All You Need to Know About APQP Process : Definition, Steps and Benefits

Who is this article for?

• Manufacturing companies, especially in the automotive industry
• Organizations launching new or updated products
• Quality managers, engineers, and technicians
• Supply chain and procurement professionals
• Product designers and developers
• Senior leadership overseeing quality initiatives

Anyone involved in bringing a product from concept to market while ensuring it meets quality standards and customer expectations will benefit from understanding and applying APQP principles.

What is Advanced Product Quality Planning (APQP)?

Advanced Product Quality Planning, or APQP, is a structured method for defining and establishing the steps necessary to ensure a product satisfies the customer. It is a comprehensive quality system for product development that was originally created by the US automotive industry.
The goal of APQP is to facilitate communication with everyone involved, achieve a high-quality product launch, and ultimately meet customer needs. It does this by focusing on up-front quality planning and defect prevention rather than defect detection.

The 5 Phases of APQP Process

The APQP process consists of five main phases:

Planning
Product Design and Development
Process Design and Development
Product and Process Validation
Launch, Feedback, Assessment & Corrective Action

Let’s look at each phase in more detail:

1. Planning

The planning phase is all about defining the program and understanding customer needs. Key activities include:

• Setting quality and reliability goals
• Creating a preliminary bill of materials
• Developing a process flow diagram
• Defining management support

Suppliers are heavily involved in this phase to ensure their input and ability to meet requirements.

2. Product Design and Development

With planning complete, the focus shifts to product design. The APQP team will:

• Conduct a Design Failure Mode and Effects Analysis (DFMEA) to identify potential issues
• Review engineering specifications
• Develop a prototype and testing plan
• Identify critical characteristics

The output is a fully defined, validated product design ready for production.

3. Process Design and Development

With a completed product design, the next step is developing the manufacturing processes to reliably produce it at volume. Key activities include:

• Creating detailed process flow charts
• Conducting a Process Failure Mode Effects Analysis (PFMEA)
• Developing a pre-launch control plan
• Designing tooling and equipment
• Establishing process parameters and instructions

The goal is capable processes that will deliver consistent, high-quality products.

4. Product and Process Validation

Before full production begins, the product and processes must be thoroughly tested and validated. This involves:

• Production trial runs
• Measurement system analysis
• Preliminary process capability studies
• Product validation testing
• Production Part Approval Process (PPAP)

Any issues are identified and resolved before the final approval to begin full production.

5. Launch, Feedback, Assessment & Corrective Action

With the planning done, APQP enters the launch phase and then transitions into ongoing production. Key activities include:

• Implementing production control plan
• Reducing variation
• Monitoring performance via quality data
• Gathering customer feedback
• Implementing corrective actions

APQP is a continuous improvement process that extends beyond the launch to drive ongoing quality and customer satisfaction.

What are the benefits of APQP?

Implementing APQP provides many benefits to an organization, including:

• Improved communication and collaboration between all stakeholders
• Increased customer satisfaction by involving them early and often
• Reduced time to market by preventing late-stage design issues
• Lower product costs through design for manufacturability
• Smoother product launches with less problems and delays
• Consistent, capable processes that deliver high quality
• Continual improvement of product quality and customer satisfaction

When done well, APQP helps deliver successful new products that delight customers.

Challenges and Risks with APQP

While the benefits are clear, implementing APQP is not without its challenges:

• Requires a significant time and resource investment
• Depends on strong cross-functional collaboration which can be difficult
• Involves many stakeholders which makes communication and coordination complex
• Generates a large amount of documentation that must be managed
• Can slow time-to-market if the process becomes bureaucratic

The key is striking the right balance between thorough planning and nimble execution. Organizations should right-size APQP to their specific needs.

How Tallyfy Supports APQP

Tallyfy’s workflow software is an ideal tool for digitizing and managing your APQP process. Here are a few key ways Tallyfy can help:

Explain it once – AI-driven documentation

Tallyfy makes it easy to document your standard APQP process and deliverables. The AI can even auto-generate task instructions to reduce manual work.

