APQP information to suppliers

Transcription

APQP information to suppliers
Volvo Construction Equipment
2012
Content
1. Background and expectations
2. What is APQP and its benefits?
3. When to start and how to share APQP planning and status with Volvo?
4. How to get started with APQP reviews?
5. Requirements for Production Part Approval (PPAP)
6. Where to find APQP information/templates?
7. What are the Volvo APQP specifics?
8. Conclusion: What to keep in mind?
Volvo CE, Purchasing & Supply Management
2 2012-10-12
1 - Background and expectations!
Background for APQP
• Since almost 10 years, Volvo CE is using PQAP (Part Quality Assurance Plan) for quality
assurance of purchased parts. This tool is unique for Volvo CE, see process below.
• Since several years, there has been discussions about changing to other more
standardized tools. Majority of other Volvo Business Areas and Business Units have
already changed to APQP.
• In 2009 a decision was made that Volvo CE shall align to the rest of Volvo and implement
APQP because there is a clear business benefit.
• The target is that APQP is implemented for all new projects during 2012.
PQAP process today
Phase 1. Planning
1.1
Review of
Technical
Specification
1.2
Process
Flow
Chart
1.3
Project
Plan
Phase 3. Confirmation
Phase 2. Preparation
2.1
RTS
Actions and
Closure
4 2012-10-12
2.2
FMEA
2.3
Control
Plan
2.4
Quality
Assurance of
sub-supplier
2.5
Initial
Sample
Approval
3.1
Process
Control
Confirmation
3.2
Production
Test Run
3.3
Product
Audit
Phase 4.
Closure
4.1
PQAP
Closure
Planning of Product Realization
Planning of Product Realization is a requirement which
means any organization ISO certified (whether 9001 or
TS 16949) MUST plan and develop the processes
needed for product realization.
5 2012-10-12
APQP Requirements towards suppliers
Summary
• Volvo CE plan to change from PQAP to APQP gradually during 2012.
For all new projects from 2012 and onwards, APQP methodology will
be used.
• APQP is a basic business requirement valid for all suppliers, this is
included in Volvo Key Element Procedures available in the Volvo
Group Supplier Portal, link here.
• APQP includes product and process validation according to PPAPmethodology.
• Certification according to ISO/TS 16949 will not be a mandatory
requirement for suppliers to Volvo CE.
• Volvo CE will to a high extent use the same routines, templates and
interface documents as Volvo Group Trucks Æ APQP will become
common within Volvo Group.
• Specific Volvo CE APQP requirements, instructions and templates
will be available in the supplier portal during 2012.
6 2012-10-12
APQP-expectations on Volvo CE supplier
base!
• APQP is a project management methodology and a quality assurance
process, which is the responsibility of the supplier. Therefore suppliers must
be ready to run projects using APQP methodology by 2012.
• Suppliers who are not familiar with APQP should take contact with 3rd party
training companies and join training. Volvo CE will not manage full supplier
APQP training. Supplier days and information sessions will be held where
specific Volvo CE APQP process and supplier expectations are
communicated.
• Suppliers should update internal processes in line with APQP requirements.
APQP requirements are available in publications from AIAG (www.aiag.org).
• Continued supplier support is very appreciated and essential for successful
implementation of projects according to APQP. Volvo CE is convinced that
working together we will achieve a higher level of QDCF on our products to
satisfy our customers.
7 2012-10-12
Available APQP publications
Requirements
Manual
ISO/TS 16949 (Automotive Quality System Requirements, International)
PPAP (Production Part Approval Process)
APQP (Advanced Product Quality Planning)
FMEA (Failure Modes & Effects Analysis)
Reference
Manual
SPC (Statistical Process Control)
MSA (Measurement System Analysis)
Above publications are published by AIAG and
can be ordered from (www.aiag.org).
Reference Manuals provide Guidelines and do not give specific instructions
8 2012-10-12
2 - What is APQP and its benefits?
APQP Definition and Objective according
to AIAG!
• Definition
– ”APQP is a guideline designed to produce a product quality
plan which will support the development of a product or
service that will satisfy the customer”
• Objective
– ”To facilitate communication with everyone involved to assure
that all required steps are completed on time”.
10 2012-10-12
Advanced Product Quality Planning is supplier’s
planning in compliance with the AIAG reference
manual!
