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‡ APQP, provides in advance reference for

developing product quality planning cycle to
support the development of a product/service which
will satisfy the needs and expectations of the
customers.

!

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‡ Better understanding of customers needs and
expectations well in advance

‡ Reference guideline for a product from inception

stage to the complete development stage

‡ A means for an organization to communicate well

in advance to its suppliers also.

‡ Reduction in complexity of product quality

planning for the customer and organization.
  

Product quality planning cycle as shown in above

figure is the graphic depiction of a typical program
which supports the product/service development phase
wise.
Main purpose of product quality planning cycle is to
emphasis :

‡  "
  |  - First three quarter of

the cycle are denoted to up front produce quality
planning through product/process validation.

‡
$

" |%
%


| : Fourth
quarter of the stage where importance of evaluating
the output scores two functions. To determine
 s To determine if customer are satisfied
s To support the pursuit of continual improvement

It is never ending pursuit of continual improvement

that can only be achieved by taking the experience in
one program and applying that acquired knowledge
to the next programme.


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   | 
‡ PQP is a structured method of defining and
establishing the steps necessary to assure that a
product satisfy the customer. Goal of PQP is to
communicate with everyone involved to assume that
all required steps are completed well in time.

Product quality planning cycle addressed in the following

Sec. 1 Plan & Define Programme

Sec. 2 Product Design & Development
Sec. 3 process Design & Development
Sec. 4 Product / Process Validation
Sec. 5 Feed back, assessment and corrective action
Sec. 6 Control Plan methodology
Sec. 1     
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‡ Main purpose of this section is to understand properly

customer¶s need and specifications well in advance.
Input and outputs applicable to the process may vary
according to product / process and customer needs &
expectation :

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# 

#

= à V o ice o f cu st o mer =à D es ig n g o als

- à M ar k et R esear ch
- à War r a nt y and q u a lit y
in sp ect io n
- à T ea m exp er ie n ce
= à B u s in es s P la n/ M ar k et ing
S tr at eg y
= à P ro d u ct . Pro cess B e nc h
M ar k ing
= à P ro d u ct R elia b ilit y st u d ies
= à C u st o mer inp u t
=à R e lia b ilit y & q u a lit y g o a ls
=à P r e lim in ar y B O M
=à P r e lim in ar y P ro cess P la n c har t
=à P r e lim in ar y list in g o f sp ec ia l
p r o d u ct s / p ro cess
char act er ist ic s
= à P ro d u ct Assu r a nce P la n
= à M a nag e me nt su p p o rt

= à V o ice o f C u st o mer =à M et ho d o lo g y/I nsp ect io n

- à M ar k et R esear ch =à C u st o mer int er ve nt io n
=à M ar k et t est & r epo rt s
=à Y ew p r o d u ct q u alit y a nd
r e lia b ilit y st u d y
=à C o mp let e p r o du ct q u alit y
= à ] ist o r ica l w ar r ant y a nd =à War r a nt y r ep o rt s
q u a lit y in s p ect io n =à C ap a b ilit y in d icat io n
=à I nt er na l p la nt q u alit y r ep o rt s
=à P ro b le m r eg u lat io n r epo rt
=à C u st o mer p la nt r et ur n &
r e ject io ns
=à F ie ld R et u r n r ep o rt ana lys is

= à T ea m exp er ie n ce =à M ag az in e, new s p ap er r ep o rt s
=à Q FD
=à C u st o mer let t er and su g g est io ns
=à D ea ler co mme nt s
=à F ie ld S er v ice R ep o r t s