Real time tracking – track the status of a workflow without asking anyone

With Tallyfy, you can see the real-time status of every APQP project. No more manual updates or wondering if a deliverable is on track.

If this then that – set simple conditional rules

Tallyfy allows you to easily automate APQP tasks and decisions. For example, you can automatically assign a DFMEA to the quality engineer once the design is complete.

Customer facing links – login free, signup free, forever links

Need to collect input from customers or suppliers? Tallyfy lets you send them a link to provide information without needing a login. It’s a seamless experience.

Key Takeaways

APQP is a proven method for launching successful, high-quality products that satisfy customer requirements. While it requires an investment and has its challenges, the benefits of improved communication, faster time-to-market, and delighted customers are well worth it.
As Isroilova (2022) states, “It is recommended to use the APQP method not only in the automotive industry, but also in any design and manufacturing areas.” So no matter your industry, consider applying APQP principles to your next product launch.
And if you need a tool to help manage the process, give Tallyfy a try. Our workflow software is purpose-built for making processes like APQP more efficient and effective.

Risks and Warning Signs

• Lack of management support and resources for APQP
• Poor communication and collaboration between functions
• Incomplete or inaccurate planning inputs (e.g. customer requirements)
• Skipping or short-cutting key APQP steps to save time
• Inadequate risk identification and mitigation (DFMEA, PFMEA, etc.)
• Insufficient testing and validation before production launch
• Software that is overly complex and difficult to use for managing APQP

Be on the lookout for these warning signs that your APQP process may need improvement. Address issues early before they impact product quality and customer satisfaction.

How Is AI Changing APQP Processes in the Automotive Industry?

Advanced Product Quality Planning (APQP) has become a critical methodology for ensuring high quality products in the automotive industry. By following a structured approach to defining the steps needed to satisfy customers, APQP helps automotive companies deliver on time and at competitive prices (Misztal et al., 2014). However, new technologies like artificial intelligence (AI) are starting to transform and enhance traditional APQP processes in several key ways.

First, AI can enable more modularized and collaborative product design as part of APQP. For example, Trappey & Hsiao (2008) developed an AI-based “APQP hub” system that facilitates modularized design for assembly (MDfA) and collaborative design processes (CDP) between an automotive manufacturer and its suppliers. By intelligently integrating product data across the supply chain, their system improves the efficiency of collaborative design and helps bring products to market faster.

AI is also being applied to optimize measurement system analysis (MSA) activities within APQP. Rewilak (2015) proposed using AI-based risk analysis to determine the appropriate frequency and scope of MSA for each measurement system, based on factors like process capability and the impact of product characteristics. This helps automate and prioritize MSA planning in a more intelligent way.

Beyond product development, AI and data analytics are being integrated with process improvement frameworks like Six Sigma to optimize manufacturing operations. Li & Lin (2011) demonstrated a unified model combining CMMI process maturity with Six Sigma that improved automotive process performance by 70%. AI will likely play an increasing role in identifying critical processes to optimize.

What Does the Future Hold for AI-Driven APQP?

As AI matures, we can expect it to enable further automation and optimization of APQP activities like:

• Generative AI design tools to rapidly create and test product concepts
• Digital twins and simulations to validate product and process designs virtually
• AI planning and scheduling for prototype builds and production ramp-up
• Computer vision and machine learning for automated quality inspections
• Predictive models to proactively identify and mitigate quality risks

Ultimately, AI promises to make APQP faster, smarter and more efficient – compressing product development timelines while improving quality. Automotive companies that harness AI throughout their APQP processes will likely gain a significant competitive advantage in the years ahead. However, realizing the full potential of AI will require not just technology investments but also change management to upskill the workforce on AI and evolve APQP best practices.

Tallyfy Tango – A cheerful and alternative take

Meet Appy and Cappy, two quality control experts on a mission to streamline their company’s product development process. Little did they know, their quest would lead them to an unexpected dance with destiny… and the APQP process.