APQP is a Volvo
requirement (incl. RTS,
PAA, PHR) as specified
in Key Element
Procedures available at
the supplier portal!
Pre-requisite: supplier is trained to
APQP and its own development
process is in compliance with it!
11 2012-10-12
What does APQP mean for Volvo?
Supplier Project team is responsible for planning APQP activities and
report Planning Status to Volvo team during the APQP review meetings,
using the APQP review check-list!
• A Project Management Method according to VOLVO development stages!
• A very detailed Supplier Timing Plan synchronized with Volvo project
milestones!
• A regular Volvo-Supplier APQP follow-up meeting with formal reviews prior
to VOLVO releases!
• A very detailed APQP checklist supporting the reviews to identify and
manage risks!
• Additional 3 Volvo specific best practices (RTS, PAA, PHR)!
Æ A robust cross-functional way of working between Volvo and supplier aiming
to deliver a project in respect with QDCF!
12 2012-10-12
APQP is supplier's planning that integrates
Volvo input, constraints and deliverables and is
synchronized with VOLVO project milestones!
13 2012-10-12
APQP Objective for
Volvo!
Have suppliers develop a realistic
plan for new part launch
Plan for
All necessary activities
interactions (Volvo and
supplier)
Regular follow up on the plan
Deliver to the plan
Successful activities on time!
14 2012-10-12
The planning objective
Planning
Execution
Process
Parts
15 2012-10-12
APQP content for Volvo
35 Elements
1
2
3
4
APQP REVIEWS & MANAGEMENT SUPPORT
APQP PLAN & TIMING CHART
CUSTOMER INPUT
BENCHMARK DATA
19
20
21
22
5
PRODUCT RELIABILITY STUDIES & QUALITY
RELIABILITY GOALS
23 PROCESS INSTRUCTION
6
7
8
9
10
TRAINING
INVESTMENT & CAPACITY PLAN
TIER 2 MANAGEMENT (tier 2 APQP status)
DFMEA
SPECIAL CHARACTERISTICS
24
25
26
27
28
11
DESIGN REVIEW FOR MANUFACTURABILITY
& ASSEMBLY
29 SIGNIFICANT PRODUCTION RUN
12
13
14
15
16
17
18
DESIGN REVIEWS
REVIEW OF TECHNICAL SPECIFICATION (RTS)
PRODUCT APPLICATION AGREEMENT (PAA)
ENGINEERING DRAWINGS (including math data)
DESIGN/PROCESS CHANGES & TRACEABILITY
ENGINEERING & MATERIAL SPECIFICATIONS
CONTROL PLAN
16 2012-10-12
30
31
32
33
34
35
DESIGN VERIFICATION PLAN & REPORT
PROTOTYPES
FLOOR PLAN LAYOUT
PROCESS FLOW CHART
PFMEA
PACKAGING
PART HANDLING REVIEW (PHR)
MEASUREMENT SYSTEM ANALYSIS
PROCESS AUDIT
PROCESS CAPABILITY
PRODUCTION VALIDATION TESTING
PRODUCTION PART APPROVAL
RUN @ RATE
LESSON LEARNED
CONCLUSION OF APQP Review
Benefits of APQP
• Standardized well proven process
• Secures Supplier project management is in place
• Provides cross-functional mindset
• Ensures early planning takes place and framework for
Early Supplier Involvement (ESI)
• Identifies required changes early in the process and
reduces need for late design changes
• Provides quality product on time and at lower cost
• Improves Gates passed on time in projects
• Improves PPAP approved on time
• Reduces PPM levels at Start Of Production
• Reduces field failures (reduce warranty)
17 2012-10-12
3 - WHEN to start and HOW to share
APQP planning and status with Volvo?
APQP plan starts with
Request For Quotation
The supplier is requested to submit with
the RFQ-answer a preliminary APQPplan based upon major project activities
and milestones including tool
manufacturing, facility installation, part
testing/validation and process prove out
for both Quality and Capacity!
19 2012-10-12
APQP follow up in Projects!
• APQP Volvo monitored!
– For selected Key Components, APQP status must be shared with
Volvo through the process of APQP reviews. (See next pages)
– To report APQP status, use of VOLVO APQP review template is
requested.
