How do you use QFD and FMEA together in APQP?

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Advanced Product Quality Planning (APQP) is a structured approach to product development and quality management that aims to ensure customer satisfaction and prevent defects. APQP involves five phases: planning, product design and development, process design and development, product and process validation, and feedback and corrective action. In each phase, various tools and techniques are used to identify customer needs, design specifications, potential risks, and improvement opportunities. Two of the most important tools are Quality Function Deployment (QFD) and Failure Mode and Effects Analysis (FMEA). How do you use QFD and FMEA together in APQP?

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Juan Valdez, CLSSBB

Mechanical Engineering | Program Management |Lean Six Sigma Black Belt | NPI | Continuous Improvement | R&D |…
Eduardo L. Garcia

Creating productive and motivating environments in manufacturing | Kaizen Leader | TPS Sensei | MBA | Black Belt

1 QFD: The Voice of the Customer

QFD is a method of translating customer requirements into measurable design features and process parameters. QFD uses a matrix called the House of Quality (HOQ) to link customer needs, competitive benchmarks, technical characteristics, target values, and correlation factors. QFD helps to prioritize the most critical customer needs and align them with the best design solutions. QFD also helps to reduce the gap between customer expectations and product performance, and to improve communication and collaboration among cross-functional teams.

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Eduardo L. Garcia

Creating productive and motivating environments in manufacturing | Kaizen Leader | TPS Sensei | MBA | Black Belt
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Interesting Topic... the modern QFD is a 5-phase (4 usually) waterfall deployment, and the APQP roadmap can be visualized throughout this cascade-QFD. 1- Starting with Voice Of Customer (VOC), we get Critical To Quality (CTQ) characteristics or the design Requirements. 2- From the CTQ, we get the Engineering Design Characteristics. 3- From Engineering Design Characteristics, we get the Product Characteristics. 4- From Product Characteristics, we get Manufacturing & Purchasing Characteristics. 5- From Manufacturing & Purchasing Characteristics, we get Production Quality Controls. 6- From Production Quality Controls, we get the MSA. Then, we can visualize the entire process in a simple cascade.

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Rahul Ghorpade

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QFD translates customer needs and wants into technical requirements for a product or service. FMEA, or Failure Mode and Effects Analysis, identifies potential failures, assesses their severity, and determines the likelihood of occurrence. FMEA helps identify failures that could impact customer satisfaction, allowing us to trace back to the root causes through QFD. FMEA helps prioritize corrective actions based on the severity and likelihood of failures, ensuring that resources are allocated effectively. QFD helps ensure that customer needs are met throughout the product development process, while FMEA helps identify and mitigate potential failures before they occur.

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2 FMEA: The Risk Assessment Tool

FMEA is a technique of identifying and evaluating the potential failures of a product or process, and their causes and effects. FMEA uses a table to list the failure modes, their severity, occurrence, and detection ratings, and their risk priority numbers (RPNs). FMEA helps to prevent or reduce the impact of failures, and to prioritize the actions for improvement. FMEA also helps to document the current knowledge and assumptions, and to track the progress and results of corrective actions.

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Juan Valdez, CLSSBB

Mechanical Engineering | Program Management |Lean Six Sigma Black Belt | NPI | Continuous Improvement | R&D | Increase Sales & EBIT% | Reduce Costs | Innovator |
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Quality Function Deployment (QFD) and Failure Mode and Effects Analysis (FMEA) are pivotal in Advanced Product Quality Planning (APQP). 1. QFD captures customer requirements and translates them into design specifications, ensuring products meet customer needs. 2. FMEA, the risk assessment tool, identifies potential failure modes, their causes, and effects. This proactive approach prioritizes risks and develops mitigation strategies. Best Practices: - Use QFD to ensure customer requirements drive the design process. - Implement FMEA to assess risks, and integrate tools like Bowtie XP for comprehensive risk analysis. - Regularly review and update both tools to adapt to evolving requirements and risks.

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3 QFD and FMEA: The Dynamic Duo

QFD and FMEA are complementary tools that can be used together in APQP to enhance the quality and reliability of a product or process. These tools can be integrated in several ways, such as taking the output of QFD as the input of FMEA or vice versa. Additionally, a feedback loop between QFD and FMEA can be created to update and revise the HOQ and FMEA, as well as to identify new customer needs, design features, process parameters, failure modes, and corrective actions. This feedback loop can be initiated by using the results of product and process validation from APQP.

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4 QFD and FMEA: The Benefits

Using QFD and FMEA together in APQP can bring several advantages, such as improving customer satisfaction by ensuring the product or process meets their expectations, enhancing quality and reliability, reducing costs and waste, increasing efficiency and effectiveness, and fostering innovation and creativity. By doing so, it can help eliminate or reduce the need for rework, scrap, warranty, and recalls, as well as streamline product development and quality management processes to reduce time to market and cycle time.

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5 QFD and FMEA: The Challenges

Using QFD and FMEA together in APQP can be challenging, requiring a high level of commitment and involvement from the top management and all stakeholders. It also demands a high level of data collection and analysis, which can be time-consuming, complex, and subjective. Additionally, it involves a high level of uncertainty and ambiguity that can lead to conflicts, misunderstandings, and errors. Finally, it needs a high level of training and education that can be costly, difficult, and inconsistent.

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6 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?

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Advanced Product Quality Planning (APQP)

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How do you use QFD and FMEA together in APQP?

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1 QFD: The Voice of the Customer

2 FMEA: The Risk Assessment Tool

3 QFD and FMEA: The Dynamic Duo

4 QFD and FMEA: The Benefits

5 QFD and FMEA: The Challenges

6 Here’s what else to consider

Advanced Product Quality Planning (APQP)

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