Quality Management & Training

APQP – Advanced Product Quality Planning

Advanced Product Quality Planning (APQP) is a set of procedures and techniques used to develop products in industry. Although, specifically for the automotive industry it has application in many other organisations. It is quite similar to the concept of Design For Six Sigma (DFSS).

It is a defined process for a product development system for organisations such as; General Motors, Ford, Chrysler and their suppliers. Its general objective is to produce a product quality plan which will support development of a product or service that will satisfy the customer needs and requirements.

Also see Production Part Approval Process (PPAP)


  • Understand the APQP requirements and process.
  • Identify how the APQP process fits with an organisation and its processes.
  • Correlate the Plan Do Study Act (PDSA) model with the APQP cycle.
  • Identify and prioritise the APQP gaps within an organisation.
  • Provide an understanding of the type of tools needed to introduce quality products in the fastest possible time.


  • Management and employee team members from all aspects of the organisation who participate in the activities associated with Advanced Product Quality Planning activities, i.e. manufacturing, engineering, sales, service, quality, etc.
  • ISO/TS 16949 internal auditors or second party auditors
  • Anyone involved in product quality planning activities
  • Anyone involved in the implementation of ISO/TS 16949
  • Anyone interested in learning more about APQP


The delegates should be able to:

  • Understand the objective and phases of APQP
  • Understand the interaction between the customer and supplier during APQP
  • Understand the phases and timings of APQP
  • Be confident in completing a APQP exercise in a work place setting
  • Be QM&T validated and certificated APQP practitioner.


  1. Phase 1: Plan and Define Programme – Determining customer needs, requirements and expectations using tools such as QFD. Reviewing the entire quality planning process to enable the implementation of a quality programme and how to define and set the inputs and the outputs.
  2. Phase 2: Product Design and Development – Review the inputs and execute the outputs, which include FMEA, DFMA, design verification, design reviews, material and engineering specifications.
  3. Phase 3: Process Design and Development – Addressing features for developing manufacturing systems and related control plans.  These tasks are dependent on the successful completion of phases 1 and 2.
  4. Phase 4: Product and Process Validation – Validation of the selected manufacturing process and its control mechanisms through production run evaluation. Including outlining mandatory production conditions and requirements, together with identifying the required outputs.
  5. Phase 5: Launch, Feedback, Assessment and Corrective Action – Focuses on reduced variation and continuous improvement to identify outputs. This links to customer expectations and any future product programmes.
  6. Control Plan Methodology: Discusses use of control plan and relevant data required to construct and determine control plan parameters. Stressing the importance of the control plan in the continuous improvement cycle.


0845 – 1000 Planning and defining an APQP programme
1000 – 1015 Coffee
1015 – 1145 APQP in Product Design and Development and exercises
1145 – 1230 APQP in Process Design and Development and exercises
1230 – 1330 Lunch
1330 – 1415 APQP Product and Process Validation
1415 – 1500 APQP Case Study
1500 – 1515 Coffee
1515 – 1600 Feedback, Assessment and Corrective Action
1600 – 1700 Control Plans and Methodology


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