How do you implement continuous improvement and feedback in phase 5 of APQP?

* Establishing a process for collecting and analyzing data. * Creating a system for communicating feedback to the team. * Implementing changes based on the data and feedback. * Evaluating the results of the changes. Here are some additional tips for implementing continuous improvement and feedback in phase 5 of APQP: * Make sure that everyone on the team is aware of the importance of continuous improvement and feedback. * Set aside time each week or month to review the data and feedback. * Don't be afraid to make changes to the product or the process. * Be patient.

An effective feedback system should be in place to evaluate the effectiveness. Score card from internal and external customers should be maintained and reviewed. Team must be involved in this process so that they should also understand it's importance. And most important, it should be done at frequently at regular intervals.

Phase 5 of the APQP is Assessment, feedback and corrective actions. Basically after launch of the product the effectiveness of the product design and process design is validated atleast for 90 days period from the time of launch. During this period mass production gets kick started. When the products are being made at large scale, the product feedback from the market provides clear insights about the product acceptance, its reliability interms of product perspective and its manufacturing perspective. We must establish right KPIs & have a close watch during this period to stabilize all loop holes in the product and process thru DFMEA and PFMEA tools. Few KPIs of phase 5 shall be FTT, PPM, No of change requests after launch and warranty cost

In the final phase, the emphasis lies on continuous improvement and feedback mechanisms to ensure the highest standards of quality. A robust feedback system is established to gather insights from stakeholders. This system integrates SPC tools to monitor & analyze KPI's, enabling a proactive approach to QMS. Lessons learned from previous projects are documented across the organization, fostering a culture of continuous improvement. Customer feedback is actively sought & incorporated into the improvement cycle, aligning products more closely with customer expectations. Recognition & rewards are implemented to incentivize & acknowledge individuals or teams contributing to quality enhancements.

The continuous improvement cycle in Phase 5 of APQP follows a systematic approach, identifying areas for enhancement and implementing corrective actions. A robust feedback mechanism involves stakeholders like customers, suppliers, and internal teams. Utilizing tools such as Six Sigma, Lean principles, and Root Cause Analysis (RCA) aids in structured process analysis to optimize efficiency. The cycle, aligned with the PDCA framework, applies feedback data to plan, do, check, and act on products and processes. This iterative process fosters quality improvement, waste reduction, variation elimination, and enhanced efficiency.

In my experience this has been helpful the process begins with collecting feedback from customers and internal teams to identify potential issues. performance monitoring using KPIs, regular audits, Data analysis, corrective action plan, Continuous improvement method e.g Kaizen events & PDCA cycle, documentation, and standardization of processes to ensure consistency, training & clear communication. Engage suppliers for feedback, and conduct regular audits. Regular management reviews and performance assessments ensure alignment with quality objectives and customer satisfaction. This systematic approach embeds a culture of continuous improvement, leading to sustained product quality and customer satisfaction. experience

PDCA is the systematically repeating this cycle helps in reducing waste, eliminating variation, and increasing efficiency, leading to sustained improvements over time.

Lessons learned is the continuous improvement. By systematically documenting and sharing these insights, organizations can enhance their processes, avoid past mistakes, and build on successful practices. Ensuring that lessons learned are validated and communicated effectively across the organization.

Lessons learned should be documented, validated and communicated to all stakeholders in your company who have a rol in upholding this new level off Quality. This level also applies for your customer and suppliers.

* The customer is "THE ULTIMATE". Hence, any positive or negative feedback should be registered. * Positive feedback should be welcomed and praised. * Negative feedback should be embraced and detailed root cause analysis to be done to avoid repetitive mistakes and try to implement error proofing mechanism. * Feedback should be communicated to respective stakeholders.