Process of Quality Planning by the Method APQP
Marek Šolc
Department of Integrated Management Systems
Institute of Materials, Faculty of Metallurgy
Košice, Slovakia
Marek.Solc@tuke.sk
Filip Forrai
Department of Safety and Quality Production
Faculty of Mechanical Engineering
Košice, Slovakia
Forrai.filip@gmail.com
Abstract— The article deals with the advanced quality planning
process according to the APQP method. This method provides
manufacturing organizations with guidance on product quality
planning, which is a major goal to meet customer needs. The
method was based on a five-year exploration of the current
development and production of cars. The beginning of the article
describes the quality and process of quality planning in terms of
general characteristics in practice. The article then describes the
method of advanced product quality planning. The next chapter
describes the individual steps of using the advanced product
quality planning method, inputs and outputs of each step of the
method APQP. Finally, the article describes the importance of
advanced APQP product quality planning method.
Keywords- process, quality, planning, management, method
I. INTRODUCTION
At the present time the quality became one of the most
essential branches of our lives. Everyone demands a certain
quality, but each of us considers of it differently. For each
subject the concept of quality varies and that is why this term
of quality gets very subjective concept. The quality can be
viewed in connection with the final product, i.e. either with the
commodity, or provided service. Quality of final product is
important both for the final consumer as well as for the
producers. Very important is the fact, that the quality is even
Juraj Kliment
Department of Integrated Management Systems
Institute of Materials, Faculty of Metallurgy
Košice, Slovakia
Juraj.Kliment@lr.org
Adriana Divoková
Department of Safety and Quality Production
Faculty of Mechanical Engineering
Košice, Slovakia
judrdivokova@gmail.com
more emphasised also regarding to choice of suppliers. All
operations are based on specific customer requirements, which
are necessary to be met, in order to his full contentment. To
achieve this, we have to very carefully plan and consider all
individual activities in order to achieve the desired results. So
thus it is convenient to apply quality planning in every part of
product life cycle, which we specify by utilizing a quality
spiral in practice.
II. QUALITY AND PROCESSES OF QUALITY PLANNING
The product duality depends on quality of manufacturing
process [3]. Organizations must be able to adapt of market
customer requirements because the seller’s market is
transformed into the buyer‘s market [4].
We can include the basic indices of quality [13]:
a) Applicability – suitability of the product for its
intended use. Applicability determines objectively
detectable properties and subjective evaluation that is
influenced by individual needs of consumers.
b) Functionality and performance – belong to the basic
features of the product. Functionality is the ability of
a product to fulfill the best possible function at a
given time. The measurable characteristics of the
products or services are the expression of features
 Distribution and
sales
that can be used to compare individual products or
brands. Choice of quality Review of the
Packaging and strategy proposal
c) Equipment (version) – these are secondary characters storage
that complement the essential function of the product
and which can increase customer interest. Review of the Product and
Control and proposal process design
d) Reliability – it is the ability of the product to ensure experience
that the required function is fulfilled for a specified
period of use without failures or errors. Ensuring the
e) Compliance with the requirements – compliance with Production quality of the
Verification
the required technical requirements. It is one of the production
production
factors
oldest quality signs. Reliability and compliance with
requirements are closely linked to the production
approach to quality.
f) Compliance with the requirements can be considered
as a relatively objective quality measure. Figure 1. Quality spiral model
g) Durability – is the ability of the product to retain its
ability to function for a certain period of time. It also
includes the ability of the product to retain properties
under specified storage and repair conditions.
h) Servis level – this is about the possibility of repair, its
speed, willingness, simplicity, availability of spare
parts.
i) Ecological safety – in view of the great importance of
protecting the environment, the environmental
friendliness of products is an important feature of
quality assessment.
j) Safety – is a condition where the risk of harm to
persons or things is limited to an acceptable level
(Frequency of accidents, occurrence of occupational
diseases, physical and psychological load in handling
devices, ergonomic point of view).
