1. APQP Quality Planning in ISO 9000/ QS-9000 or ISO/ TS 16949 or .....
Heribert Nuhn, QMS
APQP Quality Planning in ISO 9000/ QS-9000 or ISO/ TS or .....
Q_Planning_QS-9000_E

2. QM System Documentation
Heribert Nuhn, QMS
QM System Documentation
Level 1:
Approach & Responsibility
Quality Manual
Level 2:
Who, What, When
Procedures
Level 3:
How
Job Instructions
Level 4:
Quality Record/ Evidence
Other Documentation
Q_Planning_QS-9000_E

3. APQP - Elemente Definition and Fundamentals
Heribert Nuhn, QMS
APQP - Elemente
Definition and Fundamentals
APQP is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer.
The goal is to facilitate communication with everyone involved to assure that all required steps are completed on time.
Q_Planning_QS-9000_E

4. APQP - Elemente Definition and Fundamentals
Heribert Nuhn, QMS
APQP - Elemente
Definition and Fundamentals
direct resources to the new project
promote early identification of required changes
avoid late changes
provide
quality product
on time
lowest cost
Q_Planning_QS-9000_E

5. APQP Fundamentals of APQP organize the team define the scope
Heribert Nuhn, QMS
APQP
Fundamentals of APQP
organize the team
define the scope
establish team-to-team communication
provide training
define customer and supplier involvement
simultaneous engineering
Control Plans (all phases)
concern resolution
product quality timing plan
Product Quality Planning Timing Chart
Q_Planning_QS-9000_E

6. APQP Timing Chart 01.12.2018 Q_Planning_QS-9000_E Concept Initiation/
Heribert Nuhn, QMS
APQP Timing Chart
Concept
Initiation/
Approval
Program
Approval
Prototype
Pilot
Launch
Planning
Planning
Product Design & Development
Process Design & Development
Product & Process Validation
Production
Feedback Assessment and Corrective Action
Q_Planning_QS-9000_E

7. APQP - Elements Planning: Input voice of the customer business plan
Heribert Nuhn, QMS
APQP - Elements
Planning: Input
voice of the customer
business plan
product/ process benchmark data
craftmanship (Ford)
product/ process assumptions
product reliability studies
customer input: QS-9000 Section II & Appendix
Q_Planning_QS-9000_E

8. APQP - Elements Planning: Output Product Design & Development: Input
Heribert Nuhn, QMS
APQP - Elements
Planning: Output
Product Design & Development: Input
design goals
reliability and quality goals
preliminary bill of material
preliminary process flow chart
Q_Planning_QS-9000_E

9. APQP - Elements Planning: Output Product Design & Development: Input
Heribert Nuhn, QMS
APQP - Elements
Planning: Output
Product Design & Development: Input
preliminary listing of special product and process characterisics
product assurance plan
management (sign-off and) support
sourcing decision (Ford)
customer input requirements (Ford)
Q_Planning_QS-9000_E

10. APQP - Elements Product Design & Development: Output
Heribert Nuhn, QMS
APQP - Elements
Product Design & Development: Output
Process Design & Development: Input
Design Failure Mode & Effects Analysis (D-FMEA)
Design for manufacturing and assembly
Design Verification (Plan and Sign-Off Report) DVP&SOR
Design Reviews
Q_Planning_QS-9000_E

11. APQP - Elements Product Design & Development: Output
Heribert Nuhn, QMS
APQP - Elements
Product Design & Development: Output
Process Design & Development: Input
Prototyp Build Control Plan
engineering drawings (including math. data)
engineering specifications
material specifications
drawing and specification changes
Q_Planning_QS-9000_E

12. APQP - Elements Product Design & Development: Output
Heribert Nuhn, QMS
APQP - Elements
Product Design & Development: Output
Process Design & Development: Input
new: equipment, tooling and facilities requirements
logistics (Ford)
special product and process characteristics
gages/ testing equipment requirements
supplier APQP: requirements & involvement (Ford)
Team Feasibility Commitment & Mgmt. Support
Q_Planning_QS-9000_E

13. APQP - Elements Process Design & Development: Output
Heribert Nuhn, QMS
APQP - Elements
Process Design & Development: Output
Product & Process Validation: Input
packaging standards
product/ process Quality System Review
Process Flow Chart
Floor Plan Layout
(special) characteristics matrix
Process Failure Mode and Effects Analysis (P-FMEA)
Q_Planning_QS-9000_E

