【正文】 在隨後的設(shè)計(jì)活動(dòng) 52 ?可靠目標(biāo)是依據(jù)顧客的需要及期望，設(shè)計(jì)的目標(biāo)及可靠度最佳典範(fàn) ?可靠度目標(biāo)應(yīng)以機(jī)率及信賴水準(zhǔn)表示 ?品質(zhì)目標(biāo)係持續(xù)改善的方向，如： PPM、缺點(diǎn)水準(zhǔn)或報(bào)廢降低 可靠及品質(zhì)目標(biāo) 53 初步料表（結(jié)構(gòu)表） BOM ? BOM係依據(jù)對(duì)產(chǎn)品 /製程假設(shè)訂定流程圖 ?為了明訂初步特殊產(chǎn)品及製程特性，必需選擇適當(dāng)?shù)脑O(shè)計(jì)及製造步驟 /過程 54 ? 依據(jù)初步 BOM及產(chǎn)品 /製程假設(shè)訂定流程圖 ? 將預(yù)期製造流程，以作業(yè)流程圖的方式表示 初期製造流程 初步特殊產(chǎn)品 /製程特性清單 供應(yīng)商依據(jù)顧客所定義及對(duì)產(chǎn)品 /製程的了解， 建立如下之資料： – 依顧客之需要及期望做產(chǎn)品假設(shè) – 明定之可靠度目標(biāo) /需求 – 依預(yù)期之製程明定特殊製程特性 – 類似零件的 FMEAs 55 係將設(shè)計(jì)目標(biāo)轉(zhuǎn)換成具體設(shè)計(jì)需求，可以任何 可被知道的格式表示，包括： – 研發(fā)計(jì)畫之需求大綱 – 明定可靠度、耐久性及配置目標(biāo)及需求 – 評(píng)估各項(xiàng)需求，包括新技術(shù)、複雜性、材料、環(huán)境，使用、包裝、服務(wù)及製造之需求，與任何造成研發(fā)計(jì)畫風(fēng)險(xiǎn)之項(xiàng)目 – 建立失效模式分析制度 – 建立初步工程標(biāo)準(zhǔn)需求 （ 產(chǎn)品品保計(jì)畫是產(chǎn)品品質(zhì)計(jì)畫重要的部份 ） 品質(zhì)保證計(jì)劃 56 ?高階管理階層的參與、承諾及支持，是研發(fā)計(jì)畫小組成功的關(guān)鍵 ?更新各階段研發(fā)就是促使管理階層參與、支持及承諾之方法 ?展示研發(fā)工作符合文件規(guī)定及解決問題之期限，是為了維持管理階層參與支持 ?產(chǎn)品品質(zhì)規(guī)劃會(huì)議希望高階能參與 管理階層的支持 57 APQP Phase 2: Product Design and Development 產(chǎn)品設(shè)計(jì)及開發(fā) 58 DFMEA設(shè)計(jì) FMEA ? Disciplined analytical tool: Assess probability of failure, Effect of failure系統(tǒng)性的分析工具 : 評(píng)估失效的機(jī)率及其影響 ? Must be continually updated必須經(jīng)常更新 ? Causes changes and/or additions to previously selected special product and/or process characteristics提供變更及增添以前選擇的產(chǎn)品及過程特性的機(jī)會(huì) ? If you do not have design control, you (should) have customer DFMEA如無設(shè)計(jì)責(zé)任也應(yīng)取得客戶的 FMEA ? Check list (AIAG APQP Manual Appendix A1) 59 DFM and DFA製造性及裝配設(shè)計(jì) ?Design, concept, function and sensitivity (tolerance) to manufacturing variation設(shè)計(jì) , 概念 , 功能 , 公差 , 考慮 製造變異 ?Manufacturing and/or assembly process製造及組立過程 ?Dimensional tolerances尺寸公差 ?Performance requirements性能要求 ?Number of ponents (plexity)零件數(shù)量 ?Process adjustments調(diào)整製程 ?Material handling物料搬運(yùn) 60 Design Verification設(shè)計(jì)驗(yàn)證 ?Inspection methods檢驗(yàn)方法 ?Testing methods測(cè)試方法 ?Ensure that all design outputs meet design input requirements: Alternate calculations, CAD/math data, Review design stage documents before release確保設(shè)計(jì)輸出符合輸入要求 , 例如替代性計(jì)算 , CAD 方法 , 審查設(shè)計(jì)階段文件 61 Design Reviews Evaluations設(shè)計(jì)審查 ? Design/functional requirement(s) and considerations 包括設(shè)計(jì)功能要求的考慮 ? Formal reliability and confidence goals正式可靠度及信賴性目標(biāo) ? Component/subsystem/system duty cycles工作循環(huán) ? Computer simulation and benchmarking test results電腦模擬及標(biāo)竿測(cè)試結(jié)果 ? DFMEA(s) ? Review of the DFM and DFA ? Design of experiments (DOE) and assembly build variation results實(shí)驗(yàn)計(jì)劃法及組裝造成的變異分析 ? Test failure 測(cè)試失效 ? Design verification progress設(shè)計(jì)驗(yàn)證進(jìn)度 62 Design Review Tracking設(shè)計(jì)審查的追蹤 ?Track verification progress using a design verification plan and report (DVPamp。 Control Plan reference manual page 4 and appendix B, page 81) 如因果圖 , 特性矩陣圖 , 標(biāo)竿法 , 裝配變異分析 33 Timing Plan 日程計(jì)劃 ?Depends upon Product plexity, Customer expectations 考慮產(chǎn)品複雜性及客戶要求 ?Team plan for Training, Event and Action 訓(xùn)練 , 事件及行動(dòng) ?Framework for tracking 追蹤的機(jī)制 ?Basis for status reporting 狀況回報(bào) ?Prepare a timing chart using available project or similar software 使用軟體製作時(shí)間表 Do NOT Under Estimate the Importance of Timing! 