Brief introduction of five core tools of TS 16949;
1, statistical process control
SPC is a manufacturing control method, which is based on the data collected by the control project in manufacturing, analyzes the process capability and standardizes the process, finds the abnormality in the process, and immediately takes improvement measures to restore the process to normal.
Purpose of SPC implementation:
Make a reliable evaluation of the process;
Determine the statistical control limit of the process, and judge whether the process is out of control and whether the process is capable;
Provide early warning system for the process, monitor the process in time to prevent the occurrence of waste products;
Reduce the dependence on routine inspection, regular observation and systematic measurement methods replace a lot of detection and verification work.
2. Measurement system analysis
Measurement system analysis (MSA) is to analyze the measurement system that can repeatedly read all parts, evaluate the quality of the measurement system, and judge the acceptability of the data generated by the measurement system.
The purpose of implementing MSA is to understand the measurement process, determine the total error in the measurement process, and evaluate the adequacy of the measurement system used in production and process control. MSA promotes understanding and improvement (reduces differences).
In daily production, we often analyze the state of the process, the ability of the process and monitor the changes of the process according to the measured data of the process parts. So, how to ensure that the analysis results are correct? We must guarantee it from two aspects:
(1) To ensure the accuracy/quality of the measurement data, the measurement system is evaluated by the method of measurement system analysis (MSA);
(2) Ensure the use of appropriate data analysis methods, such as SPC tools, experimental design, analysis of variance, regression analysis, etc. MSA uses mathematical statistics and charts to analyze the resolution and error of the measurement system, so as to evaluate whether the resolution and error of the measurement system are suitable for the measured parameters and determine the main components of the measurement system error.
3. Failure Mode and Impact Analysis (FMEA)
Potential Failure Mode and Consequence Analysis (FMEA), as a planning tool and a preventive measure, aims to find and evaluate potential failures and their consequences in products/processes. Look for measures to avoid or reduce potential failures, and make continuous improvement.
The purpose of implementing FMEA is:
The product or process can be easily modified at low cost, thus reducing the risk of modification afterwards.
Find measures to avoid or reduce these potential failures;
4. Advanced Product Quality Plan (APQP)
APQP is a structured method for determining and formulating the steps needed to ensure that products meet customer requirements.
Functions of APQP:
In order to meet the requirements of products, projects or contracts, before new products are put into use, the method used to determine and formulate a structured process to ensure the production of a specific product or series of products that meet customer requirements. Provide guidelines for making product quality plans to support the development of products or services that customers are satisfied with.
5. Production Parts Approval Procedure (PPAP)
The approval procedure of production parts is a practical technology, and its purpose is to verify that the products manufactured by production tools and processes meet the technical requirements through the product approval and recognition procedures before the first batch of products leave the factory.
Purpose of PPAP implementation:
Determine whether the supplier correctly understands all the requirements of customer engineering design records and specifications.
And in the actual production process, it has the potential to continuously meet these requirements under the condition of executing the required production rhythm.
Five quality tools are the core of TS 16949, which have been proved to be suitable for the automobile industry and will play an important role in improving the quality management level and competitiveness of the automobile industry.
The relationship between the five tools of TS 16949:
If there is no practice on this topic, people must be confused, even those who have practice may not understand it, because they are intertwined. It took Ford a hundred years to draw the classic APQP network diagram, which shows its good intentions. Here I briefly introduce five tools, hoping to give you a basic concept.
APQP is a task that a parts company must complete when providing new products to an automobile factory. It is intended to solve all the problems before the product is produced, so it is a complex process and needs many iterations to become the final planning result.
FMEA is the failure mode analysis in the second and third stages of APQP, including products and processes. The most important point here is that the product is not produced at this time, but a potential possibility analysis. Many enterprises are always unaccustomed to this and always regard it as a product that is already being produced.
SPS and MSA are both formed in the process planning, that is to say, what kind of process needs SPC to control. Generally speaking, SPC should be used for processes with special characteristics, but this is certainly not absolute. What needs to be explained here is the control plan, which is the result of APQP plan. In this result, measuring tools must be used. Whether these measuring tools can meet the needs of process measurement needs MSA analysis. Simply put, all measuring instruments involved in the control plan should be MSA, and then in the initial control plan, that is, the trial production control plan, the planned measuring tools or SPC may not have good results, because some may be adjusted and improved. Finally, SPC and MSA in the formal production control plan should meet the needs of mass production.
Simply put:
APQP is a quality plan, but it is also a project development plan. Since it is a plan, its time starting point is from the official start of the project to the end of PPAP. After normal mass production, it is concluded that there are no other problems and the development project can be closed. The performer is the whole APQP team.
PPAP is the approval procedure of production parts, which is only a link in the whole APQP plan, usually in the second half of the APQP plan and generally the core of the APQP plan. If PPAP is not recognized by customers, then APQP's plan is basically ruined. So when we talk about APQP, we always put them together: APQP/PPAP. This shows the importance of PPAP. The main executors are (development, production and quality) engineers. 、
FMEA/SPC/MSA are all tools of quality management.
A friend pointed out that FMEA includes DFMEA and PFMEA, and the import events of these jobs are mostly the early, middle and early stages of APQP. They are mainly related to product design, production technology or technology. This is a prevention plan.
MSA is very simple, that is, check the quantity and tools. Don't complicate everything.
SPC is also very simple, that is, controlling some important parameters and monitoring their production stability. If there is a big fluctuation, take immediate measures to correct the process or production process.
MSA, like SPC, was correctly implemented in PPAP stage (there are many factors leading to the premature failure of MSA). Most of the implementers are quality engineers. SPC is often implemented in the long-term process of formal mass production according to different requirements of customers.