APQP

Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
By: Pankaj Nalwa

APQP, but for what?
Purpose of APQP is to produce a product quality plan which will support
development of a product or service that will satisfy the customer.
In simple words, APQP is intended to ensure that the supplier / manufacturer meets
all of the customer's requirements on time.
How to achieve this purpose?
By :
 Up-front quality planning
 Evaluating the output to determine if customer are satisfied & support continual
improvement.
APQP, but for what?
Purpose of APQP is to produce a product quality plan which will support
development of a product or service that will satisfy the customer.
In simple words, APQP is intended to ensure that the supplier / manufacturer meets
all of the customer's requirements on time.
How to achieve this purpose?
By :
 Up-front quality planning
 Evaluating the output to determine if customer are satisfied & support continual
improvement.
By: Pankaj Nalwa

Product Quality Planning Cycle
By: Pankaj Nalwa

The purpose of Product Quality Planning Cycle is to emphasize:
 Up-front planning.
The first three quarters of the cycle are devoted to up-front product quality planning
through product / process validation.
 The act of implementation.
The fourth quarter is the stage where importance of evaluating the output serves two
functions: to determine customer satisfaction and to support the pursuit of continual
improvement.
The purpose of Product Quality Planning Cycle is to emphasize:
 Up-front planning.
The first three quarters of the cycle are devoted to up-front product quality planning
through product / process validation.
 The act of implementation.
The fourth quarter is the stage where importance of evaluating the output serves two
functions: to determine customer satisfaction and to support the pursuit of continual
improvement.
By: Pankaj Nalwa

PQP usually doesn’t work effectively in organizations.
By: Pankaj Nalwa

PDCA
Plan
DoAct
Always
Always
Sometimes
Check
Sometimes
By: Pankaj Nalwa

If quality is to become a business strategy, top management must
understand quality as a planning strategy and provide leadership for
carrying out this strategy.
By: Pankaj Nalwa

Advanced product Quality Planning (APQP) is a structured
approach to the design and development of new products and
manufacturing processes, designed to ensure that:
 Suppliers understand the requirements of clients, end users and
consumers.
 The proposed product or process design satisfies those
requirements.
 The supplier has the ability to consistently meet the clients
requirements for quality, cost and delivery.
Advanced product Quality Planning (APQP) is a structured
approach to the design and development of new products and
manufacturing processes, designed to ensure that:
 Suppliers understand the requirements of clients, end users and
consumers.
 The proposed product or process design satisfies those
requirements.
 The supplier has the ability to consistently meet the clients
requirements for quality, cost and delivery.
By: Pankaj Nalwa

Roadblocks for APQP.
 Lack of commitment from Top Management.
 Lack of discipline.
 Undefined priorities.
 Undefined responsibilities.
 Lack of accountability.
 Personal egos and lack of team spirit.
 Unclear approach.
 Lack of resources.
 Lack of knowledge.
Roadblocks for APQP.
 Lack of commitment from Top Management.
 Lack of discipline.
 Undefined priorities.
 Undefined responsibilities.
 Lack of accountability.
 Personal egos and lack of team spirit.
 Unclear approach.
 Lack of resources.
 Lack of knowledge.
By: Pankaj Nalwa

The APQP process includes five main functions:
 Planning of APQP elements.
 Execution of APQP elements.
 Monitoring the “Quality-of-Event” of the execution of the elements, as well as the
timing, by the team in-between FPDS milestones.
 Issues Resolution
 Status Reporting
The APQP process includes five main functions:
 Planning of APQP elements.
 Execution of APQP elements.
 Monitoring the “Quality-of-Event” of the execution of the elements, as well as the
timing, by the team in-between FPDS milestones.
 Issues Resolution
 Status Reporting
By: Pankaj Nalwa

Prepare for
APQP
Plan and Define
Program
Product
Design and
Development
Product &
Process
Validation
Process
Design and
Development
Feedback,
Assessment &
Corrective Action
Process Flow for APQP
• Organize the Team
• Define the Scope
• Establish Team-to-
Team
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
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
By: Pankaj Nalwa

Phase 1: Planning and defining the program
This phase is meant to determine customer needs and expectations. Purpose of this
phase is to ensure that the customer’s needs and expectations are fully understood
before proceeding with the “design & development of the product” or “manufacturing
process associated with product”.
By: Pankaj Nalwa

Prepare for
APQP
Plan and Define
Program
Product
Design and
Development
Product &
Process
Validation
Process
Design and
Development
Feedback,
Assessment &
Corrective Action
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
INPUT• Organize the Team
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
By: Pankaj Nalwa

