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LaunchConcept Initiation/ApprovalProgram Approval PrototypePlanningLinks Between the ToolsContract Review Program PlanDFMEATeam Feasibility CommitmentProduce Process Flow DiagramsConduct Process FMEADevelop Control PlanWork Instruction DevelopmentProduct and Process ValidationEnsure Continuous ImprovementPhase IPhase IIPhase IIPhase IIIPhase IIIPhase IIIPhase IIIPhase IVPhase VDetermine Customer Expectations and Plan for QualityIdentify Key Characteristics Determine Risk and FeasibilityAssociate Characteristics with Process Steps and Identify Key CharacteristicsExpose Sources of Variation and Finalize Key CharacteristicsDetermine Methods to Improve Process and Control VariationImplement Control Plan and Standardize the ProcessEnsure Customer Expectations are MetExercise Management OversightThe Target and The GoalLink Between the DocumentsProcess Flow Diagrams? Updated after production trial run.? Need to indicate special characteristics generated at each step.? Completed Along with Control Plan (APQP Process).? Generally contains same information as process traveler.Process Flow Diagram ExampleAPQP Links to PFMEAProcess FMEA? Must follow flow of the process flow diagram.? Must include ALL process special characteristics (as a minimum).How a PFMEA Works? Where does the data for the PFMEA e from?? What types of people are a part of the PFMEA team?? What types of activities should we spend a lot of time on?PFMEAs/Control Plans and 8Ds During APQP? PFMEAs should be driven by real data, including 8Ds (internal and external), warranty and returned part analysis? PFMEAs should be pleted by process experts and should be a driver of the control plans and work instructions? Work instructions (Post control log, process parameter logs, preventive maintenance, etc.) implement the control plan in the process? When there is a quality problem there is an opportunity to improve the control plan and the work instructionsAPQP Links to Control PlanControl Plans? Includes product and process special characteristics.? Includes SPC requirements.? Follows flow of process flow chart and PFMEA.? May require customer approval.Types of Control Plans? Prototype build control plan(s) ? Prelaunch control plan? Production control planPrototype Build Control Plan? A description of the dimensional measurements.? Material tests– Function