• APQP Supplier monitored!
– For components not specified as Volvo monitored, the Supplier
shall be ready to submit its APQP plan and status upon request
any time and invited to report upstream any roadblock foreseen.
In any case Æ
• Supplier owns APQP
• Supplier shall develop and follow up its APQP planning
20 2012-10-12
APQP Reviews: share supplier APQP
status with Volvo!
DEFINITION
OBJECTIVES
A formal meeting where Volvo
reviews supplier's APQP plan
for Key Components.
•Detects any deviation,
assesses the risks and
assigns actions
Volvo and supplier check that
the project at component level
is on track with respect to
deadlines and results.
•Gives visibility of the
progress to Volvo and
supplier teams
•Escalate the roadblocks
to project management /
line organization for
decision or action
ATTENDEES
At minimum:
•Supplier team (project
leader, engineering, sales,
quality etc)
•Volvo Supplier
Development Engineer
•Volvo Design engineer(s)
•Volvo Buyer
WHEN REQUESTED
•Volvo QA, logistics, After
Market etc
21 2012-10-12
How to match with GDP? Development supplier
VOLVO Project team performs
APQP activities under its
responsibility and consult
supplier APQP deliverables!
DG
Concept Study
AKey
Component Release
Selection
SDE coordinates
completion of VOLVO
APQP activities with
the Project Team
Supplier performs
APQP activities under
its responsibility
FDCG
Detailed development
IG
Final development
RG
Industrialization
Volvo
CRelease PPAP
order
BRelease
Supplier
selected
PPG
PRelease
PPAP
Approved
APQP
APQP
APQP
APQP
APQP
KICK-OFF
PRODUCT DESIGN
PROCESS DEVELOPMENT
INDUSTRIALIZATION
LAUNCH
review
review
review
review
review
Supplier
Product
Design
22 2012-10-12
Supplier
Process
Design
Supplier
Process
Development
Supplier
Product &
Process
Validation
How to match with GDP? Production supplier
DG
VOLVO Project team performs
APQP activities under its
responsibility and consult
supplier APQP deliverables!
Concept Study
ARelease
FDCG
Detailed development
Key
Component
Selection
BRelease
SDE coordinates
completion of VOLVO
APQP activities with
the Project Team
Supplier performs
APQP activities under
its responsibility
23 2012-10-12
IG
PPG
Final development
Industrialization
CVolvo
Release PPAP
order
Supplier
selected
RG
PRelease
PPAP
Approved
APQP
APQP
APQP
APQP
KICK-OFF
PROCESS DEVELOPMENT
INDUSTRIALIZATION
LAUNCH
review
review
review
review
Supplier
Process
Design
Supplier
Process
Development
Supplier
Product &
Process
Validation
Who does what in APQP reviews?
•Organizes the APQP reviews for
Key Components
•Participates in APQP
reviews for key components
•Ensures APQP activities
under his responsibility are
integrated/completed:
timing and results
Buyer
SD
Supplier project
team updates the
APQP-plan and
APQP Review file
to evaluate the
project status,
timing, risks!
•Makes sure that all PROCESS
design, verifications & validations
activities are integrated/completed :
timing and results
•Ensures that the overall supplier
APQP plan is complete, realistic and
matches project milestones
Design
engineer
•Participates in APQP reviews for Key Components
•Ensures that all PRODUCT design, specifications, verifications & validations activities are integrated/completed.
•Works close with Design Responsible Suppliers as they develop of their D-FMEA and identify Special
Characteristics early on
24 2012-10-12
APQP Review File
Checklist for each APQP review!
1900-01-00
0
Review date
Project code
Supplier & component name
Leading part number
Status at each review
Kick-off review
1
1.1
1.2
The contact directory is completed.
Supplier personnel identified for all APQP activities.
Software APQP has started (for Software development)
and QDPR matrix is filled in (QDPR: Quality and
Development Process Requirement document)
ISSUES/COMMENTS/RISKS
2.2
2.3
2.4
3
3.1
3.2
3.3
3.4
Product
G/Y/R
Process
G/Y/R
Actual Status
Indus
G/Y/R
Launch Status
G/Y/R G/Y/R
N/A
N/A
N/A
The main Volvo project milestones are communicated to
the supplier (drawing releases/ APQP reviews/ Prototype
builds/tooling release/PPAP/ SOP). The co-signed time
plan is fulfilled and agreed.
