The document outlines the Advanced Product Quality Planning (APQP) process flow, which consists of 6 main steps: 1) Prepare for APQP, 2) Plan and Define Program, 3) Product Design and Development, 4) Process Design and Development, 5) Product and Process Validation, and 6) Feedback, Assessment and Corrective Action. Each step involves inputs, outputs, and activities to ensure new products and processes meet quality objectives and customer requirements. The goal of APQP is to develop and launch defect-free products and achieve reduced variation, customer satisfaction, and on-time delivery.

1. APQP PROCESS FLOW
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Process Design
and
Development
Product and
Process
Validation
Feedback,
Assessment and
Corrective Action
1

2. APQP PROCESS FLOW
Prepare for
APQP
Plan and Define
Program
Product Design
and
Development
Process Design
and
Development
Product and
Process
Validation
Feedback,
Assessment and
Corrective Action
• Organize the
Team
• Define the Scope
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
2

3. APQP PROCESS FLOW
Plan and Define
Program
Product Design
and
Development
Process Design
and
Development
Product and
Process
Validation
Feedback,
Assessment and
Corrective Action
INPUT
Prepare for
APQP
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• Develop Control
Plan Format
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
3

4. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
Product Design
and
Development
Process Design
and
Development
Product and
Process
Validation
Feedback,
Assessment and
Corrective Action
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• 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
• Decide on
Concern Resolution
• Develop Product
Quality Timing Plan
4

5. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• Design Goals
• Reliability and
Quality Goals
Process Design
and
Development
Product and
Process
Validation
Feedback,
Assessment and
Corrective Action
OUTPUT
INPUT
Product Design
and
Development
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• Design Failure
Mode and Effects
Analysis (DFMEA)
• Preliminary Bill of
Material
• Design for
Manufacturability and
Assembly
• Preliminary
Process Flow Chart
• Design Verification
• Preliminary Listing
of Special Product
and Process
Characteristics
• Design Reviews
• Prototype Build –
Control Plan
• Product
Assurance Plan
• Engineering
Drawings (Including
Math Data)
• Management
Support
• Engineering
Specifications
• Decide on
Concern Resolution
• Material
Specifications
• Develop Product
Quality Timing Plan
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
5

6. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• Reliability and
Quality Goals
INPUT
OUTPUT
INPUT
• Design Goals
• Design Failure
Feedback,
Assessment and
Corrective Action
• Packaging
Mode and Effects
Analysis (DFMEA)
Standards
• Preliminary Bill of
Material
• Design for
Manufacturability and
Assembly
• Preliminary
Process Flow Chart
• Design Verification
• Preliminary Listing
of Special Product
and Process
Characteristics
Product and
Process
Validation
OUTPUT
Process Design
and
Development
Product Design
and
Development
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• Design Reviews
• Prototype Build –
Control Plan
• Product
Assurance Plan
• Engineering
Drawings (Including
Math Data)
• Management
Support
• Engineering
Specifications
• Decide on
Concern Resolution
• Material
Specifications
• Develop Product
Quality Timing Plan
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Product/Process
Quality System
Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Support
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
6

7. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• Reliability and
Quality Goals
Feedback,
Assessment and
Corrective Action
OUTPUT
• Design Failure
• Packaging
• Production Trial
Mode and Effects
Analysis (DFMEA)
Standards
Run
• Product/Process
Quality System
Review
• Measurement
Systems
Evaluation
• Process Flow Chart
• Preliminary
Process Capability
Study
• Preliminary Bill of
Material
• Design for
Manufacturability and
Assembly
• Preliminary
Process Flow Chart
• Design Verification
• Preliminary Listing
of Special Product
and Process
Characteristics
Product and
Process
Validation
INPUT
INPUT
OUTPUT
INPUT
• Design Goals
OUTPUT
Process Design
and
Development
Product Design
and
Development
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• Design Reviews
• Prototype Build –
Control Plan
• Product
Assurance Plan
• Engineering
Drawings (Including
Math Data)
• Management
Support
• Engineering
Specifications
• Decide on
Concern Resolution
• Material
Specifications
• Develop Product
Quality Timing Plan
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Packaging
Specifications
• Management
Support
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
7

8. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
• Reliability and
Quality Goals
• Packaging
• Production Trial
Mode and Effects
Analysis (DFMEA)
Standards
Run
• Product/Process
Quality System
Review
• Measurement
Systems
Evaluation
• Process Flow Chart
OUTPUT
INPUT
OUTPUT
Feedback,
Assessment and
Corrective Action
• Design Failure
• Preliminary
Process Capability
Study
• Preliminary Bill of
Material
• Design for
Manufacturability and
Assembly
• Preliminary
Process Flow Chart
• Design Verification
• Preliminary Listing
of Special Product
and Process
Characteristics
Product and
Process
Validation
INPUT
INPUT
OUTPUT
INPUT
• Design Goals
OUTPUT
Process Design
and
Development
Product Design
and
Development
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• Design Reviews
• Prototype Build –
Control Plan
• Product
Assurance Plan
• Engineering
Drawings (Including
Math Data)
• Management
Support
• Engineering
Specifications
• Decide on
Concern Resolution
• Material
Specifications
• Develop Product
Quality Timing Plan
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
• Special Product and
Process
Characteristics
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Packaging
Specifications
• Management
Support
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
8

9. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Reliability and
Quality Goals
• Product/Process
Assumptions
• Product Reliability
Studies
Run
• Product/Process
Quality System
Review
• Measurement
Systems
Evaluation
• Process Flow Chart
OUTPUT
• Preliminary
Process Capability
Study
• Preliminary
Process Flow Chart
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Product
Assurance Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Decide on
Concern Resolution
• Material
Specifications
• Develop Product
Quality Timing Plan
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
FMEA
INPUT
• Production Trial
Standards
• Management
Support
• Customer Inputs
OUTPUT
• Packaging
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Preliminary Listing
of Special Product
and Process
Characteristics
Feedback,
Assessment and
Corrective Action
• Design Failure
• Preliminary Bill of
Material
• Product/Process
Benchmark Data
Product and
Process
Validation
INPUT
INPUT
OUTPUT
INPUT
• Design Goals
OUTPUT
Process Design
and
Development
Product Design
and
Development
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• Special Product and
Process
Characteristics
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Packaging
Specifications
• Management
Support
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
9

10. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Reliability and
Quality Goals
• Product/Process
Assumptions
• Product Reliability
Studies
Run
• Product/Process
Quality System
Review
• Measurement
Systems
Evaluation
• Process Flow Chart
OUTPUT
• Preliminary
Process Capability
Study
• Preliminary
Process Flow Chart
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Product
Assurance Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Decide on
Concern Resolution
• Material
Specifications
• Develop Product
Quality Timing Plan
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
FMEA
INPUT
• Production Trial
Standards
• Management
Support
• Customer Inputs
OUTPUT
• Packaging
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Preliminary Listing
of Special Product
and Process
Characteristics
Feedback,
Assessment and
Corrective Action
• Design Failure
• Preliminary Bill of
Material
• Product/Process
Benchmark Data
Product and
Process
Validation
INPUT
INPUT
OUTPUT
INPUT
• Design Goals
OUTPUT
Process Design
and
Development
Product Design
and
Development
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• Special Product and
Process
Characteristics
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Packaging
Specifications
• Management
Support
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
APQP
10

11. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Reliability and
Quality Goals
• Product/Process
Assumptions
• Product Reliability
Studies
Run
• Product/Process
Quality System
Review
• Measurement
Systems
Evaluation
• Process Flow Chart
OUTPUT
• Preliminary
Process Capability
Study
• Preliminary
Process Flow Chart
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Product
Assurance Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Decide on
Concern Resolution
• Material
Specifications
• Develop Product
Quality Timing Plan
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
FMEA
INPUT
• Production Trial
Standards
• Management
Support
• Customer Inputs
OUTPUT
• Packaging
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Preliminary Listing
of Special Product
and Process
Characteristics
Feedback,
Assessment and
Corrective Action
• Design Failure
• Preliminary Bill of
Material
• Product/Process
Benchmark Data
Product and
Process
Validation
INPUT
INPUT
OUTPUT
INPUT
• Design Goals
OUTPUT
Process Design
and
Development
Product Design
and
Development
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• Special Product and
Process
Characteristics
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Customer
Satisfaction
• Delivery and
Service
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Packaging
Specifications
• Management
Support
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Reduced Variation
APQP
SPC
11

12. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Reliability and
Quality Goals
• Product/Process
Assumptions
• Product Reliability
Studies
Run
• Product/Process
Quality System
Review
• Measurement
Systems
Evaluation
• Process Flow Chart
OUTPUT
• Preliminary
Process Capability
Study
• Preliminary
Process Flow Chart
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Product
Assurance Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Decide on
Concern Resolution
• Material
Specifications
• Develop Product
Quality Timing Plan
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
FMEA
INPUT
• Production Trial
Standards
• Management
Support
• Customer Inputs
OUTPUT
• Packaging
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Preliminary Listing
of Special Product
and Process
Characteristics
Feedback,
Assessment and
Corrective Action
• Design Failure
• Preliminary Bill of
Material
• Product/Process
Benchmark Data
Product and
Process
Validation
INPUT
INPUT
OUTPUT
INPUT
• Design Goals
OUTPUT
Process Design
and
Development
Product Design
and
Development
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• Special Product and
Process
Characteristics
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Production
Validation Testing
• Customer
Satisfaction
• Delivery and
Service
MSA
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
• Packaging
Specifications
• Management
Support
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Production Part
Approval
• Reduced Variation
APQP
SPC
12

13. APQP PROCESS FLOW
• Organize the
• Voice of the
Team
Customer
• Define the Scope
• Business
Plan/Marketing
Strategy
• Establish Team-toTeam
Communication
• Provide Core
Tools Training
• Involve Customers
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
• Design Goals
• Reliability and
Quality Goals
• Product/Process
Assumptions
• Product Reliability
Studies
• Product/Process
Quality System
Review
• Measurement
Systems
Evaluation
• Process Flow Chart
OUTPUT
INPUT
OUTPUT
Run
• Preliminary
Process Capability
Study
• Preliminary
Process Flow Chart
• Design Verification
• Design Reviews
• Prototype Build –
Control Plan
• Product
Assurance Plan
• Engineering
Drawings (Including
Math Data)
• Engineering
Specifications
• Decide on
Concern Resolution
• Material
Specifications
• Develop Product
Quality Timing Plan
• Drawing and
Specification Changes
• New Equipment,
Tooling and Facilities
Requirements
FMEA
INPUT
• Production Trial
Standards
• Management
Support
• Customer Inputs
OUTPUT
• Packaging
Mode and Effects
Analysis (DFMEA)
• Design for
Manufacturability and
Assembly
• Preliminary Listing
of Special Product
and Process
Characteristics
Feedback,
Assessment and
Corrective Action
• Design Failure
• Preliminary Bill of
Material
• Product/Process
Benchmark Data
Product and
Process
Validation
Process Design
and
Development
INPUT
OUTPUT
INPUT
Product Design
and
Development
OUTPUT
Plan and Define
Program
INPUT
Prepare for
APQP
• Special Product and
Process
Characteristics
• Floor Plan Layout
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
• Pre-Launch Control
Plan
• Process Instructions
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Production
Validation Testing
• Customer
Satisfaction
• Delivery and
Service
MSA
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
PPAP
• Packaging
Specifications
• Management
Support
• Gages/Testing
Equipment
Requirements
• Team Feasibility
Commitment and
Management Support
• Production Part
Approval
• Reduced Variation
APQP
SPC
13