ACME APQP Advanced Product Quality Planning

Customer request
Development
Phase 1: Plan and Define Program Customer RFQ
Marketing
Development
product documents
delivery requirements (customer statement)

Customer
Credit Criteria failed Credit
Check 
Marketing
Credit / Audit Report

 Project risk assessment Quotation reject, Counter proposal

Vendor No
Organization authorization Request Customer
information Development
Specific Requirement
Manufacturing
Preliminary RFQ Purchasing
RFQ vendor outsource CSR
analysis Engineering

Vendor RFQ Statement of Deliverables (internal RFQ form)

Preliminary process flow
APQP checklist
Vendor feedback Draft APQP organization chart

APQP team counter

Vendor preliminary proposals  Technical feasibility Reject
proposal

Accept:
No go Team Feasibility Commitment

Machine cycle time

Preliminary planning Development
Costing assumption
Project Development Costing
Manufacturing costing
Preliminary project schedule

Project schedule Accounts

Project schedule documents

Document compilation
Marketing
Quotation analysis, Proposal Change
Quotation letter request

Marketing

Mana Change
geme request
Inform customer Close project order nt Marketing
suppo
No
rt

Signed quotation
Project Authorization
RFQ rejection
memo Document submission Marketing

Customer quotation forms, packaging

Delivery/Acceptance document

No
Project close reject letter  Customer Marketing
from customer accept?

Record in quotation file

Product
Design &
Quotation file Development
 
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 ACME APQP Advanced Product Quality Planning

Contract amendment
Change
proposal

Customer ECN/ change

product documents
delivery requirements

Technical concept
study

Technical feasibility evidence

Counter proposal
Preliminary Go/No Go

Customer endorsement

Commercial Feasibility not OK Commercial feasibility

Team Feasibility commitment not OK study
Commercial Feasibility study OK
Team Feasibility commitment OK

Start decision
 

proceed

Outsource Preliminary planning

Not feasible

RFQ approved vendor Preliminary process analysis

Project Development Costing
Vendor RFQ Manufacturing costing
Change request
Preliminary project schedule
Project feasibility study
Vendor feedback

Vendor proposals Document compilation

Analysis documents

Preliminary quotation

Quotation Letter Change

request

Counter proposal

Management support
Counter proposal
 

Signed quotation
Project Authorization

Transmit to customer

Confirmation of receipt

Customer accept?
 

Product Design & Development

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 ACME APQP Advanced Product Quality Planning

Phase 2: Product Design and Development

Customer authorization

Design document avail? No, new design

Yes, resourcing / localization
  product validation req

Customer liaison

Sample available?
no Correspondents, minutes
 

yes
Customer product specs, stds avail? Customer needs
No / incomplete
  analysis

Customer requirements
Reverse engineering
Yes; drawing, spec, testing std
Product analysis
QFD / DFMEA

Quality Requirement Product specification

QFD, DFMEA form
analysis proposal

Bill of materials Product design /

revise
incoming material requirement verification
process requirements
Specification list
Manual calculations
Finite Element Analysis output
No
product design drawing
testing list approval proto PFMEA, control plan
 
(Specifications not compatible, emerging Requireme
Prototype part,
interfaces
Customer-approved purchase / mfg
Product inspection std
Sample parts

Product validation
Test planning/design
Fitting, performance
analysis
Testing documentation requirement Test eqpt, method requirement

Sample purchase documents

Testing arrangement Fitting trial checksheet

Test document
equipment prep Testing checksheets
preparation

Status reports
No
Prototype testing, Design review
Inspection checksheet template Sample testing results
analysis  

PRODUCT SPECIFICATIONS
Product drawing (component & assy)
Testing specification,
Part Inspection Standard
Packaging specification

Product design
document release
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 ACME APQP Advanced Product Quality Planning

PRODUCT DESIGN DOCUMENT RELEASE

Product specification

product document
draft / update / correction

draft drawing

document log update

update drawing log

change request

Customer EC approval req?

yes
 

EC Request
no

(customer preliminary document review)

 

approve for final submission

final document preparation

final document

document
check - approve

signed document

document submission

proof of delivery

contract ammendment req?

customer endorsement yes
 
 

customer-approved document
Contract Ammendment

Document Control
no

Process Design and Development

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 ACME APQP Advanced Product Quality Planning

