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Alliance New Product Quality Procedure

Version 3.0 Training


day 2
Training Agenda

Day 1:
Introductions & Objectives
General Outline
ANPQP structure
Using ANPQP
Categories details 1,2,3 and 4
University challenge

Day 2:
Categories details 5,6,7,8,9,10 and 11
How to work with Nissan.
How to work with Renault.
University challenge
Expectation review.
Exam/course evaluation
2
Alliance New Product Quality Procedure

Day 1 Review
Review of Day 1

1. What is the application scope of ANPQP?


Vehicle parts, Modular assemblies, Powertrain parts/units, Service parts.

2. What are the part development milestones?


RFQ, nomination letter, design release, part approval

3. What are the Ground Rules of Document


Submission?
Document submission level,
Document submission timing,
Document revision record,
Document record retention.

4
Review of Day 1

4. What are the Renault and Nissan Special


Characteristics?
Renault CSR and Nissan Important A, B, C and OBD

5. What is the purpose of the Special Characteristics


and Key Features Diagram
To document all Special Characteristics and Key Features

6. What does DRBFM stand for?


Design Review Based on Failure Modes

5
ANPQP Category 5

Manufacturing Process Development


5 - Manufacturing Process Development

Category Purpose:

 Design a manufacturing process to meet Renault /


Nissan’s requirements for QCD:

– Ensure that the manufacturing process will be capable of


producing the required product quality level

– Ensure that the manufacturing process will be capable of


producing the required quantity of products

7
5 - Manufacturing Process Development

5.1 Process Failures Mode and Effect Analysis

5.2 Manufacturing Process Design

5.3 Tooling, Gauges & Facility Management

5.4 Process Capability Study and Improvement

5.5 Confirmation of Full Volume Conditions

5.6 Activities during Ramp-up

5.7 Identification and Traceability

8
5 - Manufacturing Process Development

Timing:
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5
5.1 Process Failure Mode
& Effects Analysis
5.2 Manufacturing
Process Design
5.3 Tooling, Gauges &
Facility Management
5.4 Process Capability
Study and Improvement
5.5 Confirmation of Full
Volume Conditions
5.6 Activities during
Ramp-up
5.7 Identification and
Traceability

9
5 - Manufacturing Process Development

5.1 Analysis of Process Potential Failures and Effects

5.2 Manufacturing Process Design

5.3 Tooling, Gauges and Facility Management

5.4 Process Capability Study and Improvement

5.5 Confirmation of Full Volume Conditions

5.6 Activities during Ramp-up

5.7 Identification and Traceability

10
5 – Manufacturing Process Development
5.1 – Analysis of Process Potential Failures and Effects

Activity Purpose:
 Identify potential process failure modes, their associated causes
and their effects
 Implement effective countermeasures to minimize the probability
of failure occurring

Notes:
The supplier must consider historical concerns, recurrence prevention,
and customer satisfaction targets on assemblies and sub-assemblies /
components when deciding the scope of the activity

11
5 – Manufacturing Process Development
5.1 – Analysis of Process Potential Failures and Effects
Renault Supplier
Nissan
Product Prepare PFMEA and relevant documents
Technical
Specifications
Review the PFMEA and
Identify Potential
Countermeasures

Review Update the Prevention Implement


PFMEA Activities Countermeasures

Confirm Countermeasure
Effectiveness

12
5 – Manufacturing Process Development
5.1 – Analysis of Process Potential Failures and Effects

What happens if the activity is not carried out


correctly?

Failure to identify and action potential concerns at the correct


timing leads to:
 Increased potential to manufacture and deliver non-
conforming product.
 Failure to meet reliability and durability requirements
 Increased necessity to modify product design during
manufacturing process development

Failure to Achieve Customer Requirements

For details of how to correctly perform this activity, attend a specific


training course on Potential Failure Modes and Effects Analysis.

13
5 – Manufacturing Process Development
5.1 – Analysis of Process Potential Failures and Effects

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H

Process Potential FMEA 3 3 2

14
5 - Manufacturing Process Development

5.1 Process Failure Mode and Effects Analysis

5.2 Manufacturing Process Design

5.3 Tooling, Gauges and Facility Management

5.4 Process Capability Study and Improvement

5.5 Confirmation of Full Volume Conditions

5.6 Activities during Ramp-up

5.7 Identification and Traceability

15
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Activity Purpose:
 Design a manufacturing process to achieve all Renault / Nissan
Quality, Cost and Delivery targets.

Key Points of Activity:


 For manufacturing process design to be effective, a thorough
understanding of the main stages of the activity is necessary.

16
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Main Stages of Manufacturing Process Design:

What to control Special Characteristics


IDENTIFY & Key Feature Diagram
Where to control

PFMEA
ANALYSE How to control
How often to control MSA

Maintenance
MANAGE How to ensure control
What to do if out of control Non-Conformance
Procedure
DOCUMENT Record & communicate the
output of the above stages

17
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Process Flowchart – A schematic layout of the


complete process
Floorplan Layout – Document to
show the facilities installation and
product flow

Matrix Quality Assurance –


document which demonstrates that no
process failing will reach the customer

Control Plan – description of all


product and process control
operations implemented in the
production process

Work Instructions – defines the actions required to


carry out an operation
18
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Process Flowchart

 Does the flowchart illustrate the entire process from receiving


through shipping, including outside processes and services?

 Is the flowchart consistent with the product and process checks in


the control plan?

 Does the flowchart describe how the product will move i.e. roller
conveyor, slide containers, etc?

