APQP.docx

1、APQPXXX PUBLIC COMPANY LIMITED.Page01020304050607080910111213141516171819Rev.08080808080808080808080808080808080808Page20212223242526272829303132333435363738Rev.08080808080808080808-08Extension Scope toTianjin/ China and add Appendix 7.1 Chinese Version.S070001102 Oct0707Add remark Special Character

2、istic (SC) in item 5.5050143719Jan0506To revise form for updating with position040560728 May0405To put the gantt chart which defined to the Process Validation, and revise contents to comply with chart.040145329 Jan0404Add forms for PPAP-file preparation030515530 May0303Add PSW form into the procedur

3、e as the appendix 7.3021168327 Nov0202Add Delivery requirement review in Appendix 7.1021104305 Nov0201Initial release020800908 Aug02Rev.Description Of ChangeECN. No.Eff. DateOriginatorK. PanupongApprovalK. YingyosDocument ControlCustomer Name : N/AProject No. : N/ATitleAdvanced Product Quality Plann

4、ing ProcedureRev.08Doc. No.72-351-0034Page1 of 29 Form 01 rev.B ref.72-350-00021. PURPOSE : 1.1 To establish for guidance of Advanced Product Quality Planning.1.2 To prepare the Production Part Approval Process (PPAP) for new project or develop the existing project.1.3 To instruct the method of defi

5、ning and establishing the steps necessary to assure that a product satisfies the customer. 2. SCOPE : 2.1 This document is applied for satisfying customer requirements as input to the product realization process, in accordance with the automotive supplier.2.2 To define process of machine and part ve

6、rification and validation by First Article Sample Build.3. REFERENCE DOCUMENTS : 3.1 Contract Review Procedure 72-155-00013.2 Require For Quotation Procedure 72-155-00123.3 Document and Data Control Procedure 72-350-00013.4 Documents and Data Change/ Modification Procedure72-351-00043.5 Control of N

7、on-Conformance material Procedure72-351-00053.6 Material Review Board Procedure72-351-00083.7 Corrective and Preventive Action Procedure72-351-00123.8 Incoming Inspection Procedure72-351-00153.9 Quality Plan Procedure72-351-00263.10 First Article Sample Procedure72-351-00283.11 Production Part Appro

8、val Process Procedure72-351-00343.12 Failure Mode Effect Analysis (FMEA) Procedure72-351-00353.13 HPU Generating Procedure72-405-00013.14 Process Control Procedure 72-409-00023.15 Engineering change notice 72-409-00033.16 Vendor Approval Procedure 72-409-00093.17 13 Digits part numbering Procedure72

9、-409-00103.18 Bill of Materials Creation Procedure 72-409-00113.19 Jig & Fixture Set up Verification Procedure 72-650-00114. MATERIALS OR EQUIPMENTN/A 5. PROCEDURE5.1 APQP team will take the Feasibility and do Framework agreement between team member and customer, prior to make decision for quotation

10、 preparing, ref. Require for Quotation (RFQ) Procedure (72-155-0005), HPU Generating Procedure (72-405-0001) which will be generated the New project receipt form, HPU, and RFQ package.5.2 After customer accept our quotation and we receive the customer order (or any contracts), APQP team will set pla

11、n as Gantt Chart, and team review for the “New project start up Gantt Chart Review”.5.3 The shipment confirmation has to be coordinated between PGMNT and MC, via the Master Delivery Schedule Procedure (72-155-0004). 5.4 All the customer requirements and information will be reviewed and set plan up f

12、or ensuring all are sufficeint for the trial run or first article preparation, depend on the customers requistion. PGMNT will coordinate with team members to review by “The Completion Check List of Specification Required for Manufacturing” (see appendix).5.4.1 APQP team reviews the customer requirem

13、ents and concerned documents such as specification, special characteristics, and others concerned for decision whether XXX can achieve the customer requirements. In case, XXX need to modify or waive some customer requirements, they must get customer approval.5.4.2 In case therere insufficient inform

