Fundamentals of APQP Training

Course Outline
Course Objectives

Intended Audience

Product design engineers, product development professionals, quality engineers.

Time To Complete

6 hours (0.6 CEUs)

What is APQP?

Advanced Product Quality Planning, or APQP for short, creates a roadmap for developing new products complete with time-based milestones and decision points along the way. A major objective of APQP is to provide a vehicle for suppliers and customers to work together when developing a new product. This helps assure that the product is delivered on time and with the highest added-value. New Product Introductions (NPIs) have a greater success rate when the principles of the APQP approach are followed.

APQP has five formal phases. Each phase is connected to and triggers the next. APQP is not a “use what I like and ignore the rest” approach. It represents a continuum in which each phase builds upon the next. Some organizations precede the “official” five phases with a “Phase 0” that includes forming a team, defining the scope of the project, conducting an initial assessment of the projects’ feasibility and establishing documentation and communication protocols.

Fundamentals of APQP Online Training

The Fundamentals of APQP online training walks learners through all phases of the APQP process beginning at Phase 0 and ends with a lesson on Control Plans.  Throughout the training there are exercises and upon completion of the content, learners complete the Fundamentals of APQP Challenge that tests their understanding of the material.

The course is designed for employees who are responsible for conducting or participating in the APQP process.  We also offer an Overview of APQP course for managers and personnel responsible to overseeing departments responsible for conducting APQPs but who are not intimately involved in conducting them.

This Training Enables Learners To…

  • Work through the five phases of the APQP process.
  • Create a Design Verification Plan and Report.
  • Use Control Plans from Prototype to Pre-Launch to Production Phases.
  • Describe the Production Part Approval Process.

Recommended Prerequisites

  • Mistake-Proofing or Error-Proofing or the equivalent understanding of the difference between fixing problems after they happen and preventing problems from happening in the first place.

You May Also Be Interested In…

  • PPAP Training – A Targeted Training Course on the Production Part Approval Process.
  • Advanced SPC Training – Comprehensive training in how to implement statistical process control including setting up control charts and conducting process capability studies.
  • FMEA Training – Complete online training in how to conduct Design and Process FMEAs and to reduce high Risk Priority Numbers, how to customize FMEAs for a specific business and how to maintain improved processes using a control plan.
  • Measurement Systems Analysis – Comprehensive training in how to statistically measure the accuracy and reliability of measurement systems.

Fundamentals of APQP Course Outline

Lesson 0 | Overview of APQP

  • Overview of the five phases of the APQP Process.

Lesson 1 | Phase 1: Plan and Define the Program

  • Information and data are compiled to build a business case.
  • The output of this phase defines specifically what product will be studied.

Lesson 2 | Phase 2: Product Design and Development

  • The design of the product is fleshed out.
  • After the design is verified, a prototype is built, specifications developed and inputs for the process design are generated.

Lesson 3 | Phase 3: Process Design and Development

  • The manufacturing process for the product is designed.
  • Major outcomes include development of the process flow and layout.
  • Additionally, a Characteristics Matrix, PFMEA, Pre-Launch Control Plan and Process Instructions are developed.

Lesson 4 | Phase 4: Product and Process Validation

  • The process and the product design are validated.
  • The output product from the production run is used to evaluate the measurement system and check the process capability.

Lesson 5 | Phase 5: Feedback Assessment & Corrective Action

  • Start the cycle of continuous improvement.
  • Control charts can be used to identify special causes of variation, capability studies and the use of design of experiments can help reduce common cause variation.
  • Work to ensure the product fully meets customer’s needs.

Lesson 6 | (Unofficial) Phase 6: Control Plans

  • Identify control factors, control points and control methods for the product and its corresponding manufacturing process.
  • Develop a comprehensive Control Plan.

Challenge

  • An assessment of the learner’s progress in this course.

Fundamentals of APQP Course Objectives

  • Explain the purpose of the APQP process.
  • Describe the five phases of the APQP process.
  • List the steps necessary to prepare for an APQP effort.
  • Be aware of techniques used to identify the VOC (Voice of the Customer.)
  • Understand how Design-FMEAs can help reduce risks in the design phase and Process-FMEAs can help reduce process related risks.
  • Be familiar with a Design Verification Plan and Report.
  • Understand the sequential progress of Control Plans from Prototype to Pre-Launch to Production Phases.
  • Understand how Engineering Change Requests generate vital documentation.
  • Be familiar with a Team Feasibility Checklist (to conclude Phase 2.)
  • Select appropriate flowcharting and process mapping techniques to aid in design of the process.
  • Be familiar with a Characteristics Matrix to plot the relationship between product parameters and operational steps of the process.
  • Know the importance of Measurement System Analyses and a Preliminary Process Capability studies in evaluating the process and product output.
  • Be familiar with the Production Part Approval Process.
  • Be acquainted with a Quality Planning Sign-Off (that confirms completion of Phases 1 through 4.)
  • Know about tools and techniques that are used to continuously improve both the product its corresponding process.

Fundamentals of APQP Course Outline

Lesson 0 | Overview of APQP

  • Overview of the five phases of the APQP Process.

Lesson 1 | Phase 1: Plan and Define the Program

  • Information and data are compiled to build a business case.
  • The output of this phase defines specifically what product will be studied.

Lesson 2 | Phase 2: Product Design and Development

  • The design of the product is fleshed out.
  • After the design is verified, a prototype is built, specifications developed and inputs for the process design are generated.

Lesson 3 | Phase 3: Process Design and Development

  • The manufacturing process for the product is designed.
  • Major outcomes include development of the process flow and layout.
  • Additionally, a Characteristics Matrix, PFMEA, Pre-Launch Control Plan and Process Instructions are developed.

Lesson 4 | Phase 4: Product and Process Validation

  • The process and the product design are validated.
  • The output product from the production run is used to evaluate the measurement system and check the process capability.

Lesson 5 | Phase 5: Feedback Assessment & Corrective Action

  • Start the cycle of continuous improvement.
  • Control charts can be used to identify special causes of variation, capability studies and the use of design of experiments can help reduce common cause variation.
  • Work to ensure the product fully meets customer's needs.

Lesson 6 | (Unofficial) Phase 6: Control Plans

  • Identify control factors, control points and control methods for the product and its corresponding manufacturing process.
  • Develop a comprehensive Control Plan.

Challenge

  • An assessment of the learner's progress in this course.

Fundamentals of APQP Course Objectives

  • Explain the purpose of the APQP process.
  • Describe the five phases of the APQP process.
  • List the steps necessary to prepare for an APQP effort.
  • Be aware of techniques used to identify the VOC (Voice of the Customer.)
  • Understand how Design-FMEAs can help reduce risks in the design phase and Process-FMEAs can help reduce process related risks.
  • Be familiar with a Design Verification Plan and Report.
  • Understand the sequential progress of Control Plans from Prototype to Pre-Launch to Production Phases.
  • Understand how Engineering Change Requests generate vital documentation.
  • Be familiar with a Team Feasibility Checklist (to conclude Phase 2.)
  • Select appropriate flowcharting and process mapping techniques to aid in design of the process.
  • Be familiar with a Characteristics Matrix to plot the relationship between product parameters and operational steps of the process.
  • Know the importance of Measurement System Analyses and a Preliminary Process Capability studies in evaluating the process and product output.
  • Be familiar with the Production Part Approval Process.
  • Be acquainted with a Quality Planning Sign-Off (that confirms completion of Phases 1 through 4.)
  • Know about tools and techniques that are used to continuously improve both the product its corresponding process.