4
Section:
Project management for product realisation

4.1. Overview of manuals
Manuals for the core tools of the automobile industry:
Topic: QS9000 Manual: VDA Volume:
Advance Quality APQP VDA4, VDA4.3
planning
Approval Process PPAP VDA2
Risk analysis FMEA VDA4.2
Statistics SPC VDA3.1-3.3
Spec. APQP / FMEA VDA1
characteristics
Capability of test MSA VDA5
equipment

4.2. Field of application
What for do I need it:
“Guideline for support at
launch of new products“
With and without
product development

4.2. Field of application
Why do I need it?
• It makes complex processes
transparent
and reproducible
• It helps to prevent redundant activities
• It offers a continous check in a project
• It exonerates at product liabilities
• It is a recommended demand of
Daimler/Chrysler, Ford and General
Motors (Opel)

4.2. Field of application
Why do I need it?
Are you sure
that our
calculation
was
correct??

4.2. Field of application
Reasons of customer
•In order to provide means which satisfy the
customer
•In order to identify necessary modifications as
early as possible
•In order to prevent late modifications
•In order to produce a quality product timely
with lowest costs

Goals
Objective PLAN
Supplement Information
Standards
Key persons Structure
Preparation
Meetings
ACT
Review
Closing
Negative differences
or corrective action plan
Action plan
or correction
DO
Positive differences
Stopp
Overtake benefits
Improve Plan conducted?
“Customer” happy?
CHECK

4.3. Phase model
Concept Release Prototype Pre-series Series
PLAN
PRODUCT deve./engi.
PROCESS development/engineering
PRODUCT & PROCESS validation
Feedback, appraisal, corrections

4.3. Phase model
PLAN
PRODUCT deve./engi.
INPUT PROCESS development/engineering
OUTPUT
PRODUCT & PROCESS validation
Feedback, appraisal, corrections

4.3. Phase model
Dropped if no
X
PLAN
development responsibility
PRODUCT deve./engi.
PROCESS development/engineering
PRODUCT & PROCESS validation
Feedback, appraisal, corrections

Customer
Inquiry
Whe
New Product
n do
es i
Contract
t star
review
t ?
Offer
Order
APQP

4.4. Development
Definition according to QS9000:
“If the supplier may compile or change specifications for
the customer.“
Definition according to VDA6.1:
“If the supplier bears the written development
responsibility.“
Supplement according to TS 16949:
“Development then exists when the supplier specifies
products in cooperation with the customer.“

4.4. Development
Supplier
Customer
Idea
Specification
Compiled
by supplier Compiled
(Cooperation with customer
or also in subcontract)
by customer

4.5. Basic prerequisites
Support of management
Capacities and means have to available; development order
placed in writing.

4.5. Basic prerequisites
Overlapping team:
Employees of quality management, development
department, production, logistics, purchase, distribution, field
consulting, sub-suppliers and customers.

4.5. Basic prerequisites
Define the volume!
•Define a team leader who keeps track of the planning
process.
•Defining of roles and responsibilities of each co-operating
sector.
•Define internal and external customers (interface matrix)
•Choose which methods, persons and sub-suppliers are
needed in the team and which not.
•Understanding of customer expectations
•Inspection of doability of provided design, reliability features
and manufacturing process.
•Costs, time and requirements have to be considered.
•Determine if support by customer is needed.
•Determine documentation process or method.

4.5. Basic prerequisites
Communication

4.5. Basic prerequisites
SIMULTANEOUS ENGINEERING:
ACTIVITY „A“
ACTIVITY „B“
ACTIVITY „C“
Total period

PLAN
PRODUCT deve./engi.
PROCESS development/engineering
PRODUCT & PROCESS validation
Feedback, appraisal, corrections

4.6. Phase 1
The voice of the customer:
Complaints
Recommendations
Customer satisfaction analyses
Internal customer information
Market surveys
Warranties / liabilities
Quality analyses
Experiences of the team

4.6. Phase 1
Defaults of the business plan:
Market strategies
Timing
Investments
Budget
Customer areas
Turnovers
Competition

4.6. Phase 1
Product and process benchmarking:
Ascertain „best in class“
Define and understand deficiencies
Compile a plan in order to fill the gap
Repeat analysis

4.6. Phase 1
Product and process assumptions:
Design concepts
Innovations
New techniques
Modern materials

4.6. Phase 1
Product reliability analysis:
Repair
Spare part market
Endurance tests

4.6. Phase 1
Customer information:
Information of next user (customer and end customer)
Needs and expectations
Inspections and tests of customer
Customer satisfaction bar

