A P REMIER G R OU P COMPAN Y

W W W. P R E M I E R S E A L S . C O M

ADVANCED PRODUCT QUALITY PLANNING (APQP)

APQP TRAINING PROGRAM

© By Premier Seals – All rights reserved. Confidential – no passing on to third parties

What is APQP?

Advance Product Quality Planning is a structured method

of defining and establishing the steps necessary to assure
that a product satisfies the customer.

The goal of product quality planning is to facilitate

communication with everyone involved to assure that all
required steps are completed on time.
Effective product quality planning depends on a company’s
top management commitment to the effort required in
achieving customer satisfaction.
Fundamentals of Product Quality Planning

Organizing the team

 Define the scope
 Team-to-Team Communication
 Training
 Customer, supplier and subcontractor involvement
 Simultaneous \ Concurrent Engineering
 Control plans
 Concern Resolution
 Timing plan and chart
PRODUCT QUALITY PLANNING RESPONSIBILITY
MATRIX
The matrix shown below depicts the Product Quality Planning Functions for three
types of organizations. It is to assist organizations in defining the scope of their
planning responsibilities.
Service
Organization i.e.
Design Manufacturing
Heat Treat,
Responsible Only
Warehousing,
Transportation, etc.
Define the Scope X X X
Plan and Define Chapter 1.0 X
Product Design and Development
X
Chapter 2.0
Feasibility Section 2.13 X X X
Process Design and Development
X X X
Chapter 3.0

Product and Process Validation

X X X
Chapter 4.0

Feedback, Assessment and Corrective

X X X
Action Chapter 5.0

Control Plan Methodology Chapter

X X X
6.0
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
1.0 Plan and Define Program
Inputs Objectives
Voice of the Customer Determine customer needs.
Market Research Define and plan a quality program.
Historical Warranty and Quality Information
Team Experience
Business Plan/Marketing strategy
Plan and Define Program
Product/Process Benchmark Data
Product Reliability Studies
Customer Inputs

Outputs
Design Goals
Reliability and Quality Goals
Preliminary Bill of Material
Preliminary Process Flowchart
Preliminary Listing of Special Product and
Process Characteristics
Product Assurance Plan
Management Support
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
2.0 Product Design and Development
Inputs Objectives
The outputs of Section 1.0  Develop design features and characteristics.
 Review engineering requirements.
 Assess potential manufacturing problems that
could occur.

Outputs
Design Failure Mode and Effects Analysis (DFMEA)
Design for Manufacturability and Assembly
Design Verification
Design Reviews
Prototype build – Control plan
Engineering Drawings
Engineering Specifications
Material Specifications
Drawing and Specification Changes
New Equipment, Tooling and Facilities Requirements
Special Product and Process Characteristics
Team Feasibility Commitment and Management
Support
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
3.0 Process Design and Development

Inputs Objectives
The outputs of Section 2.0 Develop comprehensive and effective
manufacturing process.
Ensure process capability to meet customer
requirements.
Outputs
Packaging Standards
Product/Process Quality System Review
Process Flow Chart
Floor Plan Layout
Characteristics Matrix
Process Failure Mode and Effects Analysis
(PFMEA)
Pre-Launch Control Plan
Process Instructions
Measurement Systems Analysis Plan
Preliminary Process Capability Study Plan
Management Support
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
4.0 Product and Process Validation

Inputs Objectives
The outputs of Section 3.0 Validate the product
 Validate the manufacturing process
 Validate the control plan
 Ensure product meets customer Requirements
Outputs
Identify concerns
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
AIAG PPAP: PRODUCT QUALITY PLANNING
TIMING CHART
5.0 Feedback, Assessment and Corrective Action

Inputs Objectives
The outputs of Section 4.0 Evaluate all variation (variable and attribute data).
 Evaluate effectiveness of product quality planning.
 Use control plan and corrective action.

Outputs
Reduced Variation
Customer Satisfaction
Delivery and Service
Application to Different Mfg. Environments

High Volume
APQP plans and activities are organized by part
number and are very specific to the part.

Low Volume
APQP plans may be specific to part families with
activities focused on the parent part
More limited validation would be done on child parts
Family part differences should be understood and
higher risk differences incorporated into APQP
plans.
APQP Benefits
Manufacturing process functions that are clearly planned, validated,
documented and communicated that result in:
Robust and reliable designs
Reduced process variation
Enhanced confidence in supplier’s capabilities
Better controlled process changes
Defect free launches
CONC

Improved Customer satisfaction

$$ Total Cost of Quality

Improved Delivery and Service Redesign
Re-qualifications
Escape Investigations

Maximum ROI
Minimum Waste Prevention through APQP
Current state

Minimum Cost of Non-conformance Development Production

Time
Key Take Aways

APQP is cross-functional planning and execution to produce product

that fully meets the customer’s expectations the first time.

AIAG APQP phases are Planning, Product Design, Process Design,

Validation, Production.

Phase approach ensures activities are completed in the appropriate

order.

Can be applied to different manufacturing environments – High

Volume, Low Volume.

It’s cross-functional – Marketing/Design/Manufacturing/SCM/Quality.

AIAG PPAP: Contents And Submission levels
A PREMIER G RO UP CO MPAN Y
TECHNICAL
PA R T N E R

THANK
YOU!
Mailing Address Email Address Phone Number Website Link
20/8, D-1, M.I.D.C, Chinchwad, Pune, India - 411019 [email protected] +91-7558796170 www.premierseals.com