ADVANCED

PRODUCT QUALITY
PLANNING

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 “QUALITY IS NEVER AN
ACCIDENT,
IT IS ALWAYS THE
RESULT OF INTELLIGENT
EFFORT”.
- John Ruskin
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 RAOD MAP
 What is APQP ?
 Objectives
 Benefits
 QS9000 Requirements
 APQP Phases
 Project Management
 APQP Status Reporting System
 Phase wise Documents Required
 APQP Phase Details
 Process Flow
 FMEA
 Control Plan
 Exercise
 Presentation 3
 WHAT IS APQP ?
 Advanced Product Quality Planning is a
structured method of defining &
establishing the steps necessary to assure
that a product satisfies the customer.

 Effective product quality planning depends

on a company’s top management
commitment to the effort required in achieving
customer satisfaction.

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 OBJECTIVES OF APQP ?

The goals of product quality are

 Effective communication with everyone
involved.
 On-time completion of all required steps.

 Minimal or no quality problems.

 Minimal product launch quality risks.

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 THE BENEFITS OF APQP ?

 Resources are directed towards customer

satisfaction.
 Required changes are identified early.

 Changes close to or after product launch

are avoided.
 A quality product is provided on time at the
lowest cost.

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 QS9000 REQUIREMENTS
4.2 QUALITY SYSTEM
4.2.3.1 APQP
The supplier shall establish & implement an APQP
process. The supplier should convene internal
multidisciplinary teams to prepare for production of new
or changed products. These teams should use appropriate
techniques identified in the APQP reference manual
Team action should include :
Development/finalization of special characteristics.
Development & review of FMEA’s
Establishment of actions to reduce the failure modes with
high RPN.
Development & review of control plans. 7
 APQP PHASES

 Plan & Define the program.

 Product Design & Development.

 Process Design & Development.

 Product & Process Validation

 Feedback assessment & corrective action.

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PRODUCT QUALITY PLANNING CYCLE
PLAN

Feedback assessment &

corrective action

Plan & Define

Product & Process
ACT

validation

DO
Product design &
development

Process design &

development

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STUDY
 PLAN AND DEFINE PROGRAM
This step is basically to determine customers needs and
expectations in order to plan and define a quality program.
All work must be done with customer in mind. Providing
better products and services than the competition. The
early stage of product planning process is designed to
assure that customer needs & expectations are clearly
understood.
PRODUCT DESIGN & DEVELOPMENT
This step deals with the elements of the planning during
which design features & characteristics are developed into
a near final form. The product quality planning team
should consider all design factors in the planning process
even if the design is owned by the customer. This step
include prototype build to verify the product or service10
 PROCESS DESIGN & DEVELOPMENT

This step is basically for developing a manufacturing

system and its related control plans to achieve quality
products.

PRODUCT & PROCESS VARIATION

This step is for validating the manufacturing process
through an evaluation of a production trial run.

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 APQP STATUS REPORTING SYSTEM
Objectives :
To ensure that all program management teams use a
standard method & form for reporting current status
To guarantee that suppliers receive specific system,
subsystem & component objectives on time to support
complete vehicle program objectives.
To facilitate communications between suppliers &
customers, particularly when information, direction or
support is required
To define roles & responsibilities for APQP elements
Purpose :
Reduced miscommunication
Lower costs
Higher quality products 12
Timely delivery of parts
 PROJECT MANAGEMENT
A) Decide upon the program manager :
Ensure that PND are met
Is responsible for resources and organization
Is responsible until product launch
Forms & manage one or more APQP teams

B) Team composition :
Shall be cross functional

C) Team Responsibilities :
Is the product launch steering committee responsible
Works with the program manager to establish PNDs
Determine the extent of required APQP activities
Determines initial risk assessment & feasibility
Demonstrate that all planning requirements are met
Ensure that concerns have been documented
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 PROJECT MANAGEMENT RESPONSIBILITY

 Conducting focus element rating

assessment and GYR assessment on the 23
APQP elements.
 Ensuring that reporting requirements are
met.
(Submission to the customer at all major program
reviews, conduct more frequent reviews as needed,
provide supporting documentation to the customer as
required).
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 GYR
Green : “G” rating given on the PND indicates the
element is complete & meets all quality expectations
Yellow : “Y” rating indicates a need for program
management attention
Red : “R” indicates the program is at risk and requires
immediate management attention

Risk Assessment : The section identifies risk

associated with the supplier & on product. Check the
boxes as appropriate for new sites, new technology or
new processes if applicable, briefly describe other
risks & check the box.

Notice level : Enter the latest Engg.release notice

number associated with the part 15
PIST % : Percentage indices that satisfy
tolerance – Enter the percentage of inspection
points that satisfy tolerance for each build.

PIPC % : Percentage indices that are Process

Capable- Enter the percentage of Ppk indices
process capable for each build.

