【正文】 Base Documentation 文件 ? Critical Characteristics Matrix 特性矩陣 ? Process Flow Diagram 流程圖 ? Design FMEA ? Process FMEA ? Control Plan Chicken or Egg 先有雞先有蛋 ? ? Which is First? Second? Third? Control Plan? Process Flow Diagram? Design FMEA? Process FMEA? Process Documentation (?Work? Instructions)? ? Why Does it Matter? 為何重要 Typical Automotive Trilogy Development 開(kāi)發(fā)三部曲 APQP Timeline Process Flow Diagram (Includes ALL Processes) Design FMEA Process FMEA (On ALL Processes) Critical Characteristics Failure Effects Issues Process Control Plan(Critical Processes from FMEA)Critical Characteristics Characteristic Control Issues Some Elements may be Included On The Links 連接 ? Each Flow Chart ‘element’ with historical issue must have a matching FMEA element. As a ‘trilogy’, remember the links must all match. 流程 , 歷史事件及 FMEA的連接 /三部曲 ? The ?trilogy? documents must precisely link to your process documentation (work instructions or however your pany addresses this issue)三部曲文件與製程文件的連接 The Control Plan 管制計(jì)劃 ? A Control Plan is a written description of systems for parts and processes 是一文件化的描述零件及過(guò)程系統(tǒng) ? Process Dominated 過(guò)程導(dǎo)向 ? Prototype 原形 *A Design Output 是一設(shè)計(jì)輸出 ? Used During Prototype Build, Dimensional Measurements, Material and Performance Tests 於原形階段使用 , 包括尺寸確認(rèn) , 材質(zhì)及功能測(cè)試 ? PreLaunch 量試 ? Update After Prototype and Before Production 於原形階段之後量產(chǎn)之前使用 ? Production 量產(chǎn) ? Comprehensive, Process Controls, Test and Measurement Systems Used, Reaction Plan, Sampling Plans, SPC Requirements 包括完整的製程管制 , 測(cè)試及量測(cè)系統(tǒng) , 應(yīng)變計(jì)劃 , 抽樣計(jì)劃 , SPC QS9000:1998 FMEAs ? Quality Planning ? Process Failure Mode and Effects Analysis (Process FMEAs) ? Process FMEAs shall consider all special characteristics. Efforts shall be taken to improve the process to achieve defect prevention rather than defect detection. Certain customers have FMEA review and approval requirements that shall be met prior to production part approval (see customer specific pages). Refer to the Potential Failure Mode and Effects Analysis reference manual. 所有特殊特性都要包括 , 預(yù)防勝於偵測(cè) QS9000:1998 Control Plans ? Quality Planning ? The Control Plan ? Suppliers shall develop Control Plans at the system, subsystem, ponent and/or material level, as appropriate for the product supplied. 包括系統(tǒng) ,子系統(tǒng) , 零件及材料 ? The Control Plan requirement enpasses processes producing bulk material (., steel, plastic resin, paint) as well as those producing ? The output of the advanced quality planning process, beyond the development of robust processes, is a Control Plan. Control Plans may be based on existing plans (for mature products and capable processes). New plans are required when products or processes differ significantly from those in current production. APQP的輸出是管制計(jì)劃 , 可基於現(xiàn)有計(jì)劃 , 當(dāng)產(chǎn)品或過(guò)程有明顯差異時(shí) , 應(yīng)有新計(jì)劃 QS9000:1998 Control Plans ? Quality Planning ? The Control Plan (continued) ? The Control Plan shall cover three distinct phases as appropriate: 應(yīng)包括三階段 ? Prototype 原形 a description of the dimensional measurements and material and performance tests that will occur during Prototype build. Supplier shall have prototype control plans when required. 當(dāng)有客戶要求時(shí) Prototype CP 要有 ? Prelaunch量試 a description of the dimensional measurements and material and performance tests that will occur after Prototype and before full Production. ? Production 量產(chǎn) a prehensive documentation of product/process characteristics, process controls, tests, and measurement systems that will occur during mass production. QS9000:1998 Quality Planning ? Suppliers shall establish crossfunctional teams to develop Control Plans . 應(yīng)建立跨功能小組以發(fā)展管制計(jì)劃 Develop FMEA 發(fā)展 FMEA Establish Actions to reduce RPN 提出行動(dòng)以降低 RPN Develop CCSC 發(fā)展 CCSC Semiconductor Supplement 半導(dǎo)體補(bǔ)充件 ? Quality Planning ? During the advanced quality planning processes, the supplier shall include all processes from the ining material through shipping and warehousing 從進(jìn)料到出貨及倉(cāng)儲(chǔ)都要包括 ? Failure Mode and Effects Analysis and Control Plan documents shall include these processes. FMEA/ CP 要考慮 /包括所有製程 ? ? The Intent:The supplier shall *consider* all processes. But does it mean that all process shall be included in the FMEA and Control Plan?包括所有製程 ? APQP Manual : 1995 ? Overview ? “A control plan is a written description of the system for controlling parts and processes” ? “In effect, the Control Plan describes the actions that are required at each phase of the process including receiving, inprocess, outgoing, and periodic requirements to assure that all process outputs will be in a state of control” 描述個(gè)階段所需的各項(xiàng)管制以確保期為管制狀態(tài) Concern Resolution 問(wèn)題的解決 ? Design or Process concerns 設(shè)計(jì)或過(guò)程問(wèn)題 ? Responsibility matrix 職責(zé) ? Disciplined problem solving methods 解決問(wèn)題的手法 ? Use analytical techniques (*as appropriate) (See AIAG?s APQP 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 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! 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 Project Plan Definitions 專案計(jì)劃的定義 ? Mission Goal, customer and approach 任務(wù) , 目標(biāo) ,