What is APQP?
APQP or Advanced Product Quality Planning is a structured method of defining and establishing the necessary steps to ensure that a product satisfies the customer. Effective product quality planning depends on the commitment of a company's top management to the effort required in meeting customer specifications.
The objectives of APQP
Some of the goals of the Product Quality Planning Fund are…
- Effective communications with all who are involved in the implementation scheme. Timely completion of required goals. No quality minimal problems or. 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 Regeneration 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 Material Account Preliminary Process Flowchart Preliminary Listing of Special Product and Process Features Product Assurance Plan Management Support
Suppliers may consider this phase of APQP equivalent to the design and development planning and design entered into Qs-9000
Product Design & Development
This area encompasses a careful review of product design (engineering) requirements and concludes with a sign-off on design reliability.
Departures by activity responsible for the design.
- Design failure mode and effects analysis Design for fabrication and assembly Design verification Design reviews Prototype build-control plan Engineering drawings (including math data) Engineering specifications Drawing and specification changes.
Departures from advanced product quality planning equipment.
- New equipment, tooling and facilities requirements Consensus on key / critical product and process characteristics Gages / testing equipment requirements Equipment feasibility commission and management support
Process Design & Development
This phase ensures that customer expectations and design requirements are carefully incorporated into the manufacturing process.
Departures:
- Packaging standards Product / process quality system review Floor plan layout Process flow chart Features matrix PFMEA (process failure mode effects analysis) Pre-release control plan Process instructions Measurement system analysis plan Preliminary measurement study plan process capability Packaging specifications Management support
Product And Process Validation
Outputs:
- Production trial performance Measurement system performance analysis Preliminary process capacity study Production Part Approval (PPAP) Production validation test Packaging evaluation Production control plan Quality planning sign-off and support from management
Regeneration, Assessment and Corrective Action
Outputs:
- Reduced variation Customer satisfaction Documentation and service
Advantages of APQP
- Resources are directed toward customer satisfaction. Required changes are early changes identified near or after product launch is avoided. On time delivery of a quality product at the lowest cost.
Management must develop and document a quality policy concerning the degree of service provided.
- The image and reputation of the organization in the domain of quality objectives to improve product quality. Approach to be adopted in the pursuit of quality objectives. The role of company staff in setting the quality policy in action.
Systems Requirements For APQP
Documented procedures implementing the quality policy to
- manage advanced product quality planning activities manage all required elements establish appropriate organizational structures manage necessary technical interfaces meet all customer requirements
Charter of organization in displaying quality manual
- the overall structure of the organization and the hierarchy level the organization of the quality department the organization of each department (optional)
Step 1
Plan and Define the Program - Determining customer needs, requirements and expectations using tools such as QFD Review
the entire quality planning process to enable the implementation of a quality program How to define and set inputs and outputs.
Step 2
Product Design and Development - Review inputs and execute outputs, including FMEA, DFMA, design verification, design reviews, material, and engineering specifications.
Step 3
Process Design and Development - Addressing features for developing
manufacturing systems and related control plans, these tasks are dependent on the successful completion of Phases 1 and 2 implement outputs.
Step 4
Product and Process Validation - Validation of the selected manufacturing process and its control mechanisms through the evaluation of production performance outlining the mandatory production conditions and requirements that identify the required outputs.
Step 5
Release, Feedback, Assessment and on Corrective Action - Focuses reduced variation and continuous improvement identifying outputs and links to customer expectations and future product programs.
Check Plan Methodology
Discusses the use of determining the control plan and the relevant data required to build and control plan parameters stresses the importance of the control plan in the continuous improvement cycle.
