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This document explains the concept and process of "Advance Product Quality Planning" (A.P.Q.P) in very easy way.
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Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
APQP, but for what?
Purpose of APQP is to produce a product quality plan which will support
development of a product or service that will satisfy the customer.
In simple words, APQP is intended to ensure that the supplier / manufacturer meets
all of the customer's requirements on time.
How to achieve this purpose?
By :
Up-front quality planning
Evaluating the output to determine if customer are satisfied & support continual
improvement.
APQP, but for what?
Purpose of APQP is to produce a product quality plan which will support
development of a product or service that will satisfy the customer.
In simple words, APQP is intended to ensure that the supplier / manufacturer meets
all of the customer's requirements on time.
How to achieve this purpose?
By :
Up-front quality planning
Evaluating the output to determine if customer are satisfied & support continual
improvement.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Product Quality Planning Cycle
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
The purpose of Product Quality Planning Cycle is to emphasize:
Up-front planning.The first three quarters of the cycle are devoted to up-front product quality planningthrough product / process validation.
The act of implementation.The fourth quarter is the stage where importance of evaluating the output serves twofunctions: to determine customer satisfaction and to support the pursuit of continualimprovement.
The purpose of Product Quality Planning Cycle is to emphasize:
Up-front planning.The first three quarters of the cycle are devoted to up-front product quality planningthrough product / process validation.
The act of implementation.The fourth quarter is the stage where importance of evaluating the output serves twofunctions: to determine customer satisfaction and to support the pursuit of continualimprovement.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PQP usually doesn’t work effectively in organizations.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PDCA
Plan
DoAct
Always
AlwaysSometimes
CheckSometimes
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
If quality is to become a business strategy, top management mustunderstand quality as a planning strategy and provide leadership forcarrying out this strategy.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Advanced product Quality Planning (APQP) is a structuredapproach to the design and development of new products andmanufacturing processes, designed to ensure that:
Suppliers understand the requirements of clients, end users andconsumers.
The proposed product or process design satisfies thoserequirements.
The supplier has the ability to consistently meet the clientsrequirements for quality, cost and delivery.
Advanced product Quality Planning (APQP) is a structuredapproach to the design and development of new products andmanufacturing processes, designed to ensure that:
Suppliers understand the requirements of clients, end users andconsumers.
The proposed product or process design satisfies thoserequirements.
The supplier has the ability to consistently meet the clientsrequirements for quality, cost and delivery.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Roadblocks for APQP.
Lack of commitment from Top Management.
Lack of discipline.
Undefined priorities.
Undefined responsibilities.
Lack of accountability.
Personal egos and lack of team spirit.
Unclear approach.
Lack of resources.
Lack of knowledge.
Roadblocks for APQP.
Lack of commitment from Top Management.
Lack of discipline.
Undefined priorities.
Undefined responsibilities.
Lack of accountability.
Personal egos and lack of team spirit.
Unclear approach.
Lack of resources.
Lack of knowledge.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
The APQP process includes five main functions:
Planning of APQP elements.
Execution of APQP elements.
Monitoring the “Quality-of-Event” of the execution of the elements, as well as thetiming, by the team in-between FPDS milestones.
Issues Resolution
Status Reporting
The APQP process includes five main functions:
Planning of APQP elements.
Execution of APQP elements.
Monitoring the “Quality-of-Event” of the execution of the elements, as well as thetiming, by the team in-between FPDS milestones.
Issues Resolution
Status Reporting
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Prepare forAPQP
Plan and DefineProgram
ProductDesign and
Development
Product &Process
Validation
ProcessDesign and
Development
Feedback,Assessment &
Corrective Action
Process Flow for APQP
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Phase 1: Planning and defining the program
This phase is meant to determine customer needs and expectations. Purpose of thisphase is to ensure that the customer’s needs and expectations are fully understoodbefore proceeding with the “design & development of the product” or “manufacturingprocess associated with product”.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Prepare forAPQP
Plan and DefineProgram
ProductDesign and
Development
Product &Process
Validation
ProcessDesign and
Development
Feedback,Assessment &
Corrective Action
Process Flow for APQP
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
INPU
T• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Prepare forAPQP
Plan and DefineProgram
ProductDesign and
Development
Product &Process
Validation
ProcessDesign and
Development
Feedback,Assessment &
Corrective Action
Process Flow for APQP
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
INPU
T• Design Goals
• Reliability andQuality Goals
• Preliminary Billof Material
• PreliminaryProcess FlowChart
• PreliminaryListing of SpecialProduct andProcessCharacteristics
• ProductAssurance Plan
• ManagementSupport
OU
TPU
T
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
• Design Goals
• Reliability andQuality Goals
• Preliminary Billof Material
• PreliminaryProcess FlowChart
• PreliminaryListing of SpecialProduct andProcessCharacteristics
• ProductAssurance Plan
• ManagementSupport
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Phase 2: Product design and development
In this phase, design features and characteristics are developed into near final form.
