Materi Training APQP

Cileungsi, 30 Sep 2014
Advanced Product Quality Planning
1
Hendra Hendrasmara – Industrial Battery Development Dept.
APQP
• Memahami proses APQP

• Mengidentifikasi input dan output 5 phase APQP
• Memahami APQP sebagi methodology dalam
“new Product Development”
2
30 Sep 2014 – by Hendra Hendrasmara
3
APQP (Advanced Product Quality Planning)

adalah metode yang terstruktur mendefinisikan dan
menetapkan langkah-langkah yang dibutuhkan
untuk menjamin produk yang akan dihasilkan
memenuhi atau sesuai dengan keinginan
Customer.
4
Apa itu Advanced ?
SPC MSA
Control Plan
PPAP
FMEA
Team Planning 5W 2H + Core Tools Implementation
5
APQP dijelaskan dalam AIAG (Automotive Industry Action

Group) 810-358-3003.
Organisasi ini didirikan oleh visioner dari tiga produsen
otomotif Amerika Utara terbesar - Chrysler, Ford, dan
General Motors.
Keanggotaan AIAG telah berkembang dengan masuknya

perusahaan-perusahaan Jepang seperti Toyota, Honda dan
Nissan, dan part suppliers serta services providers mereka.
6
Tujuan dari product quality planning adalah untuk

memfasilitasi komunikasi dengan semua orang
yang terlibat untuk memastikan bahwa langkah-
langkah yang diperlukan semua selesai tepat
waktu.
Perencanaan kualitas produk yang efektif

tergantung pada komitmen manajemen puncak
perusahaan untuk upaya yang diperlukan dalam
mencapai kepuasan pelanggan.
7
APQP mengatur tahap-tahap perencanaan product (dan

proses manufaktur), mulai dari tahap konsep sampai
produksi massal.
Beberapa manfaat dari Product Quality Plan adalah:

• Mengatur Sumber Daya dalam upaya memenuhi
kepuasan Customer (persyaratan customer)
• Menghasilkan identifikasi awal terhadap kemungkinan
perubahan
• Menghindari adanya perubahan yang terlambat
• Menyediakan produk yang berkualitas tepat waktu dan
dengan cost yang serendah mungkin.
8
APQP dalam ISO/TS 16949
Phase Description Kalusul ISO/TS 16949

Phase 1 Plan define Program 7.3.1, 7.3.2, 7.3.2.1
7.3.2.1, 7.3.2.3, 7.3.3, 7.3.3.1,
Phase 2 Product Design and Development
7.3.4, 7.3.4.1
Phase 3 Process Design and Development 7.3.2.2, 7.3.3.2, 8.2.3.1
Phase 4 Product and Process Validation 7.3.5, 7.3.6.3
Feedback Assessment and
Phase 5 8.2.3.1
Corrective Action
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Dasar-dasar APQP
ORGANIZE THE TEAM
Tahap awal yang harus dibvangun oleh pemasok adalah

penetapan penanggung jawab untuk cross functional team.
Product Quality Planning yang efektif membutuhkan

keterlibatan seluruh perwakilan yang mencakup
engineering, manufacturing, material control, procurement,
quality, sales, pelayanan lapangan, serta subkontraktor dan
pelanggan yang terkait.
10
Dasar-dasar APQP
DEFINE THE SCOPE

Hal ini penting untuk Product Quality Planning Team dalam
tahap awal perencanaan produk untuk mengidentifikasi
kebutuhan, harapan dan persyaratan pelanggan.
• Pilih pemimpin tim proyek yang bertanggung jawab untuk mengawasi proses
perencanaan.
• Tentukan peran dan tanggung jawab masing-masing area yang diwakili.
• Mengidentifikasi pelanggan - internal dan eksternal.
• Tentukan kebutuhan pelanggan.
• Pilih ahli-ahli, individu, dan / atau subkontraktor yang harus ditambahkan ke tim.
• Memahami harapan pelanggan, yaitu, desain, sistem pengujian.
• Menilai kelayakan desain yang diusulkan, persyaratan kinerja dan proses manufaktur.
• Mengidentifikasi biaya, waktu, dan kendala yang harus diperhatikan.
• Tentukan bantuan yang diperlukan dari pelanggan.
• Mengidentifikasi proses dokumentasi atau metode.
11
Dasar-dasar APQP
Team-to-Team
Product Quality Planning Team harus membangun jalur
komunikasi dengan tim pelanggan dan tim pemasok lainnya.
Ini mungkin termasuk pertemuan rutin dengan tim lain.
Tingkat kontak tim-to-tim tergantung pada sejumlah isu yang
membutuhkan kesepakatan.
12
Dasar-dasar APQP
Training
Keberhasilan Product Quality Plan tergantung pada program
pelatihan yang efektif untuk mengkomunikasikan semua
persyaratan dan pengembangan keahlian untuk memenuhi
kebutuhan dan harapan pelanggan.
13
Dasar-dasar APQP
Customer and Organization Involved

