This is very informative presentation on APQP and its importance as a Core tool in Quality Management System

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ADVANCED PRODUCT QUALITY PLANNING
Prepared By: Mr. Prashant S. Kshirsagar
(Sr.Manager-QA dept.)

2. -: ADVANCED PRODUCT QUALITY PLANNING :-

3. -: Content :-
• Types of Core Tools
• History of APQP
• Definition of APQP
• Various Organizational
Road blocks
• Importance of APQP
• PDSA cycle in APQP
• APQP various Stages
• Input/Outputs of APQP
in every Stages/Phases
• Benefits of APQP
• Some examples for APQP

4. -: What are the Core tools for IATF 16949 compliance? :-
Tools that have the Greatest Impact on Product and Process Success
are called the Core Tools.
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4.
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5. -: History of APQP :-
Product Quality Planning and Control
Plan guidelines developed jointly by
Chrysler, Ford and General Motors.
Ford Motor Company published the
first Advanced Quality Planning
handbook for suppliers in the early
1980’s.

6. = Advanced
Let’s start early,
with the concepts
and collaboration
= Product
This is what the
customer is requesting
= Quality
Let’s get it right the
first time, efficiently
and every time
= Planning
Through
Collaboration we’ll
create a robust plan
Advanced Product Quality Planning (APQP) is a Structured Methodology to
define and establish all necessary steps to standardized & meet all quality
requirements to satisfies the customer
Structured collaboration involving Engineering, Manufacturing, Material
Control, Purchasing, Quality, Sales and Management
-: What is APQP?:-

7. -:Organizational Road Blocks :-

9. -:Goals of APQP:-
Plan before
Acting
Anticipate and
Prevent issues
Validate/
Confirm
before moving
forward
Facilitate/
Expedite
communication

10. -: Why do we need APQP?:-
 Achieve cost and
budgeted targets
 Optimization of
Cost
 Improve profit
 Minimal or No
Quality problem
 Defect free products
 Increase Yields
 Mitigate & Minimal
launch Quality risks
 Shorten
Lead Times
 On-time
delivery
 Continual
improvement
 Enhance
customer
satisfaction
There are plenty of possibilities for failure, especially when
new products are being launched. E.g. Car wheel tyre
APQP is used to assure Quality and Performance through Planning.
It focus on Utilization of Tools and Methods for Mitigating the risks
associated with change in the New Product or Process. It helped to
Develop appropriate Prevention & Detection controls for new products

11. -: APQP House:-

12. -: What are the stages/phases of APQP?:-
80%ofAPQPprocess:
Planning&Prevention
20%ofAPQPprocess:
Validation&Evidence

13. -: What is the importance of PDSA cycle in APQP?:-
 What are we trying to accomplish ?
 How will we know that change is an improvement?
 What changes can we test that results in an improvement?
“Finding risk in
product and
process
development is
more desirable
than finding late
failure”!

14. -: When to Apply Advanced Product Quality Planning (APQP):-
APQP is used in 2 ways:
1. New Product Introduction (NPI):-
APQP supplements product development processes by adding a focus
on risk as a substitute for failure. This allows the team to take action on
the risk instead of having to wait for failure to occur in testing or worse,
in the hands of the customer. APQP utilizes risk based tools that
focus on all aspects of product and process design, service, process
quality control, packaging and continuous improvement. Each
application of APQP may be unique to a previous application because
of the percentage of new content, changes to current off-the-shelf
technology or past failure history.
2. Product or Process Change (Post Release):-
APQP follows a product or process change outside of Product
Development and assures the risk of change is managed successfully
by preventing problems created by the change.

15. -: How to plan? :-

16. -: APQP Timing Chart:-

17. Outcome of Various Process Stages of APQP
PFMEA
Control Plan
Launch Containment Plan
Ram Up Plan
PPAPApproval
-: Different stages/phases of APQP:-
Preliminary SC/CC Review
Engineering Release
DFMEA
DV Test
Equip & Facilities Review
Gage & Fixture Review
Control Plan
Feasibility
Dimensional & Appearance Approval
Packaging Approval
Doc, Process & SC/CC Review
Engineering Release
Process Flow/Floor Plan
PFMEA & Control Plan
Process / Operator Instructions
Production Tooling Complete
PPAP Submission
Team Feasibility

