APQP introduction

APQP timing chart and phases

APQP application
APQP sum up & key take aways
Training Outline
PPAP introduction
When is PPAP required?
PPAP submission level
PPAP status
application of PPAP
PPAP sum up & key take aways

2019 1
 What is APQP?
Advanced Product Quality  Advanced Product Quality Planning
Planning Cycle
method to assure that a product satisfies
the customer (both internal and external)
 The goal of APQP is to:
 Plan before acting
 Anticipate and prevent issues
 Validate before moving forward
 Facilitate communication

 Each Advanced Product Quality Plan is unique and is a living document

 Particular emphasis should be placed on identifying critical path activities and

ensuring those are fully resourced

2019 2
 APQP at

• PDP: Product Development Process

• Same approach: Plan, Do, Check,
Act
• Phases: Portfolio, Project proposal,
Feasibility… till Project Closure
• Milestones: scope approval, tech
solution approval…
• Roles and Responsibilities:
deliverables per project function

2019 3
 APQP Background

• Automotive and Non Automotive industries challenges:

• Innovation, product complexity
• Reduce NPD times (Time to Market!)
• Complicated Supply chain (Global presence)
• Increasing customer and quality requirements (Zero Defect!)
• Solution:
• Ford, GM, Chrysler APQP Task Force jointly developed in the late 80’s to standardize their
respective supplier quality systems.
• Continuous Improvement:
• Many industries outside the Automotive industry have embraced the AIAG APQP process to
achieve similar benefits

2019
 APQP – timing chart and phases - AIAG

• The Advanced Product Quality

Planning process consists of
four phases and five major
activities and has some 20+
supporting tools (e.g. DFMEA,
PFMEA, CTQ, Special
Characteristics, Control Plan,
SPC) along with ongoing
feedback assessment and
corrective action.

2019 5
 Phase 1: Plan and Define Program

INPUTS: OUTPUTS:
 Voice of the Customer  Design Goals
 Market Research (ie IHS  Reliability & Quality goals
Markit)  CONC targets
 Historical Warranty and  Preliminary Bill of Materials
Quality Information  Preliminary Process Flow Chart
 Team Experience  Preliminary list of Special
 Business Plan/Marketing Strategy Product and Process
Assure that customer  Product/Process Benchmark Data Characteristics
needs and  Product/Process Assumptions  Product Assurance Plan
expectations are  Product Reliability Studies  Management Support
clearly understood  Customer Inputs
and assessed

* The inputs and outputs applicable to the process may vary according to the
product process and customer needs and expectations. 2019 6
 Phase 2: Product Design and Development

INPUTS: OUTPUTS:

 Design Goals  Design Failure Mode and Effects

 Reliability & Quality goals Analysis (DFMEA)
 Preliminary Bill of Materials  Design For Manufacturability and
 Preliminary Process Flow Assembly
Chart  Design Verification
 Preliminary list of Special  Design Reviews
Product and Process  Prototype Build – Control plan
Develop design into a Characteristics  Engineering Drawings (Including
near final form.  Product Assurance Plan Math Data)
Prototype and  Engineering Specifications
feasibility studies –  Material Specifications
volumes, schedule,  Drawing and Specification
manufacturing. Changes
Cont. next slide
2019 7
Phase 2: Product Design and Development
8

INPUTS: OUTPUTS:

 Design Goals  New Equipment, Tooling and

 Reliability & Quality goals Facilities Requirements
 Preliminary Bill of Materials  Special Product and Process
 Preliminary Process Flow Characteristics
Chart  Gages/Testing Equipment
 Preliminary list of Special Requirements
Product and Process  Team Feasibility Commitment
Develop design into a
Characteristics  Management Support
near final form.
Prototype and  Product Assurance Plan
feasibility studies –
volumes, schedule,
manufacturing.

