Training Module

On
Advance Product Quality Planning
- APQP
Refer-APQP AIAG Manual-2th Edition
Neel Auto Private Limited,
Human Resources Department.
Gurgaon
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Contents
 What is APQP
 Why APQP
 Benefits of APQP
 Requirements of APQP
 APQP Phases
 APQP PDCA Cycle
 Phase-1- Plan and Define
Inputs & Outputs
Key Terms
 Phase-2- Product Design & Development
Inputs & Outputs
Key Terms
 Phase-3- Process Design & Development
Inputs & Outputs
Key Terms
 Phase-4- Product & Process Validation
Inputs & Outputs
Key Terms
 Phase-5-Feedback Assessment & Corrective Action
Inputs & Outputs
Key Terms
 APQP Responsibility Matrix
 APQP Timing Plan

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 What is Advance Product Quality Planning
APQP is valid for all suppliers whether they are responsible for design or not.

APQP is a structured method for tracking, establishing and improving the

steps necessary to assure that a product (either new or changed) satisfies the
customer.

it will satisfy the requirements of Quality Planning , Contract Review , Design

Control and Part Approval Process .

Quality Planning
SYSTEMATIC APPROACH TO UNDERSTAND CUSTOMER REQUIREMENTS AND
ENSURING THAT ALL REQUIREMENTS ARE MET

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 WHY APQP

 FOR TRACKING AND CHECKING CONTINGENGY PLANNING

 ANTICIPATES PROBLEMS IN ADVANCE CONTINUAL
IMPROVEMENT
 REDUCTION IN CYCLE TIME BY UPFRONT PLANNING
 BETTER COMMNUNICATION
 DO IT RIGHT FIRST TIME
 ONTIME INPUTS

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 Benefits of APQP
 To direct resources to satisfy the customer

 To promote early identification of required

changes

 To avoid late changes

 To provide a quality product on time at the

lowest cost.

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 Requirements of APQP
• Involvement of customer and supplier to identify issues and resolving them
• Concern resolution :Documenting and assigning responsibilities . Use of
disciplined problem solving method in difficult situations.
• Product quality timing plan : developing activity plans for all activities ,
review of activities and corrective actions
• Plans relative to timing chart : sub plans for associated activities

• Team Formation -multi disciplinary team from engineering, quality,

materials, sales ,services , subcontractors and suppliers.
• Define the scope : Team leader , roles and responsibilities , customer
(internal/external), customer requirements ,additional members ,
feasibility assessment , cost , timings ,constraints , customer assistance
and documentation.
• Communication : line of communication with customer team and other in-
house teams
• Trainings : identification and organizing for providing training

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 APQP- Phases
Concept initiation / Approval
Program Approval Prototype Pilot Launch

Phase-1 Plan and Define Planning

Phase-2 Product Design & Development
Phase-3 Process Design & Development

Phase-4 Product & Process Validation

Production

Phase-5 Feedback Assessment & Corrective Action

APQP TIMING PLAN

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APQP- PDCA CYCLE

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 Phase-1- PLAN AND DEFINE
INPUTS
OUTPUTS
Voice of the customer
Design Goals
Market Research
Reliability and Quality Goals
Historical warranty and quality information
Preliminary Bill of Material
Team Experience
Preliminary Process Flow Chart
Business Plan/ Marketing Strategy
Preliminary listing of special product
Product/ Process Benchmark Data
and process characteristics
Product/ Process Assumptions
Product Assurance plan
Product Reliability Studies
Gantt Chart with Responsibilities
Customer Inputs
Management Support

This stage is designed to assure that customer needs and expectations

are clearly understood. The input to this stage comes from contract
review for full service suppliers.

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 KEY TERMS
 DETERMINES CUSTOMER NEEDS AND EXPECTATIONS
 TO WORK WITH CUSTOMER IN MIND
 TO PROVIDE CUSTOMERS BETTER PRODUCTS AND SERVICES THAN COMPETITORS
 VOICE OF CUSTOMER-TAKES INTO ACCOUNT OF COMPLAINTS,RECOMMENDATIONS,
DATA AND INFORMATIONS OF INTERNAL AND EXTERNAL CUSTOMERS
 MARKET RESEARCH:CAN BE IN THE FORM OF
CUSTOMER INTERVIEWS
CUSTOMER QUESTIONNAIRES AND SURVEYS
MARKET TEST AND POSITIONING REPORTS
NEW PRODUCT QUALITY AND RELIABILITY REPORTS
COMPETITIVE PRODUCT QUALITY STUDIES
TGR REPORTS
HISTORICAL WARRANTY AND QUALITY INFORMATION:
TGW REPORTS