14、ation, PGMNT manager will request the additional ones from customer.5.5 APQP team will prepare for the process design and development, i.e. materials verification, material preparedness, facility/equipment/tooling, Process Flow chart, PFMEA, Quality Plan, and instructions, etc.Remark Special Charact

15、eristic (SC) will be reviewed and specified in PFMEA, Q-Plan, Process Flow chart and Work Instruction.5.6 In the process of trial run or first article preparation, APQP team will plan and take the review and evaluation for ensuring the comprehensive development are established and produced the outpu

16、t compliance with the customer requirement. The APQP team will validate that the quality plan and process flow chart are being followed the products meet customer requirements. The additional concernes will be identified for corrective action prior to regular production run.5.7 The change of documen

17、tation will be controlled based on Documents and Data Change/Modification Procedure (Doc# 72-350-0004) and Engineering Change Order Analysis Procedure(Doc# 72-409-0003), and Documentation and Data Control Procedure (Doc# 72-350-0001)5.8 The FAS will be inspected by QA according to FAS procedure.5.9

18、The accepted sample can be shipped to customer with all requested documents as Production Part Approval Process (PPAP) File.5.9.1 In case the customer disagree with the quality of FAS, APQP team will conduct meeting to take the corrective action in order to improve the process and quality.5.9.2 The

19、mass production will be released after obtain the authorization from the customer.5.10 While the PPAP file is arranged, the Part Submission Warrant (PSW) will prepared.6. RESPONSIBILITYAPQP Team is responsible to verify and validate the product realization plan and process for satisfying to customer

20、s. Team leader : PGMNT department manager or customer representativeTeam member : PE, TE, PDE, and QETeam Specialist : IE and PD/Mfg.Team Supporting : MC, Tooling, PUR, IQA, and WarehouseAPQP team is responsible to prepare, the machine program and fabricating part as : a. Process engineer and PD wil

21、l prepare the machine program, b. Process engineer will develop the fabricating part with the supplier.c. QE will be in part of part verification which coordinated by PE, TE, PDE, and Tooling.d. Any discrepancy of above preparations shall be immediately taken the correction.f. Material Control depar

22、tment and Purchasing dept. responsible to procure materials according to BOM & AVL. Then the materials will be passed to Incoming Inspection Procedure. APQP team for file fulfillment, and shall be kept as reference at Document Control Center.7. APPENDIX7.1 Chinese Version7.2 Responsible Matrix7.3 Co

23、mpletion Checklists of Specification Required for Manufacturing (Form 01)7.4 Control Plan Design & Review Form (Form 02)7.5 Line configuration and materials flow review form (From 03)7.6 Machine Programming Review List (Form 04)7.7 List of Machine / Jig&Fixture / Test Equipment / Checking Aid (Form

24、05)7.8 Assembly Jig & Fixture Verification and Review (Form 06) 7.9 Test Jig / Fixture Vertification & Review (Form 07)7.10 Packaging Goods Design Review (Form 08)7.11 Product Run Result Review (Form 09)7.12 Part Submission Warrant (Form 10)7.13 Team Feasibility Commitment (From 11)7.14 New Project

25、Start up Gantt Chart Review (Form 12)7.15 Example of standard Gantt Chart (please find the sequence doc.preparation).7.16 APQP Process APPENDIX 7.1Chinese Version1. 目的1.1 为高级产品质量计划建立指导方针。1.2 为新项目准备生产零件批准过程或发展已有项目。1.3 定义建立必要知道方法步骤以确保客户能够满意此产品。2. 范围2.1 此文件适用于实现产品过程与供应商推进相一致以满足客户需求。2.2 通过建立试生产报告定义机器工艺及

