APQP (Advanced Product Quality Planning)
Updated: Sep 11, 2020
What is APQP?
It is a Structure method of defining and establishing the steps necessary to assure that a product satisfies to customer.
Advanced Product Quality Planning tool is extensively used by Automotive industries to assure quality and performance through effective planning.
a quality planning is a systematic approach to understand the customer requirements and to ensure that all the requirement are met
Five core tools of IATF 16949
1-Advanced product Quality planning (APQP)
2-Production parts approval process (PPAP)
3-Failure mode effect analysis (FMEA)
4-Measurement system analysis (MSA)
5-Statistical process control (SPC)
The Objectives of APQP
effective communications with all those who are involved in the implementation scheme.
timely completion of required goals.
minimal or no quality problems.
minimal risks related to quality during product launch.
APQP Timing plan
APQP Overview
5 different Phase of APQP
Phase – 1 : Plan & Define Program
Phase – 2 : Product Design & Development
Phase – 3 : Process Design & Development
Phase – 4 : Product & Process Validation
Phase – 5 : Feedback, Assessment & Corrective Action
Phase – 1 : Plan & Define Program
The purpose of this phase is to understand the customer requirements (needs and expectation)
Inputs of this phase
Customer requirements
voice of customer
Business plan
Product and process bench mark data
Product and process assumption
Product reliability study
Customers inputs
Outputs of this phase
Design goals
Reliability & quality Goals
Preliminary bill of material
Preliminary Process flow chart
Preliminary list of Special product and process Characteristics
Product assurance plan
Phase – 2 : Product Design & Development
The purpose of this is to develop design features and characteristics in to the near final form of product.
it should consider all design factor to ensure the final product will satisfy the "Voice of the customer".
Inputs of this phase
Inputs of Phase-II are the output of Phase-I
Outputs of this phase
DFMEA
Design for manufacturing and assy
Design Verification
Design review
Prototype build -control plan
Engineering Drawing
Engineering specification
Materials Specification
Drawing & Specification Change
New equipment , tooling and facilities requirements
Special product and process characteristics
Gauges/testing equipment requirements
Team Feasibility commitment & Management support
Phase – 3 : Process Design & Development
The purpose of this phase is to develop a comprehensive manufacturing system and its related control plans to achieve quality product.
Effective management system to ensure that customer requirements , need and expectation are met
Inputs of this phase
Inputs of Phase-III are the output of Phase-II
Outputs of this phase
Process flow Chart
Floor plan layout
System review
Characteristics Matrix
PFMEA
Pre-launch control plan
work instruction/work standard/SOP
Inspection Standards
measurements System analysis plan
Capability study plan
Packing std. (customer define)
Packing transportation specification etc.
Phase – 4 : Product & Process Validation
The purpose of this phase is to validate the manufacturing process through an evaluation of production trial run
Inputs of this phase
Inputs of Phase-IV are the output of Phase-III
Outputs of this phase
Production trial run
MSA Result
Capability result
Product part Approval process (PPAP)
Production Control plan
packaging/Transportation evaluation
Quality Planning sign off
Phase – 5 : Feedback, Assessment & Corrective Action
The purpose of this phase is
To review the effectiveness of total quality
Planning system outputs
To initiate improvement action
To confirm all customer requirements are met and documented
Inputs of this phase
Inputs of Phase-V are the output of Phase-IV
Outputs of this phase
Reduce variation
Improved Customer satisfaction
Improved delivery and service
Benefits of APQP
A common approach throughout supply chain
Better Customer -supplier communication
Reduced no-value added time and cost of processes
Faster access of product and project data
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