Pelanggan utama dapat memulai proses perencanaan
kualitas dengan pemasok. Namun, pemasok memiliki
kewajiban untuk membentuk tim lintas fungsional untuk
mengelola proses Product Quality Planning.
Pemasok harus mengharapkan kinerja yang sama dari

subkontraktor mereka.
14
Dasar-dasar APQP
Simultaneous Engineering
Simultaneous Engineering adalah proses di mana cross
functional team berusaha untuk mencapai tujuan bersama.
Tujuannya adalah untuk mempercepat pengenalan produk-

produk berkualitas lebih cepat. Product Quality Planning
team menjamin bahwa area lain / tim lain merencanakan
dan melaksanakan kegiatan yang mendukung tujuan
bersama.
15
Dasar-dasar APQP
Control Plans
Control Plans adalah deskripsi yang tertulis untuk
mengendalikan part dan proses.
Terbagi dalam 3 phase :
• Prototype
Penjelasan mengenai pengukuran dimensi dan material, test performance yang akan
terjadi selama pembuatan Prototype.
• Pre-launch
Penjelasan mengenai pengukuran dimensi dan material, test performance yang akan
terjadi setelah Prototype dan sebelum mass Production.
• Production
Sebuah dokumentasi lengkap dari karakteristik produk / proses, kontrol proses, tes, dan
sistem pengukuran yang akan terjadi selama produksi massal.
16
Dasar-dasar APQP
Concern Resolution
Permasalahan-permasalahan yang terjadi selama proses
perencanaan harus didokumentasikan dalam matrik
penanggungjawab dan target waktu. Meminta rekomendasi
dari ahli sangat disarankan untuk masalah yang sulit.
17
Dasar-dasar APQP
Product Quality Timing Plan

Keberhasilan program apapun tergantung pada pemenuhan
kebutuhan dan harapan pelanggan pada waktu yang tepat
dengan biaya yang sesuai.
Plans Relative to the Timing Chart

Suksesnya sebuah program bergantung kepada kepuasan
pelanggan terutama waktu dan cost.
Tim perencana harus memastikan product qulity planning
bisa disesuaikan dengan harapan pelanggan
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PRODUCT QUALITY PLANNING TIMING CHART
Concept
Initiation/Approval
Problem
Program
Approval Prototype Pilot Launch
PLANNING PLANNING
PRODUCT DESIGN AND DEV.
PROCESS DESIGN AND DEVELOPMENT
PRODUCT AND PROCESS VALIDATION
PRODUCTION
FEEDBACK ASSESSMENT AND CORRECTIVE ACTION
PRODUCT PROCESS Time

PLAN AND PRODUCT FEEDBACK
DESIGN AND DESIGN AND
DEFINE AND PROCESS ASSESSMENT AND
DEVELOPMENT DEVELOPMENT
PROGRAM VALIDATION CORRECTIVE ACTION
VERIFICATION VERIFICATION
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1.0 PLAN AND DEFINE PROGRAM
Concept INPUTS OUTPUTS

Initiation / Approval
Program • Voice of the Customer • Design Goals
Approval
• Market Research • Reliability and Quality Goals
• Historical Warranty and Quality Information • Preliminary Bill of Material
PLANNING • Team Experience • Preliminary Process Flow Chart

• Business Plan/Marketing Strategy • Preliminary Listing of Special
Product and Process
• Product/Process Benchmark Data Characteristics
• Product/Process Assumptions • Product Assurance Plan
• Product Reliability Studies • Management Support
• Customer Inputs
PLAN AND
DEFINE
PROGRAM
Tujuan :
 Menentukan kebutuhan pelanggan
 Menentukan dan merencanakan
Program quality
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2.0 PRODUCT DESIGN AND DEVELOPMENT
Program
Approval Prototype INPUTS OUTPUTS
• Design Goals • Design Failure Mode and Effects
Analysis (DFMEA)
• Reliability and
• Design for Manufacturability and
Quality Goals Assembly
• Preliminary Bill of • Design Verification
PRODUCT DESIGN AND DEV. Material
• Design Reviews
• Preliminary Process
• Prototype Build – Control Plan
Flow Chart
• Engineering Drawings (Including
• Preliminary Listing of Math Data)
Special Product and
• Engineering Specifications
Process
Characteristics • Material Specifications
• Product Assurance • Drawing and Specification Changes
PRODUCT Plan • New Equipment, Tooling and

