AQP-PARTS

March 2003

Advanced Quality Planning Process For Sheet Metal Parts

The automotive and appliance sheet metal parts process progresses from conception to production in a series of steps that include Part Design, Material Selection, Tool Design, Tool Tryout, and Part Production Launch. To supply quality products and technical support, a material supplier is involved in the early stages of Part Development, a process known as Early Vendor Involvement (EVI). 

Suppliers typically document the performance of the supplied material and the stamping tool for each part included in the EVI program. Detailed reports are then sent to the customer that identify the essential components and key results of each tool trial. Suppliers typically rely on Forming Limit Diagrams (FLD) to quantify these results. 

Once a part is in production, suppliers continue to evaluate the stamping process using FLD and similar analytical tools. When problems arise in the production of a part, suppliers and stamping plant personnel typically review pre-production tool trial reports to provide an insight on the problems that were overcome during the early stages of the part's development. This historical referencing is necessary to provide quick and proper corrective actions that are critical during the production phase.

The Advanced Quality Planning process for sheet metal parts addresses the supplier and customer requirements during part development and part production by implementing standardized procedures, analyses and documentation. By maintaining quality and customer support at the highest level during the EVI process, and by providing consistency in applying the procedures and satisfying documentation requirements, continuous improvement is ensured throughout the production cycle.

 
The Advanced Quality Planning Process requirements during Part Pre-Production & Production include:

DEI recognized the importance of computerizing the Advanced Quality Planning Process to create an Advanced Quality Planning System for suppliers and customers – the result of which is AQP-Parts.

AQP-Parts Executive Summary

AQP-Parts is a Computerized Advanced Quality Planning System for Sheet Metal Parts developed by DEI primarily for material suppliers but also for tool shops, stamping plants, and customers.

AQP-Parts computerizes the processes and documentation requirements needed for supporting Part Production and Tooling Development for automotive sheet metal parts.

AQP-Parts is a user-friendly quality control system that provides comprehensive part tracking, FLD and Small Strain analyses, and standardized reports for office and mobile users. The System is structured to allow users to follow the Advanced Quality Planning Procedures (Guidelines) to consistently record and document critical Customer, Program and Part information into the comprehensive Part Tracking Database.

AQP-Parts stores detailed Part Information including Part Blank (and Tailored Blanks) dimensions and material properties, Customer Specifications, and Program Production Volumes. Part Development progresses though a series of Tool Tryouts also referred to as Tool Trials.

AQP-Parts documents each Tool Trial with standardized Tool Trial Reports to the customer documenting critical information including Part, Blank, Tool Shop, Press Parameter, Material Property, Part Image and Strain Analysis Data. Utilities such as the Material Production Capability Database and the Advanced Strain Analysis calculations simplify Tool Trial Report generation. The consistent documentation of the ongoing Part Tool Trials enables a material supplier to maintain a complete Part History within the Tool Trial Reports.

AQP-Parts provides Management Reports that summarize Part information at the Program, Production Location, or Customer level. Log Reports provide the necessary details for all key activities logged while using the System.

AQP-Parts is a key component of a material supplier's Early Vendor Involvement program and provides continuous monitoring and control during Part Development, Pre-Production, Production and Post-Production.

AQP-Parts standardizes Documentation and Reporting Methods by providing:

AQP-Parts standardizes procedures for Part Pre-Production and Production Support by providing:

AQP-Parts also includes tools for assisting in program planning, as well as diagnostic and database management tools.

AQP-Parts Features

AQP-Parts includes the following features:

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AQP-Parts handles detailed material information for each part blank. During a Tool Trial, material specifications, mechanical properties (in all three directions), surface properties, and chemical composition are documented. The System provides an interactive Material Property Range or Production Capability Comparison Database. Based on the material specification and thickness, a comparison is generated for the material properties specified for the longitudinal, transverse and diagonal directions, and is included in the Tool Trial Report.

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AQP-Parts provides management reports summarizing Part Severity Ranking, Program Material Volumes and Advanced Product Quality Planning. Additional reports include summaries for Material Forecasts, Program Log, Parts List Report, and customer-specific reports. Data export options provide unlimited report capabilities and can be customized to individual management requirements. Key data fields can be exported to a spreadsheet for pivot table generation and further analysis or sent electronically to centralized systems such as Ford's FLD Report Summary and Supplier Information Reporting System (SIRS).

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The AQP-Parts System is a Quality Control Tool. It is to be used to maintain Quality and provide feedback for Continuous Improvement during the Part Development and Part Production cycles. Standardized reporting options and ease of data availability contribute to its effectiveness.

Multiple levels of quality control are also maintained within the System itself. Quality is initiated with the centralized database and maintained through logical controls. Standardized input selection lists, consistent unit usage, automated calculations, error checking and warning systems, standardized reports, manual and automatic program log entries, cross linked checklists and guidelines, all contribute to the data consistency and integrity needed to maintain a high standard of quality.

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	Greater Process Up-Time Problem parts are resolved quicker by reducing the time for trial evaluation and report generation.  Cost Savings: Thousands of dollars for each problem part by restarting the presses sooner.  Accurate data analysis and evaluation will improve the success rate of proposed process modifications. Cost Savings: Thousands of dollars if identifying a part to be safe that may otherwise have failed. Since it will be quicker to perform the FLD analysis and report generation, there will be much more time to do additional trials and process evaluations of other parts.  Cost Savings: Thousands of dollars if preventing an unanticipated failure. Reducing the evaluation and report generation time may reduce overall staff requirements.  Cost Savings: Thousands of dollars annually, depending on the staff reduction.
	Improved Process Documentation The AQP-Parts relational database records all essential part information and process conditions.  Hardcopy reports include all recorded trial data and analyses. Automated summary reports from the database provide historical comparisons of key process parameters. Tailor Welded Blanks' are fully documented in the database and reports. The automated procedures and documentation in AQP-Parts fully address QS 9000 requirements.
	Increased Analysis Capability FLD data input can be % major and % minor strain, or thickness and % minor strain. Strain analyses includes the standard FLD, Thickness Stain and Surface Strain analysis. Analysis options include a Reference FLD curve, Library FLD curves, Maximum Thinning Limits, and Buyoff FLDo based on direct entry of FLDo or as a function of n Values. Constant Volume analysis ensures accurate data entry and strain analysis. Automated strain status calculations provide accurate status and safety margins. Automated summary reports provide the data for continuous improvements and process optimizations. Networked, Synchronized, and Mobile editions of AQP-Parts address all possible user configurations.
	Reduced Investigation/Report Generation Time The automated FLD analysis can be performed in minutes with the click of a button. The specific analysis and reporting requirements of GM, Ford, and DCX are fully automated. Reports are generated in seconds in standardized report formats. The AQP-Parts menu driven software with tabbed and sub-tabbed groupings makes it quicker to locate and record process data. The database provides access to the complete part history, which is essential when analyzing problem parts.
	Improved Report Understanding Reports include all entered data and analysis results clearly labeled. Pre-formatted reports are consistent and easy-to-read. Standardized input selection lists ensures report consistency.  Summary Reports and Pivot Table spreadsheet reports provide superior management tools.
	Automated Error Checking Quality Control is provided by standardized selection lists, automated constant volume checks, and Engineering-specific error checks.

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