Advanced Product Quality Planning Research Articles

EFFICIENCY OF THE PRODUCT-DEVELOPMENT PROCESS AS A FACTOR DETERMINING THE EFFECTIVENESS OF IMPLEMENTATION FOR SUBSEQUENT PROJECT PHASES ACC APQP

This study presents a tool integrating PDCA Deming cycle and Design for Six Sigma principles to aid component development (especially dedicated for innovative projects). Designed for universal use across APQP (Advanced Product Quality Planning) phases, the tool guides through five key stages: Identify, Define, Design, Optimize, and Validate. Each stage involves specific actions and approvals, ensuring thorough development and risk assessment. Notably, the tool accommodates changing product requirements and validation challenges, allowing for adjustments without project delays. Its adaptability within the APQP framework is crucial for complex product development. The implementation at Tenneco demonstrates its effectiveness in structuring and overseeing development processes and improving project outcomes. Future analyses will delve into its impact and guide further research.

Design for Additive Manufacturing (DFAM) applied in the manufacture of Master Sample for the automotive industry

In order to supply auto parts to the automotive industry the companies must meet all Advanced Product Quality Planning (APQP) requirements. One of the biggest difficulties in obtaining the approval of the APQP is in the preparation of the “Master Sample,” which will be used for the validation of jigs, production, and dimensional control devices. The procedures for manufacturing Master Samples through conventional manufacturing processes are outdated, slow, and cost-effective, which goes against the concepts of Industry 4.0. Therefore, this work aims to propose a procedure for Design for Additive Manufacturing (DFAM) that analyzes the feasibility and systematizes the manufacture of Master Sample through Additive Manufacturing (AM). Two model parts were submitted to the procedure, manufactured by AM and validated as Master Samples. In this work, a comparative analysis between the parts produced conventionally and those produced by AM showed that the time and costs in order to obtain the Master Samples using the proposed procedure was significantly shorter. The reduction in time to obtain Master Samples speeds up the evaluation and validation of control devices from suppliers, can speed up the acquisition of APQP documentation and reduce the time in the development of the serial parts by manufacturing process. Furthermore, the use of the proposed DFAM procedure is innovative in the context of the automotive industry, as it suggests a change in the production concept and inserts AM as another option in the manufacturing process and not just as a rapid prototyping tool.

IMPLEMENTATION OF THE GP12 QUALITY ASSURANCE SYSTEM: CASE STUDY OF A SUPPLIER OF THERMOPLASTICS IN THE AUTOMOTIVE SEGMENT OF JOINVILLE.

GP-12 (Early Production Containment) is a quality tool used by General Motors to ensure the conformity of its suppliers' products during the new product development process. The objective of the study is to show how the GP12 was implemented in a thermoplastic injection company in Joinville in the recently launched GEM project, verifying if the implementation of the GP12 can guarantee the shipment of components to the assemblers with zero defects, since the guarantee of the quality is a system required by automakers to maintain contracts with their suppliers. If, during the 90-day period, the supplier presents zero defects, then it will be qualified to meet the production requirements as specified in the PPAP (Production Part Approval Process). To support this study, a bibliographic review was carried out on the quality process adopted by General Motors, known as advanced product quality planning ("advanced product quality planning" - APQP). The study was carried out from the determination of the area manager, delimitation of the conogram, definition of the physical arrangement, analysis of the project products, operational training until the arrival of the departure of the GP12 of the items that were submitted by the anticipated containment. This work concluded that the tool was effective, since all the objectives were achieved within the launch period, reaching the level of quality required by the automakers, despite the appearance of some problems detected internally, the implemented action plans were robust, guaranteeing the compliance of the processes at the automaker, thus preventing any non-compliance in the cars during their launch.

Tools of product quality planning in the production part approval process

The article concerns the analysis of the applicable normative requirements in the field of product quality planning in the process of approving parts for production.The analysis, in particular, concerns the correlation of appropriate methods and quality management tools in the quality planning process.Correct use of quality planning tools in product and process development determines the effectiveness of implementing individual phases of APQP (Advanced Product Quality Planning).It is important that the organisation skilfully and consciously uses the quality tools required by APQP; they usually require multiple uses during the project implementation time, which depends on the specificity of a particular project.The study presents how core quality planning tools are related, proving that they cannot be treated as an individual tool, but only their correct use can protect the project/organisation against nonconformities or misunderstandings between the supplier and the customer.The study's originality and novelty show the relations and dependence between APQP phases and core quality tools/evidence developed in the PPAP (Production Part Approval Process), according to PPAP level 3. The article presents a practical approach to the use or multiuse of particular core quality planning tools according to APQP phases.

