Controlled Production Quantity Release Applicability Determination Method

During product development or design change, the aim is to fully validate all potential issues. On programs with significant complexity, it is difficult or impossible to fully retire all combinations of risk factors even with comprehensive analysis and testing approaches. These complex projects have the highest risk to launching with hidden defects can result in high warranty costs and erosion of customer satisfaction. This paper discusses a conservative approach called Controlled Production Quantity Release (CPQR) to manage the risks of these complex releases or changes by presenting a decision framework executed by a cross-functional team to identify those complex releases that deserve the methodical and monitored approach necessary to manage risk. The purpose of this method is to gain early concurrence with the program team with documented decision criteria rather than relying on individual opinions. This paper focus on structured approach of determining the applicability criterion of CPQR for a project by collaborating with cross functional teams such as Engineering, Program Management, Service, Supply Chain, Supplier Quality, Reliability etc. at the beginning of the project. This proposed method will enhance a team’s ability to decide the CPQR applicability. Three case studies are discussed in this paper to show how this method has helped the team making sound judgement by incorporating the CPQR schedule in project timelines upfront with stakeholders’ alignment avoiding program delays and enabling on time quality product launch. This is not intended as a checklist but is intended as a guideline for CPQR evaluation. This method may not be all inclusive dependent upon the specifics of the project/ program application. These CPQR units are not intended to demonstrate reliability for product but for uncovering the system interaction related failure modes.