Plan & Define Section 1

IDEA

RELIABILITY BY DESIGN Tool Linkage

Design & Development - Section II
GD & T - Drawings - Math Data

Opportunity Defined

Process Design & Development - Section III

Process Flow Finalized
Pr oo

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Form Team - Timing - Resources Customer Wants/Needs/Desires - QFD

Collect Market Research

Input From 5 - Failure Mode Analysis - History - Past Performance - Lessons Learned

Priorities Wants/Needs/ Desires

Develop Concepts - Product - Process

Design Change

Design Actions

Test Plans - Design Verification IF Design OK

Yes

Packaging Designs

PFMEA - Manufacturing - Assembly

Mi s ta

ke

DFMEA DFMEA

Special Characteristics

Prototype Control Plan

Characteristic Matrix

Pre - Launch Control Plan - Risk/Action YES - Special Characteristics IF - Current Controls
NO

f?

Process Validation - Section IV

Process Trial Run Min 300 pcs/Hits/shots Validation Testing Plan
OK?

No

Develop Product Specifications - Linked to Customers

Process Validation Plan - Gage Plan - Capability Plan

Special Controls

Feasibility - Team

Instructions - Initial

GR & R - Gage Plan Repeatability Reproducibility

NO

No IF Feasible Yes

Design Risk Assessment - Open Issues - Spec. Agreements - Materials - Budget - Manufacturing - Program Risks

IF
YES

Process Risk Assessment

- Equipment - Gages - Controls - Instructions - Plans - Status of Open Issues

Process Development
Initial Process
Kick Off Tools / Equipment Gages
- Equipment Installation - Tooling Progress - Gage Design & Progress

Revisit III PFMEA For Additional Potential Failures

YES Can we change process to IF contain? NO

Statistics - Via Control Plans - Capability Plan

STABLE? NO

IF
YES

NO

CAPABLE?

IF
YES

Concept Initiation/Approval Program Approval Prototype Pilot Launch

Design Change Back to II

Sample The Process Create Production Control Plan

- Reduced (n) - Reduced (f) - Optimizing Characteristics - Source Warrants - Supporting Documentation - Level of PPAP

PLANNING PRODUCT DESIGN AND DEV. PROCESS DESIGN AND DEVELOPMENT. PRODUCT AND PROCESS VALIDATION.

PLANNING

PRODUCTION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

CONTROL PLANS

Open Issues / Time Line

REVISION: 030303

Concept

QFD
Market Research Customer Want - Fits my cup holder - wont leak

RELIABILITY BY DESIGN Tool Linkage

QAI Mug Example Specification
No noticeable leaks when filled 1/2 and toppled from a height of 3 ft. on carpet.

(313) 565 - 6266 US (888) FOR - FMEA CDN (877) 609-0999 AUS 011 61 (03) 9585 - 6423 www.quality-one.com

Significant Characteristics

Control Plan Can Do Feasibility Testing Design Verification

- Test # Drop 001 - Spring Rate/ .5 Lbs. - Fit Margins 1mm Max

3 Levels / Progressive - Prototype - Pre Launch - Production

Can we do this yes

Design/Development - DFA/DFM - FMEA

Function Sev. Occ. Det. 7 x 5 x 2 RPN = 70

Process Improvement - Tools - Machines (to reduce occurrence) Process Development P Flow FMEA
- Injection Molds (2) - Lid Features Sev. Occ. Det. 7 x 3 x 2 RPN = 42

Ford APQP Element

1) Sourcing Decision 2) Customer Input Requirements 3) Design FMEA 4) Design Review(s) 5) Design Verification Plan 6) Subcontractor APQP Status 7) Facilities, Tools, and Gages 8) Prototype Build Control Plan 9) Prototype Builds 10) Drawings and Specifications 11) Team Feasibility Commitment 12) Manufacturing Process Flow Chart 13) Process FMEA 14) Measurement Systems Evaluation 15) Pre - Launch Control Plan 16) Operator Process Instructions 17) Packaging Specifications 18) Production Trial Run 19) Production Control Plan 20) Preliminary Process Capability Study 21) Production Validation Testing 22) Production Part Approval (PSW) 23) PSW Part Delivery at MRD

Adjust to Optimize Cpk = Cp Process Capability

- Ppk > 1.67 for lid features - Actual 1.55 Ppk 2.50 Pp

Design Improvement to reduce occurrence or eliminate failure

Feasibility & APQP Checklists Completed QFD A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 Design FMEA Design Information New Equipment, Tooling & Test Equipment Product/Process Quality Floor Plan Process Flow Chart Process FMEA Control Plan

Software Tools Available - FMEA Builder - QFD Designer www.quality-one.com (313) 565 - 6266 1 (888) FOR - FMEA

Launch & Feed Back Continuous Improvement

- X & R Charts