APQP

Advanced product quality planning

1. WHAT IS IS0 9000
In 1987 , the INTERNATIONAL ORGANISATION FOR
STANDARDISATION (ISO) published the ISO 9000
series of international Standards.
The standard applies to all type of companies.
The basic ISO-9000 series comprises of five standards

2. ISO-9000:
Quality Management and Quality Assurance Standards-
Guidelines for selection & use.
ISO-9001:
Quality System : Model for Quality Assurance in Design
/ Development , Production Installation & Servicing . It
includes all items listed in ISO-9002 and ISO-9003.It has
20 Clauses.

3. •ISO-9002:
Quality System –Model for Quality Assurance in
Production Servicing and installation.It does not included
the design function.
•IS0-9003
Quality System : Model For Quality Assurance in Final
inspection & Testing. It has only 16 clauses.
•ISO-9004:
Quality Management and Quality System Elements –
Guidelines.

4. •QS-9000
Developed by Chrysler , Ford General Motors And
Truck Manufacture.
GOAL:
To provides Continual Improvement , Defects Prevention,
Reduction of Variation and Waste reduction in supply
chain.

5. •ApplicabilityQS –9000: Applies to all internal and external
supplier`s Production Materials, Production or Service Parts , Heat
treatment & Finishing Services.
•QS –9000 Layout:
1.ISO 9000 Based requirements
-20 Clause 4.1 to 4.20 Element.
2.Sector –Specific requirements
-APQP , PPAP , FMEA , MSA and SPC.
3.Customer –Specific requirements
-HONDA, MUL, GM, TOYOTA …

6. •ISO / TS 16949:2002
•The goal of this TS is the development of a Quality Management
System that provides for
-Continual Improvement
-Emphasizing Defect prevention ,
-Reduction of variation and waste.
•SHALL -Indicates requirements
•NOTE –Guidance for understanding or clarifying
•SHOULD -Appearing in a note : for guidance only
•BOXEDTEXT -ISO 9001:2000 test.
•OUTSIDEBOX -Sector Specific supplemented requirements.
•SUCHAS -Is used any suggestions given are for
guidance only.

7. •ISO / TS 16949:2002 clause:
1.Scope
2.Normative reference
3.Terms and definitions
4.Quality management system
5.Management responsibility
6.Resources management
7.Product realization
8.Measurement , analysis and improvement.

8. APQP
ADVANCED PRODUCT
QUALITY PLANNING

9. ADVANCED PRODUCT QUALITY PLANNING
It is a structured method of defining and establishing the steps
necessary to assure that a product satisfies the customer.
Goal :
•Is to facilitate communication with everyone involved.
•To assure that all required steps are completed in time.
PURPOSE
To emphasize:-
•Upfront (Early stage / Advance) planning
•The act of implementation
•Continuous improvement.

10. FUNDAMENTALS OF PRODUCT QUALITY PLANNING:
1.ORGANISE THE TEAM
-Supplier first responsibility is to assign responsibility to a
product Quality Planning team.
-This PQP team must be cross functional.
2.Define the scope
3.Team –to –Team
4.Training
5.Customer and Subcontractors involvement
6.Simultaneous Engineering.
7.Control Plans
8.Concern Resolution
9.Product Quality Timing plan
10.Plans relative to the timing chart

11. HOW TO DO APQP ?
APQP IS ACCOMPLISHED THROUGH
1.A five phased approach
2.Simultaneous Engineering
3.Cross Functional Teams
4.Up front Planning
5.Documenting Control Plans
6.PDSA Leading to continuous improvement.

12. FIVE PHASE
CONCEPT PROGRAM PROTOTYPE PILOT LAUNCH
Initiation/Approval Approval
Planning
Product Design & Dev
Product & Process Validation
Process Design & Dev.
Production
Feed back Assessment and Corrective Action

13. 1.Plan and Define Program
2.Product Design and Development (Prototype)
3.Process Design and Development (Pilot)
4.Product & Process validation (PPAP)
5.Feedback Assessment and corrective Action

14. PHASE I-PLANNING
1.This phase determines customer needs and expectations.
2.The inputs and outputs applicable to the process may vary
according to the product process and customer needs and
expectations.

