The QS-9000 ‘Quality’ System

ISO 9001:1994

Ford’s Q1

GM’s Targets for Excellence

Chrysler’ PentaStar

Ford, GM and Chrysler’s ‘Mutual Needs’

QS-9000 Support manuals

APQP & Control Plan

• Potential Failure Mode and Effects Analysis (FMEA)
• Measurement Systems Analysis (MSA)
• Statistical Process Control (SPC)

Production Part Approval Process

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Supplements

QS-9000 Origins

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Customer Requirements

NOTE: GM, Ford and Chrysler each have their own additional requirements!

Includes a ‘Warrant’

(read responsibility)

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Before we go any further with this discussion, if you are new to automotive you should know that the APQP and Control Plan manual is a ‘reference’ manual. It is a part of Ford, GM and Chrysler’s QS-9000 ‘quality’ systems requirements. QS-9000 is a ‘standard’ but not in the usual sense. When I think of what I call a standard I think of something more or less world wide. Bottom line it is a ‘standard’ containing ‘quality’ system requirements of Ford, GM and Chrysler which was derived from their individual requirements. GM’s old Targets for Excellence, for example, included their GP’s (General Procedures - now called the GM-9000) and general quality systems requirements for suppliers. Ford has their Q1. Chrysler had their PentaStar requirements. This discussion is focused on one support manual of this system - the APQP and Control Plan manual. Note that the FMEA, MSA, and SPC support manuals are ‘sub-’ manuals of the APQP manual in that they further define output parameters (e.g.: your MSA analysis has to include analysis of Bias, linearity and R&R as a minimum).

As much as anything else, the APQP manual is a set of data requirements. Proof your process is capable. Proof (through an FMEA) that you have made certain risk evaluations. Proof you know you can actually produce a part and in the expected quantities. Proof you have assessed ‘all’ customer requirements.

The Juran Trilogy	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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