Objectives

Understand the APQP Process

Identify the inputs / outputs of

the 5 APQP phases

Understand APQP as a

methodology for new product

development
What is Quality Planning?

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 The AIAG APQP Model
What is APQP?

Advance Product Quality Planning is a structured
method of defining and establishing the steps
necessary to assure that a product satisfies the
customer.

The goal of product quality planning is to facilitate
communication with everyone involved to assure
that all required steps are completed on time.

Effective product quality planning depends on a
company’s top management commitment to the
effort required in achieving customer satisfaction.
 Why Product Quality Planning?

The bulk of cost of a product is committed at the early stages
of a development cycle even though they are not expended
until later.

The cost of fixing a design and faulty decisions at later stages
is exponentially greater than at an earlier stage.

The opportunity costs of being late to market are very high,
ex., lower market share, lower margins.

Cross-functional teams typically provide a better quality
solution to complex dynamic product development problems
than single individuals.

Early simultaneous involvement in product development by
cross-functional teams using structured development process
saves time and money over the product life cycle.
Fundamentals of Product
Quality Planning

Organizing the team

Define the scope

Team-to-Team Communication

Training

Customer, supplier and subcontractor
involvement

Simultaneous \ Concurrent Engineering

Control plans

Concern Resolution

Timing plan and chart
 Product Quality Planning Chart
Concept Program
Initiation/Approval Approval Prototype Pilot Launch

Planning Planning

Product Design and Dev.

Process Design and Development

Product and Process Validation

Production

Feedback Assessment and Corrective Action

Plan and Product Process Product Feedback

Define Design and Design and and Process Assessment and
Program Development Development Validation Corrective Action
 1.0 Plan and Define Program
Inputs Objectives
Concept Program Voice of the Customer
Initiation/Approval Approval  Determine customer needs.
- Market Research  Define and plan a quality
- Historical Warranty program.
and Quality Information
Planning - Team Experience
Business Plan/Marketing strategy
Product/Process Benchmark Data
Product Reliability Studies
Customer Inputs
Outputs
Design Goals
Reliability and Quality Goals
Preliminary Bill of Material
Preliminary Process Flowchart
Preliminary Listing of Special Product and Process Characteristics
Plan and Product Assurance Plan
Define Management Support
Program
 2.0 Product Design and Development
Program Objectives
Approval Prototype Inputs  Develop design features and
The outputs of Section 1.0 characteristics
 Review engineering requirements
 Assess potential manufacturing
problems that could occur
Product Design and Dev. Outputs
Design Failure Mode and Effects Analysis (DFMEA)
Design for Manufacturability and Assembly
Design Verification
Design Reviews
Prototype build – Control plan
Engineering Drawings
Engineering Specifications
Material Specifications
Drawing and Specification Changes
Product New Equipment, Tooling and Facilities Requirements
Design and Special Product and Process Characteristics
Development Team Feasibility Commitment and Management Support
 3.0 Process Design and Development
Prototype Pilot Objectives
Inputs  Develop comprehensive and
The outputs of Section 2.0 effective manufacturing process
 Ensure process capability to
meet customer requirements
Outputs
Packaging Standards
Process Design and Development
Product/Process Quality System Review
Process Flow Chart
Floor Plan Layout
Characteristics Matrix
Process Failure Mode and Effects Analysis (PFMEA)
Pre-Launch Control Plan
Process Instructions
Measurement Systems Analysis Plan
Process Preliminary Process Capability Study Plan
Design and Packaging Specifications
Development Management Support
 4.0 Product and Process Validation
Prototype Pilot Launch Objectives
Inputs  Validate the product
The outputs of  Validate the manufacturing process
Section 3.0  Validate the control plan
 Ensure product meets customer
requirements
 Identify concerns
Product and Process Validation Outputs
Production Trial Run
Measurement Systems Evaluation
Preliminary Process Capability Study
Production Part Approval
Production Validation Testing
Packaging Evaluation
Production Control Plan
Product Quality Planning Sign-Off and Management Support
and Process
Validation
 5.0 Feedback, Assessment
and Corrective Action
Pilot Launch Inputs Objectives
The outputs of Section 5.0  Evaluate all variation (variable
and attribute data)
Planning
 Evaluate effectiveness of product
quality planning
 Use control plan and corrective
action

Outputs
Reduced Variation
Production Customer Satisfaction
Delivery and Service
Feedback Assessment and Corrective Action

Feedback
Assessment and
Corrective Action
 Summary:
The 5 Phases of APQP
1.Plan and Define the Program 1.
2.Product Design and Development
2.
3.Process Design and Development
4.Product and Process Validation 3.
5.Feedback, Assessment and 4.
Corrective Action 5.
Questions