Advanced Product Quality Planning (APQP)

© Operational Excellence Consulting. All rights reserved.
APQPAdvanced Product Quality Planning

© Operational Excellence Consulting. All rights reserved. 2
Learning Objectives
Provide
background
knowledge on
APQP
Gain an
overview of the
APQP process
and the key
activities
Define the 5
phases of APQP,
including the
input and output
requirements
Learn how to
define a Control
Plan
NOTE: This is a PARTIAL PREVIEW. To
download the complete presentation, please
visit: http://www.oeconsulting.com.sg

Contents
2
3
APQP Process
Control Plan
1 Overview of APQP

Working in silos results in poor quality design
How the customer
explained it
How the project
leader understood it
How the analyst
designed it
How the
programmer wrote it
What the beta
testers received
How the business
consultant
described it
How the project was
documented
What operations
installed
How the customer
was billed
How it was
supported
What marketing
advertised
What the customer
really need

What is APQP?
§  Advance Product Quality Planning (APQP) is a
structured method of defining and establishing the steps
necessary to assure that a product satisfies the
customer
§  It provides a set of detailed requirements to be
undertaken at each stage in the APQP system
§  It involves the utilization of various techniques to be
employed to identify and resolve problems before going
into full production

Goal of APQP
§  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

© Operational Excellence Consulting. All rights reserved. 7© Operational Excellence Consulting. All rights reserved. 7
Benefits of APQP to the Customer
Higher quality
product delivered to
the customer.
Timing is
significantly reduced
for new product
launch.
Effective
communication
between customer
and supplier
improves PPAP
process.
Establishes
confidence in the
supplier base to
deliver the product
on time and at a
competitive price.

Benefits of APQP to the Supplier
Enhances customer
satisfaction to
launch a product on
time.
Meets the customer
specific
requirements.
APQP enforces a
structured,
standardized and
well documented
system.
Meets regulatory
requirements (IATF
16949:2016) and is
one of the 5 core
tools.
APQP connects all
stakeholders with
effective
communications.
Effective APQP
improves profit
margins!
APQP is not limited
to Automotive, as all
industries can
improve their design
and process
development.

9
“It is most important
that top management
be quality-minded. In
the absence of sincere
manifestation of
interest at the top, little
will happen below.”
Joseph M. Juran

APQP Process Flow
Phase 0
Prepare for APQP
Phase 1
Plan & Define Program
Phase 2
Product Design &
Development
Phase 5
Feedback, Assessment
& Corrective Action
Phase 4
Product & Process
Validation
Phase 3
Process Design &
Development

The 5 Phases of 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
•  Design Goals
•  Reliability & Quality
goals
•  Preliminary Bill of
Materials
•  Preliminary Process
Flow Chart
•  Preliminary list 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
•  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
Capability Study Plan
•  Packaging
Specifications
•  Production Trial Run
•  Measurement Systems
Evaluation
Capability Study
•  Production Part
Approval
•  Production Validation
Testing
•  Packaging Evaluation
•  Production Control Plan
•  Quality Planning Sign-
Off and Management
Support
•  Reduced Variation
•  Improved Customer
Satisfaction
•  Improved Delivery and
Service
Prepare for APQP
Feedback, Assessment &
Corrective Action
Product &
Process
Validation
Process
Design &
Development
Product
Design &
Development
Plan & Define Program
INPUT
INPUT
OUTPUT
INPUT
OUTPUT
INPUT
OUTPUT
OUTPUT
INPUT
OUTPUT
4 5321

12
“Quality has to be
caused, not
controlled.”
Philip B. Crosby

The APQP Process is Based on the Plan-Do-
Study-Act (PDSA) Cycle
Plan and define
Feedback,
Assessment and
corrective action
Product
and process
validation Product design
and development
Process design
and development

APQP Timing Chart
Planning Planning
Feedback, Assessment & Corrective Action
Product Design &
Development
Process Design &
Development
Product & Process
Validation
Concept Initiation/
Approval
Program
Approval
Prototype LaunchPilot
Production

Core Tools
§  Tools and techniques that have the greatest impact on
product and process success are called the Core Tools
§  The Core Tools are:
•  Advanced Product Quality Planning (APQP)
•  Failure Mode and Effects Analysis (FMEA)
•  Measurement Systems Analysis (MSA)
•  Statistical Process Control (SPC)
•  Production Part Approval Process (PPAP)

APQP: Key Takeaways
§  APQP is cross-functional planning and execution to
produce product that fully meets the customer’s
expectations the first time
§  AIAG APQP Key Activities are Planning, Product Design,
Process Design, Validation and Production
§  Phase approach ensures activities are completed in the
appropriate order
§  Can be applied to different manufacturing environments
– High Volume, Low Volume and ETO

17
“In the race for
quality, there is
no >inish line.”
David Kearns,
former CEO of Xerox

Control Plan
§  What is It?
•  A document that describes how to control the critical inputs (FMEA)
so as to continue to meet customer expectations
§  Why use it?
•  Needed gaging, testing and error-proofing
•  Sampling and frequencies
•  How to react when something fails a test or inspection
§  When to use it?
•  Implementing a new process
•  Implementing a process change
Since processes are expected to be continuously
updated and improved, the control plan
is a living document!

Control Plan Template
CONTROL PLAN
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
PART/
PROCESS
NUMBER
PROCESS NAME/
OPERATION
DESCRIPTION
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.
CHARACTERISTICS
SPECIAL
CHAR.
CLASS
METHODS
REACTION
PLANNO. PRODUCT PROCESS
PRODUCT/PROCESS EVALUATION/ SAMPLE
CONTROL
METHODSPECIFICATION/ MEASUREMENT
SIZE FREQ.
TOLERANCE TECHNIQUE
Prototype Pre-launch Production

END OF PREVIEW
To download this presentation,
please visit:
www.oeconsulting.com.sg

Advanced Product Quality Planning (APQP)

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