Process engineering Quality controls

Objectives Advanced product quality planning (APQP) is a system used for designing a quality product that meets the customers needs. APQP can be applied to any industry. Its purpose is to produce a quality plan which supports the development of a product or service that will satisfy the customer.

Why use APQP? The APQP assists with: Understanding the customer needs Determine customer needs and translate into product characteristics and requirements. Proactive feedback and corrective action Provides other feedback for similar projects with the objective of developing solutions for potential failures. Ensuring that the design is within your process capabilities This brings the processes under statistical control and ensures that your manufacturing process can meet customer requirements and quantities.

Why use APQP? The APQP assists with: Identify and analyse potential failure modes This uses failure modes and effects analysis (FMEA) to solve potential failures. Verification and validation of design process and product This is testing to assure that the design output meet design input requirements.

Why use APQP? The APQP assists with: Conduct reviews These are formal reviews carried during the development of a product to assure it meets the specified requirements. Control special or critical characteristics Special/critical characteristics are identified and the process is assessed to assure it can meet the requirements. A control plan is prepared to indicate how this will be achieved.

Phases of APQP The advanced quality planning process consists of: four phases five major activities ongoing feedback corrective actions.

Phases of APQP The Plan define program phase is made up of steps which include: Define goals Reliability and quality goals Preliminary bill of materials Preliminary process flow Preliminary listing of special product and process characteristics Product assurance plan.

Phases of APQP The Product design and development verification phase is made up of steps which include: Design FMEA DFMA Design verification Design reviews Prototype build Engineering drawings Engineering specifications Material specifications Drawing specification changes New equipment, tooling and facilities requirements Special product and process characteristics Prototype control plan Gauges and testing equipment requirements.

Phases of APQP The Process design and development verification phase is made up of steps which include: Packaging standards Product and quality process systems review Process flow chart Floor plan layout Characteristics matrix Process FMEA Pre launch control plan Process instructions Measurements systems analysis plan Preliminary process capability study plan Packaging specifications.

Phases of APQP The Product and process validation phase is made up of process steps, which include: Production trial run Measurement systems evaluation Preliminary process capability study Production part approval Production validation testing Packaging evaluation Production control plan Quality planning sign-off.

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