18. -: Different stages/phases of APQP:-
Phase 0: Pre-Planning
APQP begins with assumptions,
concepts and past knowledge.
Bookshelf knowledge and standard
work practices are listed as well as
where significant change is expected.
This section compiles the inputs into
Section 1 – Plan and Define.
 Aspects of Pre-Planning include:
 Scope of the project
 Product and Process Assumptions
 Past Failure
 Team size, structure and experience
 Methods for issue resolution
 Space and resources required
 Timing of the project

20. -: Different stages/phases of APQP:-
Phase 1: Plan and Define
Section 1 links customer expectations,
wants, needs and desires to requirements.
Plan Development will assure the output of
this section is satisfactory product quality.
Resource planning, process and product
assumptions are made. A list of
preliminary special characteristics and
design/reliability goals are also established.
The Cross Functional Team (CFT) in APQP evolves and changes as the
process progresses. Preliminary details required to begin Product Quality
Planning are collected by a CFT prior to project kick-off. This process is
typically short and does not involve any product or process design effort.
The CFT adds members as certain disciplines are required.
Each CFT discipline communicates with their colleagues on items which
can impact quality, cost or delivery, either positively or negatively.

21. -: APQP phase 1: Plan and Define :-
Inputs & Outputs of Phase 1
• Voice of the Customer
°Market Research
°Historical Warranty and
Quality Information
°Team Experience
• Business Plan and Marketing
Strategy
• Product/Process Benchmark
Data
• Product/Process Assumptions
• Product Reliability Studies
• Customer Inputs
• Service
• Design Goals
• Reliability and Quality Goals
• Preliminary Bill of Material
• Preliminary Process Flow Chart
• Preliminary Listing of Special
Product and Process
Characteristics
• Product Assurance Plan
• Management Support
Phase 1
Phase 1: Inputs
Phase 1: Outputs (= Phase 2: Inputs)

22. -: APQP phase 1: Objective of Plan and Define phase:-
- To plan & Define
Advanced product quality
planning (APQP) for the
program.
- To ensure that the
supplier clearly
understands customer
needs and expectations in
order to plan and define a
quality program.
- The supplier is
responsible for completing,
using and updating the
planning documents
throughout the program.

23. -: APQP phase 2: Product Design and Development :-
 Phase 2: Product Design and
Development
The focus in Phase 2 is on product
design and development. Geometry,
design features, details, tolerances and
refinement of special characteristics
are all reviewed in a formal Design
Review. Design verification through
prototypes and testing are also part of
this section.
• Tools: Tools which typically provide
great benefit in this section
are DFM/A, Design Failure Mode
and Effects Analysis
(DFMEA) and Design Verification
Plan and Report (DVP&R).

24. -: APQP phase 2: Product Design and Development :-
Inputs & Outputs of Phase 2
• Design Goals
• Reliability and
Quality Goals
• Preliminary Bill of
Material
• Preliminary Process
Flow Chart
• Preliminary Listing
of Special Product
and Process
Characteristics
• Product Assurance
Plan
• Management Support
Phase 2
• Outputs by
Design
Responsible
Activity
• Outputs by
Advanced
Product
Quality
Planning
Team
• Design FMEA
• DFM and DFA
Design for
Manufacturability
Design for Assembly
• Design Verification
• Design Reviews
• Prototype Build Control Plan
• Engineering Drawings
(including Math data)
• Engineering Specifications
• Material Specifications
• Drawing and Specification
Changes
• New equipment, tooling and
facilities requirements
• Special product and process
characteristics
• Gage and testing equipment
requirements
• Team feasibility commitment
and management support
• Subcontractor build
• Supplier build
Phase 1 Outputs
(Phase 2 Inputs)
Phase 2 Outputs
(Phase 3 Inputs)

25. -: APQP phase 2:- Objective of Product Design and Development :-
- Identify the
product's potential
failure modes,
assess the probability
of the failure modes
occurring, review
the effects of such
failures and
formulate action
plans to improve the
product designs to
prevent or
counteract the
failures and their
effects.

26. -: APQP phase 3: Process Design and Development :-
 Phase 3: Process Design
and Development :-
This Phase explores
manufacturing techniques
and measurement methods
that will be used to bring the
design engineer’s vision into
reality.
- Tools: Process Flow
Charts, Process Failure
Mode and Effects Analysis
(PFMEA) and Control Plan
Methodology are examples of
tools used in this section.

