Advanced product quality planning (APQP) is a framework for developing new products with a focus on meeting customer requirements. It involves 5 phases - planning, product design, process design, validation, and feedback. Key aspects of APQP include establishing cross-functional teams, using tools like FMEAs to prevent issues, designing control plans and statistical process control methods, conducting validation trials, and promoting continuous improvement. APQP aims to standardize quality planning processes for increased collaboration with suppliers.

1. Advanced product quality
planning (APQP) Training for
beginners
Overview and APQP implementation

2. Advanced product quality planning is a
framework of procedures and techniques
to develop products.

3. APQP
What is it?
• Advanced Product Quality Planning
• Framework (Methodology) for developing
New Product
• Originally Automotive Industry
• Up front Quality Planning
• Validation
• Focus on meeting Customer Requirements
• Similar to DFFS (Design for Six Sigma)

4. Why APQP?
• Standardised approach to make it
easier for suppliers
• Build components fit for purpose
• Plan how it is to be designed
• For communication and collaboration
• Prevent risks, variation, oversight
and issues
• Continuous improvement

5. The process
Plan & Define
Product Design & Development
Process Design & Development
Product & Process Validation
Feedback, Assessment & CA

6. APQP > Plan
• Phase 1: Plan and define
Establish Team
Establish Communications
APQP Training
Customer Requirements & Scope
Historical Data (Int & Ext)
Benchmark Data (Product &
Process)
Assumptions (Product &
Process)
Market Opportunity
Competitors
Customer Design Inputs
Design Goals
Quality & Reliability Goals
IPR / Patents
Manufacturing Feasability
Pricing
Preliminary BOM
Preliminary Process Flowchart
Preliminary Key Characteristics
Marketing Strategy
Management Review

7. APQP > Do
• Phase 2 - Product Design & Development
Block Diagram
Design FMEA
Drawings
Specifications
Materials Specifications
BOM
Warranty / Maintenance
Design Verification
Design review
Change Control
Make or Buy Decisions
Supplier Selection
Tooling, Measurement & Test
Equip.
Pricing Review
Prototype
Prototype Customer Approval
Update Designs
Management Review

8. APQP > Do
• Phase 3 - Process Design & Development
Process Flowchart
Floor Plan
Key Characteristics (Product
& Process)
Control Plans
Process FMEA
Process Capability Plan
Packaging Specifications
Work Instructions
Quality System Review
Management Review

9. APQP > Check
• Phase 4 - Product & Process Validation
Materials Inspections
Trial Production Run (Not Pilot)
Measurement Systems Evaluation
Process Capability Study
Production Validation Testing
Packaging Evaluation
Production Part Approval
Customer Approval
Production Control Plan
Quality Plan
Management Review

10. APQP > Act
• Phase 5 – Feedback, Assessment & CA
Production
SPC / Reduction of Variation
Continuous Improvement
Non- Conformance Management
Delivery / Service / Warranty
Monitoring
Customer Satisfaction
Reporting
Management Review

11. SPC: Statistical process control

12. SPC / Reduction of variation
SPC / Reduction of variation
• Establish Engineering Tolerances (Phase 2)
• Establish Key Characteristics (KCs / KPs) (Phase 1&3)
• Determine Process Steps for Measurement (Phase 3)
• Raise Control Plans (Phase 3)
• Select Control Charts (Phase 3)
• Perform Gauge Variation Study’s (Phase 4 or Earlier)
• Test Control Plan / Charts (Phase 4)
• Implement Control Plan (Phase 5)

13. APQP > FMEA
• Failure Modes and Effects
Analysis
• Failure Mode – What can go
wrong
• Effects Analysis -
Consequences
• US Military – 1950s
• Systems, subsystems,
assembly, parts
• Process, sub-process, tasks

14. FMEA > Spreadsheets versus Risk Manager
• Engage leadership with Risk Manager
• Collect risks from across your
business
• Risk Manager integrates with other
modules e.g. Issue Manager, for a
systematic approach to assessing
risks
• Roles and responsibilities are
communicated and shared within the
system, with a full audit trail
• Demonstrate compliance and due
diligence in a robust, incorruptible

15. Gauge variation study
• Gauge R&R
• Variation due to Measurement Process
• Reproducibility – variation due to different Operators
• Repeatability – variation due to Gauge itself
• Measurement Variation = R+R
• Total Variation = MV + Product Variation
• Typically use Three Test Operators, each measuring Five
Parts, Ten Times. (50 measurements / Operator)

16. Document Manager and Record Management
• QMS Documentation
(Processes, SOPs, WIs)
• Planning Documentation
(Phase 1)
• Design Documentation
(Phase 2&3)
• Flowcharts / Block
diagrams
• Drawings
• Specifications
• Records of Reviews
• Records of Approvals
• Production Part Approval

17. Issue Manager
• Historical Data (Lessons Learnt)
(Phase 1)
• Planning Control (Phase 1,2,3,4)
• Non-Conformance Management
(Phase 5)

18. Audit Manager
• Historical Data (Lessons Learnt)
(Phase 1)
• Planning Control – Process
Checklists (Phase 1,2,3,4)
• Planning Control – Process
Validation (Phase 1,2,3,4)
• Audit - Continuous Improvement
(Phase 5)
• In Process Inspections (Phase 5)

19. Training Records Manager
• Records staff competency
• Demonstrate and test
competency

20. Aizlewood’s Mill,
Nursery Street,
Sheffield
S3 8GG
+44 114 282 3338
info@qualsys.co.uk
Request a live demonstration of our
software for APQP here:
http://quality.eqms.co.uk/eqms-software-
demonstration