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5 Phases of Advanced Product Quality Planning

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).

Advanced Product Quality Planning

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.

InputsOutputs
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.

InputsOutputs
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. 

InputsOutputs
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.

InputsOutputs
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.

InputsOutputs
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.

Posted in Quality Management

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