Materi Training APQP

Cileungsi, 30 Sep 2014
APQP
Advanced Product Quality Planning

1
Hendra Hendrasmara – Industrial Battery Development Dept.
APQP
Tujuan
• 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
Apa itu
APQP
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
9
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
• Team Experience • Preliminary Process Flow Chart
PLANNING
• 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
20
2.0 PRODUCT DESIGN AND DEVELOPMENT
Program
Approval Prototype INPUTS OUTPUTS
• • Design Failure Mode and
Design Goals
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 • Prototype Build – Control Plan
Process Flow
Chart
• Engineering Drawings (Including
Math Data)
• Preliminary Listing • Engineering Specifications
of Special Product
and Process • Material Specifications
Characteristics • Drawing and Specification
Changes
• Product
PRODUCT Assurance Plan • New Equipment, Tooling and
DESIGN AND Facilities Requirements
DEVELOPMENT
• Management
• Special Product and Process
VERIFICATION Support
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
21
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
• Process Failure Mode and
• Prototype Build –
Control Plan Effects Analysis (PFMEA)
• Engineering Drawings • Pre-Launch Control Plan
(Including Math Data) • Process Instructions
• Engineering • Measurement Systems Analysis
Specifications
PROCESS Plan
• Material Specifications
DESIGN AND • Preliminary Process Capability
DEVELOPMENT • Drawing and Study Plan
VERIFICATION Specification Changes
• Packaging Specifications
• New Equipment,
Tooling and Facilities • Management Support
Requirements
Tujuan :
 Mengembangkan proses manufactur • Special Product and
Process Characteristics
yang komprehensif dan efektif • Gages/Testing
 Pastikan kapabilitas proses untuk Equipment
memenuhi kebutuhan pelanggan Requirements
• Team Feasibility
Commitment and 22
Management Support
4.0 PRODUCT AND PROCESS VALIDATION
Prototype Pilot Launch

INPUTS OUTPUTS
• Packaging Standards • Production Trial Run
• Product/Process Quality System • Measurement
Review Systems Evaluation
• Process Flow Chart • Preliminary Process
Capability Study
• Floor Plan Layout
• Production Part
• Characteristics Matrix
Approval
• Process Failure Mode and • Production Validation
Effects Analysis (PFMEA)
PRODUCT AND PROCESS VALIDATION Testing
• Pre-Launch Control Plan • Packaging Evaluation
• Process Instructions • Production Control
• Measurement Systems Analysis Plan
Plan
PRODUCT • Quality Planning
AND PROCESS
• Preliminary Process Capability Sign-Off and
VALIDATION Study Plan Management Support
• Packaging Specifications
• Management Support
Tujuan :
 Validasi produk
 Validasi control plan
 Pastikan produk sesuai kebutuhan pelanggan
 Identifikasi masalah
23
5.0 FEEDBACK ASSESMENT AND CORRECTIVE ACTION
Pilot Launch
INPUTS OUTPUTS
• Production Trial Run • Reduced Variation
• Measurement • Customer Satisfaction
PLANNING Systems 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 Support
FEEDBACK
ASSESSMENT AND
CORRECTIVE ACTION
Tujuan :
 Mengevaluasi semua variasi (data variabel dan data attribut)
 Mengevaluasi efektivitas Product quality planning
 Penggunaan Control Plan dan Corrective action
24
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 • Business
Scope Plan/Marketing
Strategy
• Establish
Team-to-Team •
Communication Product/Proces
s Benchmark
• Provide Core
Data
Tools Training
•
• Involve
Product/Proces
Customers and
s Assumptions
Suppliers
• Implement
• Product
Reliability
Simultaneous
Studies
Engineering
• Develop
• Customer
Inputs
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 • Business Quality Goals
Scope Plan/Marketing • Preliminary Bill
Strategy
• Establish of Material
Team-to-Team •
• Preliminary
Process Flow
s Benchmark
• Provide Core Chart
Data
Tools Training • Preliminary
•
• Involve Listing of
Product/Proces
Customers and Special
s Assumptions
Suppliers Product and
• Implement
• Product Process
Reliability Characteristics
Simultaneous
Studies
Engineering • Product
• Develop
• Customer Assurance
Inputs Plan
Control Plan
Format • Management
• Decide on Support
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 • Reliability and Mode and
• Define the • Business Quality Goals Effects Analysis
Plan/Marketing (DFMEA)
Scope • Preliminary Bill
Strategy • Design for
Team-to-Team • Manufacturability
• Preliminary and Assembly
Process Flow
s Benchmark • Design
• Provide Core Chart
Data Verification
Tools Training • Preliminary
• Involve
•
Listing of
• Design Reviews
Product/Proces
Customers and Special • Prototype Build
s Assumptions
Suppliers Product and – Control Plan
• Implement
• Product Process • Engineering
Simultaneous Drawings
Studies
Engineering • Product (Including Math
• Develop
• Customer Assurance Data)
Inputs Plan
Control Plan • Engineering
Format • Management Specifications
• Decide on Support • Material
Concern Specifications
Resolution • Drawing and
• Develop Specification
Product Quality Changes
Timing Plan • New Equipment,
Tooling and
Facilities
Requirements
• Special Product
and Process
Characteristics
• Gages/Testing
Equipment 29
Requirements
Hendra Hendrasmara – Industrial Battery• Development
Team Feasibility Dept.
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
• Organize the • Voice of the • Design Goals • Design Failure • Packaging
Team Customer • Reliability and Mode and Standards
• Define the • Business Quality Goals Effects Analysis • Product/Process
Plan/Marketing (DFMEA) Quality System
Strategy • Design for Review
Team-to-Team • Manufacturability • Process Flow
Communication Product/Proces Chart
Process Flow
s Benchmark • Design
• Provide Core Chart • Floor Plan
Data Verification
Tools Training Layout
• Preliminary
• Involve
•
Listing of
• Design Reviews • Characteristics
Product/Proces
Customers and Special • Prototype Build Matrix
s Assumptions
Suppliers Product and – Control Plan • Process Failure
• Implement
• Product Process • Engineering Mode and
Simultaneous Drawings Effects Analysis
Studies (PFMEA)
Engineering • Product (Including Math
• Develop
• Customer Assurance Data) • Pre-Launch
Inputs Plan
Control Plan • Engineering Control Plan
Format • Management Specifications • Process
• Decide on Support • Material Instructions
Concern Specifications • Measurement
Resolution • Drawing and Systems
• Develop Specification Analysis Plan
Product Quality Changes • Preliminary
Timing Plan Process
• New Equipment,
Tooling and Capability Study
Facilities Plan
Requirements • Packaging
• Special Product Specifications
and Process • Management
Characteristics Support
• Gages/Testing
Equipment 30
Requirements
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
• Organize the • Voice of the • Design Goals • Design Failure • Packaging • Production
Team Customer • Reliability and Mode and Standards Trial Run
• Define the • Business Quality Goals Effects Analysis • Product/Process • Measurement
Plan/Marketing (DFMEA) Quality System Systems
Strategy • Design for Review Evaluation
Team-to-Team • Manufacturability • Process Flow • Preliminary
Communication Product/Proces Chart Process
Process Flow
s Benchmark • Design Capability
Data Verification Study
• Preliminary
• • Design Reviews • Production
• Involve Listing of • Characteristics
Product/Proces Part Approval
s Assumptions
• Production
• Implement
• Product Process • Engineering Mode and Validation
Reliability Characteristics Testing
Studies (PFMEA) Packaging
Engineering • Product (Including Math •
• Develop
• Customer Assurance Data) • Pre-Launch Evaluation
Inputs Plan
Control Plan • Engineering Control Plan • Production
Format • Management Specifications • Process Control Plan
• Decide on Support • Material Instructions • Quality
Concern Specifications Planning Sign-
• Measurement
Resolution • Drawing and Systems Off and
• Develop Specification Analysis Plan Management
Support
Timing Plan Process
• New Equipment,
Facilities Plan
• Gages/Testing
Equipment 31
Requirements
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
• Organize the • Voice of the • Design Goals • Design Failure • Packaging • Production • Reduced
Team Customer • Reliability and Mode and Standards Trial Run Variation
• Define the • Business Quality Goals Effects Analysis • Product/Process • Measurement • Customer
Scope Satisfaction
• Preliminary Bill
• Establish of Material • Delivery and
Team-to-Team • Manufacturability • Process Flow • Preliminary Service
Process Flow
• Preliminary
s Assumptions
• Production
• Implement
• Develop
Inputs Plan
• Measurement
Support
Timing Plan Process
• New Equipment,
Facilities Plan
• Gages/Testing
Equipment 32
Requirements
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Scope Satisfaction
Process Flow
• Preliminary
s Assumptions
• Production
• Implement
• Develop
Inputs Plan
• Measurement
Support
Timing Plan Process
• New Equipment,
FMEA Tooling and

