APQP - Advanced Product Quality Planning

Explore the goals, benefits, and phases of advanced product quality planning (APQP) and how early product stability through PCB supports reliable launches with a PCB control plan approach.

APQP provides a structured upstream planning method to ensure customer satisfaction and prevent downstream issues, using a multidisciplinary cross-functional team across design, process design, manufacturing, maintenance, purchase, and suppliers.

Define and align goals of APQP through clear communication, set zero defect targets, manage tolerances and critical parameters within specification limits, and drive continuous improvement from prototype to production.

APQP guides cross-functional, parallel product and process planning to reduce design and process changes, lower development costs, and shorten lead times through early supplier involvement and continuous improvement.

Form a cross-functional team led by engineering with product design, quality assurance, purchasing, manufacturing, and sales; define roles and a timing plan, then track plan vs actual with color codes.

Plan inputs by capturing voice of the customer from market feedback. Incorporate market research, warranty data, distributors and internal feedback, and team experience to guide design.

Benchmark data from customer samples and competitors informs practical performance targets. Collect process data from competitors, customers, and internal clients to guide long-range reliability, durability testing and life enhancement strategies.

Document product and process assumptions in the project plan, use them as inputs, and prepare alternate paths if they fail; leverage customer inputs to gauge needs, expectations, and satisfaction.

Plan phase one by translating the voice of the customer into measurable design goals. Define inputs and outputs, including design goals, cost, performance, reliability, and quality.

Explore phase two of APQP, covering product design and development from input to output, emphasizing dfm, dfa, design fmea, design verification, and design reviews, including prototype builds and evolving specs.

Develop a prototype and its control plan by detailing dimensions, materials, and tests; use FMEA to drive design for manufacturability, perform inspections, endurance testing, and manage changes.

Explore APQP phase 3 and 4 team outputs, including FMEA, control plan, MSA, and packaging standards, plus equipment, procurement plans, and production part approval.