What is the APQP (Advanced Product Quality Planning) methodology?
Born as an agreement between the three major automakers in the United States (Chrysler, General Motors and Ford), APQP is a methodology that brings together a series of techniques and procedures necessary to establish a quality plan that allows product development ) According to the needs of the customers. APQP are the initials of Advanced Product Quality Planning, or Advanced Product Quality Planning.
The three automotive firms founded a non-profit organization called AIAG (Automotive Industry Action Group) in 1982, which was later joined by volunteers from other manufacturers, including non-US companies (such as Toyota, Nissan and Honda). The objective of this organization was to produce quality standards and establish common regulations for members. Today, the role of AIAG is much more comprehensive, covering topics related to the supply chain of the automotive industry, supplier management and corporate social responsibility, among others.
The fundamentals of APQP are covered in a manual, which is usually used in conjunction with other manuals written by the same organization, among which are:
Modal Failure and Effects Analysis Manual (FMEA: Failure Mode and Effects Analysis)
Manual of Statistical Process Control (SPC)
Manual of Analysis of Measurement Systems (MSA: Measurement Systems Analysis)
Production Part Approval Process Manual (PPAP)
The purpose of this manual is to obtain products that satisfy the customer, fulfilling the requirements defined by him and involving him in the development process. Suppliers also play a key role.
The implementation of APQP is done in five well-defined phases:
Phase 1 (Planning and definition of the program): At this stage the entire market study is carried out, taking into account the “voice of the customer”. The business plan is made and goals are set for design, quality and reliability. Preliminary sketches of processes and products are also made.
Phase 2 (Product design and development verification): Here an AMFE of the design (DFMEA) is realized, which is verified and revised. A prototype is usually fabricated and engineering and materials requirements are established. It also establishes which tools / machines will be necessary for the manufacture, and for the testing of the products.
Phase 3 (Process Design and Development Verification): In this phase the processes are designed, including everything related to plant layout, packaging, quality review of processes and products and process AMFE (PFMEA). It also establishes the process instructions, determines a plan of analysis of the measurement systems and makes a plan for the preliminary study of capacity.
Phase 4 (Validation of product and process): All the final tests necessary to validate the products and processes, including validation of production processes, packaging and measurement systems, are carried out.
Phase 5 (Feedback, evaluation and corrective actions): In this phase emphasis is placed on customer satisfaction, through minimization of variation, and analysis of delivery times and customer service.
As can be seen, some analogy can be established with a PDCA cycle, following the same logic. There is also a relationship with requirements 8.1 and 8.3 of ISO 9001: 2015.
As with other standards or methods that emerged within a specific industrial activity (the automaker always leads the way), this methodology can be applied to any type of product or service.
We will delve into several points in this manual, and on concepts from other AIAG manuals in future publications