APQP

MY LEARNING
APQP (ADVANCED PRODUCT QUALITY PLANNING)
▪ Advanced Product Quality Planning (APQP) is a structured process used in the automotive and manufacturing industries to ensure
that a product meets customer requirements before mass production. It helps in early defect detection, process control, and quality
improvement, reducing risks and ensuring a smooth product launch.

Objectives of APQP
▪ Ensure customer satisfaction by delivering high-quality products.
Identify and mitigate potential risks in design and production.
Establish a systematic approach to product and process development.
Reduce waste, defects, and production costs.
Improve communication between suppliers and manufacturers.

▪ Why is APQP Important?

Reduces product defects and production risks.

Ensures customer satisfaction and regulatory compliance.
Lowers development costs and improves efficiency.
Strengthens supplier and manufacturer collaboration.
PHASES OF APQP
APQP is divided into five phases, ensuring a step-by-step approach from product concept to mass production:
1. Plan & Define Program
• Understanding customer needs and expectations.

• Defining product design goals and quality expectations.

• Conducting feasibility studies and setting project timelines.

Key Deliverables:
Customer Requirements
Product Feasibility Analysis
Initial Risk Assessment
2. PRODUCT DESIGN & DEVELOPMENT
• Developing product design based on customer requirements.

• Conducting DFMEA (Design Failure Mode & Effects Analysis).

• Creating prototypes and performing design validation tests.

• Key Deliverables:
Design FMEA
Engineering Drawings
Prototype Testing Results
DESIGN FAILURE MODE AND EFFECTS ANALYSIS
(DFMEA)
DFMEA (Design Failure Mode and Effects Analysis) is a structured approach to identify potential failures in product design, assess their
impact, and implement preventive actions before production.
Key Elements of DFMEA:
▪ Potential Failure Modes – Possible ways the product design could fail.
Effects of Failure – Impact on functionality, safety, or customer satisfaction.
Causes of Failure – Material selection, design flaws, stress factors, etc.
Severity (S), Occurrence (O), Detection (D) Ratings – Used to calculate Risk Priority Number (RPN).
Recommended Actions – Design improvements to reduce risks.
EXAMPLE OF DFMEA FOR AN AUTOMOTIVE
GEARBOX COMPONENT:
Design Failure Effect of Cause of Recommended
S O D RPN
Function Mode Failure Failure Action
Use stronger alloy,
Transmission Material
Gear Design Tooth Breakage 9 5 4 180 optimize gear
failure fatigue
profile

(RPN = Severity × Occurrence × Detection; Higher RPN = Higher Risk, Requires Action)
3.PROCESS DESIGN & DEVELOPMENT
• Designing the manufacturing process to ensure production feasibility.

• Creating a Process Flow Diagram (PFD) and PFMEA (Process Failure Mode & Effects Analysis).

• Developing a Control Plan to monitor production quality.

▪ Key Deliverables:
Process Flow Diagram
PFMEA
Control Plan
4.PRODUCT AND PROCESS VALIDATION
▪ Both the product and the process are validated through pilot runs and testing to ensure they meet performance
and quality expectations. Adjustments are made based on the feedback from these tests.

Objective of Phase 4 – Product and Process Validation:

To validate:
• That the product design meets all customer expectations.

• That the manufacturing process is capable, stable, and repeatable

 KEY DELIVERABLES IN
PRODUCT & PROCESS VALIDATION:
Deliverable Purpose
Production Trial Run (Pilot Run) Simulates actual production with all final tools, equipment, and operators.
Formal customer approval of parts, ensuring product quality and process
PPAP (Production Part Approval Process)
stability.
Process Capability Studies (Cp, Cpk) Determines if the process consistently produces parts within spec.
Verifies the accuracy and consistency of inspection and measurement
MSA (Measurement System Analysis)
systems.
Initial Process Studies Monitor the process during pilot runs to ensure quality standards.
 EXAMPLE: AUTOMOTIVE GEAR
SHAFT MANUFACTURING
Scenario:
You are launching a gear shaft for a new tractor model.
Steps in Product and Process Validation:
1. Pilot Run:
1. Run 300 parts using production tooling, fixtures, and trained operators.
2. Document actual cycle time, rejection rate, and tooling wear.