 Have provisions been made to identify and inspect reworked


product before being used?

19
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Floor Plan Layout

 Does the floor plan identify all required process and inspection
points?

 Have clearly marked areas for all material, tools and


equipment at each operation been considered?

 Has sufficient space been allocated for all equipment and


personnel?

 Are inspection points located to prevent shipment of


nonconforming products?

20
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Control Plan

 Have all the controls identified in the PFMEA been included in the
control plan?

 Are all Special Characteristics and Key Features included in the


control plan?

 Does the control plan include all processes from receiving


through to shipping, including packaging?

 Are material specifications requiring inspection identified?

 Are engineering performance testing requirements identified?

21
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Work Instructions

 Have all main steps required


 to complete the operation been included?

 Have all key points/care points and the reasons for them been
included?

 Do the work instructions include inspection requirements,


inspection criteria and reaction instructions?

 Are all Special Characteristics and Key Features identified in the


work instructions?

 Are photographs/sketches used to support operation


descriptions?

22
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Matrix Quality Assurance


• Objective :
Apply protective solution as near as possible of the operating step and
check its robustness and efficiency every day
• Key point :
To stop all Product Quality Defect, and to insure that the customer will be
protected, as long as the solutions avoiding the causes roots are not in
place.

• Implementation:
P/S
P/S : to list the defects
According to PDCA principle,
D : to apply adapted protective solutio
integrate the priority defects, to standardize them
set up the protections,
standardize them, measure A MQA
D C : To check the robustness of the
applied solutions
their efficiency, correct.
C A : To improve the situation

23
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Manufacturing Process Design


Exercise

24
Manufacturing Process Design Exercise

Exercise type:
• Group (3-4 people)

Materials Required:
• Example documents for Control Plan, Process Flowchart, Floor Plan Layout &
work Instruction
• Flipchart & pens

Instructions:
• Analyse the documents provided to find errors.
• Categorise the errors found based on the 4 main stages of the process –
Identify, Analyse, Manage, Document.
• Each group should write their findings on a flipchart
• Review all groups findings together before revealing answer slides
• After answers are revealed, compare Floor Plan Layout example to DCI to
reinforce the purpose of the DCI.

Time Allowed:
25
• 30-45 minutes
Manufacturing Process Design Exercise

The part:
MAST-Assy
( Tier2 Parts)

CASE-BODY Assy
( Tier2 Parts)

Assemble
PCB-Assy
( Tier2 Parts) Tier1 : AZ Electronics Company

ROOF-ANT Assy

BASE Assy with FEEDER


( Tier2 Parts)

26
Manufacturing Process Design Exercise

By studying the documents provided, find evidence of


where the supplier has failed to correctly carry out the
main stages of the manufacturing process design
activity:
What to control
IDENTIFY
Where to control
How to control
ANALYSE
How often to control
How to ensure control
MANAGE
What to do if out of control

DOCUMENT Record & communicate the


output of the above stages
27
Manufacturing Process Design Exercise

Identify the Weaknesses – Stage 1:

L
What to control
IDENTIFY
Where to control

• No identification of Special Characteristics or Key


Features on any document.

• Work Instruction indicates 3 different part variants but


Process Flowchart and Control Plan do not.

• Inspection occurs after every key process step except


OP10.

28
Manufacturing Process Design Exercise

Identify the Weaknesses – Stage 2:

L
How to control
ANALYSE
How often to control

• Work Instruction for INSP6 covers appearance


inspection, but Control Plan indicates electrical function
test.

• Work Instructions are listed as control methods on the


Control Plan.

• All manufacturing steps have 100% inspection except


the final assembly check.

29
Manufacturing Process Design Exercise

Identify the Weaknesses – Stage 3:

L
How to ensure control
MANAGE
What to do if out of control

• No reference to the calibration or maintenance of any of


the control methods.

• Control plan references “Rework” as a reaction plan but


there is no indication of a rework area on the Process
Flowchart or Floorplan Layout.

• Work Instruction has a rule for dropped parts but this


rule does not appear on any other document.

30
Manufacturing Process Design Exercise

Identify the Weaknesses – Stage 4:

DOCUMENT Record & communicate the


output of the above stages L
• INSP5, Labelling and the 2nd Packing operation appear
on the Process Flowchart but not on the Control Plan.

• Floorplan Layout does not indicate areas for material,


tools, equipment, staff etc.

• The core team consists of 1 person.

31
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Key points on documentation:

 If the Manufacturing Process Design activity is done correctly,


the output documents should link together to form a
coherent set.

 The links to other activities such as Identification of Special


Characteristics and Key Features on Analysis of Process
Potential Failure Modes and Effects etc. should be evident
from the documentation

 All submitted documents need to satisfy the minimum


content requirements as specified in each of the DCI’s.

32
5 – Manufacturing Process Development
5.2 – Manufacturing Process Design

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H

Control Plan (CP) (2) (2) (2) 3 2 2 1 1 1

Matrix Quality
(2) (2) (2)
Assurance (MQA) (R)
Process Flow Chart
(2) (2) (2) 3 2 2 2 2 2
(PFC)

Floor Plan Layout (FPL) 3 3 3 3 3 3

Work Instructions (WI) 3 3 3

33
5 - Manufacturing Process Development

5.1 Process Failure Mode and Effects Analysis

5.2 Manufacturing Process Design

5.3 Tooling, Gauges and Facility Management

5.4 Process Capability Study and Improvement

5.5 Confirmation of Full Volume Conditions

5.6 Activities during Ramp-up

5.7 Identification and Traceability

34
5 – Manufacturing Process Development
5.3 – Tooling, Gauges and Facility Management

Activity Purpose:
 The supplier must manage all necessary equipment to ensure
that Renault / Nissan requirements are achieved and maintained.

