The document provides an overview of Advanced Product Quality Planning (APQP) based on the AIAG reference manual. It discusses the objectives of APQP, which is a structured method for new product development to ensure customer satisfaction. The presentation outlines the 5 phases of APQP: 1) Plan and define program, 2) Product design and development, 3) Process design and development, 4) Product and process validation, and 5) Feedback, assessment and corrective action. Breakout sessions provide examples of applying APQP methodology to a new product development project. Key terms and an overview of the relationship between APQP and ISO/TS 16949 are also summarized.

1. Advanced Product Quality
Planning (APQP)
Based on the AIAG “Advanced Product
Quality Planning and Control Plan”
Reference Manual
Presented By Dr. Cecelia Venuk
November 2009

2. Objectives
Understand the APQP Process
Identify the inputs / outputs of
the 5 APQP phases
Understand APQP as a
methodology for new product
development

3. What is Quality Planning?
?
? ?
? ? ?

4. The AIAG APQP Model
What is APQP?
Advance Product Quality Planning is a structured
method of defining and establishing the steps
necessary to assure that a product satisfies the
customer.
The goal of product quality planning is to facilitate
communication with everyone involved to assure
that all required steps are completed on time.
Effective product quality planning depends on a
company’s top management commitment to the
effort required in achieving customer satisfaction.

5. Why Product Quality Planning?
The bulk of cost of a product is committed at the early stages
of a development cycle even though they are not expended
until later.
The cost of fixing a design and faulty decisions at later stages
is exponentially greater than at an earlier stage.
The opportunity costs of being late to market are very high,
ex., lower market share, lower margins.
Cross-functional teams typically provide a better quality
solution to complex dynamic product development problems
than single individuals.
Early simultaneous involvement in product development by
cross-functional teams using structured development process
saves time and money over the product life cycle.

6. Fundamentals of Product
Quality Planning
Organizing the team
Define the scope
Team-to-Team Communication
Training
Customer, supplier and subcontractor
involvement
Simultaneous Concurrent Engineering
Control plans
Concern Resolution
Timing plan and chart

7. Product Quality Planning Chart
Concept Program
Initiation/Approval Approval Prototype Pilot Launch
Planning Planning
Product Design and Dev.
Process Design and Development
Product and Process Validation
Production
Feedback Assessment and Corrective Action
Plan and Product Process Product Feedback
Define Design and Design and and Process Assessment and
Program Development Development Validation Corrective Action

8. 1.0 Plan and Define Program
Inputs Objectives
Concept Program Voice of the Customer
Initiation/Approval Approval Determine customer needs.
- Market Research Define and plan a quality
- Historical Warranty program.
and Quality Information
Planning - Team Experience
Business Plan/Marketing strategy
Product/Process Benchmark Data
Product Reliability Studies
Customer Inputs
Outputs
Design Goals
Reliability and Quality Goals
Preliminary Bill of Material
Preliminary Process Flowchart
Preliminary Listing of Special Product and Process Characteristics
Plan and Product Assurance Plan
Define Management Support
Program

9. Breakout – Quality Planning
Product Description: PPASS
(Personal Portable Automotive Sound System)
This is a new option for all mid to high price range vehicles
that allows an individuals personal MP3 or IPOD system to
be integrated with the sound system of suitably equipped
automotive vehicles. This product is a universal MP3 / IPOD
holder combined with a short-range wireless link that has
already been developed by the automotive industry.

10. Breakout – Quality Planning
PPASS Design Goals & Parameters
• Dashboard will have a built-in wireless interface receiver
that links with the any PPASS transmitter
• Must integrate with a wireless transmitter with a
dimension of .5” X 1.0” X .2”
• Maximum holder dimension: 3” X 4.5” X 1.5”
• Universal fixture for 98% of all types of players
• Safely positioned in vehicle during vehicle operation, and
is to be located within three (3) feet of the sound system.
• Robust materials of construction (portable) with an
expected lifetime of 3 years
• Single neutral color – go will all interiors

