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Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP)


The automotive industry has long been one of the most efficient and productive sectors within the global economy as a result of quality management. Many of the Lean and Quality Tools developed by them are now being used across many other organizations in Industry, as well as in the Service, Finance and Public sectors.

The Advanced Product Quality Planning method was implemented by the automotive industry to assure that a product satisfies the customer (both internal and external). The goal of APQP is to plan before acting, anticipate and prevent issues, validate before moving forward, and facilitate communication.

Within the framework of the APQP, the PPAP process is designed to demonstrate that the component supplier has developed their design and production process to meet the client's requirements, minimizing the risk of failure by effective use of APQP. Requests for part approval must therefore be supported in an official PPAP format and with documented results when needed

While the APQP and PPAP processes were developed by the automotive industry, today they are widely used across industry.



Course content:

1.     Overview of the APQP process

  • Project Management and Timing Plans
  • Defining project scope and requirements
  • Product design and development
  • Process design and development
  • Product and process validation and control plans

2.     Production Part Approval Process (PPAP)

  • Outline of process and requirements
  • Scope and limitations of approval
  • Evaluation of evidence submitted

3.     Levels of Submission and Evidence required

  • Parts submission warrant
  • Supporting evidence
  • Materials data and use of IMDS database
  • Process Capability

4.     Core tools used

  • Design Failure Modes and Effects Analysis (DFMEA) applied in special situations
  • Process Flow Diagram
  • Process Failure Modes and Effects Analysis (PFMEA)
  • Control Plan
  • Measurement Systems Analysis (MSA)
  • Statistical Process Control
  • Process Capability

5.     Appearance Approval Report (AAR)

6.     Sample Production Parts & Master Sample

7.     Checking Aids

8.     Customer-Specific Requirements

9.     Part Submission Warrant (PSW)



Benefits

APQP serves as a guide in the development process and also a standard way to share results between suppliers and automotive companies. By applying the concepts of the Advanced Product Quality Planning (APQP), you will have implemented a framework of procedures and techniques to develop products in industry, particularly the automotive industry. It will lead to a product quality plan which will support development of a product or service that will satisfy the customer.

We will be happy to discuss our APQP & PPAP course in the context of your own business needs, so please contact us for more information.