What is APQP?

APQP or Advanced Product Quality Planning is a structured method of defining and establishing the steps
necessary to ensure that a product satisfies the customer. Effective product quality planning depends on a
company's top management's commitment to the effort required in meeting customer specifications.

The Objectives of APQP

Some of the bottom line goals of product quality planning are...
effective communications with all those who are involved in the implementation scheme.
timely completion of required goals.
minimal or no quality problems.
minimal risks related to quality during product launch.

Phases of APQP
They include...
Plan and define the program
Product design and development
Process design and development
Product and process validation
Feedback assessment and corrective action

Planning and defining the program

This stage is designed to ensure that customer needs and expectations are clearly understood. The input of
this phase is furnished by the contract review for full service suppliers.
Outputs Include
Design goals
Reliability goals
Preliminary bill of material
Preliminary process flow chart
Preliminary listing of special product and process characteristics
Product assurance plan
Management support
Suppliers can consider this phase of APQP equivalent to Design and Development Planning and Design Input
in QS-9000

Product Design and Development

This area encompasses a thorough review of product design (engineering) requirements and concludes with a
sign-off on the design reliability

Outputs by Design Responsible Activity

Design failure mode and effects analysis
Design for manufacturing and assembly
Design verification
Design reviews
Prototype build-control plan
Engineering drawings (including math data)
Engineering specifications
Drawing and specification changes

Outputs by Advanced Product Quality Planning Team

New equipment, tooling and facilities requirements
Consensus on key/critical product and process characteristics?
Gages/testing equipment requirements
Team feasibility commitment and management support

Process Design and Development

This phase ensures that customer expectations and design requirements are carefully incorporated into the
manufacturing process.

Outputs:
Packaging standards
Product/process quality system review
Floor plan layout
Process flow chart
Characteristics matrix
PFMEA (process failure mode effects analysis)
Pre-launch control plan
Process instructions
Measurement system analysis plan
Preliminary process capability study plan
Packaging specifications
Management support

Product and Process Validation

Outputs:
Production trial run
Measurement systems evaluation
Preliminary process capability study
Production Part Approval (PPAP)
Production validation testing
Packaging evaluation
Production control plan
Quality planning sign-off and management support

Feedback, Assessment and Corrective Action

Outputs:
Reduced variation
Customer satisfaction
Documentation and service

Benefits of APQP
Resources are directed towards customer satisfaction.
Required changes are identified early Changes close to or after product launch are avoided.
On time delivery of a quality product at the lowest cost.
The management should develop and document a quality policy relating to grade of service provided
the organization's image and reputation in the domain of quality objectives for improving product quality.
approach to be adopted in the pursuit of quality objectives.
the role of company personnel in implementing quality policy.

Systems Requirements For APQP

Documented Procedures implementing Quality Policy tomanage Advanced Product Quality Planning Activities
address all required elements
establish appropriate organizational structures
manage necessary technical interfaces meet all customer requirements
Organizational Chart in the Quality Manual Displayingthe overall structure of the organization and the level of hierarchy
the organization of the quality department
the organization of each department (optional)