k) Duality lagel – when an independent review shows One of the quality management functions of the
that all the assumptions for reasonable and organization is therefore quality planning. We can also define
comprehensive control are met, an enterprise shall it as a process of setting goals for an organization, as well as
only be entitled to use the quality label. how to achieve them [2]. Planning represents a number of
l) Design (shape and color) – as the product looks like, activities at the design and product development stage,
what's on the touch, it is above all a matter of resulting in final product or service quality. It is proven that
personal taste. These characteristics, however, are of the pre-production or service phases contribute to the final
great importance for the position of the product on quality up to 80% or 80% of product mistakes arise in the pre-
the market as the consumer perceives them first and production stage of the production process. Thus, the
most clearly. economic effect of planning is significant, because by
m) Some of these features include measurable features of eliminating accidents prior to the product's realization, the
products, compliance with requirements, costs incurred in the event of product disruption or customer
functionality and performance, durability, operator elimination are eliminated. It can be said that the main reasons
level, others represent personal preferences (design, for quality planning are [2]:
subjective quality, brand of quality). Some are ■ quality planning makes a decisive decision on
objective, others depend on consumer behavior. customer satisfaction,
■ quality planning prevents the occurrence of
The linking of activities affecting product quality at disagreements in the implementation of the product and
different stages of its life cycle is usually illustrated by quality its use,
spirals model ”Fig. 1”. It is clear from this model that each of ■ in the pre-production stages in which quality
these stages is a measure of the quality of the product. planning is most implemented, generation the most
Activities and hence the planning stages lie at the start of the mistakes,
product lifecycle, in which the concept of a future product is
being developed. Essential decisions are made to decide ■ removing disagreements during product quality
whether a product meets customer requirements, whether it is planning requires only a fraction of the costs we would
competitive or generates profits. spend on disaster relief during product implementation
and use,
 ■ when an organization uses quality planning methods
and procedures, it demonstrates that it has used all means
of preventing disagreements and achieving customer
satisfaction, thereby increasing customer confidence in
the products of the organization,
■ the correct implementation of quality planning is an
important attribute of the organization's competitiveness.
Quality planning is defined by J. M. Juran as a process of
creating quality goals and developing resources to meet these
goals. Quality planning is one of the three basic processes of
quality trilogy (Juran's trilogy) - quality planning, quality
management and quality improvement [1].
Quality planning is generally implemented in pre-
production stages. The reason is that at this stage there is a
great deal of error that can be eliminated by appropriate
measures. In the pre-production stages, the cost of eliminating
errors is only a fraction of the costs compared to the cost of
eliminating errors in series production (not to mention hidden
costs such as loss of currency, and so on). Quality planning
procedures may be variously, for example: Figure 2. Product Quality Planning Cycle by Reference Manual [11]
 product quality planning by the procedure APQP,
 product quality planning according to methodoogy supports the development of a product or service that will
VDA 4. satisfy the customer. Guide „Advanced Product Quality
The process of product quality planning in both ways is Planning and Control Plan / Reference Manual” describes a
based on the general procedure proposed by J. M. Juran. This product quality planning cycle based on the ”Fig. 2”.
process is based on the sequence of activities from the primary
destination of customers and their needs, through the
transformation of those needs into measurable product and
process parameters up to the ultimate security of process
capability and the transfer of requirements into production
instructions. The product quality planning according to the
APQP procedure or according to the VDA 4 methodology is
then the concrete application of the general procedure [5].
These directives mainly concern the automotive industry
[6]. It is worth mentioning, however, that in the case of the
QS-9000 standard, five out of six manuals are focused on Product quality planning is described in this methodology
quality assurance in pre-production stages or on prevention of as a "structured method of defining and implementing the
poor quality. These manuals discuss this: steps necessary to ensure customer satisfaction with the
 PPAP (Production part approval process), product ”Fig. 2”. There are emphasized the main benefits of
product quality planning:
 APQP (Advanced product quality planning),
 orientates resources to customer satisfaction,
 FMEA (Failure mode and effect analysis),
 supports early detection of necessary changes (Early
 MSA (Measurement system analysis), Warning Concept),
 SPC (Statistical process control),  prevents late changes,
 As mentioned above, quality planning tools are used  helps to create good quality products on time and at
for quality planning. the lowest cost,
 improves communication with subcontractors.

III. METHOD OF ADVANCED PRODUCT QUALITY PLANNING

APQP IN QUALITY MANAGEMENT IV. THE INDIVIDUAL STEPS OF THE APQP METHOD
The procedure (methodology) was developed by Product quality planning is defined as a structured method.
companies Chrysler, Ford and General Motors. The goal is to This method determines and determines the steps necessary to
provide guidelines for developing a product quality plan that provide a satisfactory product to the customer. Product quality
planning is divided into five overlapping phases ”Fig. 3 ”. It is
in these phases [14]:
1. Planning and defining the programe,
Figure 3. Quality planning using APQP phases [11]
2. Product design and development,
3. Process design and development,
4. Product and process validation,
5. Feedback assessment and corrective action
Each product quality plan is unique [15]. The customer's
needs and expectations, as well as practical facts, are based on
actual timing and implementation of product quality planning.
It is crucial and best for workflows, tools and analytical
methods to be incorporated into the product quality planning
cycle [16,17,18].
