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A Structured Method of Defining


and establishing the steps necessary to assure that a Product satisfies the customer A planning and communication Tool

Benefits Of APQP
Focused utilisation of resources. Early identification of required change. No last minute change. On time Quality product at lowest cost

APQP Team Initial Task


Elect a leader. Assign roles and responsibilities. Define Customer requirements. Understand customer expectations. Identify constraints cost , time and others. Asses feasibility of design,requirements of performance and production process.

Stages In APQP
1. Plan and Define Program. 2. Product Design and Development 3. Process Design and Development. 4. Product and Process validation. 5. Feed back assessment and corrective action

1ST Stage In APQP


Plan and Define Program.
INPUT
Voice of customer Business Plan Benchmark Data Assumptions Reliability studies Customer Inputs

PROCESS
Design Goals

OUTPUTS

Reliability and Quality Goals. Preliminary BOM Preliminary PFC Preliminary special charact. Product Assurance plan Management Support

2ND Stage In APQP


Product Design and Development
Process
Design Goals INPUT Reliability and Quality Goals. Preliminary BOM Preliminary PFC Preliminary special charact. Product Assurance plan Management Support

OUT PUT

DFMEA Design for Manufacturability Design Verification Design Review Prototype Control Plan Engineering Drawing Engineering specification Material specification New eqpt., tooling reqmt Special chart.(Prd.,Process) Gages/Test eqpt reqt. Team Feasibility Commitment Mgmt. support

Process Design and Development Input Outputs Process


DFMEA Design for Manufacturability Design Verification Design Review Prototype Control Plan Engineering Drawing Engineering specification Material specification New eqpt., tooling reqmt Special chart.(Prd.,Process) Gages/Test eqpt reqt. Team Feasibility Commitment Mgmt. support Packing Standards PFC Floor plan layout Characteristics matrix PFMEA Process Instruction Quality system review MSA Plan Pre. Proc capab. Study plan Packaging specification Prelaunch Control Plan Management Support

3RD Stage In APQP

Product And Process validation Input Outputs Process


Packing Standards PFC Floor plan layout Characteristics matrix PFMEA Process Instruction Quality system review MSA Plan Pre. Proc capab. Study plan Packaging specification Prelaunch Control Plan Management Support Production Trial Run Preliminary process capability study Measurement system evaluation Production part approval Production validation testing Packaging evaluation Production Control Plan Quality Sign off

4 Th Stage In APQP

5 Th Stage In APQP
Feedback,Assesment and Coorective action Input
Production Trial Run Preliminary process capab study Measurement system evaluation Production part approval Production validation testing Packaging evaluation Production Control Plan Quality Sign off

Process

Outputs

Customer satisfaction Feedback from customer. Corrective actions to be taken. TGW and TGR

A C T IV IT IES S R N OP H A S E - I ( P L A N A N D D E F I N E P R O G R AR E S P O N S I B I L I T M ) 1 C u s t o m e r In p u t R e q u ire m e n t s M & S ( N P D - P re C o n t ra c t R e vie w ) 2 D e s ig n In p u t C h e c k L is t D & D 3 R is k A s s e s e m e n t c h e c k lis t A P Q P LE A D E R 4 C o s t E s t im a t io n & S u b m is s io n o f o ffe r C o s t in g / M & S 5 C u s t o m e r S o u rc in g D e c is io n (P O / L O I) M & S 6 P o s t C o n t ra c t re vie w M & S 7 Q u a lit y G o a ls QA 8 R e lia b ilit y G o a ls D & D 9 P re lim in e ry B O M D & D 1 0 P re lim in e ry P ro c e s s flo w c h a rt PRD 1 1 L is t in g o f P ro d u c t C h a ra c t e ris t ic s . D & D 1 2 R e vie w b y S e n io r M a n a g e m e n t

SR 1 2 3 4 5 6

NP OH A S E - I I ( P r o d u c t D e s i g n a n d D e v e l o D e s ig n F M E A CFT D e s ig n R e vie w CFT C o n t ro l P la n P ro t y p e D & D /Q A F i n a l l i s e D e s i g n & S p e c i fi c a t i o n s C F T T e a m fe a s i b i l i t y c o m m i t m e n t R e p C rFt T o R e vie w B y S e n io r M a n a g e m e n t

SR 1 2 3 4 5 6

NP OH A S E - I I I ( P r o c e s s D e s i g n a n d D e v P ro c e s s F lo w C h a rt P R D / IE P ro c e s s F M E A P R D / IE P re L a u n c h C o n t ro l P la n Q A G a u g e R & R S t u d ie s Q A P r e l i m i n e r y P r o c e s s C a p a b i l l i t y P SR tDa /n dIEa r F l o o r P l a n L a y O u t & P a c k a g i n Pg RS Dt a/ nIEd a

S R 1 2 3 4

PN HO A S E - I V ( P r o d u c t a n d P r o c P r o d u c t i o n V a l i d i t y T e s t i n gD & D D i m e n s i o n a l I n s p e c t i o n r e Dp o& r t D / Q M a t e ria l T e s t in g R e p o rt Q A C o m p i l e P P A P & F i l l O u t M S &W S P

S R 1 2 3 4

N O A S E - V ( F e e d b a c k , a sse sm e n t P H P ro d u c t io n C o n t ro l P la n Q A R e vie w B y S e n io r M a n a g e m e n t Q u a lit y P la n n in g S ig n O ff Q A T G W /T G R R e p o rt CFT