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How to get started with APQP
What is the benefit and outcome
Benefit
o You will know how APQP is structured
o You will understand the interfaces and workstream of APQP
o You will know how APQP supports you in your daily work to manage a project
o You will understand how to roll out APQP in your organization to ensure customer satisfaction
o You will know what steps are necessary to set up an APQP implementation
Advanced Product Quality Planning
APQP
o A workstream through all relevant departments for developing and manufacturing a product
o A method to organize interfaces between responsible stakeholders in the organization
o A structure to achieve effectiveness
APQP is….
What do you need?
Advanced Product Quality Planning
APQP
Resources
Methods/ Tools
Organization
Training/Experience
IT-Landscape
o A Method to connect interfaces
o Methods/Tools to organize data
o Training/Experience to support
efficient workflow
o Resources to run the methods and
tools
o An IT-Landscape to exchange data
o An Organization to identify interfaces
The Elements
Advanced Product Quality Planning
A description of all necessary components
APQP
Resources
Methods/ Tools
Organization
Training/Experience
IT-Landscape
Methods and Tools
History
Several methods and tools will be used during the APQP process, shown as
follows (major methods and tools):
TFC (Team Feasibility Commitment)
PRS/PDS (Product Requirement/Design Specification)
FMEA (Failure Mode & Effect Analysis) for Concept, Design and Production
CPL (Control Plan)
MSA (Measurement System Analysis)
Special Characteristics
PPAP (Product Part Approval Process)
SPC (Statistical Process Control)CpK (Short term capability Assessment)
Method to collect all information at the interface between customer and the company
Method to confirm ‚makeable‘ status of the product/project
Tool to identify and assess risk of design and production
Method to identify critical characteristics in design and production
Tool to organize all inspection and test plans
Tool and method to analyze proper effectiveness of measurement systems
Tool and method to analyze and control running production processes
Tool and method to organize the interface between customer and supplier
Training / Experience
APQP Puzzle
The APQP web page http://www.apqp4wind.org
will support you with knowledge and informationAPQP
Training/Experience
The APQP4Wind Elements
Manual Toolbox: Analysis Tool & Workbook
Web Page Training Providers
Training / Experience
APQP Puzzle
An additional source of information is the web page of
the Automotive Industry Action Group: https://aiag.org
Here the “Blue Books“ are recommended to order.
Special fields of APQP are taken care of under headlines
such as APQP, FMEA, MSA, SPC, PPAP (see slide 9)
APQP
Training/Experience
Resources
APQP Puzzle
Skilled employees out of different departments will be needed for a successful
APQP workflow. In the
o Sales
o Engineering
o Production
o Procurement
o Quality
Departments should a fundamental knowledge about APQP be available.
APQP
Resources
IT - Landscape
APQP Puzzle
The implementation of APQP will not be a problem to merge into an already
installed Integrated Management System.
If not available, a Network structure will help a lot to ensure an efficient workflow.
Together with several applications out of different business units the APQP process
can be setup lean.
Pull- and Push information systems should be considered and ‚stand alone
solutions‘ should be connected to the net.
Basic applications are MS Office or adequate,
CAD-, CAQ- and CAM solutions and ERP (Enterprise Resources Planning)
software.
APQP
IT-Landscape
Organization
APQP Puzzle
A Certification according to DIN
ISO 9001:2015 or
IATF 16949 and an Integrated
Management System (IMS) will be
a perfect foundation for a
successful operating APQP
environment.
APQP
Organization
How to get started with APQP4Wind
Advanced Product Quality Planning
The plan
APQP
Resources
Methods/ Tools
Organization
Training/Experience
IT-Landscape
Roll Out Plan
Roll out plan
It is up to the maturity of a company regarding the already installed
Quality Management System. A Roll Out Plan can look like the following overview:
Step 4: Improving, changing or implementing of needed methods and tools, restructure org.
Step 1: Gap analysis
Step 2: Training of involved employees and stakeholders (awareness and specialist training)
Step 5: Pilot phase: Training loop and ‚real data pilot‘
Step 7: Kick off - APQP as a solid process
Step 3: Introduction to organization
Step 8: Review and PDCA, Internal Audit
Step 6: Lessons learned and action plan
Start a gap analysis to find out the lack of knowledge and sources
Together with promotion activities and awareness events the new APQP process needs to be introduced to the organization
According to the gap analysis all weak resources need to be improved, changed or just created.
Run with a Project Quality Plan. The new process shall be tested for efficiency (i.e. Pilot run).
A final „improvement plan“ can be created and followed.
Complete implementation into the Quality Management System
Follow Continuous improvement process, perform internal Audit
Action:Plan:
Selection of Training Providers and execution of training plan
Further information at
www.apqp4wind.org
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APQP4Wind