Product Quality Planning in Laser Metal Processing Based on Open Innovation Using Quality Function Deployment

The results of the development of a modified quality function deployment (QFD) method, obtained for the first time to improve the product quality planning process in the metal cutting of laser technologies confirming the dynamics of open innovation, are presented. When using new marketing technologies, the requirements of consumers are established; a factorial model of customer satisfaction was determined with after an assessment by expert methods, their wishes were transformed into indicators of product quality, and its concept was developed. Product quality is enhanced by optimizing project specifications. The method of functional cost analysis (FCA) was applied for the manufacturing processes, which made it possible to reduce the costs of their implementation. New methods of product quality control were applied. The developed planning process is described by a sequence diagram, an algorithm, and a responsibility matrix. The research used search methods including Internet resources required for open innovation, namely functional modeling methods (IDEF) and the method of advanced product quality planning (APQP). The results of the achieved advantages of open innovation (reduction in research and development costs, implementation of the principles of total quality management (TQM), customer orientation, process approach, improvement) are recommended for further application both at the enterprise and in the metalworking of mechanical engineering. The practical significance of the results of this work is the reduction in internal and external failures by 12%; reduction in time for new product development by 9%; reduction in costs for online resources by 11% and quality control during production by 7%; reduction in labor costs for process management by 25%; and the stability of the process, which improved by 25%.

Supply chain resilience and industry 4.0: a evaluation of the Brazilian northeast automotive OEM scenario post COVID-19

COVID-19 outbreak has heavily impacted the manufacturing industry, including Brazilian Automotive Industry. The effects of COVID-19 created restrictions in several industry processes as supply chain. On the other hand, several industry 4.0 technologies is able to support the industry supply chain activities in the COVID 19 scenarios, as well it may contributed for the automotive industry recovery and it will define the next steps of this industry. A supply chain is a network between a company and its suppliers to produce and distribute a specific product to the final buyer. Industry 4.0 is related to the technology development and the digitalization process that improve significantly productivity. Considering the automotive process, an important reference model is described in Advanced Product Quality Planning and Control Plan, that is a manual that communicate the guidelines of the product quality planning and control plan for internal and external suppliers. In this scenario, this paper evaluated the current situation and the future outlook for the adoption of Industry 4.0 technologies in the automotive OEM post-pandemic scenario on the point of view of automotive specialists. The results of this research provide an overview of the current situation and the future outlook for the usage of Industry 4.0 technologies by the Brazilian Northeast automotive OEM, from the perspective of manufacturing engineering experts on APQP.

Towards a New Knowledge-based Framework for Integrated Quality Control Planning

This paper presents a new knowledge-based framework for integrated quality control planning. The proposed approach is based on the concepts of advanced product quality planning (APQP) and employs t...

Towards a new knowledge-based framework for integrated quality control planning

This paper presents a new knowledge-based framework for integrated quality control planning. The proposed approach is based on the concepts of advanced product quality planning (APQP) and employs the quality function deployment (QFD) for the selection of the features to be controlled. Accordingly, APQP/QFD related issues are addressed, namely the uncertainty in the customer's voice deployment, the complexity of causal interrelationships analysis, and the difficulties of knowledge exploitation. A new QFD model based on fuzzy cognitive map (FCM) and Choquet integral is thus proposed. FCM development allows the capture and modelling of product/process causality. The FCM simulation assesses the impacts of the product, parts, and process characteristics on the customer requirements (CRs). Choquet integral is used for the aggregation of these impacts in order to deal with the interactions between CRs. The effectiveness of this approach is evaluated by the results of an experimental case study. [Received: 26 April 2019; Accepted: 10 September 2020]

Effective application of the APQP quality tool in Pull Back Car toy assembly processes

The current Mexican market for the production and assembly of toys (Pull back car) demands ever higher productivity, quality, cost and delivery rates, complying with defined production requirements, as the market is becoming larger and of course competitive. For their part, companies have the need to continually launch new models to stay competitive. The current procedure is based on project management through a recognized procedure in the sector, such as APQP (Advanced Product Quality Planning), based on the implementation of a series of key management tools for DNP. The research carried out characterized the current context of toys for the development of new parts in the local toy sector of the Meccano company, in the Huauchinango Puebla region. An operational model proposal is made for the Pull back car toy assemblers, in order to improve performance in the activities of the Meccano company.

