First steps
- Review the lessons learned of the last launch.
- Gate reviews with red / yellow / green status.
- Safe launch: extra checks for the first weeks.
How to measure success
Launch PPM and gate status on time. Record the value before you start, so the effect of every action can be shown.
When these methods are the wrong choice
- APQP: Problems in a running series process.
- PFMEA / DFMEA: Fixing a problem that has already happened; update it after the 8D instead.
- Run at rate: Quality problems without a capacity question.
- PPAP: Internal process problems.
- Process capability (Cpk): Unstable processes; make them stable first.
- MSA / Gage R&R: Nothing: do it before you trust any data.
The methods in one line
| Method | What it is |
|---|---|
| APQP | Five-phase launch plan with gates, so problems are prevented before SOP. |
| PFMEA / DFMEA | Analyses how a process or design can fail, rates the risk (AP) and defines prevention and detection. |
| Run at rate | Production trial at the quoted cycle time that proves the line can deliver the volume. |
| PPAP | Evidence package that the supplier’s process can make good parts at rate. |
| Process capability (Cpk) | Compares the process spread and centring with the tolerance and predicts PPM. |
| MSA / Gage R&R | Checks that the measurement system can see the variation you want to control. |