A DVANCE P RODUCT Q UALITY P LANNING by : Wahyu Epifanto

ADVANCE PRODUCT QUALITY PLANNING

by : Wahyu Epifanto

APQP| WHAT IS IT?

A structured methodology for the design and development of new and modified products from concept through to production

It provides a set of detailed requirements to be undertaken at each stage in the APQP system

It involves the utilization of various techniques to be employed to identify and resolve problems before going into full production

The goal is to facilitate communication with everyone involved to assure that all required steps are completed on time.

Effective planning depends on a company’s top management commitment to achieving customer satisfaction.

APQP| WHAT IS IT?

Process Design & Development

Product Design & Dev.

APQP Timing ChartConcept Program

Initiation/Approval Approval Prototype Pilot Launch

Planning

Product & Process Validation

Planning

Production

Feedback Assessment and Corrective Action

Plan & Define Program

Product Design & Development Verification

Process Design & Development Verification


Feedback Assessment & Corrective action

TIDAK LENGKAP

BAKWAN TIDAK AKAN LAKU,

KARENA TIDAK SESUAI DENGAN KEBUTUHAN KONSUMEN

LENGKAP

BAKWAN AKAN LAKU,

KARENA SESUAI DENGAN KEBUTUHAN KONSUMEN

HASIL SURVEY :

1. Harga tidak mahal

2. Rasa Gurih

3. Lembut / Tidak Alot

4. Minyak tidak banyak

5. Ukuran besar (Diameter + 5cm)

6. Warna, tidak gosong

7. Bentuknya rapih

Bahan – bahan :

1. Tepung

2. Air

3. Kol

4. Wortel

5. Toge

6. Daun Bawang

7. Garam

8. Minyak

9. Cabe

Alat-Alat :

Talenan

Pisau

Sendok

Mangkok/Baskom

Wajan

Kompor

Gas

Piring

Cara Membuatnya :

Dipotong :

1. Kol

2. Wortel

3. Toge

4. Daun Bawang

Buat Adonan :

5. Tepung

6. Air

7. Garam

Digoreng :

8. Minyak

Sajikan

9. Cabe

Alat :

1. Pisau

2. Talenan

3. Mangkok/Baskom

Alat :

4. Mangkok /Baskom

5. Sendok

Alat :

6. Wajan

7. Kompor

8. Gas

9. Wajan

Alat:

