INTRODUCTION TO APQP

AIAG core tool

QM,
29.10.2023
INTRODUCTION TO APQP

Fundamentals of Product Quality Planning

• Product Quality Planning is a structured method of defining and establishing the steps necessary
to assure that a product satisfies the customer.
• The organization’s first step in product quality planning is to assign a process owner for the APQP
project.
• In addition, a cross functional team should be established to assure effective product quality
planning (representatives from multiple functions – engineering, manufacturing, materials,
purchasing, quality, HR, sales, suppliers and customers).
• Effective product quality planning depends on a company’s top management commitment to the
effort required in achieving customer satisfaction.
INTRODUCTION TO APQP

AIAG/APQP background
• APQP is utilized by US automakers and some of their affiliates. (https://www.aiag.org/)
• APQP was originated to provide a common, standardized process for planning, developing and
communicating the requirements and status of new products and services between suppliers
and their customers.
• Tier 1 suppliers are typically required to follow APQP procedures, techniques, and are also
typically required to be audited and registered to IATF 16949.
• The alternative to APQP approach is the VDA MLA (Maturity Level Assurance).
• The VDA (Verband Der Automobilindustrie) – the Association of the German Automotive Industry
recommends its members to apply the MLA standard for the implementation and maintenance
of the quality management system.
INTRODUCTION TO APQP

AIAG/APQP background

APQP (Advanced PPAP (Production MSA FMEA (Failure

SPC (Statistical
AIAG 5 core tools: Product Quality Part Approval (Measurement Mode and Effects
Process Control)
Planning) Process) System Analysis) Analysis)
INTRODUCTION TO APQP

AIAG/APQP background
The APQP process has seven major elements:
• Understanding the needs of the customer
• Proactive feedback and corrective action
• Designing within the process capabilities
• Analyzing and mitigating failure modes
• Verification and validation
• Design reviews
• Control special / critical characteristics
INTRODUCTION TO APQP

AIAG/APQP background
APQP specifies three phases: Development, Industrialization and Product Launch.

Through these phases 23 main topics will be monitored. These topics must be completed before
the production is started.

They include the following aspects:

• Design robustness
• Design testing
• Specification compliance
• Production process design
• Quality inspection standards
• Process capability
• Production capacity
• Product packaging
• Product testing
• Operator training plan
INTRODUCTION TO APQP

APQP background

3 stages of the APQP:

Methodology of APQP (Time diagram):
1. Prototyping (Development)
2. Prelaunch (Industrialization)
3. Serial mass production

APQP consist of five phases:

1. Plan and define program
2. Product design and development
verification
3. Process design and development
verification
4. Product and process validation
5. Feedback, assessment and corrective
action
INTRODUCTION TO APQP

AIAG APQP VS. VDA MLA

• Project planning phases
INTRODUCTION TO APQP

AIAG APQP VS. VDA MLA

• KEY TOOLS DURING PROJECT MANAGEMENT
INTRODUCTION TO APQP

AIAG APQP VS. VDA MLA

• VDA MLA, allows you to define the risk level of the project (A, B, C) and to carry out the
monitoring (« round tables »).
• Risk classification:
INTRODUCTION TO APQP

AIAG APQP VS. VDA MLA

• VDA MLA - Risk assessment and classification

*Calculated 28 pts for EEs

INTRODUCTION TO APQP
AIAG APQP VS. VDA MLA
• VDA MLA - „Round table“ organization
A core elements of communication in the supply chain
is the introduction of so-called „round table“ meeting
with representatives from various departments from
both customer and supplier:
• Quality management
• Project management
• Development
• Purchasing
• Sales
• Logistics
• Production planning
Responsibility must be given for:
• Chairing the „round table“ meetings
• The specification of the project contents and
objectives
• Coordinating and organizing reviews, previews, etc.
• Action management
• Reporting of results
• And the initiation of escalation, if required
INTRODUCTION TO APQP

AIAG APQP VS. VDA MLA

• VDA MLA - A-, B-, C-, D-samples
• A-samples are functional samples that are only roadworthy to a limited extent. They serve to
illustrate the basic functions. The use on public roads is not permissible in case of products
relevant for driving safety.
• B-samples are functional, roadworthy samples made with auxiliary tools that provide
sufficient operational safety for initial tests under driving conditions inside the vehicle and on
the test bench. Use on public roads is possible with a special permit and once street clearance
has been granted by the competent authority.
• C-samples are components made with series production tools. No technical restrictions that
have an impact on driving safety are allowed. Use on public roads is possible with a special
permit and once street clearance has been granted by the competent authority.
• D-samples are produced entirely with series production tools and under series production
conditions. Samples with which the production process and product approval process is carried
out, with the aim of achieving a release for series production (PPA).
INTRODUCTION TO APQP

IATF-APQP connections
Product Quality Planning Responsibilities Matrix:
INTRODUCTION TO APQP

IATF-APQP connections

• 8.3.2.1 Design and development planning – supplemental

The organization shall ensure that design and development planning includes all affected
stakeholders within the organization and, as appropriate, its supply chain.
• 8.3.4 Design and development controls / 8.3.4.1 Monitoring
Measurements at specified stages during the design and development of products and
processes shall be defined, analyzed, and reported with summary results as an input to
management review (see section 9.3.2.1 Management review inputs – supplemental)
INTRODUCTION TO APQP