15. INPUTS :
•Voice of the customer
-Market Research
-Historical Warranty &
Quality Information
-Team experience
•Business Plan / Marketing
strategy
•Product / Process Bench
mark Data
•Product / Process
Assumptions
•Product reliability studies
Customer inputs
OUT PUTS:
•Design Goals
•Reliability and Quality
Goals
•Preliminary Bill of
Materials
•Preliminary Process Flow
Chart.
•Preliminary listing of
special product and process
characteristics
•Product Assurance plan
•Management support

16. PHASE II : PRODUCT DESIGN / DEVELOPMENT
•The team considers all relevant design factors and
decides the specification which will meet customer
requirements.
•At this stage the process, a preliminary feasibility
analysis will be made to asses the potential problem
that could occur during manufacturing.
•Output of Phase –I becomes the inputs of Phase-II

17. OUTPUTS BY DESING RESPONSIBLE ACTIVITY
•DFMES
•Design for manufacturability and Assembly
•Design Verification.
•Design Reviews
•Prototype Build –Control Plan
•Engineering Drawings / Specifications
•Material Specifications
•Drawing and Specifications Changes

18. OUTPUTS BY PRODUCT QUALITY PLANNING
TEAM
•New equipments , tooling and Facilities requirements
•Special Product and process Characteristics
•Gauges / Testing Equipments requirements
•Team Feasibility Commitment and management support

19. PHASE III : PROCESS DESIGN / DEVELOPMENT
•This phase results in evolution of manufacturing process
and its related control plans. This is achieved by effective
implementation of output of earlier stages.
•Output of Phase –II becomes the inputs of Phase-III

20. OUTPUTS :
•Packaging standards
•Product / Process Quality System Review
•Process Flow Chart
•Floor Plan Layout
•PFMEA
•Pre-Launch Control Plan
•Process Instructions
•Measurement system analysis
•Preliminary Process Capability study plan
•Packaging Specifications
•Management support.

21. PHASE-4 : PRODUCT AND PROCESS VALIDATION
•During this phase the manufacturing process validate by
means of an evaluation trial run.
•The Product Quality Planning team should verify that
the control plan and process flow chart are being
followed and the products meet customer requirements

22. OUTPUTS
•Production Trail Run
•Measurement System analysis
•Preliminary Process Capability study plan
•Production Part approval
•Production Validation and testing
•Packaging Evaluation
•Production Control Plan.
•Quality Planning Sign-off and Management support.

23. PHASE-5 : FEED BACK ASSESSMENT AND
CORRECTIVE ACTION
•The result of the production trail run are evaluated during
this phase to ensure that the products satisfy customer
requirements.
•The effectiveness of the product Quality Planning process
should be evaluated during this process step.
•Result of the control plan activities to be evaluated for
identifying corrective actions.
OUTPUTS
•Reduction Variation
•Customer Satisfaction
•Delivery and Service.

24. APQP DOCUMENTS CONSISTS OF THE FOLLOWING:
•Customer Voice
•Gantt chart
•Study of Customer drawing and sample
•Preparation of company drawing (if Required)
•DFMEA and reviews
•Special Characteristics
•List of Equipments , tools and Gauge
•Team Feasibility commitment
•Process flow chart
•Plant layout and or review sheet
•Process FMEA and reviews
•Control plan
•Work instructions
•Packaging specification
•SPC documents
•MSA documents
•Product quality planning summaryand sign off
Phase I&II
Phase III&IV
Phase V

25. BENEFITS
•To direct resources to satisfy the customer
•To promote early identification of required changes.
•To avoid late changes
•To Provide a quality product on time at the lower cost.