Ideas for Tracking and Triggering updates in the APQP Process.

J

jkittle

We just went through our surveillance audit and received findings for our APQP process (again). The auditor found some control planes and PFMEA's not updated to reflect process changes that were made and customer defects. This is the second time we have been written up for APQP.

I agree that it is a very point in our quality system. Does anyone have any ideas on how to do a better job of implementing/tracking and triggering the APQP process? I would love to have an integrated database if possible.
 

Jen Kirley

Quality and Auditing Expert
Leader
Admin
I would love an integrated database too, but I have often been disappointed in commercial software.

So I'll settle for check boxes in a change form that ask:

Has the APQP been updated? Y-N-n/a
Has the PFMEA been updated? Y-N-n/a
Has a GR&R been updated? Y-N-n/a

IMO, when it's not possible to electronically automate, one must put reminders in place and apply the discipline to insist they be used.
 

Jim Wynne

Leader
Admin
We just went through our surveillance audit and received findings for our APQP process (again). The auditor found some control planes and PFMEA's not updated to reflect process changes that were made and customer defects. This is the second time we have been written up for APQP.

I agree that it is a very point in our quality system. Does anyone have any ideas on how to do a better job of implementing/tracking and triggering the APQP process? I would love to have an integrated database if possible.

Once you have PPAP approval, the APQP process for any given product is over. There are elements of it, however, that remain "live," such as the control plan and PFMEA. When processes change, the changes should be documented, and there should be a requirement in that change process to update the relevant process documentation. It seems that the problem isn't in your APQP process, but perhaps a lot of changes are being made on the fly without being properly documented.
 
J

jkittle

We have problems with both the APQP and changes after approved PPAP. What can be done to help trigger a review?
 
M

M Greenaway

Prompt to review these things at the point at which the process changes - e.g. on your 8D form include in the footer consideration of PFMEA change, etc
 
P

p_tww

We just went through our surveillance audit and received findings for our APQP process (again). The auditor found some control planes and PFMEA's not updated to reflect process changes that were made and customer defects. This is the second time we have been written up for APQP.

I agree that it is a very point in our quality system. Does anyone have any ideas on how to do a better job of implementing/tracking and triggering the APQP process? I would love to have an integrated database if possible.

Auditor concerned whether you realized the risk and whether related control was identified in the control plan/ process instruction. if you had evaluated impact of process change and verify/validate its change before implementation. update in related document is only documentation problem.

APQP is a tool for new/changed product developing/realization, it will not be end untill the product is dead in your company. Application of APQP does not just require you prepare a set of document It focuse on prevention/risk control.
you will do it better if you have a set of risk management logic (started from SC then PFMEA then Control plan then process instruction; MSA--Process capability study--SPC monitoring during manufacturing)
 
D

dna_leri

We have problems with both the APQP and changes after approved PPAP. What can be done to help trigger a review?

It sounds like your problem is in your change management process. Assuming you have defined your process, you need to ensure that it triggers changes to the related documents (PFMEA, Control Plan). I find a checksheet useful for this purpose.

Perhaps you already do this, then the problem may be that not all changes go through the change management process. This is more difficult to correct and usually requires a culture change initiated by some "quality policing" or monitoring or training.

I would suggest taking the examples found by your auditor and following it back to see if the change management process was followed correctly or was it bypasssed or does it not exist.
 
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