11. 2.0 Product Design and Development
Program Objectives
Approval Prototype Inputs Develop design features and
The outputs of Section 1.0 characteristics
Review engineering requirements
Assess potential manufacturing
problems that could occur
Product Design and Dev. Outputs
Design Failure Mode and Effects Analysis (DFMEA)
Design for Manufacturability and Assembly
Design Verification
Design Reviews
Prototype build – Control plan
Engineering Drawings
Engineering Specifications
Material Specifications
Drawing and Specification Changes
Product New Equipment, Tooling and Facilities Requirements
Design and Special Product and Process Characteristics
Development Team Feasibility Commitment and Management Support

12. Breakout – Quality Planning
Develop a design for the Personal
Portable Automotive Sound System
(PPASS) unit. Your team (4 to 6 people)
has 20 minutes to:
1. Design a fixture to safely hold a MP3 / IPOD and a
sound system interface.
2. Identify any special customer characteristics or
concerns
3. Identify the material specifications
4. Identify any special tooling and equipment

13. Inputs to Prototype Control Plan
CONTROL PLAN SUMMARY
Pre-Launch Production
x
Prototype
Control Plan Number Reference Key Contact/Phone Date (Orig.) Rev. Date (Revised)
Part Number/Latest Change Level Part Name/Description Supplier/Plant Core Team
Customer
MACHINE,
CHARACTERISTIC METHODS
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE CONTROL REACTION CORRECTIVE
NUMBER DESCRIPTION FOR MFG. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. METHOD PLAN ACTION
TOLERANCE TECHNIQUE Error proofing Other
LSL TARGET USL
#1 #1 #2 #3 #4 #5 #6 #7 #8 #9 #10
Outputs & Expectations:
1 – Assure product meets specification
2 – Ensure attention to process/product characteristics
3 – Establish preliminary process/product characteristics
4 – Communicate to the customer

14. 3.0 Process Design and Development
Prototype Pilot Objectives
Inputs Develop comprehensive and
The outputs of Section 2.0 effective manufacturing process
Ensure process capability to
meet customer requirements
Outputs
Packaging Standards
Process Design and Development
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
Process Preliminary Process Capability Study Plan
Design and Packaging Specifications
Development Management Support

15. Breakout – Quality Planning
Next Steps
Continue with the process design and
development. Your team (4 to 6
people) has 10 minutes to:
1. Develop a process flow.
2. Identify critical manufacturing parameters to
measure and control
3. Identify 3 potential failures with this product

16. Inputs to Pre-launch Control Plan
CONTROL PLAN SUMMARY
x Pre-Launch Production Prototype
Control Plan Number Reference Key Contact/Phone Date (Orig.) Rev. Date (Revised)
Part Number/Latest Change Level Part Name/Description Supplier/Plant Core Team
Customer
MACHINE,
CHARACTERISTIC METHODS
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE CONTROL REACTION CORRECTIVE
NUMBER DESCRIPTION FOR MFG. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. METHOD PLAN ACTION
TOLERANCE TECHNIQUE Error proofing Other
LSL TARGET USL
#1 #1 #2 #3 #4 #5 #6 #7 #8 #9 #10
Outputs & Expectations:
1 – Communication for process control
2 – Input to pre-launch control plan
3 – Product quality & customer satisfaction
4 – Identified opportunities for improvement

17. 4.0 Product and Process Validation
Prototype Pilot Launch Objectives
Inputs Validate the product
The outputs of Validate the manufacturing process
Section 3.0 Validate the control plan
Ensure product meets customer
requirements
Identify concerns
Product and Process Validation Outputs
Production Trial Run
Measurement Systems Evaluation
Preliminary Process Capability Study
Production Part Approval
Production Validation Testing
Packaging Evaluation
Production Control Plan
Product Quality Planning Sign-Off and Management Support
and Process
Validation

