺寸以保證可行性和工業(yè)制造和測量標(biāo)準(zhǔn)相一致。適當(dāng)時，小組應(yīng)保證數(shù)學(xué)數(shù)據(jù)和顧客的系統(tǒng)兼容以進(jìn)行有效的雙向交流。2．7工程規(guī)范對控制規(guī)范詳細(xì)的評審和了解將有助于產(chǎn)品質(zhì)量策劃小組識別有關(guān)部件或總成的功能、耐久性和外觀的要求。樣本容量、頻率和這些參數(shù)的接受標(biāo)準(zhǔn)一般在技術(shù)規(guī)范的生產(chǎn)過程中試驗一章中予以確定，否則樣本容量和頻率由供方?jīng)Q定并列入控制計劃中，在這兩種情況下，供方應(yīng)確定哪些特性影響或控制滿足功能、耐久性及外觀要求。592.8MaterialSpecificationsInadditiontodrawingsandperformancespecifications,materialspecificationsshouldbereviewedforSpecialCharacteristicsrelatingtophysicalproperties,performance,environmental,handling,andstoragerequirements.2.9DrawingandSpecificationChangeTheteammustensurethatdrawingandspecificationchangesarepromptlycommunicatedandproperlydocumentedtoallaffectedareas.2.10Newequipment,ToolingandFacilitiesRequirementsTheDesignFMEA,ProductAssurancePlanand/orDesignReviewsmayidentifynewequipmentandfacilitiesrequirements.TheteamshouldaddresstheserequirementsbyaddingtheitemstotheTimingChartaswellasinsurethatnewequipmentandtoolingiscapableanddeliveredontime.Facilitiesprogressshouldbemonitoredonanongoingbasis.RefertotheNewEquipment,ToolingandTestEquipmentChecklistinAppendixA-3.APQP602．8材料規(guī)范除了圖樣和性能規(guī)范外，對于涉及到物理特性、性能、環(huán)境、搬運和貯存要求的特殊特性應(yīng)評審材料規(guī)范，這些特性也應(yīng)包括在控制計劃中。2．9圖樣和規(guī)范的更改當(dāng)需要更改圖樣和規(guī)范時，小組應(yīng)保證這些更改能立即通知到所有受影響的領(lǐng)域并用適當(dāng)?shù)臅嫘问酵ㄖ@些部門。2·10新設(shè)備、工裝和設(shè)施要來DFMEA，產(chǎn)品保證計劃和／或設(shè)計評審可能提出新設(shè)備和設(shè)施的要求。產(chǎn)品質(zhì)量策劃小組應(yīng)在進(jìn)度圖表上增加這些以強調(diào)此要求項目。小組應(yīng)保證新的裝備和工裝可使用并能及時供貨。要監(jiān)測設(shè)施進(jìn)度情況，以確保能在計劃的試生產(chǎn)前完工。新設(shè)備、工裝和試驗設(shè)備清單參見附錄A－3。612.11SpecialProductandProcessCharacteristicsThisbuildsonthelistingofpreliminaryspecialproductandprocesscharacteristicsdescribedinsection1.0.ForthedocumentationandupdatingofspecialcharacteristicstheformsControlPlanSpecialCharacteristicsandDataPointCo-ordinatescanbeused.Theseformscanbeusedaswellasanyotherformthataccomplishedthesamedocumentationrequirement.2.12Gages/TestingEquipmentRequirementsGages/testingequipmentrequirementsmayalsobeidentifiedatthistimeandshouldbeaddedtotheTimingChart.Progressshouldthenbemonitored.APQP622·11特殊產(chǎn)品和過程特性在第一章所述的質(zhì)量策劃階段，小組應(yīng)通過了解顧客的愿望的基礎(chǔ)上識別初始特殊產(chǎn)品和過程特性進(jìn)行了標(biāo)識。產(chǎn)品質(zhì)量策劃小組應(yīng)根據(jù)特性明細(xì)通過評價技術(shù)信息在設(shè)計特性的評審和設(shè)計開發(fā)過程中達(dá)到一致。附錄C中包含有一個描述克斯勒、福特和通用汽車公司用來表示特殊特性的符號的表，達(dá)成的一致要以文件形成體現(xiàn)在適當(dāng)?shù)目刂朴媱潈?nèi)?？刂朴媱澋奶厥馓匦院蛿?shù)據(jù)點座標(biāo)值參見第六章的補充件K和L，它們是文件化和更新特殊特性，必要時也是支持樣件、試生產(chǎn)和生產(chǎn)控制計劃的推薦方法。供方可以使用任何達(dá)到相同文件化要求的表格，顧客可規(guī)定單獨的批準(zhǔn)要求。詳細(xì)資料參見第三部分的克萊斯勒、福特和通用汽車公司質(zhì)量體系要求。2·12量具／試驗設(shè)備要求量具／試驗設(shè)備要求也可在這一時間識別，產(chǎn)品質(zhì)量策劃小組應(yīng)將這些要求增加到進(jìn)度圖表中，然后監(jiān)測進(jìn)展，以保證滿足所要求的進(jìn)度。632.13TeamFeasibilityCommitmentsandManagementSupportTheteammustassessthefeasibilityoftheproposeddesignatthistime.Theteammustbesatisfiedthattheproposeddesigncanbemanufactured,assembled,tested,packagedanddeliveredinsufficientquantityatanacceptablecosttothecustomeronschedule.TheDesignInformationChecklistinAppendixA-2willserveasthebasisfortheTeamFeasibilityCommitmentform.TheTeamFeasibilityCommitmentshouldbesubmittedtomanagementforconfirmation.APQPAPQP642·13小組可行性承諾和管理者的支持在這一時間，產(chǎn)品質(zhì)量策劃小組應(yīng)評定所提出的設(shè)計的可行性，顧客的自行設(shè)計不排除供方評定設(shè)計可行性的義務(wù)。小組應(yīng)確信所提出的設(shè)計能按預(yù)定時間以顧客可接受的價格付諸于制造、裝配、試驗、包裝和足夠數(shù)量的交貨。附錄A－2中的設(shè)計信息清單使得小組能評審其在這一章中的工作并對其有效性作出評價。該清單還將作為附錄E“小組可行性承諾”中未決議題的基礎(chǔ)。小組對所提出的設(shè)計具有可行性的一致性意見和所有需要解決的未決議題應(yīng)形成文件并提交給管理者以獲取其支持。附錄E中所示的小組關(guān)于可行性承諾的表格為這類推薦的書面記錄的示例。65Section3.0ProcessDesignandDevelopment階段3.0過程設(shè)計及開發(fā)Taskofthissection:此階段的任務(wù)EnsurecomprehensivedevelopmentofaneffectivemanufacturingsystemDevelopingtherespectiveControlPlanforpre-launchEnsurethatcustomerrequirements,needsandexpectationsaremet(verificationofprocess)APQP66Input

DesignFMEADesignverificationDesignreviewsPrototypebuild-controlplanEngineeringdrawingsEngineeringspecificationsMaterialspecificationsNewequipment,toolingandfacilitiesrequirementsSpecialproductandprocesscharacteristicsGages/testequipmentrequirementsTeamfeasibilitycommitmentandmanagementsupportOutputProduct/processqualitysystemreviewProcessflowchart