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1. What do we consider to be a critical AQP Task? 2. Identify the critical AQP tasks associated with four primary AQP activities 3. Review each critical AQP task and what is expected when managing them 4. Review case studies / real world examples
What happened? How was it managed? What could have prevented it?
4 10
9 2
Step 3 Step 5
Job 1 Offline
Commercial Launch
Tooling
LATE DESIGN RELEASE
PSO/PDR
PPAP
Tooling
LATE DESIGN CHANGE
PSO/PDR
PPAP
Tooling
PSO/PDR
SUPPLIER PROGRAM MANAGEMENT
PPAP
MANUFACTURING FEASIBILITY
Tooling
PSO/PDR
PPAP
4
Manufacturing Feasibility
Supplier unable to meet requirements
For SQ purposes, we would consider any AQP Task as critical if it: 1. Has a major impact on downstream deliverables and other tasks 2. Ensures the part, as designed, meets requirements 3. Ensures the part, as manufactured, meets requirements 4. Ensures the process can meet our production needs 5. What else?
MY/VEHICLE FAMILY:
#NUM!
YEAR Month-Date Step 2 Style Freeze
#NUM!
YEAR Month-Date Month-Date
CUSTOMER LEAD
Build Date
MRD
# of Veh
# of Days
Month-Date
Month-Date
Month-Date
Month-Date
Month-Date
Month-Date
Month-Date
Month-Date
STATUS
Verification of Process
Job 1 Offline
Commercial Launch
AQP ACTIVITIES
SUPPLIER RESPONSIBLE
BEGIN
P LA N ACT P LA N
END
ACT
EF
EF
EF
EF
EF VP
EF PVP
EF
EF
Enter 1-5
1 -
Manufacturing Feasibility Assessment (MFA) Initial Risk Evaluation (IRE) Advance Quality Planning Confirm composition and commitment of Core AQP Team Members Source Package Review Volume, ramp-up curve, and product mix verified and capable - CPV, P.O, SP Verify Tooling Capacity and Required Station Cycle Time / Line Speed Plan eCIMS / Lessons Learned Master PFMEA Reviewed Prior PSO Review (similar products) Verify deliverables timing to CPCP timing Status of Open Issues from Technical Review Risk Assessment (FIAT parts only) Supplier Quality Risk Assessment (SQRA) Part Number, Description, and Change Level Design Model Status Review Part Development Plan Complete Design Review - Customer Perception targets Supplier Tooling Kick-Off (TKO) Production Tooling Complete (PTC) TAG Review (Chrysler-purchased tooling only) Review CNs and IAAs (including associated Risk) Design FMEA Test Sample Sizes and Frequencies Confirm Supplier PPAP Self-Certification status DV Testing Complete Process FMEA Process Flow Diagram & Mfg. Floor Plan Control Plan and Process Monitoring
Part Inspection Standard
Identify - 22 weeks prior to VP MRD
0 0 0 0 0
SQE SQE SQE SQE SQE SQVL ENG ENG ENG ENG ENG ENG SQE ENG ENG ENG SQE ENG SQE SQE SQE SQE
2 3 4 5 6 7 7.8
Draft
Final
SQE: Supplier Quality Engineer ENG: Release Engineer DO: Design Office
Major milestones
EF
Secondary milestones
EVENT / DELIVERABLE
Key AQP tasks and SQ deliverables (IRE, Production Tools Complete, IMDS, PPAP) All PSO Elements
CUSTOMER LEAD
Build Date
MRD
# of Veh
# of Days
3
BEGIN
P LA N ACT P LA N
AQP ACTIVITIES
SUPPLIER RESPONSIBLE
END
ACT
1 3 4 -
Initial Risk Evaluation (IRE) Advance Quality Planning Confirm composition and commitment of Core AQP Team Members 1 Source Package Review Volume, ramp-up curve, and product mix verified and capable - CPV, P.O, SP eCIMS / Lessons Learned Reviewed Prior PSO Review (similar products) Verify deliverables timing to CPCP timing Status of Open Issues from Technical Review Risk Assessment (FIAT parts only) Supplier Quality Risk Assessment (SQRA) Part Development Plan Complete Design Review - Customer Perception targets Production Tooling Complete (PTC) TAG Review (Chrysler-purchased tooling only) Review CNs and IAAs (including associated Risk) Design FMEA Test Sample Sizes and Frequencies Confirm Supplier PPAP Self-Certification status
2. Tracks Supplier responsibility for each item, with begin/end dates 3. Key build/MRD dates
STATUS
Enter 1-5
3 4 5