2019
Phase 3: Process Design and Development
9

INPUTS: OUTPUTS:

• Design Failure Mode and Effects Analysis • Packaging Standards

(DFMEA) • Product/Process Quality System Review
• Design For Manufacturability and • Process Flow Chart
Assembly • Floor Plan Layout
• Design Verification • Characteristics Matrix
• Design Reviews • Process Failure Mode and Effects Analysis
• Prototype Build – Control Plan (PFMEA)
• Engineering Drawings (Including Math • Pre-Launch Control Plan
Data) • Process Instructions
Develop a • Engineering Specifications • Measurement Systems Analysis Plan
manufacturing • Material Specifications • Preliminary Process Capability Study Plan
• Drawing and Specification Changes • Packaging Specifications
system and its • New Equipment, Tooling and Facilities • Management Support
related control plans Requirements
to achieve quality • Special Product and Process
Characteristics
products. • Gages/Testing Equipment Requirements
• Team Feasibility Commitment
• Management Support 2019
Phase 4. Product and Process Validation
10

INPUTS: OUTPUTS:
 Packaging Standards  Measurement Systems Evaluation
 Product/Process Quality System Review  Significant Production Run
 Process Flow Chart  Preliminary Process Capability Study
 Floor Plan Layout  Production Part Approval
 Characteristics Matrix  Production Validation Testing
 Process Failure Mode and Effects  Packaging Evaluation
Analysis (PFMEA)  Production Control Plan
 Pre-Launch Control Plan  Quality Planning Sign-Off - formal
Validate manufacturing  Process Instructions 
process through production Management Support
 Measurement Systems Analysis Plan
trial run.
 Preliminary Process Capability Study
Validate that the control
plan and process flow chart Plan
are effective and that the  Packaging Specifications
product meets customer  Management Support
expectation.

2019
Feedback, Assessment, Corrective actions
11

INPUTS: OUTPUTS:

 Production Trial Run  Reduced Variation

 Measurement Systems  Improved Customer Satisfaction
Evaluation  Improved Delivery and Service
 Preliminary Process Capability  Effective use of best practice,
Study lessons learned
 Production Part Approval  Maximum ROI
 Production Validation Testing  Minimum Waste
Evaluate outputs,  Packaging Evaluation
effectiveness of the  Production Control Plan
product quality  Quality Planning Sign-Off and
planning efforts. Management Support

2019
 Application to Different Mfg. Environments

• High Volume
• APQP plans and activities are organized by part number and are very specific to
the part
• Low Volume
• APQP plans may be specific to part families with activities focused on the parent
part
• More limited validation would be done on child parts
• Family part differences should be understood and higher risk differences
incorporated into APQP plans

2019 12
APQP Summary:
13
What we do: How we do it: What we get:
APQP
• Design Quality • Defect Free Launches
• DFMEA / PFMEA / DFM/A • Reduced Warranty Claims
• Manufacturing Quality UP • Zero Spills
• Control Plans
• Process Flows
FRONT • Customer Satisfaction
• Robust Products
• Measurement System DETAILED
• Greater Supplier Control
Analysis QUALITY • Reduced supplier cost
• Capability Analysis PLANNING
• Process Validation
• Run at rate
• Supplier Qualification & Quality
Requirements
• Product Qualification
• 1st Article Inspection
• PPAP
• Tooling & Gauges
• Testing

Leadership Engagement is Critical

 APQP Benefits:
• Manufacturing process functions that are
clearly planned, validated, documented and
communicated that result in:
• Robust and reliable designs CONC

• Reduced process variation

• Enhanced confidence in supplier’s capabilities

$$ Total Cost of Quality

Redesign
• Better controlled process changes Re-qualifications
Escape Investigations
• Defect free launches
• Improved Customer satisfaction
• Improved Delivery and Service Prevention through APQP
Current state
• Maximum ROI
Time
• Minimum Waste Development Production
• Minimum Cost of Non-conformance
2019 14
 Key Take Aways:

• APQP is cross-functional planning and execution to produce product that

fully meets the customer’s expectations the first time
• AIAG APQP phases are Planning, Product Design, Process Design,
Validation, Production
• Phase approach ensures activities are completed in the appropriate order
• Can be applied to different manufacturing environments – High Volume,
Low Volume
• It’s cross-functional – Marketing/Design/Manufacturing/SCM/Quality

2019
Production Part Approval Process (PPAP)
2019 16
 What is PPAP?

• Production Part Approval Process

• Standard used to formally reduce risks prior to product or service
release, in a team oriented manner using well established tools and
techniques
• Initially developed by AIAG (Auto Industry Action Group) in 1993 with
input from the Big 3 - Ford, Chrysler, and GM
• AIAG’s 4th edition effective June 1, 2006 is the most recent version
• PPAP has now spread to many different industries beyond automotive

2019 17
 PPAP at

• Aligned to AIAG PPAP Manual rev 4

• Requirements set up during Technical Reviews (DPAR Process*)
• Continuous validation approach
• Embedded to our APQP (output of phase 4 – Production Part Approval)

*DPAR: Design, Process & Assembly Review – you can refer to DPAR Training Material for further information
2019 18
 Production Run

• PPAP data must be submitted from a production run using:

• Production equipment and tooling
• Production employees
• Production rate
• Production process

All data shall reflect the actual production process that will be used at start-up!
2019 19
 Purpose of PPAP

• Provide evidence that all customer engineering design record

and specification requirements are properly understood by the
organization
• To demonstrate that the manufacturing process has the potential to
produce product that consistently meets all requirements during an
actual production run at the quoted production rate

2019 20
 When is PPAP Required?

