APQP consists of five phases, each with its own objectives, tasks, and deliverables. Here is a brief overview of each phase and how you can use it to identify quality issues before they become problems.
Phase 1: Plan and Define. In this phase, you define the scope and objectives of your project, and identify the customer needs and expectations. You also establish a team, a timeline, a budget, and a communication plan. You can use tools such as QFD, VOC, KPIs, and project charter to clarify your requirements and goals.
Phase 2: Product Design and Development. In this phase, you design and develop your product specifications, features, functions, and materials. You also verify and validate your design through simulations, prototypes, and tests. You can use tools such as FMEA, DFMEA, DFM, DVP&R, and design reviews to identify and prevent potential design flaws and failures.
Phase 3: Process Design and Development. In this phase, you design and develop your process specifications, parameters, controls, and capabilities. You also verify and validate your process through trials, experiments, and tests. You can use tools such as PFMEA, PFD, CP, SPC, DOE, and process reviews to identify and prevent potential process errors and variations.
Phase 4: Product and Process Validation. In this phase, you validate your product and process performance, reliability, and quality through production runs, inspections, audits, and customer feedback. You also prepare and submit your documentation and records for approval and certification. You can use tools such as PPAP, MSA, GRR, Cpk, and customer satisfaction surveys to ensure that your product and process meet the standards and expectations.
Phase 5: Feedback, Assessment, and Corrective Action. In this phase, you collect and analyze data and information from your product and process performance, quality, and customer satisfaction. You also identify and implement corrective and preventive actions to address any issues or gaps. You can use tools such as control charts, Pareto charts, fishbone diagrams, 8D, and PDCA to monitor and improve your quality and performance.