Focusing on the "why" behind the "what" and "when," the APQP 3rd edition manual addresses how to improve successful new product launches with updates to reflect agile product management and new sections on sourcing, change management, APQP program metrics, risk assessment mitigation plans, and gated management. Along with the removal of control plan content - now a standalone document - further revisions include new information on "part traceability," various checklists, and examples of common analytical techniques used during the APQP process to help enhance your understanding.
Foreword
Introduction
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Fundamentals of Advanced Product Quality Planning (APQP)
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Purpose of this Manual
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Product Quality Planning Responsibility
Getting Started
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0.1 Organize the Team
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0.2 Define the Scope
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0.3 Team-to-Team
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0.4 Training
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0.5 Sourcing
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0.6 Customer and Organization Involvement
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0.7 Simultaneous Engineering
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0.8 Control Plans
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0.9 Concern Resolution
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0.10 Product Quality Timing Plan
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0.11 Plans Relative to the Timing Chart
Chapter 1 : Plan and Define Program
Introduction
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1.1 Voice of the Customer
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1.2 Business Plan and Marketing Strategy
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1.3 Product/Process Benchmark Data
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1.4 Product/Process Assumptions
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1.5 Product Reliability Studies
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1.6 Customer Inputs
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1.7 Design Goals
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1.8 Reliability and Quality Goals
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1.9 Preliminary Bill of Materials
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1.10 Preliminary Process Flow Chart
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1.11 Preliminary Identification of Special Product and Process Characteristics
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1.12 Product Assurance Plan
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1.13 Capacity Planning
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1.14 Leadership Support
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1.15 Change Management Implementation
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1.16 APQP Program Metrics
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1.17 Risk Assessment Mitigation Plan
Chapter 2 : Product Design and Development
Introduction
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2.1 Design Failure Mode and Effects Analysis (DFMEA)
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2.2 Design for Manufacturability, Assembly, and Service
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2.3 Design Verification
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2.4 Design Reviews
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2.5 Prototype Build Control Plan
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2.6 Engineering Drawings (Including Math Data)
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2.7 Engineering Specifications
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2.8 Material Specifications
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2.9 Drawing and Specification Changes
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2.10 New Equipment, Tooling and Facilities Requirements
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2.11 Special Product and Process Characteristics
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2.12 Gages/Testing Equipment Requirements
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2.13 Team Feasibility Commitment and Leadership Support
Chapter 3 : Process Design and Development
Introduction
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3.1 Packaging Standards and Specifications
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3.2 Product/Process Quality System Review
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3.3 Process Flow Chart
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3.4 Floor Plan Layout
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3.5 Process Failure Mode and Effects Analysis (PFMEA)
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3.6 Pre-Launch Control Plan
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3.7 Process Instructions
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3.8 Measurement Systems Analysis Plan
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3.9 Preliminary Process Capability Study Plan
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3.10 Leadership Support
Chapter 4 : Product and Process Validation
Introduction
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4.1 Significant Production Run
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4.2 Measurement Systems Analysis
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4.3 Preliminary Process Capability Study
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4.4 Production Part Approval
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4.5 Production Validation Testing
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4.6 Packaging Evaluation
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4.7 Production Control Plan
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4.8 Quality Planning Sign-Off and Leadership Support
Chapter 5 : Feedback, Assessment and Corrective Action
Introduction
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5.1 Reduced Variation
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5.2 Improved Customer Satisfaction
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5.3 Improved Customer Service and Delivery
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5.4 Effective Use of Lessons Learned/Best Practices
Appendix A : Product Quality Planning Checklists
Purpose of the Checklists
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A-0 APQP Risk Factors Checklist
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A-1 Design FMEA Checklist
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A-2 Design Information Checklist
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A-3 New Equipment, Tooling, and Test Equipment Checklist
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A-4 Product/Process Quality Checklist
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A-5 Floor Plan Checklist
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A-6 Process Flow Chart Checklist
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A-7 Process FMEA Checklist
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A-8 Change Management Checklist
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A-9 Sourcing Checklist
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A-10 Control Plan Checklist
Appendix B : Gated Management
Introduction
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Gate 0 (Program Concept) Section Instructions
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Gate 1 (Program Approval) Section Instructions
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Gate 2 (Design Feasibility) Section Instructions
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Gate 3 (Process Feasibility) Section Instructions
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Gate 4 (Launch Readiness) Section Instructions
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Gate 5 (Feedback, Assessment and Corrective Action) Section Instructions
Appendix C : Analytical Techniques
Introduction
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APQP Program Metrics
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Assembly Build Variation Analysis
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Benchmarking
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Cause and Effect Diagram
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Control Plan Special Characteristics
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Critical Path Method
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Design for Experiments (DOE)
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Design for Manufacturability and Assembly
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Design for Serviceability
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Design Verification Plan and Report (DVP&R)
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Failure Mode and Effects Analysis (FMEA)
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Mistake-Proofing/Error-Proofing
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OEE (Overall Equipment Effectiveness)
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Process Flow Charting
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Risk Assessment Mitigation Plan
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Traceability
Appendix D : Team Feasibility Commitment
Appendix E : Quality Planning Summary and Approval
Appendix F : Reference Material
Appendix G : Sector Specific Guidance
Appendix H : Glossary
Appendix I : Index
