APQP Archives | ¿Û¿Û´«Ã½ The design Experts Tue, 13 Feb 2024 08:24:02 +0000 en-US hourly 1 Stages in a Robust APQP Process /blog/stages-in-a-robust-apqp-process/ Thu, 09 Sep 2021 09:38:22 +0000 https://enventure.com/?p=19008 The APQP process consists of five stages: The flow of stages involved in the APQP are such that the output of one stage acts as

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]]> The APQP process consists of five stages: The flow of stages involved in the APQP are such that the output of one stage acts as input of subsequent stage. null
  • Planning
  • Product Design and Development
  • Process Design and Development
  • Product and Process Validation
  • Feedback and Continuous Improvement

Stage 1: Planning

In this stage supplier understanding the customer requirements and expectations. APQP Stage 1 - Planning
Input
Output
Voice of Customer
  • Market research
  • Historical warranty and quality information
  • Team experience
 Design goals
Business plan/marketing strategy Reliability and quality goals
Product/process benchmark data Preliminary Bills of Materials
Product reliability studies Preliminary listing of special products and process characteristics
Customer inputs Product assurance plan
Management support

Stage 2: Product Design and Development

Stage 2 verifies design feasibility and compliance. APQP Stage 2 - Product Design and Development
Inputs (from Stage 1 outputs)
Output
Design goals Design failure mode and effects analysis (DFMEA)
Reliability and quality goals Design for manufacturability and assembly
Preliminary bill of materials Design verification
Preliminary process flow chart Design reviews
Preliminary listing of special products and process characteristics Design reviews
Product assurance plan Engineering drawings (including math drawing)
Management support Material specifications
Drawing and specification changes

Stage 3: Process Design and Development

Stage 3 verifies the manufacturing capability and measurement methods. APQP Stage 3 - Process Design
Inputs (from Phase 2 outputs)
Outputs
Design failure mode and effects analysis (DFMEA) Packaging standards and specifications
Design for manufacturability and assembly Product/process quality system review
Design verification Process flow chart
Design reviews Floor plan layout
Prototype build – control plan Characteristics matrix
Engineering drawings (including math drawing) Process failure mode and effects analysis (PFMEA)
Material specifications Process instructions
Drawing and specification changes Measurement systems analysis plan
Preliminary process capability study plan
Management support (including operator staffing and training plan)

Stage 4: Product and Process Validation

Stage 4 validates the complete manufacturing process and final product. APQP Stage 4 - Product and Process Validation
Inputs (from Phase 3 outputs)
Outputs
Packaging standards and specifications Significant production run
Product/process quality system review Measurement systems evaluation
Process flow chart Preliminary process capability study
Floor plan layout Production part approval
Characteristics matrix Production validation testing
Process failure mode and effects analysis (PFMEA) Packaging evaluation
Process instructions Product control plan
Measurement systems analysis plan Quality planning sign-off and management support
Preliminary process capability study plan
Management support (including operator staffing and training plan)

Stage 5: Feedback and Continuous Improvement

Stage 5 closes the feedback loop. APQP Stage 5 - Feedback and Continuous Improvement
Inputs (from Phase 4 outputs)
Outputs
Significant production run Reduced variation
Measurement systems evaluation Improved customer satisfaction
Preliminary process capability study Improved delivery and service
Production part approval Effective use of lessons learned
Production validation testing
Packaging evaluation
Control plan
Part submission warrant
Quality planning sign-off and management support
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]]> Enhance PPAP with Advanced Product Quality Planning (APQP) /blog/enhance-ppap-with-advanced-product-quality-planning-apqp/ Sun, 01 Aug 2021 15:41:31 +0000 https://enventure.com/?p=18992 Understanding the needs, requirements and expectations of the customer is what Advanced Products Quality Planning (APQP) is all about. APQP helps in mitigating the risk

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]]> Understanding the needs, requirements and expectations of the customer is what Advanced Products Quality Planning (APQP) is all about. APQP helps in mitigating the risk involved in the product manufacturing and quality improvisation of the product hence making way for efficient and profitable business.

In the 1980s automotive giants such as General Motors (GM), Chrysler and Ford majorly implemented APQP. After realizing the benefits of APQP in their organizations they came together to form a common platform and standardized the entire APQP process in supply chain.

What is APQP?

The complexity involved in building an automotive product increases the occurrence of errors in the manufacturing process. Taking manufacturing of vehicle as an example – producing a vehicle includes thousands of parts; way from small screws to big frames. Each of these parts may not have been built by single manufacturer. In order to ensure the quality throughout the supply chain there should be a well-built monitoring methodology and APQP is such methodology, which facilitates the minimization of errors.

APQP is a set of procedures that documents the capability, reliability & repeatability of the process throughout the risk assessment.

APQP along with , FMEA, MSA and SPC forms five core tools, which ensures the streamlined quality management system throughout the IATF 16949 adhering industries.

When is APQP necessary?

APQP is required to develop/introduce a new product when the OEM and its suppliers are working together. APQP can be used while modifying the product or process changes after release.

What is the purpose of APQP?

  • To provide guideline designed to produce a product quality plan
  • Supports development of a product that satisfies requirements of the customer
  • Reduction of complexity of product development planning
  • Easy communication of product quality planning requirements to suppliers

The Cross Functional Team (CFT) takes care of APQP process implementation in any organization. APQP usually consists of members from Engineering, Product Development, Operation, Purchasing, Marketing and other functions with a team lead.

Benefits of APQP
  • Better quality product through collaboration
  • Catch risks earlier in the lifecycle to minimize delays
  • Consistent production runs with better lead times
  • Validation ensures product conformity across multiple suppliers
  • Suppliers are given better direction and expectations before cutting metal
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