Phase 1
Plan and Define the Program - Determination of customer needs, requirements and expectations using tools such as QFD Review the entire quality planning process to enable the implementation of a quality program How to define and set inputs and outputs.
Phase 2
Product Design and Development - Review inputs and execute outputs, including FMEA, DFMA, design verification, design reviews, material, and engineering specifications.
Phase 3
Process Design and Development - Addressing features for developing manufacturing systems and related control plans, these tasks are dependent on the successful completion of Phases 1 and 2 implement outputs.
Phase 4
Product and Process Validation - Validation of the selected manufacturing process and its control mechanisms through the evaluation of production performance outlining the mandatory production conditions and requirements that identify the required outputs.
Phase 5
Release, Feedback, Assessment and Corrective Action - Focuses on reduced variation and continuous improvement identifying outputs and links to customer expectations and future product programs.
Control Plan Methodology - discusses the use of the control plan and the relevant data required to construct and determine control plan parameters stresses the importance of the control plan in the continuous improvement cycle.
Control plan
The provider must:
- develop control plans for the system, sub-system, at the component and / or material level, as appropriate for the supplied product, have a control plan for pre-launch and production and also for the prototype when required by the customer use a multi-disciplinary treatment to develop control plans list in the control plan the controls used to control the process include the information required by the client in the control plan initiate the specific reaction plan when necessary appropriate.
NOTE 1 The control plan requirement covers processes that produce bulky materials such as steel, plastic resin, paint, and those that produce parts.
Control plans should be reviewed and updated appropriately, when any of the following occurs:
- the product is changed, the processes are changed, the processes become unstable, the processes become incapable, the inspection method, frequency, etc. is revised.
NOTE 2 Customer approval may be required.
Product approval process
The supplier must comply with a customer-recognized product and process approval procedure.
NOTE 1 Part approval is the final step in the product realization process and must be completed after the process is verified.
This product approval process should also apply to subcontractors.
NOTE 2 Where no customer procedure exists, such as Tier 3 suppliers, the supplier should comply with the part approval manuals listed in the bibliography.
The supplier must verify that the changes are validated, including all subcontractor changes.
All changes must require customer notification and may require customer approval. In proprietary designs, impact on form, fixture, function, performance, and / or durability should be reviewed with the customer so that all effects can be properly evaluated.
When required by the customer, additional verification / identification requirements such as those required for the introduction of a new model must be met.
Plant, facility and equipment planning.
The supplier must use a multi-disciplinary treatment for development plans of plant facilities and equipment. Plant layouts must minimize material flow and handling, facilitating the synchronized flow of material and optimizing the added value of the use of space. Methods should be developed to evaluate the effectiveness of existing operations considering the following factors:
- work plan appropriate automation ergonomic and human factors balance between operator and line storage levels and safety stock inventoried value-added labor content.
NOTE The supplier should identify and define appropriate metrics to monitor the effectiveness of existing operations.
Multidisciplinary treatment
The supplier will use a multidisciplinary treatment to prepare the realization of the product, including:
- development / completion of special features development and review of FMEAs including actions to reduce potential risks development and reviews of Control Plans