DESIGN AND Facilities Requirements
• Management
DEVELOPMENT Support • Special Product and Process
VERIFICATION Characteristics
• Gages/Testing Equipment
Requirements
• Team Feasibility Commitment and
Tujuan : Management Support
 Develop design features and characteristic
 Review engineering requirement
 Menilai masalah manufactur yang mungkin terjadi
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3.0 PROCESS DESIGN AND DEVELOPMENT
Prototype Pilot
INPUTS OUTPUTS
• Design Failure Mode • Packaging Standards
and Effects Analysis
(DFMEA) • Product/Process Quality System
Review
• Design for
Manufacturability and • Process Flow Chart
Assembly
• Floor Plan Layout
• Design Verification
PROCESS DESIGN AND DEVELOPMENT • Characteristics Matrix
• Design Reviews
• Prototype Build – • Process Failure Mode and Effects
Control Plan Analysis (PFMEA)
• Engineering Drawings • Pre-Launch Control Plan
(Including Math Data)
• Process Instructions
• Engineering Specifications
• Measurement Systems Analysis
PROCESS • Material Specifications Plan
DESIGN AND
• Drawing and Specification
DEVELOPMENT • Preliminary Process Capability
Changes
VERIFICATION Study Plan
• New Equipment, Tooling
and Facilities Requirements • Packaging Specifications
Tujuan : • Special Product and • Management Support

Process Characteristics
 Mengembangkan proses manufactur
• Gages/Testing Equipment
yang komprehensif dan efektif Requirements
 Pastikan kapabilitas proses untuk
• Team Feasibility
memenuhi kebutuhan pelanggan Commitment and
Management Support
22
4.0 PRODUCT AND PROCESS VALIDATION
Prototype Pilot Launch

INPUTS OUTPUTS
• Packaging Standards • Production Trial Run
• Product/Process Quality System • Measurement Systems
Review Evaluation
• Process Flow Chart • Preliminary Process
Capability Study
• Floor Plan Layout
• Production Part
• Characteristics Matrix
Approval
• Process Failure Mode and Effects
• Production Validation
PRODUCT AND PROCESS VALIDATION Analysis (PFMEA)
Testing
• Pre-Launch Control Plan
• Packaging Evaluation
• Production Control
• Measurement Systems Analysis Plan
PRODUCT Plan
• Quality Planning Sign-
AND PROCESS
• Preliminary Process Capability Off and Management
VALIDATION
Study Plan Support
• Packaging Specifications
Tujuan : • Management Support