2. PPAP Submission:
1. Submit samples along with documentation (like Dimensional Report, Control Plan, PFMEA, MSA, etc.) to
the customer.
3. Process Capability Study (e.g., Shaft Outer Diameter):
1. Measure 30 consecutive parts.
2. Calculate Cp and Cpk; values >1.33 indicate a capable process.

4. MSA Study:
1. Gage R&R to ensure the micrometer used to measure shaft OD is repeatable and reproducible across
different inspectors.
5. Customer Approval:
1. After PPAP approval, customer gives a “Production Go-Ahead.”
 BENEFITS OF PRODUCT & PROCESS
VALIDATION:
• Confirms the process can produce defect-free parts.
• Reduces warranty claims and rework.
• Ensures readiness for mass production.
• Builds customer confidence.
5.FIFTH PHASE OF APQP: FEEDBACK,
ASSESSMENT & CORRECTIVE ACTIO
▪ This is the final phase (Phase 5) of the Advanced Product Quality Planning (APQP) process. It focuses on continuously improving product
quality and process performance through data analysis and customer feedback.
Objectives of Phase 5:
• Monitor product and process performance during actual production.

• Capture customer feedback and field data.

• Identify and implement corrective and preventive actions (CAPA).

• Drive continuous improvement using real-world data.

 KEY ACTIVITIES IN PHASE 5:
Activity Description
Production Monitoring Collect data on defects, scrap, downtime, and customer complaints.
Customer Feedback Analysis Use warranty data, complaints, and customer audits to assess performance.
Implement root cause analysis (e.g., 5 Why, Fishbone Diagram) and take
Corrective Actions (CAPA)
corrective steps.
Quality Audits Internal and external audits (IATF 16949, customer-specific requirements).
Verify if the process remains capable and stable; update control plans and
Process Audits and Reviews
PFMEA.
Lessons Learned Documentation Record learnings to prevent recurrence in future projects.
Continuos Improvement (Kaizen, Six Sigma) Use tools like PDCA, lean methods, and Six Sigma to improve product/process.
 EXAMPLE (TRACTOR GEAR SHAFT
- AFTER SOP):
• Customer Complaint: Field report says gear shaft has excess play after 200 hours of usage.

• Action Taken:
• Analyzed shaft hardness and found it below spec due to inconsistent heat treatment.
• Updated heat treatment SOP and implemented 100% hardness inspection.
• Revised control plan and PFMEA.

• Result: Complaint resolved, and no recurrence in the next 3 months.

Key Deliverables:
• Non-conformance Reports (NCR)

• Root Cause & Corrective Action (RCCA) reports

• Updated FMEA, Control Plan

• Audit Reports

• Improvement Project Reports (if any)

 CORE TOOLS OF APQP
▪ APQP relies on 5 Core Quality Tools to ensure robust planning and execution:
1️⃣ DFMEA (Design Failure Mode & Effects Analysis) – Identifies potential design failures.
2️⃣ PFMEA (Process Failure Mode & Effects Analysis) – Identifies risks in manufacturing.
3️⃣ Control Plan – Ensures consistency in production.
4️⃣ MSA (Measurement System Analysis) – Validates measuring instruments.
5️⃣ SPC (Statistical Process Control) – Monitors process stability .
PROCESS FLOW DIAGRAM (PFD)
A Process Flow Diagram (PFD) is a visual representation of the step-by-step sequence of a manufacturing process. It helps identify key
operations, material flow, and inspection points.
Key Elements of PFD:
▪ Process Steps – Sequential stages of production.
Material Flow – How raw materials move through the process.
Inspection & Testing Points – Quality control steps.
Inputs & Outputs – Materials used and finished products.
EXAMPLE OF PFD STEPS FOR A MACHINING
PROCESS:
▪ 1️⃣ Raw Material Incoming Inspection
2️⃣ Cutting & Shaping
3️⃣ Heat Treatment
4️⃣ Machining (Drilling, Milling, etc.)
5️⃣ Surface Treatment
6️⃣ Assembly
7️⃣ Final Inspection
8️⃣ Packing & Dispatch
PROCESS FAILURE MODE AND EFFECTS
ANALYSIS (PFMEA)
PFMEA (Process Failure Mode and Effects Analysis) is a risk assessment tool used to identify potential failures in a manufacturing process,
their causes, and their effects. It helps in preventive action planning.
Key Elements of PFMEA:
▪ Process Steps – Based on the Process Flow Diagram.
Potential Failure Modes – How the process might fail.
Effects of Failure – Impact on quality and production.
Causes of Failure – Root causes like material issues, machine errors, human mistakes, etc.
Severity (S), Occurrence (O), Detection (D) Ratings – Used to calculate Risk Priority Number (RPN).
Recommended Actions – Preventive measures to reduce risk.
EXAMPLE OF PFMEA FOR DRILLING PROCESS:

