Professional Documents
Culture Documents
APQP REVISITED
W
h is
hen
i the
th last
l t time
ti
you thought
th
ht
about APQP/PPAP? Advanced
Product Quality Planning and Control
Plan (APQP) was originally printed in
1994 with the second edition in 2008.
Production Part Approval Process
(PPAP) was originally issued in 1993,
the second edition in 1995 and the
third edition in 1999.
In the past 17 years, from 1993 to
the present, computer technology has
done amazing things. Basic office software has done wonders to help fi ll out
and standardize documents. There is
no excuse for not having professional
looking documentation that is organized and easy to produce.
First, assume the following:
1. You have read and understood the
latest document.
TECH TIPS
There is no excuse for not having professional looking documentation that
is organized and easy to produce.
38
038-QM0210soft.indd 38
www.qualitymag.com
1/20/10 12:31:05 PM
www.qualitymag.com
038-QM0210soft.indd 39
1 IPTV
Part XXXXXXX MY 09
en
VALIDATION PROCESSES
12 MO IPTV
em
ov
pr
Im
Engineering Change
Started May 07
25%
minus .25
.55 IPTV
Engineering Change 1
Start for MY 09
10%
minus .1
Process Change 1
Start for MY 09
10%
minus .1
Engineering Change 2
Start MY09
-10%
plus .1
Engineering Change 3
MY 10
10%
minus .1
Projected MY 11 Warranty
0.35
.7 IPTV
As this warranty projection chart shows, warranty is a huge line item on annual reports.
IPTV stands for incident per thousand vehicles. Quickly addressing and preventing warranty issues puts money right to the bottom line. Source: Lou Ann Lathrop
How does one test that the product satisfies the customer? Start with the thingsgone-wrong category first: warranty.
Get the warranty data for the products in question and look at warranty
from the paradigm of every warranty
issue is an unhappy customer.
When one looks at every data point
as one unhappy customer, the data is
staggering. Act as if that customer is
yourself or a family member. Now act
as if you are the owner of the company:
how can you react to help prevent the
problem from ever happening again?
A lot of data, and relatively recent
data, is available. Get all of the data
possible. Get every part back and run
through a standard and rigorous failure
analysis as new model years are started.
Do this for the entire model year. Get
trend data on a regular, monthly basis
and review. Understand the data, and
what affects it. Learn what is driving
the numbers. Understand the concepts
of statistical process control.
Compare the warranty data of all the
companys products against each other,
compare and contrast the data, and
figure out why some products are better
than others. This fulfi lls the requirement of benchmarking.
Understand and Pareto the causes
of warranty issues. Do deep dives to
fi nd permanent and irreversible corrective action. Predict the improvement
in warranty by understanding current
warranty and what is driving it. Look at
all upcoming changes that will address
warranty concerns to predict a projected warranty. Implement as soon as
possiblethe sooner the better. Make
sure all appropriate change management procedures are followed.
Warranty is a huge line item on
annual reports. Preventing warranty
issues or quickly addressing them puts
money right to the bottom line.
WARRANTY
Months in Service
This is an example of a warranty chart comparing model years. Manufacturers would
do well to learn what is driving the numbers and understand the concepts of statistical
process control. Source: Lou Ann Lathrop
CPK
PPM
IPTV
.33
317,310
317
YIELD
68%
% OF
TOLERANCE
303
.5
133,614
133
.66
45,500
45
.83
12,419
12
1.00
2,700
2.7
1.17
465
.47
1.33
64
.064
1.5
6.8
.0068
67
1.66
.6
.0006
60
200
95%
152
121
99.73%
100
86
99.99%
75
50
39
1/20/10 12:31:08 PM
supplier testing, all component testing, all sub system testing completed
and all vehicle level testing are rigorously tracked for completion. Every
test result from validation testing
should be rigorously reviewed and
scrutinized. There are very few test
properties these days, so every test
and test result counts.
The tests are run, so it would be a
waste if the results were not studied to
every last detail. The test properties
should be autopsied in detail.
t High Quality
t Low Prices
t Large Selection
t Same Day Shipping
t Satisfaction Guaranteed
40
QLT10094Carl.indd 1
038-QM0210soft.indd 40
100% Inspection
Up to 10,000 Parts/Hour
Optical Measurements to 0.0001
Flexibility for Different Parts
Easy to Operate
Low Cost Benchtop Units
www.qualitymag.com
9/15/09 11:45:37
QLT02101resec.indd
AM
1
1/20/10 12:27:40 PM
1/22/10 9:48:50 AM
INSTRUMENT CO.
1742 Sixth Avenue York, PA 17403-2675
www.qualitymag.com
038-QM0210soft.indd 41
9/17/09 1:48:03 PM
41
1/20/10 12:31:09 PM
Copyright of Quality is the property of BNP Media and its content may not be copied or emailed to multiple
sites or posted to a listserv without the copyright holder's express written permission. However, users may print,
download, or email articles for individual use.