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 KEY TERMS
 PRELIMINARY BILL OF MATERIAL:
PREPARE BILL OF MATERIAL BASED ON PRODUCT/PROCESS ASSUMPTIONS AND
EARLY SUBCONTRACTOR LIST
 PRELIMINARY PROCESS FLOW CHART:
DESCRIBE ANTICIPATED MANUFACTURING PROCESSES USING PRILIMINARY BOM
AND PRODUCT/PROCESS ASSUMPTIONS
 PRELIMINARY LIST OF SPECIAL PRODUCT&PROCESS CHARACTERISTICS:
CFT AND CUSTOMER IDENTIFY THE CHARACTERISTICS BASED ON KNOWLEDGE OF
PRODUCT AND PROCESS
LIST CAN BE DEVELOPED FROM
PRODUCT ASSUMPTIONS BASED ON NEEDS AND EXPECTATIONS
RELIABILITY GOALS
ANTICIPATED MANUFACTURING PROCESS
SIMILAR PART FMEAS
 PRODUCT ASSURANCE PLAN:
TRANSLATE DESIGN GOAL INTO DESIGN REQUIREMENTS

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 Phase-2 - PRODUCT DESIGN AND
DEVELOPMENT
INPUTS
OUTPUTS
Design Goals
Design Failure Mode and Effects
Reliability and Quality Goals
Analysis
Preliminary Bill of Material
Design for Manufacturing and
Preliminary Process Flow Chart
Assembly
Preliminary listing of special product and
Design Verification
process characteristics
Design Review
Product Assurance plan
Prototype Build-Control Plan
Gantt Chart with Responsibilities
Engineering Drawing
Management Support
Engineering Specifications
Materials Specifications
Drawings and Specification Changes

This phase encompasses a thorough review of product design

(engineering) requirements and concludes with a sign-off on the
design reliability.

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 KEY TERMS
• DEVELOP DESIGN FEATURES AND CHARACTERISTICS INTO NEAR FINAL
FORM
• PRODUCT QUALITY PLANNING TEAM SHOULD CONSIDER ALL DESIGN
FACTORS IN THE PLANNING PROCESS TO ENSURE THAT FINAL PRODUCT
WILL SATISFY THE VOICE OF CUSTOMER
• DESIGN FACTORS SHOULD BE CONSIDERED EVEN IF RESPONSIBIITY IS
SHARED BY CUSTOMER OR OWNED
• FEASIBLE DESIGN MUST PERMIT MEETING PRODUCTION VOLUMES
SCHEDULES,ABILITY TO MEET ENGINEERING REQUIREMENTS WITH
QUALITY, RELIABILITY, INVESTMENT, COST ,WEIGHT, UNIT COST AND
TIMING OBJECTIVES
• DESIGN PLANNING PROCESS MUST ASSURE COMPREHENSIVE AND
CRITICAL REVIEW

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 KEY TERMS
• DESIGN FAILURE MODE AND EFFECT ANALYSIS
 A DISCIPLINED ANALYTICAL TECHNIQUE TO ASESS THE PROBABILITY
OF FAILURE AND EFFECT OF SUCH FAILURES
 DFMEA PROVIDES AN OPPORTUNITY TO REVIEW THE PREVIOUSLY
SELECTED PROCESS AND PRODUCT CHARACTERISTICS.MAKE
NECESSARY ADDITIONS,CHANGES AND DELETION
 USE DFMEA DHECK LIST TO ASSURE APPROPRIATE DESIGN
CHARACTERISTICS ARE CONSIDERED.
• DESIGN FOR MANUFACTURING AND ASSEMBELY
• DESIGN VERIFICATION:
PRODUCT DESIGN MEETS THE CUSTOMER REQUIREMENTS
• DESIGN REVIEW:
REGULARLY SCHEDULED MEETING LED BY DESIGN ENGINEERING
ACTIVITIES AND MUST INCLUDE OTHER AFFECTED AREA
• PROTOTYPE BUILD-CONTROL PLAN

