Apqp Masl

APQP
Advanced Product
Quality Planning
In Consonance with the AIAG’s (QS-9000) APQP Manual
© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 1
Wednesday, March 22, 2023 Advanced Product Quality Planning The Cove! -- 16949.com
What Is APQP?
• APQP is a ‘defined’ process for a product
development ‘system’ for Ford, GM, Chrysler
and their suppliers.
• APQP is an attempt to provide a common
path and synchronization of product
development activities.
• APQP is an attempt to ensure communication
both within a company and between a
company and their customer.

The Target & Goal
Continuous Improvement
Production
Pre-Launch
Prototype
LSL USL

APQP Phases
Think Critical Paths
• Phase 1: Plan & Define Program

° Where do we want to go?
• Phase 2: Product Design & Development Verification

° Can we design one?
• Phase 3: Process Design & Development Verification

° Can we make one?
• Phase 4: Product & Process Validation

° Proof of Phases 2 and 3.
• Phase 5: Feedback Assessment & Corrective Action

° Production, Continuous Improvement, Prevent Recurrence

Advanced Product Quality Planning
There are Customer specific requirements in addition to the APQP and Control Plan manual requirements.
Concept
Initiation - Program AIAG APQP & Ctrl Plan Reference Guide, Page 5
Approval Approval
Prototype
Phase 1 Planning Pilot Planning
Phase 2 Product
Design & Development
Phase 3 Process Launch
Phase 4 Validation Product - Process
Production
Phase 5 Feedback Assessment & Corrective Action
Plan & Product Process Product &

Define Design & Design & Process
Program Dev. Dev. Validation
Verification Verification
This is how the APQP and Control Plan manual graphically represents the process it describes.
To a large degree, this can be looked at as Critical Paths in the process. You have to do planing
before you do product and process design and development. You have to do product and process
design and development before you can do product and process validation. Another way of saying
this is to say the phases are Dependent. Each phase (except Phase 1) is dependent upon
elements of (outputs from) the previous phase.
Inputs / Outputs - Phase 1
Phase 1 Inputs
• Voice of the Customer
° Market Research Phase 1 Outputs (= Phase 2 Inputs)
° Historical Warranty and Quality • Design Goals
Information
• Reliability and Quality Goals
° Team Experience
• Preliminary Bill of Material
• Business Plan and Marketing
Strategy • Preliminary Process Flow Chart
• Product/Process Benchmark Phase 1 • Preliminary Listing of Special
Data Product and Process Characteristics
• Product/Process Assumptions • Product Assurance Plan
• Product Reliability Studies • Management Support
• Customer Inputs
• Service

• Design FMEA
• DFM and DFA
Phase 1 Outputs Phase 2 Outputs Design for Manufacturability
(Phase 2 Inputs) (Phase 3 Inputs) Design for Assembly
• Design Goals • Outputs by • Design Verification
• Reliability and Quality Design • Design Reviews
Goals Responsible • Prototype Build Control Plan
• Preliminary Bill of Activity • Engineering Drawings (including
Phase 2
Material • Outputs by Math data)
• Preliminary Process Advanced • Engineering Specifications
Flow Chart Product Quality • Material Specifications
Planning Team • Drawing and Specification
• Preliminary Listing of
Changes
Special Product and
Process Characteristics
• Product Assurance Plan • New equipment, tooling and
• Management Support facilities requirements
• Special product and process
characteristics
• Gage and testing equipment
requirements
• Team feasibility commitment
and management support
• Subcontractor build
• Supplier build
Phase 2 Outputs (Phase 3 Inputs)
Phase 2 Design • Outputs by Design Phase 2 APQP
Activity Outputs Responsible Activity Team Outputs
• Outputs by Advanced Product