Key Points of Activity:


 The supplier must ensure that all equipment is capable, reliable
and in a stable condition during use.

– Equipment includes, but is not limited to, machinery, tools,


gauges, inspection and test equipment.

35
5 – Manufacturing Process Development
5.3 – Tooling, Gauges and Facility Management

Create a plan
Specify the related to the Implement Validate the
required procurement of the the plan equipment, tools,
Supplier

equipment equipment dies and gauges

Gauge Specification Gauge Approval

Sheet Sheet
Renault
Nissan

Review Review /
Technical
Approve
Specifications

36
5 – Manufacturing Process Development
5.3 – Tooling, Gauges and Facility Management

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H
Gauge Specification and
3 2 2 3 1 1
Approval Sheet (GSAS)

37
5 - Manufacturing Process Development

5.1 Process Failure Mode and Effects Analysis

5.2 Manufacturing Process Design

5.3 Tooling, Gauges and Facility Management

5.4 Process Capability Study and Improvement

5.5 Confirmation of Full Volume Conditions

5.6 Activities during Ramp-up

5.7 Identification and Traceability

38
5 – Manufacturing Process Development
5.4 – Process Capability Study and Improvement

Activity Purpose:
 Evaluate, monitor and manage process capabilities in order to
continuously achieve Renault / Nissan targets.

Note:
 All product shall be subjected to additional confirmation activities
until capability requirements are achieved
 The supplier shall continuously monitor and reduce variation in both
product and manufacturing process characteristics.

39
5 – Manufacturing Process Development
5.4 – Process Capability Study and Improvement

Identify characteristics Create the Measure, monitor and


Supplier

whose process capabilities Capability improve process


shall be evaluated Study Plan capability

Process Process
Capability Capability
Study Plan Study Result
Renault/Nissan

Technical
Specifications Review Review

40
5 – Manufacturing Process Development
5.4 – Process Capability Study and Improvement

Quality Target

Renault/Nissan requires all products / parts to be free from defects

Capability Process & Target


Index Nissan Renault
Quality Target All products / parts to be The requirement is different if
free from defects the bought-out is a Vehicle
Process Capability Cpk engineering part or a powertrain
Studies & Minimum  Normal Characteristics part.
Target >1.0 See
 Special Characteristics https://suppliers.renault.com
>1.33 then clic Quality/Get a
(Important A, B, C, OBD and standard/Download Tools
other notified specific cases)

41
5 – Manufacturing Process Development
5.4 – Process Capability Study and Improvement

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H
Process Capability Study
3 2 2
Plan (PCSP)
Process Capability Study
(2) 2 2 (2) 2 2 (2) (2) (2)
Results (PCSR)

42
5 - Manufacturing Process Development

5.1 Process Failure Mode and Effects Analysis

5.2 Manufacturing Process Design

5.3 Tooling, Gauges and Facility Management

5.4 Process Capability Study and Improvement

5.5 Confirmation of Full Volume Conditions

5.6 Activities during Ramp-up

5.7 Identification and Traceability

43
5 – Manufacturing Process Development
5.5 – Confirmation of Full Volume Conditions

Activity Purpose:
 Conduct a manufacturing trial to confirm that the process
achieves Renault / Nissan targets

Note:
 Examples of manufacturing trial are:
– Run @ Rate trial
– significant production trial
– line speed demonstration
– T2000
– Capacity Audit

44
5 – Manufacturing Process Development
5.5 – Confirmation of Full Volume Conditions
Supplier

Conduct and manufacturing trial Review and audit the


that represents mass production process during the trial.
conditions

Full Volume
Confirmation Audit
Results – Self Audit
Renault/Nissan

Observe / participate if required


Review

45
5 – Manufacturing Process Development
5.5 – Confirmation of Full Volume Conditions

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H
Full Volume
Confirmation Audit 3 3 3
Results (FVCAR)

46
5 - Manufacturing Process Development

5.1 Process Failure Mode and Effects Analysis

5.2 Manufacturing Process Design

5.3 Tooling, Gauges and Facility Management

5.4 Process Capability Study and Improvement

5.5 Confirmation of Full Volume Conditions

5.6 Activities during Ramp-up

5.7 Identification and Traceability

47
5 – Manufacturing Process Development
5.6 – Activities During Ramp-up

Activity Purpose:

• Plan and implement additional activities to ensure quality and


delivery requirements are maintained during the launch period.

Key Points of Activity:

• The activities during ramp-up have two distinct objectives:


-achievement and maintenance of the quality requirements
-achievement and maintenance of the delivery requirements

• The Ramp-up activity shall have clearly specified exit criteria.