4.6. Phase 1
Development targets:
Measurable
Customer expectations
values

4.6. Phase 1
Reliability and quality targets:
Reliability targets:
•probabilities
•confidence limits
•Customer expectations
•Benchmark analysis Quality targets:
•Reports, statistics •targets of continual improvement
•Repairs •e.g.: PPM. Reduction of rejects, error margins

4.6. Phase 1
Preliminary process flow plan:
•Material list
•Product assumption
•Process assumption

4.6. Phase 1
Preliminary listing of specific features:
Definition:
“Features which have effect on safety and/or fulfilment of
legal restraints resp. are functional important.“
•Given by customer.
•Ascertained by supplier (at design responsibility).
INPUTS: product assumptions, customer information, FMEA of similar parts

PLAN
PRODUCT deve./engi.
PROCESS development/engineering
PRODUCT & PROCESS validation
Feedback, appraisal, corrections

4.7. Phase 2
Design FMEA:
“Methodical analysis of all possible potential errors of a
design,
their effect and importance on the customer as well as
planning
and operating of activities for risk reduction.“

4.7. Phase 2
Design for manufacturing and
assembly:
MANUFACTURING
PRODUCT
ASSEMBLY

4.7. Phase 2
The activities of phase 1
have to lead to this that
the design result fulfils the
design defaults

4.7. Phase 2
Design defaults Design result
(requirement specification, (CAD, drawing,
inputs phase 1) specification etc.)

4.7. Phase 2
Regularly Design Reviews:
Meetings in order to determine if the given plan is
observed:
• Consider design/function
• Reliability and confidence targets
• Components, sub-systems and systems
• Computer simulations, Benchmark
• DFMEA
• Checking of producibility and assembly
• DOE methods
• Test errors

4.7. Phase 2
“Control plans are written descriptions of systems which
serve for this to dominate parts and processes.“
It differs in:
•Prototype – A description of dimensional measurements, material
and performance tests which are carried out during prototype
phase.
•Pre-series – A description of dimensional measurements, material
and performance tests which are carried out after prototype phase
but before series.
•Series – A comprehensive documentation of product/process
features, process control inspections and measuring systems
which are carried out during mass production.

4.7. Phase 2
Manufacturing of the prototype has to lead to this
that…
• the product fulfils the specification resp.
provides required data.
• specific product and process features have
been considered.
• data and information are used in order to define
preliminary process parameters and packaging
standards.
• all doubts, deviations and influences are
reported
to the customer.

4.7. Phase 2
Preparation of engineering drawing
•Legal demands
•Safety features
•Determination of features for „fit & function“
•Tolerated dimensions
•Documented inspection of the drawing

4.7. Phase 2
Preparation of engineering drawing
Test equipment available for all features?
Dimensions producible?
CAD data compatible to customer?

4.7. Phase 2
Preparation of technical specifications
(can be included in engineering drawing!)
Functional requirements
Reliability requirements
Features dependent on appearance
(Kind of inspection, volume,
frequentness and carrying out are
defined in standards, specifications,
test instructions and control plans,
etc.)

4.7. Phase 2
Preparation of material specification
(can be included in engineering drawing!)
Have to be tested with reference to:
Specific features
Physical characteristics
Performance
Environment (disposal)
Handling
Stocking (conservation)

4.7. Phase 2
New equipment, tools
and facilities
Tools = Formative means of production
Equipment = Constructive auxiliary means of production
Facility = New areas, assembly line and plant extensions
•Include into schedule
•Tools and equipment have to be process-capable
•Delivered and provided in time

4.7. Phase 2
Discussion which specific features are determined
(basis is the preliminary determination of phase 1)
•Find accordance (involve customers)
•Consult attachment C of QS 9000 (determinations of features)
•Include into control plan
•Consider customer release procedure
•Consider documentation requirements
•Use auxiliary means APQP forms

4.7. Phase 2
Determination of
requirements on all test
equipment and teachings.
=> include into schedule and monitoring!

4.7. Phase 2
Team doability declaration:
The APQP team confirms in writing that the
suggested design…
1. can be manufactured
2. can be assembled (if claimed)
3. can be verified positively
4. can be packaged
5. can be delivered
... in satisfying quality and quantity as well as
according to given costs.
Attention! Please use form „Team Feasibility Commitment“

PLAN
PRODUCT deve./engi.
PROCESS development/engineering
PRODUCT & PROCESS validation
Feedback, appraisal, corrections

4.8. Phase 3
Packaging standars are given by customer and
have to be worked into the own QM-system.
Packaging specifications are
developed by supplier and
have to be worked into the
own QM-system. Thereby it
has to be considered how far
packaging has effect on
product quality (drop test,
conservation, etc.)

