Professional Documents
Culture Documents
Planning (APQP)
Based on the AIAG “Advanced Product
Quality Planning and Control Plan”
Reference Manual
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The AIAG APQP Model
What is APQP?
Advance Product Quality Planning is a structured
method of defining and establishing the steps
necessary to assure that a product satisfies the
customer.
The goal of product quality planning is to facilitate
communication with everyone involved to assure
that all required steps are completed on time.
Effective product quality planning depends on a
company’s top management commitment to the
effort required in achieving customer satisfaction.
Why Product Quality Planning?
The bulk of cost of a product is committed at the early stages
of a development cycle even though they are not expended
until later.
The cost of fixing a design and faulty decisions at later stages
is exponentially greater than at an earlier stage.
The opportunity costs of being late to market are very high,
ex., lower market share, lower margins.
Cross-functional teams typically provide a better quality
solution to complex dynamic product development problems
than single individuals.
Early simultaneous involvement in product development by
cross-functional teams using structured development process
saves time and money over the product life cycle.
Fundamentals of Product
Quality Planning
Organizing the team
Define the scope
Team-to-Team Communication
Training
Customer, supplier and subcontractor
involvement
Simultaneous \ Concurrent Engineering
Control plans
Concern Resolution
Timing plan and chart
Product Quality Planning Chart
Concept Program
Initiation/Approval Approval Prototype Pilot Launch
Planning Planning
Production
Control Plan Number Reference Key Contact/Phone Date (Orig.) Rev. Date (Revised)
Customer
MACHINE,
CHARACTERISTIC METHODS
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE CONTROL REACTION CORRECTIVE
NUMBER DESCRIPTION FOR MFG. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. METHOD PLAN ACTION
TOLERANCE TECHNIQUE Error proofing Other
#1 #1 #2 #3 #4 #5 #6 #7 #8 #9 #10
Control Plan Number Reference Key Contact/Phone Date (Orig.) Rev. Date (Revised)
Customer
MACHINE,
CHARACTERISTIC METHODS
PART/ PROCESS NAME/ DEVICE, SPECIAL
PROCESS OPERATION JIG,TOOLS, CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE CONTROL REACTION CORRECTIVE
NUMBER DESCRIPTION FOR MFG. PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. METHOD PLAN ACTION
TOLERANCE TECHNIQUE Error proofing Other
#1 #1 #2 #3 #4 #5 #6 #7 #8 #9 #10
Outputs
Reduced Variation
Production Customer Satisfaction
Delivery and Service
Feedback Assessment and Corrective Action
Feedback
Assessment and
Corrective Action
Summary:
The AIAG APQP Model
What is APQP?
APQP is a process, not just an event
Integration of quality tools with
management functions
Status Reporting and Program Management
Multi-disciplinary team approach to quality
planning
Satisfies requirement of TS, with linkage to
several ISO/TS 16949:2002 elements
Tool for continuous improvement
Summary:
The 5 Phases of APQP
1.Plan and Define the Program 1.
2.Product Design and Development
2.
3.Process Design and Development
4.Product and Process Validation 3.
5.Feedback, Assessment and 4.
Corrective Action 5.
APQP Acronyms
APQP – Advance Product Quality
Planning
D/P-FMEA – Design/Process Failure Mode
Effect Analysis
DVP&R – Design Verification Plan &
Report
AIAG – Automotive Industry Action
Group
TS 16949 – (Sector-specific) Technical
Specification (for automotive industry)
MSA – Measurement Systems Analysis
I/M/T – Inspection/Measurement/Test
Questions
Related Information
New Product Development and Launch Process
New Process Concept
Development Initiation/Approval
Project Program Ramp to
Start First Silicon Production
Approval Volume
APQP
Planning Planning
Product Design and Development
Process Design and Development and Validation
Product and Application Validation
Production
Feedback Assessment and Corrective Action
APQP and
ISO/TS Applicable ISO/TS 16949 Requirements
16949:2002 Design & Dev. Planning 7.3 (Product) Production & Service Provision 7.5
16949:2002
ISO/TS
7.1 Planning of
Product Realization Monitoring & Measurement of Product
7.2 Customer- 8.2.4
Related Processes
Production Part Approval - 7.3.6.3
Feedback Assessment - 8
1. Design/Development Records R S S • R
-for proprietary components/details R R R • R
-for all other components/details
AIAG PPAP:
R S S • R
2. Engineering Change Documents, if any R S S • R
3. TI Engineering Final Approval R R S • R
4. Design FMEA (or Risk Assessment) R R S • R
Contents 5.
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7.
Process Flow Diagrams
Process FMEA (or Risk Assessment)
Dimensional Results
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and 8.
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Material, Performance Test Results
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Submission 11.
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Qualified Laboratory Documentation
Control Plan
Part submission Warrant (PSW)
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14. Appearance Approval Report, (AAR)
S S S • R
if applicable
15. Bulk Material Requirements Checklist
R R R • R
(for bulk material PPAP only)
16. Sample Product R S S • R
17. Master Sample (See I.2.2.17) R R R • R
Note: the PPAP form and 18. Checking Aids R R R • R
is from the AIAG reference S = The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items
at appropriate locations, including manufacturing.