% PIPC = (How many of them are having Ppk >

1.67 x 100) / No.of SCs

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 PLAN AND DEFINE PROGRAM

1) Sourcing Decision
2) Customer Input Requirements

DESIGN & DEVELOP PRODUCT

1) Design FMEA
2) Design Review
3) Design Verification Plan
4) Subcontractor APQP status
5) New facilities tools & gauges
6) Prototype control plan
7) Prototype builds
8) Engineering drawings and specifications 17
9) Team feasibility commitment
DESIGN AND DEVELOP PROCESS
1) Process flow chart
2) PFMEA
3) MSA
4) Pre- launch control plan
5) Operator process instructions
6) Packaging specifications

DESIGN AND DEVELOP PROCESS

1) Production trial run
2) Preliminary process capability study
3) Production validation testing
4) Production part approval
5) Production control plan
6) Part submission warrant delivery 18
 PLAN AND DEFINE PROGRAM

INPUT
Voice of the customer
• Market research
• Historical warranty and quality information
• Team experience
Business plan/ Marketing strategy

Product/process benchmark data

• Identify the appropriate benchmark
• Understand the reason of gap between your
current status & the benchmark
• Develop a plan
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 PLAN AND DEFINE PROGRAM
INPUT
Product/process assumptions
• There will be assumptions that the product has
certain feature, design or process concepts. These
include technical innovations advanced materials,
reliability assessment and new technology. All
should be utilized as inputs
Product reliability studies
• This type of data considers frequency of repair or
replacement of components within designated
periods of time and the results of long term
reliability/durability tests.
Customer inputs
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 PLAN AND DEFINE PROGRAM
OUTPUT
Design Goals
• Verification of the voice of the customer into
tentative and measurable design objectives
Reliability & quality goals
e.g. Reliability Goals - No safety failures, serviceability,
Quality Goals – PPM, scrap reduction
Preliminary Bill Of Material
• the term should establish a preliminary BOM based
on product/process assumptions & include an early
sub-con list
Preliminary process flow chart
• The anticipated mfg.process should be described
using a process flow chart developed from preliminary 21
BOM & product/process assumptions
 PLAN AND DEFINE PROGRAM
OUTPUT
Preliminary list of special product/process characteristics
The listing could be developed from :
• Product assumptions based on analysis of customer needs
•Identification of reliability goals/requirements
•Identification of special process chess. From the anticipated mfg.
Product assurance plan
•It translates design goals into design requirement
The PQA can be developed in any understandable
format and should include
•Outlining of program requirements
•Identification of reliability, durability & appointment/allocation
goals & or requirements
• Assessment of new technology ,complexity, materials,
application, environmental, packaging, service & mfg.
Requirements or any other factors that may place the program risk. 22
•Development of FMEA
•Development of Preliminary engg. standards requirements
 PRODUCT DESIGN & DEVELOPMENT
OUTPUTS BY DESIGN RESPONSIBLE ACTIVITY

• DFMEA
•Design for manufacturability and assembly –
It is a simultaneous engg. process designed to
optimize the relationship between design
function, manufacturability & ease of
•assembly
Design Verification –
Verifies that the product design meets the customer
requirements derived from the activities of planning
• Design Reviews -
It is cross-functional. It is an effective method to prevent
problems & misunderstandings. It provides mechanism to
monitor progress & report to management 23
 PRODUCT DESIGN & DEVELOPMENT
AT THE MINIMUM IT SHOULD INCLUDE
• Design/functional requirements considerations
•Formal reliability & confidence goals
•Component/subsystem/system duty cycles
•Component simulations & bench test data
•DFMEA
•Review of design for mfg. & assembly effort
•DOE & Assembly variation results
•Test failures
•Design verification process
The major function of design review is the tracking of
design verification process
PROTOTYPE BUILD CONTROL PLAN
• Description of dimensional measurements & material
& functional tests that will occur during prototype build
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ENGINEERING DRAWING
 PRODUCT DESIGN & DEVELOPMENT
• ENGINEERING SPECIFICATIONS
A detail review & understanding of the controlling specs. Will help
the team to identify the functional, durability & appearance
requirements of the subject item. Sample size, frequency,
acceptance criteria of these parameters are generally defined in
the inprocess test section of the engg.specs. Otherwise the
sample size & frequency are to be determined by the supplier &
listed in the control plan

• MATERIAL SPECIFICATIONS

• DRAWING & SPECIFICATIONS CHANGE

In case of such changes the team must ensure that the changes
are promptly communicated & properly documented to all affected
areas.
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 PRODUCT DESIGN & DEVELOPMENT
OUTPUT FROM APQP TEAM
•New equipment, tooling & facilities requirements
(can be identified from DFMEA, PAP, Design reviews)