48
5 – Manufacturing Process Development
5.6 – Activities During Ramp-up

Determine the activities Monitor the progress


Obtain agreement with
required to assure quality and of the ramp-up
Renault / Nissan to stop
delivery during the ramp-up activities until exit
ramp-up activities
period criteria is achieved
Supplier

Establish clear exit criteria Investigate concerns


for the activities and implement
countermeasures
where required
Create and implement a
ramp-up activity plan that will
achieve both the quality and
delivery requirements
Ramp-up Activity
Ramp-up Activity Concern and
plan Countermeasure
Report
Renault
Nissan

Review Review Agree

49
5 – Manufacturing Process Development
5.6 – Activities During Ramp-up

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H

Ramp-Up Activity Plan 3 2 2

Ramp-up Activity
Concern and (2) (2) (2)
Countermeasure Report

50
5 - Manufacturing Process Development

5.1 Process Failure Mode and Effects Analysis

5.2 Manufacturing Process Design

5.3 Tooling, Gauges and Facility Management

5.4 Process Capability Study and Improvement

5.5 Confirmation of Full Volume Conditions

5.6 Activities during Ramp-up

5.7 Identification and Traceability

51
5 – Manufacturing Process Development
5.7 – Identification and Traceability

Activity Purpose:
 To ensure that all products / parts are identified and controlled for
traceability purposes.

Key Points of Activity:


 Identification and traceability requirements may be specified on
the Renault-Nissan approved drawings and/or data notes.

 The Tier 1 supplier shall:


– manage traceability for all products and components
delivered to Renault/Nissan facilities.
– deploy the identification and traceability requirements to
their sub-suppliers
 Renault and Nissan have specific requirements for identification and
traceability (for Nissan, refer to the unique requirements for each
main Nissan region)
52
5 - Manufacturing Process Development

5.1 Analysis of Process Potential Failures and Effects

5.2 Manufacturing Process Design

5.3 Tooling, Gauges and Facility Management

5.4 Process Capability Study and Improvement

5.5 Confirmation of Full Volume Conditions

5.6 Activities during Ramp-up

5.7 Identification and Traceability

53
ANPQP Category 6

Product Confirmation
6 - Product Confirmation

Category Purpose:

 Verify that the product design meets Renault / Nissan requirements

 Validate that the products made from production tools and


processes meet the Renault / Nissan requirements

55
6 - Product Confirmation

6.1 Design Verification and Product / Process Validation

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5


6.1 Design Verification
and Product / Process
Validation

56
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

Activity Purpose:
The supplier shall carry out:

 Simulations or tests to ensure that the product design meets


Renault / Nissan design requirements (Design Verification).
 Tests to confirm that the design verification results have not
been compromised by the production process (Product /
Process Validation).
 A series of production trials in order to provide measured
sample parts for use in Renault/Nissan assembly activities.

57
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

Create a Design Perform Design Perform Product / Perform


Verification and Verification Process Validation Continuous
Supplier

Product/ Process activities as activities as Conformance


Validation plan planned and planned and Testing as planned
report results report results and report results

Supplier Digital Test Report


Supplier Test Plan and Report
Renault/Nissan

Inspection Report

Technical Review / Approve


Specification

58
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

Supplier Digital Test Report:

DD Lot Results DF Lot Results DFC Lot Results

Test Details

59
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

Supplier Test Plan & Report:

Engineering Product/Process
Development Results Design Verification Validation Results
(where applicable) Results (Off Tool) (Off Process)

Test Details

Ongoing Test Frequency


Predicted Results
60
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

INSPECTION REPORT
Activity Purpose:

 Describes the product compliance with the specifications, and how


the part is produced

Key Points of Activity:


 The Supplier gives information on the part (including any comment,
e.g. on definition, for use, etc.)
 The Supplier signs off
Note:
To be applied to any part batch (prototype, off tool, off process) which
will be delivered to Renault/Nissan
Format mandatory
61
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

The Supplier gives detail about the Part


Product Yes No Comments (if "No" explain)
Part complies with the drawing issue level released in the system

Part is grained
Raw material is mass production

IMDS data validated by R/N IMDS


Report of IMDS ID Number (When there are plural parts for this IR, use part number detail)

Part is OK (Inspection Report, Supplier Test Plan and Report)

Manufacturing Status Definitive Not Definitive Comments


Plant

Assembly line
Operators

Process Instructions & Production facilities Definitive Not Definitive Comments


Control Plan / Process Flow Chart

Work Instructions
Toolings
Inspection facilities (gauges…)
Specific facilities (production facilities…)
Parameters / Process tuning
Full Capacity facilities
Cycle time

62
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

Example: comments on most critical sub supplier


components status

Logistics & Packaging

Inspection Report copies should be delivered with the part

63
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

APPEARANCE APPROVAL
Activity Purpose:
 Confirm that product meets Renault / Nissan appearance
requirements.
 Obtain Appearance Approval from Renault / Nissan

Key Points of Activity:


The product / part to be reported upon will be agreed with the Renault /
Nissan relevant department prior to submission and will normally be
either:
 Grained or other textured finish.
 Painted or other colored finish.

64
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

Appearance Approval Report:

Information from Colour Computer Results Visual Colour Assessment


Master Plaque (if applicable) (Supplier & Nissan)

Approval by Supplier Gloss Measurement Comments


Results

65
6 – Product Confirmation
6.1 – Design Verification and Product / Process Validation

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H

Supplier Digital Test Report (2) (2) (2) 2

Supplier Test Plan and


2 2 2 2 2 2
Report

Inspection Report (2) (2) (2) 2 2 2 2 2 2

Appearance Approval
(1) (1) (1)
Report (N)

66
ANPQP Category 7

Production Part Approval


7 - Production Part Approval

Category Purpose:

 Confirm that off-process products meet Renault / Nissan QCD


targets at full volume condition

PPA

68
7 - Production Part Approval

7.1 Production Part Approval

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5


7.1 Production Part
Approval

69
7 - Production Part Approval
7.1 - Production Part Approval

Activity Purpose:
 Confirm that product and mass production process meets
Renault/Nissan requirements
 Obtain Production Part Approval from Renault / Nissan

Key Points of Activity:


 Mass production starting in supplier is not acceptable until
Production Part Approval is provided.
 Shipment of product to Renault/Nissan is acceptable only after the
Part Submission Warrant is approved.
 Renault/Nissan not fully approve PSW until report of Confirmation of
full volume conditions is provided.