This phase focuses on developing the design of the product or service, and onensuring that it is feasible and will meet the customer’s expectations.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Prepare forAPQP
Plan and DefineProgram
ProductDesign and
Development
Product &Process
Validation
ProcessDesign and
Development
Feedback,Assessment &
Corrective Action
Process Flow for APQP
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
INPU
T• Design Goals
• Reliability andQuality Goals
• Preliminary Bill ofMaterial
• Preliminary ProcessFlow Chart
• Preliminary Listingof Special Productand ProcessCharacteristics
• Product AssurancePlan
• ManagementSupport
OU
TPU
T
• Design Failure Modeand Effects Analysis(DFMEA)
• Design forManufacturability andAssembly
• Design Verification
• Design Reviews
• Prototype Build –Control Plan
• Engineering Drawings(Including Math Data)
• EngineeringSpecifications
• Material Specifications
• Drawing andSpecification Changes
• New Equipment, Toolingand FacilitiesRequirements
• Special Product andProcess Characteristics
• Gages/TestingEquipment Requirements
• Team FeasibilityCommitment andManagement Support
INPU
T
OU
TPU
T
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
• Design Goals
• Reliability andQuality Goals
• Preliminary Bill ofMaterial
• Preliminary ProcessFlow Chart
• Preliminary Listingof Special Productand ProcessCharacteristics
• Product AssurancePlan
• ManagementSupport
• Design Failure Modeand Effects Analysis(DFMEA)
• Design forManufacturability andAssembly
• Design Verification
• Design Reviews
• Prototype Build –Control Plan
• Engineering Drawings(Including Math Data)
• EngineeringSpecifications
• Material Specifications
• Drawing andSpecification Changes
• New Equipment, Toolingand FacilitiesRequirements
• Special Product andProcess Characteristics
• Gages/TestingEquipment Requirements
• Team FeasibilityCommitment andManagement Support
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Phase 3: Process design and development
This phase concentrates on developing a manufacturing system and related controlplans to achieve quality products.
This phase focuses on creating a process that will ensure the design that wasdeveloped in the previous phase at the same quality level, quantity and cost, and atthe same time assuring that any other customer requirements and expectations willbe met.
Activities of this phase make sure that the product represents a value to customer.
Phase 3: Process design and development
This phase concentrates on developing a manufacturing system and related controlplans to achieve quality products.
This phase focuses on creating a process that will ensure the design that wasdeveloped in the previous phase at the same quality level, quantity and cost, and atthe same time assuring that any other customer requirements and expectations willbe met.
Activities of this phase make sure that the product represents a value to customer.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Prepare forAPQP
Plan and DefineProgram
ProductDesign and
Development
Product &Process
Validation
ProcessDesign and
Development
Feedback,Assessment &
Corrective Action
Process Flow for APQP
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
INPU
T• Design Goals
• Reliability andQuality Goals
• Preliminary Bill ofMaterial
• Preliminary ProcessFlow Chart
• Preliminary Listingof Special Productand ProcessCharacteristics
• Product AssurancePlan
• ManagementSupport
OU
TPU
T
• Design Failure Modeand Effects Analysis(DFMEA)
• Design forManufacturability andAssembly
• Design Verification
• Design Reviews
• Prototype Build –Control Plan
• Engineering Drawings
• EngineeringSpecifications
• Material Specifications
• Drawing andSpecification Changes
• New Equipment, Toolingand FacilitiesRequirements
• Special Product andProcess Characteristics
• Gages/TestingEquipment Requirements
• Team FeasibilityCommitment andManagement Support
INPU
T
OU
TPU
T
• PackagingStandards
• Product/ProcessQuality SystemReview
• Process Flow Chart
• Floor Plan Layout
• CharacteristicsMatrix
• Process FailureMode and EffectsAnalysis (PFMEA)
• Pre-Launch ControlPlan
• Process Instructions
• MeasurementSystems AnalysisPlan
• PreliminaryProcess CapabilityStudy Plan
• PackagingSpecifications
• ManagementSupport
INPU
T
OU
TPU
T
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
• Design Goals
• Reliability andQuality Goals
• Preliminary Bill ofMaterial
• Preliminary ProcessFlow Chart
• Preliminary Listingof Special Productand ProcessCharacteristics
• Product AssurancePlan
• ManagementSupport
• Design Failure Modeand Effects Analysis(DFMEA)
• Design forManufacturability andAssembly
• Design Verification
• Design Reviews
• Prototype Build –Control Plan
• Engineering Drawings
• EngineeringSpecifications
• Material Specifications
• Drawing andSpecification Changes
• New Equipment, Toolingand FacilitiesRequirements
• Special Product andProcess Characteristics
• Gages/TestingEquipment Requirements
• Team FeasibilityCommitment andManagement Support
• PackagingStandards
• Product/ProcessQuality SystemReview
• Process Flow Chart
• Floor Plan Layout
• CharacteristicsMatrix
• Process FailureMode and EffectsAnalysis (PFMEA)
• Pre-Launch ControlPlan
• Process Instructions
• MeasurementSystems AnalysisPlan
• PreliminaryProcess CapabilityStudy Plan
• PackagingSpecifications
• ManagementSupport
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Phase 4: Product and process validation
This phase concentrates on validating the manufacturing process through evaluationof production trial run and all the activities related to it.
