What is APQP [Advanced Product Quality Planning]?
→ APQP [Advanced Product Quality Planning] is a structured approach that is used to design and develop the product and_process to meet customer needs and expectations.→ Advanced Product Quality Planning tool is extensively used by Automotive industries to assure quality and performance through effective planning.
→ In other words, APQP is a framework for developing new_product
→ More precisely we can say this method is rigorously used in the automotive industry.
→ This method is very much similar to the concept of Design for Six Sigma (DFSS).
→ As per AIAG, this tool is to help us to prepare a product quality plan to fulfill all requirements of the_product and satisfy our customers.
→ APQP is one of the important tools among the Five Core Tools of IATF 16949 Standard.
History of APQP:
→ The "Big Three" [Ford, GM, and Chrysler.] has developed the_process of advanced product_quality planning in the late 1980s.→ Initially, the representatives from the Big Three and the Automotive Division of American Society for Quality Control (ASQC) have developed the guidelines for the Quality Requirements of automotive suppliers. This is a common criterion for all suppliers.
→ Today, APQP is adopted by many automotive industries.
→ Tier 1 suppliers of automotive OEMs are generally required to follow the APQP_guideline.
→ This will be audited during the certification of IATF16949.
→ The Automotive Industry Action Group (AIAG) is a non-profit organization of automotive companies founded in 1982.
→ This technique is being used in other manufacturing industries.
→ This is controlled and published by AIAG.
→ It is also known as the Five Core Tools of IATF 16949.
➨ The Five Core Tools of IATF 16949:
- Advanced Product Quality Planning - APQP_Manual
- Production Part Approval Process - PPAP Manual
- Failure Mode and Effect Analysis - FMEA Manual
- Measurement System Analysis - MSA Manual
- Statistical Process Control - SPC Manual
Objectives of APQP
→ Facilitate effective communication with everyone involved in the APQP_process.→ Timely Completion of all required steps.
→ No or minimum quality complaints.
→ Assure product_quality, process_quality, and performance.
→ Meeting customer’s requirements
Main Focus Points of APQP
→ Understanding the customer's need & expectation→ APQP_focus on Proactive approach and corrective action
→ Designing within the process_capabilities
→ Analyzing and mitigating failure modes
→ Verification and validation and design_reviews
→ Control special/critical characteristics.
What is the APQP time plan?
→ The APQP_Time Plan is mentioned in the below picture.
What are the 5 phases of APQP?
→ The Five Phases of APQP are mentioned below.- Plan & define program
- Product design & development
- Process Design_and Development
- Product and Process Validation
- Feedback, Assessment & Corrective Action
Phase 1: Plan & define program
→ The purpose of this_phase is to ensure that customer’s needs and expectations are clearly understood.➨ Inputs of this_phase:
- Understand the Voice of the customer
- Market research
- Historical warranty & quality_information
- Team experience
- Business plan/marketing strategy
- Product_& process_Benchmark data
- Product_& process_Assumptions
- Product_Reliability studies
- Customer inputs-such as Product_Identification & traceability, Special characteristics, and Packaging requirements, etc.
- Design_goals
- Reliability & quality goals
- Preliminary bill of material-BOM
- Preliminary process flow chart-PFC
- A preliminary listing of special_product & process_characteristics
- Product_Quality Assurance_plan
- Management support
Phase 2: Product design & development
→ The purpose of this_phase is to develop design features into nearly the final form of the product.➨ Inputs: Inputs of Phase_2 are the Outputs of Phase_1.
➨ Outputs of Phase 2:
- DFMEA – Design Failure Mode & Effects Analysis
- DFMA or DMA – Design for Manufacturability & Assembly
- DVP & R – Design Verification_Plan and Report
- Design Verification through Prototype Model
- Design verification through Product_Testing
- Prototype control_plan
- Engineering drawings review
- Engineering specifications review
- Material specifications review
- Drawing & specification changes
- Target setting for Productivity and Process_capability
- Gauge /Testing Equipment Requirements
- New Tooling/Equipment and Facilities requirement review
- Team Feasibility Commitment Sign off
Phase 3: Process Design and Development
→ The purpose of this_phase is to develop an effective management system to assure that customer’s needs and expectations are met.➨ Inputs: Inputs of Phase 3 are the Outputs of Phase 2.
➨ Outputs:
- PFD – Process Flow Diagram
- PFMEA – Process failure mode and effects analysis
- Pre-Launch Control_Plan
- Floor plan layout
- Packaging standards
- Measurement System Analysis_Plan
- Data for Quality, Reliability, Measurability, and Maintainability
- Method of rapid detection and feedback
- Result of Error-proofing activities
Phase 4: Product and Process Validation
→ The purpose of this_phase is to validate the manufacturing_process with the help of a production trial run and to finalize the Production control plan.➨ Inputs: Inputs of Phase 4 are the Outputs of Phase 3
➨ Outputs:
- Production Trial Run
- Production control plan
- Measurement systems evaluation
- Preliminary Process_capability study
- Production part approval – PPAP
- Production validation testing
- Packaging evaluation
- Quality_planning sign-off and management support
Phase 5: Feedback, Assessment & Corrective Action
→ The aim of this_phase is to make continual improvements in the Product_and Process to enhance customer satisfaction levels.➨ Inputs: Inputs of Phase 5 are the Outputs of Phase 4.
➨ Outputs:
- Reduced Variation (Common and Special cause of Variations)
- Improved Customer Satisfaction
- Improved Delivery and Services
- Effective Use of Lessons Learn/ Best Practices
- Activities include in this_phase to enhance customer satisfaction are:
- Evaluation of the Effectiveness of APQP_Efforts based on customer feedback.
- Making the necessary changes to correct non-conformance/deficiencies.
- Continuation of Customer and Supplier partnership.
- Organization participation in problem-solving and continuous improvement activities.
- APQP_Timing Chart
Benefits of APQP
→ Increase Customer Satisfaction level→ Early identification of required changes
→ Changes after product_launch are avoided
→ On-time delivery of quality_products with competitive prices.
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