Prepare for
APQP
Plan and Define
Program
Product
Design and
Development
Product &
Process
Validation
Process
Design and
Development
Feedback,
Assessment &
Corrective Action
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
INPUT
• 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
OUTPUT
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
• 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
By: Pankaj Nalwa

Phase 2: Product design and development
In this phase, design features and characteristics are developed into near final form.
This phase focuses on developing the design of the product or service, and on
ensuring that it is feasible and will meet the customer’s expectations.
By: Pankaj Nalwa

Prepare for
APQP
Plan and Define
Program
Product
Design and
Development
Product &
Process
Validation
Process
Design and
Development
Feedback,
Assessment &
Corrective Action
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
INPUT
• 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
OUTPUT
• Design Failure Mode
and Effects Analysis
(DFMEA)
• Design for
Manufacturability and
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
• Gages/Testing
Equipment Requirements
• Team Feasibility
Commitment and
Management Support
INPUT
OUTPUT
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
• Design Goals
• Reliability and
Quality Goals
Material
Flow Chart
of Special Product
and Process
Characteristics
Plan
• Management
Support
(DFMEA)
• Design for
Assembly
• Design Reviews
Control Plan
(Including Math Data)
• Engineering
Specifications
• Drawing and
and Facilities
Requirements
• Gages/Testing
Commitment and
Management Support
By: Pankaj Nalwa

Phase 3: Process design and development
This phase concentrates on developing a manufacturing system and related control
plans to achieve quality products.
This phase focuses on creating a process that will ensure the design that was
developed in the previous phase at the same quality level, quantity and cost, and at
the same time assuring that any other customer requirements and expectations will
be met.
Activities of this phase make sure that the product represents a value to customer.
Phase 3: Process design and development
This phase concentrates on developing a manufacturing system and related control
plans to achieve quality products.
This phase focuses on creating a process that will ensure the design that was
developed in the previous phase at the same quality level, quantity and cost, and at
the same time assuring that any other customer requirements and expectations will
be met.
Activities of this phase make sure that the product represents a value to customer.
By: Pankaj Nalwa

Prepare for
APQP
Plan and Define
Program
Product
Design and
Development
Product &
Process
Validation
Process
Design and
Development
Feedback,
Assessment &
Corrective Action
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
INPUT
• Design Goals
• Reliability and
Quality Goals
Material
Flow Chart
of Special Product
and Process
Characteristics
Plan
• Management
Support
OUTPUT
(DFMEA)
• Design for
Assembly
• Design Reviews
Control Plan
• Engineering
Specifications
• Drawing and
and Facilities
Requirements
• Gages/Testing
Commitment and
Management Support
INPUT
OUTPUT
• Packaging
Standards
• 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
INPUT
OUTPUT
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
• Design Goals
• Reliability and
Quality Goals
Material
Flow Chart
of Special Product
and Process
Characteristics
Plan
• Management
Support
(DFMEA)
• Design for
Assembly
• Design Reviews
Control Plan
• Engineering
Specifications
• Drawing and
and Facilities
Requirements
• Gages/Testing
Commitment and
Management Support
• Packaging
Standards
• Product/Process
Quality System
Review
• Characteristics
Matrix
• Process Failure
Mode and Effects
Analysis (PFMEA)
Plan
• Measurement
Systems Analysis
Plan
• Preliminary
Process Capability
Study Plan
• Packaging
Specifications
• Management
Support
By: Pankaj Nalwa

Phase 4: Product and process validation
This phase concentrates on validating the manufacturing process through evaluation
of production trial run and all the activities related to it.
This phase focuses on methods and techniques for determining that the long-term
production process is capable of meeting all the requirements that have been
researched and documented through the previous phases.
Phase 4: Product and process validation
This phase concentrates on validating the manufacturing process through evaluation
of production trial run and all the activities related to it.
This phase focuses on methods and techniques for determining that the long-term
production process is capable of meeting all the requirements that have been
researched and documented through the previous phases.
By: Pankaj Nalwa