70
7 - Production Part Approval
7.1 - Production Part Approval

Plan & implement Start Shipment


countermeasure actions of Parts
to obtain full approval

Start Mass
Supplier

Complete and
submit the PSW Identify reason Production
with all necessary for failure to
supporting achieve full
documentation approval

Part Submission Warrant


& supporting documents
Renault/Nissan

Rejection Interim Approval Approval

Review

71
7 - Production Part Approval
7.1 - Production Part Approval

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H
Part Submission
1 1 1
Warrant

72
ANPQP Category 8

Non Conforming Product Management


8 - Non Conforming Product Management

Category Purpose:
 Implement a process that provides prompt and systematic activities
to:

 identify the root cause of the concern,

 implement robust countermeasures for identified Non-


Conforming product

 prevent further delivery of Non-Conforming Product.

74
8 - Non Conforming Product Management

Activity:

8.1 Non Conforming Product Management

Timing:

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5


8.1 Non Conforming
Product Management

75
8 - Non Conforming Product Management
8.1 - Non Conforming Product Management

Activity Purpose:
 When non conforming product is identified, the supplier must have
a process that provides prompt and systematic activities to
identify the root cause of the concern, implement robust
countermeasures and prevent delivery of further suspect
product.

Key Points of Activity:


 Renault/Nissan require suppliers to provide product with
zero defects.

76
8 - Non Conforming Product Management
8.1 - Non Conforming Product Management

Implement Determine root


immediate causes using Deploy
Confirm the countermeasures
temporary suitable methods
effectiveness of to similar parts
countermeasures and implement
all /processes
Supplier

, inc. segregation permanent


countermeasur
of suspect countermeasures
es implemented
product in the
supply chain.
Update relevant
documentation

8D Concern and Countermeasure Report Summary


& supporting documents
Renault/Nissan

Notification of
Concern Review

77
8 - Non Conforming Product Management
8.1 - Non Conforming Product Management

Example : 5 Why Analysis


1. Analyse the concern from 2 perspectives:
- Why was the defect made?
- Why was the defect not found?
2. Clearly state the problem
- Avoid using non-specific adjectives such as “broken”
3. Do not jump to conclusions
4. Review every step from a 4M perspective
5. There can be many answers to each level of why. Each
of the answers need to be investigated in order to
determine all of the possible root causes.

A PROBLEM THAT CANNOT BE REPRODUCED IS A


PROBLEM THAT HAS NOT BEEN RESOLVED YET.

78
8 - Non Conforming Product Management
8.1 - Non Conforming Product Management
t0 t0 + t0 + t0 +
Incident claim sent
48Hours max 10Days max 30Days max
by RENAULT with
supplier admitted S S S
liability Olivier  Nishimura-san

80 + 81  80 R R R

1 2 3 4 5 6 7 8
Initial Perma- Follow up
Concern Similar Part Temporary Final Action
Analysis nent action
Details Conside- Imediate analysis confirmati
(of non Action Standardiz
ration Action on
detection) ation

P D C A

S Supplier Responsibility : Communicate 8D & enclose evidence

R RENAULT Plant SQA / Logistics Department Responsibility : validation of the


efficiency of the action plans (questions or if needed 8D audit)

79
8 - Non Conforming Product Management
8.1 - Non Conforming Product Management EUR

Rank
A B
General Vehicle / Powertrain
Definition Important Product / Part Concern
Product / Part concern
Excluding items in Rank A, any
A concern on a Special product / part that is non-
Description
Characteristic conforming to the agreed
specification.
Fax / E-mail / Telephone Response required within Response required within
reply 24 hours 24 hours
Response required within Response required within
8D-CCR reply
30 days 30 days
Detailed root cause
Yes Yes
analysis required
Nissan Audit / Review Yes Depending upon concern
Supplier 8D-CCR
Yes Depending upon concern
presentation at Nissan

80
8 - Non Conforming Product Management
8.1 - Non Conforming Product Management JPN
Supplier response requirements:
Rank
A B C
Damage for
Concern which has a
Concern relating to merchantability or
Judgment Criteria risk for Safety or
Safety or Regulation high dissatisfaction
Regulation
with customers

Non-conformance Non-conformance Non-conformance


Definition which does not comply which may not comply relating to
with Regulation with Regulation merchantability

Fax/E-mail/Telephone
Within 24 hours Within 24 hours Not required
reply
Within 10 working Within 10 working Within 10 working
8D-CCR reply
days. days. days.
Depending upon Depending upon
Nissan Audit / Review Yes
concern concern

Supplier 8D-CCR Depending upon Depending upon


Yes
presentation at Nissan concern concern

81
8 - Non Conforming Product Management
8.1 - Non Conforming Product Management NA

Supplier response requirements


 Response requirements to nonconforming material varies from plant to
plant.
 It is recommend to work with the NNA or NMEX facility to determine the
type of response required and the timing.

