- LEAN-TPM

Results-oriented production with continuous improvement, systematically reducing losses by making production "lean".

Value: Determine what is truly valuable to the end user. Only those processes that bring the product or service closer to satisfying the customer's needs are worth paying for.
Value Stream: Map the product/service's path from suppliers to the customer and identify all steps. Eliminate unnecessary, non-value-creating activities.
Flow: Ensure that value-creating processes proceed continuously, without interruptions, congestion and waiting times.
Pull principle: Production or service is always determined by the actual needs of the customer.
Perfection: LEAN is a continuous improvement cycle. Strive to reduce errors and achieve perfection with the Kaizen (continuous improvement) approach
The 7+1 main losses (Muda)
Overproduction: Producing more or earlier than necessary.
Inventory: Accumulating unnecessary raw materials, semi-finished or finished products.
Waiting: Wasting time due to unavailability of materials, information or machines.
Unnecessary transportation: Unnecessary movement of materials or tools.
Unnecessary movement: Inefficient and inconvenient movements performed by workers.
Defective products: Scrap and the associated repair work.
Overwork: Forcing processes or functions that the customer does not require.
+1 Unused human resources: Ignoring the ideas, creativity and skills of workers.
The two pillars
The Lean methodology is built on two fundamental cultures:
Continuous improvement (Kaizen): The pursuit of perfection, the constant improvement of processes in small steps.
Respect for people: Involving and appreciating employees, since real solutions to problems come from those working on the front lines.

- Automotive modules

PPAP - product approval process, its elements

Design Records: Technical drawings or CAD models approved by the customer.
Engineering Change Request (ECR): Official documentation of possible changes.
Engineering Approval: Written approval by the customer's engineering department (e.g. prototypes).
FMEA (Design Failure Mode and Effects Analysis): Design risk analysis, which examines possible product failures and their effects.
Process Flow Diagram: A visual and logical description of the steps in a manufacturing process from raw material to finished product.
PFMEA (Process Failure Mode and Effects Analysis): A manufacturing/process risk analysis that evaluates the potential for failure and its consequences during manufacturing.
Control Plan: A summary table of manufacturing steps, in-process and final inspection steps, that ensures process stability.
Measurement System Analysis (MSA): Verification of measurement reliability (e.g., Gage R&R tests).
Dimensional Results: Verification of batch measurements of manufactured parts against drawing specifications.
Material Performance Results: Verification of chemical, physical, or other compositional tests.
Initial Process Studies: Statistical analysis of process stability and capability (e.g., Cpk metrics).
Qualified Laboratory Documentation: Accreditation certificates for laboratories performing testing.
Appearance Approval Report (AAR): Approval of appearance testing (color, texture, gloss) for visible parts.
Sample Production Parts: Typically reference samples made with the production tool under normal production conditions for the customer.
Master Sample: A sample jointly signed and retained by the customer and supplier as a reference for subsequent production.
Checking Aids: Verification of calibration and compliance of special measuring or checking templates.
Customer-Specific Requirements: Fulfillment of specific, unique requirements of the given automobile manufacturer (OEM).
Part Submission Warrant (PSW): Final document of the process. A summary data sheet where the supplier formally declares that all elements of the package meet the specifications and requests product approval.
Submission Levels
Not all elements need to be submitted in all cases. Based on the agreement between the buyer and the supplier, 5 levels are distinguished:
Level 1: Submission of the Part Submission Statement (PSW) and Appearance Approval only.
Level 2: Submission of the PSW, samples and limited supporting data.
Level 3: (Most common) Submission of the PSW, samples and full documentation.
Level 4: PSW and specific requirements defined by the customer.
Level 5: PSW and full documentation review at the supplier’s site.
To conclude the process, the automotive customer reviews the documentation based on the above levels and either Approves, Interim Approvals, or Rejects the part for serial production.

APQP - The 5 main phases of APQP

The process from concept to serial production can be divided into the following phases:
Program Design and Definition: Gathering customer requirements, defining goals (quality, reliability), and initial project plan.
Product Design and Development: Detailed development of product features, prototyping, and performing Design Fault Finding Analysis (DFMEA).
Process Design and Development: Designing efficient manufacturing processes and performing Production Fault Finding Analysis (PFMEA).
Product and Process Approval: Testing the production line and compiling PPAP (Production Part Approval Process) documentation for customer approval.
Feedback, Evaluation and Corrective Action: Starting serial production, continuously monitoring the processes and correcting any problems that arise.
Related Basic Tools
Control Plan: Documents the steps of in-process and final inspections.
FMEA (Failure Mode and Effects Analysis): Preliminary analysis of possible failure modes and their effects.