Prepare for
APQP
Plan and Define
Program
Product
Design and
Development
Product &
Process
Validation
Process
Design and
Development
Feedback,
Assessment &
Corrective Action
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
INPUT
• Design Goals
• Reliability and
Quality Goals
Material
Flow Chart
of Special Product
and Process
Characteristics
Plan
• Management
Support
OUTPUT
(DFMEA)
• Design for
Assembly
• Design Reviews
Control Plan
• Engineering
Specifications
• Drawing and
and Facilities
Requirements
• Gages/Testing
Commitment and
Management Support
INPUT
OUTPUT
• Packaging Standards
• Product/Process
Quality System Review
• Characteristics Matrix
• Process Failure Mode
(PFMEA)
Plan
• Measurement
Systems Analysis Plan
Capability Study Plan
• Packaging
Specifications
• Management Support
INPUT
OUTPUT
• Production Trial
Run
• Measurement
Systems
Evaluation
• Preliminary
Process Capability
Study
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
• Quality Planning
Sign-Off and
Management
Support
INPUT
OUTPUT
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
• Design Goals
• Reliability and
Quality Goals
Material
Flow Chart
of Special Product
and Process
Characteristics
Plan
• Management
Support
(DFMEA)
• Design for
Assembly
• Design Reviews
Control Plan
• Engineering
Specifications
• Drawing and
and Facilities
Requirements
• Gages/Testing
Commitment and
Management Support
• Product/Process
Quality System Review
(PFMEA)
Plan
• Measurement
Systems Analysis Plan
• Packaging
Specifications
• Production Trial
Run
• Measurement
Systems
Evaluation
• Preliminary
Process Capability
Study
• Production Part
Approval
• Production
Validation Testing
• Packaging
Evaluation
• Production
Control Plan
Sign-Off and
Management
Support
By: Pankaj Nalwa

Phase 5: Feedback, assessment and corrective action.
At this point, output is evaluated for all special and common cause variation. This is
also the time to evaluate the effectiveness of the quality planning effort itself.
In this phase, variation can be studied and reduced over the time.
Results of organization’s continuous improvement philosophy will be most visible.
Phase 5: Feedback, assessment and corrective action.
At this point, output is evaluated for all special and common cause variation. This is
also the time to evaluate the effectiveness of the quality planning effort itself.
In this phase, variation can be studied and reduced over the time.
Results of organization’s continuous improvement philosophy will be most visible.
By: Pankaj Nalwa

Prepare for
APQP
Plan and Define
Program
Product
Design and
Development
Product &
Process
Validation
Process
Design and
Development
Feedback,
Assessment &
Corrective Action
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
INPUT
• Design Goals
• Reliability and
Quality Goals
Material
Flow Chart
of Special Product
and Process
Characteristics
Plan
• Management
Support
OUTPUT
(DFMEA)
• Design for
Assembly
• Design Reviews
Control Plan
• Engineering
Specifications
• Drawing and
and Facilities
Requirements
• Gages/Testing
Commitment and
Management Support
INPUT
OUTPUT
• Product/Process Quality
System Review
(PFMEA)
Plan
• Measurement Systems
Analysis Plan
• Packaging
Specifications
INPUT
OUTPUT
• Production Trial Run
• Measurement
Systems Evaluation
Capability Study
• Production Part
Approval
• Production Validation
Testing
• Packaging Evaluation
• Production Control
Plan
Sign-Off and
Management Support
INPUT
OUTPUT
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
OUTPUT
INPUT
Team
Communication
Training
and Suppliers
• Implement
Simultaneous
Engineering
• Develop Control
Plan Format
Resolution
• Develop Product
Quality Timing Plan
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
Studies
• Customer Inputs
• Design Goals
• Reliability and
Quality Goals
Material
Flow Chart
of Special Product
and Process
Characteristics
Plan
• Management
Support
(DFMEA)
• Design for
Assembly
• Design Reviews
Control Plan
• Engineering
Specifications
• Drawing and
and Facilities
Requirements
• Gages/Testing
Commitment and
Management Support
• Product/Process Quality
System Review
(PFMEA)
Plan
• Measurement Systems
Analysis Plan
• Packaging
Specifications
• Production Trial Run
• Measurement
Systems Evaluation
Capability Study
• Production Part
Approval
• Production Validation
Testing
• Packaging Evaluation
• Production Control
Plan
Sign-Off and
Management Support
By: Pankaj Nalwa

An important phase of APQP is the development of “Control Plan”.
What is a Control Plan?
It is a written description of the system for controlling parts and processes. Control
plan describes the actions that are required at each phase of the process including
receiving, in-process, out-going and periodic requirements to assure that all process
outputs will be in state of control.
When to generate this document and for how long to use it?
Control plan is maintained and used throughout the product life cycle. Early in
product life cycle, its primary purpose is to document and communicate the initial
plan for process control. Subsequently, it guides manufacturing in how to control the
process and ensure product quality.
The control plan remains a living document, reflecting the current methods of control,
and measurement systems used. It is updated as measurement systems and control
methods are evaluated and improved.
An important phase of APQP is the development of “Control Plan”.
What is a Control Plan?
It is a written description of the system for controlling parts and processes. Control
plan describes the actions that are required at each phase of the process including
receiving, in-process, out-going and periodic requirements to assure that all process
outputs will be in state of control.
When to generate this document and for how long to use it?
Control plan is maintained and used throughout the product life cycle. Early in
product life cycle, its primary purpose is to document and communicate the initial
plan for process control. Subsequently, it guides manufacturing in how to control the
process and ensure product quality.
The control plan remains a living document, reflecting the current methods of control,
and measurement systems used. It is updated as measurement systems and control
methods are evaluated and improved.
By: Pankaj Nalwa

