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. 

APQP 3rd Edition and Control Plan 1st Edition

The new APQP (Advanced Product Quality Planning) manual is here. The new version is more than a methodology; it's a commitment to excellence, ensuring every product meets and exceeds customer expectations. Updated for Industry 4.0, higher automation, autonomous driving, electrification, and the expanding definition of mobility, the updated standard provides steps and tools to avert quality issues, elevate customer satisfaction, and foster an environment of continuous improvement.

Decoupling the two documents will also facilitate more timely updates as systems evolve and emphasize the importance of Control Plans in product development.

Why a Separate Control Plan

The decision to separate the control plan manual into a standalone document is driven by two key factors: flexibility and agility. This change allows for greater flexibility in adapting to future changes, especially as technologies evolve. It also facilitates a quicker feedback loop, enabling continuous improvement. The collaboration between General Motors and STIs has resulted in more harmonized Control Special Requirements (CSRs), potentially leading to a reduction in CSRs. The intention is to provide clear requirements related to top opportunities for improvement. 

The control plan now outlines essential steps and offers enhanced guidance for developing and managing control plans. This reorganization aligns with how core tools have been taught historically, with the control plan serving as the operational expression of the FMEA, ensuring consistency and complementarity within the core tool stack.

Changes to APQP

The changes to the APQP manual focus on three main areas: program management, sourcing, and additional clarifications. In program management, there is an emphasis on risk assessment and mitigation, including checklists for assessing and mitigating risks within the APQP process. A new appendix addresses gated management, offering guidance on expectations. KPIs related to the APQP process are introduced to measure progress.

Sourcing receives increased attention, recognizing its importance in supplier capability assessment. Checklists are added to assess and mitigate risks during the sourcing stage. The gated management approach extends to the supply chain.

Clarifications and details cover change management during the APQP process, capacity planning using OEE measures, traceability guidelines, and error-proofing and mistake-proofing. These changes aim to provide clarity and standardization, benefiting both suppliers and OEMs.

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

eLearning

Introduction to APQP eLearning - Focusing on high level topics, this eLearning reviews the history and structure of APQP, benefits and best practices, and key concepts such as gateways and activities.

Introduction to Control Plan eLearning: - Familiarize yourself with the language and techniques used in everyday control plan activities with this 30-minute eLearning.

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 standards

Supplier Quality Requirements 6-Pack - Includes all the Core Tools

Training

APQP and Control Plan Fundamentals - Covering both the APQP 3rd Edition and Control Plan 1st Edition in a single day, this unique hybrid training includes a range of presentation materials to help attendees better understand key updates and associated deliverables. (Note: Copies of both publications are also included in the cost of registration!)

APQP Overview - Designed to provide an overview of the new APQP 3rd Edition, this one-day course covers both the technical and managerial aspects of APQP to help you gain a more well-rounded understanding of program management. Course content focuses on general expectations for APQP tasks and the higher system level of phases, along with using new APQP tools in real-world contexts, and more.

APQP and Control Plan: Transitioning - This two-day “transitioning” training – intended for current APQP practitioners, managers, and auditors – focuses on updates and changes in the APQP 3rd Edition to facilitate a better understanding of how your APQP program will be impacted, provide examples of new elements, and explore the managerial side of APQP in more detail.

APQP, Control Plan and PPAP - Understanding and Implementing - Focusing on both the managerial and technical aspects of APQP, this three-day course includes case studies for practical analysis, along with various other techniques successful practitioners have used over the years. If you’re looking for a comprehensive APQP training to move above and beyond conformance, this course is for you.

Control Plan Understanding and Implementing - Looking for a comprehensive training on control plans, covering everything from development to maintenance? Designed for a variety of learners (and particularly geared toward beginners), this one-day course focuses on certain areas that are often overlooked, along with best practices for monitoring your control plan.

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.