Training Material on APQPCP

Q Nathan & Nathan Consultants Pvt. Ltd.,

COURSE MATERIAL

ON

ADVANCED PRODUCT QUALITY PLANNING &

CONTROL PLAN
(APQP & CP)

No 41, Old No:730, First Main Road, Vayalikaval Extension,

Aramanae Nagar,
Bangalore 560 003
Ph: 080-23463193 / 23445235, Fax: 080-41138109
Email: rcnathan@blr.vsnl.net.in

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ADVANCED PRODUCT QUALITY PLANNING AND

CONTROL PLAN (APQP & CP)

• A P Q P STANDS FOR ADVANCED PRODUCT QUALITY PLANNING

• BIG THREE HAS PUBLISHED A MANUAL ON APQP

• THIS IS TO SERVE AS A GUIDELINE FOR CONSISTENT APPROACH TO ALL

USERS.

ISO/TS 16949 REFERS TO APQP IN THE FOLLOWING CLAUSES:

SL.NO. CLAUSE NO. DESCRIPTION

1. 7.1 PLANNING OF PRODUCT REALIZATION

2. 7.2.2.2 ORGANIZATION MANUFACTURING
FEASIBILITY
3 7.3 PRODUCT DESIGN AND DEVELOPMENT
4. 7.3.1.1 MULTI DISCIPLINARY APPROACH

CONTENTS OF A P Q P

1. PLAN AND DEFINE PROGRAM

2. PRODUCT DESIGN AND DEVELOPMENT PROGRAM
3. PROCESS DESIGN AND DEVELOPMENT PROGRAM
4. PRODUCT AND PROCESS VALIDATION PROGRAM
5. FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION
6. CONTROL PLAN METHODOLOGY

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PHILOSOPHY:

- SPEND A LITTLE EXTRA TIME UPSTREAM, SO THAT LIFE

DOWNSTREAM IS ERROR FREE

- HOW YOU SPEND THE TIME IS VERY IMPORTANT

ELEMENTS OF GOOD PLANNING:

• COMMITMENT
• TRAINING
• TEAMWORK
• LOGICAL METHODOLOGY ROBUST DESIGN
• SOUND TECHNIQUES
• DOCUMENTATION
• COMMUNICATION
• FEEDBACK

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1.0 PLAN AND DEFINE PROGRAM

INPUTS

• VOICE OF THE CUSTOMER

- MARKET RESEACH (INCLUDING OEM VEHICLE BUILD TIMING AND OEM

VOLUME EXPECTATIONS)
- HISTORICAL WARRANTY AND QUALITY INFORMATION
- TEAM EXPERIENCE

• BUSINESS PLAN / MARKETING STRATEGY

• PRODUCT / PROCESS BENCHMARK DATA
• PRODUCT / PROCESS ASSUMPTIONS
• PRODUCT RELIABILITY
• CUSTOMER INPUTS

OUTPUTS (BECOMING INPUTS FOR SECTION 2.0)

• DESIGN GOALS
• RELIABILITY AND QUALITY GOALS
• PRELIMINARY BILL OF MATERIAL
• PRELIMINARY PROCESS FLOW CHART
• PRELIMINARY LISTING OF SPECIAL PRODUCT AND PROCESS
CHARACTERISTICS
• PRODUCT ASSURANCE PLAN
• MANAGEMENT SUPPORT (INCLUDING PROGRAM TIMING AND PLANNING
FOR RESOURCES AND STAFFING TO SUPPORT REQUIRED CAPACITY)

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2.0 PRODUCT DESIGN AND DEVELOPMENT

INPUTS (DERIVED FROM THE OUTPUTS OF SECTION 1.0)

• DESIGN GOALS
• RELIABILITY AND QUALITY GOALS
• PRELIMINARY BILL OF MATERIAL
• PRELIMINARY PROCESS FLOW CHART
• PRELIMINARY LISTING OF SPECIAL PRODUCT AND PROCESS
CHARACTERISTICS
• PRODUCT ASSURANCE PLAN
• MANAGEMENT SUPPORT (INCLUDING PROGRAM TIMING AND PLANNING
FOR RESOURCES AND STAFFING TO SUPPORT REQUIRED CAPACITY)

