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6-New APQP Manual 3rd Edition - Advanced Product Quality Planning 2024
6-New APQP Manual 3rd Edition - Advanced Product Quality Planning 2024
What is APQP?
APQP stands for Advanced Product Quality Planning. It is a methodology that originated in the automotive industry to ensure the development and
production of high-quality products that meet customer requirements and expectations.
APQP includes a series of steps and tools, such as risk assessment, design and process FMEAs (Failure Mode and Effects Analysis), control plans,
and production trials, to ensure that all necessary planning and preparations are made before mass production. The goal of APQP is to prevent quality
problems, improve overall customer satisfaction, and drive continuous improvement. Continuous Improvement applies not just to the product just
launched (culminating with PPAP (Production Part Approval Process)), but for the NEXT products produced, incorporating lessons learned from prior
programs.
APQP is a "core tool" developed by AIAG (https://www.aiag.org/quality/automotive-core-tools/apqp) to attain and maintain product quality. The
automotive quality core tools are standardized methodologies assisting companies in many industries (https://www.aiag.org/quality/automotive-core-
tools) to improve their processes and generate high-quality products. The other core tools include:
FMEA (Failure Modes and Effects Analysis) (https://www.aiag.org/quality/automotive-core-tools/fmea) - an analytical methodology used to ensure
that potential problems have been considered and addressed throughout the product and process development process.
PPAP (Production Part Approval Process) (https://www.aiag.org/quality/automotive-core-tools/ppap) - the industry standard that defines the
production part approval process and demonstrates engineering design records and specification requirements are achieved by the supplier's
manufacturing process.
MSA (Measurement Systems Analysis) (https://www.aiag.org/quality/automotive-core-tools/msa) - a methodology to assess the quality of
measurement systems, providing a basis for recognizing where improvements can be made, resulting in knowledge that can be used to improve
your measurement process and repeatable product quality.
SPC (Statistical Process Control) (https://www.aiag.org/quality/automotive-core-tools/spc) - the use of statistical techniques such as control charts to
analyze a process or its output so as to take appropriate actions to achieve and maintain a state of statistical control and to improve the process
capability.
APQP is the overarching framework that brings together all these tools and methodologies to create a comprehensive quality planning and control
system.
APQP is a flexible methodology that can be adapted to the specific needs and requirements of any product.
Improved product quality - APQP’s rigorous risk assessments, design and process FMEAs, control plans, and production trials prevent a host of
quality problems before parts are mass produced.
Enhanced customer satisfaction - To put it simply, higher quality products result in greater customer satisfaction and happiness. When customers are
satisfied, their relationships with manufacturers and suppliers improve.
Increased efficiency - Quality problems in the development and manufacturing process hinder efficiency and time-to-market. APQP provides a
reliable framework to catch and address these problems early to reduce the need for reworks.
Reduced costs - Quality problems, hangups in the development and manufacturing process, reworks, product returns, warranty claims, and more all
result in greater costs to the manufacturer. APQP drastically reduces these issues to save significant costs.
Improved supplier relations - By factoring in a detailed understanding of customer requirements and expectations, APQP allows suppliers to better
understand their customers which leads to improved customer <> supplier relationships and a more collaborative working relationship.
Better risk management - APQP’s risk assessment processes allow suppliers and manufacturers to identify, address, and develop measures to
mitigate potential quality issues early.
Improved process control - the combined methodologies outlined above in combination with APQP’s statistical process control (SPC) processes
allow suppliers and manufacturers to monitor/control the production process in even greater detail.
Decoupling the two documents will also facilitate more timely updates as systems evolve and emphasize the importance of Control Plans in product
development.
The control plan now outlines essential steps and offers enhanced guidance for developing and managing control plans. This reorganization aligns with
how core tools have been taught historically, with the control plan serving as the operational expression of the FMEA, ensuring consistency and
complementarity within the core tool stack.
Changes to APQP
The changes to the APQP manual focus on three main areas: program management, sourcing, and additional clarifications. In program management,
there is an emphasis on risk assessment and mitigation, including checklists for assessing and mitigating risks within the APQP process. A new
appendix addresses gated management, offering guidance on expectations. KPIs related to the APQP process are introduced to measure progress.
Sourcing receives increased attention, recognizing its importance in supplier capability assessment. Checklists are added to assess and mitigate risks
during the sourcing stage. The gated management approach extends to the supply chain.