The supplier APQP plan matches Volvo milestones in a
realistic way. All APQP activities, related tasks and
owners are included.
All timing issues are solved (if some remaining,
escalation is needed).
Software APQP planning is synchronized with APQP
planning (when Software development).
CUSTOMER INPUT
The supplier has got all needed technical documentation
from Volvo (e.g. PVR, Technical Requirements,
Functional Specifications, Drawing etc.).
The Volvo APQP expectations are understood. The
supplier has access to supplier portal and has reviewed
the APQP documentation.
The forecast of P-builds, ramp-up and serial production
volume is shared.
All necessary customer input is received by the supplier
(technical, agreements, administrative, etc.).
Roadblock
Y/N
1.3
2
2.1
Kick Off
G/Y/R
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
CUSTOMER INPUT
N/A
N/A
N/A
APQP review file is owned by the supplier and shared with Volvo
during the complete project!
25 2012-10-12
C
4 - HOW to get started with APQP
reviews?
READ APQP Review GUIDELINES
SUPPLIER RESPONSIBILITY :
Supplier is responsible to document and maintain this file.
This file shall be reviewed by Supplier on a regular basis to maintain a good follow up of his porject with VOLVO . SQE, buyer and Design
engineer will participate on demand (Supplier or Volvo) to these APQP reviews. The Status of these reviews has to reach a good level of
achievement for each of the official reviews : Kick off, Product Design, Process Design, Industrialization & Launch.
The co-signed time plan has to be shared at the Kick Off review and in case of deviations to original targets, it will have to be shared
again with a new commitment . The traceability of the original agreement must be kept inserting a line with the new objectives.
HOW TO PRACTICALLY USE THE FILE
1 - Fill out the top part of the cover sheet: component identification
Project code (leading project): Other projects using this component
Plant parma code :
Supplier name (short) :
Plant location (country / city) :
Component Name
Leading part Number
Date when document issued/revised:
2 -Fill out the contact directory sheet
The contact directory shall be reviewed and updated at each APQP review
3 - Fill out the co-signed time plan sheet. The project milestones dates are given by Volvo
The co-signed time plan shall be reviewed and updated at each APQP review and each time there is a change to be agreed on.
4 - Fill out the APQP review sheet, starting with the APQP kick off requirements, the related issues , comments and the status Y/G
Status at each review
KICK OFF REVIEW
1
1.1
Kick Off
G/Y/R
ISSUES/COMMENTS/RISKS
Product
G/Y/R
Process
G/Y/R
N/A
Write the issue/comment/ risk for the given requirement Definition of Green / Yellow / Red for each requirement
G
Requirement is met
Y
Requirement is partially met
R
Requirement is not met
Rate Green/yellow or Red
Action Plan
Volvo's Responsible
Name
Roadblock
Y/N
Supplier's Responsible
Name
N/A
Put a Yes in case of Roadblock
Roadblock definition
Yes Requirement not met and HIGH impact
Action plan could not be managed by the team
Additional escalation is needed (normal escalation failed)
then fill out the righ part: action plan.
Corrective Actions
Launch Status
G/Y/R G/Y/R
The contact directory completed
Supplier personnel identified for all APQP activities
List of requirement, for each APQP review and APQP activity
Actual Status
Indus
G/Y/R
Open Date
yyyy-mm-dd
Due Date
yyyy-mm-dd
Close Date
yyyy-mm-dd
27 2012-10-12
APQP Review File
Preparation of APQP Kick-off
• Volvo to prepare the file by Volvo data.
• Parts- and common header data
• Contact information and co-signed time plan
• Share with supplier!
• Supplier should review the following tabs:
APQP REVIEWS
HOW TO USE THIS XCEL FILE
PRELIMINARY NOTES :
1/ This APQP excel sheet should be used for any new component purchased for use on serial production - MANDATORY for Key Components
2/ Multiple components can be covered in the same APQP file if the design and processes are very similar. In that case all the part numbers
considered need to be mentioned in the "Co-signed Time plan" sheet
3/ There is a difference made between development suppliers and non-development suppliers.
Secure you are using the right APQP Reviews Status Xcel document.
