APQP / PPAP

Advanced Product Quality Planning (from AIAG) provides the framework for the development and manufacturing of a product for a vehicle. The approach describes gathering customer input, developing the product; develop the process from which the product will be built at volume; validate the product and the processes; finally launch the product – production.

Voice of Customer/Requirements

The voice of the customer drives our product development endeavor. This is an understanding of the scope of the work and requirements are generated. The scope is refined to the level to which a strategy or approach to meet these customer demands can be identified and planned. This often entails the use of decision matrices (example: Pugh Matrix) and tools such as Quality Function Deployment (QFD).

Product Development

The product is iteratively and incrementally developed in the product development portion of the process. This consists of building models and prototypes of varying degrees of complexity and fidelity to the proposed final product. During each build, the product is explored, something is learned and alterations and refinements are made to the design. A tool known as the Design Failure Mode Effects Analysis (DFMEA) will help us to learn from the product as progress is made.

Process Development

In parallel with the development of the product comes the development of the processes that will ultimately produce the product at volume (Design for Manufacture and Assembly). This is often referred to as concurrent engineering. This shortens the product development cycle as well as limiting or greatly reducing rework. This work will entail setting up the manufacturing line, developing control plans, work instructions, poke yoke, DFMEA, process capability and much more.

Process/Product Validation

The validation of the product and the process helps ascertain the abilities of both the product and the manufacturing processes to meet the expectation or defined project and business goals. This phase includes trial production runs, run at rate runs, Measurement System Evaluation, Production Part Approval, and much more.

Launch

Quality management is the practices the organization employs to meet the customer quality expectation. There are techniques and tools used to deliver a cost effective quality product. This includes quality control, quality assurance, quality improvement, and quality planning. Product reliability is the quality of the product over time, and Total Quality Management is a comprehensive approach to continuous quality improvement.

APQP – Advance Product Quality Planning – an approach to automotive product development and manufacturing which includes tools and techniques in addition to processes for designing and manufacturing a quality product at automotive production volumes.

    1. https://www.aiag.org/
    2. https://www.sae.org/
    3. https://vda-qmc.de/en/software-processes/automotive-spice/
    4. https://www.assemblymag.com/
    5. https://www.ai-online.com/

Project Management for Automotive Engineers

Gemba Walk

Go to the place where the work is performed, that is the Gemba walk.  This does not apply just to manufacturing, but also line managers and their respective departments as well as to project management. You want to know what is going on, what could be better, go unto the work space and watch and […]

Common Cause and Special Cause Variation

Variation! Though sometimes we may refuse to recognize it, the world is a full of variation, even in the things we think or believe are constant. For example, my wife has been known to say, “you always do…” or “you never do…”, to which I retort, I am human and I am not that repeatable.  […]

Instead of No Estimates

Instead of  No Estimates Instead of no estimates, we should consider adjusting our approach to estimates that eliminate the abuse, and still allows for the answers to the business questions, “does this project improve our bottom line” allowing the business to determine if the company really wants to undertake the project, and if so, do […]

Abuses from Estimating

I would like to start off with has anybody seen an appropriate study of estimating when it comes to doing the work? Not a study that already knows the conclusion they want, but an actual scientific study.  The thoughts below are not based upon anything like that but, having seen many estimating boondoggles. I have […]

Risk Management Through the Project Class

Risk Management Through the Project In modern life, risk management is a fundamental discipline for success. This does not just apply to work life, or project management but also personal life. Today we are going to discuss the approaches and impacts on the project when there is insufficient attention to the risks to which the […]

Poke Yoke

Poke Yoke Jon M Quigley There are a set of tools and techniques that come with developing products for the automotive industry and are part of the Advanced Product Quality Planning for the product.  We have written about APQP or some years and have decades of experience in this approach to product development.  In general, […]

Independent Test and Verification

We are composing a glossary of test terms and we take one from that work today and discuss here. A development organization can be structured in many ways. The development and testing can be essentially one department under one management structure, or these two areas, development and test can be separated each with a respective […]

Measurement effects and analysis on personnel and organizations

by: Shawn P. Quigley Whereas we have discussed some of the possible flaws in measurements we can all still agree that they are needed to provide both improvement in processes and the organization. However, other aspects of obtaining data for the production of quantifiable information: trend analysis and process evaluation, is the human factor both […]

Analysis of Measurements

by: Shawn P. Quigley & Jon M Quigley Measurements and Bias Solely by the process of observing something we can alter the thing which is being observed. This is a known as the observer-expectancy effect.  This effect is born out of conscience and subconscious biases of the observer.  In the case of observing people, we […]

The Un-repeatable Fault

Testing Complex and Embedded Systems What set of conditions could cause this event to occur? When we have elicited all we can from the customer about fault information, it is time to proceed further in our analysis. This next step requires investigation of the design to understand how the symptom of failure described could happen […]

Contact Value Transformation about APQP