jcl:
To start please remember the key:
APQP = RFQ Stage to Begin Production and really continues through to end of production (see AIAG's APQP Manual).
You ask:
--> Another question. You said the APQP is for planning out
--> processes. Our actual production process is the same. We
--> don't create a new line for each product. We switch a die to
--> form a different shape but the process is the same. Of course
--> we have a way to notate special characteristics, special
--> notes, etc. In this case is the APQP really not applicable in
--> the sense the big 3 meant it? Or i mean we have to do it once
--> to think out the process we use but its not something we have
--> to do individually for each product?
First I want to say I lied when I said APQP was only for planning out processes:
--> ...the APQP is for planning out processes.
As I said above:
APQP = RFQ Stage to Begin Production and really continues through to end of production (see AIAG's APQP Manual).
APQP is to ensure you have a planning system and that the system involves communication with the customer. There are details to this - for example there are required design reviews (not to mention contract review), so I do not mean to over simplify what APQP is.
In my humble opinion (IMHO) the key here for you is that your
process design is essentially done with the exception of the die.
This in essence means you have gone through
some elements of APQP prior to the customer order which eliminates
some of the typically required customer timing communications and elements.
For example - with a press for injection molding. Your process is known and stable with certain molds. With metal forming it may be simplier (I doubt it), but with injection molding there are many dynamics of the mold. Temperature, thickness (in many areas different, seldom consistent throughout), etc. I am sure there are similar criticalities with metal forming (both press and machining), but I don't have the intimate background to discuss metal forming specifics.
BUT - this is just a part of APQP. What about Contract Review?
My point in all this is that some parts of APQP are specific to your product and processes -
Others are not.. When you have a process where you are only changing a die, my concern would be limited to the areas of change - contract review, the aspects of the die, etc.
I would like to see your APQP procedure to see what it consists of. It may be that you are going beyond what is neccessary for your business.
APQP is a general requirement which you really have to think about. Remember there are a lot of different types of parts producers who have to go through with it. And - you must remember that it actually
starts at the RFQ stage. Your arguement addresses things that come down the line a bit -
parts of the APQP process.
If you take a look at
https://Elsmar.com/pdf_files/ - Look for AQP_Matr.pdf Simple APQP Matrix - you will see a simple outline of the things one company goes through in its APQP process. Compare it to the APQP Manual from the AIAG. This is from several years ago and auditors are being a bit more picky but it passed in 1996. The Design Procedure addressed design reviews in this case. My point with this is some things will be redundant and they can thus use existing documents. Examples are the Process
FMEA, Review Suppliers and Process Review. On the other hand
some line items are applicable. An example is
Critical Characteristics.
Summary: Ask yourself what changes with each new order. Those items you have to address.
Have I confused you (and everyone else)??? HeHeHe....
Now I'm waiting for barb's response...
barb - Are you there???
[This message has been edited by Marc Smith.]