Advanced product quality

planning (APQP) Training for

beginners
Overview and APQP implementation
Advanced product quality planning is a
framework of procedures and techniques
to develop products.
APQP

What is it?

• Advanced Product Quality Planning

• Framework (Methodology) for developing
New Product
• Originally Automotive Industry
• Up front Quality Planning
• Validation
• Focus on meeting Customer Requirements
• Similar to DFFS (Design for Six Sigma)
Why APQP?

• Standardised approach to make it

easier for suppliers
• Build components fit for purpose
• Plan how it is to be designed
• For communication and collaboration
• Prevent risks, variation, oversight
and issues
• Continuous improvement
The process

Feedback, Assessment & CA

Plan & Define

Product Design & Development

Product & Process Validation
Process Design & Development
APQP > Plan
• Phase 1: Plan and define
Establish Team
Establish Communications
APQP Training
Customer Requirements & Scope
Historical Data (Int & Ext)
Benchmark Data (Product &
Process)
Assumptions (Product &
Process)
Market Opportunity
Competitors
Customer Design Inputs
Design Goals
Quality & Reliability Goals
IPR / Patents
Manufacturing Feasability
Pricing
Preliminary BOM
Preliminary Process Flowchart
Preliminary Key Characteristics
Marketing Strategy
Management Review
APQP > Do

• Phase 2 - Product Design & Development

Block Diagram Change Control

Design FMEA Make or Buy Decisions

Drawings Supplier Selection

Tooling, Measurement & Test
Specifications Equip.
Materials Specifications Pricing Review
BOM Prototype
Warranty / Maintenance Prototype Customer Approval
Design Verification Update Designs
Design review Management Review
APQP > Do

• Phase 3 - Process Design & Development

Process Flowchart
Floor Plan
Key Characteristics (Product
& Process)
Control Plans
Process FMEA
Process Capability Plan
Packaging Specifications
Work Instructions
Quality System Review
Management Review
APQP > Check

• Phase 4 - Product & Process Validation

Materials Inspections
Trial Production Run (Not Pilot)
Measurement Systems Evaluation
Process Capability Study
Production Validation Testing
Packaging Evaluation
Production Part Approval
Customer Approval
Production Control Plan
Quality Plan
Management Review
APQP > Act

• Phase 5 – Feedback, Assessment & CA

Production
SPC / Reduction of Variation
Continuous Improvement
Non- Conformance Management
Delivery / Service / Warranty
Monitoring
Customer Satisfaction
Reporting
Management Review
SPC: Statistical process control
SPC / Reduction of variation

SPC / Reduction of variation

• Establish Engineering Tolerances (Phase 2)
• Establish Key Characteristics (KCs / KPs) (Phase 1&3)
• Determine Process Steps for Measurement (Phase 3)
• Raise Control Plans (Phase 3)
• Select Control Charts (Phase 3)
• Perform Gauge Variation Study’s (Phase 4 or Earlier)
• Test Control Plan / Charts (Phase 4)
• Implement Control Plan (Phase 5)
APQP > FMEA

• Failure Modes and Effects

Analysis
• Failure Mode – What can go
wrong
• Effects Analysis -
Consequences
• US Military – 1950s
• Systems, subsystems,
assembly, parts
• Process, sub-process, tasks
FMEA > Spreadsheets versus Risk Manager

• Engage leadership with Risk Manager

• Collect risks from across your
business
• Risk Manager integrates with other
modules e.g. Issue Manager, for a
systematic approach to assessing
risks
• Roles and responsibilities are
communicated and shared within the
system, with a full audit trail
• Demonstrate compliance and due
diligence in a robust, incorruptible
Gauge variation study

• Gauge R&R
• Variation due to Measurement Process
• Reproducibility – variation due to different Operators
• Repeatability – variation due to Gauge itself
• Measurement Variation = R+R
• Total Variation = MV + Product Variation

• Typically use Three Test Operators, each measuring Five

Parts, Ten Times. (50 measurements / Operator)
Document Manager and Record Management

• QMS Documentation
(Processes, SOPs, WIs)
• Planning Documentation
(Phase 1)
• Design Documentation
(Phase 2&3)
• Flowcharts / Block
diagrams
• Drawings
• Specifications
• Records of Reviews
• Records of Approvals
• Production Part Approval
Issue Manager

• Historical Data (Lessons Learnt)

(Phase 1)
• Planning Control (Phase 1,2,3,4)
• Non-Conformance Management
(Phase 5)
Audit Manager

• Historical Data (Lessons Learnt)

(Phase 1)
• Planning Control – Process
Checklists (Phase 1,2,3,4)
• Planning Control – Process
Validation (Phase 1,2,3,4)
• Audit - Continuous Improvement
(Phase 5)
• In Process Inspections (Phase 5)
Training Records Manager

• Records staff competency

• Demonstrate and test
competency
Request a live demonstration of our
software for APQP here:
http://quality.eqms.co.uk/eqms-software-
demonstration
Aizlewood’s Mill,
Nursery Street,
Sheffield
S3 8GG

+44 114 282 3338

info@qualsys.co.uk