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How can you document and communicate process changes in APQP?

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Advanced Product Quality Planning (APQP) is a structured methodology for developing and validating new or modified products and processes in the manufacturing sector. It aims to ensure that customer requirements are met and potential risks are minimized throughout the product life cycle. However, sometimes changes are inevitable due to customer feedback, design revisions, supplier issues, or regulatory updates. How can you document and communicate process changes in APQP without compromising quality, safety, or efficiency?

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Christian McWorkman

Manufacturing Engineer at Vista

1 Identify the change

The first step is to identify the nature, scope, and impact of the change on the product and process specifications, customer expectations, and satisfaction. To do this, you should use a formal change request form that includes the reason and justification for the change, a description and details of the change, the affected product and process characteristics and features, potential benefits and risks of the change, and approval authority and responsibility for the change.

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2 Assess the change

The next step is to assess the feasibility, compatibility, and implications of the change on the existing or planned APQP activities and deliverables. To evaluate the change and its effects, a cross-functional team should be used that includes representatives from engineering, quality, production, purchasing, and sales. This team should consider the design and development plan and timeline, the product and process validation plan and methods, the product and process control plan and measures, the product and process documentation and records, as well as customer requirements and feedback.

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3 Implement the change

The third step is to implement the change according to the approved plan and specifications, and to monitor and verify the results and outcomes of the change. Appropriate tools and techniques should be used to guarantee that the change is executed appropriately and consistently, while meeting or surpassing customer expectations and standards. Design of experiments (DOE) can be used to optimize process parameters and settings, failure mode and effects analysis (FMEA) can be used to identify and reduce potential failures and risks, statistical process control (SPC) can be employed to monitor and control process variation and performance, measurement system analysis (MSA) can be utilized to guarantee accuracy and reliability of measurement data, and production part approval process (PPAP) can demonstrate conformity and capability of product and process.

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4 Communicate the change

Communicating the change to all relevant stakeholders, both internally and externally, is the final step. You should use clear and consistent channels and formats to inform and educate the stakeholders about the change and its impact on product and process quality, safety, and efficiency. Change notification letters or emails can be used to notify customers and suppliers about the change. Additionally, change management meetings or workshops can be held to discuss and review the change with a cross-functional team and management. A change log or register should be used to track and record the change history and status, while a change summary or report can be used to summarize and document the objectives, actions, results, and lessons learned.

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Christian McWorkman

Manufacturing Engineer at Vista
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Communication is not just via email. It involves verbally communicating to the production supervisors and operators, it involves posting a written signage regarding the change, and it involved written/verbal acknowledgement by any and all stakeholders.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Christian McWorkman

Manufacturing Engineer at Vista
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Spend time at the process! Any engineer can analyze a given data set to death, but to spend time at the process will give you insight into what problems are causing customer complaints, and what problems are being encountered by the production operators.

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How can you document and communicate process changes in APQP?

1

2

3

4

5

1 Identify the change

2 Assess the change

3 Implement the change

4 Communicate the change

5 Here’s what else to consider

Manufacturing Operations

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How can you document and communicate process changes in APQP?

1

2

3

4

5

1 Identify the change

2 Assess the change

3 Implement the change

4 Communicate the change

5 Here’s what else to consider

Manufacturing Operations

给文章评分

感谢您的反馈

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