= à B u s in es s P la n/M ar k et st r at eg y
( C u sto mer )
= à P ro d u ct / P ro cess & B e nc h
M ar k d at a
= à P ro d u ct r elia b ilit y st u d ie s
= à C u st o mer s inp u t s / d es ig n
g o als/r e lia b ilit y a nd q u a lit y
g o als
= à P r e lim in ar y B O M
= à P ro d I nsp ect io n
= à M a nag e me nt co mme nt s and
d ir ect io ns
= à P ro b le ms & is su es r ep o rt ed
fr o m cu st o mer
= à G o vt. r eq u ir e me nt s &
r eg u lat io ns
= à C o nt r act r ev iew
= à S ha ll p r o v id e in fo r mat io n o n
= à T im in g /co st /in v est me nt p ro d u ct
p o sit io n in g r esear c h &
d eve lo p me nt r eso u r ces
= à T ar g et C u sto mer
= à e y sa le s p o int s
= à e y co mp et it o r s
= à P ro d u ct / P ro cess p er fo r ma nce
t ar g et s
= à B e nc h mar c h id e nt if icat io n
= à G ap u nd er st and in g
= à C lo se g ap /e xceed be nc h mar k
= à T ech n ica l in no v at io n s
= à Ad va nc e mat er ia l
= à R e lia b ilit y as ses s me nt and new
t echno lo g y.
= à Fr eq u e nc y o f r ep a ir s o r
r ep lace me nt o f co mp o ne nt s et c.
=à C u st o mer need s/e xp ect at io ns
=à M easu r a b le d es ig n o b ject ives
=à S a fet y st and ar d s
=à S er v icea b ilit y
=à P ro d u ct R elia b ilit y
=à Fr eq u e nc y o f r ep o rt s
=à BOM
= à Ôreliminary Ôrocess lo = à Ôrocess lo harts
hart

= à Ôreliminary listing o special = à pecial characteristics E s

product process
characteristics

= à Ôroduct ssurance Ôlan = à Identi ication o reliability,

durability complexity, oals /
equirements
= à ÷ssessment o ne tech/
material, application,
environment, packaging,
service and m g. equirements
= à mevelopment o ÷

= à Èanagement upport = à memonstration to top

management on the progress on
Ô Ô cycle. To have interest,
top management note is
important or success o
programme
Sec.2 

#| &

%

| 

A s o ut p ut o f S ect io n 1
 


= à D FM A
= à D es ig n fo r ma nu fact u r ib ilit y a nd
asse mb ly
= à D es ig n ver if ic at io n
= à D es ig n r ev iew s
= à P ro to t yp e bu ild s co ntro l p la n
= à  ng in eer ing d r aw in g inc lu d in g
( mat h d at a)
= à  ng in eer ing sp e c if icat io n s
= à M at er ia l sp e c if icat io n s
= à D r aw ing & sp e c if icat io n c ha ng e
= à Y ew to o lin g , eq u ip me nt and
r eq u ir e me nt s
= à S p ec ia l p r o d u ct /p ro cess cha n
= à G au g es / T est ing eq u ip me nt
r eq u ir e me nt
= à T ea m fea s ib ilit y co mm it ment and
ma nag e me nt su p p o rt

= à D FM  A = à A na lyt ica l ap p r o ach t hat asses ses

t he p ro bab ilit y o f fa ilu r e as w e ll
as t he e ffe ct o f su c h fa ilu r e
= à u iv e d o cu me nt fo r u p d at io n
co nt inu a lly as p er cu sto mer need s
and e xcep t io ns r eq u ir e

= à D es ig n fo r
ma nu fact u r ab ilit y a nd
asse mb ly
C o ns id er at io n fo r
= à D es ig n, co ncep t , fu nct io n and
se ns it iv it y t o mfg . var iat io n
= à M a nu fa ct u r ing / As se mb ly
p r o cess
= à D ime n s io n a l to ler a nc es
= à P er fo r ma nce r eq u ir e me nt s
= à Y o . o f co mp o ne nt s
= à P ro cess ad ju st me nt
= à M at er ia l ha nd lin g
= à I f a n y g o vt . r u le s/r eg u lat io n s o f
ser v ic e r eq u ir e me nt s
= à D es ig n V er ific at io n = à A sse ss mino r cu st o mer s
r eq u ir e me nt ad d r essed

= à D es ig n R ev iew = à I t is a n e ffect ive met ho d to

p r eve nt p ro b le m a nd
u nd er st and in g . It also p ro v id e s
a mec ha n is m t o mo n it o r
p r o gr ess and r ep o rt to
ma nag e me nt .
I t sho u ld in c lu d e e va lu at io n o f :
= à D es ig n/Fu nct io na l r eq u ir e me nt s
= à R e lia b ilit y/co n f id e nce g o a ls
= à C o mp o ne nt / su bs yst e m /
s yst e m d u t y g o a ls
= à C o mp u t er s imu lat io n / B enc h
t est r esu lt s
= à D FM  As
= à D es ig n fo r ma nu fact u r ing /
asse mb ly
=à DOs
= à T est Failu r e
= à D es ig n ver if ic at io n p r o gr ess

