應用專案APQP與FMEA於新產品開發製程改善之研究--汽車零件廠為例

A STUDY ON THE APPLICATION APQP & FMEA TO THE IMPROVEMENT OF NEW PRODUCT DEVELOPMENT PROCESS — TAKING CAR SPARE PART MANUFACTURER AS AN EXAMPLE

　　專案先期產品品質規劃(APQP)及失效模式與效應分析(FMEA)是在製程中將品質活動作及早規劃，提早發現問題在品質管理上作好防禦工程，有效的採用管制計劃(Control Plan)與製程失效模式與效應分析(PFMEA)，可以在所有的製程中找出製程中每一步驟的潛在失效模式，並提供風險優先指數(RPN)或相關資訊，透過製程設計改善製程中不適當模組的可靠性，提升產品製造品質，有效的節省設計變更的次數及縮短製程的週期與製程中的浪費。因此本研究將以專案APQP及FMEA導入汽車零件製造廠中，分析製程中所有機台模組及製程作業，透過專案管理的模式，找出管制計劃中的管制特性及所有製程中之失效模式，完成製程FMEA資料分析評估，收集製程參數，決定關鍵製程特性，作為製程設計改善與修正管制計劃的依據。

　　The Project management Advanced Product Quality Planning (APQP) and Failure Mode & Effect Analysis (FMEA) aim to build up solid and sound defensive engineering in the quality management by adopting early quality activity planning in the production process and early discovering problems. By adopting effective Control Plan and Process Failure Mode & Effect Analysis (PFMEA), the industry can uncover potential failure mode hidden in each step of the process and provide Risk Priority Number (RPN) or related information. By improving the reliability of the inappropriate module through process design and upgrading product’s manufacturing quality, the industry can decrease the frequency of design change, shorten the process cycle and cut unnecessary waste in an effective way. Based on the preceding presumption, this study intends to analyze all machine sets and processing operation during the production process by introducing the Advanced Product Quality Planning (APQP) and Failure Mode & Effect Analysis (FMEA) into car spare part manufacturers. Secondly, to find out control features and failure mode in all processes through Project Management mode and to complete analysis and evaluation of FMEA data by collecting process parameters to determine key process features, which are then used as the basis for improving process design and modifying control plan. Findings of this study show that not only new product quality is improved by increasing employees’ capability and knowledge of new product development and control plan, but also the frequency of design change is decreased, process cycle is shortened and the unnecessary waste in the process is saved effectively by adopting Advanced Product Quality Planning (APQP). A systematic set of process data for Advanced Product Quality Planning (APQP) is thus designed as the basis for subsequent mass production by using early planning of quality activity, early discovering of problems and advanced analysis, prevention and improvement in the sample trial stage through process confirmation trial stage. All data and information generated from the study will be used as the source of documented knowledge management and provide updates for future similar new product or Failure Mode & Effect Analysis.