Improving the Effectiveness in Research and Developments Department from Automotive Industry

Abstract The scope of this paper is to propose a solution for decreasing the rework that has to be made inside a team, in a new offshore Research and Development department, mainly because of assumptions and lack of experience. This is based on learning and applying the lessons learned. First, it will be presented an order assignment in an offshore branch in the field of automotive software companies. From the concept, further on, the usual process that takes place is presented and the potential flaws are analyzed. The major problems identified are random allocation of the orders and assumptions that are made in the branch offices. After inspecting the steps of the process, a model of process is proposed in order to avoid the problems identified at the usual process. This proposal has the principles from Advanced Product Quality Planning and the Scrum framework. The goal is to reduce the rework using the learning process presented. If no assumptions are made, if everything is clear from the beginning, if all the necessary documentation is done, if the proper mentoring is made and if the process is continuously improved, the probability of the identified problems to occur again is highly decreased. The most important points in the proposed process for improvement are the following: weekly meeting for status update, assigning the orders according with the needs, assign a mentor for new entries, eliminating the assumptions, discuss the problems as fast as possible and obtain feedback fast from the client to check the direction of the work.

Implementation of Advanced Product Quality Planning in Engineering Project

Engineering Design (ED) process is the foundation on which Automobile Engineering students currently base their project work. Though efficient in addressing the primary academic requirements, it is nevertheless open ended and hence the methodology for project execution will differ from team to team. ED at higher semesters, in the author's perspective, is less structured and feel there is a need for a defined industrial methodology based on ED, especially to address the needs of automobile engineering students. This requirement can be fulfilled by Advanced Product Quality Planning (APQP), a framework of procedures and techniques followed by the automotive industry worldwide. An attempt was made to implement APQP on experimental basis in a project titled Solar Array Electric Vehicle. The following four stages were incorporated in the project: Plan and Define Program, Product Design and Development, Feedback and Corrective actions and Control Plan Methodology. This paper highlights the scope, implementation methodology and results of application of APQP in Solar Array Electric Vehicle project.

A REVIEW OF APPLICATION OF SOME PRODUCT DEVELOPMENT TECHNOQUES APPLIED IN ENGINEERING INDUSTRY

New product development is always challenging and creative task in today’s era of globalization. Various internal and external factors are to be considered in the entire product development process. The concerned internal factors are skilled workforce with the organization, Budgetary provision for new product development, infrastructural and other resources available with organizations etc. While the external factors are requirement of the Customers, legal issues, Government policies, market segments and prevailing situations in the market. Considering the complexity in the product development process various new techniques of product development are being introduced by the industries, as well as proposed by researchers and academia. Lean product development, Quality Function Deployment, Six sigma is some of the techniques. In recent years there is a new technique being opted by the industry called as Advanced Product Quality Planning (APQP) .This paper is an attempt to review the developments of APQP and efforts being taken by the researchers in the development of APQP.

MSA Planning - A Proposition of a Method

Measurement System Analysis (MSA) comprises a set of methods aiming to identify and assess variation of measurement results that can be assigned to a measurement system (gauge, personnel, procedure, standard, ambient conditions, etc.). It became a requirement of quality management systems in automotive industry, according to ISO/TS 16949. Moreover, most of automotive suppliers have to meet OEMs requirements specified in APQP (Advanced Product Quality Planning), PPAP (Production Part Approval Process) and MSA manuals. Many other industries adopted the same approach, expecting their suppliers to perform MSA in compliance with the above guidelines. The basic requirement regarding MSA scope is that it should be carried out for all measuring instruments referred to in Control Plans. Among methods available, gauge R&R seems to be the most popular method of measuring system capability assessment. However, although the assessment has to be performed periodically, none of the above mentioned guidelines suggest any method for MSA planning. The paper describes a few propositions on how the problem can be practically resolved basing on a risk associated with each measurement system. The first proposed method is based on simple risk analysis, which can be easily run together with developing a Control Plan. It uses process capability index (required or achieved) and characteristics impact on product/process function for making a decision on MSA frequency and scope. The variant of the method uses gauge robustness assessment as another risk factor.The other proposition assumes that a process FMEA (Failure Mode and Effects Analysis) is developed. The method uses performed FMEA to establish priorities for MSA. Basing on the priorities, frequency and scope of MSA can be planned.

Improving Product Quality by Implementing ISO / TS 16949

An organization operating in the auto industry who wishes to become a first hand supplier of major automotive manufacturers in the world should plan to get certified under the standard ISO/TS 16949 because it may be a contractual requirement imposed by most of the manufacturers. The purpose of this standard is developing a quality management system that will generate continuous improvement through prevention of defects, reduction of variation and waste minimization, on the entire supply chain of the automotive industry. Among the basic means used for certification the following should be mentioned: SPC (Statistical Process Control), MSA (Measurement System Analysis), PFMEA (Potential Failure Modes and Effect Analysis), APQP (Advanced Product Quality Planning), PPAP (Production Part Approval Process). This paper describes the implementation and improvement of SPC in an ISO 9001:2008 certified organization in Romania, that planned the implementation of ISO/TS 16949 quality standard.

