APQP

ADVANCED PRODUCT
QUALITY PLANNING AND
CONTROL PLAN (APQP)

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 APQP
What is APQP ?
It is a structured method of
•Advanced planning
•Programming and
•Implementation
to ensure that the product fully satisfies the customer.

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 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

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 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 lower cost

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 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
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 APQP
BASIC STEPS IN APQP:
Organise the team:
• Select the Team Leader and provide him
authority and resources
• Organize the CFT’s : select members
representing different functions
•Define responsibility of each member

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 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.

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 APQP
BASIC STEPS IN APQP (Contd)
-Determine assistance required from customer – reach
agreement on all issues
-Identify timings, costs and constraints
-Team to Team communication requirements
-Customer & Supplier involvement required.

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 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.

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 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

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 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 defined and identified

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 APQP
PHASE 2: PRODUCT DESIGN & DEV.

Consider all relevant design factors and

develop the design inputs, 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
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 APQP
PHASE 3: PROCESS DESIGN & DEV
Consider all relevant design requirements and
developing

-A suitable manufacturing system, and

-Relevant Control plans

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 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.
•Quality planning sign-off

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 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

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 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

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 APQP
PHASE 1: PLAN & DEFINE PRORAM
INPUTS (Typical)
•Customer Voice – Market Research
Historical Data (Internal/ External)
Team Experience(Ex. TGR/ TGW)
•Customer Business Plan/ marketing Strategy
•Customer inputs
•Bench Mark data (Product & Process) (Own/ Others)
•Product / Process assumptions (Ex. New Technology)
•Product Reliability studies (short term / long term)

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 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
•Standardization
•No. of components
•Compatibility of components with each other
•Useful Life
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 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 etc.

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 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
Power Consumed / Unit
Material Movement, etc.

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 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
Product Assurance Plan – part of Quality Plan
Management Support

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 APQP
PHASE 1. PLAN & DEFINE PROGRAM
Product Assurance Plan:
Translation of Design Goals into Design requirements
including:
•Assessment of all factors that have a bearing on the
programme (Ex. Technology, Environment, Service
and manufacturing requ irements, application etc.)
•Failure Mode & Effect Analysis
•Development of Preliminary Engineering Standards

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 APQP
PHASE 1. PLAN & DEFINE PROGRAM

GOAL

Capture customers’ voice

Deploy customer needs and

requirements
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 APQP
PHASE 2: PRODUCT DESIGN and DEV.
OUTPUTS: TYPICAL
BY DESIGN RESPONSIBLE ACTIVITY
•Design FMEA (at Assembly, Sub-Assy. & Part level)
•Design output documents (based on DFM/ DFA/ VE/
GD&T. etc.)
•Design Review (Cross-functional, Multi-stage)
•Design Verification
•Prototype Build – Control Plan
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 APQP
PHASE 2. PRODUCT DESIGN And DEV.
OUTPUTS (Typical)
BY PRODUCT QUALITY PLANNING TEAM
New Equipment, Tooling and Facilities requirements
Special Product & Process Characteristics
Gage/Testing Equipment requirement
Team Feasibility Commitment
Management Support

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 APQP
PHASE 2. PRODUCT DESIGN And DEV.

GOAL

A feasible Design

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 APQP
PHASE 3. PROCESS DESIGN And DEV.
OUTPUTS (Typical)

Process flow charts

Characteristic Matrix
Process FMEA
Pre-launch control plan
Process Instruction

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 APQP
PHASE 3. PROCESS DESIGN And DEV.
OUTPUTS TYPICAL (Contd.)

•Plans – MSA
•Plans – Preliminary Process Capability Study
•Quality System review
•Floor Plan Layout Get
•Packing Standards
Management
•Packing Specifications, etc.
Support
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 APQP
PHASE 3. PROCESS DESIGN And 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

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 APQP
PHASE 3 PROCESS DESIGN And DEV.

