Song Jinghan Quality and Innovation 2022-02-19 19:39
I have answered the questions raised by students about what is the difference and connection between IPD and APQP, and the specific tweet can be flipped through Teacher Song's public account. So, how do IPD and APQP merge?
Since the automotive industry has always used APQP as a method of R&D quality management, enterprises represented by Huawei and ZTE in the telecommunications industry or electronic product manufacturing industry use IPD as the system to build R&D management systems. However, with the rise of new energy vehicles and the advent of the era of the Internet of Everything, the application of automotive electronics and the Internet of Vehicles, we suddenly discovered. Huawei has also begun to enter the automotive industry, and the integration of software and ICT technology in automobiles is also increasing, so my friends and I discussed how to integrate APQP requirements in IPD. Many companies in the automotive industry talk to Mr. Song about consulting projects, mainly on how to transform the R&D management built by the original APQP to IPD, because the current automobile manufacturing will involve the development and integration of a large number of IoT devices and software. Therefore, Mr. Song combined his own understanding and experience in the consultation to share with you, and welcome everyone to discuss with Mr. Song's WeChat.
As I have mentioned before, IPD is a product management system, and the relatively complete process system is as follows:
Major main process reports: market management, product development, technology development, demand management
APQP, as mentioned in previous articles, is defined in the Ford APQP3.0 Guide:
Advanced Product Quality Planning (APQP) is a structured approach to defining and executing the activities necessary to ensure that a product satisfies customers.
target
It is to facilitate communication between all people and actions involved in the project and to ensure that all development phases are completed on time, at an acceptable cost and with a level of quality.
Let's look at an APQP framework
In fact, we can find that APQP itself is similar to the "small IPD" in the IPD system, that is, the product development process. Although IPD uses PACE to define the product development stage, in fact, the overall idea is not much different from APQP, in the dimension of product development, except for localization requirements.
Therefore, in the IPD product development process, the requirements for integrating APQP are actually very simple problems, and the APQP phase activities can be mapped to the development stage of IPD:
APQP focuses on planning and defining projects, corresponding to the IPD, Introduction and Planning
APQP Product Design and Validation/Process Design and Development, corresponding to IPD, Planning, Development
APQP products and processes confirm that correspond to IPD, validation
The production of APQP corresponds to the release of IPD
In the corresponding stage of the IPD process, it is enough to add the control requirements of specific OEMs and the standard element requirements specified in APQP.
APQP from a product management perspective
Therefore, the content covered by APQP is actually only one of the links compared to the IPD product management system, so IPD and APQP are not comparable, but the product development process of APQP and IPD can be well integrated.
What content can APQP integrate from IPD?
1. Market management
The planning and definition of APQP before, from the input in the guide, we can see that the premise of APQP launch is that the target customers, selling points and competitors have been clarified. However, with the intensification of competition in the automotive market and the improvement of personalized demand, the automotive industry is undergoing tremendous changes, the market is unpredictable, and it is difficult for auto parts companies at the front end of the supply chain to grasp the pulse of the market, so customer demand has become one of the very important market signals
In fact, the accuracy of the target customer and selling point is far more important than meeting the customer's requirements. Therefore, the automotive industry should strengthen the tools and methods of IPD in market management to determine the right target customers and selling points.
The market management methodology in IPD is as follows:
2. Marketing innovation
In the APQP content requirements, more focus on the development of products according to cost and quality standards. However, the IPD product development process considers product management, so in addition to developing products, it is also necessary to consider how to sell products, so in the product development process, product marketing innovation, sales kit development, service and supply chain development. Truly realized, GTM, listing is the upper volume, the upper quantity is the sale.
From the product development process of Huawei and Apple mobile phones, the development of the listing process is actually very important, but this one is lacking in APQP.
3. Borrow the parallel engineering and reusability theory in IPD theory to optimize cross-functional collaboration and improve the speed of new product development while controlling the cost of new product development
In fact, there are methods of synchronous parallel engineering in IPD and APQP, but in APQP, the content of product platform and module standardization is less involved, which is of great help to improve the development speed.
In fact, it was also discussed whether the technology development process in IPD is important?
Personally, I believe that the most important thing in the current automotive industry is maturity, stability and consistency, so the iteration speed of technology cannot be too fast. Therefore, at least for now, I think that the asynchronous development of technology development processes and products may be important but not important for many automotive industry companies, and they can be gradually improved.
In addition, the synchronous engineering theory mentioned by IPD and APQP plays a very important role in the optimization of the new product development process. Here is an application project example:
Development cycle improvement in the product development process for Company A
1. The development cycle of raw materials and tooling is too long and the process is cumbersome
Combined with the ideas and methods of reusability in IPD theory, Company A establishes a common module system for raw materials and a common module system for welding tooling, and creates a database of design process verification data. Through the application of the database, the number of sample submissions and experimental verification can be reduced, the process can be optimized, and the time of project development can be reduced.
2. The quality of the first batch of samples is not high
The main reason for the analysis is that first, the supplier's ability itself is limited, it cannot provide qualified products within the specified time, and there is no process control over the access of model sample suppliers. Second, the supplier's production process was not sufficiently quality controlled, resulting in repeated revision submissions.
Optimize:
Model sample suppliers are screened to form a list of qualified model suppliers, and the qualified model sample suppliers in the list will be used to develop model samples for future new projects.
The work of the supplier quality personnel is put forward, the supplier quality colleagues should intervene in the technical communication before the production of the model sample, in the technical communication, should identify the technical key points of product development in advance, and communicate all the quality concerns to the supplier, for the development of new products with very urgent new products if necessary, need to track the process quality on site, and control the production process of new products. In addition, the number of required samples needs to be evaluated in conjunction with the project forecast to confirm that the supplier's mold can meet the life requirements of the sample and avoid wasting time caused by the need to redevelop the mold. At the same time, special inspection plans are required for the model samples, especially the customer's interface dimensions and the dimensions involving the special characteristics of the product. this
3. Mass production only found that logistics could not meet the requirements, resulting in increased costs
Set up the position of bridging logistics, which is mainly responsible for connecting with customer needs in the process of new product development and communicating customer needs to the company, and directly connecting with suppliers to form a professional supply chain for the development of new products. The supply chain system developed by this new product not only accelerates the transfer of information from the supplier to the client, but also makes the material flow smoother during the development phase.
4. There are many problems of low conversion efficiency
Field process colleagues are also involved in the early stages of new product development, especially when the following milestones are reached: (1) product concept approval milestones. At this time, the conceptual design of the product has just been finalized, and if it is not manufacturable, the on-site process can give good suggestions; (2) Approval milestones for the design process. At this time, the model sample has been manufactured, which is necessary to summarize and summarize the problems that actually occur in the production process; (3) Milestones of commissioning of mass production equipment. This is the first trial production closest to the mass production time node, which is very helpful for discovering potential problems in the mass production process; (4) verification milestones of the technical process; (5) Mass production verification milestones. Through the above five milestones to advance step by step, the on-site process can achieve a smooth transition when it finally fully takes over the production process, reducing the possibility of original problems.
Company A's new product rapid development project has been optimized through the process, and under the premise of ensuring product quality and cost controllability, the project development cycle has been greatly shortened, from the original 21 months to 12 months, and the quality has also been guaranteed.
IPD and APQP are actually a guide or methodology in themselves, and it is best to adopt them in combination with the actual situation of enterprises and the problems encountered. It is not appropriate, blindly fusing together for the sake of integration.
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This article is reproduced from the WeChat public account "Quality and Innovation", the original WeChat tweet link: How to integrate IPD and APQP?