 Validasi produk
 Validasi control plan
 Pastikan produk sesuai kebutuhan pelanggan
 Identifikasi masalah
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5.0 FEEDBACK ASSESMENT AND CORRECTIVE ACTION
Pilot Launch
INPUTS OUTPUTS
• Production Trial Run • Reduced Variation
• Measurement Systems • Customer Satisfaction
PLANNING
Evaluation
• Delivery and Service
• Preliminary Process
Capability Study
• Production Part
Approval
• Production Validation
Testing
• Packaging Evaluation
PRODUCTION
• Production Control
Plan
FEEDBACK ASSESSMENT AND CORRECTIVE ACTION
• Quality Planning Sign-
Off and Management
FEEDBACK Support
ASSESSMENT AND
CORRECTIVE ACTION
Tujuan :
 Mengevaluasi semua variasi (data variabel dan data attribut)
 Mengevaluasi efektivitas Product quality planning
 Penggunaan Control Plan dan Corrective action
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APQP PROCESS FLOW
Prepare for Plan and Define Product Design Process Design Product and Feedback,
APQP Program and and Process Assessment and
Development Development Validation Corrective Action
25
APQP PROCESS FLOW
• Organize the
Team
• Define the Scope
• Establish Team-to-
Team
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
26
APQP PROCESS FLOW
INPUT
• Organize the • Voice of the
Team Customer
• Define the Scope • Business
Plan/Marketing
• Establish Team-to-
Strategy
Team
Communication • Product/Process
Benchmark Data
• Provide Core
Tools Training • Product/Process
Assumptions
and Suppliers • Product Reliability
Studies
• Implement
Simultaneous • Customer Inputs
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
27
APQP PROCESS FLOW
OUTPUT
INPUT
• Organize the • Voice of the • Design Goals
Team Customer
• Reliability and
• Define the Scope • Business Quality Goals
Plan/Marketing
• Establish Team-to- • Preliminary Bill of
Strategy
Team Material
• Preliminary
Benchmark Data
• Provide Core Process Flow Chart
Tools Training • Product/Process
• Preliminary Listing
Assumptions
• Involve Customers of Special Product
and Suppliers • Product Reliability and Process
Studies Characteristics
• Implement
Simultaneous • Customer Inputs • Product
Engineering Assurance Plan
• Develop Control • Management
Plan Format Support
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
28
APQP PROCESS FLOW
OUTPUT
OUTPUT
INPUT
INPUT
• Organize the • Voice of the • Design Goals • Design Failure
Team Customer Mode and Effects
• Reliability and
Analysis (DFMEA)
• Define the Scope • Business Quality Goals
Plan/Marketing • Design for
Strategy Manufacturability and
Team Material
Assembly
• Preliminary
Benchmark Data • Design Verification
• Provide Core Process Flow Chart
Tools Training • Product/Process • Design Reviews
• Preliminary Listing
Assumptions
• Involve Customers of Special Product • Prototype Build –
and Suppliers • Product Reliability and Process Control Plan
• Implement • Engineering
Simultaneous • Customer Inputs • Product Drawings (Including
Engineering Assurance Plan Math Data)
• Develop Control • Management • Engineering
Plan Format Support Specifications
• Decide on • Material
Concern Resolution Specifications
• Develop Product • Drawing and
Quality Timing Plan Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
Commitment and
Management Support 29
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
• Organize the • Voice of the • Design Goals • Design Failure • Packaging
Team Customer Mode and Effects Standards
• Reliability and
Analysis (DFMEA)
• Define the Scope • Business Quality Goals • Product/Process
Plan/Marketing • Design for Quality System
Strategy Manufacturability and Review
Team Material
Assembly
Communication • Product/Process • Process Flow Chart
• Preliminary
Benchmark Data • Design Verification
• Provide Core Process Flow Chart • Floor Plan Layout
• Preliminary Listing • Characteristics
Assumptions
• Involve Customers of Special Product • Prototype Build – Matrix
• Process Failure
• Implement • Engineering Mode and Effects
Simultaneous • Customer Inputs • Product Drawings (Including Analysis (PFMEA)
Engineering Assurance Plan Math Data)
• Pre-Launch Control
• Develop Control • Management • Engineering Plan
Plan Format Support Specifications
• Measurement
Concern Resolution Specifications
Systems Analysis
• Develop Product • Drawing and Plan
• Preliminary
• New Equipment, Process Capability
Tooling and Facilities Study Plan
Requirements
• Packaging
• Special Product and Specifications
Process
• Management
Characteristics
Support
• Gages/Testing
Equipment
Requirements
Commitment and
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
• Organize the • Voice of the • Design Goals • Design Failure • Packaging • Production Trial
Team Customer Mode and Effects Standards Run
• Reliability and
Analysis (DFMEA)
• Define the Scope • Business Quality Goals • Product/Process • Measurement
Plan/Marketing • Design for Quality System Systems
Strategy Manufacturability and Review Evaluation
Team Material
Assembly
Communication • Product/Process • Process Flow Chart • Preliminary
• Preliminary
Benchmark Data • Design Verification Process Capability
Study
Assumptions • Production Part
Approval
• Process Failure
Studies Characteristics • Production
Validation Testing
Engineering Assurance Plan Math Data) • Packaging
Evaluation
Plan Format Support Specifications • Production
Control Plan
• Measurement
Concern Resolution Specifications • Quality Planning
Systems Analysis
Sign-Off and
Management
• Preliminary Support
Requirements
• Packaging
Process
• Management
Characteristics
Support
• Gages/Testing
Equipment
Requirements
Commitment and
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
• Organize the • Voice of the • Design Goals • Design Failure • Packaging • Production Trial • Reduced Variation
• Reliability and • Customer
Analysis (DFMEA)
• Define the Scope • Business Quality Goals • Product/Process • Measurement Satisfaction
• Establish Team-to- • Preliminary Bill of • Delivery and
Team Material Service
Assembly
• Preliminary
Study
Approval
• Process Failure
Validation Testing
Evaluation
Control Plan
• Measurement
Systems Analysis
Sign-Off and
Management
Requirements
• Packaging
Process
• Management
Characteristics
Support
• Gages/Testing
Equipment
Requirements
Commitment and
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Analysis (DFMEA)
Assembly
• Preliminary
Study
Approval
• Process Failure
Validation Testing
Evaluation
Control Plan
• Measurement
Systems Analysis
Sign-Off and
Management
Requirements
• Packaging
FMEA Process
Characteristics
• Management
Supportc
• Gages/Testing
Equipment
Requirements
Commitment and
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Analysis (DFMEA)
Assembly
• Preliminary
Study
Approval
• Process Failure
Validation Testing
Evaluation
Control Plan
• Measurement
Systems Analysis
Sign-Off and
Management
Requirements
• Packaging
FMEA Process
Characteristics
• Management
Support
• Gages/Testing
Equipment
Requirements
Commitment and
Management Support
APQP 34
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Analysis (DFMEA)
Assembly
• Preliminary
Study
Approval
• Process Failure
Validation Testing
Evaluation
Control Plan
• Measurement
Systems Analysis
Sign-Off and
Management
Requirements
• Packaging
FMEA Process
Characteristics
• Management
Support
• Gages/Testing
Equipment
Requirements
SPC
Commitment and
Management Support
APQP 35
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Analysis (DFMEA)
Assembly
• Preliminary
Study
Studies
of Special Product
and Process
Characteristics
• Prototype Build –
Control Plan
Matrix
• Process Failure
Approval
• Production
MSA
Validation Testing
Evaluation
Control Plan
• Measurement
Systems Analysis
Sign-Off and
Management
Requirements
• Packaging
FMEA Process
Characteristics
• Management
Support
• Gages/Testing
Equipment
Requirements
SPC
Commitment and
Management Support
APQP 36
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Analysis (DFMEA)
Assembly
• Preliminary
Study
Studies
of Special Product
and Process
Characteristics
• Prototype Build –
Control Plan
Matrix
• Process Failure
Approval
• Production
MSA
Validation Testing
Evaluation
Control Plan
• Measurement
Systems Analysis
Sign-Off and
Management
• New Equipment,
Tooling and Facilities
• Preliminary
Process Capability
Study Plan
Support
PPAP
Requirements
• Packaging
FMEA Process
Characteristics
• Management
Support
• Gages/Testing
Equipment
Requirements
SPC
Commitment and
Management Support
APQP 37
ANALYTICAL TECHNIQUES
1. Assembly Build Variation Analysis
2. Benchmarking
3. Cause and Effect Diagram
4. Characteristics Matrix
5. Critical Path Method
6. Design of Experioments (DoE)
7. Design for Manufacturability and Assembly
8. Design Verification Plan and Report (DVP&R)
9. Mistake Proofing / ErrorProofing
10. Process Flow Charting
11. Quality Function Deployment (QFD)
38

