What is APQP?

APQP stands for Advanced Product Quality Planning. It is a methodology that originated in the automotive industry to ensure the development and production of high-quality products that meet customer requirements and expectations.

APQP includes a series of steps and tools, such as risk assessment, design and process FMEAs (Failure Mode and Effects Analysis), control plans, and production trials, to ensure that all necessary planning and preparations are made before mass production. The goal of APQP is to prevent quality problems, improve overall customer satisfaction, and drive continuous improvement. Continuous Improvement applies not just to the product just launched (culminating with PPAP (Production Part Approval Process)), but for the NEXT products produced, incorporating lessons learned from prior programs.

APQP is a "core tool" developed by AIAG to attain and maintain product quality. The automotive quality core tools are standardized methodologies assisting companies in many industries to improve their processes and generate high-quality products. The other core tools include:

• FMEA (Failure Modes and Effects Analysis) - an analytical methodology used to ensure that potential problems have been considered and addressed throughout the product and process development process.
• PPAP (Production Part Approval Process) - the industry standard that defines the production part approval process and demonstrates engineering design records and specification requirements are achieved by the supplier's manufacturing process.
• MSA (Measurement Systems Analysis) - a methodology to assess the quality of measurement systems, providing a basis for recognizing where improvements can be made, resulting in knowledge that can be used to improve your measurement process and repeatable product quality.
• SPC (Statistical Process Control) - the use of statistical techniques such as control charts to analyze a process or its output so as to take appropriate actions to achieve and maintain a state of statistical control and to improve the process capability.

APQP is the overarching framework that brings together all these tools and methodologies to create a comprehensive quality planning and control system.

Where else is APQP applicable?

APQP’s ideas, methodologies, and processes aren’t limited to one single industry, despite initially being developed for the automotive industry. There are now many outside industries using APQP to improve their product processes, like: 

• Aerospace and Defense
• Medical Devices
• Electronics 
• Consumer Products

APQP is a flexible methodology that can be adapted to the specific needs and requirements of any product. 

What are the benefits of APQP?

APQP has a host of benefits for both manufacturers/suppliers as well as the customers they serve. These benefits include:

• Improved product quality - APQP’s rigorous risk assessments, design and process FMEAs, control plans, and production trials prevent a host of quality problems before parts are mass produced. 
• Enhanced customer satisfaction - To put it simply, higher quality products result in greater customer satisfaction and happiness. When customers are satisfied, their relationships with manufacturers and suppliers improve.
• Increased efficiency - Quality problems in the development and manufacturing process hinder efficiency and time-to-market. APQP provides a reliable framework to catch and address these problems early to reduce the need for reworks. 
• Reduced costs - Quality problems, hangups in the development and manufacturing process, reworks, product returns, warranty claims, and more all result in greater costs to the manufacturer. APQP drastically reduces these issues to save significant costs. 
• Improved supplier relations - By factoring in a detailed understanding of customer requirements and expectations, APQP allows suppliers to better understand their customers which leads to improved customer <> supplier relationships and a more collaborative working relationship. 
• Better risk management - APQP’s risk assessment processes allow suppliers and manufacturers to identify, address, and develop measures to mitigate potential quality issues early. 
• Improved process control - the combined methodologies outlined above in combination with APQP’s statistical process control (SPC) processes allow suppliers and manufacturers to monitor/control the production process in even greater detail. 

AIAG offers several resources to learn more and implement APQP, including:

eLearning

Implementing APQP, Control Plan and PPAP - Learn the skills needed to implement the APQP process, develop control plans and complete the production part approval process

Quality Core Tools Connect the Dots - Provides an understanding of how the Core Tools work together to assure quality

Core Tools Overview eLearning -Provides a brief summary of the Core Tools, with a primary focus on how they can help your organization in its journey for continuous improvement

Publications

Advanced Product Quality Planning and Control Plan - The industry standard

Supplier Quality Requirements 5-Pack - Includes all the Core Tools

Training

Advanced Product Quality Planning Overview - This one-day class provides an overview of the tools, procedures and reporting requirements specified in the APQP and Control Plan reference manual

Understanding and Implementing APQP with PPAP - Learn the skills needed to implement the APQP process, develop control plans, and complete the Production Part Approval Process

Certification

APQP/PPAP Certification Exam - Verifies competency in product quality planning, control plans and production part approval as defined in AIAG's APQP and PPAP reference manuals

Other Resources

Core Tools Self-Assessment - Baseline your knowledge in the automotive quality Core Tools to see where you should focus your training efforts

Quality Core Tools Knowledge Badge - Earning Quality Core Tools Knowledge Badge is great way to show current and prospective employers that you possess an understanding of the Core Tools

AIAG Core Tools Support™ Software - Developed by our member OEM and Tier 1 suppliers to meet your customer’s requirements for electric reporting of FMEAs

Implementing APQP requires a commitment to continuous improvement and the active involvement of all stakeholders. But when done correctly, all stakeholders can celebrate in confidence that quality is assured and not only don’t we have problems, but we know why we don’t!

FAQ

• What is APQP? 
• APQP stands for Advanced Product Quality Planning. It is a methodology that originated in the automotive industry to ensure the development and production of high-quality products that meet customer requirements and expectations.
• Where is APQP applicable?
• APQP’s ideas, methodologies, and processes aren’t limited to one single industry, despite initially being developed for the automotive industry. There are now many outside industries using APQP to improve their product processes, like Aerospace and Defense, Medical Devices, Electronics, Consumer Products, and more.
• What are the benefits of APQP?
• APQP has a host of benefits for both manufacturers/suppliers as well as the customers they serve. These benefits include Improved product quality, Enhanced customer satisfaction, Increased efficiency, Reduced costs, Improved supplier relations, Better risk management, Improved process control, and more.
• What are the steps in APQP?
• While a detailed understanding of APQP’s steps requires professional training, a simple overview of the steps would include: Plan and Define The Program, Product Design and Development, Process Design and Development, Product and Process Validation, Feedback Assessment and Corrective Action, Production Launch, Ongoing Monitoring and Feedback, and more.