OUTPUTS BY DESIGN RESPONSIBLE ACTIVITY (BECOME INPUTS FOR

SECTION 3.0)

• DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA)

• DESIGN FOR MANUFACTURIBILITY AND ASSEMBLY
• DESIGN VERIFICATION
• DESIGN REVIEWS
• PROTOTYPE BUILD – CONTROL PLAN
• ENGINEERING DRAWINGS (INCLUDING MATH DATA)
• ENGINEERING SPECIFICATIONS
• MATERIAL SPECIFICATIONS
• DRAWING AND SPECIFICATION CHANGES

OUTPUTS BY PRODUCT QUALITY PLANNING TEAM (BECOMES INPUTS FOR

SECTION 3.0)

• NEW EQUIPMENT TOOLING AND FACILITIES REQUIREMENTS

• SPECIAL PRODUCT AND PROCESS CHARACTERISTICS
• GAGES / TESTING EQUIPMENT REQUIREMENT
• TEAM FEASIBILITY COMMITMENT AND MANAGEMENT SUPPORT

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3.0 PROCESS DESIGN AND DEVELOPMENT

INPUTS (DERIVED FROM THE OUTPUTS OF SECTION 2.0)

• DESIGN FAILURE MODE AND EFFECTS ANALYSIS (DFMEA)

• DESIGN FOR MANUFACTURIBILITY AND ASSEMBLY
• DESIGN VERIFICATION
• DESIGN REVIEWS
• PROTOTYPE BUILD – CONTROL PLAN
• ENGINEERING DRAWINGS (INCLUDING MATH DATA)
• ENGINEERING SPECIFICATIONS
• MATERIAL SPECIFICATIONS
• DRAWING AND SPECIFICATION CHANGES
• NEW EQUIPMENT TOOLING AND FACILITIES REQUIREMENTS
• SPECIAL PRODUCT AND PROCESS CHARACTERISTICS
• GAGES / TESTING EQUIPMENT REQUIREMENT
• CUSTOMER REQUIREMENTS IF ANY
• TEAM FEASIBILITY COMMITMENT AND MANAGEMENT SUPPORT

OUTPUTS (BECOME INPUTS FOR SECTION 4.0)

• PACKAGING STANDARDS
• PRODUCT PROCESS QUALITY SYSTEM REVIEW
• PROCESS FLOW CHART
• FLOOR PLAN LAYOUT
• CHARACTERISTICS MATRIX
• PROCESS FAILURE MODE AND EFFECTS ANALYSIS (PFMEA)
• PRE-LAUNCH CONTROL PLAN
• PROCESS INSTRUCTION
• MEASUREMENT SYSTEMS ANALYSIS PLAN
• PRELIMINARY PROCESS CAPABILITY STUDY PLAN
• PACKAGING SPECIFICATION
• MANAGEMENT SUPPORT (INCLUDING OPERATOR STAFFING AND
TRAINING PLAN)

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4.0 PRODUCT AND PROCESS VALIDATION

INPUTS (DERIVED FROM THE OUTPUTS OF SECTION 3.0)

• PACKAGING STANDARDS
• PRODUCT PROCESS QUALITY SYSTEM REVIEW
• PROCESS FLOW CHART
• FLOOR PLAN LAYOUT
• CHARACTERISTICS MATRIX
• PROCESS FAILURE MODE AND EFFECTS ANALYSIS (PFMEA)
• PRE-LAUNCH CONTROL PLAN
• PROCESS INSTRUCTION
• MEASUREMENT SYSTEMS ANALYSIS PLAN
• PRELIMINARY PROCESS CAPABILITY STUDY PLAN
• PACKAGING SPECIFICATION
• MANAGEMENT SUPPORT (INCLUDING OPERATOR STAFFING AND
TRAINING PLAN)