= à P ro to t yp e bu ild ~ co ntro l p la n S ho u ld en su r e t hat

= à P ro d u ct / ser v ice meet s
sp ec if ic at io n a nd r ep o rt d at es
= à C o mmu n icat io n a n y co n cer n,
d ev iat io n a nd o r co st imp act to
cu st o mer

= à  ng in eer ing D r aw in g Whe n cu st o mer d r aw ing is no n

ex ist e nt , t he co nt ro llin g d r aw in g
sho u ld be r ev ie w ed fo r
= à A ffe ct , fu nct io n, d u r ab ilit y/
G o vt. r eg u lat o r y s a fet y
r eq u ir e me nt s
= à S u ff ic ie nt in fo r mat io n fo r p art s
d ime ns io na l la yo u t , co nt ro l o f
d ev iat io ns, su r fa ces / lo cato r s
fo r fu n ct io n a l g au g e s d es ig n.
T ea m s ho u ld assu me mat h d at a
is co mp at ib le w it h cu st o mer
= à  ng in eer ing S p ec ific at io ns
= à M at er ia l sp e c if icat io n
= à D r aw ing a nd sp ec if ic at io n
cha ng e
= à Y ew eq u ip me nt to o lin g a nd
fac ilit y r eq u ir e me nt s
= à S p ec ia l p r o d u ct and p ro cess
char act er ist ic s
= à G au g es / T est eq u ip me nt
r eq u ir e me nt s
= à T ea m fea s ib ilit y co mm it ment
and ma nag e me nt su p p o rt
I d ent ify t he fu nct io na l d u r a b ilit y
and ap p ear a nce r eq u ir e me nt s o f
co mp o ne nt / su b asse mb ly, s a mp le
s ize, fr eq u e n c y a nd accep t a nce
cr it er ia o f t hese p ar a met er s
d e fin ed .
M at er ia l sp e c if icat io n fo r sp ec ia l
char act er ist ic s i. e. p h ys ica l
p r o p ert ie s, p er fo r ma nce,
en v ir o n me nt a l, lo ad ing and
sto r ag e r eq u ir e me nt . T hese s ho u ld
be in c lu d ed in co nt ro l p la n
T ea m s ho u ld co mmu n icat e and
d o cu me nt cha ng e s to be do ne to
a ll a ffect ed ar eas.
D FM  A/P AP o r d es ig n r ev iew w ill
ad d r ess n ew eq u ip me nt , to o lin g ,
r eq u ir ed .
S p ec ia l c har act er ist ic s o f p r o d u ct /
p r o cess sho u ld be ad d r es sed a nd
d o cu me nt o n co nt ro l p la n
S ho u ld be id e nt ified a nd list ed ,
t im in g char t fo r ar r ang e me nt s to
be me nt io ned .
T ea m mu st assess t he fea s ib ilit y o f
t he p ro po sed d es ig n at t he t ime
w it h r esp ect to :
= à M a nu fa ct u r ib ilit y
= à A sse mb ly
= à T est ing
= à P ack ag ing
= à D e liv er y ( t ime p la n)
= à C o st po int o f v iew

| '()
 |       

 **  * ** + ,- *- . 

--+ -  **+ /  ** *  *+
 + *0  * 1.  *+2

| 

Fr o m S ect io n s 2 as o ut p ut
 


= à P ack ag ing st and ar d s
= à P ro d u ct / P ro cess q u a lif icat io n r e v iew
= à P ro cess flo w c har t
= à F lo o r p la n la yo u t
= à C h ar act er ist ics mat r ix
= à P FM  A
= à P r e lau nc h co nt r o l p la n
= à P ro cess in st r u ct io n s
= à M easu r e me nt s yst e m a na lys is p la n
= à P r e lim in ar y p r o cess cap ab ilit y s yst e m
p la n
= à P ack ag ing sp e c if icat io n s
= à M a nag e me nt su p p o rt

3.1 P ack ag ing S t and ar d s = à P ack ag ing st and ar d s as p er cu sto mer

o r sho u ld d e s ig n a s to ensu r e p r o d u ct
int eg r it y at po int o f u se.

