Advanced Product Quality Planning (APQP) is a structured approach to product and process development that aims to ensure suppliers understand customer requirements and are able to meet them. It involves 5 phases - planning and defining the program, product design and development, process design and development, product and process validation, and feedback and assessment. The key goals of APQP are up-front quality planning, satisfying the customer, and supporting continual improvement. Common roadblocks to effective APQP implementation include a lack of management commitment, unclear responsibilities, and insufficient resources or knowledge.
More https://quality.eqms.co.uk/blog/introduction-to-apqp
New to the advanced product quality planning framework?
Don't despair. In this article, Mike Bendall, Business Mentor at Qualsys, explains APQP, provides a checklist for each APQP phase, and there is a link to download his APQP training course for beginners.
More https://quality.eqms.co.uk/blog/introduction-to-apqp
New to the advanced product quality planning framework?
Don't despair. In this article, Mike Bendall, Business Mentor at Qualsys, explains APQP, provides a checklist for each APQP phase, and there is a link to download his APQP training course for beginners.
What is MSA .
1. Why we Need MSA
2. How to use data.
3.Measurement Error Sources of Variation
• Precision (Resolution, Repeat ability, Reproducibility)
•Accuracy (Bias, Stability, Linearity)
4.What is Gage R&R?
5.Explain MSA Sheet
A Process Failure Mode Effects Analysis (PFMEA) is a structured analytical tool used by an organization, business unit, or cross-functional team to identify and evaluate the potential failures of a process. PFMEA helps to establish the impact of the failure, and identify and prioritize the action items with the goal of alleviating risk. It is a living document that should be initiated prior to process of production and maintained through the life cycle of the product.
PFMEA evaluates each process step and assigns a score on a scale of 1 to 10 for the following variables:
Severity — Assesses the impact of the failure mode (the error in the process), with 1 representing the least safety concern and 10 representing the most dangerous safety concern. In most cases, processes with severity scores exceeding 8 may require a fault tree analysis, which estimates the probability of the failure mode by breaking it down into further sub-elements.
Occurrence — Assesses the chance of a failure happening, with 1 representing the lowest occurrence and 10 representing the highest occurrence. For example, a score of 1 may be assigned to a failure that happens once in every 5 years, while a score of 10 may be assigned to a failure that occurs once per hour, once per minute, etc.
Detection — Assesses the chance of a failure being detected, with 1 representing the highest chance of detection and 10 representing the lowest chance of detection.
RPN — Risk priority number = severity X occurrence X detection. By rule of thumb, any RPN value exceeding 80 requires a corrective action. The corrective action ideally leads to a lower RPN number.
What is a PPAP (production part approval process) and how does it work? We answer the basic questions about PPAP and how it's used in this presentation.
What is MSA .
1. Why we Need MSA
2. How to use data.
3.Measurement Error Sources of Variation
• Precision (Resolution, Repeat ability, Reproducibility)
•Accuracy (Bias, Stability, Linearity)
4.What is Gage R&R?
5.Explain MSA Sheet
A Process Failure Mode Effects Analysis (PFMEA) is a structured analytical tool used by an organization, business unit, or cross-functional team to identify and evaluate the potential failures of a process. PFMEA helps to establish the impact of the failure, and identify and prioritize the action items with the goal of alleviating risk. It is a living document that should be initiated prior to process of production and maintained through the life cycle of the product.
PFMEA evaluates each process step and assigns a score on a scale of 1 to 10 for the following variables:
Severity — Assesses the impact of the failure mode (the error in the process), with 1 representing the least safety concern and 10 representing the most dangerous safety concern. In most cases, processes with severity scores exceeding 8 may require a fault tree analysis, which estimates the probability of the failure mode by breaking it down into further sub-elements.
Occurrence — Assesses the chance of a failure happening, with 1 representing the lowest occurrence and 10 representing the highest occurrence. For example, a score of 1 may be assigned to a failure that happens once in every 5 years, while a score of 10 may be assigned to a failure that occurs once per hour, once per minute, etc.
Detection — Assesses the chance of a failure being detected, with 1 representing the highest chance of detection and 10 representing the lowest chance of detection.