PURPOSE OF THE APQP REVIEWS :
The purpose of this document is to make sure the supplier manage his project with VOLVO in the right way and to provide him some support in
doing so.
This document also targets to give a status of the project at the Supplier to VOLVO project team and inform VOLVO about difficulties the
suppliers is facing as soon as possible. This in order to get the appropriate support for resolution and avoid putting the project at risk.
The ultimate goals of the APQP process are to have :
- the PPAP approved on time
- low PPM level from the SOP
– Contact Directory
SUPPLIER RESPONSIBILITY :
– Co-signed time plan
– Relevant review meeting (1st is Kick-Off)
Supplier is responsible to document and maintain this file.
This file shall be reviewed by Supplier on a regular basis to maintain a good follow up of his porject with VOLVO . SQE, buyer and Design
engineer will participate on demand (Supplier or Volvo) to these APQP reviews. The Status of these reviews has to reach a good level of
achievement for each of the official reviews : Kick off, Product Design, Process Design, Industrialization & Launch.
The co-signed time plan has to be shared at the Kick Off review and in case of deviations to original targets, it will have to be shared
• Supplier must be well prepared to each review! again with a new commitment . The traceability of the original agreement must be kept inserting a line with the new objectives.
• Set up the meeting.
Required: SDE (chair), Buyer, Design Engineer,
Supplier Team. When requested: QA, logistics,
after market representative.
• Conduct meeting
• Report status and set up feedback process
28 2012-10-12
HOW TO PRACTICALLY USE THE FILE
1 - Fill out the top part of the cover sheet: component identification
Project code (leading project): Other projects using this component
Plant parma code :
Supplier name (short) :
Plant location (country / city) :
Component Name
Leading part Number
Date when document issued/revised:
APQP Review File
Contact directory
• Always fill in!
• Update prior to or during each APQP
Review
Co-signed time plans:
• Always fill in!
• Update prior to or during each APQP
Review
29 2012-10-12
APQP Review Template
Cover sheet and KPI
1)
Component / project / supplier
identification
2)
Overall Status: Green /Yellow / Red
3)
“Number of roadblocks” is reported
from the roadblocks status in the
APQP reviews sheet
4)
“Percentage of requirements met”
calculated from the requirements with
Green status for each review. It is
displayed also per category of activity
5)
“Overall conclusion of the team” is
used to write the overall comments,
summary of the risks, what are the
next steps etc.
6)
“Issues identified in APQP review”
shows automatically all requirements
with Red status
1)
2)
3)
4)
5)
6)
30 2012-10-12
c) - After the Kick-off
Volvo Supplier Development Engineer
Suppliers…
• Make sure all major risks are summarized
by the Kick-Off team in the yellow field in
the cover sheet
• Work on all open issues continuously
• Follow up on Volvo actions.
• Call for next APQP follow-up meeting
• Report status to Project Management
team and Line management.
31 2012-10-12
• Work on activities in order to be prepared
and ready for the next review
5 – Requirements for Production Part
Approval (PPAP)
Purpose of Production Part Approval
Process (PPAP)!
• To secure that all Volvo engineering design records and
specification requirements are properly applied by the supplier,
• That the manufacturing process has the potential to produce
products meeting these requirements during an actual production
run at the quoted serial production rate.
33 2012-10-12
When is Production Part Approval
Process (PPAP) required?
The Supplier shall obtain PPAP approval from Volvo prior to the
first production shipment in the following situations:
• A new part (initial release),
• When first PPAP submission was not approved,
• Engineering change to design records, specifications or materials for
production product/part number(s),
• Process technology new to the supplier not previously used for this
product,
• When requested by Volvo, for example following a significant change
to the production set up, such as a large and rapid increase to
production volume requiring significant production changes.
34 2012-10-12
Significant Production Run (SPR)
• Sample Parts for PPAP should be taken from a significant production
run.
• When performing the significant production run, all aspects of
variability within the production process should be considered and
tested where practicable, e.g. set-ups.
• Approved PPAP or Initial sample from 2nd tier suppliers is required.
• The significant production run shall be conducted at the production
site, using the production tooling, production gaging, production
process, production operators and production materials.