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 KEY TERMS
• ENGINEERING SPECIFICATIONS
• SPECIFICATION REVIEW HELPS TO IDENTIFY FUCTIONAL DURABILITY AND
APPEARANCE REQUIREMENTS
• MATERIAL SPECIFICATIONS
 MATERIAL SPECIFICATIONS SHOULD BE REVIEWED FOR SPECIAL
CHARACTERISTICS
• WHERE CHANGES ARE REQUIRED IN DRAWINGS&SPECIFICATIONS,TEAM
MUST ENSURE THAT THE CHANGES ARE PROMPTLY COMMUNICATED TO
ALL AFFECTED AREAS AND PROPERLY DOCUMENTED
• TEAM FEASIBILITY COMMITMENT AND MANAGEMENT SUPPORT
 TEAM MUST BE SATISFIED THAT THE PROPOSED DESIGN CAN BE
MANUFACTURED,ASSEMBLED,TESTED,PACKAGED AND DELIVERED IN
SUFFICIENT QUANTITY,AT AN ACCEPTABLE COST TO THE CUSTOMER ON
SCHEDULE

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 Phase-3 - PROCESS DESIGN AND
INPUTS
DEVELOPMENT
OUTPUTS
Design Failure Mode and Effects Analysis Packaging Standards
Design for Manufacturing and Assembly Product/ Process Quality System
Design Verification Review
Design Review Floor Plan Layout
Prototype Build-Control Plan Process Flow Chart
Engineering Drawing Characteristic Matrix
Engineering Specifications Process Failures Mode and Effects
Materials Specifications Analysis (PFMEA)
Drawings and Specification Changes Pre-launch Control Plan
New equipment, tooling and facilities requirements Process Instructions
Consensus on key/ critical product and process Measurement System Analysis Plan
characteristics Preliminary process Capability Study
Gauges/ testing equipment requirements Plan
Team Feasibility Commitment and Management Packaging Specifications
Support Management support

This process ensures that customer expectations and design

requirements are carefully incorporated into the manufacturing
process.

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 KEY TERMS
• PACKAGING STANDARD
 INCORPORATE CUSTOMER PACKAGING STANDARD INTO PACKAGING SPECIFICATIONS FOR THE
PRODUCT.IF NOT PROVIDED PACKAGING DESIGN SHOULD ENSURE PRODUCT INTEGRITY AT POINT OF
USE
• PRODUCT/PROCESS QUALITY SYSTEM REVIEW
 TEAM SHOULD REVIEW THE QUALITY SYSTEM.ADDITIONAL CONTROLS/PROCEDURAL CHANGES
SHOULD BE UPDATED.ALSO AN OPPORTUNITY TO IMPROVE THE EXISTING QUALITY SYSTEM BASED
ON CUSTOMER INPUT,TEAM EXPERTISE,PREVIOUS EXPERIENCE
• PROCESS FLOW CHART
 PROCESS FLOW CHART IS A SCHEMATIC REPRESENTATION OF CURRENT/PROPOSED PROCESS FLOW
 USED TO ANALYSE SOURCES OF VARIATION & THEIR
 ASSIST TO FOCUS ON PROCESS WHEN CONDUCTING PFEMA AND DESIGNING CONTROL PLAN
• FLOOR PLAN LAYOUT
 DETERMINE THE ACCEPTABILITY OF INSPECTION POINTS,CONTROL PLAN LOCATION,APPLICABILITY
OF VISUAL AIDS,INTERIM REPAIR STATIONS,AND STORAGE AREAS TO CONTAIN DEFECTIVE MATERIAL
• CHARACTERISTICS MATRIX
 RECOMMENDED ANALYTICAL TECHNIQUE FOR DISPLAYING THE RELATIONSHIP BETWEEN PROCESS
PARAMETERS AND MANUFACTURING STATIONS
• PROCESS FAILURE MODE AND EFFECTS ANALYSIS(PFMEA)
 SHOULD BE CONDUCTED DURING PRODUCT PLANNING AND BEFORE BEGINNING PRODUCTION

