Advanced Product Quality Planning - LSS Glossary

Advanced Product Quality Planning (APQP) is a structured process that helps organizations to plan and implement the necessary steps to produce products that meet or exceed customer expectations. It is a framework that helps companies to identify and manage the risks associated with new product development and to ensure that products are designed, developed, and produced to meet customer requirements.

Advanced Product Quality Planning was first developed by the Big Three American automakers (Ford, General Motors, and Chrysler), also known as the Automotive Industry Action Group (AIAG), in the late 1980s. It was a response to the increasing global competition in the automotive industry. The goal of APQP was to create a standardised process for planning and executing the development and launch of new products, in order to ensure they met or exceeded customer expectations for quality.

Implementing Advanced Product Quality Planning (APQP)

Plan and Define Program: This step involves creating a detailed plan for the development of the new product, including timelines, milestones, and resources required.
Product Design and Development: This step involves the design and development of the new product, including the creation of detailed engineering drawings and specifications.
Process Design and Development: This step involves the design and development of the manufacturing processes that will be used to produce the new product.
Product and Process Validation: This step involves testing and validating both the product and the manufacturing processes to ensure they meet the required specifications and quality standards.
Feedback Assessment and Corrective Action: This step involves gathering feedback on the new product and manufacturing processes, and taking corrective action as necessary to address any issues that are identified.
Introduction of the Production: This step involves the launch of the new product into full production.

Benefits and Advantages of Advanced Product Quality Planning (APQP)

Advanced Product Quality Planning helps to ensure that new products are developed and launched in a timely and efficient manner, while meeting or exceeding customer expectations for quality.
APQP also helps to identify and address potential issues with the product or manufacturing process before they become a problem in mass production.
This leads to cost savings by reducing the need for rework and scrap, and it increases customer satisfaction.
It also helps to improve communication and coordination between different departments and teams involved in the product development process.

Limitations of Advanced Product Quality Planning (APQP)

Advanced Product Quality Planning can be time-consuming and resource-intensive to implement, particularly for small or medium-sized companies.
It may also be difficult to change or adapt the APQP process once it has been implemented, which can limit its flexibility.
Additionally, it requires a significant level of commitment from all employees to make it a success.

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Example

A automotive manufacturing company decided to implement Advanced Product Quality Planning for the development and launch of a new electric vehicle model. The company’s APQP team began by creating a detailed plan for the development of the new vehicle, including timelines, milestones, and resources required. They then designed and developed the vehicle, including the creation of detailed engineering drawings and specifications. They also designed and developed the manufacturing processes that would be used to produce the vehicle.

The company then conducted extensive testing and validation of both the vehicle and the manufacturing processes to ensure they met the required specifications and quality standards. Any issues that were identified during this process were addressed through a feedback assessment and corrective action process.

Finally, the new electric vehicle model was launched into full production, and it was well-received by customers for its high quality and performance. The company also saw significant cost savings by reducing the need for rework and scrap, and it increased customer satisfaction.

Conclusion

Advanced Product Quality Planning is a comprehensive and efficient method of planning and executing the development and launch of new products, which helps to ensure they meet or exceed customer expectations for quality. While it can be time-consuming and resource-intensive to implement, it can also bring significant benefits and advantages to the organization such as cost savings and customer satisfaction.

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Sachin Naik

Passionate about improving processes and systems | Lean Six Sigma practitioner, trainer and coach for 14+ years consulting giant corporations and fortune 500 companies on Operational Excellence | Start-up enthusiast | Change Management and Design Thinking student | Love to ride and drive