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(ISSN
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A
BSTRACT
This article deals with paragraph 8.3 of the IATF 16949: 2016 International Automotive Standard and the
APQP Guide developed by the AIAG (Automotive Industry Action Group) Automotive Industry
Standardization Group and the Automotive Division of the American Society for Quality Management in
the automotive industry. It is recommended to use the APQP method not only in the automotive industry,
but also in any design and manufacturing areas.
K
EYWORDS
IATF 16949:2016, AIAG, APQP method, flow chart, control plan, SPC, MSA, FMEA, PQC process steps and
so on.
I
NTRODUCTION
The Fourth Guide to the Automotive Industry
APQP- Advanced Product Quality Planning and
Control Plan (internal and external) sets general
requirements for suppliers to plan and manage
the quality of future products [1-7].
Journal
Website:
http://sciencebring.co
m/index.php/ijasr
Copyright:
Original
content from this work
may be used under the
terms of the creative
commons
attributes
4.0 licence.
Research Article
THE ORGANIZATION DEVELOPS A STANDARD IN QUALITY
MANAGEMENT
Submission Date:
June 10, 2022,
Accepted Date:
June 20, 2022,
Published Date:
June 30, 2022
Crossref doi:
https://doi.org/10.37547/ijasr-02-06-09
S.X. Isroilova
Assistant, Fergana Polytechnic Institute, Fergana, Uzbekistan
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Product quality planning focuses on a single goal
- to achieve mass production of automotive
components in accordance with the wishes and
requirements of the consumer. Paragraph 8.3 of
IATF 16949: 2016 is based on the requirements
of the APQP method in product design and
technology and the APQP manual developed by
the AIAG Automotive Industry Standardization
Task Force and the ASQC Automotive Division of
the American Society for Quality Management.
The following organizational standard has been
developed for [8-17]. By applying this APQP
method in the design and production processes of
products in any field of automotive industry, it is
possible to achieve a high level of product quality.
We have developed the following organizational
standard for managing this APQP and
recommend its use [16-21].
Ts-Organization Standard
Future Product Quality Planning And Plan
Control Program (APQP Process).
1. Purpose
The purpose of this standard is to ensure the
planned quality of mass production of automotive
components in accordance with consumer
demand. The APQP process is to ensure that all
participants are clearly collaborated and that
stage requirements are met in a timely manner at
an acceptable cost. The APQP process ensures
that internal and external automotive component
suppliers meet quality requirements based on the
rule of their own initiative [22-28]. The
implementation of the APQP process steps
requires the participation of all departments in
the design, production preparation and
component development.
2. Scope of application
This standard applies to all participants in the
APQP process stages, concept, prototype
development, production preparation, and mass
(serial) production processes.
3. Normative sources
3.1 GOST R 51814.6-2005 Systems of quality
management in automobile construction. Quality
management in planning, development and
preparation of automotive components.
3.2 Planning the quality of perspective
production and the quality of the program
APQP.Perevod s angl.-N.Novgorod. Russia: SMTs
"Priority" 2001-126 p.
3.3 Ts 23677708-14: 2020 Process Statistical
Management-SPC
3.4 Ts 23677708-15: 2020 Measurement System
Analysis-MSA
3.5 Ц 23677708-16: 2020 Analysis of types and
consequences of possible inconsistencies-FMEA
4. Terms and definitions
4.1 Automobile components - raw materials,
components and assemblies used in the
manufacture and assembly of automobiles.
4.2 Future Product Quality Planning and Planning
Control Program (APQP) is a guide to identify and
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implement all the steps necessary for the
implementing company to meet the needs and
desires of the consumer [29-34].
4.3 Process flow chart (Flor chart) - a diagram
consisting of no more than 7-10 typical characters
and showing a visual sequence of production
processes.
4.4 A control plan is a documented description of
the systems and processes required to manage a
product (usually in tabular form). The control
plan includes the content of quality indicators
specified in the technology process. Quality
indicators can be customer-set, supplier-chosen,
and significant.
4.5 Basic description of the vehicle component -A
/ V The level of the detail (part) is determined by
the parts that affect the safety, environmental or
functional (quality, reliability) performance of the
vehicle.
4.6 Quality Control Point (PQC) is a key indicator
of the product that affects the vehicle or its
assembly.