•Special product & process characteristics

•Gauges/testing equipment requirements`

•Team feasibility commitment & management support

(The team must be satisfied that the proposed design can be
manufactured, assembled, tested, packed & delivered in
sufficient quantity at an acceptable cost to the customer on
schedule)
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 PRODUCT DESIGN & DEVELOPMENT
OUTPUT
• Packaging standards
•Product/process quality system review
(Review of quality system manual for any additional controls & or
procedural changes)
• Process flow chart
• Floor plan layout
(developed & reviewed to determine the acceptability of inspection
points, control charts location, applicability of visual aids, interim
repair stations & storage areas to contain the defective material)
• Characteristic matrix
(It is a recommended analytic technique for displaying the
relationship between process parameters & manufacturing stations)
• PFMEA 27
 PRODUCT & PROCESS VALIDATION
• Production validation testing
It refers to engg.tests that validates product made from production
tools and processes meet engg.requirements`
• Packaging evaluation
All test shipments & test methods must access the protection of
the product from the normal transportation damage & adverse
environment factors

• Production control plan

• Quality planning sign-off & management support

The team should perform its review at the manufacturing location
and co-ordinate a formal sign-off. Review of following items is
required – control plans, process instructions, Gage & test
equipment 28
FEEDBACK, ASSESSMENT & CORRECTIVE ACTION

OUTPUTS

Reduced Variation
Customer satisfaction
Delivery & service

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 PROCESS FLOW
• OPERATION DESCRIPTION

• INCOMING SOURCE OF VARIATION

(Assume that process characteristics are OK and question the raw
material )

• PROCESS FLOW DIAGRAM

• PRODUCT CHARACTERISTICS
( Assume that the incoming raw material is OK question the
process )

• PROCESS CHARACTERISTICS

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 PROCESS FLOW

BENEFITS OF PROCESS FLOW

• Shows entire process at once
•It allows each operation to be questioned
•It exposes sources of variation
•It highlights non-value added steps
•It can be used as a tool in many contexts
•It meets selected QS9000 requirements

It is a first step towards developing a control strategy

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 PROCESS FMEA
Purpose
 Aiding in the objective evaluation of design requirements and
design alternatives.
 Aiding in the initial design for manufacturing and assembly
requirements.
 Providing additional information to aid in the planning of
thorough and efficient design test and development programs.
 Developing a list of potential failure modes ranked according to
their effect on “customers”.
 Providing an open issue format for recommending and tracking
risk reducing actions.
 Providing future reference to aid in analysing field concerns.
Outputs
 A list of potential process/part failure modes
 A list of potential critical & significant characteristics
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 A list of process improvement actions to eliminate or reduce the
frequency of product failure modes
 CONTROL PLAN

 Process analysis
To identify the sources of variation
To initiate appropriate control methods
Supplier should determine the best methods to analyse his process
Fault Tree Analysis
Design of Experiment
Cause & effect diagram
 APQP manual uses the cause and effect diagram model to organize
the various types of processes where the primary grouping are people,
materials, equipment, methods and systems and environment

 APQP manual gives for each grouping an example of a typical

manufacturing and assembly situation with a corresponding control
plan. 33
 CONTROL PLAN
The supplier shall develop control plan at the system, subsystem,
component & or material level for the product supplied

The output of APQP process beyond the development of robust

process is a control plan

The control plans shall be revised or updated when products or

processes differ significantly from those in current production
The supplier shall use a multi-disciplinary approach to develop
control plans
Control plan shall be reviewed and updated as appropriate when any
of the following occurs :
The product is changed
The process is changed
The processes become unstable
The processes become non-capable 34
Inspection method, frequency etc. is revised.
 BENEFITS OF DEVELOPING & IMPLEMENTING
CONTROL PLAN

1) QUALITY
• Reduces the waste & improves the quality of products during
design, mfg. & assembly
• Provides through evaluation of the product & process.
•Identifies process characteristics & help to identify their sources of
variation which cause variation in product characteristics
2) CUSTOMER SATISFACTION
• Control plans focus resources on processes & products related to
characteristics that are important to the customer. The proper
allocation of resources on these major items helps to reduce costs
without sacrificing quality
3) COMMUNICATION
• As a living document the control plan identifies & communicates
changes in the product/process characteristics, control method 35
&
characteristics measurement
 PRODUCT QUALITY TIMING CHART
Concept Program
Approval Prototype Pilot Launch
PLANNING
approval
PLANNING

PRODUCT DESIGN & DEVT.

PROCESS DESIGN & DEVT.

PRODUCT/PROCESS VALIDATION

PRODUCTION

FEEDBACK ASSESSMENT & CORRECTIVE ACTION

Plan & Product Process Product/ Feedback

define design/devt. design/devt. process assessment
program verification verification validation & Corrective
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action