IN-HOUSE TRAINING ON

IATF Core Tools

APQP

ADVANCED PRODUCT QUALITY PLANNING

 INTRODUCTION-APQP
This program is designed to provide a working knowledge of the
Advanced Product Quality Planning Process as per the requirements Of
IATF 16949:2016. This topics should be understood in the broader
perspective of a New Product Development rather than as a
technique.
The two main requirements of a good Product Development are
developing a robust product and developing it in a short time. All the
methods discussed in this program are oriented towards these
objectives. One of the essential requirements for the success of this
approach is the ability to work in teams. Team working is a culture which
has to be developed and practiced in the organization. If we do not
adhere to this principle of team working, we may end up without the
benefits expected from this process of product development.
 INTRODUCTION-APQP

“ IT IS BETTER TO SPEND A LITTLE EXTRA TIME DURING

THE UPSTREAM PROCESS SO THAT THE DOWNSTREAM
PROCESSES ARE FREE FROM ERRORS ”.
 THE APQP MODEL

THE ADVANCED PRODUCT QUALITY PLANNING (APQP)

MODEL

WHAT IS APQP?

Advanced Product Quality Planning is a structured & systematic

method of defining and establishing the steps necessary to assure
that a product satisfies the customer’s requirements.

The commitment from the Top Management is an essential

requirement for the success of this process.
 THE APQP MODEL
THE OBJECTIVENESS OF APQP

The goals of Quality Planning are :

Effective communication with everyone involved.

On-time completion of all required steps

Minimal or no quality problems

Minimal product launch quality risks

Minimal cycle time to launch the product

 THE APQP MODEL

THE BENEFITS OF APQP

• Resources are directed toward customer satisfaction

• Required changes are identified early

• Changes close to or after product launch are avoided

• A quality product is provided on time at the lowest cost.

• An element of Continuous Improvement is built into the company.

 THE APQP PHASES

Plan and Define

Product Design and Development

PHASES

Process Design and Development

Product and Process Validation

Feedback, Assessment and Corrective Action

 RESPONSIBILITY MATRIX
THE PRODUCT QUALITY PLANNING RESPONSIBILITY MATRIX
S e rv ic e
S u p p lie r H e a t
D e s ig n
M a n u fa c tu T re a t,
Respons
rin g O n ly W a re h o u s in g ,
ib le
T ra n s p o rta tio n
e tc .,
D e fin e th e S c o p e X X X
P la n a n d D e fin e S e c tio n 1 .0
X
P ro d u c t D e s ig n a n d
D e v e lo p m e n t S e c tio n 2 .0 X

F e a s ib ility S e c tio n 2 .1 3
X X X
P ro c e s s D e s ig n a n d
D e v e lo p m e n t 3 .0 X X X

P ro d u c t a n d P ro c e s s V a lid a tio n
S e c tio n 4 .0 X X X

Fe edb ack, A ssessm ent and

C o rre c tiv e A c tio n -S e c tio n 5 .0 X X X

C o n tro l P la n M e th o d o lo g y
X X X
S e c tio n 6 .0
PDCA

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 PRODUCT QUALITY TIMING PLAN

The product quality planning team’s first effort should be the development
of a timing plan. This timing plan should list all tasks with responsibility
and target dates. It is a good practice to follow the project management
techniques like Gantt Chart, Critical Path Method, PERT etc. This plan
can be regularly reviewed and updated as the planning evolves.
 PROGRAM MANAGEMENT
TEAM LEADER

Each program has a team leader, but a team leader may manage one
or more programs. The team leader:

- is typically a senior Production or Quality Manager

- interfaces with the customer
- ensures that the Program Need Dates (PND) are met
- is responsible for resources and organization
- is responsible until product launch
- forms and manages one or more APQP Teams
 PROGRAM MANAGEMENT
APQP TEAMS

Team Composition
Team should be cross-functional; it is not composed of only people
from the Quality Department. Typical members might come from:
- Engineering
- Manufacturing
- Material Control
- Purchasing
- Sales
- Field Service
- Subcontractors
- Quality
- Industrial Engineering
- Maintenance
- Customers(as appropriate)
- Finance
 PROGRAM MANAGEMENT
Team Responsibilities

· Success of the Product Quality Planning Team is dependent upon

the interest, commitment, support and direction of upper
management. The APQP team:

- is the Product launch Steering Committee responsible for quality

planning
- works with the programme manager establish PNDs
- determines the extent of require APQP activities
- determines initial risk assessments and feasibility requirements
- demonstrates that all planning requirements have been met
- ensures that concerns have been documented and scheduled for
resolution

• Overall, through this process, the team initiates the building of a

Culture of Simultaneous Engineering in the Organization.
 IATF 16949:2016 – QMS Requirements

APQP Definition

Advanced product quality planning (APQP) product quality

planning process that supports development of a product or
service that will satisfy customer requirements; APQP serves as a
guide in the development process and also a standard way to
share results between organizations and their customers; APQP
covers design robustness, design testing and specification
compliance, production process design, quality inspection
standards, process capability, production capacity, product
packaging, product testing and operator training plan, among
other items