4.7 Supplier (automotive component) - a legal
entity that plans and (or) manufactures
automotive parts for the purpose of delivery.
4.8 Consumer - a legal entity that purchases
automotive components and manufactures them
for automobiles or their components.
4.9 Analysis of Potential Failure Mode and Effects
Analysis (FMEA- Potential Failure Mode and
Effects Analysis) is an effective tool for improving
the quality of the technological processes being
created, aimed at eliminating the defect or
reducing its adverse effects [31-37].
4.10 Statistical Process Control (SPC) is a method
of statistical analysis of a process and control of
its variability.
4.11 Measurement System Analysis (MSA) - A
method of statistical analysis of measurement
processes in the general process of production
and control of the variability of measurement
systems.
4.12 APQP group / team - a team consisting of
representatives
of
quality,
production
technology, product design, localization, supplier
and consumer specialist if necessary.
5. Responsibilities and rights
5.1 The head of the enterprise:
-Approval of APQP group members; continuous
verification of the effectiveness of the decisions
made;
periodic
monitoring
of
project
implementation;
5.2 Head of Technology Department:
- team building, working as a team, ensuring
solidarity with other teams and individuals;
sequential and parallel execution of design stages
in accordance with the established plan period;
identification of internal and external consumers;
determination of selection criteria for specialists
to be recruited from the supplier to the team;
taking into account consumer requirements in
design and testing. Evaluate the design,
implementation and preparation processes;
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determination of costs, taking into account the
norms; identification of consumer assistance
requirements; identify process or method
documentation [39-42].
5.3 APQP Group / Team Leader:
- Ensuring the knowledge of team members in
meeting the needs and desires of consumers;
ensuring that each APQP team member is
assigned responsibilities and rights in accordance
with the identified responsibilities.
5.3 APQP group / team members:
-participate in group meetings and make
suggestions; ensuring compliance with consumer
requirements and wishes; duty, responsibility
and observance of rights.
6. Job content
6.1 Head of Technology Department
APQP should form a team.
- selection of the APQP team leader; create an
inter-functional APQP command; the team should
include representatives of marketing, design,
production, quality, procurement, sales, service,
etc. If necessary, specialists from other
organizations can be invited to the APQP-team.
Each APQP-team member should be assigned
responsibilities and rights in accordance with the
defined tasks; planning and coordination of all
tasks on the APQP-process to ensure quality
assurance in the mass production of future
products. Disclosure of consumer interests and
desires (QFD - Quality Function Deployment
method);
members
assign
duties
and
responsibilities (responsibility matrix); defining
the responsibilities and rights of each person and
/ or subcontractor involved; attracting the
consumer and the main supplier; determination
of costs, deadlines and other limitations;
assessment of the feasibility of the requirements
and the proposed technical and organizational
decisions; identify documentation of processes
and methods. Ensuring the knowledge of team
members in fulfilling customer demands and
wishes. Planning, development of the concept
(idea) and planning of product quality assurance;
design and development of automotive
components; design and development of
technological processes; final preparation for the
production of auto components; measures for
production
and
improvement
(feedback,
evaluation and corrective). All the above steps
should be aimed at a single goal to achieve mass
production of automotive components in
accordance with the wishes and requirements of
the consumer.
6.2 Create a temporary sample graph of the APQP
process
The APQP team should use the quality program to
develop a temporary schedule plan, set a clear
execution time in flour stages, and focus all
attention on eliminating the root causes of
nonconformity (DFMEA, PFMEA, MSA, SPC, etc.)
by properly allocating costs.
6.3 Develop an APQP process calendar plan
APQP-process development of a calendar plan
based on a temporary sample schedule. The plan
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should specify all measures, deadlines and
necessary resources. The term in the plan
depends on the needs and desires of the
consumer, as well as the type and complexity of
the auto component. Ensure that all members are
in agreement. It is necessary to monitor the
implementation of the plan.
6.4 Development of Quality Control (S / R) Plan
A management plan for troubleshooting should
be prepared: prepare an experimental sample,
develop a specified quantity, and develop for
mass development stages (Appendix A).
6.5 Develop a process flow map
The process of making autocomponents is to
create a visual flow chart of the processes.
The process flow chart and control plan should be
mutually agreed. The FMEA team should
periodically review the process flow chart to
improve and analyze the auto component
manufacturing process.
6.6 Ensure serial and parallel operation
Ensure that input and output results are executed
sequentially and in parallel during the process
stages.
