Wednesday 10 August 2022

Quality One Australia

APQP Product Programs

APQP   APQP Consulting   APQP Training   APQP Facilitation

APQP Product Programs from Quality One

APQP Training APQP Training
APQP Process Implementation APQP Process Implementation
APQP Systems Integration APQP Systems Integration
APQP Tool Development APQP Tool Development
APQP Product Development APQP Product Development
APQP Feedback Loops APQP Feedback Loops

APQP Product Programs Home APQP Training

This APQP workshop focuses on the five APQP phases for quality planning and the tools associated with each phase, with primary emphasis on product development. Individuals will learn that the APQP process is a fundamental method for assuring quality of the product throughout its development from concept through obsolescence.

The following topics will be covered in detail:

  • Introduction and benefits of APQP
  • Implementation of APQP through product concepts through obsolescence
  • APQP activities through all development phases
  • APQP activity checklist
  • APQP deliverable review and interfaces (tools and techniques)
  • Team feasibility commitments
  • Production part approval process (PPAP) interface
  • Dynamic control plan (DCP) introduction
Duration: 2 Days
Format: Public Courses or On site at your facility
To seek assistance in APQP training please contact us via our contact page.

APQP Product Programs Home APQP Process Implementation

APQP is comprised of one pre-planning stage and five concurrent phases. Once begun, the process never ends and is often illustrated in the Plan Do Study Act (PDSA) cycle. PDSA was made famous by W. Edwards Deming. Each section is aligned with analytical risk discovery tools and techniques. Finding risk in product and process development is more desirable than finding late failure.

The APQP Sections are defined below:

Section 0: Pre-Planning
APQP begins with assumptions, concepts and past knowledge. Bookshelf knowledge and standard work practices are listed as well as areas where significant change is expected. This section compiles the inputs into Section 1 – Plan and Define.

Section 1: Plan and Define
Section 1 links customer expectations, wants, needs and desires to requirements. Plan Development will assure the output of this section is satisfactory product quality. Resource planning, process and product assumptions are made. A list of preliminary special characteristics and design / reliability goals are also established.

Section 2: Product Design and Development
The focus in Section 2 is on product design and development. Geometry, design features, details, tolerances and refinement of special characteristics are all reviewed in a formal Design Review. Design verification through prototypes and testing are also part of this section. Tools which typically provide great benefit in this section are DFM/A, Design Failure Mode and Effects Analysis (DFMEA) and Design Verification Plan and Report (DVP&R).

Section 3: Process Design and Development
Section 3 explores manufacturing techniques and measurement methods that will be used to bring the design engineer’s vision into reality. Process Flow Charts, Process Failure Mode and Effects Analysis (PFMEA) and Control Plan Methodology are examples of tools used in this section.

Section 4: Product and Process Validation
Validation of the process quality and volume capabilities is the focus of Section 4. Statistical Process Control (SPC), Measurement Systems Analysis (MSA) and Process Capability Studies are introduced in this section. Product Part Approval Process (PPAP) is ready for submission and production begins upon approval.

Section 5: Feedback Assessment and Corrective Action
Section 5 explores learnings from the ongoing manufacturing process, RPN reduction, corrective actions (both internal and external), Eight Disciplines of Problem Solving (8D) and the capture of information pertinent for future use.

To seek assistance in implementing APQP please contact us via our contact page.

APQP Product Programs Home APQP Systems Integration

Robustness is the main key element within the APQP process and in any product and process development cycle. Each of the APQP Tools needs to be integrated to allow robustness to occur. This will ensure a natural flow from APQP phase to phase and APQP tool to tool.

APQP Systems Integration includes robust links as:

  • Critical and Significant Characteristics Flow
  • Boundary and Parameter Diagrams Requirements and Functions into DFMEA
  • DFMEA characteristics into Characteristics Matrix and PFMEA
  • DFMEA and DVP&R interaction
  • System, Subsystem, Component Interaction
  • MSA interaction with DFMEA and PFMEA
  • PFMEA Flow into Control Plan
  • Control Plan Flow into SPC results
  • SPC Results flow into Process Capability Studies and new programs
  • 8D/RCA interation with DFMEA, PFMEA, DVP&R, MSA, SPC
Quality One Australia is embarking on the development of an APQP tool that delivers the robustness requirements within APQP. Please visit our iProgent™ page for further details.

To seek assistance in implementing APQP Systems Integration please contact us via our contact page.

APQP Product Programs Home APQP Tool Development

Quality One is developing a comprehensive and robust APQP Tool under the iProgent™ banner. The APQP tool will be released in a progressive manner as each tool becomes integrated into the APQP Professional Tool.

These release phases will include:
Version 1 - APQP Product Risk Analysis
APQP Professional Version 1 will allow organisations to breakdown a product and apply risk based questions to each system, subsystem and component and identify where key risks occur and where priority of analysis should be concentrated.

Future versions will include

  • Flow through from risk levels to Boundary Diagram, Parameter Diagram and DFMEA
  • DFMEA link to PFMEA
  • DFMEA link to DVP&R
  • PFMEA flow through to PCP
  • Audit trailing through system, subsystem and component
  • Audit trailing through APQP tool links
  • Action Reporting
  • Full APQP Tool Reporting
  • Linking capability data to PCP and future analysis
To enquire on the progress of the APQP Professional Tool please contact us via our contact page.

APQP Product Programs Home APQP Product Development

Introduction to APQP Support

Many companies find it confusing to implement Advanced Product Quality Planning (APQP). The lack of resources may also contribute to the need for APQP Support. Quality-One provides APQP Support for strategy development, tools facilitation and contract services, which enhance problem prevention during product and process development. Quality-One has developed an approach to determine the level of applicability of APQP, based on potential value.