Facilities
Requirements
Capability Study
Plan
• Packaging
Characteristics Supportc
• Gages/Testing
Equipment 33
Requirements
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Scope Satisfaction
Process Flow
• Preliminary
s Assumptions
• Production
• Implement
• Develop
Inputs Plan
• Measurement
Support
Timing Plan Process
• New Equipment,
FMEA Tooling and

Facilities
Requirements
Capability Study
Plan
• Packaging
• Gages/Testing
Equipment
Requirements
APQP 34
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Scope Satisfaction
Process Flow
• Preliminary
s Assumptions
• Production
• Implement
• Develop
Inputs Plan
• Measurement
Support
Timing Plan Process
• New Equipment,
FMEA Tooling and

Facilities
Requirements
Capability Study
Plan
• Packaging
and Process
Characteristics
• Management
Support
SPC
• Gages/Testing
Equipment
Requirements
APQP 35
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Scope Satisfaction
Process Flow
MSA
• Preliminary
s Assumptions
• Production
• Implement
• Develop
Inputs Plan
• Measurement
Support
Timing Plan Process
• New Equipment,
FMEA Tooling and

Facilities
Requirements
Capability Study
Plan
• Packaging
and Process
Characteristics
• Management
Support
SPC
• Gages/Testing
Equipment
Requirements
APQP 36
APQP PROCESS FLOW
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
INPUT
INPUT
Scope Satisfaction
Process Flow
MSA
• Preliminary
s Assumptions
• Production
• Implement
• Develop
Inputs Plan
Measurement
PPAP
•
Support
Timing Plan Process
• New Equipment,
FMEA Tooling and

Facilities
Requirements
Capability Study
Plan
• Packaging
and Process
Characteristics
• Management
Support
SPC
• Gages/Testing
Equipment
Requirements
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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Materi Training APQP

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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:

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-

Terbagi dalam 3 phase :

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

Prototype Pilot Launch

FMEA Tooling and

FMEA Tooling and

FMEA Tooling and

FMEA Tooling and

FMEA Tooling and

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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