ADVANCE PRODUCT QUALITY PLANNING by Wahyu Epifanto APQP

ADVANCE PRODUCT QUALITY PLANNING 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

APQP| WHAT IS IT? 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 Timing Chart Program Approval Concept Initiation/Approval Prototype Pilot Launch Planning Product Design & Dev. Process Design & Development Product & Process Validation Production Feedback Assessment and Corrective Action Plan & Define Program Product Design & Development Verification Process Design & Development Verification Product & Process Validation Feedback Assessment & Corrective action

HASIL SURVEY : 1. Harga tidak mahal 2. Rasa Gurih 3. Lembut / Tidak Alot 4. Minyak tidak banyak 5. Ukuran besar (Diameter + 5 cm) 6. Warna, tidak gosong 7. Bentuknya rapih TIDAK LENGKAP BAKWAN TIDAK AKAN LAKU, BAKWAN AKAN LAKU, KARENA TIDAK SESUAI DENGAN KEBUTUHAN KONSUMEN KARENA SESUAI DENGAN KEBUTUHAN KONSUMEN

Cara Membuatnya : Bahan – bahan : Dipotong : 1. Tepung Alat : 1. Kol 2. Air 1. Pisau 2. Wortel 3. Kol 2. Talenan 3. Toge 4. Wortel 3. Mangkok/Baskom 4. Daun Bawang 5. Toge 6. Daun Bawang Buat Adonan : 7. Garam Alat : 1. Tepung 8. Minyak 1. Mangkok /Baskom 2. Air 9. Cabe 2. 3. Garam Sendok Alat-Alat : Digoreng : Talenan Alat : 1. Pisau Minyak 1. Sendok 2. Wajan Kompor Mangkok/Baskom 3. Gas Wajan 4. Wajan Kompor Sajikan Gas Alat: 1. Piring 1. Cabe Piring

BOD PURCHASING WAREHOUSE PRODUKSI 1. MEMBELI BAHAN YG FRESH QUALITY CONTROL MAINTENANCE 1. MEMASTIKAN BAKWAN BERKUALITAS 2. MURAH 2. MENYIMPAN BAHAN DELIVERY - CARI CUSTOMER - PROMOSI 2. BERSIHKAN 3. MEMBUAT ADONAN - TDK ENCER - TAKARAN 4. MENGORENG BAKWAN - SUHU - MINYAK 5. KEMASAN - TDK PENYOK - KUAT - TIDAK RUSAK HRD MEMBAYAR GAJI KARYAWAN 1. MERAWAT ALAT-ALAT 1. MEMOTONG BAHAN - 1 CM KEUANGAN MENGONTROL PEMAKAIAN DAN PENGELUARAN 1. MEMASARKAN BAKWAN - WARNA - RASA - UKURAN - BENTUK 1. MENSORTIR BAHAN PEMASARAN MENCARI ORANG 1. MENGANTAR KAN BAKWAN - TEPAT WAKTU MENGONTROL ABSENSI MENGEMBANG KAN ORANG

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

PHASE 1 |PLANNING Phase 1 Inputs Phase 1 Outputs • Voice of the costumer • Market Research • Design Goals • Historical Warranty and Quality Information • Reliability & Quality Goals • Team Experience • Business Plan/MKT Strategy • Product/process Assumptions • Product Reliability Studies • Cuctomer Inputs • Preliminary Process Flow Chart PLANNING • Preliminary Listing of special Product & Process Characteristics • Product Assurance Plan • Management Support

APQP PHASE 1 PHASE 2 PHASE 3 APQP Phase 2: Product Design & Dev. Concept Initiation/Approval Program Approval Prototype Pilot Launch Planning Product Design & Dev. Process Design & Development Product & Process Validation Production PHASE 4 Feedback Assessment and Corrective Action Plan & Define Program PHASE 5 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 • Design Goals • Design FMEA • Reliability & Quality Goals • Design for Manufactturability and assembly • Preliminary Bill of Material • Preliminary Listing of Special Product & Process Characteristic • Product Assurance Plan • Management Support • Design Verification PRODUCT & DESIGN DEVELOPMENT • Design Reviews • Prototype CP • Engineering Drawings • Engineering Spesifications • Material Spesifications • Drawing & Spec. Changes

PHASE 2 |PROCESS DESIGN & DEVELOPMENT Phase 2 Inputs Phase 2 Outputs • Design Goals • Reliability & Quality Goals • New equipment, Tooling and Facilities Requirement • Preliminary Bill of Material • Preliminary Listing of Special Product & Process Characteristic • Product Assurance Plan • Management Support PROCESS DESIGN & DEVELOPMENT • Special Product and Process Characterictics • Gages/Testing Equipment Requirements • Team Feasibility Commitment and Management Support

APQP Phase 3: Process Design & Validation PHASE 1 Concept Initiation/Approval Program Approval Prototype Pilot Planning PHASE 2 Launch Product Design & Dev. Process Design & Development PHASE 33 PHASE Product & Process Validation Production PHASE 4 PHASE 5 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 3 |PROCESS DESIGN & DEVELOPMENT Phase 3 Inputs Phase 3 Outputs • Packaging Standards & Specs. Phase 2 Design Outputs • Prod/Proc. Quality System Review • Process Flow Chart • Floor Plan Layout Process Design & Development • Characteristics Matrix • PFMEA • Pre-launch CP • Process Instructions • MSA Plan Phase 2 APQP Outputs • Preliminary Process Capability Study Plan • Management Support (including operator staffing & training plan)

APQP Phase 4: Product & Process Validation PHASE 1 PHASE 2 Concept Initiation/Approval Program Approval Prototype Pilot Launch Planning Product Design & Dev. PHASE 3 Process Design & Development Product & Process Validation PHASE 44 PHASE 5 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 • Packaging Standards & Specs. • Prod/Proc. Quality System Review • Significant production Run • Measurement Systems Evaluations • Process Flow Chart • Floor Plan Layout • Characterictics Matrix • PFMe. A • Pre –Launch CP Product and Process Validation • Preliminary Process Capability Study • PPAP • Production Validation • Process Instructions • Testing • MSA Plan • Packaging Evaluation • Preliminary process Capability Study Plan • Production CP • Management support (including operator staffing & training plan) • Quality Planning Sign off and management Support

APQP PHASE 1 Feedback Assessment & Corrective Action Concept Initiation/Approval PHASE 2 Program Approval Prototype Pilot Launch Planning Product Design & Dev. PHASE 3 Process Design & Development s Product & Process Validation PHASE 4 PHASE 55 PHASE 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 5|Feedback Assessment & Corrective Action Phase 5 Inputs Phase 5 Outputs • Significant Production Run • Measurement Systems Evaluation • Preliminary Process Capability Study • PPAP • Production Validation Testing • Packaging Evaluation • Production CP • Quality Planning Sign-off and Managementn. Suport • Reduced Variation Feedback Assessment & Corrective Action • Improved Customer Satisfication • Improved Delivery and Service • Effective Use of Lessons Learned/Best Practices

QUALITY MANAGEMENT SYSTEM Continual improvement of the quality management system 5 Management Responsibility Customers 8 6 Measurement, analysis and improvement Resource management Requirements Input 7 Product Realisation Product Satisfaction Output