OUTPUTS (BECOME INPUTS FOR SECTION 5.0)

• SIGNIFICANT PRODUCTION RUN

• MEASUREMENT SYSTEMS EVALUATION
• PRELIMINARY PROCESS CAPABILITY STUDY
• PRODUCTION PART APPROVAL
• PRODUCTION VALIDATION TESTING
• PACKAGING EVALUATION
• PRODUCTION CONTROL PLAN
• QUALITY PLANNING SIGN-OFF AND MANAGEMENT SUPPORT

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5.0 FEEDBACK, ASSESSMENT AND CORRECTIVE ACTION

INPUTS (DERIVED FROM THE OUTPUTS OF SECTION 4.0)

• SIGNIFICANT PRODUCTION RUN

• MEASUREMENT SYSTEMS EVALUATION
• PRELIMINARY PROCESS CAPABILITY STUDY
• PRODUCTION PART APPROVAL
• PRODUCTION VALIDATION TESTING
• PACKAGING EVALUATION
• PRODUCTION CONTROL PLAN
• QUALITY PLANNING SIGN-OFF AND MANAGEMENT SUPPORT

OUTPUTS

• REDUCED VARIATION
• CUSTOMER SATISFACTION
• DELIVERY AND SERVICE
• EFFECTIVE USE OF LESSONS LEARNT / BEST PRACTICES

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CONTROL PLANS

• THIS IS A DESCRIPTION OF SYSTEMS FOR CONTROLLING PARTS AND

PROCESSESS.

• A SINGLE CONTROL PLAN MAY APPLY TO A GROUP OR FAMILY OF

PRODUCTS THAT ARE PRODUCED BY THE SAME PROCESS

• PREPARED FOR EACH PHASE OF THE PROCESS INCLUDING INCOMING,

IN-PROCESS, FINAL AND PRODUCT AUDIT REQUIREMENTS TO ASSURE
THAT ALL PROCESS OUTPUTS IN A STATE OF CONTROL.

• PREPARED BY A MULTI-DISCIPLINARY TEAM

• PROVISION FOR CUSTOMER APPROVAL.

• REFER SPC REQUIREMENTS, MISTAKE PROOFING AS CONTROL

METHODS.

• PREPARED FOR THREE DISTINCT PHASES

- PROTOTYPE
- PRE-LAUNCH
- PRODUCTION

• CONTROLSHALL BE DERIVED FROM THE OUTCOME OF PROCESS FMEA

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• THE DOCUMENT SHALL BE REVIEWED & UPDATED – WHEN PROCESS IS

CHANGED, UNSTABLE OR NOT CAPABLE.

• DESCRIBE THE CONTROLS REQUIRED ON PRODUCT AS WELL AS

PROCESS CHARACTERISTICS

• IDENTIFY SPECIAL CHARACTERISTICS

(ALL SPECIAL CHARACTERISTICS MUST BE LISTED IN CONTROL PLAN)

• IDENTIFY THE MEASUREMENT PROCESS

• SPECIFY THE CORRECTIVE ACTION REQUIRED, WHENEVER THE

PROCESS GOES OUT OF CONTROL, SPECIFY THE PEOPLE RESPONSIBLE
TO CARRY OUT THIS.

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CONTROL PLAN METHODOLOGY

A) GENERAL DATA

1. CONTROL PLAN NUMBER

2. ISSUE DATE, & REVISION DATE IF ANY

3. CUSTOMER INFORMATION (SEE CUSTOMER REQUIREMENTS)

4. ORGANIZATION’S NAME / SITE DESIGNATION

5. PART NUMBER (S)

6. PART NAME / DESCRIPTION

7. ENGINEERING CHANGE LEVEL

8. PHASE COVERED (PROTOTYPE, PRE-LAUNCH, PRODUCTION)

9. KEY CONTACT

10. PART/PROCESS STEP NUMBER

11. PROCESS NAME / OPERATION DESCRIPTION

B) PRODUCT CONTROL

12. PRODUCT RELATED SPECIAL CHARACTERISTICS

13. OTHER CHARACTERISTICS FOR CONTROL (NUMBER, PRODUCT

OR PROCESS)

