APQP 3rd Edition and Control Plan 1st Edition:

What You Need to Know to Be Ready

 Webinar Presenters
Dave Mimms, AIAG Jeremy Hazel, Plexus International
• Quality Professional
with 30+ years
automotive experience
(Toyota, AIAG)
• AIAG Participant in
APQP and Control Plan
revision workgroup
• Dave supports various
projects & workgroups
as AIAG quality staff
2
• Experienced Trainer and
curriculum developer
specializing in core tools
implementation and
utilization.
• Jeremy specializes in small
team development and risk
based-thinking
implementation strategy
 Poll Time!

Q1 Q2
What area are you currently in with What is your tier within the automotive
your organization? space
• Program management • OEM
• Supplier Quality • Tier 1
• Plant/ corporate quality • Tier 2
• Operations • Sub tier below 2
• Manufacturing
• Other

3
 Why the Need for APQP and CP Update?
• It’s about time! (1st Edition 1994; 2nd 2008 – minor changes)
• Industry changes in program management cycles/methods
• Technology changes (product and processes)
• Supply Chain expansion (“New to Auto”, cross-sector suppliers)
• Opportunity to harmonize CSRs and suggest “best practices” based on
Lessons Learned from past programs
• Alignment to IATF 16949 (2015), leverage related AIAG publications
• Customer expectations evolving (consumer, regulatory, etc.)

4
 Why Separate Control Plan manual?
Flexibility and Agility
• Anticipate more frequent updates
than APQP as technologies evolve
• Flexibility to revise/upgrade based
on Lessons Learned, Best
Practices, and alignment to other
standards and harmonized
expectations
5
Continuous Improvement
• Ford, General Motors and Stellantis
collaboration to list frequent weak
points and how to address
✓Harmonized CSRs
✓Clear Requirements related to top
opportunities for improvement
✓Increased guidance on process to
develop and manage Control Plans
The core tools hierarchal structure
APQP

Alignment with the current model

FMEA
• The breakout of the control plan is
consistent with the way we have
Control Plan been teaching the core tools for
years
MSA • The measurement studies required
for PPAP are driven by the control
plan
SPC
• The control plan remains the
operational expression of the FMEA
PPAP
 Changes to APQP

Program Management Sourcing Clarification/Detail

• Risk Assessment • Increase focus on • Change Management
and Mitigation Sourcing stage, just during APQP
• Gated Management as important as • Capacity Planning
expectation and “readiness” using OEE
guidance • Checklist to assess • Traceability
• KPIs related to APQP & mitigate risk
during Sourcing • Error-Proofing and
process Mistake-Proofing
• Gated Management
includes sub-tiers
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 At a Glance: APQP Sourcing (section 0.5)
0.5 Sourcing
• New AND Existing suppliers (sub-
tier) require thorough vetting to
ensure design and manufacturing
capability
• Sourcing checklist should be
completed to confirm supplier
suitability (based on CQI-19 Sub-
Tier Supplier Management Process)
• Scope for Sourcing ends with
acceptable vetting results. All other
APQP activities cascade to sub-tier.
0.5.1 High Risk Supplier Evaluation
• Organization must have a method to
identify “high risk” suppliers
• Criteria to define high risk include:
− New supplier to Organization
− New location or site
− New technology
− History of poor quality
− Supplied components have Safety or
Regulatory requirements
− No certification to ISO 9001 or IATF
16949
At a Glance: APQP Gated Management (App B)
• New Gated Management Section
• Suggested documentation
checklists for each “gate” review
• Aligned to typical Program
milestones
• Supports expectation for “gate
review” in 1.14 Leadership Support
• Includes review of Supplier (sub-
tier) APQP activity, not just
Organization’s
Managerial vs technical aspects
Technical
• An increase in number of tasks
• Change in the graphic to extend
product development
Managerial or Governance
• Increased number of gates
• More up-front planning
• Higher focus on lessons learned
• More focus on risk-based thinking
The governance framework
 Control Plan Manual Overview
Evolved from “how to fill in the form” in APQP/CP 2nd edition to:
• Chapter 0 Introduction
− Clarify linkage to APQP processes; emphasize “Living Document”
• Chapter 1 Requirements and Guidelines
− Clear requirements for key topics (common weak points, harmonized CSRs)
• Chapter 2 How to Develop Control Plan
− Expanded guidance with emphasis on process approach
• Chapter 3 Control Plan Stages
− Importance of each stage, harmonized CSRs for Safe Launch
• Chapter 4 Effective Use of Control Plans
− Maximize Control Plan effectiveness in context of holistic QMS

