AVB APQP

ADVANCED PRODUCT
QUALITY PLANNING
AND CONTROL PLAN
(APQP for ISO/TS)
 AVB APQP
What is APQP ?
It is a structured method of :
* advanced planning,
* programming, and
* implementation

to ensure that the product fully satisfies the

customer.
 AVB APQP
OBJECTIVES OF APQP :
To plan, establish and implement the steps
necessary to ensure that the product :

• Meets the requirements of customer

• Is delivered on time
• Is produced at optimum cost
 AVB APQP
BENEFITS OF APQP :

• To facilitate communication with all involved

• To direct resources to satisfy the customer
• To promote early identification of changes
• To avoid late changes
• To provide product on time at the lowest cost.
 AVB APQP
APQP Key Strategies :
* Up-front planning
* Cross functional teams
* Simultaneous development
* Focus on Special Characteristics
* Comprehensive control plans
* Effective Implementation
* PDCA leading to continuous improvement
 AVB APQP
BASIC STEPS IN APQP

* Organise the Team :

- Select the Team Leader and provide him

authority and resources.
- Organise the CFTs : select members
representing different functions.
- Define responsibility of each member.
 AVB APQP
BASIC STEPS IN APQP

* Define Scope :
- Identify customers - internal and external
- Define customer requirements
- Understand customer expectations
- Select other team members
- Assess feasibility of proposed design,
performance requirements, Mfg. Processes.
AVB APQP
BASIC STEPS IN APQP (Contd)

- Determine assistance / involvement

required from customer and sub-contractors
- reach agreement on all issues.
- Identify timings, costs and constraints.
- Identify Team to Team communication
requirements.
 AVB APQP
BASIC STEPS IN APQP (Contd)

* Develop a timing plan and a detailed

timing chart with schedules.
* Review periodically to ensure timely
implementation of plans.
* Concern resolution - through disciplined
problem solving approach.
 AVB APQP
5 PHASES OF APQP

• Plan and define Program

• Product Design and Development
• Process Design and Development
• Product and Process Validation
• Feedback Assessment & Corrective Action
 AVB APQP
PHASE 1 : PLAN & DEFINE PROGRAM

* This phase determines customer’s needs and

expectations in order to plan and define a
quality programme, including specifications
of the product.

* The inputs to and outputs of each of the 5 Phases

are identified and defined.
 AVB APQP
PHASE 2 : PRODUCT DESIGN & DEV.
* Consider all relevant design factors and develop the
design outputs, meeting all customer requirements.

* Establish the manufacturing feasibility including

quality, reliability, volumes, schedules, costs, etc.
* Certain activities applicable even for Organisations
who do not have design responsibility.
 AVB APQP
PHASE 3 : PROCESS DESIGN & DEV.

* Consider all relevant design requirements and

developing
- A suitable Manufacturing System, and
- Relevant Control Plans
 AVB APQP
PHASE 4 : PRODUCT & PROCESS
VALIDATION
* Validation of the manufacturing process by means
of a production trial run.
* Confirmation that the Process Flow Charts and
Control Plans are followed and are effective.
* Approval of parts for production by customer.
* Product Quality Planning Summary & Sign-off.
 AVB APQP
PHASE 5 : FEEDBACK ASSESSMENT /
CORRECTIVE ACTION
* Evaluation of the effectiveness of the Quality
Planning efforts, especially when all Special
and Common causes of variation are present.

* Make appropriate changes where required.

 AVB APQP
PHASE 5 : FEEDBACK ASSESSMENT /
CORRECTIVE ACTION
* This Phase ensures that customer requirements
on all characteristics and process indices are
always met. This phase is continuous and ongoing.

* One of the outputs of this phase should be

preparation of TGR / TGW reports for preparing
base for next product quality planning.
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
INPUTS (Typical)
* Customer Voice - Market Research
Historical Data (Internal/External)
Team Experience (Ex. TGR/TGW)
* Customer Business Plan / Marketing Strategy
* Inputs - from Customer, Suppliers, Field, Internal
* Bench Mark data (Product & Process) (Own/Others)
* Product/process assumptions (Ex. New Technology)
* Product Reliability studies (short term / long term)
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
INPUTS (Typical)
* Contract review results, including requirements
of special characteristics, identification, traceability,
packaging etc.
* Reports of past problems (Ex. TGR/TGW reports)
* Requirements on recycling, environmental impact
* Government, safety and environmental regulations
* Homologation requirements
* Industry practices in the country of use
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
INPUTS - BENCH MARK DATA (Product)
* Weight of product
* Material Cost
* Easiness of mounting, easiness to adjust
* Easiness of serviceability
* Standardisation
* No. of components
* Compatibility of components with each other
* Useful Life
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
INPUTS - BENCH MARK DATA (Product)
* Failure Rate
* Operating Conditions
* Aesthetics
* Transportability
* Compactness
* Failure Indication
* Usage of undesirable materials
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
INPUTS - BENCH MARK DATA (Product)
OTHER PRODUCT SPECIFIC FEATURES -
Ex. For automotive brakes :
* Braking effectiveness
* Response time
* Pedal Comfort
* Lining Life
* Seal Life
* Servo Ratio
* Noise level
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
INPUTS - BENCH MARK DATA (Product)
OTHER PRODUCT SPECIFIC FEATURES -
Ex. For automotive brakes (contd) :