14. SPECIFICATION / TOLERANCE

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C) PROCESS CONTROL

15. PROCESS PARAMETERS

16. PROCESS – RELATED SPECIAL CHARACTERISTICS

17. MACHINES, JIGS, FIXTURES, TOOLS FOR MANUFACTURING

D) METHODS

18) EVALUATION MEASUREMENT TECHNIQUE

19) ERROR – PROOFING

20) SAMPLE SIZE AND FREQUENCY

21) CONTROL METHOD

E) REACTION PLAN & CORRECTIVE ACTIONS

22) REACTION PLAN (INCLUDE OR REFERENCE)

23) CORRECTIVE ACTION

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RISK ASSESSMENT CHECK LIST YES NO

1) Quality History

¾ Does the Organization have a history of high warranty or Things Gone

Wrong (TGWs) on current model or surrogate product?

¾ Are there frequent Quality Rejects (QRs) and/or campaigns at the

receiving plant?

¾ Was there a recall action due to a similar component or system?

2) Organization Profile

¾ Is it a new Organization or new manufacturing location?

¾ Is the product or manufacturing technology new to the Organization

Manufacturing location?

¾ Is the Organization’s historic launch performance poor?

¾ Are the Organization’s resources stretched due to significant amount of

new business?

¾ Is the Organization location under Q-1 probation?

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RISK ASSESSMENT CHECK LIST YES NO

3) Engineering Profile

¾ Is it a new design?

¾ Are the manufacturing techniques new to the industry?

¾ Are similar products subject to numerous design changes that

threaten program timing?

¾ Is there high product or process complexity?

¾ Is the product strategically important due to high visibility or

functional performance?

4) Performance versus Targets

¾ Will the design goals (weight, materials, functional performance,

etc.) and Reliability goals be difficult to achieve?

¾ Will the quality goals (warranty, TGW, scrap rates, rework rates,
etc.) be difficult to achieve?

¾ Is the program timing compressed?

¾ Are the cost targets aggressive?

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TEAM FEASIBILITY COMMITMENT

Date: ____________________

Customer Part Name

Part Number

Feasibility Considerations

Our product quality planning team has considered the following questions, not intended to be all-inclusive in
performing a feasibility evaluation. The drawings and/or specifications provided have been used as a basis for
analyzing the ability to meet all specified requirements. All “NO” answers are supported with attached comments
identifying our concerns and/or proposed changes to enable us to meet the specified requirements.

YES NO CONSIDERATION
Is product adequately defined (application requirements, etc.) to enable
feasibility evaluation?
Can Engineering Performance Specifications be met as written?
Can product be manufactured to tolerances specified on drawing?
Can product be manufactured with Cpk’s that meet requirements?
Is there adequate capacity to produce product?
Can the product be manufactured without incurring any unusual:
‰ Costs for capital equipment?
‰ Costs for tooling?
‰ Alternative manufacturing methods?
Is statistical process control required on product?
Is statistical process control presently used on similar products?
Where statistical process control is used on similar products:
‰ Are the processes in control and stable?
‰ Are Cpk’s greater than 1.33?

Conclusion
Feasible Product can be produced as specified with no revisions

Feasible Changes recommended (see attached).

Design revision required to produce product within the specified
Not Feasible
requirements.

