APQP | Advanced Product Quality Planning | 5 Phases

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 the American Society for Quality Control (ASQC) 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:

1. Advanced Product Quality Planning - APQP_Manual
2. Production Part Approval Process - PPAP Manual
3. Failure Mode and Effect Analysis - FMEA Manual
4. Measurement System Analysis - MSA Manual
5. 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.

1. Plan & define program
2. Product design & development
3. Process Design_and Development
4. Product and Process Validation
5. 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.

➨ Outputs of this_phase

• 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.
• Organizational 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.

👉 See Also:

➨ All Topics

➨ Lean Manufacturing

➨ ISO 9001:2015 & IATF 16949:2016

➨ 7 QC Tools

➨ MSA, FMEA, PPAP, APQP_SPC

➨ Six Sigma & Lean Six Sigma

➨ QA & QC Topics