ACME APQP Advanced Product Quality Planning
Customer request
Development
Phase 1: Plan and Define Program Customer RFQ
Marketing
Development
product documents
delivery requirements (customer statement)
Customer
Credit Criteria failed Credit
Check
Marketing
Credit / Audit Report
Project risk assessment Quotation reject, Counter proposal
Vendor No
Organization authorization Request Customer
information Development
Specific Requirement
Manufacturing
Preliminary RFQ Purchasing
RFQ vendor outsource CSR
analysis Engineering
Vendor RFQ Statement of Deliverables (internal RFQ form)
Preliminary process flow
APQP checklist
Vendor feedback Draft APQP organization chart
APQP team counter
Vendor preliminary proposals Technical feasibility Reject
proposal
Accept:
No go Team Feasibility Commitment
Machine cycle time
Preliminary planning Development
Costing assumption
Project Development Costing
Manufacturing costing
Preliminary project schedule
Project schedule Accounts
Project schedule documents
Document compilation
Marketing
Quotation analysis, Proposal Change
Quotation letter request
Marketing
Mana Change
geme request
Inform customer Close project order nt Marketing
suppo
No
rt
Signed quotation
Project Authorization
RFQ rejection
memo Document submission Marketing
Customer quotation forms, packaging
Delivery/Acceptance document
No
Project close reject letter Customer Marketing
from customer accept?
Record in quotation file
Product
Design &
Quotation file Development
1
ACME APQP Advanced Product Quality Planning
Contract amendment
Change
proposal
Customer ECN/ change
product documents
delivery requirements
Technical concept
study
Technical feasibility evidence
Counter proposal
Preliminary Go/No Go
Customer endorsement
Commercial Feasibility not OK Commercial feasibility
Team Feasibility commitment not OK study
Commercial Feasibility study OK
Team Feasibility commitment OK
Start decision
proceed
Outsource Preliminary planning
Not feasible
RFQ approved vendor Preliminary process analysis
Project Development Costing
Vendor RFQ Manufacturing costing
Change request
Preliminary project schedule
Project feasibility study
Vendor feedback
Vendor proposals Document compilation
Analysis documents
Preliminary quotation
Quotation Letter Change
request
Counter proposal
Management support
Counter proposal
Signed quotation
Project Authorization
Transmit to customer
Confirmation of receipt
Customer accept?
Product Design & Development
2
ACME APQP Advanced Product Quality Planning
Phase 2: Product Design and Development
Customer authorization
Design document avail? No, new design
Yes, resourcing / localization
product validation req
Customer liaison
Sample available?
no Correspondents, minutes
yes
Customer product specs, stds avail? Customer needs
No / incomplete
analysis
Customer requirements
Reverse engineering
Yes; drawing, spec, testing std
Product analysis
QFD / DFMEA
Quality Requirement Product specification
QFD, DFMEA form
analysis proposal
Bill of materials Product design /
revise
incoming material requirement verification
process requirements
Specification list
Manual calculations
Finite Element Analysis output
No
product design drawing
testing list approval proto PFMEA, control plan
(Specifications not compatible, emerging Requireme
Prototype part,
interfaces
Customer-approved purchase / mfg
Product inspection std
Sample parts
Product validation
Test planning/design
Fitting, performance
analysis
Testing documentation requirement Test eqpt, method requirement
Sample purchase documents
Testing arrangement Fitting trial checksheet
Test document
equipment prep Testing checksheets
preparation
Status reports
No
Prototype testing, Design review
Inspection checksheet template Sample testing results
analysis
PRODUCT SPECIFICATIONS
Product drawing (component & assy)
Testing specification,
Part Inspection Standard
Packaging specification
Product design
document release
3
ACME APQP Advanced Product Quality Planning
PRODUCT DESIGN DOCUMENT RELEASE
Product specification
product document
draft / update / correction
draft drawing
document log update
update drawing log
change request
Customer EC approval req?
yes
EC Request
no
(customer preliminary document review)
approve for final submission
final document preparation
final document
document
check - approve
signed document
document submission
proof of delivery
contract ammendment req?
