APQP (Advanced Product Quality Planning)

PPAP (Production Part Approval Process)

Quality Core Tools

Helping organisations Implement APQP & PPAP

APQP Prevents Expensive Repetition.

APQP and PPAP aren’t paperwork exercises. They are structured ways to prevent

So why don’t organisations fully adopt it? Because the effort is required today, the payoff comes later. Humans are wired to delay uncomfortable work.

Think: Retirement planning, Health and fitness, Difficult conversations We know avoiding them has consequences. But we still postpone. APQP is no different.

The question is: Are you preventing problems or paying for them later?

Course Content -

Can also be tailored depending on skills and experience.

1. Introduction to APQP and PPAP

Understanding APQP: Overview of the Advanced Product Quality Planning framework and its role in managing product development and quality planning.
What is PPAP?: Comprehensive look at the Production Part Approval Process, how it fits into the product lifecycle, and why it’s critical for customer approval.

2. APQP: Five Phases of Quality Planning

Phase 1: Planning & Defining the Program
- Aligning customer requirements with internal processes.
- Defining project objectives, timelines, and goals.
Phase 2: Product Design and Development
- Conducting Design Failure Mode and Effect Analysis (DFMEA).
- Design validation, reviews, and prototype testing.
Phase 3: Process Design and Development
- Process flowcharts, Process Failure Mode and Effect Analysis (PFMEA), and Control Plans.
Phase 4: Product and Process Validation
- Pre-production trial runs and validation.
- Measurement System Analysis (MSA) and Statistical Process Control (SPC) studies.
Phase 5: Continuous Feedback & Corrective Actions
- Implementing continuous feedback loops.
- Addressing corrective actions to improve future production runs.

3. PPAP: Ensuring Production Readiness

The 18 Key Elements of PPAP: In-depth coverage of each element, including design records, process flows, control plans, and process capability studies.
Preparing PPAP Documentation: How to create, submit, and manage the Part Submission Warrant (PSW) and supporting documents for customer approval.

4. Key Tools and Techniques

Risk Management Tools: Using DFMEA and PFMEA to identify and mitigate risks early in the design and production processes.
Statistical Analysis: Conducting Measurement System Analysis (MSA) and Statistical Process Control (SPC) to ensure process capability and quality.
Control Plans: Developing and maintaining control plans to ensure consistent, repeatable production quality.

5. Deployment & Integration into Organizational Culture

Sustainable Implementation: Strategies to embed APQP and PPAP into the organizational culture, ensuring they become part of everyday operations.
Cross-Functional Teams: Training on how to build and manage cross-functional teams to improve communication and collaboration between departments.
Leadership and Continuous Improvement: How leaders can drive continuous improvement efforts and foster a culture that supports APQP and PPAP practices.

6. Real-World Applications

Case Studies: Real-life examples of successful APQP and PPAP implementations in various industries.
Hands-On Exercises: Practical workshops that simulate real-world scenarios, allowing participants to practice creating control plans, conducting PFMEA, and preparing PPAP documentation.

7. Sustaining Results

Best Practices: Insights on how to sustain the benefits of APQP and PPAP through ongoing audits, performance reviews, and continuous improvement initiatives.

Training Outcomes

Participants will leave the training with:

A comprehensive understanding of APQP and PPAP processes.
The ability to develop and implement control plans, DFMEA/PFMEA, and process validation methods.
Skills to integrate these quality planning processes into their organizational culture to ensure long-term success.
Practical experience preparing PPAP submissions and engaging with customers during the approval process.