6.7 Identify project management risks
The APQP-team should formalize the problems
encountered during the design process.
When a problem occurs, the team should analyze
the risks and suggest the necessary measures to
solve the problem. In severe cases, special
methods of problem solving should be adopted
and approved by the organization's management.
6.8 Procedure for implementing the process steps
of the APQP command
Phase 1, planning, developing the idea and
implementing the product quality assurance plan:
- entry information; general information or
“consumer voice” (market research results,
collected quality and warranty information,
experience of team members); business plan and
marketing
strategy;
key
indicators
of
competitors' products / processes; product /
process analysis; the results of the study of
product reliability; information from a trusted
consumer.
Phase 1 results (Phase 2 introduction data):
- purpose of the project; quality and reliability
goals; list of source materials; initial flow chart of
processes; preliminary data of specific
descriptions of products and processes; product
quality assurance plan; support by management.
Phase 2) product design and development
- determine the final characteristics and design
characteristics of the vehicle component (a / c) on
the basis of all volumetric and critical analysis of
technical requirements, technical data, test
results, etc. Whether the project was created by a
customer or an external organization, the APQP
team should consider the source of all
developments.
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Phase 2 should ultimately be an initial analysis of
the possibility of creating an autocomponent
design by assessing the problems that may occur
during the manufacturing process.
Phase 2 results: (for DFMEA)
Analysis of the types and consequences of
possible design inconsistencies (DFMEA):
- Ensuring technology and aggregation; project
approval;
project
analysis;
creating
an
experimental model and a management plan for
it; material descriptions; technical drawing
(including mathematical results); technical
requirements; changes in drawings and technical
requirements.
Phase 2 results (for APQP-command):
- New requirements for equipment, tools and
fittings; special descriptions of products and
processes; requirements for measuring and
testing instruments; the team's conclusion on the
feasibility of the project; support the leadership.
Step 3. Process design and development
Phase 3 is the creation of all technological and
production process developments in the final
form, reviewing the key features of production
processes in relation to the management plan to
achieve quality product production.
Phase 3 results:
- process flow map; shop location plan;
description matrix (process: product); process
PFMEA (analysis of types and consequences of
possible inconsistencies in processes); packaging
standard and requirements; management plan
for the specified number of products; product /
process quality system analysis; instructions for
workers (operators); measurement system
analysis
plan
(Ts
23677708-15:
2020
Measurement system analysis-MSA); product /
process quality system analysis; process
feasibility study plan (Ts 23677708-14: 2020
Process Statistical Management-SPC); leadership
support.
Phase 4 Final preparation for the production of
auto components
- Ensuring all quality requirements and achieving
full production of automotive components, taking
into account the growth of production. At this
stage it is necessary to evaluate the mass
production and highlight key aspects. It is
necessary to confirm that the product meets the
requirements of the consumer, the management
plan and the process flow chart are followed.
Identify additional measures in order to solve the
problem before the start of mass production and
study their root causes.
Step 4 results:
- Ensuring agreed mass production; evaluation of
the measurement system analysis; initial study of
the possibility of processes; agreeing on the
production of components; testing for production
approval; evaluation of packaging; production
quality program; mass production management
plan; approval of auto component production;
production readiness (act) act and support of
management.
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Phase 5 Measures for production and
improvement
- approval of the readiness of technological
components for production and technological
processes; assessment of their output at the stage
of preparation of auto components (all the usual
and special causes of variability); Evaluate the
effectiveness of previous stages of the APQP
process; assessment of compliance with product
or service quality requirements; creating a
management plan for mass production;
evaluation of quantitative and qualitative results;
fulfillment of consumer requirements by all
descriptions; setting specific descriptions.
Phase 5 results:
-reduction of variability ((Ts 23677708-14: 2020
Statistical control of processes-SPC); GOST R
51814.3); increase consumer satisfaction;
shipping and service.
6.9 The APQP team leader should arrange for the
following applications to be completed and
maintained in good condition. It is recommended
to use the APQP guide when filling them out.
C
ONCLUSION
1
It can be done
It is possible to develop a product without rethinking how
it is installed.
2
It can be done
Modification recommended (see appendix)
3
It is impossible
to do
A design revision is required for the product i / ch
according to the established requirements.
Name / surname, signature, position and date of team members:
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