82
8 - Non Conforming Product Management
8.1 - Non Conforming Product Management

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H
8D Concern and
Countermeasur e Report (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2)
Summary

83
ANPQP Category 9

Change Management
9 - Change Management

Category Purpose:
 Manage potential risks associated with changes to product, process
and/or facility site

Activities:

9.1 Design Change Management

9.2 Process / Facility Site Change Management

85
9 - Change Management

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5


9.1 Design Change
Management
9.2 Process/ Facility Site
Change Management

86
9 - Change Management

Basic Change Management Requirements


The supplier shall have a change management system which includes:
 Scheduling & planning for the change
 Risk analysis & management
 Product Verification & Validation activities

Renault/Nissan will identify/confirm the ANPQP activities which will


need to be carried out in order to implement the change and confirm
its successful adoption.

Once the adoption of the change is confirmed as successful,


Production Part Approval from Renault/Nissan is mandatory
before shipment of any change affected product.

87
9 - Change Management

REMINDER
The supplier must inform Renault/Nissan and obtain agreement
about any change relative to its commitments, e.g. :

 Product, material,
 Process,
 Control Plan, Gauges,
 Facility site change/transfer/relocation,
 Change within/to a tier n supplier (facility site change, resourcing,
including changes to sub-supplied services as heat treatment, …)
 Delivery/loading site/warehouse change,
 Organisation,
 ...

88
9 - Change Management

Before the change decision:


-Risk analysis of change
-Detailed schedule of all activities to be carried out
-Cost impact

-New Production Part Approval required

Design Change Process/Facility


Site Change

89
9 - Change Management

9.1 Design Change Management

9.2 Process / Facility Site Change Management

90
9 – Change Management
9.1 - Design Change Management

Activity Purpose:
 Manage the introduction of Design Changes in order to ensure that
there is no negative impact on quality, cost or delivery.

Key Points of Activity:


 Design Change Management covers all design changes made by
the tier 1 supplier or their supply chain
 Design changes include any change affecting the form, fit,
function, performance and/ or durability of a part.
 Authorisation to proceed with any change is only given through the
issue of an approved design note by Renault/Nissan.

91
9 – Change Management
9.1 - Design Change Management

Renault/Nissan Supplier
Review Design Change
Request Prepare and submit Design Change Request
Y
Y
Joint DR? Joint DR
Amend
Proposal? End

Approval?

Y
CAD Update and submit CAD data & associated
documents
Y
Approval ?
Y Design Note Implement activities required to introduce change
Release
D-Note Prepare and submit documents required for part
Part Submission
Warrant approval
Approval?

Y Supply of post change product

92
9 – Change Management
9.1 - Design Change Management

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H
Design Change Request
(1) (1) (1) (1) (1) (1) (1) (1) (1)
(DCR)

93
9 - Change Management

9.1 Design Change Management

9.2 Process / Facility Site Change Management

94
9 – Change Management
9.2 – Process/Facility Site Change Request

Activity Purpose:
• To manage the introduction of Process / Facility Site changes in
order to ensure that there is no negative impact on quality, cost or
delivery.

Key Points of Activity:


• The scope of Process / Facility Site Change Management covers all
changes made by the tier 1 supplier or their supply chain.
• The supplier must ensure that all requests for Process/ Facility site
changes are authorized by Renault / Nissan prior to any change
taking place.

Important note: For Process Changes, the Process/Facility Site Change


Request document shall be submitted at least 3 months before
initiation of any physical change or move, unless otherwise
agreed with Renault/Nissan.

95
Process/Facility Site Change
Management Exercise
Exercise
Process / Facility Site Change Management

Exercise type:
• Group (4—6 people)

Materials required:
• Flipchart & pens

Instructions:
• In groups, make a list of the activites that should be done
before a change takes place and after a change takes place.
• Review all groups lists together before revealing the answer
slides

Time Allowed:
• ~20 minutes

97
Exercise
Process / Facility Site Change Management

List items to consider:

Before a change takes place

After a change takes place

98
Exercise
Process / Facility Site Change Management

Items to consider before the change:


– Process Change Request (PCR)
– Detailed Project Plan
– QMS evaluation / ASES audit
– Updated Capability, Process Flow, Floor Plan
– Updated Control Plan and PFMEA
– Test Plans
– Implementation and Verification of all Countermeasures
– Translations
– Training Plan
– CSCC
– Security stock build requirements
– Ramp-up plan
– Packaging
– ……. 99
Exercise
Process / Facility Site Change Management

Items to consider after the change:


– Part Submission Warrant (PSW) and all related
Documentation
– Parts for Functional Trial Run (if required)
– Run-at-Rate
– Capability study, Process Flow and Floor Plan
– Updated Control Plan and PFMEA
– Test Reports
– Re-ASES (if necessary)
– CSCC
– Inspection Report
– ……..

100
9 – Change Management
9.2 - Process - Facility Site Change Request

Renault/Nissan Supplier
Review Process Change Prepare & submit Process/ Facility Site
Request Change request
Y
Determine Change
Contingency Reqmts Amend
Proposal? End

Approval? Include contingency requirements in


Y change plan
Review Part Submission
Implement change as planned
Warrant
Y
Req. Audit? Conduct Prepare & submit documents required for
audit part approval
Approval?

Y
Authorise supply of
Supply of post change product
post change product

101
9 – Change Management
9.2 - Process - Facility Site Change Request

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H
Process/ Facility Site
(1) (1) (1)
Change Request

The supplier shall not carry out any facility site transfers between
the suppliers' initial "off-process" trials and SOP.

102
ANPQP Category 10

Logistics & Packaging


10 - Logistics & Packaging

Category Purpose:
 Implement Renault/Nissan specific requirements for logistics &
packaging

 Select the best logistics option & packaging specifications to ensure


the conformity of the product.

