APQP Training Course Outline

• 5 Phases of APQP
  • Phase 1 : Plan and Define Program
  • Phase 2 : Product Design and Development
  • Phase 3 : Process Design and Development
  • Phase 4 : Product and Process Validation
  • Phase 5 : Feedback, Assessment, and Corrective Action

• What is the origin of APQP?
  • Advanced Quality Planning (AQP)
  • AIAG APQP Second Edition

• What is the Relationship to PPAP?

• Section 0 – Inputs required for APQP
  • Voice of the Customer (VOC)
  • Market research
  • Historical issues
  • Team experience
  • Business Plan and Marketing Plan
  • Product and Process Benchmark
  • Product and Process Assumptions
  • Product Reliability Studies
  • Customer Inputs (as applicable)

• Section 1 – Review of Tools and Techniques to Prepare for APQP
  • Design Goals
  • Reliability and Quality Goals
  • Preliminary Bill of material
  • Preliminary Process Flow
  • Preliminary list of Special characteristics
  • Product Assurance Plan
  • Gateway approval

• Section 2 – Design and Develop Tools Review
  • Design Failure Mode and Effects Analysis (DFMEA)
  • Design for Manufacturing and Assembly (DFM/A)
  • Design Verification
  • Design Review
  • Prototype Control Plan
  • Engineering Drawings
  • Engineering Specifications
  • Material Specifications
  • Change Control for Drawings
  • New Equipment, Tooling and Facilities Requirements
  • Special Product and Process Characteristics
  • Gages/Testing Equipment Requirements
  • Team Feasibility Commitment and Gateway Approval

• Section 3 – Process Design and Develop Tools Review
  • Packaging Standards and Specifications
  • Quality System Review
  • Process Flow Chart
  • Floor Plan Layout
  • Characteristics Matrix
  • Process Failure Mode and Effects Analysis (PFMEA)
  • Pre-Launch Control Plan
  • Process Instructions
  • Measurement Systems Analysis (MSA) Plan
  • Preliminary Process Capability Plan
  • Gateway Approval

• Section 4 – Product and Process Validation
  • Significant Production Run
  • MSA Results
  • Process Capability Studies
  • Production Part Approval Process (PPAP)
  • Production Validation Testing
  • Packaging Evaluation
  • Production Control Plan
  • Quality Planning Sign-Off and Gateway Approval

• Section 5 – Feedback Assessment and Continuous Improvement
  • Reduced Variation
  • Improved Customer Satisfaction
  • Improved Delivery Performance
  • Effective Use of Lessons Learned