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IATF 16949:2016 – QMS Requirements

8.1 Operation Planning and Control

8.3 Design and Development
8.3.1 / 8.3.1.1 General
8.3.2 / 8.3.2.1 Design and Development Planning
8.3.2.2 Product Design Skills
8.3.2.3 Development of products with embedded software
8.3.3 / 8.3.3.1 Design and Development / Product Design Inputs
8.3.3.2 Manufacturing Process Design Inputs
8.3.3.3 Special Characteristics
8.3.4 Design and Development Controls
8.3.4.1 Monitoring
8.3.4.2 Design and development validation
8.3.4.3 Prototype programme
8.3.4.4 Product Approval Process
8.3.5 / 8.3.5.1 Design and Development Outputs
8.3.5.2 Manufacturing Process Design Outputs
8.3.6/8.3.6.1- Design and Development Changes

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 PLAN AND DEFINE PROGRAM
OBJECTIVES
• Determine customer needs
• Plan a quality program (which includes Scope, Time, Budget, etc.)

INPUTS

·Voice of the customer

- market research (Including OEM Vehicle Build Timing
and OEM Volume Expectations)
- historical warranty and quality information
- team experience
·Business plan/marketing strategy
·Product/process benchmark data
·Product/process assumptions
·Product reliability
·Customer inputs
 IATF 16949:2016 – QMS Requirements

8.2.3.1.3 Organization manufacturing feasibility

The organization shall utilize a multidisciplinary approach to conduct an

analysis to determine if it is feasible that the organization's
manufacturing processes are capable of consistently producing product
that meets all of the engineering and capacity requirements specified by
the customer. The organization shall conduct this feasibility analysis for
any manufacturing or product technology new to the organization and
for any changed manufacturing process or product design.

Additionally, the organization should validate through production runs,

benchmarking studies, or other appropriate methods, their ability to
make product to specifications at the required rate.

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 PLAN AND DEFINE PROGRAM
OUTPUTS

· Preliminary bill of material

· Preliminary process flow chart
· Preliminary listing of special product and process characteristics
· Product assurance plan
· Management support (Including program timing and planning for
resources and staffing to support required capacity)
PRODUCT DESIGN & DEVELOPMENT
OBJECTIVES

·Develop design features and characteristic

·Critically review engineering requirements
·Assess potential manufacturing problems
 IATF 16949:2016 – QMS Requirements

8.3.3.1 Product design input

The organization shall identify, document, and review product design input requirements as a result of
contract review. Product design input requirements include but are not limited to the following:
a) product specifications including but not limited to special characteristics (see Section 8.3.3.3);
b) boundary and interface requirements;
c) identification, traceability, and packaging;
d) consideration of design alternatives;
e) assessment of risks with the input requirements and the organization's ability to mitigate /
manage the risks, including from the feasibility analysis;
f) targets for conformity to product requirements including preservation, reliability, durability,
serviceability, health, safety, environmental, development timing, and cost;
g) applicable statutory and regulatory requirements of the customer-identified country of
destination, if provided;
h) embedded software requirements.

The organization shall have a process to deploy information gained from previous design projects,
competitive product analysis (benchmarking), supplier feedback, internal input, field data, and other
relevant sources for current and future projects of a similar nature.
NOTE: One approach for considering design alternatives is the use of trade-off curves

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 IATF 16949:2016 – QMS Requirements

8.3.5.1 Design and development outputs - supplemental

The product design output shall be expressed in terms that can be verified and validated
against product design input requirements.

The product design output shall include but is not limited to the following, as applicable:

a) design risk analysis (FMEA); b) reliability study results; c) product special characteristics;
d) results of product design error-proofing, such as DFSS, DFMA, and FTA; e) product
definition including models, technical data packages, product manufacturing information,
and geometric dimensioning & tolerancing (GD& T); f) 2D drawings, product manufacturing
information, and geometric dimensioning & tolerancing (GD&T); g) product design review
results; h) service diagnostic guidelines and repair and serviceability instructions; i) service
part requirements; j) packaging and labeling requirements for shipping.

NOTE: Interim design outputs should include any engineering problems being resolved
through a trade-off process

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 IATF 16949:2016 – QMS Requirements

8.2.3.1.2 Customer-designated special characteristics

The organization shall conform to customer requirements for

designation, approval documentation and control of special
characteristics.