This phase focuses on methods and techniques for determining that the long-termproduction process is capable of meeting all the requirements that have beenresearched and documented through the previous phases.
Phase 4: Product and process validation
This phase concentrates on validating the manufacturing process through evaluationof production trial run and all the activities related to it.
This phase focuses on methods and techniques for determining that the long-termproduction process is capable of meeting all the requirements that have beenresearched and documented through the previous phases.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Prepare forAPQP
Plan and DefineProgram
ProductDesign and
Development
Product &Process
Validation
ProcessDesign and
Development
Feedback,Assessment &
Corrective Action
Process Flow for APQP
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
INPU
T• Design Goals
• Reliability andQuality Goals
• Preliminary Bill ofMaterial
• Preliminary ProcessFlow Chart
• Preliminary Listingof Special Productand ProcessCharacteristics
• Product AssurancePlan
• ManagementSupport
OU
TPU
T
• Design Failure Modeand Effects Analysis(DFMEA)
• Design forManufacturability andAssembly
• Design Verification
• Design Reviews
• Prototype Build –Control Plan
• Engineering Drawings
• EngineeringSpecifications
• Material Specifications
• Drawing andSpecification Changes
• New Equipment, Toolingand FacilitiesRequirements
• Special Product andProcess Characteristics
• Gages/TestingEquipment Requirements
• Team FeasibilityCommitment andManagement Support
INPU
T
OU
TPU
T
• Packaging Standards
• Product/ProcessQuality System Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process Failure Modeand Effects Analysis(PFMEA)
• Pre-Launch ControlPlan
• Process Instructions
• MeasurementSystems Analysis Plan
• Preliminary ProcessCapability Study Plan
• PackagingSpecifications
• Management Support
INPU
T
OU
TPU
T
• Production TrialRun
• MeasurementSystemsEvaluation
• PreliminaryProcess CapabilityStudy
• Production PartApproval
• ProductionValidation Testing
• PackagingEvaluation
• ProductionControl Plan
• Quality PlanningSign-Off andManagementSupport
INPU
T
OU
TPU
T
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
• Design Goals
• Reliability andQuality Goals
• Preliminary Bill ofMaterial
• Preliminary ProcessFlow Chart
• Preliminary Listingof Special Productand ProcessCharacteristics
• Product AssurancePlan
• ManagementSupport
• Design Failure Modeand Effects Analysis(DFMEA)
• Design forManufacturability andAssembly
• Design Verification
• Design Reviews
• Prototype Build –Control Plan
• Engineering Drawings
• EngineeringSpecifications
• Material Specifications
• Drawing andSpecification Changes
• New Equipment, Toolingand FacilitiesRequirements
• Special Product andProcess Characteristics
• Gages/TestingEquipment Requirements
• Team FeasibilityCommitment andManagement Support
• Packaging Standards
• Product/ProcessQuality System Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process Failure Modeand Effects Analysis(PFMEA)
• Pre-Launch ControlPlan
• Process Instructions
• MeasurementSystems Analysis Plan
• Preliminary ProcessCapability Study Plan
• PackagingSpecifications
• Management Support
• Production TrialRun
• MeasurementSystemsEvaluation
• PreliminaryProcess CapabilityStudy
• Production PartApproval
• ProductionValidation Testing
• PackagingEvaluation
• ProductionControl Plan
• Quality PlanningSign-Off andManagementSupport
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Phase 5: Feedback, assessment and corrective action.
At this point, output is evaluated for all special and common cause variation. This isalso the time to evaluate the effectiveness of the quality planning effort itself.
