Introduction to APQP and its phases.

Five phases of APQP (Advanced Product Quality Planning)

Objective of the content:

·        To be familiar with APQP methodology and its relation with TS / IATF 16949.

·        To understand the five phases and benefits acquired from the implementation of APQP.

·       To understand the inputs and outputs of each phase.

Goals of TS 16949 / IATF 16949:2016 implementation

1.Continual Improvement for Quality Management System.

2. Defect Prevention.

3. Variation Reduction.

4. Waste Reduction.

5. Customer Specific Requirements.

IATF 16949 has only 4 goals as the 5th Customer Specific Requirement is included in the clauses.

Core tools of quality

1. APQP (Advanced Product Quality Planning)

2. PPAP (Production Part Approval Process)

3. FMEA (Failure Mode Effect Analysis)

4. SPC (Statistical Process Approach)

5. MSA (Measurement System Analysis)

Relation of Core tools with TS / IATF goals

1. Continual Improvement for Quality Management System – APQP

2. Defect Prevention – FMEA

3. Variation Reduction – SPC & MSA

4. Waste Reduction – SPC & MSA

5. Customer Specific Requirements – PPAP

As described above APQP is a Continual Improvement Tool and is covered under clause 8.1 Operational Planning and control in the QMS system.

Objectives of APQP:

• ·        To identify the risks involved in new product development.
• ·        Achieve cost and budgeted targets through optimum use of resources leading into quality, on time delivery and defect free products.
• ·        Continual Improvement.

Concept of APQP (Advanced Product Quality Planning)

APQP is a structure methodology used to achieve customer satisfaction through Continual Improvements.

                Fig AIAG Model for Quality Planning

The above figure shows the concept and the five phases of APQP process.

Definitions of Phases of APQP:

1.     Planning and defining the program:

Defining the customer requirements and expectations to plan and define an APQP program.

2.     Product Design and Development:

Developing a product design features considering customer requirements into a almost final form. The developed product design should be in such a way that it is feasible for manufacturing, it should meet engineering requirements, and fulfill quality objectives, reliability, cost etc.

3.     Process Design and Development:

Development of manufacturing system, process and control plan such that it meets customer requirements with optimum use of all the resources.

4.     Product and Process Validation:

Validating the process and the product to check whether the customer requirements are met.

Process flow and Control plans are validated by significant production runs to check the produced part is as per customer expectations.

5.     Feedback, Assessment and Corrective Actions:

Monitoring the effectiveness of the product quality planning to meet the customer expectations, identify and improve for any continual improvement opportunities.

Phase’s description, Inputs and Outputs for each phase:

Output of each phase is input to the other subsequent phase.

Phase 1: Planning and defining the program-

This phase covers defining the customer requirements and expectations into a planned and well defined APQP process.

Inputs to Phase 1:

• ·        Voice of customer through marketing and historical data (warranty and quality)
• ·        Customer inputs (dealers, direct customer feedbacks, visits and exhibitions)
• ·        Marketing strategy
• ·        Business plan. (whether to reuse the same design with few modifications or develop a complete new product design, Process standardization)
• ·        Process and product benchmarking.
• ·        Process and product assumptions.
• ·        Product functional and endurance information.

Outputs from Phase 1:

• ·        Statement of work with defined objectives and goals.
• ·        Quality Goals.
• ·        Initial Bill of Material.
• ·        Initial Process Flow Chart.
• ·        Initial list of Special Product and Process characteristics.

Phase 2: Product Design and Development-

Developing a product design features considering customer requirements into an almost final form. The developed product design should be in such a way that it is feasible for manufacturing, it should meet engineering requirements, and fulfill quality objectives, reliability, cost etc.

Scope of Work:

• ·        Develop a design considering all customer requirements.
• ·        Assess Potential and actual problems through DFMEA.
• ·        Verify if design meets customer requirements.
• ·        Inputs to feasibility and design review.
• ·        Check the design for convenience in manufacturing and assembly through DFM/A.
• ·        Design Verification Plan and Review.
• ·        Identify special product characteristic.

Inputs to Phase 2:

• ·        Defined objectives and goals in the form of a timeline or Gantt Chart.
• ·        All outputs of phase 1.

Outputs of Phase 2:

• ·        DFMEA (Design Failure Mode Effect Analysis)
• ·        Boundary Diagram.
• ·        DFM/A (Design For Manufacturing / Assembly)
• ·        Prototype of the product.
• ·        Prototype Control plan.

Phase 3: Process Design and Development-

Development of manufacturing system, process and control plan such that it meets customer requirements with optimum use of all the resources.

Scope of Work:

• ·   Development of effective manufacturing system and process for optimum use of resources.
• ·  Ensure that the manufacturing system meets the customer requirements and expectations.
• ·        Manufacturing system should meet all the plans and goals of the program.

Inputs to Phase 3:

• ·        All outputs of Phase 2

Outputs of Phase 3:

• ·        PFD (Process Flow Diagram)
• ·        PFMEA (Process Failure Mode Effect Analysis)
• ·        Work Instructions
• ·        Production Control Plan
• ·        Pre production trial runs
• ·        Special process Identification.
• ·        Preventive Maintenance Plan.

Phase 4: Product and Process Validation-

Validating the process and the product to check whether the customer requirements are met. Process flow and Control plans are validated by significant production runs to check the produced part is as per customer expectations.

Scope of Work:

• ·        Ensuring that both product and process meets the customer requirements.
• ·        All data collection required for PPAP (Production Part Approval Process)
• ·        Provides basic data for future continual improvements.

Inputs to Phase 4:

• ·        All outputs of phase 3

Outputs of Phase 4:

• ·        Significant production run.
• ·        Measurement system analysis.
• ·        Process capability study.
• ·        Product validation testing.
• ·        PPAP approval.
• ·        PSW sign off (Quality Planning sign off)

Phase 5: Feedback, Assessment and Corrective Actions-

Monitoring the effectiveness of the product quality planning to meet the customer expectations, identify and improve for any continual improvement opportunities.

Scope of Work:

• ·        Get PPAP feedback.
• ·  Evaluation of the effectiveness of APQP planning by Gantt chart review from top management.
• ·        Continual Improvements identification and improvement.

Inputs to Phase 5:

• ·        All outputs of Phase 4

Outputs of Phase 5:

• ·        Reduced variations
• ·        Improved Customer satisfaction.
• ·        Improved delivery, support and service.

Benefits of APQP:

• ·        Customer Satisfaction.
• ·        Continual Improvements.
• ·        Avoiding costly changes.
• ·        Optimum use of resources.
• ·        Timely completion of projects and on time launch.

Figure Reference: ASQ Automotive Division Webinar on APQP