What is APQP?

APQP (Advance Product Quality Planning) methodology is developed by AIAG (Automotive Industry Action Group).

Therefore it is the systematic way of tracking, defining and planning the steps.

This steps present in product and process development phase to satisfies the customer (Internal & External).

Therefore this process capture the voice of customer (VoC) to satisfies the customer. 

APQP is the automotive core tool and apply during product & process development phase.

Why are APQP so important?

There now solution on these challenges, automotive industry adopted this APQP process.

APQP method is use to achieve similar benefits. such as

• Avoid late changes in Product and process.
• First time right quality product
• Low cost
• Reduce risk at early stage

How to Implement APQP process?

Specifically, Advance Product Quality Planning (APQP) cycle works as per PDCA methods.

Therefore the APQP process consist of Four phases and Five major activities.

Also it has 20+ supporting tools along with ongoing feedback and action plans. 

Similarly the supporting tools include DFMEA, PFMEA, CTQ, Special Characteristics, Control Plan, SPC etc…

Fundamentals of APQP

APQP fundamentals

The management should assign the responsible person for the APQP process. Also to form the cross functional team for effective planning.

The team should include the persons from various departments in the organization.

Such as Marketing, Engineering, Quality, Purchasing, Packaging, Customer representative etc.

Therefore for each functions like in product development need Product design team. 

And for process development need the process manufacturing experts in CFT.

However the project scope is too important initially. So that the scope includes the customer voice, roles and responsibilities and quality, cost and delivery impact.

Finally the APQP process is start with the product quality plan.

Therefore the CFT will review the product concept, past experience and milestone. So that they can make the product quality plan to satisfies the customer.

As a result the product quality planning team focus on defect prevention to meet customer expectation.

So to achieve the quality plan, it is linked with product timing plan to complete the APQP process within timeline.

Phases in APQP process

Phase #1 – Planning

The objectives of plan and define phase is To determine customer needs and To plan a Quality Program.

Therefore in this phase #1 the voice of customer should be clearly define and understood by team members.

So for each phases start with the inputs requirement.

And finally we get the output from each phase.

Lets see what are the input require in planning phase and similar output of that phase?

Phase #2 – Product design & development

The objectives of Product design & development phase is To develop design features and characteristics

Also critically review engineering requirements, and finally to assess potential manufacturing problems.

Therefore in this phase #2 development of design into near final form to be done.

And prototype, feasibility, volume study and manufacturing schedule to be review.

Lets see what are the input require in Product Design and Development and similar output of that phase?

Output of phase#1 is input for phase#2

Output of Product Design and Development

• Design FMEA (DFMEA)
• Manufacturing and Assembly Design (DFM/A)
• Design Verification
• Prototype Control Plan
• Engineering Drawings CAD the Master
• Material Specifications
• Design Review
• Engineering Specifications
• Change Control for Drawings
• New Equipment, Tooling and Facilities Requirements
• Special Product and Process Characteristics
• Gages / Testing Equipment Requirements
• Team Feasibility Commitment and Gateway approval

Phase #3 – Process design and development

The objectives of Process design and development phase is To develop a comprehensive and effective manufacturing system.

Also to ensure that the manufacturing systems meets customer requirements.

Therefore in this phase #3 Develop a manufacturing system and its related control plans to achieve quality products.

Lets see what are the input require in Product Design and Development and similar output of that phase?

Output of phase#2 is input for phase#3

Output of Process design and development

• Packaging Standards and Specifications
• Quality System Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process FMEA (PFMEA)
• Pre-Launch Control Plan
• Process Instructions
• Measurement Systems Analysis (MSA) Plan
• Preliminary Process Capability Plan
• Gateway Approval

Phase #4 – Product and Process validation

The objectives of product and process validation phase is to validate the manufacturing process.

Also to ensure that customer expectations will be met So to identify additional concerns.

Therefore in this phase #4 Validate manufacturing process through
production trial run.

So validate that the control plan and process flow chart are effective and that the product meets customer expectation

Lets see what are the input require in Product Design and Development and similar output of that phase?

Output of phase#3 is input for phase#4

So the outputs are

Output of Product and Process validation

• Significant Production Run
• Production Part Approval Process (PPAP)
• MSA Results
• Process Capability Studies
• Production Validation Testing
• Packaging Evaluation
• Production Control Plan
• Quality Planning Sign-Off and Gateway approval

Phase #5 – Feedback assessment and corrective action

Lets see what are the input require in feedback assessment and corrective action and similar output of that phase?

Output of phase#4 is input for phase#5

Output of feedback assessment and corrective action phase

• Reduced Variation
• Improved Customer Satisfaction
• Effective Use of Lessons Learned
• Improved Delivery Performance

Summary of APQP (Advance Product Quality Planning)

Benefits of APQP (Advance Product Quality Planning)

Finally during the development manufacturing process functions are clearly planned.

So it will validate, documented and communicate the results in:

• Robust and reliable designs
• Reduced process variation
• Enhanced confidence in supplier’s capabilities
• Better controlled process changes
• Defect free launches
• Improved Customer satisfaction
• Maximum ROI
• Improved Delivery and Service
• Minimum Waste
• Minimum Cost of Non-conformance

This is a complete guide to learn about APQP. If you really want to learn detail APQP process in easy way, you will enjoy and learn in this post. APQP (Advance Product Quality Planning)