Incomplete and: Late to required milestone and may cause other deliverables to be late to their required milestone/vehicle launch Risk Mitigation Plan exists but is not acceptable or requires unrealistic timing to meet milestone High Risk to milestone/vehicle launch (may cause delay in milestone/vehicle launch) Incomplete and: Late to required milestone Risk Mitigation Plan exists and is acceptable Low Risk to milestone/vehicle launch Incomplete and: Progressing according to required milestone timing No Risk to milestone/vehicle launch
6. Brief description of the risk mitigation plan (or reference to a more detailed action plan)
9
Month-Date
Month-Date
Month-Date
Month-Date
Month-Date
Month-Date
Month-Date
Month-Date
Verification of Process
Job 1 Offline
Commercial Launch
EF
EF
EF
EF
EF VP
EF PVP
EF
EF
7
High risk; PO + 8 wks All Other
10
Tooling Design & Development Tasks involved with managing the proper design and on-time kickoff and construction of production tooling
Capacity Verification Tasks involved with ensuring the process will meet (or exceed) Chryslers volume requirements
Testing Tasks involved with ensuring the part, as designed and manufactured, functions as intended and meets requirements
11
PV Testing PSO On-Site Visit Production Demonstration Run Initial Process Study / Capability Appearance Approval Color Harmony / Match PPAP What Else?
Red = Key Performance Indicators
12
13
Design FMEA
Expectations:
Supplier-designed parts require a DFMEA developed by the Supplier with Chrysler Engineering input & approval Should include evidence that Lessons Learned from previous / similar designs have been considered Highest risk items should have action plans Items with Severity of 8 or higher should have Error /Mistake Proofing planned for the tooling and assembly equipment DFMEA should be complete early enough to allow for tooling design If no DFMEA exists for a Chrysler-designed part, we need to ask the question Why?
14
Managing the DFMEA task DFMEA does not exist (Supplier-design) 1 DFMEA incomplete prior to TKO 2 No input from the Chrysler Engineer 2 or No evidence of Lessons Learned 2 No Error/Mistake Proofing for Severity 8+ Risk Mitigation
or
Focus should be on completing the DFMEA before TKO. High risk or high severity items should have actions plan with a focus on total prevention of errors. Chrysler Engineer should review and approve.
15
Risk Mitigation
Focus should be on completion of Design Model before TKO
16
Risk Mitigation
Focus should be on completion of all deliverables before TKO Target should be Production Tools Complete by VP TKO should not be signed until tooling is ready to start construction
18
19
Risk Mitigation
Focus should be on completion of tooling by VP Plans will often rely on using prototype tooling longer than intended ensure process controls equal or exceed intended production levels! Ensure backup tools are capable of producing the quantity of parts required, both daily and in total
21
TAG Review
Expectations:
TAG follows some tooling (Chrysler-built) Hold regular reviews with the TAG SQE to follow status of tooling
Risk Mitigation
Same as for Production Tooling Complete
22
23
24
Volume, ramp-up curve, and product mix verified and capable - CPV, P.O., SP
Expectations:
Review program volume requirements, planned product mix, and planned launch ramp-up curve. Ensure the Source Package details the required information and that the Supplier understands the requirements. Ensure the Purchase Order is complete by the required timing and that it correctly lists Daily Tooling Capacity, Capacity Planning Volume, and Shift Pattern Buyer and Supply/Logistics should be at the meetings to discuss
25
or
Risk Mitigation
Focus should be on ensuring volumes are correct and the Supplier understands what they are. Additional focus on understanding volumes prior to TKO
26
Verify Tooling Capacity and Required Station Cycle Time / Line Speed
Expectations:
Ensure the Daily Tooling Capacity is sufficient to meet Chrysler's needs and meets or exceeds the Capacity Planning Volume. Review the shift pattern (shifts/hours/days) to ensure that it supports production and allows enough time for PM activities.