RPN — Risk priority number = severity X occurrence X detection. By rule of thumb, any RPN value exceeding 80 requires a corrective action. The corrective action ideally leads to a lower RPN number.
What is a PPAP (production part approval process) and how does it work? We answer the basic questions about PPAP and how it's used in this presentation.
APQP Training, Learn APQP Process, Phases (Advanced Product Quality Planning).
Interested in Advanced Product Quality Planning ? Go through this presentation and learn more about APQP process, top 5 phases.
Go for advanced training. Sign up for APQP course by Tonex.
https://www.tonex.com/training-courses/advanced-product-quality-planning-training-apqp-training/
The topic was delivered by Mr. S. Shanmugasundaram, General Manager – Engineering Quality, Renault-Nissan Technology & Business Centre India Pvt. Ltd., Chennai.
Apqp bumming you out briefing may 30 2013John Cachat
Sales can’t update the customer on launch status. Engineering spends more time updating Gantt charts than they do actually engineering stuff. Quality can’t find the documentation. Purchasing has no idea when the supplier status is. Sound familiar?
What this means is:
• Products are late
• Quality is unacceptable
• Resources are wasted
• Problems are repeated
What we have found is that Project Management is done with the wrong tools and/or people
• Resources are over-scheduled
• Issues are not resolved
• True costs are unknown / inaccurate
What we have found with Project Management Software
• Tools are cumbersome, force detailed information that is unknown
• People resort back to XLS
• Management cannot support the team and resort to firefighting issues
Learn about an approach to APQP and a SaaS technology that allows you to implement APQP the right way and engage your people and suppliers to improve communication, and launch higher quality products faster and on-time and under budget.
Product Descriptions The Best Thing Since Sliced Breaddwhelbourn
PRINCE advocates writing product descriptions to help define the products that your project will deliver. But Product descriptions provide much more aid to your project beyond specification of the products.
2. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
4. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
5. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PQP usually doesn’t work effectively in organizations.
By: Pankaj Nalwa
6. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PDCA
Plan
DoAct
Always
Always
Sometimes
Check
Sometimes
By: Pankaj Nalwa
7. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
8. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
9. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
10. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
11. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
• 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
By: Pankaj Nalwa
12. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
13. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
INPUT• 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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
Studies
• Customer Inputs
By: Pankaj Nalwa
14. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
• 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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
15. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
16. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
• 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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
• 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
By: Pankaj Nalwa
17. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
18. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
• 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
• 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
• 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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
• 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
• New Equipment, Tooling
and Facilities
Requirements
• Special Product and
Process Characteristics
• Gages/Testing
Equipment Requirements
• Team Feasibility
Commitment and
Management Support
• 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
By: Pankaj Nalwa
19. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
20. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
• 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
• 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
• 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
• 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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
• 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
• New Equipment, Tooling
and Facilities
Requirements
• Special Product and
Process Characteristics
• Gages/Testing
Equipment Requirements
• Team Feasibility
Commitment and
Management Support
• 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
• 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
By: Pankaj Nalwa
21. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
22. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
• 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
• 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
• 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
• Reduced Variation
• Customer
Satisfaction
• Delivery and
Service
OUTPUT
INPUT
• 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
• Voice of the
Customer
• Business
Plan/Marketing
Strategy
• Product/Process
Benchmark Data
• Product/Process
Assumptions
• Product Reliability
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
• 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
• New Equipment, Tooling
and Facilities
Requirements
• Special Product and
Process Characteristics
• Gages/Testing
Equipment Requirements
• Team Feasibility
Commitment and
Management Support
• 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
• 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
By: Pankaj Nalwa
23. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
24. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
25. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
26. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
27. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
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
28. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – I (Planning & Defining the program)
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1
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2
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3
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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
29. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – II (Product design & development)
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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
30. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – II (Product design & development)
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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
Management review & support
By: Pankaj Nalwa
31. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – III (Process design & development)
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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)
Management review & support
By: Pankaj Nalwa
32. Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – IV (Product & process validation)
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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
Management review & support
Regular production
By: Pankaj Nalwa