Tab Article

Foreword
Introduction

• Fundamentals of Advanced Product Quality Planning (APQP)
• Purpose of this Manual
• Product Quality Planning Responsibility

Getting Started

• 0.1 Organize the Team
• 0.2 Define the Scope
• 0.3 Team-to-Team
• 0.4 Training
• 0.5 Sourcing
• 0.6 Customer and Organization Involvement
• 0.7 Simultaneous Engineering
• 0.8 Control Plans
• 0.9 Concern Resolution
• 0.10 Product Quality Timing Plan
• 0.11 Plans Relative to the Timing Chart

Chapter 1 : Plan and Define Program

Introduction

• 1.1 Voice of the Customer
• 1.2 Business Plan and Marketing Strategy
• 1.3 Product/Process Benchmark Data
• 1.4 Product/Process Assumptions
• 1.5 Product Reliability Studies
• 1.6 Customer Inputs
• 1.7 Design Goals
• 1.8 Reliability and Quality Goals
• 1.9 Preliminary Bill of Materials
• 1.10 Preliminary Process Flow Chart
• 1.11 Preliminary Identification of Special Product and Process Characteristics
• 1.12 Product Assurance Plan
• 1.13 Capacity Planning
• 1.14 Leadership Support
• 1.15 Change Management Implementation
• 1.16 APQP Program Metrics
• 1.17 Risk Assessment Mitigation Plan

Chapter 2 : Product Design and Development

Introduction

• 2.1 Design Failure Mode and Effects Analysis (DFMEA)
• 2.2 Design for Manufacturability, Assembly, and Service
• 2.3 Design Verification
• 2.4 Design Reviews
• 2.5 Prototype Build Control Plan
• 2.6 Engineering Drawings (Including Math Data)
• 2.7 Engineering Specifications
• 2.8 Material Specifications
• 2.9 Drawing and Specification Changes
• 2.10 New Equipment, Tooling and Facilities Requirements
• 2.11 Special Product and Process Characteristics
• 2.12 Gages/Testing Equipment Requirements
• 2.13 Team Feasibility Commitment and Leadership Support

Chapter 3 : Process Design and Development

Introduction

• 3.1 Packaging Standards and Specifications
• 3.2 Product/Process Quality System Review
• 3.3 Process Flow Chart
• 3.4 Floor Plan Layout
• 3.5 Process Failure Mode and Effects Analysis (PFMEA)
• 3.6 Pre-Launch Control Plan
• 3.7 Process Instructions
• 3.8 Measurement Systems Analysis Plan
• 3.9 Preliminary Process Capability Study Plan
• 3.10 Leadership Support

Chapter 4 : Product and Process Validation

Introduction

• 4.1 Significant Production Run
• 4.2 Measurement Systems Analysis
• 4.3 Preliminary Process Capability Study
• 4.4 Production Part Approval
• 4.5 Production Validation Testing
• 4.6 Packaging Evaluation
• 4.7 Production Control Plan
• 4.8 Quality Planning Sign-Off and Leadership Support

Chapter 5 : Feedback, Assessment and Corrective Action

Introduction

• 5.1 Reduced Variation
• 5.2 Improved Customer Satisfaction
• 5.3 Improved Customer Service and Delivery
• 5.4 Effective Use of Lessons Learned/Best Practices

Appendix A : Product Quality Planning Checklists

Purpose of the Checklists

• A-0 APQP Risk Factors Checklist
• A-1 Design FMEA Checklist
• A-2 Design Information Checklist
• A-3 New Equipment, Tooling, and Test Equipment Checklist
• A-4 Product/Process Quality Checklist
• A-5 Floor Plan Checklist
• A-6 Process Flow Chart Checklist
• A-7 Process FMEA Checklist
• A-8 Change Management Checklist
• A-9 Sourcing Checklist
• A-10 Control Plan Checklist

Appendix B : Gated Management

Introduction

• Gate 0 (Program Concept) Section Instructions
• Gate 1 (Program Approval) Section Instructions
• Gate 2 (Design Feasibility) Section Instructions
• Gate 3 (Process Feasibility) Section Instructions
• Gate 4 (Launch Readiness) Section Instructions
• Gate 5 (Feedback, Assessment and Corrective Action) Section Instructions

Appendix C : Analytical Techniques

Introduction

• APQP Program Metrics
• Assembly Build Variation Analysis
• Benchmarking
• Cause and Effect Diagram
• Control Plan Special Characteristics
• Critical Path Method
• Design for Experiments (DOE)
• Design for Manufacturability and Assembly
• Design for Serviceability
• Design Verification Plan and Report (DVP&R)
• Failure Mode and Effects Analysis (FMEA)
• Mistake-Proofing/Error-Proofing
• OEE (Overall Equipment Effectiveness)
• Process Flow Charting
• Risk Assessment Mitigation Plan
• Traceability

Appendix D : Team Feasibility Commitment
Appendix E : Quality Planning Summary and Approval
Appendix F : Reference Material
Appendix G : Sector Specific Guidance
Appendix H : Glossary
Appendix I : Index