* Retraction time
* Straight Line Stability when fully applied
* Failure Indication
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
INPUTS - BENCH MARK DATA (Process)
* Manufacturing technology
* Set-up times, Process times
* FPR/FTR/Rejection ratios
* Manpower / Unit - direct / indirect
* Space requirements
* Investments, Tooling Costs, Inventories
* Power consumed / Unit
* Material movement
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
INPUTS - BENCH MARK DATA (Process)

* Process capability to reduce variation

* No. of accidents per year
* Ambient Noise level in manufacturing areas
* Use of undesirable chemicals in manufacturing
(Ex. Trichloro Ethylene, Methanol etc.)
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
OUTPUTS (Typical)
- Design Goals
- Quality & Reliability Goals
- Preliminary Bill of Material
- Preliminary Process Flow Charts
- Preliminary listing of Special Characteristics
- Preliminary Quality / Test Plans
- Management Support
 AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM
Goals for Design include:
- Product Design: Targets to be fixed for:
Product Quality, Life, Reliability, Durability,
Maintainability, Timing, Cost and Impact on
Environment.

- Process Design: Targets to be fixed for:

Productivity, Process Capability and Cost.
AVB APQP
PHASE 1. PLAN & DEFINE PROGRAM

GOAL

Capture customers voice

Deploy customers needs and

requirements
 AVB APQP
PHASE 2 - PRODUCT DESIGN and DEV.
OUTPUTS: TYPICAL
BY DESIGN RESPONSIBLE ACTIVITY

- Design FMEA (at Assembly, Sub-Assy. & Part level)

- Product Definition, Design documents, Diagnostics,
- Product error proofing, Reliability results,
- Design Reviews (Cross-functional, Multi-stage)
- Prototype Control Plan, Prototype Build
- Product Design Verification activities as appropriate
 AVB APQP
PHASE 2 - PRODUCT DESIGN and DEV.
OUTPUTS: TYPICAL
BY PRODUCT QUALITY PLANNING TEAM

- New Equipment, Tooling and Facilities requirements

- Gage / Testing Equipment requirement
- Special Product & Process Characteristics
Get
- Feasibility / Risk Analysis & Commitment Management
Support
- Input for Management Review.
 AVB APQP
PHASE 2 - PRODUCT DESIGN and DEV.
OUTPUTS: TYPICAL
Manufacturing Feasibility Analysis to include
Risk Analysis. Mitigation plans are required.
Risks may relate to inability to develop products on
time, products not performing as contracted, non-
availability of required materials, breakdown of
key equipment and tools, supplier delivery issues,
labor problems, political unrest, etc., etc.
 AVB APQP
PHASE 2 - PRODUCT DESIGN and DEV.

GOAL

A feasible Design
 AVB APQP
PHASE 3 : PROCESS DESIGN & DEV.
OUTPUTS: TYPICAL
- Process Flow Charts / Process Layouts
- Characteristic Matrix
- Process FMEA
- Process error proofing details
- Methods of rapid detection & feedback
- Pre-launch Control Plan
- Set-up and Process Instructions
- Process Approval Acceptance Criteria (all processes).
 AVB APQP
PHASE 3 : PROCESS DESIGN & DEV.
OUTPUTS: TYPICAL (Contd.)

- Plans for MSA

- Plans for Preliminary Process Capability Study
- QMS Review and identification of new requirements
- Floor Plan Layout
- Packaging Standards
- Packaging Specifications
 AVB APQP
PHASE 3 : PROCESS DESIGN & DEV.
OUTPUTS: TYPICAL (Contd.)

- Data for Quality, Reliability, Maintainability,

and Measurability (processes & equipment)
- Process Design Review
- Process Design Verification Get
- Inputs for Management Review. Management
Support
 AVB APQP
PHASE 3 : Characteristic Matrix
DIM No. DESCRIPTION Tolerance OPN. 10 OP.20 OP.30 OP.40 OP.50

1 ID +.05 X C C
2 FACE +/-0.5 X C R
3 X L
4 X
5 X C
6 OD -.05 X
 AVB APQP
PHASE 3 : PROCESS DESIGN & DEV.
Packaging Standards Packaging Specs (Ex)
* How to pack * Packaging design
* How many to pack * Partition design
* What protection req.. * Lining requirements
* What labeling req.. * Size / pattern of labels
* How to handle * Handle design
* How to transport * Transportation design
* Testing Standards * Testing specifications
AVB APQP

PHASE 3 : PROCESS DESIGN & DEV.