Clarifications and details cover change management during the APQP process, capacity planning using OEE measures, traceability guidelines, and
error-proofing and mistake-proofing. These changes aim to provide clarity and standardization, benefiting both suppliers and OEMs.
AIAG offers several resources to learn more and implement
APQP, including:
eLearning
Introduction to APQP eLearning (https://www.aiag.org/store/training/details?CourseCode=IAPE) - Focusing on high level topics, this eLearning reviews
the history and structure of APQP, benefits and best practices, and key concepts such as gateways and activities.
Introduction to Control Plan eLearning: (https://www.aiag.org/store/training/details?CourseCode=ICPE) - Familiarize yourself with the language and
techniques used in everyday control plan activities with this 30-minute eLearning.
Quality Core Tools Connect the Dots (https://www.aiag.org/store/training/details?CourseCode=QDOT) - Provides an understanding of how the Core
Tools work together to assure quality
Core Tools Overview eLearning (https://www.aiag.org/store/training/details?CourseCode=ELCTO) -Provides a brief summary of the Core Tools, with a
primary focus on how they can help your organization in its journey for continuous improvement
Publications
Advanced Product Quality Planning and Control Plan (https://go.aiag.org/apqp-cp) - The industry standards
Supplier Quality Requirements 6-Pack (https://www.aiag.org/store/publications/details?ProductCode=CT6-K) - Includes all the Core Tools
Training
APQP and Control Plan Fundamentals (https://www.aiag.org/store/training/details?CourseCode=ACPO) - Covering both the APQP 3rd Edition and
Control Plan 1st Edition in a single day, this unique hybrid training includes a range of presentation materials to help attendees better understand key
updates and associated deliverables. (Note: Copies of both publications are also included in the cost of registration!)
APQP Overview (https://www.aiag.org/store/training/details?CourseCode=APTP) - Designed to provide an overview of the new APQP 3rd Edition, this
one-day course covers both the technical and managerial aspects of APQP to help you gain a more well-rounded understanding of program
management. Course content focuses on general expectations for APQP tasks and the higher system level of phases, along with using new APQP tools
in real-world contexts, and more.
APQP and Control Plan: Transitioning (https://www.aiag.org/store/training/details?CourseCode=ACPT) - This two-day “transitioning” training – intended
for current APQP practitioners, managers, and auditors – focuses on updates and changes in the APQP 3rd Edition to facilitate a better understanding
of how your APQP program will be impacted, provide examples of new elements, and explore the managerial side of APQP in more detail.
APQP, Control Plan and PPAP - Understanding and Implementing (https://www.aiag.org/store/training/details?CourseCode=ACPU) - Focusing on both
the managerial and technical aspects of APQP, this three-day course includes case studies for practical analysis, along with various other techniques
successful practitioners have used over the years. If you’re looking for a comprehensive APQP training to move above and beyond conformance, this
course is for you.
Control Plan Understanding and Implementing (https://www.aiag.org/store/training/details?CourseCode=CPUI) - Looking for a comprehensive training
on control plans, covering everything from development to maintenance? Designed for a variety of learners (and particularly geared toward beginners),
this one-day course focuses on certain areas that are often overlooked, along with best practices for monitoring your control plan.
Certification
APQP/PPAP Certification Exam (https://www.aiag.org/store/training/details?CourseCode=APQPEXAM) - Verifies competency in product quality
planning, control plans and production part approval as defined in AIAG's APQP and PPAP reference manuals
Other Resources
Core Tools Self-Assessment (https://www.aiag.org/store/training/details?CourseCode=ELCTSA)- Baseline your knowledge in the automotive quality
Core Tools to see where you should focus your training efforts
AIAG Core Tools Support™ Software (https://www.aiag.org/quality/automotive-core-tools/core-tools-software) - Developed by our member OEM and
Tier 1 suppliers to meet your customer’s requirements for electric reporting of FMEAs
Implementing APQP requires a commitment to continuous improvement and the active involvement of all stakeholders. But when done correctly, all
stakeholders can celebrate in confidence that quality is assured and not only don’t we have problems, but we know why we don’t!
FAQ
What is APQP?
APQP stands for Advanced Product Quality Planning. It is a methodology that originated in the automotive industry to ensure the development
and production of high-quality products that meet customer requirements and expectations.
Where is APQP applicable?
APQP’s ideas, methodologies, and processes aren’t limited to one single industry, despite initially being developed for the automotive industry.
There are now many outside industries using APQP to improve their product processes, like Aerospace and Defense, Medical Devices,
Electronics, Consumer Products, and more.
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