APQP (Advanced Product Quality Planning)

Updated: Sep 11

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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