Comparative Analysis of Awareness and Knowledge of APQP Requirements in Polish and Romanian Automotive Industry

In the present financial and economic context, the automotive industry faces new challenges posed by the current crisis. Companies have to ensure that the quality products are delivered on time and in a competitive price. One of the most recommended techniques of quality management by specific standards of the automotive industry for product development is Advanced Product Quality Planning (APQP). Product Quality Planning is a structured method of defining and establishing the steps which are necessary to ensure the customer satisfaction from the product. The goal of this paper is to present the results of evaluation of awareness and knowledge the APQP techniques in Polish and Romanian automotive industry. The research method was a questionnaire with indicators to measure the awareness APQP tools. The research was conducted among design and technology professionals in Polish and Romanian automotive companies. On the basis of questionnaire it was performed a comparative analysis of results from Poland and Romania. In this way it is shown which methods and tools of APQP are better known and understood in each country. It was pointed out which tools are difficult to use or there is lack of knowledge about them. It was also shown which methods are most often used in the Polish and Romanian automotive companies. They were also summarized the similarities and differences in the knowledge and using the APQP in both countries.

Concurrent realisation and quality assurance of products in the automotive industry

The aim of the concurrent product realisation and quality assurance of products is to shorten the realisation time, reduce realisation costs, increase the quality of products and thus increase customer satisfaction. In a case study of a project of the concurrent realisation of products (components for the automotive industry), it is shown how the requirements of quality standards for the automotive industry can be integrated in processes of the concurrent product realisation project, based on track-and-loop principle and three strategies: parallelness, standardisation and integration. This article gives an overview of quality-related standards in the automotive industry, the principles of sequential and concurrent product realisation and the course of concurrent product realisation and quality assurance of products in the automotive industry. Five loops of concurrent product realisation processes are defined for the automotive industry, as well as seven milestones of advanced product quality planning. A course of concurrent realisation and quality assurance of products in the automotive industry is shown in the case of the concurrent realisation of a car component.

Advanced Quality Planning of Manufacturing Products - APQP

Implementation of management by processes in Romania it is a problem if we consider its effects: improving performances of organizations expressed in terms of quality, process duration, cost, etc. Taking into account the sequence of steps corresponding to the specific managerial process and quality management, it is considered that its functions are: planning, organizing, coordinating, controlling, quality assurance and improvement. This paper presents a detailed approach of advanced product quality planning (APQP) of technological products and the case study regarding the analysis of industrial product defects implementing statistical process control (SPC). The Production Part Approval Process (PPAP) purpose continues to be to provide the evidence that the specification requirements are clearly understood by the organization and the manufacturing processes are the designed capability. Implementing the APQP technique permits us to define and establish the steps necessary to ensure that a product satisfies the customers requirements.

Evidence of APQP in quality improvement: An SME case study

Advanced Product Quality Planning (APQP) has had an impressive impact as it is significantly better than other quality management systems which merely provide detailed statistics based on analytical methods. However, the APQP scope is still restricted to new product development only. This paper looks at the application of APQP methodology for quality improvement in small and medium sized enterprises (SMEs), using a specific die casting unit case. The study could be a paradigm initiative towards high quality products and services at low cost for every SME.

Steps for the advanced product quality planning approach to improve product quality: a case of fastener manufacturing

Advanced product quality planning (APQP) is a robust production strategy and a real-time improvement method with a comprehensive quality processing procedure that uses statistical tools and technologies to improve product quality. APQP product development processes thus allow accurate and efficient production. The present paper proposes a procedure for APQP for the fastener industry. Realistic processes are used to explain the procedures used, including the activities involved in the five stages of the APQP approach: the planning and definition stage, the product design stage, process design stage, the manufacturing certification stage, and the improvement and feedback stage. The empirical study results show that the proposed APQP procedure can ensure product quality and capability of manufacturing equipment with improved Ppk, Cpk, and Cpm values.

适于汽车钣金零件生产的APQP信息管理系统研究<br>APQP Information Management System for Production of Sheet Metal Parts in Automobile

介绍了基于Ruby On Rails 框架开发的钣金零件产品质量先期策划(APQP)信息管理系统，着重研究了系统的基本结构、主要功能及开发中所需要的关键技术。该系统通过与企业计算机辅助工艺设计(CAPP)系统实施信息集成，提高了企业工艺信息管理水平，促进了企业信息一体化建设。 This paper introduces an information management system of Advanced Product Quality Planning (APQP) for sheet metal parts, developed by using Ruby On Rails development framework. Basic structure, main functions of the system and key technology in the development process are presented. The integration between APQP and Computer Aided Process Planning system (CAPP) has realized, that can greatly improve the level of process information management and promote the construction of information integration in the company.