“Appy, have you heard about this new ‘apqp process’ thing?” Cappy asked, sipping his morning coffee.

“APQP? Isn’t that some sort of fancy apple pie?” Appy replied, raising an eyebrow.

“No, silly! It’s Advanced Product Quality Planning. Apparently, it’s a game-changer for ensuring high-quality products and customer satisfaction.”

“Huh, sounds intriguing. But how do we even begin to implement it?” Appy wondered aloud.

“Fear not, my friend! I’ve got a plan,” Cappy declared, striking a heroic pose. “We’ll break it down into five phases: planning, product design and development, process design and development, product and process validation, and feedback and corrective action.”

“Whoa, slow down there, Captain APQP! That sounds like a lot of work,” Appy said, feeling a bit overwhelmed.

“True, but think about the benefits! By following the apqp process, we’ll be able to identify potential issues early on, reduce costs, and deliver top-notch products to our customers. It’s like a carefully choreographed dance – each step builds upon the last, leading us to success!”

Appy’s eyes widened with realization. “You know what? You’re right! Let’s do this, Cappy. We’ll be the Fred Astaire and Ginger Rogers of quality control!”

And so, Appy and Cappy embarked on their APQP journey, twirling and dipping their way through each phase with grace and determination. Their colleagues marveled at their newfound passion for quality, and soon, the entire company was swept up in the apqp process dance craze.

Related Questions

What are the 5 phases of APQP?

APQP, or Advanced Product Quality Planning, is a structured process that helps ensure a product satisfies the customer. It consists of five key phases: Planning, Product Design and Development, Process Design and Development, Product and Process Validation, and Launch, Feedback and Assessment. Each phase has specific deliverables and checkpoints, all aimed at proactively preventing issues and delivering a successful product launch.

What is APQP and PPAP?

APQP and PPAP are two closely related quality planning methodologies in the automotive industry. APQP focuses on the entire product development process, from concept to launch, ensuring that all steps are properly planned and executed. PPAP, or Production Part Approval Process, is a standardized process for establishing confidence in component suppliers and their production processes. PPAP is typically one of the final steps in the APQP process, validating that the supplier can consistently produce parts that meet all requirements.

What is the APQP checklist?

The APQP checklist is a comprehensive list of tasks and deliverables that need to be completed during each phase of the APQP process. It serves as a roadmap and tracking tool to ensure that all necessary steps are taken, and no critical items are overlooked. The checklist typically includes items such as design reviews, FMEA, process flow diagrams, control plans, measurement system analysis, and production trial runs. By following the APQP checklist, teams can effectively manage the product development process and minimize the risk of costly quality issues.

What is APQP and FMEA?

APQP and FMEA are two important tools used in quality planning and risk management. APQP provides the overall framework for product development, while FMEA, or Failure Mode and Effects Analysis, is a specific tool used within the APQP process. FMEA is a systematic method for identifying potential failure modes, assessing their risks, and implementing corrective actions. It is typically conducted during the product design and process development phases of APQP. By integrating FMEA into the APQP process, teams can proactively identify and mitigate potential quality issues, resulting in a more robust and reliable product.

References and Editorial Perspectives

Isroilova, S. (2022). The Organization Develops a Standard in Quality Management. International Journal of Advance Scientific Research, 03, 62 – 72. https://doi.org/10.37547/ijasr-02-06-09

Summary of this study

This study examines the APQP (Advanced Product Quality Planning) methodology, which was developed by the AIAG (Automotive Industry Action Group) and the American Society for Quality Management. The authors recommend using APQP not just in the automotive industry, but in any design and manufacturing areas to improve quality management processes.

Editor perspectives

At Tallyfy, we find the broad applicability of APQP to various industries very interesting. Implementing a structured approach to quality planning, like APQP provides, could significantly streamline and improve product development workflows across many sectors.