27. -: APQP phase 3: Process Design and Development :-
Inputs & Outputs of Phase 3
• Outputs by Design Responsible
Activity
• Outputs by Advanced Product
Quality Planning Team• Design FMEA
• DFM and DFA
Design for
Manufacturability
Design for Assembly
• Design Verification
• Design Reviews
• Prototype Build Control
Plan
• Engineering Drawings
(including Math data)
• Engineering Specifications
• Material Specifications
• Drawing and Specification
Changes
• New equipment, tooling
and facilities
requirements
• Special product and
process characteristics
• Gage and testing
equipment requirements
• Team feasibility
commitment and
management support
• Subcontractor build
• Supplier build
Phase 3
Phase 3 Outputs (Phase 4 Inputs)
• Packaging Standards
• Product / Process Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process Failure Mode and Effects
Analysis
• Pre-Launch Control Plan
• Process Instructions
• Measurement Systems Analysis Plan
• Preliminary Process Capability Study
Plan
• Packaging Specifications
Phase 2 Outputs (Phase 3 Inputs)
Phase 2 Design
Activity Outputs
Phase 2 APQP
Team Outputs

28. -: APQP phase 3: Objective of Process Design and Development :-
- Develop a process flow
diagram and process
map of layout of the
manufacturing area.
- Develop comprehensive
and effective
manufacturing system to
ensure the manufacturing
systems meets customer
requirements.

29. -: APQP phase 4: Product and Process Validation:-
Phase 4: Product and
Process Validation
Validation of the process
quality and volume
capabilities is the focus of
Section 4. Statistical
Process Control (SPC),
Measurement Systems
Analysis (MSA)
and Process Capability
Studies are introduced in
this section. Product Part
Approval Process (PPAP)
is ready for submission
and production begins
upon approval.
Juran Trilogy diagram:-

30. -: APQP phase 4: Product and Process Validation:-
• Production Trial Run
• Measurement Systems
Evaluation
• Preliminary Process Capability
Study
• Production Part Approval
(PPAP)
• Production Validation Testing
• Packaging Evaluation
• Production Control Plan
• Quality Planning Sign-off
Phase 4
• Packaging Standards
• Product / Process Quality
System Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process Failure Mode and
Effects Analysis
• Pre-Launch Control Plan
• Process Instructions
• Measurement Systems Analysis
Plan
• Preliminary Process Capability
Study Plan
• Packaging Specifications
Phase 3 Outputs
(Phase 4 Inputs)
Phase 4 Outputs
(Phase 5 Inputs)
Inputs & Outputs
of Phase 4

31. -: APQP phase 4: Objective of Product and Process Validation:-
- Validate the
manufacturing processes
& the product, and to
ensure that customer's
requirement will be
meet. The supplier shall
develop a PPAP
document package and
submit to the customer
for approvals. The
supplier should
communicate with
customer to determine
PPAP submission level
requirements.

32. -: APQP phase 5: Feedback Assessment and Corrective Action:-
Phase 5: Feedback
Assessment and
Corrective Action
Section 5 explores
learning's from the
ongoing manufacturing
process, RPN reduction,
corrective actions (both
internal and
external), Eight
Disciplines of Problem
Solving (8D) and the
capture of information
pertinent for future use.

33. -: APQP phase 5: Feedback Assessment and Corrective Action:-
• Reduced
Variation
• Customer
Satisfaction
• Delivery
and Service
Phase 5
• Production Trial Run
• Measurement Systems
Evaluation
• Preliminary Process
Capability Study
• Production Part Approval
(PPAP)
• Production Validation Testing
• Packaging Evaluation
• Production Control Plan
• Quality Planning Sign-off
Phase 5 Outputs
Phase 4 Outputs
(Phase 5 Inputs)

34. -: APQP phase 5: Objective of Feedback Assessment and Corrective Action :-
The objective of this
phase is to assess
the effectiveness of
APQP for the
program and to
incorporate the
changes or
practices in
upcoming program
planning to improve
the system.

35. -: APQP Complete House structure :-
NPI: New Product
Introduction

36. • Directing/ Aiming resources by defining the
vital few items from the trivial many
• Promote early identification of change
• Intentional & Incidental
• Avoid late changes (post release) by anticipating
failure and preventing it
• On-time quality product at lowest cost
• Multiple options for mitigating the risk when
found earlier
• Higher capability of verification and validation of
a change
• Improved collaboration between Design of the
Product and Process
• Improved Design for Manufacturing
and Assembly (DFM/A)
• Lower cost solutions selected earlier in the
process
• Advancement of Tribal Knowledge and standard
work creation and utilization
-: What are the benefits of APQP?:-

37. -: Example of APQP :-