Core Tools

APQP

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Welcome to training programme on

Advanced Product Quality Planning
(APQP Reference Manual,
Second Edition, July 2008)

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 Introduction
Introduction

The purpose of APQP is to communicate to organizations (internal and external) and suppliers,
common Product Quality Planning and Control Plan guidelines developed jointly by Chrysler, Ford
and General Motors. It provides guidelines designed to produce a product quality plan, which will
support the development of a product or service that will satisfy the customer

Some of the expected benefits in using these guidelines are:

§ A reduction in the complexity of product quality planning for the customers and organizations.

§ A means for organizations to easily communicate product quality planning requirements to

suppliers.

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IATF 16949:2016 Requirements

Introduction

Main Clause requirement:

8.0 - Operation
8.3 - Design and Development
8.3.2.1 - Design and Development Planning
8.3.2.1.1 - Design and Development Planning – Supplemental

Note: APQP is not only methodology, or mandatory requirement of IATF.

Interface Clauses requirement: (With respect to product which has been considered for APQP)
4.3.2 – Customer Specific Requirements
7 - Support ( i.e. resources, competence and documentation requirement specific to Product)
8 - Performance Evaluation (i.e. specific to performance and feedback of Product)
9 - Improvement (i.e. specific to Product and related processes)
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 Product Quality Planning Cycle

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Product Quality Planning Cycle

Product Quality Planning Cycle

The Product Quality Planning Cycle shown on the above slide is a graphic depiction of a typical
program. The various phases are sequenced to represent planned timing to execute the functions
described. The purpose of the Product Quality Planning Cycle is to emphasize:

§ Up-front planning. The first three quarters of the cycle are devoted to up-front product quality
planning through product/process validation.

§ The act of implementation. The fourth quarter is the stage where the importance of evaluating
the output serves two functions: to determine if customers are satisfied, and to support the
pursuit of continual improvement.

Depicting product quality planning as a cycle illustrates the never-ending pursuit of continual
improvement that can only be achieved by taking the experience in one program and applying that
acquired knowledge to the next program.

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 Product Quality Planning Responsibility
Product Quality Planning Responsibility

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Fundamentals of Product Quality Planning

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 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. Some of the benefits of Product Quality Planning
are:
§ To direct resources to satisfy the customer
§ To promote early identification of required changes
§ To avoid late changes
§ To provide a quality product on time at the lowest cost.

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 Organize the Team
Organize The Team

The first step in Product Quality Planning is to assign responsibility to a cross functional team.
Effective product quality planning requires the involvement of more than just the quality department.

The initial team should include representatives from engineering, manufacturing, material control,
purchasing, quality, sales, field service, subcontractors, and customers, as appropriate.

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APQP

Training:
The success of a Product Quality Plan is dependent upon an effective training program that
communicates all the requirements and development skills to fulfill customer needs and
expectations.
Training Plan may include members of Organization who are not a part of APQP team but are
indirectly supporting APQP activities
As appropriate Suppliers may also be trained to ensure effective implementation of Product Quality
Planning at supplier’s end.

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 APQP

Management Support:
One of the keys to the product quality planning team’s success is the interest, commitment and
support of upper Management.
The team should update management at the conclusion of every product quality planning phase to
maintain their interest, plus reinforce their commitment and support.
Updates and / or requests for assistance can occur more frequently as the team requires.
The updates should be formal with the opportunity for questions and answers.
Participation by management in product quality planning meetings is vital to ensuring the success
of the program.

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Define the Scope

Define The Scope

It is important for the Product Quality Planning Team in the earliest state of the product program to
identify customer needs, expectations, and requirements. Team must meet to:
1. Select Project Team Leader (Review and Decision making)
2. Define roles and responsibilities of each team member
3. Identify internal and external customers
4. Define Customer requirements
5. Select individuals, subcontractors and customer in the team
6. Assess the feasibility of proposed design, performance requirement and manufacturing
process
7. Identify costs, timing, and constraints that must be considered
8. Determine assistance required from the Customer
9. Identify documentation process and method.

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 Product Quality Timing Plan
Product Quality Timing Plan

The Product Quality Planning Team’s first order of business following organizational activities
should be the development of a Timing Plan. The type of product, complexity and customer
expectations should be considered in selecting the timing elements that must be planned and
charted.

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Product Quality Planning Timing Chart

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 Product Quality Timing Plan

The product quality planning team’s first order of business following organizational activities should
be the development of a Timing Plan.
All team members should agree with each event, action and timing.
A well organized timing chart should list tasks, assignments, and/or other events. Also the chart
provides the planning team with a consistent format for tracking progress and setting meeting
agendas.
To facilitate status reporting, each event must have a “start” and a “completion” date with the actual
point of progress recorded. Macro and Micro level Timing Plans are recommended to ensure
monitoring of each and every small activity. Effective status reporting supports program monitoring
with a focus on identifying items that require special attention.
The success of any program depends on meeting customer needs and expectations in a
timely manner at a cost that represents value.

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Chapter 1 – Plan and Define Programme

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 Chapter 1 - Plan and Define Program

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Chapter 1 – Plan and Define Program

Chapter 1 - Plan and Define Program

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 Chapter 1 - Plan and Define Program

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Chapter 1 - Plan and Define Program

Chapter 1 - Plan and Define Program

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 Chapter 2 – Product Design and Development

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Chapter 2 – Product Design and Development

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 Chapter 2 – Product Design and Development
Chapter 2 – Product Design and Devlopement

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Chapter 2 – Product Design and Development

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 Chapter 2 – Product Design and Development
Chapter 2 – Product Design and Devlopement

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Chapter 2 – Product Design and Development

Chapter 2 – Product Design and Devlopement

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 Chapter 3 – Process Design and Development

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Chapter 3 – Process Design and Development

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 Chapter 3 – Process Design and Development

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Chapter 3 – Process Design and Development

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 Chapter 3 – Process Design and Development

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Chapter 4 – Product and Process Validation

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 Chapter 4 – Product and Process Validation

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Chapter 4 – Product and Process Validation

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 Chapter 4 – Product and Process Validation

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Chapter 4 – Product and Process Validation

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 Chapter 5 – Feedback, Assessment
and Corrective Action

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Chapter 5 – Feedback, Assessment and Corrective Action

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 Chapter 5 – Feedback, Assessment and Corrective Action

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Chapter 5 – Feedback, Assessment and Corrective Action

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 Chapter 5 – Feedback, Assessment and Corrective Action

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