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 KEY TERMS
• PRELAUNCH CONTROL PLAN
 A DESCRIPTION OF THE DIMENSIONAL MEASUREMENTS,MATERIAL AND FUNCTIONAL TESTS
THAT WILL OCCUR AFTER PROTOTYPE AND BEFORE FULL PRODUCTION
• PROCESS INSTRUCTIONS
 ENSURE THAT UNDERSTANDABLE PROCESS INSTRUCTIONS,PROVIDE SUFFICIENT DETAIL FOR
ALL OPERATING PERSONNEL WHO HAVE DIRECT RESPONSIBILITY FOR THE OPERATION OF
THE PROCESSES.THESE SHOULD BE DEVELOPED FROM THE FOLLOWING
 FMEAs
 CONTROL PLANS
 ENGINEERING DRAWINGS,PERFORMANCE SPECIFICATIONS,MATERIAL SPECIFICATIONS,VISUAL
STANDARDS AND INDUSTRY STANDARDS
 PROCESS FLOW CHART
 FLOOR PLAN LAYOUT
 CHARACTERISTICS MATRIX
 PACKAGING STANDARDS
• Measurement system analysis plan
Ensure that a plan to accomplish the required measurement system analysis is developed.
This should include at a minimum the responsibility to ensure gauge
linearity ,accuracy ,repeatability ,reproducibility , correlation for duplicate gauges

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 KEY TERMS
• PRELIMINARY PROCESS CAPABILITY STUDY PLAN

ENSURE THE DEVELOPMENT OF A PRELIMINARY PROCESS STUDY CAPABILITY PLAN.THE

CHARACTERISTICS IDENTIFIFIED IN THE CONTROL PLAN WILL SERVE AS THE BASIS FOR THE
PRELIMINARY PROCESS STUDY CAPABILITY PLAN
• MANAGEMENT SUPPORT

PURPOSE OF THIS REVIEW IS TO INFORM UPPER MANGEMENT OF PROGRAM STATUS AND

GAIN THEIR COMMITMENT TO ASSIST IN RESOLUTION OF ANY OPEN ISSUES.

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 Phase-4- PRODUCT AND PROCESS
VALIDATION
INPUTS OUTPUTS
Packaging Standards Production Trial Run
Product/ Process Quality System Review Measurement System Evaluation
Floor Plan Layout Preliminary Process Capability Study
Process Flow Chart Part Approval Process Production
Characteristic Matrix Validation Testing
Process Failures Mode and Effects Analysis Packaging Evaluation
(PFMEA) Production Control Plan
Pre-launch Control Plan Quality planning sign-off and management
Process Instructions support
Measurement System Analysis Plan
Preliminary process Capability Study Plan
Packaging Specifications
Management support
This stage is concerned with validating the manufacturing
process and product by a trial run and a PPAP, providing that all
customer requirements are incorporated into the production
process.
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 KEY TERMS
• PRODUCTION TRIAL RUN
 MINIMUM QUANTITY FOR APRODUCTION TRIAL RUN IS USUALLY SET BY THE CUSTOMER.BUT
CAN BE EXCEEDED BY THE PRODUCT QUALITY PLANNING TEAM.OUTPUT OF PRODUCTION
TRIAL RUN IS USED FOR
 PRELIMINARY PROCESS CAPABILITY PLAN
 MEASUREMENT SYSTEM EVALUATON
 FINAL FEASIBILITY
 PROCESS REVIEW
 PRODUCTION VALIDATION TESTING
 PRODUCTION PART APPROVAL
 PACKAGING EVALUATION
 FIRST TIME CAPABILITY(FTC)
 QUALITY PLANNING SIGN OFF
• PRODUCTION PART APPROVAL
• PRODUCTION VALIDATION TESTING

VALIDATE THAT PRODUCTS MADE FROM PRODUCTION TOOLS AND PROCESES MEET
ENGINEERING STANDARDS

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 KEY TERMS
• PACKING EVALUATION
ASSESS THE PROTECTION OF THE PRODUCT FROM NORMAL TRANSPORTATION
DAMAGES AND ADVERSE ENVIRONMENTAL FACTORS.USE TEST
SHIPMENT&METHODS WHERE FEASIBLE
• PRODUCTION CONTROL PLAN
A WRITTEN DESCRIPTION OF THE SYSTEMS FOR CONTROLLING PARTS AND
PROCESSES. A LIVING DOCUMENT AND SHOULD BE UPDATED
• QUALITY PLANNING SIGN OFF AND MANAGEMENT SUPPORT
 ENSRE THAT ALL CONTROL PLANS AND PROCESS FLOW CHARTS ARE BEING
FOLLOWED.IT IS SUGGESTED THAT THE QUALITY PLANNING TEAM PERFORMS ITS
REVIEW AT THE MANUFACTURING LOCATION AND COORDINATES A FORMAL SIGN
OFF.A REVIEW OF THE FOLLOWING ITEMS PRIOR TO FIRST PRODUCTION
SHIPMENT IS REQUIRED.
 CONTROL PLANS SHOULD EXIST AND BE AVAILABLE FOR ALL AFFECTED
OPERATIONS.

