APQP: the 5 phases of advanced product quality planning
APQP (Advanced Product Quality Planning) is a structured project method for developing a product and its manufacturing process so that they meet customer requirements from the very start of production. Its core is early, team-based risk management: problems should be prevented during planning rather than sorted out on the shop floor. The outputs of APQP form the content of the PPAP submission.
The 5 phases and their main outputs
| Phase | Main outputs |
|---|---|
| 1. Plan and define program | design goals, reliability and quality goals, preliminary bill of materials and process flow, preliminary list of special characteristics, product assurance plan |
| 2. Product design and development | DFMEA, design for manufacturing and assembly, design verification and reviews, prototype control plan, drawings and specifications, tooling and equipment requirements |
| 3. Process design and development | packaging standards, process flow chart, floor plan layout, PFMEA, pre-launch control plan, work instructions, MSA plan, preliminary capability study plan |
| 4. Product and process validation | significant production run, MSA evaluation, preliminary process capability, PPAP, production validation testing, production control plan, quality planning sign-off |
| 5. Feedback, assessment and corrective action | reduced variation, customer satisfaction, delivery and service performance, lessons learned |
Three kinds of control plan
- Prototype control plan: describes measurements and tests during prototype builds.
- Pre-launch control plan: after prototypes and before series production, usually with tighter and more frequent checks.
- Production control plan: a complete description of product and process characteristics, measurement methods, sampling and reaction plans.
Practical tips
- Make the APQP team cross-functional: design, manufacturing engineering, quality, purchasing, logistics and, where relevant, suppliers.
- Identify special characteristics (safety and fit/function) early and carry them from the DFMEA through the PFMEA into the control plan.
- Close each phase with a gate review: move on only when open items are resolved or the risk is formally accepted.
- Capture lessons learned and use them in the next project.