Cross Functional Team (CFT) is required to develop Control Plan by utilizing all
available information to gain better understanding of process, like:
• Process flow diagram
• Design / Process failure mode and effect analysis (FMEA)
• Special characteristics
• History of similar parts
• Team’s knowledge of process
• Design review
• Optimization methods
Cross Functional Team (CFT) is required to develop Control Plan by utilizing all
available information to gain better understanding of process, like:
• Process flow diagram
• Design / Process failure mode and effect analysis (FMEA)
• Special characteristics
• History of similar parts
• Team’s knowledge of process
• Design review
• Optimization methods
By: Pankaj Nalwa

Collect &
Interpret Data
Select
Measures
Is
Process
Stable?
Investigate &
Fix Special
Causes
No
Define
Process
Develop Control
Plan
Is
Process
Capable?
Improve
Process
Capability
Is
Process
Stable?
Investigate &
Fix Special
Causes
No
Yes
No
Yes
By: Pankaj Nalwa

Monitor variables for out of
control conditions
Develop alarm and
recording strategy
Finalize process sampling
plan
Finalize process sampling
plan
Document control plan for
each key variable
Identify Opportunities for
Mistake Proofing
By: Pankaj Nalwa

Control Plan
Preliminary
Analysis
Measurement
System
Process
Maps
FMEA
Measurement
System Analysis
Calibration
Requirements
Sampling & Testing Plans
Customer requirements
Short Term
Capability
Control Plan
Procedures
Improvement
Activities
SPC Plans
Operating
Windows
DOE's
Maintenance Schedules
Training Materials
SOP's
Long Term
Capability
Reaction plans
Trouble shooting Aids
By: Pankaj Nalwa

PHASE – I (Planning & Defining the program)
Wk
1
Wk
2
Wk
3
Wk
4
Wk
5
Wk
6
Voice of customer
Historical data (Internal & External)
Bench mark data (Product & Process)
Assumptions (Product & Process)
Customer design inputsCustomer design inputs
Design goals
Reliability & quality goals
Preliminary bill of material
Preliminary process flow diagram
Preliminary list of special characteristics
Management review & support
By: Pankaj Nalwa

PHASE – II (Product design & development)
Wk Wk Wk Wk Wk Wk
Block diagram
Design FMEA
Engineering drawing (for Prototype)
Engineering specifications (for Prototype)
Material specifications (for Prototype)Material specifications (for Prototype)
Final bill of material
Design verification
Design review
Changes in drawing & specifications
Make or buy decision
Supplier selection & allocation
By: Pankaj Nalwa

PHASE – II (Product design & development)
Wk Wk Wk Wk Wk Wk
Preparation of inspection standards for BOP
Procurement of BOP
Prototype control plan
Identification of new equipment, tooling,
gauges, test facilities
Acquisition of new equipment, tooling,
gauges & test facilities
Acquisition of new equipment, tooling,
gauges & test facilities
Prototype samples
Prototype approval from customer
Changes in drawing & specifications
Team feasibility & commitment
Final drawing & specifications
By: Pankaj Nalwa

PHASE – III (Process design & development)
Wk Wk Wk Wk Wk Wk
Final process flow diagram
Floor plan layout
Final special characteristics (Product &
Process)
Process FMEA
Prelaunch control planPrelaunch control plan
Process control standards / Work
instructions
M.S.A. plan
Preliminary process capability study plan
Packaging standards & specifications
Quality system review (Product &
Process)
By: Pankaj Nalwa

PHASE – IV (Product & process validation)
Wk Wk Wk Wk Wk Wk
Material for trial production (Pilot lot)
Trial production run (Pilot lot)
Measurement system analysis
Process capability study
Process validation testing
Packaging evaluationPackaging evaluation
PPAP documents compilation & submission
Customer approval
Release : Production control plan
Quality planning & summary sign off
Initial supply control initiation
Regular production
By: Pankaj Nalwa

PHASE – V (Feedback assessment & corrective action)
Wk Wk Wk Wk Wk Wk
Reduction of variation
Continual improvement
Delivery of regular product
By: Pankaj Nalwa

Notes:
Thanks for the participation.
slideshare.net/pankajnalwa
pankajnalwa@gmail.com
By: Pankaj Nalwa
Thanks for the participation.
slideshare.net/pankajnalwa
pankajnalwa@gmail.com

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