3.2 P ro d u ct / p ro cess = à T ea m s ho u ld r ev iew t he ma nu fact u r ing

Q u a lit y S yst e m R e v iew lo cat io ns q u a lit y s yst e m ma nu a l, if a n y
ad d it io na l co nt ro l o r pro ced u r al
cha ng e, M anu a l t o be u p g r ad ed

3.3 P ro cess flo w C har t = à ] e lp s to ana lyze t he to t al p r o cess

r at her t han ind iv id u a l st ep s
= à I t he lp s t eam t o fo cu s o n t he p r o cess
w he n co nd u ct ing P FM  AS a nd
d es ig n ing co nt r o l p la n

3.4 F lo o r P la n ua yo u t F lo o r p la n s ho u ld be d e ve lo p ed w h ic h w ill
p r o v id e in fo r mat io n o n :
= à I nsp ect io n p o int s
= à C o nt ro l C har t uo cat io n
= à Ap p lica b ilit y o f v is u a l a id
= à I nt er im r ep a ir st at io ns
= à S to r ag e ar ea fo r d efect ive mat er ia l
3.5 h ar act er ist ics È at r ix ÷ c har act er ist ics mat r ix h ic h s ho s t he
r e lat io ns h ip bet een p r o cess p ar a met er
and ma nu act u r ing s yst e m

3.6 Ô
È E ÷ ÷ Ô
È E ÷ is t o be co nd u ct ed d ur ing
p r o d u ct q u alit y p la n n ing be o r e
p r o d u ct io n. T his ill he lp s in r e v ie in g
and a na lyz in g o ne / r ev ised p r o cess t o
u p d at e co ntro l p la n, is u sed a s
d o cu me nt o r an y u r t her r ev ie

3.7 Ô r e Lau nc h co nt ro l Ô lan Ô u r po se o p r e- lau nc h co nt ro l p la n is ;

= à m et er min e a n y p o t ent ia l no n
co n o r min g d r a in g o r p r io r to in it ia l
p r o d u ct io n
= à È o r e r eq u ent insp e ct io n
= à È o r e in p r o cess and check p o int
= à  t at ist ica l e va lu at io n
= à I ncr eased au d it s

3.8 Ô ro cess I nst r u ct io ns T ea m s ho u ld en su r e t hat su ic ie nt

in o r mat io n o n p r o cess is p r o v id ed o r
act u al p er so n ne l ho p er o r m o p er at io n.
T hese in st r u ct io ns s ho u ld b e d eve lo p ed
ro m :
= à
È E ÷
= à › o nt ro l Ô la n s
= à E ng in eer ing d r a in g s/ p er o r ma nce
sp ec i ic at io n, mat er ia l sp ec i icat io n,
v isu a l st and ar d and ind u st r y st and ar d s
= à Ô ro cess lo › har t
= à
lo o r p la n la yo u t
= à › h ar act er ist ics mat r ix
= à Ô ack ag ing st and ar d s
= à Ô ro cess p ar a met er s
= à Ô ro d u ct io n exp er t ise a nd k no led g e o
t he p ro cess and p r o d u ct s
= à ] and lin g r eq u ir e me nt s
= à V p er ato r s o t he p ro cess
= à  et u p p ar amet er su ch as mac h in e
sp eed , eed , c yc le t ime
3.9 Èeasurement system =à Team should ensure that a plant to
analysis Ôlan accomplish the required measurement
system analysis i.e. developed
=à Ôlan should indicate :
-à auge
-à ÷ccuracy
-à epeatability
-à eproducibility and correction or
duplicate gauges

3.10 Ôreliminary process =à ›ontrol Ôlan should have preliminary

capability study plan process capability studies or
processes / operations

3.11 Ôackaging speci ication =à Team should ensure that steps or

individual product packaging
(including interior partitions)
=à Ôackaging design must assure that the
product per ormance and
characteristics ill remain unchanged
during packaging, transit and
unpacking.

