2. ADVANCED PRODUCT QUALITY
PLANNING (APQP)
APQP or Advanced Product Quality Planning is a structured method
of defining and establishing the steps necessary to ensure that a
product satisfies the customer. Effective product quality planning
depends on a company's top management's commitment to the effort
required in meeting customer specifications.
Advanced product quality planning is a process developed in the
late 1980s by a commission of experts gathered from the 'Big Three'
US automobile manufacturers: Ford, GM and Chrysler.
The four stages of the planning cycle are Plan, Do, Study and Act.
The first three stages are devoted to development and planning
process through product and process validation. Lastly, Act is the
implementation phase - focusing on customer satisfaction .
3. APQP- QBJECTIVES
Effective communications with all those who
are involved in the
implementation scheme.
Timely completion of required goals.
Minimum or no quality problems.
Minimum risks related to quality during product
launch
4. How Does APQP Work?
APQP is comprised of one pre-planning stage and five
concurrent, collaborative sections. This process is never ending
and is often illustrated with the Plan, Do, Study, Act Cycle. Each
section has analytical techniques and tools used to discover
risk and weakness.
Working concurrently per the project timeline,
Project Management team completes the Plan and Design
activity
Product Engineering addresses Product Design and
Development
Process and Manufacturing Engineering completes the
Process Design Development.
5. Phases of APQP
Phase 1: Plan & Define Program
Where do we want to go?
Phase 2: Product Design & Development
Verification
Can we design one?
Phase 3: Process Design & Development
Verification
Can we make one?
Phase 4: Product & Process Validation
Proof of Phases 2 and 3.
Phase 5: Feedback Assessment & Corrective
Action
Production, Continuous Improvement, Prevent Recurrence
6. PHASE 1: Plan and Define
objective: Develop a Plan that meets customer’s requirements
Cross-functional team formed to define scope.
Define scope: define customer requirements (use Quality
Function Deployment if applicable). Formal feasibility
assessments.
Key deliverables for this phase:
• Identify design intent: life and quality goals
• Preliminary Bill of Materials (BOM)
• Initial process flow chart
• Initial critical product and process characteristics
• Initial product assurance plan and signed-off management
support statement
7. PHASE 2: Design and
Development
objective : Detailed Review of Engineering Requirements Feasibility
Analysis
This is a thorough and robust review of engineering or
service requirements along with all related critical technical
or system information.
Key deliverables for this phase:
• Design/service Failure Mode Effects Analysis (FMEA)
• Design for successful execution of the manufacturing,
assembly of service path
• Design/service validation
• Preliminary control plans for early prototype/service trail
phase
• Engineering documentation and proofs
• Engineering/service specifications
8. PHASE 3:Process Design and
Development
objective :Develop an Effective Manufacturing System
This phase is designed to develop a robust, high-quality
manufacturing or service system. This phase must
ensure the key and important customer needs,
requirements and expectations are 100% satisfied.
Key deliverables for this phase:
• Process Failure Mode Effect Analyses (PFMEA)
• Product/process quality system review
• System layout
• Characteristics matrix
• Process/service flow chart
• Beta control plan prior to first run
• Packaging and delivery standards
• Process/service instructions
9. PHASE 4: Product and Process
Validation
Objective: Validate Manufacturing Process
This phase is a full evaluation and confirmation of the
manufacturing /service process , which includes trial runs with
the Quality Planning Team evaluating control plans, flow
charts and checking that customer requirements are met
throughout the system.
This phase resolves problems prior to the first official
production runs.
Key deliverables for this phase:
• Trial runs
• Initial capability analyses
• Measurement Systems Analysis (MSA) and validation
• Production Part Approval Process (PPAP)
• Production control plan
• Packaging validation: quality planning sign-off and
management presentation
10. PHASE 5: Feedback, Assessment and
Corrective Action
objective : Evaluate Manufacturing Output
The total quality planning system outputs and effects are
reviewed for effectiveness and improvement . All customer
requirements are reviewed and measured to confirm they are
met (or exceeded) and documented.
Key deliverables for this phase:
• Reduce unwanted variation
• Confirm customer satisfaction or delight
• Delivery and service requirements have been met
12. APQP PROCESS ELEMENTS
Understanding the needs of the customer
Proactive feedback and corrective action
Designing within the process capabilities
Analyzing and mitigating failure modes
Verification and validation
Design reviews
Control special / critical characteristics
13. APQP BENEFITS
Ensures early planning takes place
Directs resources to the customer
Identifies required changes early in the process
Provides quality product on time and at lowest cost
Enables cross-functional inputs and outputs
Addresses potential problems early in
• Design
• Manufacturing