customer endorsement yes
customer-approved document
Contract Ammendment
Document Control
no
Process Design and Development
4
ACME APQP Advanced Product Quality Planning
Phase 3: Process Design and Development
Product Specifications
Process requirement
analysis
Process flow diagram
Sourcing plan PFMEA
Special Process characteristics
Production
Process, inspection
planning
Pre-launch Control Plan
Factory layout,
manpower plan
Engineering Development
Development Inspection / test eqpt spec MSA plan
Material, component Analysis
sourcing
Development process flow
Process validation plan Testing instructions
Prelaunch control plan development/acquisition
Equipment Specifications analysis
Development project
planning Test equipment requirement / development plan
Production machine requisition /engineering development plan
Development Project schedule,
resource requirement, cost estimate
Final proposal
preparation / revision
change Project Proposal
request
change request No
Management review
Authorization to proceed
Confirmed project plan
Transmit final proposal to
customer
management approved proposal
Customer review
Process Development
5
ACME APQP Advanced Product Quality Planning
Phase 3: Process Development Authorization to proceed
PROCESS VALIDATION ENGINEERING DEVELOPMENT VENDOR DEVELOPMENT
Inspection development Equipment Vendor selection
/ training purchase/development
checking aids Purchasing records
inspection jig
Part inspection standard
checksheet Equipmentment testing / Agreement development
confirmation work instruction ng not possible
Vendor drawing
Change terms
Equipment testing checksheet Draft Product inspection
test equipment product characteristic
fail ng arbitration
Equipmenttesting
Vendor inspection agreement
Approved checksheets development contract Vendor
Equipment test reports Development
approved quality checksheets
failed
Hard tooling Line trials
product samples Vendor development
Product testing line operation status OK Vendor progress reports
improvement areas
line improvement Vendor monitoring
Dimensional inspection
report, AAR, testing report
improvement needed Child
part Vendor evaluation sample
Line trials ng
Product evaluation eveluation
Child part testing
Prelaunch Control Plan
PFMEA update
sample submission Module testing results
Sample approval Child part evaluation
satisfactory
RPN
Child part approval
PPAP appointment
Subsupplier
Product and Process Validation
Approval Record master parts PPAP Vendor PPAP
sign-off
6
ACME APQP Advanced Product Quality Planning
Phase 4: Product and Process Validation process development
Review prelaunch
control plan
updated prelaunch, production control plan
list equipment, instrument, work instruction, QC checksheets, manpower
list material & child part ordering
prelaunch preparation
meeting
prelaunch checksheet update
prelaunch, production
equipment servicing, prelaunch production prelaunch material
QC checksheet work instruction, operator
instrument MSA planning order
training
preparation
not ready monitoring
prelaunch checksheet complete
prelaunch briefing
small batch
trial production
product, process data
product
minor issues audit
process ok
line production
confirmation trial
product, process data
product
audit major issues
process ok
Process Quality Council
Line run at rate Development Enquiry
Production part
APQP records project exit review
documentation compilation
minutes
correction request PPAP report
PPAP APQP Sign off
project file document update
PSW Sign off product quality standard update
Project APQP doc
Early production containment QMS update
7
ACME APQP Advanced Product Quality Planning
SCHEDULED PRODUCTION
Phase 5: Feedback, Assessment and Corrective Action
Improvement needed?
Operational problem
Production no
QC report
Quality problems?
Quality problem
Improvement possible
Request for change
Problem analysis Improvement ideas
proposals
Change submission
Change
evaluation
Proposal accepted
Project planning Change proposal
Minutes project schedule
Modification
Tooling / machine redesign,
fabrication
Process information update
Problem description machine maintenance log update
Off-line testing
machine maintenance log update
Problem resolved?
Target achieved
Supervised production
Statistical data
PFMEA updates
Acceptable?
process improvement activities update
SPC data update
improvement
Improvement award
project close
presentation
8
ACME APQP Advanced Product Quality Planning
PROJECT GO/NO-GO DECISION
Volume commitment
Material
cost quotation
Compute costs / part cost,
Dev cost estimate Process cost estimate
capital investment
Standard costing sheets
Marginal cost meet customer price?
No
Yes
Management prerogative Full costing meet customer price?
No
Yes
Project Authorization Memo
GO FOR IT!
Quotation
Inform customer NG