• New part
• Engineering change(s)
• Durable Tooling: transfer, replacement, refurbishment, or additional
• Tooling inactive > one year
• Correction of discrepancy
• Change to optional construction or material
• Sub-supplier or material source change
• Change in part processing
• Parts produced at a new or additional location

PPAP is required with any significant

2019
change to product or process! 21
 Benefits of PPAP Submissions

• Helps to maintain design integrity

• Identifies issues early for resolution
• Reduces warranty charges and prevents cost of poor quality
• Assists with managing supplier changes
• Prevents use of unapproved and nonconforming parts
• Identifies suppliers that need more development
• Improves the overall quality of the product & customer satisfaction

2019 22
PPAP Submission Levels

Production Warrant and Appearance Approval Report (if applicable)

Level 1
submitted

Level 2 Production Warrant, product samples, and dimensional results submitted

Production Warrant, product samples, and complete supporting data

Level 3
submitted

Level 4 Production Warrant and other requirements as defined by

Production Warrant, product samples and complete supporting data (a

Level 5
review will be conducted at the supplier's manufacturing location)

2019 23
PPAP Submission Requirements
Requirement Level 1 Level 2 Level 3 Level 4 Level 5
1.Design Record R S S * R
2.Engineering Change Documents, if any R S S * R
3.Customer Engineering approval, if required R R S * R
4.Design FMEA R R S * R
5.Process Flow Diagrams R R S * R
6.Process FMEA R R S * R
Note: For each level, full
7.Control Plan R R S * R PPAP is required. The
8.Measurement System Analysis studies R R S * R
PPAP level simply
9.Dimensional Results R S S * R
10.Material, Performance Test Results R S S * R indicates which
11.Initial Process Studies R R S * R elements you submit,
12.Qualified Laboratory Documentation R S S * R
13.Appearance Approval Report (AAR), if applicable S S S * R and which you retain at
14.Sample Product R S S * R your site.
15.Master Sample R R R * R
16.Checking Aids R R R * R
17.Records of Compliance With Customer Specific Requirements R R S * R
18.Part Submission Warrant S S S S R
19.Bulk Material Checklist S S S S R

S = The organization shall submit to the customer and retain a copy of records or documentation items at appropriate
locations
R = The organization shall retain at appropriate locations and make available to the customer upon request
* = The organization shall retain at the appropriate location and submit to the customer upon request

2019 24
 PPAP Element 17: Requirements

• Depending on the specific business, may require:

• Measurement Agreement
• Gage Drawing
• Safe Launch Control Plan
• Annual layout
• Special Processes qualification
• Packaging Specification Data Sheet
• Submit Bar Code Label Packaging Approval
• Capacity R@R Worksheet
• MSDS
• …

2019 25
 PPAP Status

• Approved
• The part meets all requirements
• Supplier is authorized to ship production quantities of the part
• Interim Approval
• Permits shipment of part on a limited time or piece quantity basis
• Rejected
• The part does not meet requirements, based on the production lot from which it
was taken and/or accompanying documentation

Production quantities shall not2019

be shipped before Approval + Order! 26
 PPAP Sum up & Take Aways
• PPAP is a result of a good APQP!
• DPAR* is an important activity to determine PPAP expectations!
• Commitment on part and process feasibility
• We plan a good Control Plan: Measurement Agreement on key characteristics
• determines PPAP level based on component risk
• Submission requirements are increased for higher risk components
• Requirements are defined and agreed during DPAR phase
• provides a standard PPAP workbook with all necessary tools
• Supplier can use their own templates and tools if they meet the AIAG requirements
• Let’s be Smart!
• Going through PPAP process as a routine
• Identifying opportunities: Master PFMEA, Master CP…

*: refer to DPAR Training – DPAR = Design Process & Assembly Review

2019 27
Thanks
2019 28