Process Failure Effect of Cause of

S O D RPN Action Plan
Step Mode Failure Failure
Hole out Change drill
Assembly Worn-out
Drilling of 7 5 6 210 bit
issues drill bit
tolerance periodically

(RPN = Severity × Occurrence × Detection; Higher RPN = Higher Risk, Requires Action)
CONTROL PLAN
A Control Plan is a structured document outlining how to monitor and control the manufacturing process to ensure quality standards are met. It
includes inspection methods, control limits, and corrective actions.
Key Elements of a Control Plan:
▪ Process Steps – Taken from PFD.
Key Characteristics – Critical dimensions, tolerances, material properties.
Measurement Methods – Inspection tools like calipers, micrometers, CMM (Coordinate Measuring Machine).
Control Methods – How to monitor and maintain process stability.
Reaction Plan – Actions to take if defects or deviations occur.
EXAMPLE OF A CONTROL PLAN FOR A
MACHINING PROCESS
Measurement
Process Step Key Characteristic Control Method Reaction Plan
Method
Hole Diameter Rework if out of
Drilling Vernier Caliper 100% Inspection
(Ø10±0.1mm) tolerance
PRODUCT & PROCESS VALIDATION
• Conducting trial production runs and verifying process capability.

• Performing PPAP (Production Part Approval Process).

• Ensuring Statistical Process Control (SPC) for consistent production quality.

▪ Key Deliverables:
Initial Production Run
Process Capability Study
PPAP Submission
PRODUCTION, FEEDBACK & CONTINUOUS
IMPROVEMENT
• Monitoring production performance and implementing improvements.

• Conducting customer feedback analysis and addressing quality issues.

• Implementing Corrective Actions for continuous improvement.

▪ Key Deliverables:
Ongoing Process Monitoring
Customer Feedback & Corrective Actions
Continuous Improvement Initiatives
MSA (MEASUREMENT SYSTEM ANALYSIS)
Purpose: Evaluates the accuracy, repeatability, and reliability of measurement systems.
Key Focus:
Gauge R&R (Repeatability & Reproducibility)
Calibration & accuracy of instruments
Operator influence on measurement variation
Ensuring data reliability for decision-making
Example:
• Instrument: Vernier Caliper

• Test: Gauge R&R Study

• Result: Acceptable variation within limits

SPC (STATISTICAL PROCESS CONTROL)
Purpose: Uses statistical techniques to monitor and control process stability.
Key Focus:
Control charts (X̄-R, P-charts)
Process capability (Cp, Cpk)
Trend analysis to detect process variations
Preventive action before defects occur
Example:
• Process: CNC Machining

• Control Chart: X̄-R Chart to monitor hole diameter

• Observation: Process is stable within tolerance limits

SUMMARY OF 5 CORE TOOLS
Tool Purpose Focus Area
DFMEA Prevent design failures Product design risks
PFMEA Prevent process failures Manufacturing risks
Control Plan Ensure process consistency Inspection & control methods
Accuracy & repeatability of
MSA Validate measurement systems
measurements
SPC Monitor process stability Control charts & process capability

These tools work together to ensure high-quality production, reduce defects, and improve efficiency