10. Piring

1.MEMBELI BAHAN YG FRESH

2. MURAH

1.MERAWAT ALAT-ALAT - TIDAK RUSAK

MENGONTROLPEMAKAIAN DANPENGELUARAN

MEMBAYARGAJI KARYAWAN

MENCARIORANG

MENGONTROLABSENSI

MENGEMBANGKAN ORANG

1.MENSORTIR BAHAN 2. MENYIMPAN BAHAN

1.MEMOTONG BAHAN - 1CM

2. BERSIHKAN 3.MEMBUAT ADONAN - TDK ENCER - TAKARAN 4. MENGORENG BAKWAN - SUHU - MINYAK

5.KEMASAN - TDK PENYOK - KUAT

1.MEMASTIKAN BAKWAN BERKUALITAS - WARNA - RASA - UKURAN - BENTUK

1.MEMASARKAN BAKWAN - CARI CUSTOMER - PROMOSI

1.MENGANTAR KAN BAKWAN - TEPAT WAKTU

PURCHASING WAREHOUSE PRODUKSI QUALITY CONTROL MAINTENANCE PEMASARAN DELIVERY KEUANGAN HRD

BOD

PHASE 2

PHASE 3

PHASE 4

PHASE 1

PHASE 5

APQP

PLANNINGPHASE 1



Concept ProgramInitiation/Approval Approval Prototype Pilot Launch

Planning


Planning

Production







PHASE 1 |PLANNING

Phase 1 Inputs Phase 1 Outputs

PLANNING

• Voice of the costumer

• Market Research

• Historical Warranty and Quality Information

• Team Experience

• Business Plan/MKT Strategy

• Product/process Assumptions

• Product Reliability Studies

• Cuctomer Inputs

•Design Goals

•Reliability & Quality Goals

•Preliminary Process Flow Chart

•Preliminary Listing of special Product & Process Characteristics

•Product Assurance Plan

•Management Support

PHASE 3

PHASE 4

PHASE 1

PHASE 5

APQP

PHASE 2



APQP Phase 2: Product Design & Dev.Concept Program

Initiation/Approval Approval Prototype Pilot Launch

Planning


Planning

Production







PHASE 2 |PRODUCT DESIGN & DEVELOPMENT


PRODUCT & DESIGN

DEVELOPMENT

•Design Goals


•Preliminary Bill of Material

•Preliminary Listing of Special Product & Process Characteristic



•Design FMEA

•Design for Manufactturability and assembly

•Design Verification

•Design Reviews

•Prototype CP

•Engineering Drawings

•Engineering Spesifications

•Material Spesifications

•Drawing & Spec. Changes

PHASE 2 |PROCESS DESIGN & DEVELOPMENT


PROCESS DESIGN &

DEVELOPMENT

•Design Goals


•Preliminary Bill of Material

•Preliminary Listing of Special Product & Process Characteristic



•New equipment, Tooling and Facilities Requirement

•Special Product and Process Characterictics

•Gages/Testing Equipment Requirements

•Team Feasibility Commitment and Management Support

PHASE 2

PHASE 3

PHASE 4

PHASE 1

PHASE 5

APQP

PHASE 3Process Design & Development


Concept ProgramInitiation/Approval Approval Prototype Pilot Launch

Planning


Planning

Production







APQP Phase 3: Process Design & Validation

PHASE 3 |PROCESS DESIGN & DEVELOPMENT

•Packaging Standards & Specs.

•Prod/Proc. Quality System Review

•Process Flow Chart

•Floor Plan Layout

•Characteristics Matrix

•PFMEA

•Pre-launch CP

•Process Instructions

•MSA Plan

•Preliminary Process Capability Study Plan

•Management Support (including operator staffing & training plan)

Phase 3 Outputs

Phase 2 Design Outputs

Phase 2 APQP Outputs


Phase 3 Inputs

PHASE 2

PHASE 3

PHASE 4

PHASE 1

PHASE 5

APQP

PHASE 4



APQP Phase 4: Product & Process ValidationConcept ProgramInitiation/Approval Approval Prototype Pilot Launch

Planning


Planning

Production







PHASE 4 |Product & Process Validation


Product and Process

Validation

•Significant production Run

•Measurement Systems Evaluations

•Preliminary Process Capability Study

•PPAP

•Production Validation

•Testing

•Packaging Evaluation

•Production CP

•Quality Planning Sign off and management Support

•Packaging Standards & Specs.

•Prod/Proc. Quality System Review

•Process Flow Chart

•Floor Plan Layout

•Characterictics Matrix

•PFMeA

•Pre –Launch CP

•Process Instructions

•MSA Plan

•Preliminary process Capability Study Plan

•Management support (including operator staffing & training plan)

s

PHASE 2

PHASE 3

PHASE 4

PHASE 1

PHASE 5

APQP

PHASE 5



Feedback Assessment & Corrective ActionConcept ProgramInitiation/Approval Approval Prototype Pilot Launch

Planning


Planning

Production








Feedback Assessment & Corrective

Action

•Reduced Variation

•Improved Customer Satisfication

•Improved Delivery and Service

•Effective Use of Lessons Learned/Best Practices

•Significant Production Run

•Measurement Systems Evaluation

•Preliminary Process Capability Study

•PPAP

•Production Validation Testing

•Packaging Evaluation

•Production CP

•Quality Planning Sign-off and ManagementnSuport

PHASE 5|Feedback Assessment & Corrective Action

QUALITY MANAGEMENT SYSTEM

Continual improvement of the quality management system

Continual improvement of the quality management system

Requirements

Satisfaction

Customers

Resourcemanagement

Resourcemanagement

Measurement,analysis andimprovement

Measurement,analysis andimprovement

ProductRealisation

ProductRealisation

ManagementResponsibility

ManagementResponsibility

Input OutputProductProduct

Customers

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Documents

A DVANCE P RODUCT Q UALITY P LANNING by : Wahyu Epifanto