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 Control Plan Key Content/Changes
Characteristics Address Common Clarified
Management Weaknesses Expectations
• Special • Error-proofing • Directed Supply
Characteristics confirmation information
identification and • Volume-based gathering activity
classification sampling frequency • Safe Launch,
• Pass-Through (ensure containment) including “exit
Characteristics • Reaction Plan criteria”
identification and documentation
management (action & responsible)

13
 At a Glance: Control Plan Chapter 1
Requirements and Guidelines for 12 topics based on past problems
Key examples:
• Special Characteristics
− Allow use of “correlation matrix” (correlate organization symbols to customer's)
− Customer may also designate "key" or "critical" characteristics for special handling
• Pass-Through Characteristics
− Organization must have a process to identify and ensure adequate control of PTC
throughout supply chain, and must communicate control methods to customer
− Recommended CQI-19 PTC Matrix to communicate control methods to customer
• Directed Supply
− Organization must get necessary information from Supplier to develop
Organization's control plan unless otherwise specified by mutually signed
agreement (MPA, etc.)

14
At a Glance: Control Plan Chapter 3
Control Plan Stages
• Addition of “Safe Launch” requirements
• Typical Application (figure 3.1)
• Pre-Launch: Customer may require during
Pilot Stage and continued into launch; how
to document
• Production: Start of Production WILL
include Safe Launch
• Must establish judgment criteria to exit
Safe Launch - typically 90 days no
problems to customer and no problems
Typical application of Safe Launch Control Plan identified by Safe Launch
additional/enhanced controls/containment
 At a Glance: Control Plan Chapter 4
Considerations for using QMS elements to maximize effectiveness
Key concept, why it’s important, what to do, and how to do it for:
• Reverse PFMEA
• Using Software to Develop and Manage Control Plan
• Layered Process Audit as Control Plan Verification
• Control Plans in Highly Automated Processes
• Using Family/Foundation Control Plans and FMEAs
• Control of Storage and Handling Related Risks
• Abnormality Management related to Control Plans

16
 Poll Time Part Deux!

Q3
Given what you saw in the presentation
how ready do you feel you are for the new
version and the subsequent deadline to
adopt it
• Very ready
• Somewhat ready
• We have a lot of work to do
Q4
When it comes to utilization how will you
be using the new APQP and Control plan
• We will be adopting it for our own
organization as an existing
automotive supplier
• We will be driving through our
supply chain
• We will be implementing it for the
first time as an automotive supplier

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 Enabling Rapid Electrification of Industry

Framework Flexibility New Suppliers to Auto New Technology

• Quicker cycles of • Customers will still • Sector Specific
development expect APQP and guidance proposals
• Sequence and CP execution can be made
duration of actions (process agreed)
may be flexible
(consult customer)
Consistent Intention/Purpose
APQP manual: “The intent of APQP is to proactively assess and mitigate risk factors impacting product launch.”
CP manual: “The goal of a Control Plan is to facilitate communication with everyone involved to assure that all required
controls are completed on time and in full, every time.”
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 Fast Feedback Team – accelerated development
• Suppliers/OEMs Consulted • Key Contributions
Diverse demographics & opinions Suggestions, best practices, concerns
− Bosch ➢APQP
− Freudenberg-NOK ✓ Gated Management guidance
− Geely
− GKN ✓ Traceability expectations
− Honda ✓ Checklist expansion (best practices)
− Rivian
− Magna ➢Control Plan
− Nexteer ✓ Special Characteristics classifications
− NXP Semiconductors
− Paccar ✓ Pass-Through Characteristics assurance
− Shape Corporation ✓ Reaction Plan details
− Panasonic Battery Solutions ✓ Directed Supply relationships

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 Implementation Timing Targets

Ford General Motors Stellantis

• 6 months after • 6 months after • 6 months after
publication publication publication

All will ACCEPT immediately after publication

(Nothing new is contrary to current, positively enhanced new content is OK)

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 What Should You Do to Be Ready?

