Hi,

Hello... everyone. I'm new to this forum.

We are a small manufacturer and recently got our ISO9001:2000 certification. Now, we are preparing for the TS16949.

I'm in the process of revising and adding new procedures.

My question is.... would it be a good idea for me to establish documented APQP, PPAP, FMEA, SPC procedures?

(Some sample APQP and PPAP procedures would be very helpful to me)

Actually, what would be the best strategy to upgrade from our ISO9001:2000 QMS to TS16949, at least, documentation wise.

I really wish to build and implement a good QMS for the benefit of the company. I would certainly welcome any help and mentoring that I could get.

Chester

Let me be the first to welcome you to the Cove, the best online source for quality pros.

I do not have much experience with what you are asking about, but may I suggest that you use the search function for each of those areas of interest? I know they have been discussed to some length.

Again, welcome!

Craig

Being a fan of keeping it simple (KISS), I would not write procedures for each of those techniques. Simply refer to them in your existing procedures with a reference to the instructional manuals already available (through www.aiag.org).

Oh, and welcome to the Cove, Chester. :bigwave:

YUP, what Rob said.

Welcome to the Cove Chester.

Dave

Hi Chester

First of All. Welcome to Cove!

Regarding your question, let me try to reply one by one.

You have done your job atleast 55% Complete by acheiveing ISO 9001:2000. As you are aware TS 16949:2002 is based on 9K2K.
Now, Rest 45%.

Regarding Documented procedures, One more Documented Procedure is required over and above 9K2K SIX Procedures. i.e. Procedure for Training wherin you have to describe how Trg. need is identified How Skill Gap is Fullfilled by way of TRG and How Trg. Effectivness is measured.

Now, Regarding APQP, PPAP, FMEA , SPC and MSA procedures, I wish to tell you that There is NO NEED to frame the procedures for all above. However, all thease are to be implemented in your System. PPAP, APQP etc Procedures are not required but APQP and PPAP etc are very much required.

I further, wish to say that even though I have made mistake to frame almost 48 Procedures inwhich APQP, MSA and SPC procedures are also included.But That has not resulted any benifit for my Company.
I am attaching APQP procedure of mine, If you wish further more I can send further documented procedures to you through my mail.

Hi Chester and welcome.

We mentioned in our procedure that we would conduct APQP in the customers prscribed method and that if they did not indicate a specific method we would use the AIAG methodology. What was very helpful to us and to our auditors was a "mockup" APQP binder. We took one of processes and created an APQP binder for from start to finish for it. (We have not yet been required to do an APQP). This provided objective evidence to the auditor that we knew how to do APQP and it also gives us an example to use when we are required to do one.

Hope this helps.

Jan T :rolleyes:

Chester my welcome as well.

Remember that we are process orientated.
APQP is a process which should be defined, with reference to the manual etc. The most important part of the definition is to really define how you intend to run this. The important part of your implementation is not the procedure rather that the follow up to ensure that the people concerened are really working as they should be.
Procedures do not ensure this, they only ensure that there is something on the shelf.
FMEA is a tool for use in the APQP process and training not a procedure is what is important here. The manual describes the process, what you should do is define for yourselves the ranking system that you are going to use and a RPN number that means you have to take further action. This is some form of WI or other document.
PPAP is one of the outputs of the APQP process (the other the part), as such it is in fact defined in the APQP process. This is again why the effective implementation of APQP is vital, you don't have to chase the paper it is already in place.

SPC is also a tool and as such I don't see why you need a procedure, instructions to use are enough., but know how to use!

All the best

First of all, Merry Christmas... and I like to thank all of you for your warm welcome and valuable advice. Really appreciate it.

Coming back to the topic.... I think I'll try to define our APQP process, even though we don't really have a proper one yet....

I agree that the most important part of our implementation would be ensuring the people to do what we describe in our procedures our manuals.... but even before that, we need to know and understand what we have to do. Most of the time we get stuck at this stage.

I'm in a situation where some of these new 'processes' are non-existent. In other words, I need to design and put in place these new 'processes' and I need some guidance.

I was told the APQP requirements would be:

1. Organizing the team
2. Define the scope
3. Team-to-team (commmunication)
4. Training
5. Customer and Supplier Involvement
6. Simultaneous Engineering
7. Control plans
8. Concern Resolution
9. Product Quality Timing Plan
10. Plans Relative to the Timing Chart

Actually, how would all these things fit together in terms of a flowchart? So far, what I have read about APQP is still floating in the air in pieces... an actual example of APQP implementation would be very helpful... especially... the outputs and records (evidence). Actually, Jan's 'binder' was a good example.

Sigh... my mind tends to think sequentially. Step-by-step guidelines and flowcharts tend to work better for me.

One more thing... about product design & development, we usually accept design drawings and samples from our customers for product development. We are only required to design and develop the mold according to the given product design or sample, and then mass-produce the products using injection molding machines. We don't really do the product design but we design and develop the mold for the product. How would this affect our TS implementation (and also APQP) with reference to the design clause?

Chester asks,
"One more thing... about product design & development, we usually accept design drawings and samples from our customers for product development. We are only required to design and develop the mold according to the given product design or sample, and then mass-produce the products using injection molding machines. We don't really do the product design but we design and develop the mold for the product. How would this affect our TS implementation (and also APQP) with reference to the design clause?"

Clause 7.3 of TS2 applies to product and Process design. Mold design (tooling) is a part of the process and would be covered by the elements of 7.3.