What are the most effective ways to reduce costs in your product development process using APQP?

1 What is APQP?

APQP stands for Advanced Product Quality Planning, and it is a framework for managing the quality aspects of product development from the initial concept to the final launch. APQP is based on the principles of quality management, customer satisfaction, and continuous improvement, and it aims to ensure that the product meets or exceeds the customer's needs and expectations. APQP is not a one-size-fits-all approach, but rather a flexible and adaptable process that can be tailored to different products, industries, and organizations. APQP is widely used in the automotive industry, where it was developed by a group of major manufacturers and suppliers in the 1980s, but it can also be applied to other sectors and domains.

2 How does APQP work?

APQP consists of five phases, each with its own set of activities, deliverables, and milestones. In the Plan and Define phase, you define the scope, objectives, and specifications of the product, as well as the roles and responsibilities of the project team. You also identify the customer's needs and expectations, and conduct a feasibility analysis to assess the technical and financial viability. The Product Design and Development phase involves designing and developing the product according to the specifications and requirements; performing various tests and validations to ensure that the product meets the quality standards; and documenting the design and development process. During the Process Design and Development phase, you design and develop the production process that will manufacture the product. You also perform tests and validations to ensure that it is capable, reliable, and efficient. The Product and Process Validation phase requires validating both by conducting trials, inspections, audits, and reviews; collecting data; evaluating performance; implementing corrective or preventive actions; etc. Lastly, in the Launch, Feedback, and Assessment phase you launch the product to the market; obtain feedback from customers; assess effectiveness/efficiency of product development process; identify opportunities for improvement; celebrate success of project; recognize contribution of project team; etc.

3 How can APQP reduce costs?

Using APQP can help you reduce costs in your product development process in several ways. Firstly, following a structured and systematic process can prevent errors, defects, and deviations that cause waste and rework. This can also ensure that the product and the process meet customer needs and quality standards. Secondly, planning and defining the product and the process in advance can optimize resource use while reducing uncertainty and variability. Additionally, streamlining workflows and eliminating redundant steps can improve efficiency and productivity. Lastly, involving stakeholders in the product development process can provide insights to improve the product and process, as well as foster a culture of continuous improvement. This can enhance innovation and creativity, giving you a competitive edge in the market.

4 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?