Advanced Product Quality Planning

APQP is essential to improving the way companies develop products and services. It is a standardized, universally accepted fundamental business strategy. This strategy is applicable to all types of organizations including manufacturing and service companies, schools, hospitals, and governmental agencies. The aim of APQP is to enable the organization to produce products and provide services focused on satisfying customer’s needs, wants, and expectations. Following this standardized approach promotes the integration of design, development and implementation activities with those of suppliers and customers. As a standardized methodology it is recognized as a strategy for meeting the ISO9001: 2015 (Quality Management System Standard) product realization clauses. The IATF16949:2016 (Automotive Industry Quality Management System Standard) goes one step further making APQP a specified requirement. The Automotive Industry Action Group (AIAG) identifies and documents the process for APQP and the related manual is the standard for APQP.

This course provides a basic foundation for implementing and working with the APQP process. The course defines the process, identifies the phases and the key deliverables for each phase. The course is based upon the AIAG defined process and manual. Templates and process steps are explained. In addition to templates and deliverables the course identifies and explains basic Quality tools used in the APQP Process such as Quality Function Deployment (QFD) and Robust Design. A highly interactive case study with appropriate student exercise activities is employed to demonstrate key concepts. Alternatively a company specific case can be employed for in-house seminars.

What Will You Learn

Upon completion of this course participants will be able to:
  • Define the need for Advanced Product Quality Planning (APQP) and describe how APQP sets the stage for all subsequent business activities aimed at creating and producing products/services that consistently meet or exceed customer expectation
  • Identify and the phases of the APQP process.
  • List the key deliverables for each phase of the APQP process and identify how, at a high level to produce the deliverables.
  • Identify when and how to use traditional Quality tools within the APQP process.
  • Introduce the use of Project Management techniques to guide the process.
  • More effectively fulfill their role(s) within their organization’s APQP efforts

Is This Course For You

Any job role that is traditionally involved with the APQP process such as:
  • Product Engineers and Designers
  • Program Managers
  • Manufacturing and Process Development Engineers
  • Quality Personnel
  • Validation Engineers
  • R&D Personnel
  • Department Heads associated with above job roles
  • Senior Management

Materials Provided

This data is not available at this time

Course Requirements

This data is not available at this time

Topics

I. Introductions
  • Instructor
    • Quality and Training Background
  • Students
    • Experience with quality tools (in particular quality planning)
    • Concerns regarding quality
    • Expectations
  • Course Content and Agenda
II. Define the need for APQP and describe how APQP sets the stage for all subsequent business activities aimed at creating and producing products that consistently meet or exceed customer expectations
  • APQP and the Product Development Process
  • Distinguish the "Voice of the Customer" and identify the various levels of customers
  • Identify quality attributes and characteristics
  • Identify the roles of various groups/job functions within the APQP process
  • Recognize how APQP meets quality system requirements
  • Implement APQP within your organization
III. Review the Application of APQP at participant’s organizations. (Participants complete checklist)


IV. The APQP process broken into executable phases or quality gates. (90 minutes)

  • Blending with customer and supplier activities
  • Identify inputs required and deliverables generated for each phase or quality gate
  • Determine the timing for the APQP phases or quality gates and identify the interaction(s)
  • Participants complete activity: Matching activities, inputs and outputs with the phases of APQP
V. Identify when and how and when to use the following tools within the APQP process, to effectively achieve required deliverables:
  • Risk Analysis
  • Team Feasibility Commitment
  • Gathering inputs; S.O.R/S.O.W., Surveys, Lessons Learned
  • Quality Function Deployment (QFD)
  • Benchmarking
  • Concept Design
  • Cause and Effect Diagram
  • Design of Experiment (DOE)
  • Robust Design
  • Flow Charts
  • DFM/DFA
  • Error Proofing
  • Failure Mode Effect Analysis (FMEA)
  • Statistical Process Control (SPC)
  • Concurrent Engineering
  • Lessons Learned Databases (TGW/TGR)
VI. Participants work on case selecting and identifying how and when to use previously discussed Quality Tools

VII. Determine the role of required documentation such as:
  • Process flowcharts
  • Engineering Drawings and other Specifications (Product, Equipment and Tooling)
  • DFMEA and PFMEA
  • Control Plans
  • Bills of Materials
  • PPAP submission package
VIII. Participants work on case selecting and completing examples of previously discussed documents

IX. Use Project Management to guide the APQP Effort
  • Build and follow a basic template
X. Discussion focusing on what was learned and how this knowledge will be applied. If possible member of participant's Management team will present and discuss APQP application at this site