Phase 3: Process Design and Development

Product Specifications

Process requirement
analysis

Process flow diagram

Sourcing plan PFMEA
Special Process characteristics

Production
Process, inspection
planning

Pre-launch Control Plan

Factory layout,
manpower plan

Engineering Development
Development Inspection / test eqpt spec MSA plan
Material, component Analysis
sourcing
Development process flow
Process validation plan Testing instructions
Prelaunch control plan development/acquisition
Equipment Specifications analysis

Development project
planning Test equipment requirement / development plan

Production machine requisition /engineering development plan

Development Project schedule,
resource requirement, cost estimate

Final proposal
preparation / revision

change Project Proposal

request

change request No
Management review
 

Authorization to proceed
Confirmed project plan

Transmit final proposal to

customer

management approved proposal

Customer review
 

Process Development

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 ACME APQP Advanced Product Quality Planning

Phase 3: Process Development Authorization to proceed

PROCESS VALIDATION ENGINEERING DEVELOPMENT VENDOR DEVELOPMENT

Inspection development Equipment Vendor selection

/ training purchase/development

checking aids Purchasing records

inspection jig
Part inspection standard
checksheet Equipmentment testing / Agreement development
confirmation work instruction ng not possible
Vendor drawing
Change terms
Equipment testing checksheet Draft Product inspection
test equipment product characteristic
fail ng arbitration
Equipmenttesting  
 
Vendor inspection agreement
Approved checksheets development contract Vendor
Equipment test reports Development
approved quality checksheets
failed
Hard tooling Line trials
product samples   Vendor development

Product testing line operation status OK Vendor progress reports

  improvement areas

line improvement Vendor monitoring

Dimensional inspection  
report, AAR, testing report
improvement needed Child
part Vendor evaluation sample
Line trials ng
Product evaluation eveluation  
  Child part testing
Prelaunch Control Plan
PFMEA update
sample submission Module testing results

Sample approval Child part evaluation

satisfactory  
RPN
Child part approval
PPAP appointment

Subsupplier
Product and Process Validation
Approval Record master parts PPAP Vendor PPAP
sign-off

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 ACME APQP Advanced Product Quality Planning

Phase 4: Product and Process Validation process development

Review prelaunch
control plan

updated prelaunch, production control plan

list equipment, instrument, work instruction, QC checksheets, manpower
list material & child part ordering

prelaunch preparation
meeting

prelaunch checksheet update

prelaunch, production
equipment servicing, prelaunch production prelaunch material
QC checksheet work instruction, operator
instrument MSA planning order
training

preparation
not ready monitoring
 

prelaunch checksheet complete

prelaunch briefing
small batch
trial production
product, process data

product
minor issues audit
 

process ok

line production
confirmation trial

product, process data

product
audit major issues
 

process ok

Process Quality Council

Line run at rate Development Enquiry

Production part
APQP records project exit review
documentation compilation
minutes
correction request PPAP report

PPAP APQP Sign off

 
project file document update
PSW Sign off product quality standard update

Project APQP doc

Early production containment QMS update

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 ACME APQP Advanced Product Quality Planning

SCHEDULED PRODUCTION
Phase 5: Feedback, Assessment and Corrective Action

Improvement needed?
Operational problem
 

Production no
QC report

Quality problems?
Quality problem
 

Improvement possible

Request for change

Problem analysis Improvement ideas
proposals

Change submission

Change
evaluation
 

Proposal accepted
Project planning Change proposal

Minutes project schedule

Modification
 

Tooling / machine redesign,

fabrication

Process information update

Problem description machine maintenance log update

Off-line testing

machine maintenance log update

Problem resolved?
 

Target achieved

Supervised production

Statistical data

PFMEA updates
Acceptable?
process improvement activities update
 
SPC data update

improvement
Improvement award
project close
presentation

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 ACME APQP Advanced Product Quality Planning

PROJECT GO/NO-GO DECISION

Volume commitment
Material
cost quotation

Compute costs / part cost,

Dev cost estimate Process cost estimate
capital investment

Standard costing sheets

Marginal cost meet customer price?

 

No
Yes

Management prerogative Full costing meet customer price?

No
   

Yes
Project Authorization Memo

GO FOR IT!
Quotation

Inform customer NG