In this phase, variation can be studied and reduced over the time.
Results of organization’s continuous improvement philosophy will be most visible.
Phase 5: Feedback, assessment and corrective action.
At this point, output is evaluated for all special and common cause variation. This isalso the time to evaluate the effectiveness of the quality planning effort itself.
In this phase, variation can be studied and reduced over the time.
Results of organization’s continuous improvement philosophy will be most visible.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Prepare forAPQP
Plan and DefineProgram
ProductDesign and
Development
Product &Process
Validation
ProcessDesign and
Development
Feedback,Assessment &
Corrective Action
Process Flow for APQP
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
INPU
T• Design Goals
• Reliability andQuality Goals
• Preliminary Bill ofMaterial
• Preliminary ProcessFlow Chart
• Preliminary Listingof Special Productand ProcessCharacteristics
• Product AssurancePlan
• ManagementSupport
OU
TPU
T
• Design Failure Modeand Effects Analysis(DFMEA)
• Design forManufacturability andAssembly
• Design Verification
• Design Reviews
• Prototype Build –Control Plan
• Engineering Drawings
• EngineeringSpecifications
• Material Specifications
• Drawing andSpecification Changes
• New Equipment, Toolingand FacilitiesRequirements
• Special Product andProcess Characteristics
• Gages/TestingEquipment Requirements
• Team FeasibilityCommitment andManagement Support
INPU
T
OU
TPU
T
• Packaging Standards
• Product/Process QualitySystem Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process Failure Modeand Effects Analysis(PFMEA)
• Pre-Launch ControlPlan
• Process Instructions
• Measurement SystemsAnalysis Plan
• Preliminary ProcessCapability Study Plan
• PackagingSpecifications
• Management Support
INPU
T
OU
TPU
T
• Production Trial Run
• MeasurementSystems Evaluation
• Preliminary ProcessCapability Study
• Production PartApproval
• Production ValidationTesting
• Packaging Evaluation
• Production ControlPlan
• Quality PlanningSign-Off andManagement Support
INPU
T
OU
TPU
T
• Reduced Variation
• CustomerSatisfaction
• Delivery andService
OU
TPU
T
INPU
T
• Organize the Team
• Define the Scope
• Establish Team-to-TeamCommunication
• Provide Core ToolsTraining
• Involve Customersand Suppliers
• ImplementSimultaneousEngineering
• Develop ControlPlan Format
• Decide on ConcernResolution
• Develop ProductQuality Timing Plan
• Voice of theCustomer
• BusinessPlan/MarketingStrategy
• Product/ProcessBenchmark Data
• Product/ProcessAssumptions
• Product ReliabilityStudies
• Customer Inputs
• Design Goals
• Reliability andQuality Goals
• Preliminary Bill ofMaterial
• Preliminary ProcessFlow Chart
• Preliminary Listingof Special Productand ProcessCharacteristics
• Product AssurancePlan
• ManagementSupport
• Design Failure Modeand Effects Analysis(DFMEA)
• Design forManufacturability andAssembly
• Design Verification
• Design Reviews
• Prototype Build –Control Plan
• Engineering Drawings
• EngineeringSpecifications
• Material Specifications
• Drawing andSpecification Changes
• New Equipment, Toolingand FacilitiesRequirements
• Special Product andProcess Characteristics
• Gages/TestingEquipment Requirements
• Team FeasibilityCommitment andManagement Support
• Packaging Standards
• Product/Process QualitySystem Review
• Process Flow Chart
• Floor Plan Layout
• Characteristics Matrix
• Process Failure Modeand Effects Analysis(PFMEA)
• Pre-Launch ControlPlan
• Process Instructions
• Measurement SystemsAnalysis Plan
• Preliminary ProcessCapability Study Plan
• PackagingSpecifications
• Management Support
• Production Trial Run
• MeasurementSystems Evaluation
• Preliminary ProcessCapability Study
• Production PartApproval
• Production ValidationTesting
• Packaging Evaluation
• Production ControlPlan
• Quality PlanningSign-Off andManagement Support
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
An important phase of APQP is the development of “Control Plan”.
What is a Control Plan?
It is a written description of the system for controlling parts and processes. Controlplan describes the actions that are required at each phase of the process includingreceiving, in-process, out-going and periodic requirements to assure that all processoutputs will be in state of control.
When to generate this document and for how long to use it?
Control plan is maintained and used throughout the product life cycle. Early inproduct life cycle, its primary purpose is to document and communicate the initialplan for process control. Subsequently, it guides manufacturing in how to control theprocess and ensure product quality.