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Cileungsi, 30 Sep 2014

Advanced Product Quality Planning

• Memahami proses APQP

APQP (Advanced Product Quality Planning)

Apa itu Advanced ?

Team Planning 5W 2H + Core Tools Implementation

APQP dijelaskan dalam AIAG (Automotive Industry Action

Keanggotaan AIAG telah berkembang dengan masuknya

Tujuan dari product quality planning adalah untuk

Perencanaan kualitas produk yang efektif

APQP mengatur tahap-tahap perencanaan product (dan

Beberapa manfaat dari Product Quality Plan adalah:

Phase Description Kalusul ISO/TS 16949

ORGANIZE THE TEAM

Tahap awal yang harus dibvangun oleh pemasok adalah

Product Quality Planning yang efektif membutuhkan

DEFINE THE SCOPE

Customer and Organization Involved

Pemasok harus mengharapkan kinerja yang sama dari

Tujuannya adalah untuk mempercepat pengenalan produk-

Product Quality Timing Plan

Plans Relative to the Timing Chart

PRODUCT DESIGN AND DEV.

PROCESS DESIGN AND DEVELOPMENT

PRODUCT AND PROCESS VALIDATION

FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

PRODUCT PROCESS Time

Concept INPUTS OUTPUTS

PLANNING • Team Experience • Preliminary Process Flow Chart

• Product Assurance • Drawing and Specification Changes

PRODUCT Plan • New Equipment, Tooling and

Tujuan : • Special Product and • Management Support

Prototype Pilot Launch

Tujuan : • Management Support

1. Assembly Build Variation Analysis

3. Cause and Effect Diagram

5. Critical Path Method

6. Design of Experioments (DoE)

7. Design for Manufacturability and Assembly

8. Design Verification Plan and Report (DVP&R)

9. Mistake Proofing / ErrorProofing

10. Process Flow Charting

11. Quality Function Deployment (QFD)

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