A DVANCED

P RODUCT

Q UALITY

P LANNING
Advanced Product Quality Planning (APQP) and
APQP Overview Training

Production Part Approval Process (PPAP)

@ Confidential data- TJR
Objective…
• To understand the process of New
Product Development based on APQP
to provide
– a quality product
– on time
– at the lowest cost

Will lead to Customer Satisfaction

@ Confidential data - TJR 2

Why Plan…
• Do it right first time
• On time
• Better quality product
• Reduction in time cycle
• Better communication
• Means for tracking and correcting
• Contingency planning
• Worst case planning
• Anticipate problems
• Identify ways to improve
• Continual improvement
• Ensure customer satisfaction

@ Confidential data - TJR 3

Roadblocks for planning…
• Lack of discipline
• Time management
• Unclear priorities
• Unclear responsibilities
• Lack of accountability
• Lack of faith in systematic approach
• Personal egos
• Lack of team spirit
• Lack of knowledge
• Lack of resources
• Lack of management commitment
• Unclear directions
• Non-competitive operating environ

@ Confidential data - TJR 4

Fundamentals of Product Quality Planning
• Organize the team
– Cross functional team with leader
• Define the scope
– Customer requirements (stated, implied)
– Feasibility
– Costs
– Help required from customer
– Assumptions
• Team to Team
– Define team interfaces with customer and suppliers
• Training
• Simultaneous engineering
• Control plans
• Concern resolution
• Product quality timing plan

@ Confidential data - TJR 5

Product quality planning timing chart
Program Proto- PPAP -
Sample
approval type Pilot

Phase 1 PLANNING
Phase 2 PRODUCT DESIGN & DEV.
Phase 3 PROCESS DESIGN & DEV.
Phase 4 PRODUCT & PROCESS VALIDATION
PRODUCTION

FEEDBACK & CORRECTIVE ACTION

@ Confidential data - TJR 6

 Phases – Inputs & outputs
Voice of the customer PPAP
Market research Production trial run with mass
Historical information production system
Team experience Measurement system evaluation Phase – 4
Business plan & marketing strategy Prelim process capability study PRODUCT/ PROCESS
Production Control Plan VALIDATION
Product/ Process benchmark data
Product/ Process assumptions Product testing
Customer inputs Sample to Customer
Service inputs Customer approval
Quality planning sign-off

Review Process FMEA

Phase – 1 Process Flow chart
PLANNING Pre-launch control plan
Packaging standards
Floor plan layout
Process instructions for operators
Gauge Design
MSA plan
Design goals
Process capability study plan
Reliability & quality goals
Preliminary Bill Of Material Sample
Preliminary process flow chart
Preliminary special characteristics
Design FMEA
Engineering drawing (review)
Material specifications

Team feasibility (Design information checklist) Phase – 3

Phase – 2 New equipment, tooling, facilities PROCESS DESIGN
PRODUCT DESIGN Process FMEA & DEV
& DEV
Proto Control Plan
Special characteristics
Prototype sample
@ Confidential data - TJR 7
Person Planning

@ Confidential data - TJR 8

What is APQP?
Advanced Product Quality • Advanced Product Quality Planning method to
Planning Cycle
assure that a product satisfies the customer (both
internal and external)
• The goal of APQP is to:
• Plan before acting
• Anticipate and prevent issues
• Validate before moving forward
• Facilitate communication

• Each Advanced Product Quality Plan is unique and is a living document

• Particular emphasis should be placed on identifying critical path activities and ensuring those
are fully resourced

@ Confidential data - TJR 9

 APQP Background

• Automotive industry challenges:

• Innovation, more complex product
• Reduce NPD times
• Complicated Supply chain
• Increasing customer and quality requirements
• Solution:
• Ford, GM, Chrysler APQP Task Force jointly developed in the late 80’s to standardize
their respective supplier quality systems.
• Continuous Improvement:
• Many industries outside the Automotive industry have embraced the AIAG APQP
process to achieve similar benefits

@ Confidential data - TJR 10

APQP – timing chart and phases - AIAG
The Advanced Product Quality Planning process consists of four phases and five major activities and has
some 20+ supporting tools (e.g. DFMEA, PFMEA, CTQ, Special Characteristics, Control Plan, SPC) along with
ongoing feedback assessment and corrective action.

@ Confidential data - TJR 11

1. Plan and Define Program
INPUTS: OUTPUTS:
• Voice of the Customer • Design Goals
• Market Research • Reliability & Quality goals
• Historical Warranty • CONC targets
and Quality • Preliminary Bill of
Information Materials
• Team Experience • Preliminary Process Flow
• Business Plan/Marketing Chart
• Preliminary list of Special
Strategy
• Product/Process Product and Process
Characteristics
Benchmark Data • Product Assurance Plan
• Product/Process • Management Support
Assure that customer Assumptions
needs and • Product Reliability Studies
expectations are • Customer Inputs
clearly understood.
* The inputs and outputs applicable to the process may vary according to the product process and customer
needs and expectations.

