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Quality Planning
and
Control Plan
(APQP)
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APQP - Elements
Definition and Fundamentals
• APQP is a structured method of defining and
establishing the steps necessary to assure that a
product satisfies the customer.
• The goal is to facilitate communication with
everyone involved to assure that all required steps
are completed on time.
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APQP Timing Chart
Concept
Initiation/
Approval
Program
Approval
Prototype
Pilot
Launch
Planning
Planning
Product Design & Development
Process Design & Development
Product & Process Validation
Production
Feedback Assessment and Corrective Action
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APQP Timing Chart
Customer Program Timing Chart: FPDS Milestone
S1 = 18
S6 = 42 Months to J1
KO
0
Product: Vehicle
SI
Sub-System
PH
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CP
CC
LR
LS
J1
System
SC
Strategic
Intent
PR
PT
Part
PA
ST
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Job 1
Start of Production
SOP
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APQP Timing Chart
• Correlation of Planning Phases
• preceding phases enable and support subsequent
phases
• terms used:
• Sources of information - results applicable to this phase
• Input - derived from output of previous phase
• Output - Input
.....
for next phase
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Planning
Business Plan/ Marketing Strategy
1 Sourcing Decision (Ford)
2 Customer Input Requirements (Ford)
Product/ Process Benchmark Data
3 Craftmanship (Ford)
12 Team Feasibility Commitment
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Product Design & Development
4 Design FMEA
6 Design Verification Plan & Sign Off Report
7 APQP Status (Sub-) Suppliers
11 Drawings and Specifications
Special Product & Process Characteristics
9 Prototyp Control Plan(s)
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Product Design & Development
10 Prototype Build/ Design Verification
Analysis, CAD
Lab/ Rig/ Dynamometer
AP - Attribute Prototype
10 Prototype Builds/ Design- and Process Validation
CP - Confirmation Prototype
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Product Design & Development
Production Build
(HTFB - Hard Tooled Functional Build)
1PP - First Pre-Production Units
FEU - Field Evaluation Units
IB - Integrated Build
Start of Production: SOP, Job1, ....
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Process Design & Development
Gages/ Testing Equipment Requirements
8 Facilities, Tools and Gages
(Special) Characteristics Matrix
13 Process Flow Chart
14 Process-FMEA
15 Measurement System Analysis
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Process Design & Development
Preliminary Process Capability Study Plan
16 Pre-Launch Control Plan
17 Operator Process Instructions
Packaging Standards
18 Packging Specifications
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Product & Process Validation
19 Production Trial Run
Measurement Systems Evaluation
20 Production Control Plan
21 Preliminary Process Capability Study
22 Production Validation Testing
23 Part Submission Warrant - PSW
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Feedback, Assessment & Corrective
Action
5 Design and Process Reviews
Reduced Variation
Customer Satisfaction
Delivery and Service
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Risk Assessment: GYR-Status
• Checklist for risk assessment, typical criteria
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•
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•
•
•
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quality history, quality goals
complexity part/ component
timing plan
supplier profile
production volume
logistics und delivery
finances and cost
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Risk Assessment: GYR-Status
• Definition:
Using GYR-Status Reportimg (Green - Yellow Red) progress and completion of an entire project is
evaluated based on the successful completion of any
APQP-Element.
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Risk Assessment: GYR-Status
• "Red" is reported to the customer, if
• a major risk prevails for Start of Production
• the responsible APQP-Team, including the customer
representative, tried unsuccessfully to solve the
problem
• actions needed are beyond the control of the APQPTeam
• management support is needed
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Risk Assessment: GYR-Status
• General rules for reporting
• the customer informs the supplier that for specified
components or parts APQP-Status Reporting is
requested
• suppliers are instructed to report to the responsible
Program Module Team if "Yellow" and "Red" needs
to be reported on certain APQP-Elements
• for all APQP-Status Reports containing "Yellow" and
"Red" an Action- or Rcovery Plan must be included
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