GOAL

Successful production part approval

 AVB APQP
PHASE 4 : PRODUCT & PROCESS
VALIDATION
OUTPUTS: TYPICAL
- Measurement System Analysis
- Production Trial Run
- Preliminary process capability study
- Production Validation Testing (product & process)
- Packaging Evaluation
- Production Part Approval
- Production Control Plan
- Quality Planning Sign off (at MFG site)
AVB APQP
PHASE 4 : VALIDATION

GOAL

Successful Product launch

 AVB APQP
PHASE 5 : FEEDBACK ASSESSMENT
AND CORRECTIVE ACTION
OUTPUTS: TYPICAL
- Review of DFMEA, PFMEA, Control Plans
- Preparation of TGR / TGW Reports
- Evaluation of data: Variables / Attributes
- Design changes (product & process as applicable)
- Reduced Variation (Continuous Improvements)
- Continued On-time Delivery & Service
AVB APQP
PHASE 5 : FEEDBACK ASSESSMENT
AND CORRECTIVE ACTION

GOAL

Customer satisfaction
Continuous improvement
 AVB APQP
APQP : KEY FACTORS FOR SUCCESS
* Leadership
* Sincere Team work
* Open minded approach
* Timely and effective Communication
* Knowledge of processes and techniques
* Effectiveness of Reviews
* Customer and Sub-contractor involvement
* Simultaneous Engineering
* Management support
 AVB APQP
CONTROL PLANS
Control Plans are written description of a
system to control product(s) and processes.
They provide a structured approach to
selection, design and implementation of value
added control methods. They do not replace
Process or Work Instructions.
 AVB APQP
Control Plans
A single control plan may be applicable to a
group of products by the same process at the
same source.
CATEGORIES
Prototype
Pre-launch
Production
 AVB APQP
CONTROL PLAN METHODOLOGY
Control plans, prepared during APQP by
CFTs, derive inputs typically from
- Process Flow Diagrams
- FMEAs
- Design Reviews
- Lessons from the past
- Knowledge of the processes
- Process Analysis.
 AVB APQP
CONTROL PLAN METHODOLOGY
Control plans identify process characteristics
and help to identify their sources of variation
(input variables) which cause variation in the
product characteristics (output variables).

Control plans shall specify control methodology

for each process step based on the nature and
analysis of processes.
 AVB APQP
CONTROL PLAN METHODOLOGY
Control plans are required to be continuously
updated especially when product or processes
change, processes become unstable or
incapable, or inspection methods are revised.
They are living documents.
 AVB APQP
CONTROL PLAN METHODOLOGY

Control plans shall address all processes and

product / process characteristics, including all
significant / special characteristics. Control plans
shall contain all data as per Annexure - A to ISO/TS,
including details of Mistake Proofing and Corrective
Actions.
 AVB APQP
CONTROL PLAN METHODOLOGY
Control methods are directly related to the
common sources of variation in the process
and dominant factors impacting the quality
of the product.

Defining appropriate control methodology

is the most important factor contributing to
effective deployment of control plans.
 AVB APQP
PROCESS ANALYSIS
The most common sources of variation or
dominating factors determining the quality
of products are :
 Set-up
 Machine
 Tooling
 Operator
 Maintenance
 Environment
 Part / product
 AVB APQP
PROCESS ANALYSIS
In summary, we may identify processes as :
* Set up dominant
* Machine dominant
* Tooling dominant
* Operator dominant
* Maintenance dominant
* Environment dominant
* Part / product dominant
 AVB APQP
PROCESS ANALYSIS (Contd..)

Typical techniques for analysis include

- Cause and Effect diagram

- Design of Experiments
- Fault Tree Analysis
AVB APQP
CONTROL METHODS : SOME EXAMPLES

SET UP DOMINANT CONTROLS

Punching Setup Verification
Molding 1st Piece Inspection
etc.
 AVB APQP
CONTROL METHODS : SOME EXAMPLES

MACHINE CONTROLS
DOMINANT
Wave soldering Audit inspection
Wire enameling Control charts
CNC Machining Patrol inspection, etc.
AVB APQP
CONTROL METHODS : SOME EXAMPLES

TOOL DOMINANT CONTROLS

Stamping First piece inspection
Broaching Error proofing
Patrol inspection
Last off comparison
 AVB APQP
CONTROL METHODS : SOME EXAMPLES

OPERATOR CONTROLS
DOMINANT
Welding Operator qualification
Lathe Operation Audit inspection
Assembly operation Patrol Inspection, etc.
 AVB APQP
CONTROL METHODS : SOME EXAMPLES

COMPONENT CONTROLS
DOMINANT
Auto Hood Stamping First piece Inspection
Control Charts, etc.
 AVB APQP
CONTROL METHODS : SOME EXAMPLES

MAINTENANCE CONTROLS
DOMINANT
Painting Operation Periodic cleaning
Dust level monitoring
AVB APQP
CONTROL METHODS : SOME EXAMPLES

ENVIRONMENT CONTROLS
DOMINANT
Molding - Pre-heating of
Humidity plastic granules -
Monitor / record
Dryer Temperature
 AVB APQP
REACTION PLAN / CORRECTIVE ACTION:
The Reaction Plan specifies the action to be
taken by personnel close to the process to avoid
producing non-conforming products. If the
reaction plan does not work, corrective action
to be initiated.

Suspect or non-conforming product shall be

identified, quarantined and disposed off.
AVB APQP
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