The control plan remains a living document, reflecting the current methods of control,and measurement systems used. It is updated as measurement systems and controlmethods are evaluated and improved.
An important phase of APQP is the development of “Control Plan”.
What is a Control Plan?
It is a written description of the system for controlling parts and processes. Controlplan describes the actions that are required at each phase of the process includingreceiving, in-process, out-going and periodic requirements to assure that all processoutputs will be in state of control.
When to generate this document and for how long to use it?
Control plan is maintained and used throughout the product life cycle. Early inproduct life cycle, its primary purpose is to document and communicate the initialplan for process control. Subsequently, it guides manufacturing in how to control theprocess and ensure product quality.
The control plan remains a living document, reflecting the current methods of control,and measurement systems used. It is updated as measurement systems and controlmethods are evaluated and improved.
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Cross Functional Team (CFT) is required to develop Control Plan by utilizing allavailable information to gain better understanding of process, like:
• Process flow diagram• Design / Process failure mode and effect analysis (FMEA)• Special characteristics• History of similar parts• Team’s knowledge of process• Design review• Optimization methods
Cross Functional Team (CFT) is required to develop Control Plan by utilizing allavailable information to gain better understanding of process, like:
• Process flow diagram• Design / Process failure mode and effect analysis (FMEA)• Special characteristics• History of similar parts• Team’s knowledge of process• Design review• Optimization methods
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Collect &Interpret Data
SelectMeasures
IsProcessStable?
Investigate &Fix Special
Causes
No
DefineProcess
Develop ControlPlan
IsProcess
Capable?
ImproveProcess
Capability
IsProcessStable?
Investigate &Fix Special
Causes
No
Yes
No
Yes
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Monitor variables for out ofcontrol conditions
Develop alarm andrecording strategy
Finalize process samplingplanFinalize process samplingplan
Document control plan foreach key variable
Identify Opportunities forMistake Proofing
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Control Plan
PreliminaryAnalysis
MeasurementSystem
ProcessMaps
FMEA
MeasurementSystem Analysis
CalibrationRequirements
Sampling & Testing PlansCustomer requirements
Short TermCapability
Control Plan
ProceduresImprovementActivities
SPC Plans
OperatingWindows
DOE's
Maintenance Schedules
Training Materials
SOP's
Long TermCapability
Reaction plans
Trouble shooting Aids
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – I (Planning & Defining the program)Wk1
Wk2
Wk3
Wk4
Wk5
Wk6
Voice of customer
Historical data (Internal & External)
Bench mark data (Product & Process)
Assumptions (Product & Process)
Customer design inputsCustomer design inputs
Design goals
Reliability & quality goals
Preliminary bill of material
Preliminary process flow diagram
Preliminary list of special characteristics
Management review & support
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – II (Product design & development)Wk Wk Wk Wk Wk Wk
Block diagram
Design FMEA
Engineering drawing (for Prototype)
Engineering specifications (for Prototype)
Material specifications (for Prototype)Material specifications (for Prototype)
Final bill of material
Design verification
Design review
Changes in drawing & specifications
Make or buy decision
Supplier selection & allocation
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – II (Product design & development)Wk Wk Wk Wk Wk Wk
Preparation of inspection standards for BOP
Procurement of BOP
Prototype control plan
Identification of new equipment, tooling,gauges, test facilities
Acquisition of new equipment, tooling,gauges & test facilitiesAcquisition of new equipment, tooling,gauges & test facilities
Prototype samples
Prototype approval from customer
Changes in drawing & specifications
Team feasibility & commitment
Final drawing & specifications
Management review & support
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – III (Process design & development)Wk Wk Wk Wk Wk Wk
Final process flow diagram
Floor plan layout
Final special characteristics (Product &Process)
Process FMEA
Prelaunch control planPrelaunch control plan
Process control standards / Workinstructions
M.S.A. plan
Preliminary process capability study plan
Packaging standards & specifications
Quality system review (Product &Process)
Management review & support
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – IV (Product & process validation)Wk Wk Wk Wk Wk Wk
Material for trial production (Pilot lot)
Trial production run (Pilot lot)
Measurement system analysis
Process capability study
Process validation testing
Packaging evaluationPackaging evaluation
PPAP documents compilation & submission
Customer approval
Release : Production control plan
Quality planning & summary sign off
Initial supply control initiation
Management review & support
Regular production
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
PHASE – V (Feedback assessment & corrective action)Wk Wk Wk Wk Wk Wk
Reduction of variation
Continual improvement
Delivery of regular product
By: Pankaj Nalwa
Advanced Product Quality Planning (APQP)Advanced Product Quality Planning (APQP)
Notes:
By: Pankaj Nalwa