Learn the Content Gaps? More Training? Implement & Reflect

• Get the new • Assess gaps between • Pilot project with
documents as soon as current practices and limited scope
possible the new APQP and • Reflect from your
• Utilize AIAG eLearning Control Plan manual viewpoint and that of
and training resources • Knowledge and your customer
expertise gaps may • Document and
require additional Implement Lessons
training Learned

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 AIAG Training Resources Purchase Your Presale Publication
and Training Now!

• APQP and Control Plan transitioning

• Control Plan- Understanding and
Implementing
• APQP overview
• APQP Control Plan and PPAP-
Understanding and Implementing
• PPAP- How to review and improve the
effectiveness of PPAP

Join the ranks of AIAG and take advantage of member savings on critical resources like these!
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22
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Thank you
 APQP 3rd Edition and Control Plan 1st Edition FAQ’s

When is the new APQP 3rd edition and Control Plan 1st edition officially being released?

• The anticipated release date for both publications is March 1, 2024.

How much are the new publications going to cost?

APQP / CP Publication Type Member Non-Member

Hardcopy $ 55 $ 165
Individual e-Document $ 55 $ 165
Corporate Subscription $ 1,600 $ 2,600
Hardcopy $ 99 $ 297
Kit (both
e-Document $ 99 $ 297
documents)
Corporate Subscription $ 2,880 $ 4,680

What languages are the new publications going to be offered in?

• The new publications will be offered in English, Chinese, Japanese, Korean, Portuguese, and
Spanish when the document launches.

When will training be available for the new processes?

• Training will be available at launch. Please review the training classes listed above.

When will the new APQP and Control Plan be required by the OEMs?

• At this time, General Motors implementation date is six months for the release date of the
documents
o Contact your customer representative with implementation questions

When will the new APQP and Control Plan be accepted by the OEMs?

• Ford, General Motors, and Stellantis have agreed they will accept use of the new APQP and
Control Plan immediately after publication, since nothing in the new documents conflict with the
APQP 3rd edition.

Is the Control Plan form or fields changing with this update?

• The Control Plan forms have been updated

Will the AIAG Core Tools Support Software, CTS, include the new Control Plan?

• Yes, the new forms for APQP and Control Plan are anticipated to be available at launch
Is AIAG planning to offer standardized software for creating the new Control Plans?

• Yes – AIAG’s Core Tools Support Software, CTS, creates and manages Control Plan, FMEA, and
PPAP documents quickly, accurately, and globally

Do the OEMs expect suppliers to update existing Control Plans to meet the new requirements?

• No, suppliers will not have to update existing Control Plans to meet the new requirements.

Are the Core Tools Self-Assessment and Quality Core Tools Knowledge Badge being updated to include
the new versions of APQP and Control Plan?

• Yes, the current Core Tools Self-Assessment and Quality Core Tools Knowledge Badge will be
updated to include the newest versions of APQP and Control Plan.

What are the major changes to APQP*?

• Removed Control Plan content into stand-alone document

• Added Sourcing section and Sourcing Checklist
• Added Change Management section and Change Management Checklist
• Added section for APQP Program Metrics, including Example in Appendix C.
• Added section for Risk Assessment Mitigation Plan
• Added "Part Traceability“ content
• New Gated Management Section
o Suggested documentation checklists for each “gate” review
o Aligned to typical Program milestones
o Supports expectation for “gate review” in 1.14 Leadership Support
o Includes review of Supplier (sub-tier) APQP activity, not just Organization’s

*Note, this list is not all-inclusive and should not be used for gap-analysis. If your customer requires you
to complete APQP and Control Plan documents, you are encouraged to read them in their entirety.

What are the major changes to Control Plan*?

• Clarify link to APQP processes, Living Document

• Clarify Requirements (topics from lessons learned and Customer Specific Requirements)
• Provides detailed guidance how to develop, not just form fields
• Addition of “Safe Launch” requirement to the control plan phases
• Includes effective use of Control Plan guidance based on practices of excellent organizations
• App A: CP Examples - Table for Process Dependent considerations; General to illustrate key
requirements/expectations
• App B: Forms/Checklists - Updated based on changes in Chapters 1-3

*Note, this list is not all-inclusive and should not be used for gap-analysis. If your customer requires you
to complete APQP and Control Plan documents, you are encouraged to read them in their entirety.