Sign – Off

Team Member/Title/Date Team Member/Title/Date

Team Member/Title/Date Team Member/Title/Date

Team Member/Title/Date Team Member/Title/Date

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QUALITY PLANNING SUMMARY AND SIGN-OFF

DATE: ___________________
PRODUCT NAME PART NUMBER
CUSTOMER MANUFACTURING PLANT

1. PRELIMINARY PROCESS CAPABILITY

STUDY:
QUANTITY
REQUIRED ACCEPTABLE PENDING*
Ppk – SPECIAL CHARACTERISTICS

2. CONTROL PLAN APPROVAL (If Required) APPROVED: YES/NO* DATE APPROVED:

3. INITIAL PRODUCTION SAMPLES

CHARACTERISTIC CATEGORY
QUANTITY
CHARACTERISTI
SAMPLES
CS PER SAMPLE
ACCEPTABLE PENDING*
DIMENSIONAL
VISUAL
LABORATORY
PERFORMANCE

4. GAUGE & TEST EQUIPMENT

MEASUREMENT SYSTEM ANALYSIS
QUANTITY
REQUIRED ACCEPTABLE PENDING*
SPECIAL CHARACTERISTIC

5. PROCESS MONITORING QUANTITY

REQUIRED ACCEPTABLE PENDING*
PROCESS MONITORING
INSTRUCTIONS
PROCESS SHEETS
VISUAL AIDS

6. PACKAGING / SHIPPING QUANTITY

REQUIRED ACCEPTABLE PENDING*
PACKING APPROVAL
SHIPPING TRIALS
7. SIGN-OFF

Team Member/Title/Date Team Member/Title/Date

Team Member/Title/Date Team Member/Title/Date

Team Member/Title/Date Team Member/Title/Date

*REQUIRES PREPARATION OF AN ACTION PLAN TO TRACK PROGRESS

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PRODUCT QUALITY PLANNING SUMMARY AND SIGN-OFF

INSTRUCTIONS:

1. Under “required”, for each item indicate the number of characteristics required.

Under “acceptable”, for each item indicate the quantity that was accepted per Chrysler, Ford and
General Motors Production Part Approval Process manual or customer requirements.

Under “pending”, for each item indicate the quantity not accepted. Attach action plan for each item.

2. Indicate if control plan has been approved by the customer (if required) by circling ‘Yes’ or ‘No’. If
Yes, indicate date approved. If No, attach action plan.

3. Under “samples”, indicate the quantity of samples inspected for each item.

Under “Characteristics per sample”, for each item indicate the number of characteristics inspected on
each sample for each category.

Under “acceptable”, for each item indicate the quantity of characteristics acceptable on all samples.

Under “pending”, for each item indicate the quantity of characteristics not accepted. Attach action
plan for each item.

4. Under “required”, for each item indicate the number of characteristics required.

Under “acceptable”, for each item indicate the quantity acceptable per Chrysler, Ford and General
Motors Measurement Systems Analysis Reference Manual.

Under “pending”, for each item indicate quantity not accepted. Attach action plan for each item.

5. Under “required”, for each item indicate the quantity required.

Under “acceptable”, for each item indicate the quantity accepted.

Under “pending”, for each item indicate quantity not accepted. Attach action plan for each item.

6. Under “required”, for each item indicate ‘yes’ or ‘no’ to indicate if item is required.

Under “acceptable”, for each item indicate ‘yes’ or ‘no’ to indicate acceptance.

Under “pending”, if answer under “acceptable” is ‘no’ – attach action plan.

7. Each team member should sign form and indicate title and date of signature.

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CONTROL PLAN
Prototype Pre-launch Production Key Contact / Phone Date (Org.) Date (Rev.)
Control Plan Number
Part Number / Latest Change Level Core Team Customer Engg. Approval/Date (if Reqd.)

Part Name / Description Supplier / Plant Approval Date Customer Quality Approval / Date (if reqd.)

Supplier / Plant Supplier Code Other Approval Date (if reqd.) Other Approval Date (if reqd.)

Part/ Process Name / Machine, Characteristics Special Methods Reactio

Process Operation Description Device, No. Product Process Char. Product/Process Evaluation Sample Control n Plan
Number Jig. Tools specification / Measurement Size Freq Method & CA
For Mfg. Tolerance Technique . (Indicate
Error
Proofing
Methods)

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