4.8. Phase 3
Inspection of QM-system
•Inspection and practice of any modifications into the QM-manual
•Involvement of process and work instructions
•Regeneration of necessary documents and forms

4.8. Phase 3
Matrix of features
Appropriation of features (product and process)
to a process.
•The more product features are influenced by a
process the more important is the control on
this process!

4.8. Phase 3
Process FMEA:
“Methodical analysis of all possible potential errors of all
processes, their effect and importance on the customer as
well
as planning and operating of activities for risk reduction.“
Basis:
Process flow plan

4.8. Phase 3
Differences to series control plan:
• Higher frequented inspections
• More in-process and final inspections
• Statistical analyses
• Stronger audits (product and process)
Comment: With pre-series SAMPLES are
meant.

4.8. Phase 3
Information at machines:
• Name of process (relevant to process flow chart)
• Name of part and number
• Revision status
• Tools, equipment and test equipment information
• Material and disposal instructions
• Demands on specific features
• SPC requirements
• Necessary norms / standards
• Inspection and test instructions
• Reaction plans
• Visual auxiliary means
• Tool change intervals and facility instructions

4.8. Phase 3
Measurement System Analysis
(MSA)
A measuring process contains diversifications
Every ascertained measured value consists of
•every real value and
•measurement error.
Measurement error is caused by
•diversification influences of measuring equipment and
•diversification influences of the inspector or the measuring
method.
Measurement error consists of
a systematic error and
a random error.

4.8. Phase 3
Statistical Process Control
(SPC)
Analysing of proceedings
with the target to dominate the process.
Determination of preliminary process capability
on real fabrication conditions.
Determination of continous process capability
on real fabrication conditions.

PLAN
PRODUCT deve./engi.
PROCESS development/engineering
PRODUCT & PROCESS validation
Feedback, appraisal, corrections

4.8. Phase 4
PRODUCTION ATTEMPT
Production attempt should be carried
out as possible on close-to-production
conditions :
•Tool
•Equipment
•Environment
•Material
•Staff
•Plant areas

4.8. Phase 4
PRODUCTION ATTEMPT
The quantity to manufacture has to be
clarified with the customer. Targets of
pilot production are:
•Preliminary process capability studies
•Evaluation of capability of measuring
equipment
•Process inspection
•Production validation
•Production parts release
•Inspection of packaging
•„Sign Off“

4.8. Phase 4
Measurement System Analysis
(MSA)
All in control plan listed measuring
equipment is taken a inspection of capability
of measuring equipment according to
method MSA of QS 9000.
Only test equipment for fabrication is
allowed to put in which does not exceed
demonstrably a maximum R&R value of
30%.

4.8. Phase 4
Results of preliminary process capability
(SPC)
Only at features given by customer or own determination.
Arrange procedure with customer:
1. Take parts
2. Measure parts
3. Determine standard deviation
4. Determine PPK values

4.8. Phase 4
Production part approval process
(PPAP)
•Ensure that the supplier understands all customer
requirements and can translate these in
processes
and products which meet customer
requirements
Comment:
On the subject of PPAP, a separate course can be attended!

4.8. Phase 4
Inspection of packaging
•Stock test
•Conditioning
•Drop test
•Road trial

4.8. Phase 4
DEFINITION:
“A comprehensive documentation of product/process
features, process control inspections and measuring
systems which are carried out during mass production.“

4.8. Phase 4
DEFINITION:
The quality planning team should ensure that all
process flows and control plans are realised.
It is recommended to carry out and document the
“sign off“ in the production plant.

4.8. Phase 4
The „Sign off“ should enclose the following points:
1. Control plans should exist and be available at
any time at locations which need these for
realisation of contents.
2. It should be checked that all process
instructions considered the specified specific
features which are mentioned in the control
plan. Recommendations of process FMEA
should have been realised.
3. With special test equipment or in control plan
mentioned test equipment, a successful
inspection of capability of test equipment
should be present.

PLAN
PRODUCT deve./engi.
PROCESS development/engineering
PRODUCT & PROCESS validation
Feedback, appraisal, corrections