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Quality Management in Product Development Process |
The ISO / TS 16949:2002, QS 9000 and VDA 6.1 demanded APQP (Advanced Product Quality Planning) is a structured process for product quality forecasting. When APQP is applied in the beginning stages of production, necessary changes should be detected early and finally excessive effort and time loss can be corrected. The standard book called APQP was created by the Chrysler, Ford, General Motors Supplier Quality Requirements Task Force. It provides a guide for the early planning phase and development phase to process analysis. Thus it constitutes a directive for the preparation of plans and checklists to help ensure that the product quality of advance planning is being carried out by the supplier.
In advanced product quality planning there is a structured method with standardized tools (FMEA, QFD, Quality Management Plan, etc.) which ensures that all the required flow steps are completed. As a result of that process the product fits to the customer requirements and so the customer is satisfied. The tools which are used during QM process such as chronology, the application of tools and the execution of individual steps may vary. The result of product quality advance planning is the creation of QM plans.
In order to set up APQP manual certain interdisciplinary program teams (engineering, purchasing, production, logistics, quality assurance, supplier, marketing) should be established. After that the clarification and verification of tasks, the described procedures and techniques in reference manual APQP should be done, with the particularly focus on:
- development and establishment of key features (Key-Characteristics). For these features separate process control measures need to be initiated.
- feasibility study: Above all, together with the supplier, the manufacturability of parts must be verified and documented (Designs, Materials, Processes, Feasibility studies etc.)
- Process-FMEA: Taking into account the specific characteristics need for an early error prevention process FMEAs must be implemented.
- QM-Plan (control plan): QM plans must be created at the level of assemblies, sub-components and parts for prototype phase, pre-series phase and series phase and must be released by the client to be released if this is not waived. It includes a description of the dimensional and material test procedures before and after the various phases, which must be carried out.
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