APQP for Automotive Supplier Quality
Master APQP to proactively prevent defects and ensure top-tier quality in automotive supply chains.
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Introduction to APQP
Unit 1: APQP Fundamentals
What is APQP?
Why APQP Matters
Benefits for Suppliers
Benefits for OEMs
APQP Core Principles
Unit 2: APQP Principles and Process
Defect Prevention
Continuous Improvement
APQP Process Flow
Phase 0: Pre-planning
Phase 1: Plan & Define
Unit 3: APQP Integration and Context
Phase 2: Design & Dev
Phase 3: Process Design
Phase 4: Validation
Phase 5: Feedback Loop
APQP and QMS
APQP Phase 0: Pre-Planning
Unit 1: Understanding Pre-Planning
Why Pre-Planning?
Pre-Planning Activities
Customer Expectations
Documenting Requirements
Scope Definition
Unit 2: Project Planning and Risk Assessment
Project Timeline
Resource Allocation
Risk Identification
Risk Assessment
Mitigation Strategies
Unit 3: Advanced Pre-Planning Concepts
Feasibility Studies
Supplier Selection
Team Formation
Kick-off Meetings
Pre-Planning Checklist
APQP Phase 1: Plan and Define Program
Unit 1: Understanding Phase 1
Phase 1: Overview
Team Formation
Timing is Everything
Unit 2: Voice of the Customer (VOC)
What is VOC?
Gathering VOC Data
Analyzing VOC Data
Unit 3: Product Specification and Quality Goals
Defining Specs
Setting Quality Goals
Regulatory Requirements
Unit 4: BOM and Process Flow Chart
Intro to BOM
Process Flow Chart Basics
BOM & Flow Chart Together
Gantt Charts
Unit 5: Wrap Up
Phase 1 Checklist
APQP Phase 2: Product Design and Development
Unit 1: Design & Development Overview
Phase 2: The Blueprint
Inputs to Phase 2
Design Process Steps
Unit 2: DFM/DFA Principles
Intro to DFM & DFA
DFM Guidelines
DFA Guidelines
DFM/DFA in Action
Unit 3: DFMEA Deep Dive
Intro to DFMEA
DFMEA: The Columns
Severity, Occurence, Detect
Risk Priority Number (RPN)
DFMEA: Action Time
Unit 4: Engineering Drawings & Specs
Engineering Drawings
GD&T Intro
Spec Review Process
APQP Phase 3: Process Design and Development
Unit 1: Process Design Fundamentals
Phase 3: Overview
Inputs for Process Design
Process Flow Diagrams
Layout Considerations
Unit 2: Process FMEA (PFMEA)
Intro to PFMEA
Identifying Failure Modes
Assessing Severity
Assessing Occurrence
Assessing Detection
Calculating RPN
Unit 3: Process Documentation and Control
Process Instructions
Control Methods
Error-Proofing
Documentation is Key
Wrap Up: Phase 3
APQP Phase 4: Product and Process Validation
Unit 1: Understanding Product and Process Validation
Validation: Why Bother?
Validation Inputs & Outputs
Validation Team Roles
Validation Planning
Documentation is Key
Unit 2: Trial Runs and Pre-Launch Production
Trial Run Objectives
Planning Trial Runs
Pre-Launch Production
Data Analysis
Corrective Actions
Unit 3: Measurement System Analysis (MSA)
MSA: Why it Matters
Gage R&R Studies
Bias and Linearity
MSA Acceptance
MSA Best Practices
Unit 4: Statistical Process Control (SPC)
SPC: The Basics
Control Chart Construction
Responding to Variation
Control Plans
Unit 1: Understanding Control Plans
What is a Control Plan?
Control Plan Structure
Inputs and Outputs
Types of Control Plans
Customer-Specific Needs
Unit 2: Developing Control Plans
Pre-Launch Control Plans
Production Control Plans
Periodic Verification
Selecting Control Methods
Reaction Plans
Unit 3: Integrating and Maintaining Control Plans
Process Monitoring
SPC Integration
Control Plan Maintenance
Auditing Control Plans
Continuous Improvement
Measurement System Analysis (MSA)
Unit 1: MSA Fundamentals
Intro to MSA
Data Quality
MSA Key Terms
Types of MSA Studies
Planning an MSA Study
Unit 2: Gage R&R Studies
Gage R&R Intro
Conducting a GR&R
GR&R Calculations
GR&R Interpretation
GR&R Improvement
Unit 3: Bias, Linearity, and Stability
Understanding Bias
Bias Assessment
Linearity Explained
Linearity Assessment
Stability Assessment
Statistical Process Control (SPC)
Unit 1: SPC Fundamentals
Intro to SPC
SPC Key Concepts
Data Collection Basics
Unit 2: Control Charts: Variables Data
X-bar and R Charts
Interpreting X-bar Charts
Interpreting R Charts
Individuals Charts
Unit 3: Control Charts: Attributes Data
P Charts
NP Charts
C Charts
U Charts
Unit 4: Advanced SPC Techniques
Special Cause Variation
Process Capability
SPC Software
SPC Implementation
Production Part Approval Process (PPAP)
Unit 1: PPAP Fundamentals
What is PPAP?
PPAP's Core Principles
PPAP & APQP
Customer-Specific Req's
Unit 2: PPAP Documentation
Design Records
Process Flow Diagrams
PFMEA in PPAP
Control Plans
MSA Studies
Unit 3: PPAP Submission & Management
Submission Levels
The PSW
Bulk Material PPAP
Submitting PPAP
PPAP Changes
Record Retention
APQP Phase 5: Feedback, Assessment, and Corrective Action
Unit 1: Understanding Phase 5 and Data Collection
Phase 5: Overview
Data Collection Methods
Key Performance Metrics
Data Analysis Techniques
Unit 2: Corrective Action and Continuous Improvement
Root Cause Analysis
Corrective Action Plans
Implementing Corrective Actions
Continuous Improvement
Feedback Loops
Unit 3: 8D Problem Solving Methodology
8D: An Introduction
D1: Team Formation
D2: Problem Description
D3: Interim Containment
D4: Root Cause Analysis
D5-D8: Wrap Up