• Parts from each unique production process e.g. duplicate assembly
line and/or work cell, each position of a multiple cavity, die, mould,
tool or pattern, shall be measured and representative parts tested.
35 2012-10-12
Sample size for Significant Production
Run!
• The quantity of parts produced for the significant production run may
vary depending upon the manufacturing process and production
supply quantity forecasts.
• The quantity should be discussed and jointly defined between the
Supplier Development Engineer and the supplier early in the APQP
process and communicated latest when sending the PPAP sample
order.
• In Automotive industry a production run to a quantity of minimum 300
consecutive parts is done! Æ Not valid for VCE!
• When applicable , a minimum of 30 pieces should be produced
during the SPR for preliminary process capability studies.
• Agreed sample size can be exceeded by the supplier.
36 2012-10-12
There are 5 different PPAP Submission Levels!
NOTE:
The supplier must complete ALL
activities with evidence of
successful completion regardless
of which PPAP Submission Level is
requested by Volvo.
PPAP Level 3 will be default
for Key components!
PPAP Level 4 will be default
for Non-key components!
Level 4 includes requirements
nr 7, 9, 10, 12, 13, 17, 18
Requirement
1.
Design Record
- for proprietary components/ details
- for all other components/details
2.
Engineering Change Documents, if any
3.
Customer Engineering approval, if required
4.
Design FMEA
5.
Process Flow Diagrams
6.
Process FMEA
7.
Control Plan
8.
Measurement System Analysis Studies
9.
Dimensionnal Results
10.
Material, Performance Test Results
11.
Initial Process Studies
12.
Qualified Laboratory Documentation
13.
Appearance Approval Report ( AAR), if applicable
14.
Sample Product
15.
Master Sample
16.
Checking Aids
17.
Records of Compliance
With Customer Specific Requirements
18.
Part Submission Warrant ( PSW)
Bulk Material Checklist
level 1
R
R
R
R
R
R
R
R
R
R
R
R
R
R
S
R
R
R
R
R
S
S
Submission Level
level 2
level 3
level 4
S
S
*
R
R
*
S
S
*
S
S
*
R
S
*
R
S
*
R
S
*
R
S
*
R
S
*
R
S
*
S
S
*
S
S
*
R
S
*
S
S
*
S
S
*
S
S
*
R
R
*
R
R
*
R
S
*
R
S
*
S
S
S
S
S
S
level 5
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
S = The organization shall submit to the customer and retain copy of records or documentation items at
appropriate locations .
R = The organization shall retain at appropriate locations and make available to the customer upon request .
* = The organization shall retain at appropriate locations and submit to the customer upon request.
37 2012-10-12
PPAP approval/interim approval codes
CODE
EXPLANATION
Y
Fully approved and in compliance with all Volvo CE requirements
N
Not approved and does not meet Volvo CE requirements
INTERIM APPROVAL
D
Not approved but the part is OK, the drawing must be updated. Part can be used
by final customer with approved deviation, until full “Y” approval
T
Not approved since the part is from a soft tool and/or not normal production. Part
can be used by final customer with approved deviation, until full “Y” approval
P
Not approved, appropriate tests are not done or the part is not OK but can be
used by the final customer with approved deviation, until full “Y” approval.
K
Not approved, since valid environmental information is missing. Part can be used
by final customer with approved deviation, until full “Y” approval.
O
Not approved, for other reason, e.g. approved packaging missing or PAA not
signed. Part can be used by final customer with approved deviation, until full “Y”
approval
38 2012-10-12
Interim approval!
REMEMBER!
Interim Approval permits
shipment of parts for
production on a limited
time or quantity!
The supplier is responsible for
implementing containment actions
to ensure that only acceptable
material is being shipped to Volvo.
39 2012-10-12
Customer Notification!
• The supplier must notify Volvo of
any planned changes to the design,
process or manufacturing site using
the Product/Process Change
Notification form available on the
supplier portal.
Hello Volvo!
We will change
production to a
new plant!
• Upon notification and approval of
the proposed change by a Volvo
representative, PPAP submission
is required after the implementation
of the change as directed by Volvo
Purchasing.
Supplier
40 2012-10-12
41 2012-10-12
When must Volvo be notified?
1.
Use of other material than was used in the previously approved part or
product.
2.
Production from new or modified tools, dies, moulds, patterns, including
additional or replacement tooling.
