In this ever-evolving business environment, organizations strive to exceed client expectations, produce high-quality goods and services, and streamline internal operations. To achieve this organization applies the 5 core tools of quality. Quality Core Tools are defined as five supplementary techniques or methods that support the expectations of IATF 16949. They are components of a quality system throughout the product lifecycle to ensure effective production. Core Tool assists businesses in managing and enhancing their operations, goods, and services. They include Advanced Product Quality Planning & Control Plan (APQP), Production Part Approval Process (PPAP), Failure Mode and Effects Analysis (FMEA), Statistical Process Control (SPC), and Measurement System Analysis (MSA).
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What is Advanced Product Quality Planning (APQP)?
Advanced Product Quality Planning (APQP) is a structured process designed to ensure customer satisfaction with new goods or procedures. It is a collection of methods and techniques used to clarify requirements, specifications, and risks to ensure the quality of the final product. APQP is based on the supplier quality standards working group (AIAG = Automotive Industry Action Group), which was established in 1982 by the three American car manufacturers Ford, General Motors, and Chrysler. Cross-functional teams may manage quality across the whole product development lifecycle with the help of the APQP framework. Additionally, it encourages teamwork, risk reduction, and ongoing development, ultimately leading to high-quality goods that satisfy customer demands.
What are the Phases of APQP?
The Advanced Product Quality Planning (APQP) process has five phases.
Phase 1: Plan and Define Program
Customer requirements and expectations are emphasized in the Plan and Define Program. This stage’s primary goal is to convey the customer’s voice clearly. The client is taken into consideration while the interdisciplinary team organizes the initial phase of APQP operations. This phase includes tasks such as acquiring information to specify consumer needs and then using that data to establish product attributes.
| Inputs | Outputs |
| Understand the Voice of the customer Market studies Warranty services Team experience Business plan/marketing strategy Product/process Benchmark data Product and process assumptions Product reliability studies Customer details | Design goals Reliability & quality goals preliminary parts list Preliminary process flow chart A preliminary listing of special characteristics Product Quality Assurance plan Management support |
Phase 2: Product Design and Development
The goal of this stage is to complete the product design. The design, reliability, and quality goals developed in the planning phase are given a near-final shape. This phase applies to businesses that design the product, including a full product feasibility analysis. The product quality planning team considers all design elements during the planning stage to guarantee that the final product will meet consumer expectations.
| Inputs | Outputs |
| Design goals Reliability & quality goals preliminary parts list Preliminary process flow chart A preliminary listing of special characteristics Product Quality Assurance plan Management support | Design FMEA (DFMEA) Design for Manufacturing and Assembly (DFMA) Design Test Design Review Prototype Control Plan Technical Drawings Technical Specifications Material Specifications Change Control for Drawings New Equipment, Tooling, and Facilities Requirements Special Product and Process Characteristics Testing Equipment Requirements Team Feasibility Commitment and Gateway approval |
Phase 3: Process Design and Development
Process design and development aims to create and develop the manufacturing process while keeping the product criteria, product quality, and production cost in mind. The method must satisfy expected customer demand while retaining operational effectiveness. The manufacturing procedure needed to create the new or upgraded product is planned in this stage.
| Inputs | Outputs |
| Design FMEA (DFMEA) Design for Manufacturing and Assembly (DFMA) Design Test Design Review Prototype Control Plan Technical Drawings Technical Specifications Material Specifications Change Control for Drawings New Equipment, Tooling, and Facilities Requirements Special Product and Process Characteristics Testing Equipment Requirements Team Feasibility Commitment and Gateway approval | Packaging Standards and Specifications Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process FMEA (PFMEA) Pre-Launch Control Plan Process Instructions Measurement Systems Analysis (MSA) Plan Preliminary Process Capability Plan Gateway Approval |
Phase 4: Validation of Process and Product
The manufacturing process is tested, and a trial run is used to finalize the production control plan, during the process and product phase validation. The product quality planning team ensures that the control plan and process flow chart are rigorously adhered to during the manufacturing trial run procedure. Additionally, they check to see if it guarantees that the created products satisfy the needs of the customer. Additionally, if necessary, adjustments and enhancements are made before going on to the next level.
| Inputs | Outputs |
| Packaging Standards and Specifications Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process FMEA (PFMEA) Pre-Launch Control Plan Process Instructions Measurement Systems Analysis (MSA) Plan Preliminary Process Capability Plan Gateway Approval | Significant Production Run Process Capability Studies Production Part Approval Process (PPAP) Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off and Gateway approval |
Phase 5: Feedback Assessment and Corrective Actions
In this stage, the trial run’s results are examined to guarantee client satisfaction. Results often include an improved production process with fewer deviations, higher product quality and customer service, and increased customer satisfaction. This phase’s main goals are to reduce production variance and provide long-term client satisfaction. Additionally, this stage shows how corrective measures and program course modifications must be used throughout the program to guarantee the timely delivery of a high-quality result.
| Inputs | Outputs |
| Significant Production Run Process Capability Studies Production Part Approval Process (PPAP) Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off and Gateway approval | Reduced Variation Improved Customer Satisfaction Improved Delivery Performance Better documentation |
Conclusion
Advanced Product Quality Planning (APQP) is a structured framework employed by other sectors besides the automotive one. It aids in creating goods and procedures that satisfy client needs and guarantee superior quality. Additionally, APQP increases market competitiveness overall, reduces product and process risks, and increases the likelihood of successful product launches. Professionals may enroll in Certified Core Tools Practitioner Training to learn more about Advanced Product Quality Planning. Professionals get training on the fundamental tools of APQP. Further, it helps to gain knowledge and skills in using APQP tools in practice.