26、元件确认与有效性。3. 参考文件3.1 合同评审程序72-155-00013.2 报价程序72-155-00123.3 文件数据控制程序72-350-00013.4 文件数据变更/修改程序72-351-00043.5 不合格材料控制程序72-351-00053.6 材料评审程序72-351-00083.7 纠正预防措施程序72-351-00123.8 来料检验程序72-351-00153.9 质量计划程序72-351-00263.10 试生产报告程序72-351-00283.11 元件生产批准程序72-351-00343.12 失效模式分析72-351-00353.13 HPU创作程序72-4

27、05-00013.14过程控制程序72-409-00023.15 工程变更通知72-409-00033.16供应商批准程序72-409-00093.17元件数字编号程序72-409-00103.18上料清单创建程序72-409-00113.19 夹具&固定设备建立确认程序72-650-00114. 材料及设备无5. 程序5.1 APQP团队将会在队员与客户之间评估协议构架的可行性，在决定建立报价准备之前，参考报价程序（RFQ 72-155-0005），HPU创建程序（72-405-0001），且依据此程序创建新项目表格，HPU, 和RFQ。5.2 客户接受我方报价以后，我方接受客户订单（或合同

28、）。APQP团队将会为“新项目Gantt Chart 评审”建立Gantt Chart 计划及团队评审。5.3 必须通过提交日程表程序在项目管理与材料控制间协调以确认装船通知。5.4 复审所有客户需求及信息以确保所有建立的计划在依靠客户要求的情况下，能够满足试运行或试生产准备，项目管理将与队员协调管理评审“生产规格检验清单”。5.4.1 APQP团队会评审客户要求和如说明规格，特性等的相关文件，还有其它关于XXX是否能够获得客户要求的相关决定。在XXX公司需修改或放弃一些客户需求时，必须得到客户批准。5.4.2 在没有足够信息的情况下，项目经理将会从客户那里要求额外信息。5.5 APQP团队将

29、会准备设计过程及发展，如材料确认，材料准备，设备/工具，流程图，质量计划与说明等。备注 在质量计划，流程图及工作说明中需评审并指定特性(SC)。5.6 在试运行或试生产准备过程中，APQP团队将计划评审并评估，以确保建立全面实行生产的产量与客户需求相一致。APQP团队将会验证质量计划与流程图的跟踪情况且此产品是否已满足客户的要求。附加有关情况将会在正常生产运行之前由纠正措施识别。5.7 基于文件数据变更/修改程序（文件72-350-0004），工程变更分析程序（文件72-409-0003）和文件数据控制程序控制文件变更。5.8 QA将会根据试生产报告程序检验试生产报告。5.9 带有生产元件批准

30、过程的相关文件合格样本会运送到客户处。5.9.1 在客户不同意试生产报告的情况下，APQP团队将会召开会议采取纠正措施以改善过程与质量。5.9.2 在从客户那里获得授权后将会大量生产。5.10 当PPAP文件安排好后，将准备元件提交授权（PSW）。6. 职责 APQP团队负责验证确认能够满足客户的产品实现计划与过程。队伍领导：项目部门经理或客户代表队伍成员： 工艺，测试，生产工程与质量工程队伍专家：工业工程与生产队伍支持方：材料控制，工具，采购，来料检验与仓库APQP团队负责准备机器项目与构件：a. 工艺工程师与生产会准备机器项目b. 工艺工程师将会建立供应商构件。c. 质量工程师将会参与由工艺，测试，生产工程及工具相关的元件确认。d. 以上准备的任意不良将会立即采取纠正措施。f. 材料控制与采购部门负责根据BOM & AVL 获得物料。然后材料回转交到来料检验程序。 APQP团队对于文件的实行应保存在文件控制中心作为参考。7. 附件7.1 中文版本7.2 矩阵图7.3 生产规格检验清单7.4 控制计划设计&评审表格（表格02）7.5 线条构造与材料流程评审表（表格03）7.6 机器项目评审清单（表格04）7.7 机器/固定设备/测试设备/较检形态（表格05）