Introduction to Advanced Product Quality Planning (APQP)

Complex products and supply chains present plenty of possibilities for failure, especially when new products are being
launched. Advanced Product Quality Planning (APQP) is a structured process aimed at ensuring customer satisfaction
with new products or processes.

APQP has existed for decades in many forms and practices. Originally referred to as Advanced Quality Planning (AQP),
APQP is used by progressive companies to assure quality and performance through planning. Ford Motor Company
published the first Advanced Quality Planning handbook for suppliers in the early 1980’s. APQP helped Ford suppliers
develop appropriate prevention and detection controls for new products supporting the corporate quality effort. With
lessons learned from Ford AQP, the North American Automotive OEM’s collectively created the APQP process in 1994
and then later updated in 2008. APQP is intended to aggregate the common planning activities all automotive OEM’s
require into one process. Suppliers utilize APQP to bring new products and processes to successful validation and drive
continuous improvement.

There are numerous tools and techniques described within APQP. Each tool has potential value when applied in the
correct timing. Tools that have the greatest impact on product and process success are called the Core Tools. The Core
Tools are expected to be used for compliance to IATF 16949. There are five basic Core Tools detailed in separate
guideline handbooks, including Advanced Product Quality Planning (APQP). The other Core Tools are:

Failure Mode and Effects Analysis (FMEA)

Measurement Systems Analysis (MSA)

Statistical Process Control (SPC)

Production Part Approval Process (PPAP)

What is Advanced Product Quality Planning (APQP)

APQP is a structured approach to product and process design. This framework is a standardized set of quality
requirements that enable suppliers to design a product that satisfies the customer.

The primary goal of product quality planning is to facilitate communication and collaboration between engineering
activities. A Cross Functional Team (CFT), involving marketing, product design, procurement, manufacturing and
distribution, is used in the APQP process. APQP ensures the Voice of the Customer (VOC) is clearly understood,
translated into requirements, technical specifications and special characteristics. The product or process benefits are
designed in through prevention.

APQP supports the early identification of change, both intentional and incidental. These changes can result in exciting
new innovation supporting customer delight. When not managed well they translate to failure and customer
dissatisfaction. The focus of APQP is utilization of tools and methods for mitigating the risks associated with change in
the new product or process.
APQP - Concurrent Process

Why Implement Advanced Product Quality Planning (APQP)

APQP supports the never ending pursuit of continuous improvement. The first three sections of APQP focus on planning
and prevention and make up 80% of the APQP process. The fourth and fifth sections support the remaining 20% of APQP
and focus on validation and evidence. The fifth section specifically allows an organization to communicate learnings and
provide feedback to develop standard work and processes. A list of APQP benefits are:

Directing resources by defining the vital few items from the trivial many

Promote early identification of change

Intentional (what is being changed on purpose to bring value to the customer)

Incidental (environments, customer usage, degradation and interfaces)

Avoid late changes (post release) by anticipating failure and preventing it

Fewer design and process changes later in the product development process

On-time quality product at lowest cost

Multiple options for mitigating the risk when found earlier

Higher capability of verification and validation of a change

Improved collaboration between Design of the Product and Process

Improved Design for Manufacturing and Assembly (DFM/A)

Lower cost solutions selected earlier in the process

Legacy capture and reuse, advancement of Tribal Knowledge and standard work creation and utilization

Late Failure Mode Discovery

Early Failure Mode Discovery

Utilization levels at the Black Belt’s discretion.