Notes:
- The documentation used to communicate the content of this activity
with Renault/Nissan is specific by each company.
- For detailed guidelines on specific requirements, see the "Other
Supply Requirement" on ASG (Alliance Supplier Guide))

104
10 – Logistics and Packaging
10.1 - Logistics and Packaging

Activity:

10.1 Logistics and Packaging

Timing:

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5


10.1 Logistics &
Packaging

105
10 – Logistics and Packaging
10.1 - Logistics and Packaging
What is purpose of the output from this activity?
– Validate Packaging & logistics capability to preserve Parts
quality.

What happens if this activity is not done?

Don’t bend Rubber


parts acutely.

Rubber parts must be


creases bent obtusely.

106
ANPQP Category 11

Environemental Requirements
11 – Environmental Requirement

Activities:

11.1 Environmental Requirement

Timing:

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5


11.1 Environmental
Requirements

108
11 - Environmental Requirements
11.1 - Environmental Requirements

Activity Purpose:
To confirm that the supplied products conform with the
environmental regulations of each market.

Key Points of Activity:


• The supplier shall inform Renault/Nissan of the different materials
contained within their products.
• The supplier shall confirm the specific requirements for this activity
with Renault or Nissan in order to ensure that their products:
– Comply with the relevant environmental requirements for
chemical content.
– Comply with the relevant regulations relating to the use of
recycled and recyclable materials, including marking of specific
material types.

Note:
IMDS ID nbr needs to report with Inspection Report

109
11 - Environmental Requirements
11.1 - Environmental Requirements

What is IMDS (International Material Data System)?


It is an internet portal in which the Suppliers can declare the raw materials and
substances used in the parts delivered to Renault / Nissan

Principle of IMDS :
Successive sending of material and substances declarations:
① Request for Request for Request for ① Request for
declaration declaration declaration Declaration

Proposes a Proposes a Proposes a ② Proposes a


Declaration Declaration Declaration Declaration
TIER N TIER N-1 TIER 2 TIER 1

③ Accept (or reject) Accept (or reject) Accept (or reject) ③ Accept (or reject)
the Declaration the Declaration the Declaration the Declaration
 The Declaration are completed and implemented until the part is in its final definition.
 Each Supplier can accept or reject the Declarations proposed by TIER N Suppliers

110
11 - Environmental Requirements
11.1 - Environmental Requirements

Output Documents & Submission Timing

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5

L M H L M H L M H L M H L M H
International Material
1 1 1
Data System (IMDS)

111
University Challenge
University Challenge

Exercise type:
• Group (half of class)

Materials required:
• Flipchart & pens

Instructions:
• Split the class into 2 teams.
• Each team must write down 5 questions about ANPQP that they want the other team
to answer on a flipchart.
• Once the questions are completed, hold a quiz with the Trainer as a referee. Trainer
to keep track of scores from day 1 and 2 to determine overall winner

Rules:
• Each team has 15 minutes to come up with 5 questions. The opposition team gets a
point for every question missing after 15 minutes.
• Swap questions and allow a further 5 minutes for revision before starting the quiz.
• If a team gets a question wrong, the other team gets a point unless they do not know
the correct answer to the question.

113
ANPQP in Action
ANPQP in Action

Nissan Purchasing Nissan Design &


Development

Supplier Cross-functional Team

Nissan Parts Quality Nissan Parts Quality Nissan Production


Engineering Assurance Control / SCM
115
ANPQP in Action

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5


Purchasing Purchasing Purchasing Purchasing Purchasing
Design & Design & Design & Design & Design &
Development Development Development Development Development
Supplier Parts Quality Parts Quality Parts Quality Parts Quality
Quality Engineering Engineering Engineering Assurance
Assurance
Production Production Production Production Production
Control / SCM Control / SCM Control / SCM Control / SCM Control / SCM

116
ANPQP Milestones vs. Nissan
Project Milestones
Vehicle Production Trial with
Issue of Spec. Off-Tool Parts to confirm
Part
Issue of RFQ
Tender achievement of Design targets
Submission
(S-Lot or V3P Process)
Warrant

Design Data Vehicle Production Start of


Issue of Trial with Off Production
Release
Nomination Process Parts
Letter (S-Lot or V3P
Process)
117
ANPQP in Action

 ANPQP provides a framework for core tools and


processes that are common throughout the
automotive industry
 ANPQP is designed to be used by cross functional
teams.
 Within Nissan, cross functional project teams are
established to manage ANPQP.
 For a successful product launch, the supplier must also
establish a cross functional project team.
 Management of each project milestone and the
progress towards it is essential in both Nissan and
the supplier companies.

118
ANPQP in Action
ANPQP in Action - Renault

A Department is globaly responsible for one Phase or more.