GOAL

Successful production part approval

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 APQP
PHASE 4: VALIDATION
OUTPUTS: TYPICAL
Measurement System Analysis
Production Trail Run
Preliminary process capability study
Production validation testing including MFG times
Packaging Evaluation
Production Part Approval
Production Control Plan
Quality Planning & Sign off (at MFG site)

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 APQP
PHASE 4 VALIDATION

GOAL

Successful Product launch

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 APQP
PHASE 5:FEEDBACK ASSESSMENT AND
CORRECTIVE ACTION
OUTPUTS: TYPICAL
Review of (a) DFMEA & PFMEA documents
(b) Production Control plans
Preparation of TGR/TGW reports
Evaluation of data: Variables/Attributes
Reduced Variation(Continuous Improvements)
Continued On-time Delivery & Service

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 APQP
PHASE 5 FEEDBACK ASSESSMENT AND
CORRECTIVE ACTION

GOAL

Customer satisfaction
Continuous improvement
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 APQP
APQP: KEY FACTORS FOR SUCCESS
Leadership of the CFTs
Sincere Team work
Open minded approach
Timely and effective communication
Knowledge of processes and techniques
Customer and Sub-contractor involvement
Simultaneous Engineering
Management support

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 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
instruction

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 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

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 APQP
CONTROL PLAN METHODOLGY

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

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 APQP
CONTROL PLAN METHODOLGY

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

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 APQP
CONTROL PLAN METHODOLGY

Control plans required to be continuously updated

especially when product or processes change,
processes become unstable or incapable, or inspection
methods are revised. It is a living document

Control plans shall address all significant/Special

characteristics

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 APQP
CONTROL PLAN METHODOLGY

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

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 APQP
PROCESS ANALYSIS
The most common sources of variation or dominating factors
determining the quality of product are:
• Set-up
• Machine
• Tooling
• Operator
• Maintenance
• Environment
• Part / Product

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 APQP
PROCESS ANALYSIS
In summary, we may identify processes as:
•Set up dominant
•Machine dominant
•Tolling dominant
•Operator dominant
•Maintenance dominant
•Environment dominant
•Pair/ product dominant

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 APQP
PROCESS ANALYSIS (Contd..)

Typical techniques for analysis include

- Cause and Effect diagram

- Design of Experiments
- Fault Tree Analysis

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 APQP
CONTROL METHODS : SOME EXAMPLES

SET UP DOMINATE CONTROLS

Punching First place inspection

Molding Setup verification, etc.

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 APQP
CONTROL METHODS : SOME EXAMPLES

MACHINE CONTROLS
DOMINANT

Wave solidering Patrol inspection

Wire enameling control charts
Audit inspection, etc.

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 APQP
CONTROL METHODS : SOME EXAMPLES

TOOL DOMINANT CONTROLS

Stamping Patrol inspection

Broaching First piece inspection

Error proofing, etc.

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 APQP
CONTROL METHODS : SOME EXAMPLES

OPERATOR CONTROLS
DOMINANT

Welding Operator qualification

Lathe operation Audit inspection
Assembly operation Patrol Inspection, etc.

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 APQP
CONTROL METHODS : SOME EXAMPLES

COMPONENT CONTROLS
DOMINANT

Auto Hood stumping First piece Inspection

Control Charts, etc.

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 APQP
CONTROL METHODS : SOME EXAMPLES

MAINTENANCE CONTROLS
DOMINANT

Painting operation Periodic cleaning dust

level monitoring

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 APQP
CONTROL METHODS :SOME EXAMPLES

ENVIRONMENT CONTROLS
DOMINANT
Molding – Pre-heating of plastic
Humidity granules –
Monitor/Record Dryer
Temperature

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 APQP
REACTION PLAN :

The Reaction Plan Specifies the Corrective Action to

be taken by Personnel close to the Process to a avoid
Producing Non-conforming Products.

Suspect or non-conforming Product Shall be

identified, quarantined and disposed off.

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 APQP
THANK YOU !

Thank you for your attention.

Please give your comments / inputs for

making this presentation better.

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 APQP
APQP FAILURE EXAMPLE

A company specializing in making precision

components having CNC machines, is asked by its
existing customer to develop a component needing
precision machining.
But the components also has to withstand a pressure
upto 140 bar.
Its not clear what manufacturing process is to be
adopted. Company chooses casting process. The part is
subsequently machined in their CNC shop. Its
dimensionally perfect. But…………………..
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 APQP

APQP
FAILURE
EXAMPLE

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 APQP

THANK YOU !

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