apqp

Advanced Product Quality Planning (APQP)

When to use

Use this skill when:

• A new product or part is being launched and a structured quality plan is needed
• Managing an APQP project and tracking deliverables across phases
• Conducting an APQP gate review to assess launch readiness
• A customer requests an APQP status report or phase completion confirmation
• Auditing whether a supplier's APQP process is adequate

Prerequisites

• Customer requirements, specifications, and drawings (or RFQ package)
• Programme timing (SOP date, PPAP submission date, prototype gates)
• Nominated APQP team (cross-functional: engineering, quality, purchasing, manufacturing, logistics)
• Customer APQP template if OEM-specific format required

Workflow

Overview — The 5 APQP Phases

Phase 1          Phase 2          Phase 3          Phase 4          Phase 5
Plan & Define → Product Design → Process Design → Product & Process → Feedback &
                & Development   & Development      Validation         Corrective Action
     ↓               ↓               ↓                ↓                  ↓
  Program         Prototype       Pre-launch         PPAP              SOP +
  approval         build           build           submission          Production

All phases run with concurrent engineering — phases overlap and teams work in parallel.

---

Phase 1 — Plan and Define Program

Objective: Understand customer requirements and define what the product must do.

Key deliverables:

| Deliverable | Description |

|-------------|-------------|

| Voice of the Customer (VOC) | Customer wants, needs, expectations — translated to measurable requirements |

| Design Goals | Product performance targets derived from VOC |

| Reliability and Quality Goals | Target failure rate, warranty targets, Cpk targets |

| Preliminary Bill of Materials | Draft BOM from design intent |

| Preliminary Process Flow | High-level process sequence |

| Preliminary Special Characteristics | Initial list of critical/significant characteristics |

| Product Assurance Plan | Quality plan for the programme |

| Management Support | Signed-off programme charter with resources and timing |

Gate 1 pass criteria:

• Customer requirements documented and agreed
• Feasibility confirmed (technical and commercial)
• Team chartered and timing plan approved
• Special characteristics list preliminary but complete

---

Phase 2 — Product Design and Development

Objective: Translate customer requirements into a product design with verified characteristics.

Key deliverables:

| Deliverable | Description |

|-------------|-------------|

| DFMEA | Design FMEA — all failure modes analysed, H-AP items addressed |

| Design Verification Plan (DVP) | Test plan linked to DFMEA failure modes |

| Drawing and Specification Release | Fully released engineering drawings and 3D data |

| Material Specifications | Raw material specs, supplier approval plan |

| Drawing and Specification Changes | Change management process in place |

| New Equipment and Tooling | List of new equipment/tooling required |

| Special Product and Process Characteristics | Updated with design detail |

| Gauge Plan | MSA requirement list — which characteristics need MSA studies |

| Prototype Control Plan | Control plan for prototype builds |

| Prototype Build | Prototype parts manufactured and tested |

| Engineering Drawings | Released and approved |

Gate 2 pass criteria:

• DFMEA complete with all H-AP actions closed
• DVP complete and test execution started
• Prototype build results acceptable
• All special characteristics identified and confirmed
• No outstanding major design concerns

---

Phase 3 — Process Design and Development

Objective: Design and verify the manufacturing process.

Key deliverables:

| Deliverable | Description |

|-------------|-------------|

| Packaging Standards | Packaging design, labelling, MMOG/LE if required |

| Product/Process Quality System Review | Internal quality system audit against customer requirements |

| Process Flow Chart | Detailed process flow for all operations |

| Floor Plan Layout | Manufacturing floor layout approved |

| Characteristics Matrix | Matrix linking process steps to product characteristics |

| PFMEA | Process FMEA — all failure modes, AP ratings, H-AP actions complete |

| Pre-Launch Control Plan | Control plan for pre-launch production |

| Process Instructions | Work instructions for all operations |

| MSA Plan | Gauge R&R plan for all measurement systems |

| Preliminary Process Capability Study Plan | Plan for capability studies on special characteristics |

| Packaging Specifications | Final packaging specs including OEM labelling |

Gate 3 pass criteria:

• PFMEA complete, H-AP actions closed or formally accepted
• Pre-launch Control Plan approved
• Process instructions complete for all operations
• Tooling and equipment installed and qualified
• No unresolved open issues blocking pre-launch build

---

Phase 4 — Product and Process Validation

Objective: Validate the production process and prepare for PPAP submission.