3.12 Èanagement support =à Ôurpose is to apprise the revie status

o pro ect and resolve i any issue is
there
#

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4  4  -   5 4*
+* 4       **-  4 
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| 
#  

#
S ect io n 3 a ll o u t p ut =à P ro d u ct Tr ail R u n
=à M easu r e me nt s yst e m e va lu at io n
=à P r e lim in ar y p r o cess cap ab ilit y st u d y
=à P ro d u ct io n p art ap pro va l
=à P ro d u ct io n va lid at io n t est ing
=à P ack ag ing e va lu at io n
=à P ro d u ct io n C o nt ro l P la n
=à Q u a lit y P la n n in g s ig n o ff a nd
ma nag e me nt su p p o rt

4.1 P ro d u ct io n T r ia l r u n P ro d u ct io n tr ia l r u n sho u ld be co nd u ct ed
u s ing :
= à P ro d u ct io n to o lin g
= à P ro d u ct io n  q u ip me nt
= à P ro d u ct io n  nv ir o n me nt
= à P ro d u ct io n O p er ato r s
= à P ro d u ct Fac ilit y
= à P ro d u ct C yc le T ime sp eed a nd feed et c
= à M in. q u a nt it y fo r p ro d u ct tr ia l r u n is
set b y cu st o mer in cas e no t t eam

4.2 M easu r e me nt s yst e m S p ec if icat io n mea su r e me nt d ev ic es /

eva lu at io n met ho d s sho u ld be u sed to ensu r e o f
eva lu at io n measu r e me nt s yst e m

4.3 P r e lim in ar y p r o cess T h is st u d y s ha ll p r o v id es o n ass ess me nt o f

cap a b ilit y t he r ead in es s o f t he p ro cess fo r
p r o d u ct io n.

4.4 P ro d u ct p art ap p ro va l I nt ent o f P P A is to va lid at e t hat pro d u ct s

mad e fr o m p r o d u ct io n to o l a nd p r o cess
meet eng in eer in g r eq u ir e me nt .
4.5 Ôroduction validation Intent o production validation testing,
system re er to engineering test that validate
products made rom production tooling
and process meets engineering standards.

4.6 Ôackaging Evaluation hould ensure the validation o packaging

standards

4.7 Ôroduction ›ontrol hould update control plan i any change /

Ôlan addition or deletion is observed

4.8 uality planning sign e ore quality planning sign o ensure :

o and management =à ›ontrol Ôlans updation
support =à Ôrocess Instructions
=à 2auge and Test equipments here
special gauge, ixture and test
equipment are required.
=à aeri y gauge, repeatability,
reproducibility and proper usage
#

| 6" 780****+  

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7 * 7 - 4 4 # 4 *

IYPUTS OUTPUTA
A l l o u t p ut s fr o m S e c t io n 4 = à R e d u c e d v a r ia t io n
= à C u s t o me r s a t is fa c t io n
= à D e liv e r y a nd s e r v ic e

5.1 R e d u c e d V a r ia t io n = à C o nt ro l c h a r t s a nd o t he r st at is t ic a l
t e c hn iq u e s s ho u ld be is s u e d a s t o o ls t o
id e nt ify p r o c e s s v a r ia t io n
= à A na l ys is a nd c o r r e ct ive a c t io n s ho u ld
be u s e d t o r e d u c e va r ia t io n.
= à C o nt inu a l im p r o ve m e nt s s ho u ld be
d e mo n s t r at e

5.2 C u s t o me r S a t is fa c t io n T e a m s ho u ld e n s u r e fo r c u st o me r
s a t is fa c t io n

5.3 D e liv e r y a nd S e r v ic e T he d e liv e r y a nd s e r v ic e s t a g e o f q u a l it y

p la n n in g c o nt r ibu t e t he o r g a n iz a t io n/
c u s t o me r p a rt ne r s h ip in s o lv in g p r o b le m s
a nd c o nt inu a l i m p r o ve m e nt . B o t h s ho u ld
w o r k t o g et he r fo r vo ic e o f c u s t o me r .