14. APQP - Elements Process Design & Development: Output
Heribert Nuhn, QMS
APQP - Elements
Process Design & Development: Output
Product & Process Validation: Input
Pre-Launch Control Plan
process instuctions
measurements system analysis plan
preliminary process capability study plan
packaging specifications
management support
Q_Planning_QS-9000_E

15. APQP - Elements Product & Process Validation: Output
Heribert Nuhn, QMS
APQP - Elements
Product & Process Validation: Output
Feedback, Assessment & Corr. Action: Input
production trial run
measurement systems evaluation
preliminary process capability study
production part approval (process (=> PPAP/ PSW))
production validation testing
Q_Planning_QS-9000_E

16. APQP - Elements Product & Process Validation: Output
Heribert Nuhn, QMS
APQP - Elements
Product & Process Validation: Output
Feedback, Assessment & Corr. Action: Input
packaging evaluation
Production Control Plan
quality planning sign-off
management support
PSW Part Delivery at IPD/ MRD (Ford)
Q_Planning_QS-9000_E

17. APQP - Elements Feedback, Assessment & Corrective Action: Output
Heribert Nuhn, QMS
APQP - Elements
Feedback, Assessment & Corrective Action: Output
Input and Benefit for: Production
reduced variation
customer satisfaction
delivery and
service
Q_Planning_QS-9000_E

18. PPAP Definition and Fundamentals
Heribert Nuhn, QMS
PPAP
Definition and Fundamentals
PPAP defines generic requirements for production part approval, including production and bulk materials. The purpose of PPAP is to determine if all customer engineering design record and specific requirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.
Q_Planning_QS-9000_E

19. PPAP: Section I I. 1 General I. 2 PPAP Process Requirements
Heribert Nuhn, QMS
PPAP: Section I
I. 1 General
I. 2 PPAP Process Requirements
I. 3 Customer Notification and Submission Requirements
I. 4 Submission To Customer - Levels Of Evidence
I. 5 Part Submission Status
I. 6 Record Retention
Q_Planning_QS-9000_E

20. Heribert Nuhn, QMS
PPAP: Section II
II. 1 DaimlerChrysler Corporation-Specific Instructions
II. 2 Ford-Specific Instructions
II. 3 General-Motors-Specific Instructions
II. 4 Truck OEM-Specific Instructions
Appendices A-E: Forms
Appendix F: Bulk Material - Specific Requirements
Appendix D: Tire Industry - Specific Requirements
Glossary
Q_Planning_QS-9000_E

21. Applicability internal and external suppliers
Heribert Nuhn, QMS
Applicability
internal and external suppliers
bulk material (like gas, liquid, chemicals if requested)
production material (customer production part number)
production and service parts
standard catalogue production and service parts
customer can waive PPAP requirements
Q_Planning_QS-9000_E

22. Heribert Nuhn, QMS
I. 1 General
obtain full approval from the customer product approval activity for:
new part or product
correction of a discrepancy
modified product by an engineering change to:
design records, specifications, materials
any situations required by Section I. 3
Q_Planning_QS-9000_E

23. I. 4 Levels of Evidence Submission To Customer Level 1: PSW (and AAR)
Heribert Nuhn, QMS
I. 4 Levels of Evidence
Submission To Customer
Level 1: PSW (and AAR)
Level 2: PSW, product samples, limited supporting data
Level 3: PSW, product samples, complete supporting data
Level 4: PSW, requirements as defined by customer
Level 5: PSW, product samples, complete supporting data for review at suppliers manufacturing location
Q_Planning_QS-9000_E

24. I. 4 Levels of Evidence Submission To Customer
Heribert Nuhn, QMS
I. 4 Levels of Evidence
Submission To Customer
Level 3 is default for all submissions
Level 1 is default for bulk material
customer product approval activity will identify submission level for each
part or product number and
manufacturing location
Q_Planning_QS-9000_E

25. I. 4.1 Retention Table Submission Level
Heribert Nuhn, QMS
I. 4.1 Retention Table
Submission Level
Requirement Level 1 Level 2 Level 3 Level 4 Level 5
1. Design Records of Saleable Product R S S * R
4. Design FMEA R R S * R
6. Process FMEA R R S * R
13. Part Submission Warrant (PSW) S S S S R
16. Sample Product R S S * R
17. Master Sample R R R * R
19. Records of Compliance R R S * R
With Customer-Specific Req.
( see complete listing in Appendix: Retention/ Submission Requirements Table )
S: submit documents to customer and retain a copy
R: retain documents and make readily available upon request
* : retain documents and submit to customer upon request
Q_Planning_QS-9000_E