2/8/5 is the standard; if it exceeds this, why? Verify shift pattern on a regular basis; if it changes, why? Is there still enough time for maintenance and similar activities?
Verify whether or not the part(s) are included in a Common Process Group (CPG) Calculate the line speed required for the PDR and extrapolate required Station Cycle times for the SRE.
27
Risk Mitigation
Plan should be to meet volume requirements without sacrificing quality activities Identify situations when additional tooling is necessary Purchasing and Supply/Logistics included on actions
28
Determine if an Extended Run PSO will be done (Appendix D of the AQP/PSO Manual 7th Edition) Identify separate PDR dates for Stepped Tooling Plans SRE should be before VP, PDR prior to PVP
29
or less
Risk Mitigation
Plan should be to schedule SRE and PDR as close to the required timing as possible Parts for pilot builds should have additional controls if not using an approved process
30
Part Delivery Plan Review (for VP, Pre Series, V1, etc.)
Expectations:
Review the Supplier's plan for part delivery for all pilot builds and launch Verify the plan has the latest quantities and timing/MRDs for each applicable build and build phase Ensure Tool completion date is sufficient to meet MRDs
31
Risk Mitigation
Plan should be made to provide correct build quantities to Supplier Plan should also minimize any material built off of prototype tooling (i.e., staggered shipments are preferable to swapping material out of the plant) Ensure prototype parts, if used are properly marked and identified
32
What can happen when we dont fully test the product design or function?
Plant pilot build issues Late design changes / CNs Failure to meet regulatory or governmental regulations PRIs / Yardholds High Warranty / Safety Office campaigns What else?
33
Late CN
High Warranty
Quality Spill
Abbreviated Testing
34
35
Risk Mitigation
Recovery plan should ensure all testing is performed (e.g., larger sample sizes, additional test equipment, etc.), not skipping tests. Failed parts require corrective action and repeating the full test, not just replacing the failed part.
37
DV Testing Complete
Expectations:
Review DV Testing results with the Supplier and Engineer (Engineering sign-off required) Review all test failures and verify corrective actions have been implemented and successfully retested Successful DV Testing is required before PV Testing can begin, unless waived in writing by the engineer If PV Testing will begin before a DV Test failure is retested (requires Engineering waiver), discuss the reason; is this the correct decision?
38
or less
Risk Mitigation
Plan should require corrective actions for DV Test failures. If PV will be used to validate corrective actions for DV Test failures, ensure enough time exists (and backup plan is in place) to retest in the event of another failure
39
PV Testing Complete
Expectations:
PV Testing timing should identify PV Tests required by VP PV Testing timing should allow for PPAP by PVP BSR/NVH should be accounted for in the PV Test plan (as applicable) Review the status of the PV Testing start date (still on-track, slipping, etc.) Review plan and status of Chrysler-responsible testing
40
Risk Mitigation
Corrective actions for testing failures implemented and re-tested Actions should not reduce or skip tests; to compress timing, focus should be on testing larger sample sizes
41
Case Study #1 Component: Roof Racks Issue: Part does not fit to sheet metal; the sheet metal was not to print (supplied from an internal stamping plant). Late tooling changes were required which pushed tooling completion, and therefore PDR & PPAP, late.
What risk mitigation activities should be taken? What could have been done to catch this earlier?
42
Case Study #2 Component: Spoilers Issue: Deficiencies in the tool design and ergonomic issues at the Chrysler Assembly Plant required a late design change. What risk mitigation activities should be taken? What could have been done to catch this earlier?
43
Case Study #3 Component: HVAC Control Head Issue: Part could not meet the Daily Tooling Capacity requirements (most recent PDR was short by 5 pieces per hour). Primary issue was excessive machine downtime. What risk mitigation activities should be taken? What could have been done to catch this earlier?
44
All AQP Tasks are important; some require special attention Tasks that directly impact deliverables / timing Tasks that directly affect part ability to function and meet requirements Tasks that impact the Supplier meeting production capacity needs Use the AQP/PSO Scoring system to raise the red flag (or the yellow one) Risk mitigation plans when a deliverable is late / at risk (yellow and red)
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