3.
Production following upgrade or rearrangement of existing tooling/equipment.
4.
Production from tooling and equipment transferred to a different plant site or
from an additional plant site.
5.
When 1st tier supplier changes the 2nd tier supplier for parts or services.
6.
Parts produced after the tooling has been inactive for 12 months or more.
7.
Change in test/ inspection method – new technique.
8.
Production from machines and/or processes that has been a target for a
bigger repair of refurbishing.
NOTE! If there is any doubt weather notification and approval is required it is strongly
recommended that the supplier discusses the planned change PRIOR to its application with
Volvo SDE, to allow a balanced joint risk evaluation to be established.
42 2012-10-12
6 - Where to find APQP information
and Volvo templates/guidelines?
Information, guidelines and templates
• APQP- and PPAP manual can be ordered from AIAG!
– http://www.aiag.org/
• Volvo APQP guidelines and templates are available at the Volvo Group
Supplier Portal!
– http://www.volvogroup.com/suppliers/global/en-gb/Pages/home.aspx
• Ask Volvo Supplier Development Engineer or buyer for more
information!
44 2012-10-12
7 - What are the Volvo APQP specifics
(best practices)
Review of technical Specification (RTS)!
DEFINITION
A documented review of
technical specifications.
“Technical specifications”,
includes all the documentation
needed to specify and verify a
product (PVR, drawings, digital
models, technical requirements,
standards etc).
A face-to-face-review together
with the supplier will be
mandatory for Key
Components!
46 2012-10-12
OBJECTIVES
•Make sure the supplier
understands early
enough all the technical
specifications of the
components to be supplied
to Volvo
•Supplier agrees on the
feasibility of these
specifications.
ATTENDEES
At minimum:
•Supplier Development
Engineer
•Design engineer
•Buyer
•Supplier team
Product Application Agreement (PAA)!
DEFINITION
OBJECTIVES
The PAA is a signed
agreement between Volvo
and the supplier to ensure
that both parties
understand and accept the
installation conditions for a
component designed by the
supplier.
•The PAA ensures that the
supplier agrees (by written
approval) that the product
they have designed will be
compatible with
environment constraints
when installed and used in
all of the application
environments defined by
Volvo.
Temperature
Vibration
Humidity
47 2012-10-12
Electromagnetic
compatibility
Proximity of
other parts
And more...
ATTENDEES
At minimum:
• Design engineer
• Buyer
• Supplier team
Part Handling Review (PHR)!
DEFINITION
OBJECTIVES
The Part Handling Review
(PHR) is a agreement between
Volvo and the supplier which
includes process review done
by the supplier at a Volvo plant.
The purpose PHR is to
obtain the suppliers’
observations and their
written agreement on the
way of handling,
storing/warehousing and
mounting the supplied part!
ATTENDEES
At minimum:
• Supplier Development
Engineer (chair)
• Volvo Manufacturing team
(QA, production
engineering, production
manager, logistics etc.)
•Supplier team
48 2012-10-12
8 – Conclusion: what to keep in mind!
APQP – What to keep in mind?
• APQP is owned by supplier and reported to Volvo, using the
APQP review file
• Suppliers APQP plan must take into account the Volvo
constraints and Volvo project milestones
• Supplier provides his first APQP plan with the answer to the
Request for Quotation
• The APQP plan is reviewed at each APQP review meeting
• APQP should contain enough details to be understandable
• Critical path and risk areas should be identified
• The plan must drive actions
• There will be problem: they must be fixed or escalated
50 2012-10-12
Glossary
•
•
•
•
•
•
•
•
•
•
•
•
•
•
APQP: Advanced Product Quality Planning
D-FMEA: Design – Failure Mode and Effect Analysis
DVP&R: Design Validation Plan and Report
GDP: Global Development Process
MSA: Measurement System Analysis
PAA: Product Application Agreement
P-FMEA: Process – Failure Mode and Effect Analysis
PAA: Product Application Agreement
PHR: Part Handling review
PPAP: Production Part Approval Process
QDCF: Quality Delivery Cost Features
RFQ: Request For Quotation
RTS Review of Technical Specification
SDE: Supplier Development Engineer
51 2012-10-12

APQP information to suppliers

Transcription

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