18. 5.0 Feedback, Assessment
and Corrective Action
Pilot Launch Inputs Objectives
The outputs of Section 5.0 Evaluate all variation (variable
and attribute data)
Planning
Evaluate effectiveness of product
quality planning
Use control plan and corrective
action
Outputs
Reduced Variation
Production Customer Satisfaction
Delivery and Service
Feedback Assessment and Corrective Action
Feedback
Assessment and
Corrective Action

19. Summary:
The AIAG APQP Model
What is APQP?
APQP is a process, not just an event
Integration of quality tools with
management functions
Status Reporting and Program Management
Multi-disciplinary team approach to quality
planning
Satisfies requirement of TS, with linkage to
several ISO/TS 16949:2002 elements
Tool for continuous improvement

20. Summary:
The 5 Phases of APQP
1.Plan and Define the Program 1.
2.Product Design and Development
2.
3.Process Design and Development
4.Product and Process Validation 3.
5.Feedback, Assessment and 4.
Corrective Action 5.

21. APQP Acronyms
APQP – Advance Product Quality
Planning
D/P-FMEA – Design/Process Failure Mode
Effect Analysis
DVP&R – Design Verification Plan &
Report
AIAG – Automotive Industry Action
Group
TS 16949 – (Sector-specific) Technical
Specification (for automotive industry)
MSA – Measurement Systems Analysis
I/M/T – Inspection/Measurement/Test

22. Questions

23. Related Information

24. New Product Development and Launch Process
New Process Concept
Development Initiation/Approval
Project Program Ramp to
Start First Silicon Production
Approval Volume
APQP
Planning Planning
Product Design and Development
Process Design and Development and Validation
Product and Application Validation
Production
Feedback Assessment and Corrective Action
APQP and
ISO/TS Applicable ISO/TS 16949 Requirements
16949:2002 Design & Dev. Planning 7.3 (Product) Production & Service Provision 7.5
16949:2002
ISO/TS
Design & Dev. Planning 7.3 (Process) Monitoring & Measurement of
Processes 8.2.3.1
7.1 Planning of
Product Realization Monitoring & Measurement of Product
7.2 Customer- 8.2.4
Related Processes
Production Part Approval - 7.3.6.3
Feedback Assessment - 8
Continual Improvement - 8.5

25. Retention/Submission Requirements Table I.4.1 – AIAG PPAP Reference Guide 3 ed.
All listed items may not necessarily apply to every customer part from every supplier,
Consult design record and customer to determine which items or records apply
Submission Level
Requirement Level 1 Level 2 Level 3 Level 4 Level 5
1. Design/Development Records R S S • R
-for proprietary components/details R R R • R
-for all other components/details
AIAG PPAP:
R S S • R
2. Engineering Change Documents, if any R S S • R
3. TI Engineering Final Approval R R S • R
4. Design FMEA (or Risk Assessment) R R S • R
Contents 5.
6.
7.
Process Flow Diagrams
Process FMEA (or Risk Assessment)
Dimensional Results
R
R
R
R
R
S
S
S
S
•
•
•
R
R
R
and 8.
9.
10.
Material, Performance Test Results
Initial Process Study
Measurement System Analysis Studies
R
R
R
S
R
R
S
S
S
•
•
•
R
R
R
Submission 11.
12.
13.
Qualified Laboratory Documentation
Control Plan
Part submission Warrant (PSW)
R
R
S
S
R
S
S
S
S
•
•
S
R
R
R
levels
14. Appearance Approval Report, (AAR)
S S S • R
if applicable
15. Bulk Material Requirements Checklist
R R R • R
(for bulk material PPAP only)
16. Sample Product R S S • R
17. Master Sample (See I.2.2.17) R R R • R
Note: the PPAP form and 18. Checking Aids R R R • R
descriptions of each requirement 19. Records of Compliance
With Customer-Specific Requirements
R R S • R
is from the AIAG reference S = The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items
at appropriate locations, including manufacturing.
manual for PPAP, Third Edition
R = The supplier shall retain at appropriate locations, including manufacturing, and make readily available to the customer
representative upon request.
• = The supplier shall retain at appropriate locations, and submit to customer upon request.
Training/Graphics/APQP/R-S Requirement Table.doc