@ Confidential data - TJR 12

2. Product Design and Development - 1
INPUTS: OUTPUTS:
• Design Failure Mode and
• Design Goals
• Reliability & Quality Effects Analysis (DFMEA)
• Design For Manufacturability
goals
• Preliminary Bill of and Assembly
• Design Verification
Materials •
• Preliminary Process Design Reviews
• Prototype Build – Control
Flow Chart
• Preliminary list of plan
• Engineering Drawings
Develop design into Special Product and
(Including Math Data)
a near final form. Process • Engineering Specifications
Prototype and Characteristics •
feasibility studies – • Product Assurance Material Specifications
volumes, schedule,
• Drawing and Specification
Plan
manufacturing. Changes

Cont. next slide

@ Confidential data - TJR 13
2. Product Design and Development - 2
INPUTS: OUTPUTS:

• Design Goals • New Equipment, Tooling

• Reliability & Quality and Facilities
goals Requirements
• Preliminary Bill of • Special Product and
Materials Process Characteristics
• Preliminary Process • Gages/Testing Equipment
Flow Chart Requirements
• Preliminary list of • Team Feasibility
Special Product and Commitment
Develop design into • Management Support
a near final form. Process Characteristics
Prototype and
• Product Assurance Plan
feasibility studies –
volumes, schedule,
manufacturing.

@ Confidential data - TJR 14

3. Process Design and Development
INPUTS: OUTPUTS:
• Design Failure Mode and Effects
• Packaging Standards
Analysis (DFMEA)
• Design For Manufacturability and • Product/Process Quality
Assembly System Review
• Design Verification • Process Flow Chart
• Design Reviews • Floor Plan Layout
• Prototype Build – Control Plan • Characteristics Matrix
• Engineering Drawings (Including Math • Process Failure Mode and
Data) Effects Analysis (PFMEA)
• Engineering Specifications
• Pre-Launch Control Plan
• Material Specifications
• Drawing and Specification Changes • Process Instructions
Develop a • New Equipment, Tooling and Facilities • Measurement Systems
manufacturing Requirements Analysis Plan
system and its • Special Product and Process • Preliminary Process
related control Characteristics Capability Study Plan
• Gages/Testing Equipment • Packaging Specifications
plans to achieve
Requirements • Management Support
quality products. • Team Feasibility Commitment
• Management Support

@ Confidential data - TJR 15

4. Product and Process Validation
INPUTS: OUTPUTS:
• Packaging Standards
• Measurement Systems
• Product/Process Quality
Evaluation
System Review • Significant Production
• Process Flow Chart
• Floor Plan Layout Run
• Preliminary Process
• Characteristics Matrix
• Process Failure Mode Capability Study
• Production Part
and Effects Analysis
Approval
(PFMEA) • Production Validation
Validate manufacturing • Pre-Launch Control Plan
process through • Process Instructions Testing
production trial run. • Packaging Evaluation
• Measurement Systems
Validate that the control • Production Control Plan
plan and process flow Analysis Plan • Quality Planning Sign-
chart are effective and • Preliminary Process
that the product meets Off - formal
Capability Study Plan • Management Support
customer expectation. • Packaging Specifications
• Management Support
@ Confidential data - TJR 16
[Link], Assessment, Corrective actions
INPUTS: OUTPUTS:
• Production Trial Run
• Reduced Variation
• Measurement Systems
• Improved Customer
Evaluation
• Preliminary Process Satisfaction
• Improved Delivery and
Capability Study
• Production Part Service
• Effective use of best
Approval
• Production Validation practice, lessons
Evaluate outputs,
Testing learned
effectiveness of • Maximum ROI
• Packaging Evaluation
the product quality • Production Control
• Minimum Waste
planning efforts. • Minimum CONC
Plan
• Quality Planning Sign-
Off and Management
Support

@ Confidential data - TJR 17

 Application to Different Mfg. Environments
• High Volume
• APQP plans and activities are organized by part number and are very specific to the part
• Low Volume
• APQP plans may be specific to part families with activities focused on the parent part
• More limited validation would be done on child parts
• Family part differences should be understood and higher risk differences incorporated into
APQP plans
• Engineer to Order (ETO)
• APQP plans may use a part family approach for standardized elements
• Consider a manufacturing process focus for non-standard elements
• Create FMEAs and Control Plans for manufacturing processes rather than parts

@ Confidential data - TJR 18

APQP Summary:
What we do:
How we do it: What we get:
APQP
• Design Quality
• DFMEA / PFMEA / • Defect Free
DFM/A Launches
• Manufacturing Quality • Reduced Warranty
• Control Plans UP Claims
• Process Flows
• Zero Spills
• Measurement System FRONT
Analysis
• Customer
• Capability Analysis Satisfaction
• Process Validation DETAILED • Robust Products
• Run at rate • Greater Supplier
• Supplier Qualification & QUALITY Control
Quality Requirements • Reduced supplier
• Product Qualification PLANNING cost
• 1st Article Inspection
• PPAP
• Tooling & Gauges
• Testing

Leadership Engagement is Critical

1
@ Confidential data - TJR 19
 APQP Benefits:
Manufacturing process functions that are clearly planned, validated, documented and
communicated that result in:
• Robust and reliable designs
• Reduced process variation
• Enhanced confidence in supplier’s
CONC
capabilities
• Better controlled process changes

$$ Total Cost of Quality

• Defect free launches Redesign
Re-qualifications
• Improved Customer satisfaction Escape Investigations

• Improved Delivery and Service

• Maximum ROI
• Minimum Waste Prevention through APQP
Current state

• Minimum Cost of Non-conformance Time

Development Production

@ Confidential data - TJR 20

Key Take Aways:

• APQP is cross-functional planning and execution to produce product

that fully meets the customer’s expectations the first time
• AIAG APQP phases are Planning, Product Design, Process Design,
Validation, Production
• Phase approach ensures activities are completed in the appropriate
order
• Can be applied to different manufacturing environments – High
Volume, Low Volume, ETO
• It’s cross-functional – Marketing/Design/Manufacturing/SCM/Quality

@ Confidential data - TJR 21