APQP

Focus on Automotive processes

Every Supplier to the Automotive Industry, irrespective of the market, desires to successfully cooperate with Car Producers – Original Equipment Manufacturers (OEMs) worldwide. To achieve this, all Suppliers must respect certain international rules and standards related to the quality planning. During the whole development cycle and launch of new products and parts, the Advanced Product Quality Planning (APQP) procedure is generally used as the standard in this area.  It does fully describes an entire process of development phases of a new product, including product acquisition and launch into a serial production and processing of its significant changes. Another interrelated procedure related to the quality is the Production Part Approval Process (PPAP). Both standards have been created for the automotive industry but their application is wider. OEMs from other Industries use the proven features of APQP and PPAP standards because both are suitable and beneficial for products, products development and production experience.

The Advanced Product Quality Planning is a structural plan of individual phases and tasks, necessary to fulfil and ensure customer’s expected quality of a product. Phases cover:

  • capturing and understanding of the customer request
  • design and development of a product
  • design and development of a production process and its verification
  • product launch, feedback and a control mechanism

Each phase consists of the exact number of tasks and related responsibilities, like for example:

  • effective resource planning,
  • Risk, Issue & Opportunity Management (RIO),
  • formulation of control plans,
  • Failure Mode and Effects Analysis (FMEA),
  • search for changes and change  management,
  • Documentation requirement for a product.

In the other words, the structure of phases and tasks cover all stages of the Product Life Cycle.

Dassault Systèmes 3DEXPERIENCE platform support

Product Lifecycle Management (PLM) is the comprehensive set of system solutions supporting more efficient management of the product through its entire life cycle.Dassault Systèmes is one of the most significant solution providers in this area and offers a modern PLM system based on the 3DEXPERIENCE Platform. To become the leading solution provider in the Czech Republic, Dytron combined its extensive experience with automotive OEMs and Suppliers environment and the competency of the 3DEXPERIENCE platform and solutions. Dytron also enhanced the offering by applying APQP and PPAP standards. This resulted in a comprehensive solution that is adaptable to specific Customers requirements and their environments.

This unique solution relies on the integrated PLM system, where all quality standard requirements are lined up and supported. The basic data and the information structure are divided into production programs, usually based on a given automotive manufacturers and related projects. The standard norm consisting of the complete structure of phases and tasks as well as the requirements for a necessary documentation including a folder structure is stored in a pre-defined template. Individual processes lining up e.g. a change management, are defined the same way. A project manager, with ease, can establish a new project from an existing template – with an option to limit or modify a project extension or a structure – based on the character of the Customer requirement. Project manager assigns required resources based on his/her experience and capacities, determines terms of individual milestones and releases the project to a realization.  Ergonomic and well designed interface allow the end user (usually Program/Project Manager) to control and track project, budget and quality – at the same it is possible to have available data drawn from other systems, e.g. a survey of material costs from an economic system.

 

Advanced Product Quality Planning

The product development and engineering is performed by the standard CAD tools – suppliers usually work in the multi CAD environment because of different CAD systems used by cars manufacturers. The PLM solution based on 3DEXPERIENCE platform has been fully integrated into those standard CAD systems and it allows full control and CAD data administration, including sorting by versions. Obviously all activities in the development phases are subdued to the related APQP procedure and tasks. With the 3D visualization tools in 3DEXPERIENCE it is possible to graphically review 3D data and information in the project, and perform evaluations of development and engineering status (Technical Design Review).

Another significant integrated functionality is the Bill of Material (BOM) management of a product. It is possible to define BOM items not only for mechanical parts, which are usually created in the CAD system, but also to add items of electronic components, software and similar into the structure. It is possible to organize standard parts and classify them into libraries and use them repeatedly in various projects. There is ability to track supplier’s information at the individual purchased items level, determine alternative components or source an alternative supplier.  The BOM prepared this way is because of the integration transferred into the production information system (MRP). The next important integrated functionality enables companies to track, analyze, and report a products environmental compliance. Product compliance engineers can view the material content information in the context of the product BOMs, and are able to cross-reference this data against multiple regulations like the International Material Data System (IMDS).

The area of change management is solved by pre-defined processes, which reflects the process of change proposal – the Engineering Change Request (ECR). After the evaluation of the production process there is a consecutive order to change – the Engineering/Manufacturing Change Order (ECO/MCO), which has again an integrated feedback to processing and change release into the production in the ERP system.

Experience accepted by the Customer

Users log and work with the system via a web browser. Users can very easily orient themselves in convenient and intuitive environment of web application where all data is connected and accessible in real time and in corresponding quality. Such modern technology allows easy modifications of system behaviour based on customer’s requirements and reduces administration costs significantly. Required project tasks are submitted to users and their progress is monitored. At the same time, the system requires a record and documentation processing based on PPAP procedure requirements. Thanks to all of those features, the solution, built-in the PLM system based on Dassault Systèmes 3DEXPERIENCE platform, allows suppliers in the automotive industry to comply with audit requirements of cars’ manufacturers. This in turn leads to successes in acquiring and realization of new projects.

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