APQP is growing in use across a diverse spectrum of industries. It is no longer an automotive-specific process, as non-automotive industries using APQP currently out number automotive usage. Our APQP Support Services have a proven track record of providing value as measured by, time to complete product and process design, improved utilization of engineering resources, fewer problems at launch and improved customer satisfaction.

About APQP Facilitation

APQP Facilitation is very efficient. The total cost and time impact of a poor APQP activity is not initially measured by the organization. The cost of recalls, problem solving and lost customers is only felt after the product or service is launched. This is the aftermath of poor planning. With shorter development times, fewer engineers and technical personnel dedicated to a project, APQP methodology can improve Product Development (PD) efficiency.

APQP without facilitation and support is often described as tedious, boring and sluggish. The total time to complete APQP, considering resources and number of development hours, is shorter when experienced with a skilled Quality-One APQP Facilitator. Our customers report greater than 70% reduction in development time and therefore their resources are utilized more effectively on the actual design work. The results of APQP Facilitation are measured in mitigation actions on risk discovered and flawless launch.

APQP Checklist Plan and Define  APQP Checklist Design  APQP Checklist Process

APQP Checklist - Plan & Define               APQP Checklist - Design                 APQP Checklist - Process

Benefits of APQP Facilitation

Customers may experience the following benefits of APQP Facilitation:

  • Greater than 70% reduction in time to complete key tools (resources better utilized)
  • Structured Methodology which is more process oriented vs. “check-the-box”
  • Risk actions directed toward design review process
  • Earlier determination of need for prevention actions
  • Less subjective discussion time on items with small risk
  • Team size is modulated and changed, respecting the valuable time of team members
  • Responsible engineer receives an output which can immediately be used in design activity impacting performance and safety
About APQP Contract Services

APQP Contract Services are necessary when speed and effectiveness are of utmost importance. Using your Engineering and Technical Resources to apply the tools of APQP without assistance can be very time consuming. Companies with large or complex projects must discover and mitigate risk throughout the product and process development process. The number of APQP tools and depth of content is often overlooked. APQP Contract Services from Quality-One will provide value in tool use and relief to already burdened engineering and technical staff. We will join your team and provide instant results through utilization of “Best Practices” from years of experience using the APQP process. Our APQP Contract Services may be used in:

  • Tools Facilitation (i.e. FMEA, DFM/A, Control Plan Methodology, etc.)
  • Quality planning phase and scheduling
  • Management of the APQP process including Design Review structure
  • Follow Up of Actions for Risk Mitigation
  • Training and Mentoring of Suppliers in APQP
  • Training and Mentoring of Technical Staff
Benefits of APQP Contract Services

  • Ready to work personnel with expertise in APQP
  • Cost effective in reducing time for APQP product development
  • Increase in time for engineers to develop and design
  • Performed correctly and with the emphasis on discovery of failure, not filled in forms
  • Assurance that your customer’s expectations of APQP are delivered
  • Hands On skills development adopted by the team as they are exposed to the Quality One experts
To seek assistance in implementing APQP please contact us via our contact page.

APQP Product Programs Home APQP Feedback Loops

APQP Plan Do Study Act

APQP Feedback Loops provide input for new programs, next iterations of products and current programs through robust connections in:

  • VOC and Product Requirements and Specifications
  • Historical and Legacy Data and Iterative and New Products
  • Boundary Diagram, Parameter Diagram, DFMEA
  • DFMEA and DVP&R
  • DFMEA, Characteristics Matrix, Process Flow and PFMEA
  • PFMEA and PCP
  • PCP, MSA and SPC
  • SPC and future designs
  • SPC and Field Data
  • DFMEA, DVP&R, Process Flow, PFMEA, PCP, MSA, SPC and PPAP
  • DFMEA, DVP&R, Process Flow, PFMEA, PCP, MSA, SPC and 8D
To seek assistance in implementing APQP please contact us via our contact page.

Forthcoming courses

Lean Six Sigma Yellow Belt
10 August 2022 [More...]
Process Mapping
12 August 2022 [More...]
15 August 2022 [More...]

Latest News

Lean Six Sigma White Belt Training Melbourne


Lean Six Sigma White Belt Training
The next Lean Six Sigma White Belt training course in Melbourne has been scheduled for the 8th of July 2022.


8D Training Melbourne


8D Training
The next 8D training course in Melbourne has been scheduled for the 6th and 7th of July 2022.


FMEA Training Melbourne


The next FMEA training course in Melbourne has been scheduled for the 4th and 5th of July 2022.

Quality One - Discover the Value

Quality One Australia was first established as Quality Associates Australia in 2005 due to an overwhelming response for its partner company, Q1 - Quality One USA to provide quality training, consultation and facilitation services to various industries throughout the South East Asia region.  We rebranded in 2018 to more closely align with our US partner.

We specialise in end to end process and quality management from initial education, training, curriculum and certification ( Lean Six Sigma , 8D , FMEA, APQP, SPC etc. ) through to the implementation of quality management, electronic management and business and process improvements across your organisation. We deliver change, improvement and solutions to organisations locally, throughout Australia, across the Asia region and globally through our Q1 network.

If you desire this level of excellence then let us help you achieve your goals.
Learn More
Copyright © 2022      This website and its associated software are the property of Quality One Australia. This software may not be copied redistributed or modified for any purpose without the express written permission of the copyright owners. All rights reserved.