WELCOME

TO
TRAINING PROGRAMME
ON

PRODUCT QUALITY
PLANNING
( APQP )

BY

PRO-QUALITY ASSOCIATES
DELHI

APQP- 00 P QA 1/ 11
( ADVANCED ) PRODUCT QUALITY PLANNING

STRUCTURED METHOD OF IDENTIFYING AND ESTABLISHING

THE STEPS NECESSARY TO ASSURE THAT A PRODUCT MEETS

THE CUSTOMER REQUIREMENTS

GOAL

TO FACILITATE COMMUNICATION WITH EVERYONE

INVOLVED TO ASSURE THAT ALL REQUIRED STEPS ARE

COMPLETED ON TIME.

EACH PRODUCT QUALITY PLAN IS UNIQUE AND IS

DEPENDENT ON CUSTOMER NEEDS AND EXPECTATIONS.

APQP- 00 P QA 2/ 11
 P- D- C - A APPROACH
AT STRATEGIC, PROCESS AND ACTIVITY LEVEL

ACT PLAN

CHECK DO

PLAN PLAN ALL ACTIVITIES OF THE PROCESS IDENTIFYING:-

INPUTS, OUTPUTS, COMPETENCE & RESOURCES

REQUIREMENT, ACTIVITIES & THEIR SEQUENCE,
CONTROL PARAMETERS AND THEIR MEASUREMENTS,
OPPORTUNIYIES FOR IMPROVEMENT.

DO PROVISION OF COMPETENCE & RESOURCES, EXECUTION

OF PROCESS AS PLANNED

CHECK MONITORING & MEASUREMENT, COLLECTION & ANALYSIS

OF DATA , IDENTIFICATION OF ACTIONS NEEDED TO
ACHIEVE PLANNED RESULTS

ACT IMPLEMENT ACTIONS TO ACHIEVE PLANNED RESULTS

AND IMPROVE

APQP- 00 P QA 3/ 11
STEPS OF PRODUCT QUALITY PLANNING

(PLAN)
ORGANISE THE TEAM
IT REQUIRES INVOLVEMENT OF MORE THAN JUST THE

QUALITY DEPARTMENT.

THE FUNCTIONS WHO CAN EFFECTIVELY CONTRIBUTE TO

THE PROCESS OF QUALITY PLANNING ( REPRESENTATIVES

FROM ENGINEERING,MANUFACTURING, MATERIAL

CONTROL, QUALITY, SALES, FIELD SERVICE, SUPPLIERS,

CUSTOMERS, AS APPROPRIATE - CROSS FUNCTIONAL TEAM

( CFT )

SELECT TEAM LEADER

ESTABLISH COMMUNICATIONS WITH

CUSTOMER AND SUPPLIER TEAMS

DEFINE CUSTOMER REQUIREMENTS AND

EXPECTATIONS

DEFINE STATUTORY AND REGULATORY

REQUIREMENTS

CONSIDER COMPANY & CUSTOMER

OBJECTIVES

APQP- 00 P QA 4/ 11
(DO)
STUDY :-
- CUSTOMER EXPERIENCE OF THE PRODCT ( TGW /
TGR )

- COMPETITOR INFORMATION

- TEAM MEMBERS’ PAST EXPERIENCE ON SIMILAR

PRODUCTS (CAPABILITY, PRODUCTIVITY, QUALITY)

- FIELD FAILURE DATA.

- CORRECTIVE ACTION / PROBLEM RESOLUTION

REPORTS

- APPLICABLE STATUTORY & REGULATORY

REQUIREMENTS.

- APPLICABLE PRODUCT STANDARDS.

DRAW PRODUCT QUALITY PLANNING

SCHEDULE ( PQPS ) LISTING :-
- STUDY OF AVAILABLE DOCUMENTS AND INFORMATION ON
THE PRODUCT

- PRODUCT FEASIBILITY ASSESSMENT AND IDENTIFY ADDL.

INFORMATION AND RESOURCE REQUIREMENT

- ESTABLISHMENT OF QUALITY, PRODUCTIVITY AND

RELIABILITY GOALS

- PREPARATION OF PROCESS FLOW DIAGRAM ( PFD )

- IDENTIFICATION OF SPECIAL CHARACTERISTICS –

PRODUCT & PROCESS

APQP- 00 P QA 5/ 11
 - PRODUCT DESIGN ACTIVITIES

PRELIMINARY PRODUCT DESIGN

DESIGN FAILURE MODE & EFFECTS ANALYSIS ( DFMEA )

DESIGN REVIEWS AND CORRECTION

DESIGN VERIFICATION AND APPROVAL FOR

DEVELOPMENT

PROTOTYPE BUILD- CONTROL PLAN

DESIGN VALIDATION AND APPROVAL

ENGINEERING DRAWINGS / SPECIFICATIONS- SPECIAL

CHARACTERISTICS

- PACKAGING DESIGN AND DEVELOPMENT

- REVIEW OF PRODUCT FEASIBILITY AND IDENTIFICATION OF

ADDITIONAL RESOURCES

- REVIEW OF PROCESS FLOW DIAGRAM

- CONDUCTING PROCESS FAILURE MODE & EFFECTS ANALYSIS

( PFMEA )

