Apqp automotive phase 3

Process Design and Development


The purpose of a manufacturing system is to assure customers that their demands and expectations are met. 

The accomplishment of the manufacturing system relies on the success of the earlier stages of the product quality planning process. It has the following components.

The inputs of this phase are the outputs of the product design and development stage.

Outputs

  • Packaging Standards

The customer may have packaging standards. These must be incorporated into the final product. 

  • Product/Process Quality System Review

The company must have a Quality Systems Manual that contains controls, procedures, and changes of the manufacturing location. 

This gives the product quality planning team a chance to improve the current quality system.

  • Process Flow Chart

This is a schematic representation of the current process flow. It assists the team to analyze and focus on the overall process when designing the control plan. 

  • Floor Plan Layout

A floor plan layout determines inspection points, control chart position, visual aids, repair stations, and storage areas. 

  • Characteristics Matrix

This is an analytical technique to display the relationship between the process parameters and the manufacturing stations. 

  • Process Failure Mode and Effects Analysis (PFMEA)

This is a disciplined review, and analysis of a process conducted to monitor potential problems. This must be performed during product quality planning and before the beginning of the production. 

  • Pre-launch Control Plan

This is a document containing the dimensions of the products, functional tests, and additional process controls. 

Its purpose is to determine potential problems that may exist. 

  • Process Instructions

Process instructions must be easy to comprehend for all personnel operating the processes to avoid internal errors and problems. 

This must be posted and accessible to all operators and supervisors.

  • Measurements Systems Analysis Plan 

It is important for the team to develop a workable plan to accomplish the required measurements for system analysis. 

  • Preliminary Process Capability  Sudy Plan 

The characteristics derived from the control plan must be the basis for the preliminary process capability study plan.

  • Packaging Specifications

It is appropriate for the company to employ the customer packaging standards and to assure them an unchanged product performance upon delivery.

  • Management Support

The team must schedule a product review to assure management support at the end of this phase.