Advanced Product Quality Planning Training | APQP Training

Advanced Product Quality Planning Training | APQP Training

Advanced Product Quality Planning (APQP) is a structured process employed when introducing a new product in the market or incorporating changes in the product after its release.

This method ensures that there is proper documentation of the processes involved when manufacturing new products and helps detect defects during production.

APQP is also about having a clear understanding of what customers want, need, and expect in a product and then planning accordingly.

Production processes often have inherent risks, such as process failures. Following the APQP process can help minimize these risks. In turn, risk management leads to greater quality control and business success.

Primarily practiced in the automotive industry, APQP has been adopted by other manufacturing sectors such as aerospace, defense, medical, and pharmaceutical since this method is proven effective.

Professionals in engineering, quality, procurement, manufacturing and distribution often use what’s known as an APQP Checklist to make sure that a product is up to spec before released to the market. The objective of this APQP Checklist is to facilitate the CFT in evaluating a product’s quality. It verifies that certain processes have been followed, such as:

• Determining the system-level project plans utilized for the APQP
• Capturing photo evidence of the APQP process
• Documenting the product and process design, development, and validation
• Scheduling inspections and assign actions to CFT members
• Validating the advanced product quality planning with digital signatures

APQP benefits the OEM (customer) and supply chain (contractor) by having a structured agreement and procedure for product definitions and requirements. It also provides a platform to have efficient and effective decisions and communication.

This avoids any interpretation and confusion that may delay production, create a sub-standard part, and/or increase costs.

Advanced Product Quality Planning Training Course Description

At Tonex, we will provide you sufficient training and knowledge through this two-day course to keep you informed and updated. You will learn fundamentals and more, such as in order to ensure the customers’ satisfaction and meet quality standards, APQP needs to be planned up front and then implemented through production.

And, while effective product quality planning most likely depends on the company’s senior management, it is important that all the quality supervisors and managers are aware of the APQP procedures.

You will also learn about ADQP tools and the five phases of the APQP process:

• Plan and define the product
• Design and development of the product
• Design and development of the process
• Validation of the product and the process
• Feedback, assessment and corrective action

This two-day seminar will walk you through all of the above phases and teach you how to adjust APQP to your business, product and/or process. This course offers an overview of the APQP methods, principals and application.

Audience

The advanced product quality planning (APQP) training is a two-day course designed for:

• Product/process design managers
• Quality managers
• Product/process design engineers
• Production engineers
• Process development engineers
• ISO/TS internal auditors
• Outside and second-party auditors
• All individuals interested in learning and pursuing APQP

Training Objectives

Upon the completion of this course, attendees are able to:

• Relate to the concepts behind having the APQP protocol
• Discuss and describe the five phases of the APQP relevant to the product or process they are working on
• Develop and execute the steps required to organize an APQP manual
• Determine the voice of the customer (VOC)
• Learn how FMEAs can be used to reduce the risks during the process
• Learn the whole process from designing the prototype to the final produced product
• Learn about engineering change requests produce dynamic documentation
• Produce a team feasibility checklist in order to execute phase 2
• Choose the best framework and techniques to facilitate the process design
• Build a relationship between the characteristics of a product and the operational steps associated with it
• Understand how Measurement System Assessments and the Preliminary Process Capability studies are important in the outcome of the process and product evaluation
• Conduct the Production Part Approval Process
• Understand and appreciate the importance of planning in the quality chase
• Describe the role of the APQP protocol in quality of the product and the customer’s satisfaction
• Understand the timing plan
• Describe the basic steps of APQP execution for new products and processes
• Appreciate and understand the importance of a multi-disciplinary team in the planning process

Course Outline

Overview of APQP process

• What is APQP
• APQP as a Quality Framework
• APAQ versus Design for Six Sigma (DFSS)
• APAQ versus Voice of the Customer (VOC)
• How APQP works
• Identified process and product parameters
• Product Conformity
• Product Part Approval Process (PPAP)
• Requirements to obtain part approval of supplier manufactured parts
• Consistent part approval process

Phases of APQP

• Inputs and outputs for each of the five phases
• APQP linkages to Other Processes
• Failure Modes and Effects Analysis (FMEA)
• Statistical Process Control (SPC)
• Measurement System Analysis (MSA)
• Production Part Approval Process (PPA)
• APQP Control Plan

Overview of Phase 1: Plan and Define

• Compiling sufficient data to make a business case
• Defining what product should be studied

Overview of Phase 2: Developing and Designing Product

• Finalizing the product design
• Building a prototype, developing the features and specifying the inputs for the process

Overview of Phase 3: Developing and Designing Process

• Designing the production process
• Developing the process flow diagrams

Overview of Phase 4: Validating Product and Process

• Validating the product design and process
• Evaluating the measurement system and the process capability

Overview of Phase 5: Feedback, Assessment and Corrective Actions

• Initiate an algorithm to improve the process constantly
• Create charts to keep track of variations and their potential causes
• Studying the system capability and applying the DOE to reduce common failures
• Making sure the product completely satisfies customers
• Controlling the Plan
• Determine the control factors, points, and methods for the product and the process
• Developing a comprehensive control plan
• Review some examples of control plan

Workshop

• Implementing APQP with PPAP
• Core Tools
• Developing flow charts, process instructions and control plans
• Implementing APQP and Control Plan

Advanced Product Quality Planning Training | APQP Training