- REVISION OF PFD AND MAKING PRE-LAUNCH CONTROL PLAN

( PROCESS DESIGN ), TAKING MAKE OR BUY DECISION.
ESTABLISHING TOOLING AND GAUGING REQUIREMENT

- ESTABLISHING OPERATION AND INSPECTION STANDARDS

- TOOL & GAUGE DESIGN AND DEVELOPMENT

TOOL AND GAUGE DESIGN

FABRICATION

INSPECTION

TRYOUT AND TOOL CORRECTION

APQP- 00 P QA 6/ 11
 - SUPPLIER DEVELOPMENT AND MATERIAL / COMPONENT
PROCUREMENT FOR PILOT LOT

- MANUFACTURE OF PILOT LOT AND

CONDUCT AND ESTABLISH PROCESS CAPABILITY

CONDUCT PROCESS VALIDATION

CONDUCT MEASUREMENT SYSTEM ANALYSIS

CARRYOUT NECESSARY PROCESS AND TOOLING

CORRECTIONS AND ESTABLISH MANUFACTURING
PROCESSES

- COLATION AND APPROVAL OF IDENTIFIED RECORDS

- CUSTOMER APPROVAL IF REQUIRED

- REVISION AND FINALISATION OF PRODUCTION CONTROL

PLANS AND OTHER OPERATING DOCUMENTS.

- PRODUCT QUALITY PLANNING SIGN OFF.

(CHECK)
CONTINUOUS MONITORING OF EVERY
ACTIVITY OF P Q P S

(ACT)
TAKE NECESSARY ACTIONS TO CORRECT THE
SITUATION

APQP- 00 P QA 7/ 11
FEASIBILITY ASSESSMENT

STRUCTURED APPROACH TO ASSESSING FEASIBILITY OF

MEETING CUSTOMER REQUIREMENTS ( AT REGULAR
SUPPLY LEVELS ) WITHIN ORGANISATION’S ESTABLISHED
CAPABILITIES AND CAPACITIES AND IDENTIFICATION OF
ADDITIONAL RESOURCE REQUIREMENTS.

TO BE CONDUCTED BY THE IDENTIFIED CROSS FUNCTIONAL

TEAM (CFT) BEFORE TENDERING AND / OR ORDER
ACCEPTANCE

MAINTAIN RECORDS

IDENTIFICATION OF SPECIAL
CHARACTERISTICS

PRODUCT CHARCTERISTICS AFFECTING FFFSAG

FIT
FUNCTION
FORM
SAFETY
APPEARANCE
GOVERNMENT REGULATIONS
PROCESS NEEDS

USE OF CUSTOMER SPECIFIC SYMBOLS IF THESE

CHARACTERISTICS ARE IDENTIFIED BY THE CUSTOMER
CFT TO REVIEW THESE AND IDENTIFY ANY ADDITIONAL
CHRACTERISTICS AS REQUIRED.

APQP- 00 P QA 8/ 11
PRELIMINARY PROCESS FLOW DIAGRAM -PFD
COVERING ALL PRODUCTION PROCESSES FROM MATERIAL
RECEIPT TILL DESPACH

IN SEQUENCE

IDENTIFYING PRODUCT AND CONTROL

CHARCTERISTICS

HANDLING, MOVEMENT, INSPECTION AND

STORAGE REQUIREMENTS

FAILURE MODE AND EFFECTS ANALYSIS -FMEA

FAILURE MODE – WHAT CAN GO WRONG

CAUSES – EFFECTIVENESS OF CONTROLS

EFFECTS - SEVERITY OF FAILURE

OCCURANCE - PROBABILITY OF FAILURE

DETECTABILITY ( OF FAILURE )

EVALUATION CRITERIA ( TABLES )

RISK PRIORITY NUMBER ( RPN )

ACTION PLAN & RESULTANT RPN

REVIEW AND REVISION OF PFD

APQP- 00 P QA 9/ 11
 AS A RESULT OF PFMEA

CONTROL PLAN
A PROCESS ENGINEERING DOCUMENT-RESULTANT OF
PRODUCT QUALITY PLANNING ACTIVITY
FOR –
PROTOTYPE , PRELAUNCH AND PRODUCTION STAGES
CONTAINING –
a) General Data
- control plan number
- issue date & revision date if any
- customer information
- supplier name / site designation
- part number
- part name / description
- engineering change level
- phase covered ( proto, prelaunch, etc. )
- key contact
- part / process step number
- process name / operation description

b) Product control
- product related special characteristics
- other characteristics for control ( number, product or process )
- specifications and tolerance

c) Process control
- process parameters
- process related special characteristics
- machines,jigs,fixtures,tools for manufacturing

d) Methods
- evaluation / measurement technique
- error-proofing
- sample size and frequency

APQP- 00 P QA 10/ 11
 - control method
e) Reaction plan and corrective action
- reaction plan ( include or reference )
- corrective action
PPAP
Establishing process through a series of production trials in
accordance with the approved Control Plans using production
tooling at normal production speeds.

Conducted at Pilot stage and getting formal approval of

authorized functions of all listed documents and data together
with the product samples.

Formal release for regular production . This covers Supplier

items too.

APQP SIGN-OFF

APQP- 00 P QA 11/ 11