34 Timing Plan Contents日程計(jì)劃的內(nèi)容 ?Identify individual tasks 鑑別個(gè)別任務(wù) ?Track resources by task 依任務(wù)追蹤資源 ?Establishes dependencies between tasks 鑑別任務(wù)關(guān)聯(lián)性 ?Determine critical path 決定關(guān)鍵路徑 ?Track specific tasks or groups of tasks 追蹤任務(wù) ?Status reports 狀況報(bào)告 35 Project Plan Definitions 專案計(jì)劃的定義 ? Mission Goal, customer and approach 任務(wù) , 目標(biāo) , 客戶及方法 ? Scope What will and will not be included (with consideration to available technology) 範(fàn)圍 要包含哪些 , 可用的技術(shù) ? Objectives Technical, profit, performance, quality, 目標(biāo)要包含哪些 ? Requirements – Deliverables 要求 可交貨 ? Definition and specification Criteria it must meet 定義及規(guī)範(fàn) 一定要符合條件 ? Market analysis Expected annual production volume, start (delivery) target date, target price, key sales points, key petitors, etc. ? 市場(chǎng)分析 年產(chǎn)量 , 交貨時(shí)間 , 目標(biāo)價(jià) , 主要賣點(diǎn) , 主要競(jìng)爭(zhēng)者 36 Project Plan Definitions (continued) 專案計(jì)劃的定義 (續(xù) ) ? Preliminary Feasibility Degree to which current tooling and equipment can be used 初期可行性評(píng)估 , 哪些模治具及設(shè)備可用 ? Timeline Major milestones and detail task schedule 時(shí)間表 里程碑及細(xì)部專案計(jì)劃的時(shí)程 ? Control system Answers questions such as: 管制系統(tǒng) ? How will progress be measured? Who will receive reports? How are changes handled? What limits are there on authority, responsibility, and accountability?如何衡量進(jìn)度 ?誰應(yīng)收到報(bào)告 ?如何處理變更 ?權(quán)責(zé)界線為何 ? ? Cost estimate Estimate with assumptions. Often ?all? information is not , 假設(shè)法 , 通常什麼資訊都沒有 37 Analytical Techniques 分析技術(shù) ? Assembly Build Variation Analysis 組裝造成的變異分析 ? Benchmarking 標(biāo)竿比較 ? Cause amp。 Engineering ?*Your APQP Team should attend as many classes as time will allow Production Staff amp。V Rheinland Taiwan Ltd. 2020 T220。 Goal 目標(biāo) Continuous improvement持續(xù)改善 Prototype Prelaunch Mass production LSL規(guī)格下限 USL規(guī)格上限 8 產(chǎn)品品質(zhì)規(guī)劃時(shí)序圖 原型試作 量試 概念啟始 認(rèn)可 規(guī)劃 計(jì)畫 認(rèn)可 產(chǎn)品研發(fā) 製程發(fā)展 製程研發(fā) / 驗(yàn)證 產(chǎn)品研發(fā) / 驗(yàn)證 計(jì)畫 /定義 研發(fā)守案 生產(chǎn) 生產(chǎn)階段 / 迴饋矯正 產(chǎn)品 / 製程 驗(yàn)收 產(chǎn)品 /製程驗(yàn)收 生產(chǎn)計(jì)畫 迴饋與矯正 量產(chǎn) 9 QS 9000 APQP Involves: QS 條文與 APQP的關(guān)聯(lián)性 ? Management Responsibility ? Quality System ? Contract Review ? Design Control ? Document and Data Control ? Purchasing ? Process Control ? Inspection 10 QS 9000 APQP Involves: ? Inspection, Measuring and Test Equipment ? Inspection and Test Status ? Control of Nonconforming Product ? Corrective Action ? Handling, Storage, Packaging and Delivery ? Quality Records ? Training ? Servicing ? Statistical Techniques 11 Each APQP is Unique 每一 APQP都是獨(dú)一無二的 ? Because of product and program differences 產(chǎn)品及計(jì)劃不同 ? Timing and sequence are dependent upon customer needs and expectations 依客戶需求及期望展開時(shí)間及順序 ? Product plexity 產(chǎn)品複雜性 Stamping 沖壓 Subassembly 組立 ? New 新產(chǎn)品 ? Modification 設(shè)變 12 Progressive Fundamentals 成功的基礎(chǔ) ? KEY** Organize a CrossFunctional TEAM 組成跨功能小組 ? Define the scope 定義範(fàn)圍