A. Planning and defining the programe
Quality program definition and planning are tied to
customer needs and expectations. When orienting on any
product of the program, meeting the customer's needs while
ensuring competitive value with the overriding goal. It is
essential that the customer's needs and expectations are
safeguarded and understood in the process of modern product
quality planning. Depending on product development,
customer expectations and needs, process inputs and outputs
can change.
Inputs: (Market Research, Past Guarantees and Quality
Information, Team Experience); Business plan and marketing
strategy; Benchmark product / process data; Product / process
assumptions; Product reliability studies; Customer inputs.
Outputs: Objectives of the proposal; Targets of reliability
and quality; Preliminary Process Flow Diagram; Management
support (including time schedule and resource planning and
personnel protection, product security plan, preliminary
material breakdown, preliminary identification of product and
process specific features
B. Product design and development
This chapter talks about the elements of the planning
process, during which the design features and characters are
almost finite. Steps are taken to implement the prototype in
order to verify whether the product or service meets the
customer's voice goals. An achievable design must make it
possible to meet production volumes and time schedules, and
the design must correspond to the ability to meet technical
requirements along with the requirements of quality,
reliability, investment costs, weight and time objectives. The
product quality planning team should take into account all
design factors, even if it is a customer design or a joint
proposal.
Inputs: they correspond to the output from the Planning
and defining phase.
Outputs: DFMEA - Design Failure Mode and Effects
Analysis; examining and verifying the proposal; prototype
implementation - control and management plan; technical
drawings; technical specifications; changes to technical
drawings and specifications; requirements for new instruments
and equipment; special features of the product and process;
requirements for gauges / test tools.
C. Process design and development
This phase focuses on building the main system of
manufacturing and related control and management plans. It
ensures comprehensive development of the production system
that ensures compliance with the requirements, needs and
expectations of the customer. Filling tasks at this stage
depends on the quality of the outputs from the previous
phases.
Inputs: they correspond to the output from the Product
design and development phase.
Outputs: standards and specifications for packaging;
review of product/process quality system; PFMEA – Process
Failure Mode Effects Analysis; process flow chart; plan of
measurement systems analysis; layout of production facilities;
character matrix; control and management plan for series
verification; process instructions; a preliminary qualification
study of the process; support for leadership.
D. Product and process validation
Validation of the product and process is performed on the
basis of the verification of verification. The product quality
planning team should determine whether the control and
management plan is followed and the process flow chart and
whether the products meet the customer's requirements.
Verification production may uncover other problems that need
to be examined and resolved prior to the start of series
production.
Inputs: they correspond to the output from the Process
design and development phase.
Outputs: the progress of the verification process
(preliminary process capability study, demonstration of
production performance standard, process review, production
validation tests, part approval for series production, analysis of
measurement systems, final feasibility assessment, sample
production parts); measurement system analysis; a common
study of process capability; approval of parts in serial
production, production validation tests, evaluation of
packaging; control and management plan for production;
approval of quality planning and management support.
E. Feedback assessment and corrective action
Modern product quality planning does not end with
validation and process implementation. This is part of the
production stage where output can be evaluated if special and
common causes of variability occur. There is also a time to
evaluate the efficiency of product quality planning. There are
evaluated the variables and the attributable data. Organizations
that fully implement the APQP process will be better able to
meet customer requirements.
Inputs: they correspond to the output from the Product and
process validation.
Outputs: reduced variability; improved customer
satisfaction; improved service and delivery; effective use of
acquired knowledge / best practices.
CONCLUSION
Organizations that fully implement an effective APQP
process will be better able to meet customer requirements,
including specific quality factors. Each organization must
have as its main objective to increase the number of
customers, so it must take the most appropriate measures to
improve product and process quality planning. This method is
mainly used in car industry. The advanced product quality
planning is the modern method, which provides the required
steps, necessary to customer acceptance of product. It is
important, that a product or service meets customer
specifications not only during the production process and then
in stock, but mainly with the customer himself. Therefore, the
active communication between the producer and the customer
is very important element. The aim of product quality
planning is to facilitate mutual communication between all,
who are concerned in timely finalization of all steps. An
essential role in the application of this method leans on the top
management of the company. Very strong support of the top
management ensures higher satisfaction of customers. The
main benefits of this method:
- orientation of resources to meet customer´s demands
- it helps to product good quality products (including
deliverability and low cost)
- supports timely discovery of necessary changes and
prevents later.
ACKNOWLEDGMENT
This contribution is the result of the project
implementation KEGA 024TUKE-4/2015: New educational
methods in the Integrated Management Systems study
programme.
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