Slide 22 of 241

As noted earlier, one should not look at this entirely in a linear fashion. However, to some degree one may look at the phases with an eye to critical paths. For example, design goals, a Phase 1 output, is necessary for completion of certain Phase 2 outputs (for example the Design FMEA).

Step back and ask yourself: “…What do I need before I can complete my Control Plan?…” There may be inputs your company utilizes which are not listed in the APQP manual.

If you try to draw a direct line from an input to an output (such as from design goals to design FMEA above), you will not always have a clear 1 to 1 relationship. As an example, when design goals are established and documented they will probably have an effect on a number of the outputs. In this case design goals may affect the design FMEA, design verification test design, certain engineering and material specifications, and the prototype build control plan.

Inputs / Outputs - Phase 2

• Design Goals

• Reliability and Quality Goals

• Preliminary Bill of Material

• Preliminary Process Flow Chart

• Preliminary Listing of Special Product and Process Characteristics

• Product Assurance Plan

• Management Support

Phase 2

• Outputs by Design Responsible Activity

• Outputs by Advanced Product Quality Planning Team

• Design FMEA

• DFM and DFA

  Design for Manufacturability
  
  Design for Assembly

• Design Verification

• Design Reviews

• Prototype Build Control Plan

• Engineering Drawings (including Math data)

• Engineering Specifications

• Material Specifications

• Drawing and Specification Changes

• New equipment, tooling and facilities requirements

• Special product and process characteristics

• Gage and testing equipment requirements

• Team feasibility commitment and management support

• Subcontractor build

• Supplier build

Phase 1 Outputs

(Phase 2 Inputs)

Phase 2 Outputs

(Phase 3 Inputs)

	The Deming PDCA Cycle	QMS Implementation	FMEA Information	APQP Information
Auditing Information	8-D Problem Solving	Statistics	Error Proofing (Poka Yoke)	Brainstorming
Identifying Waste	Pull Systems	Lead Time Reduction	Planned Maintenance	Quick Setup
Discovering Change	Process Capability - Cp vs. Cpk	Histogram Animation	Process Loop Animation	Taguchi Loss Function
		Fishbone / Cause and Effects Animation

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