A DVANCE P RODUCT Q UALITY P LANNING 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 Chart Concept Program Initiation/Approval ApprovalPrototypePilot Launch Planning Product & Process Validation Planning Production Feedback Assessment and Corrective Action Plan & Define Program Product Design & Development Verification Process Design & Development Verification Product & Process Validation 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 : 1.Tepung 2.Air 3.Garam Digoreng : 1.Minyak Sajikan 1.Cabe Alat : 1.Pisau 2.Talenan 3.Mangkok/Baskom Alat : 1.Mangkok /Baskom 2.Sendok Alat : 1.Wajan 2.Kompor 3.Gas 4.Wajan Alat: 1.Piring

1.MEMBELI BAHAN YG FRESH 2. MURAH 1.MERAWAT ALAT-ALAT - TIDAK RUSAK MENGONTROL PEMAKAIAN DAN PENGELUARAN MEMBAYAR GAJI KARYAWAN MENCARI ORANG MENGONTROL ABSENSI MENGEMBANG KAN 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 PLANNING PHASE 1 Process Design & Development Product Design & Dev. Concept Program Initiation/Approval ApprovalPrototypePilot Launch Planning Product & Process Validation Planning Production Feedback Assessment and Corrective Action Plan & Define Program Product Design & Development Verification Process Design & Developmen t Verification Product & Process Validation Feedback Assessment & Corrective action

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 Process Design & Development Product Design & Dev. APQP Phase 2: Product Design & Dev. Concept Program Initiation/Approval ApprovalPrototypePilot Launch Planning Product & Process Validation Planning Production Feedback Assessment and Corrective Action Plan & Define Program Product Design & Development Verification Process Design & Developmen t Verification Product & Process Validation Feedback Assessment & Corrective action

PHASE 2 | PRODUCT DESIGN & DEVELOPMENT Phase 2 Inputs Phase 2 Outputs PRODUCT & DESIGN DEVELOPMENT Design Goals Reliability & Quality Goals Preliminary Bill of Material Preliminary Listing of Special Product & Process Characteristic Product Assurance Plan Management Support 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 Phase 2 Inputs Phase 2 Outputs PROCESS DESIGN & DEVELOPMENT Design Goals Reliability & Quality Goals Preliminary Bill of Material Preliminary Listing of Special Product & Process Characteristic Product Assurance Plan Management Support 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 3 Process Design & Development Product Design & Dev. Concept Program Initiation/Approval ApprovalPrototypePilot Launch Planning Product & Process Validation Planning Production Feedback Assessment and Corrective Action Plan & Define Program Product Design & Development Verification Process Design & Developmen t Verification Product & Process Validation Feedback Assessment & Corrective action 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 Process Design & Development Phase 3 Inputs

PHASE 2 PHASE 3 PHASE 4 PHASE 1 PHASE 5 APQP PHASE 4 Process Design & Development Product Design & Dev. APQP Phase 4: Product & Process Validation Concept Program Initiation/Approval ApprovalPrototypePilot Launch Planning Product & Process Validation Planning Production Feedback Assessment and Corrective Action Plan & Define Program Product Design & Development Verification Process Design & Developmen t Verification Product & Process Validation Feedback Assessment & Corrective action

PHASE 4 | Product & Process Validation Phase 4 Inputs Phase 4 Outputs 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 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 Process Design & Development Product Design & Dev. Feedback Assessment & Corrective Action Concept Program Initiation/Approval ApprovalPrototypePilot Launch Planning Product & Process Validation Planning Production Feedback Assessment and Corrective Action Plan & Define Program Product Design & Development Verification Process Design & Developme nt Verification Product & Process Validation Feedback Assessmen t & Corrective action

Phase 5 Inputs Phase 5 Outputs Feedback Assessment & Corrective Action Reduced Variation Improved Customer Satisfication Improved Delivery and Service Effective Use of Lessons Learned/Best Practices 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 Resource management Resource management Measurement, analysis and improvement Measurement, analysis and improvement Product Realisation Product Realisation Management Responsibility Management Responsibility InputOutput Product Customers