AIAG APQP THROUGH PHASES…

• APQP has five formal phases

• Each phase is connected to and triggers the next. APQP is not a „use what I like and
ignore the rest“ approach. It represents a continuum in which each phase builds upon
the next
APQP Phase 1: Plan and Define the Program
• The overall objective of Phase 1 is to define a program that translates customer
needs and expectations into a value added (and competitive) offering
• This phase establishes the overall direction and objectives of the planning process
• Inputs entail both informal and formal information gathering
• During the first phase of the APQP approach, the information and data is compiled to
build a business case
• The output od Phase 1 defines specifically what product will be studied
INTRODUCTION TO APQP

AIAG APQP THROUGH PHASES…

APQP Phase 2: Product Design and Development

• In Phase 2, the conceptual product direction from Phase 1 is formalized with a detailed
design including engineering specifications and design features
• The compiled outputs of Phase 2 form the basis for a solid product design as well as the
foundation for a comprehensive design of the process
• The design is verified, a prototype is build, specifications are developed and inputs for the
process design are generated
APQP Phase 3: Process Design and Development
• In Phase 3, the manufacturing process for the product is designed
• Major outcomes include development of the process flow and layout
• Additionally, a Characteristics Matrix, PFMEA, Pre-Launch Control Plan and Work
Instruction are developed
INTRODUCTION TO APQP

AIAG APQP THROUGH PHASES…

APQP Phase 4: Product and Process Validation

• In the Phase 4, both the product and the process design are validated
• The „significant production run“ would typically be from one hour to perhaps one shift of
product using production tooling, gauges, process setting and operators
• The output product from the production run is used to evaluate the measurement system
and check the process capability
INTRODUCTION TO APQP

AIAG APQP THROUGH PHASES…

APQP Phase 5: Feedback, Assessment and Corrective Action

• Phase 5 focuses the organization on improving the product and process
• By using feedback from customers and assessing both product and process performance
measures, inadequacies and recurring problems and / or annoyances can be addresses
• Launching a product is not the end of a quality planning process but rather the start of
cycle of continuous improvement
• Control charts can be used to identify special causes of variation, capability studies and the
use if design of experiments can help reduce common cause variation
• This is the time for the supplier to work with the customer to ensure the product fully
meets customers needs and to retarget some of the product characteristics if need be
INTRODUCTION TO APQP

APQP PHASE 1 – PLAN & DEFINE THE PROGRAM

Phase 1 Inputs:
• The VOC – Voice of the Customer
• Market research (include time planning
and volume planning by OEM)
• Previous guarantees and quality
information
• Team experiences
• Business Plan and Marketing strategy
• Product / Process Benchmark Data
• Product / Process Assumptions
• Product Reliability Studies
• Inputs from the Customer
INTRODUCTION TO APQP

APQP PHASE 1 – PLAN & DEFINE THE PROGRAM

Phase 1 Outputs:
• Design Targets (based on voice of customer transferred to KPI)
• Reliability and Quality Targets (ppm evolution, ppm targets)
• Preliminary BOM (Bill of Material) with list of potential suppliers
• Preliminary Process Flow Diagram (based on preliminary BOM; Initial draft of detailed process
flow, material flow and value stream up)
• Preliminary Product and Process Special Characteristics List (Ask customer if they have some
special characteristics, special characteristics defined by us, special characteristics we got from our
suppliers)
• Product Assurance Plan (Program requirements outline; Identification of fault-free / reliability,
lifetime and assignment of goals and/or requirements; Assessment of new technology, complexity,
materials, environment, packaging, service and manufacturing requirements, Usage of risk
analysis for potential failures and consequences (FMEA); Preparation of preliminary design
requirements)
• Management support (Management support and participation in product quality planning is
one of most important factor for the success of the program)
INTRODUCTION TO APQP

APQP PHASE 2 – PRODUCT DESIGN AND DEVELOPMENT

Phase 2 Outputs:
• Design Failure Mode and Effects Analysis (DFMEA)
• Design for Manufacturing and Assembly (DFM &
DFA)
• Design verification and review
• Prototype building – Control Plan for Proto stage
• Technical drawings
• Technical and Material specifications
• Drawing and Specification changes
• New Equipment, Tooling, Gauges, Testing
Requirements
• Special Product and process Characteristics
(IMPORTANT! Ours + ask for customer’s special char.
+ ask suppliers what are their)
• Team Feasibility Commitment and Management
support
INTRODUCTION TO APQP

Ph.2 table outputs

INTRODUCTION TO APQP

APQP PHASE 3 – PROCESS DESIGN AND DEVELOPMENT

Phase 3 Outputs:
• Packaging standards and specifications
• Product / Process Quality System Review
• Process Flow Diagram
• Layout (Floor plan)
• Characteristics Matrix
• Process Failure Mode and Effect Analysis (PFMEA)
• Control plan for Pre-Launch stage
• Work Instructions
• MSA Plan and Preliminary Process Capability Study
Plan
• Management support
INTRODUCTION TO APQP

Ph.3 table outputs

INTRODUCTION TO APQP

APQP PHASE 4 – PRODUCT AND PROCESS VALIDATION

Phase 4 Outputs:
• Significant Production Run
• Measurement System Evaluation
• Preliminary Process Capability Study
• Product Part Approval
• Production Validation Testing
• Packaging Evaluation
• Control Plan for Serial Production
• Quality Planning Sign-Off and Management
Support
INTRODUCTION TO APQP

Ph.4 table outputs

INTRODUCTION TO APQP

Ph.4 table outputs

INTRODUCTION TO APQP

APQP PHASE 5 – FEEDBACK, ASSESSMENT AND

CORECTIVE ACTION
Phase 5 Outputs:
• Reduced Variation (Control charts to identify
process variability; Analysis and corrective
actions; Continuous improvement; Reducing /
eliminating random causes; SPC)
• Improved Customer Satisfaction
• Improved Delivery and Service
• Effective Use of Lessons Learned / Best
Practices
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