• Design FMEA Quality Planning Team
• DFM and DFA
• New equipment, tooling and
Design for Manufacturability facilities requirements
Design for Assembly • Special product and process
• Design Verification characteristics
• Design Reviews • Gage and testing equipment
• Prototype Build Control Plan Phase 3 requirements
• Engineering Drawings (including • Team feasibility commitment
Math data) and management support
• Engineering Specifications Phase 3 Outputs • Subcontractor build
• Material Specifications (Phase 4 Inputs) • Supplier build
• Drawing and Specification Changes • Packaging Standards
• Product / Process Quality System Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process Failure Mode and Effects Analysis
• Pre-Launch Control Plan
• Process Instructions
• Measurement Systems Analysis Plan
• Preliminary Process Capability Study Plan
• Packaging Specifications
Phase 3 Outputs
(Phase 4 Inputs)
• Packaging Standards Phase 4 Outputs
• Product / Process Quality (Phase 5 Inputs)
System Review • Production Trial Run
• Process Flow Chart • Measurement Systems
• Floor Plan Layout Evaluation
• Characteristics Matrix • Preliminary Process Capability
• Process Failure Mode and Study
Effects Analysis Phase 4 • Production Part Approval
• Pre-Launch Control Plan (PPAP)
• Process Instructions • Production Validation Testing
• Measurement Systems • Packaging Evaluation
Analysis Plan • Production Control Plan
• Preliminary Process Capability • Quality Planning Sign-off
Study Plan
• Packaging Specifications

Phase 4 Outputs
(Phase 5 Inputs)
• Production Trial Run
• Measurement Systems
Evaluation
• Preliminary Process Capability Phase 5 Outputs
Study • Reduced Variation
• Production Part Approval Phase 5 • Customer Satisfaction
(PPAP) • Delivery and Service
• Production Validation Testing
• Packaging Evaluation
• Production Control Plan
• Quality Planning Sign-off

Base Documentation
• Critical Characteristics Matrix
• Process Flow Diagram
• Design FMEA
• Process FMEA
• Control Plan

Benefits of APQP
• Ensures early planning takes place
• Directs resources to the customer
• Identifies required changes early in the
process
• Provides quality product on time and at
lowest cost
• Enables cross-functional inputs and outputs
• Addresses potential problems early in
Design
Manufacturing
Progressive Fundamentals
• KEY** Organize a Cross-Functional TEAM
• Define the scope
• Team-to-team communications
• Training
• Simultaneous (concurrent) engineering
• Control Plan Phases
Prototype
Pre-Launch
Production
• Concern resolution
Includes analytical techniques

APQP Documents and Elements
• Action Plan • Control Plan checklist
• Product / Process Assumptions • Characteristics Matrix
• Product Reliability studies • Packaging standards
• Product / Process Characteristics • Product and Process Validation
• Cross Functional Team Members • Summary and sign-off
• Design FMEA • Process Verification Run
• Design Verification Plan and Report • Corrective Action
• Design FMEA checklist • APQP Status Report
• Design Information Checklist • PAPP- Warrant
• New equipment tooling and Equipment checklist • Appearance Evaluation
• Team feasibility Commitment • Dimensional Results
• Process Flow • Material Results
• Manufacturing Process Flow Chart Checklist • Function Results
• Process FMEA • 8 D Report
• Control Plan • Tooling instructions
• Product / Process Quality checklist • Gages Instructions
• Floor plan checklist • Preventive Maintenance Checklist
• Process Flow Chart checklist • Housekeeping Checklist
• Process FMEA checklist


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APQP

© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 2

© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 3

• Phase 1: Plan & Define Program

• Phase 2: Product Design & Development Verification

• Phase 3: Process Design & Development Verification

• Phase 4: Product & Process Validation

• Phase 5: Feedback Assessment & Corrective Action

© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 4

Plan & Product Process Product &

© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 6

• Outputs by Advanced Product

© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 9

© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 10

© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 11

© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 13

© 2001 The Cayman Cove - Rev Pre-U ß1 Slide 14

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