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 IATF 16949:2016 – QMS Requirements
8.3.3.3 Special characteristics

The organization shall use a multidisciplinary approach to establish,

document, and implement its process(es) to identify special characteristics,
including those determined by the customer and the risk analysis
performed by the organization, and shall include the following:

a) documentation of all special characteristics in the drawings (as required),

risk analysis (such as FMEA), control plans, and standard work/operator
instructions; special characteristics are identified with specific markings and
are cascaded through each of these documents; b) development of control
and monitoring strategies for special characteristics of products and
production processes; c) customer-specified approvals, when required;
d) compliance with customer-specified definitions and symbols or the
organization's equivalent symbols or notations, as defined in a symbol
conversion table.
The symbol conversion table shall be submitted to the customer, if
required.
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 PROCESS DESIGN & DEVELOPMENT

OBJECTIVES

· Develop a comprehensive and effective manufacturing system

· Ensure that the manufacturing systems meets customer
requirements.
 IATF 16949:2016 – QMS Requirements
8.3.3.2 Manufacturing process design input

The organization shall identify, document, and review manufacturing process design input
requirements including but not limited to the following: a) Product design output data
including special characteristics; (8.3.5.1)
b) targets for productivity, process capability, timing, and cost;
c) manufacturing technology alternatives;
d) customer requirements, if any;
e) experience from previous developments;
f) new materials;
g) product handling and ergonomic requirements; and
h) design for manufacturing and design for assembly.

The manufacturing process design shall include the use of error-proofing methods to a
degree appropriate to the magnitude of the problem(s) and commensurate with the risks
encountered
Other Inputs as per APQP
· New equipment tooling and facilities requirements
· Gages/testing equipment requirement
· Team feasibility commitment and management support

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 IATF 16949:2016 – QMS Requirements
8.3.5.2 Manufacturing process design output

The organization shall document the manufacturing process design output in a

manner that enables verification against the manufacturing process design inputs.
The organization shall verify the outputs against manufacturing process design input
requirements.
The manufacturing process design output shall include but is not limited to the
following:
a) specifications and drawings; b) special characteristics for product and
manufacturing process; c) identification of process input variables that impact
characteristics; d) tooling and equipment for production and control, including
capability studies of equipment and process(es); e) manufacturing process flow
charts/layout, including linkage of product, process, and tooling; capacity
analysis; f) manufacturing process FMEA; g) maintenance plans and
instructions; h) control plan (see Annex A); i) standard work and work
instructions
b) process approval acceptance criteria; k) data for quality, reliability,
maintainability, and measurability; l) results of error-proofing identification and
verification, as appropriate; m) methods of rapid detection, feedback, and
correction of product/manufacturing process nonconformities.
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 PROCESS DESIGN & DEVELOPMENT

Other Outputs as per APQP

• Packaging standards/Packaging specification

· Product process quality system review
· Characteristics matrix
· Measurement systems analysis plan
· Preliminary process capability study plan
· Management support
 PRODUCT & PROCESS VALIDATION

OBJECTIVES

· Validate the manufacturing process & the product

· Ensure that customer’s expectations will be met
· Identify additional concerns
 PRODUCT & PROCESS VALIDATION
INPUTS

· Manufacturing Process Design Inputs-8.3.5.2

· Packaging standards/Packaging specification
· Measurement Systems Analysis Plan
· Preliminary process capability study plan
· Management support
 PRODUCT & PROCESS VALIDATION
OUTPUTS

· Production trial run

· Measurement systems evaluation
· Preliminary process capability study
· Production part approval
· Production validation testing
· Packaging evaluation
· Production control plan
· Quality planning sign-off and management support
 IATF 16949:2016 – QMS Requirements

8.3.4.1 Monitoring

Measurements at specified stages during the design and

development of products and processes shall be defined,
analyzed, and reported with summary results as an input to
management review (see Section 9.3.2.1).

When required by the customer, measurements of the

product and process development activity shall be reported
to the customer at stages specified, or agreed to, by the
customer. NOTE When appropriate, these measurements
may include quality risks, costs, lead times, critical paths, and
other measurements.

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FEEDBACK, ASSESSMENT & CORRECTIVE ACTION

OBJECTIVES

· Obtain objective feedback for future planning

· To plan the next phase of product development or modification
· To improve the system of planning (from lessons learnt)
· To identify opportunities for Improvement

INPUTS

· Production trial run

· Measurement systems evaluation
· Preliminary process capability study
· Production part approval
· Production validation testing
· Packaging evaluation
· Production control plan
· Quality planning sign-off and management support
FEEDBACK, ASSESSMENT & CORRECTIVE ACTION

OUTPUTS

 Reduced Variation
 Improved Customer Satisfaction
 Improved Delivery and Service
 Effective Use of Lessons Learn / Best Practices
 CONTINUOUS IMPROVEMENT

 Effective Use of Lessons Learn / Best Practices

 Review of Things Gone Right/Things Gone Wrong

(TGR/TGW)

 Data from warranty and other performance metrics

 Corrective action plans

 "Read-across" with similar products and processes

 DFMEA and PFMEA studies
CONTROL PLAN METHODOLOGY
 CONTROL PLAN METHODOLOGY

Quality Plan
Vs
Control Plan
Quality Plan – more focus on product characteristics.
Control Plan – covers both process & product
characteristics
 CONTROL PLAN METHODOLOGY

Phases of Control Plan

• Prototype
• Pre-launch
• Production
Control Plan Requirements
Control Plan Requirements
CONTROL PLAN METHODOLOGY