APQP Jan ("Yon") Roovers President JAN ROOVERS ASSOCIATES, INC. An introduction to Advanced Product Quality Planning and Control Plans Presented by: Jan ("Yon") Roovers President JAN ROOVERS ASSOCIATES, INC. Charlotte, North Carolina • USA 1

Getting Ready for APQP • Organize the Team • Define the Scope • Establish Lines of Communication • Conduct Training • Involve Customers and Suppliers • Utilize Simultaneous Engineering • Use Formal Problem Solving Methods • Develop a Timing Plan • Focus on Defect Prevention 24

Getting Ready for APQP Organize the Team • Engineering • Manufacturing • Material Control • Purchasing • Quality • Sales • Field Service • Suppliers • Customers 25

Getting Ready for APQP Define the Scope • Select a Team Leader • Define Roles and Responsibilities • Identify Internal and External Customers • Define Customer Requirements • Identify Resources • Understand Customer Expectations • Assess Feasibility of Proposed Design • Identify Costs, Timing, and Constraints • Determine Customer Assistance Required • Identify Documentation Process 26

Getting Ready for APQP Establish Lines of Communication • Customer Teams • Internal Teams • Supplier Teams Team-to-Team contact depends on the number of issues requiring resolution. 27

Getting Ready for APQP Conduct Training • Interpersonal Skills • Effective Communication • Handling Conflict • Analytical Techniques (See Appendix B, Pages 81-85) • Guidelines of APQP and CSRs • Requirements of ISO/TS 16949:2002 • Failure Mode Effects Analysis • Statistical Techniques Tools and techniques selected depend on the type of product and complexity of the project. 28

Getting Ready for APQP Involve Customers and Suppliers • The customer may initiate the APQP with the organization • The organization has the obligation to establish the APQP Team and manage the process • The organization must expect the same performance from its suppliers 29

Getting Ready for APQP Utilize Simultaneous Engineering • Cross functional teams strive for a common goal • Replaces the traditional sequential series of project steps • Expedites the introduction of quality products sooner • APQP Team assures that other areas/teams complete activities that support the common goal 30

Getting Ready for APQP Use Formal Problem Solving Methods • Document design and/or processing concerns on a matrix with assigned responsibilities and timing • Utilize disciplined problem-solving methods (ISO/TS 16949:2002, Clause 8.5.2.1) • Use analytical techniques described in Appendix B (Pages 81-85) 31

Getting Ready for APQP Develop a Timing Plan • Consider: type of product, complexity, and customer expectations • Plan and chart timing elements • Agree with each event, action, and timing • List tasks, assignments, and events • Utilize a consistent planning format • Establish Start and Completion dates 32