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5


Purchasing Purchasing Purchasing Purchasing Purchasing
Design & Design & Design & Design & Design &
Development Development Development Development Development
Supplier Supplier Quality Supplier Quality Supplier Quality Supplier
Quality Assurance Assurance Assurance Quality
Assurance Assurance

120
ANPQP in Action - Renault
Product Supplier Test Plan & Reports
Product AMDEC
Definition
FTA
AFB / AFT Inspection Reports

Product Engineering Drawing


Definition / Special
Characteristics & Key Product/Process Confirmation
Functional Features Diagram
Drawings

Specification Capability Capability


Résultats study
Etude
s Capability
CapabilityStudy
Study
HCPP Study Plan de Results
Capabilité
Results
Results
Plan Etude de ProcessFab
Synoptique Flow
& Chart
Contrôle
Supplier Capabilité
Recommendations
Quality Plan d’Implantation
Floor Plan Layout
Technic
Certificate of
Economic Manufacturing
certification Control Plan (+ MQA)
Logistics Process AMDEC
Production
After-sale… Product
Development
Gauge Specification
Spécification & Agrément&des Manufacturing Process
Moyens Approval
de Contrôle
DCL Development
Packaging & Logistics PSW Approval
121
ANPQP Milestones vs.
Renault V3P Project Milestones

122
The core team

The PDT Pilot (engineering Dept) leads


the "Product Development Team (PDT) "

Logistics representative
Examples of contributors :

Engineering Team experts


PDT Pilot Purchasing Leader
Renault Quality Experts
Plant SPP (if high
Validations specialists
« PDT » process assesment
SQA level part)
Prototype specialists
Renault …
Purchaser Supplier

Others To work together !


Purchasing
Quality GFE = Groupe fonction élémentaire/série = PDT
SPP = Supplier Process Pilot (engineering Dept)

123
Renault ANPQP management in Phase 4

To manage the "To Do


ANPQP PPC Milestone,
List"
100% PSW K0 or
Phase 3 K10

ANPQP Phase 4

Off-tool Parts MA Milestone,


Confirmation PSW 100% K0

Kick off meeting : beginning of phase 4


Product Process Progress Status Review
Product Process Progress Status Review with "OK to present
Product/Process PSW" to Renault Plant SQA for Approval
Progress Status
report 124
Basics

 Who is in charge of the implementation of the PSW Approval process?

– The PDT Pilot through the ANPQP IS and the PSW Status report.

 When are PSW presented?

– The authorization to present the PSW is given by the PSW status Report at least and
at the latest before the PPC and MA Project Milestones.

 Who approves the PSW?

– The Plant SQA manager (Or his deputy) of the Renault assembly/machining plant.

125
Basics

Based on supplier’s evidences and its commitment


What is the objective of the PSW Approval?

 To confirm that what is implemented by the Supplier gives us


confidence in its ability to comply with his conformity
commitment.

 To confirm that what is implemented by the Supplier (including


for the Ramp-up period) guarantees the delivery of Bought Out
Parts corresponding to our requirements at full volume
conditions.

 To authorize consequently the delivery of the Bought Out Parts


by the Supplier in customer Plant in the mass production
conditions for the assembly on saleable Powertrain units or
vehicles.

126
key points to approve a PSW

•Sub-suppliers PSW or equivalent


•Eng Product Spec – Drawings
•Certificate of certification
•Control plan
•Process Flow chart
Analysis of
•Gauge approval sheet
Supplier’s •Process capability results
ANPQP •Supplier Test Report
outputs •Inspection Report
•DCL
•Idenification and Traceability
•Capacity Submission Warrant
•Ramp-up Activity Plan
•Supplier’s Process Audit Results- self audit

• Renault Process Qualification(optional)


Analysis of • Renault Assembly-Machining Agreement
Renault • Renault Product Validation Tests
• Renault Appearance Approval (if necessary)
results • Renault Cleanliness Audit Result (if necessary)
• Renault Capacity Audit Result(optional)

127
What status for the PSW for PPC?

• Approval if all criteria are satisfied.

• Interim Approval if:


 Not all criteria are satisfied
 The product can be delivered and the Vehicle is saleable.

• If not, the PSW is not presented.

To resume: Approved
PSW Status
Interim Approval Refused

At least 1 K10
ANPQP Outputs 100% K0 At least 1 K50
No K50
Authorized with
BOP Deliveries Authorized Not authorized
concessions
Vehicle / powertrain unit /
Saleable Saleable with concessions Not saleable
accessoiries saleable

128
THE KEY PRINCIPE : 1 approved PSW for each Part Reference,
Supplier site, Renault assembly/machining site.

Bought-out Part Ref 11


Supplier X Supplier
Site Y
Later

ILN
International Logistic Network

Plant 1
Plant 2
PSW New validations ? Suppliers
signed recommendations ?
by the At least the following criteria are
PSW All criteria are taken SQA 1 reviewed:
signed by into account to Assembly/ Machining, Logistics
the SQA 1 approve the PSW. (DCL) and Capacity Level for the
PSW plant 2.
signed by
the SQA 2
129
Some particular cases : Main points

• Each Product-Process-Facility site change => new PSW

• Case of carry-over parts => new PSW. The


assembly/machinability, logistic, capacity criteria are at least
reviewed. Additional validation tests can be necessary (in
compliance with the use conditions).

• If parts are manufactured with “low production” tools and all


PSW approval criteria are satisfied:
– the PSW can be approved.
– the set up of mass production tools shall be managed as a
process change and will trigger a new PSW.

130
Summary
Training Objectives

By the end of this course you will be able to:

 Understand ANPQP structure and concepts

 Be able to use the ANPQP website

 Understand the purpose and customer expectations


for the ANPQP activities

 Understand how ANPQP fits into the Nissan new


product development process

132
Summary

 ANPQP provides a framework for core tools and


processes that are common throughout the
automotive industry
 ANPQP is designed to be used by cross functional
teams.
 Within Nissan, cross functional project teams are
established to manage ANPQP.
 For a successful product launch, the supplier must also
establish a cross functional project team.
 Management of each project milestone and the
progress towards it is essential in both Nissan and
the supplier companies.

133
ANPQP Training

Expectations Review