Key deliverables:

| Deliverable | Description |

|-------------|-------------|

| Production Trial Run | Significant Production Run (minimum run to PPAP requirements) |

| MSA Studies | Gauge R&R completed for all special characteristics |

| Preliminary Process Capability | Cpk study on special characteristics (target ≥ 1.67) |

| Production Part Approval (PPAP) | All 18 PPAP elements complete and submitted |

| Production Validation Testing | Final validation tests on production parts |

| Packaging Evaluation | Production packaging validated |

| Production Control Plan | Final production control plan approved |

| Quality Planning Sign-Off | Customer approval of PPAP and APQP completion |

| Management Support Sign-Off | Internal management approval for SOP |

Gate 4 pass criteria (= PPAP approval):

• Significant production run completed (minimum 300 consecutive parts per AIAG PPAP 4th ed §4.0, unless the customer specifies otherwise in writing)
• Dimensional results 100% conforming
• Cpk ≥ 1.67 on all special characteristics (or customer-approved deviation)
• %GRR < 30% for all MSA studies
• PPAP submitted and customer approval received
• No open concerns from validation testing

---

Phase 5 — Feedback, Assessment and Corrective Action

Objective: Continuous improvement after SOP — close the loop on any issues found in production.

Key activities:

| Activity | Description |

|----------|-------------|

| Reduced variation | Monitor process capability, reduce common-cause variation |

| Improved customer satisfaction | Track warranty, field returns, and customer scorecards |

| Improved delivery and service | Monitor OTD (on-time delivery) and logistics performance |

| Lessons learned | Document lessons learned for future programmes |

| Control Plan updates | Update based on production data and any quality escapes |

| PFMEA updates | Update based on field failures and warranty data |

Phase 5 is ongoing. There is no defined end gate — it runs for the life of the programme.

---

APQP timing — rule of thumb

| Milestone | Typical timing before SOP |

|-----------|--------------------------|

| Programme approval / Phase 1 complete | 18–24 months |

| Design release / Phase 2 complete | 12–15 months |

| Process design complete / Phase 3 complete | 8–10 months |

| PPAP submission | 4–6 months |

| PPAP approval (customer) | 3–4 months |

| Pre-production builds | 2–3 months |

| SOP | 0 |

Automotive OEM programmes vary — always confirm with the customer's APQP coordinator.

Validation criteria

At each gate review, verify:

• All deliverables for the phase are complete (not "in progress")
• No open H-AP items in DFMEA or PFMEA without approved actions
• No outstanding design or process concerns without a documented resolution plan
• Team sign-off obtained from all functions (quality, engineering, manufacturing, purchasing)
• Customer confirmation received before advancing to next phase

Gate reviews are STOP gates — do not advance until all criteria are met.

Common mistakes

• Starting Phase 2 before customer requirements are fully understood and documented (Phase 1 incomplete)
• PFMEA created after process is already running — it must drive process design, not document it
• Production trial run shorter than 300 consecutive parts without written customer authorisation — the PPAP samples must come from this run; a shorter run requires an explicit customer waiver
• Capability studies run on off-tool or pre-production parts — must be from production tooling
• Prototype Control Plan used for PPAP submission — production control plan must be separate
• MSA studies done after PPAP submission — must be complete before PSW is signed
• Phase 5 never started — APQP is treated as "done" at SOP rather than as a continuous loop
• Lessons learned not captured — same problems recur on next programme

Output Format

At the start of each use, ask the user:

> "How would you like to receive the output?

> A — Structured Markdown (formatted tables and sections, ready to copy)

> B — Plain tables (simplified structure for Excel or Word)

> C — Narrative report (flowing text for a formal document or email)

>

> Default: A."

Adapt all output sections to the chosen format. If the platform or session context already defines a format preference, skip this question.

Changelog

| Version | Date | Author | Change |

|---------|------|--------|--------|

| 1.0 | 2026-06-06 | @RBraga01 | Initial release |

| 1.1 | 2026-06-06 | @migmcc | Added 300-part production trial run minimum to Gate 4 criteria and Common Mistakes |