Mittal, K., Kaushik, P., & Khanduja, D. (2012). Evidence of APQP in Quality Improvement: An SME Case Study. International Journal of Management Science and Engineering Management, 7, 20 – 28. https://doi.org/10.1080/17509653.2012.10671203

Summary of this study

This case study looks at how APQP methodology can be applied for quality improvement in small and medium-sized enterprises (SMEs). The authors suggest that implementing APQP could be a model for SMEs to achieve high quality products and services at a lower cost compared to other quality management systems.

Editor perspectives

I’m excited by the potential for APQP to benefit smaller businesses. Workflow management platforms like Tallyfy are designed to be accessible for companies of all sizes. Combining the power of APQP with an intuitive workflow tool could be transformative for SME product development.

Misztal, A., Belu, N., & Rachieru, N. (2014). Comparative Analysis of Awareness and Knowledge of APQP Requirements in Polish and Romanian Automotive Industry. Applied Mechanics and Materials, 657, 981 – 985. https://doi.org/10.4028/www.scientific.net/amm.657.981

Summary of this study

This study compares the awareness and knowledge of APQP techniques among automotive industry professionals in Poland and Romania. The researchers conducted a questionnaire to measure which APQP tools are best known, most often used, and most challenging to implement in each country.

Editor perspectives

At Tallyfy, we’re always interested in understanding the real-world adoption and challenges of process methodologies like APQP. Insights from this type of comparative research can help guide our product development to better support our users in different regions and contexts.

Rewilak, J. (2015). MSA Planning – A Proposition of a Method. Key Engineering Materials, 637, 45 – 56. https://doi.org/10.4028/www.scientific.net/kem.637.45

Summary of this study

This paper proposes a method for planning Measurement System Analysis (MSA) based on risk assessment. MSA is a required part of APQP in the automotive industry to validate measurement systems. The author suggests using process capability indexes and FMEA to prioritize and schedule MSA activities.

Editor perspectives

Integrating risk-based planning into quality workflows is a smart approach. I can envision how Tallyfy could incorporate risk assessment features to help users optimize the timing and scope of their process steps, like MSA, based on the risk profile of each project.

Trappey, A., J., & Hsiao, D., W. (2008). Applying Collaborative Design and Modularized Assembly for Automotive ODM Supply Chain Integration. Computers in Industry, 59, 277 – 287. https://doi.org/10.1016/j.compind.2007.07.001

Summary of this study

This research proposes enhancing traditional PLM (product lifecycle management) systems with modularized design for assembly (MDfA) and collaborative design processes (CDP). The authors developed an “APQP hub” plug-in for PLM to support these concepts and improve efficiency in an automotive supply chain case study.

Editor perspectives

The idea of an “APQP hub” that facilitates modular and collaborative design is compelling. At Tallyfy, we strive to create a flexible platform that can integrate with companies’ existing systems and processes. I could see us developing plug-ins or extensions to popular PLM and CAD tools to embed APQP workflows directly into the design environment.

Glossary of terms

APQP (Advanced Product Quality Planning)

APQP is a structured methodology for defining and executing the steps needed to ensure a product will meet customer requirements. It involves a cross-functional approach to product development, incorporating quality planning activities throughout the process from design to production.

PPAP (Production Part Approval Process)

PPAP is a standardized process in the automotive industry for establishing confidence that a supplier’s production processes can consistently meet customer requirements. It involves documenting and submitting evidence of process capability, measurement system validation, and product conformance.

Control Plan

A Control Plan is a document that defines the systems and processes required for controlling product quality during mass production. It specifies inspection points, measurement techniques, sampling plans, and reaction plans for out-of-control conditions.

MSA (Measurement System Analysis)

MSA is a set of methods used to quantify the amount of variation in measurement data that can be attributed to the measurement system itself. Common MSA techniques include gauge repeatability and reproducibility (GR&R) studies, bias, and linearity studies.

FMEA (Failure Mode and Effects Analysis)

FMEA is a systematic approach to identifying potential failure modes in a product or process, evaluating their risks, and implementing corrective actions to mitigate those risks. FMEA is a key tool used in APQP to anticipate and prevent quality issues.