When introducing new product and/or new projects Alloy Metal Products can offer a structured Advanced Product Quality Planning Process (APQP). 
       APQP is a structured process that includes critical tasks from concept approval through production. The focus is on creating a product quality plan that meet customer, statutory, regulatory and governmental requirements. 

      The process is based on the following steps:
    1. Product Planning and Quality Program Definition
    • Review of all applicable requirements
    • Development of the Quality Program
    • Establishing product and process effectiveness goals
    2. Product Design and Development
    • Design for manufacturability (DFM)
    • Defined material specifications and equipment requirements
    • Completed design failure mode and effect analysis to assess failure probabilities
    • Established control plans for product prototype creation
    3. Process Design and Development
    • Create a process flow diagram
    • Review, analyze, mintage and communicate all applicable risks using process failure mode and effect analysis tools
    • Establish operational process quality specifications
    • Document product preservation, storage, first in first out (FIFO) and packaging requirements
    4. Validation of Product and Process
    • Confirm capability and reliability of the manufacturing process and product quality acceptance criteria.
    • Perform production trial runs
    • Verify product performance including product effectiveness and efficiency
    • Communicate recommended adjustments with the customer before moving to the product launch
    5 Production Launch, Assessment, and Improvement
    •  Monitor and improve (as applicable) manufacturing process variations
    • Improve throughput, product effectiveness and delivery
    • Improve customer satisfaction
The QMS includes the following core tools:
  • Real time SPC, with customer access
  • Advanced Product Quality Planning (APQP)
  • Failure Mode and Effects Analysis (FMEA)
  • Measurement System Analysis (MSA)
  • Real time Statistical Process Control (SPC)
  • Production Part Approval Process (PPAP)
As well as Lean Manufacturing Tools such as:
  • 5S/6S
  • Just-In Time (JIT)
  • Kaizen (continual improvement)
  • Kanban (pull system)
  • KPIs (key performance indicators)
  • Poka-Yoke (error proofing)
  • Root Cause Investigation (5 Why, 8D)
  • Visual Factory

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