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 Phase- 5- FEEDBACK, ASSESSMENT
AND CORRECTIVE ACTION
INPUTS OUTPUTS
Production Trial Run Reduced Variation
Measurement System Evaluation Customer satisfaction
Preliminary Process Capability Study Documentation and service
Part Approval Process Production
Validation Testing
Packaging Evaluation
Production Control Plan
Quality planning sign-off and management
support

In this Phase the control plan and process instructions should

be continuously evaluated.

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 KEY TERMS
 REDUCED VARIATION
 USE PRODUCTION CONTROL PLAN AS THE BASIS TO EVALUATE PRODUCT OR SERVICE.USE
BOTH VARIABLE AND ATTRIBUTE DATA FOR EVALUATION.
 SUPPLIER MUST ENSURE THAT
 ALL CHARACTERISTICS MEET THE REQUIREMENTS
 SPECIAL CHARACTERISTICS MEET THE INDICES SPECIFIED BY THE CUSTOMER
 USE CONTROL CHART AND OTHER STATISTICAL TECHNIQUE TO IDENTIFY PROCESS VARIATION
 USE ANALYSIS AND CORRECTIVE ACTIONS TO REDUCE VARIATION
 REDUCE CONTINUALLY VARIATION BECAUSE OF SPECIAL CAUSES AND COMMON CAUSES
 DEVELOP PROPOSAL FOR IMPROVEMENT IN COST,TIMING AND OTHER AREA FOR CUSTOMER
REVIEW
 CUSTOMER SATISFACTION

DETAILED PLANNING ACTIVITIES AND DEMONSTRATED PROCESS CAPABILITY OF A PRODUCT

OR SERVICE DO NOT ALWAYS GUARANTEE CUSTOMER SATISFACTION.THE PRODUCT OR
SERVICE MUST PERFORM IN THE CUSTOMER ENVIRONMENT.THE PRODUCT USAGE STAGE
REQUIRES SUPPLIRER.THE SUPPLIER AND CUSTOMER MUST BE PARTNERS IN MAKING THE
CHANGES NECESSARY TO CORRECT THE DEFICIENCIES TO ACHIEVE CUSTOMER SATISFACTION

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 KEY TERMS
• DELIVERY AND SERVICE
 THE DELIVERY AND SERVICE STAGE OF A QUALITY PLANNING CONTINUES
THE SUPPLIER/CUSTOMER PARTNERSHIP IN SOLVING PROBLEMS AND
CONTINUAL IMPROVEMENT.THE CUSTOMER’S REPLACEMENT PARTS AND
SERVICE OPERATIONS ALWAYS MERIT THE SAME CONSIDERATION IN
QUALITY COST AND DELIVERY.FAILURE TO CORRECT A PROBLEM THE FIRST
TIME ALWAYS DAMAGES THE SUPLIER’S REPUTATION AND CUSTOMER
PARTNERSHIP.IT IS IMPORTANT THAT BOTH SUPPLIER AND CUSTOMER
LISTEN TO THE VOICE OF THE CUSTOMER.
 THE EXPERIENCE GAINED IN THIS STAGE PROVIDES THE CUSTOMER AND
SUPPLIER THE NECESSARY KNOWLEDGE TO RECOMMEND PRICE
REDUCTIONS ACHIEVED BY REDUCING PROCESS,INVENTORY AND QUALITY
COSTS AND TO PROVIDE THE RIGHT COMPONENT OR SYSTEM FOR THE
NEXT PRODUCT

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 ADVANCE PRODUCT QUALITY PLANNING
RESPONSIBILITY MATRIX
The matrix shown below depicts the Product Quality Planning Functions for three
types of suppliers. It is to assist suppliers in defining the scope of their planning
responsibilities.
Design Manufact Service Supplier i.e. Heat
Responsible uring Only Treat, Warehousing,
Transportation, etc.
Define the Scope X X X
Plan and Define X
Product Design and X
Development
Feasibility X X X
Process Design and X X X
Development
Product and Process Validation X X X
Feedback, Assessment and X X X
Corrective Action
Control Plan Methodology X X X

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APQP TIMING PLAN

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APQP TIMING PLAN-Continued

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APQP TIMING PLAN-Continued

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