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What are the best practices for documenting risks and controls in APQP?

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Advanced Product Quality Planning (APQP) is a structured process for developing and launching new products that meet customer requirements and expectations. One of the key aspects of APQP is identifying and managing the potential risks and controls that may affect the product quality, performance, safety, and reliability. In this article, you will learn what are the best practices for documenting risks and controls in APQP, and how they can help you achieve successful product outcomes.

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Chander Mohan Dhingra

OLA Electric|TATA Motors |RENAULT NISSAN| Quality Assurance| Supplier Quality | Project Management | Battery Electric…
Dr. RVS Praveen Ph.D

Director - Product Engineering at LTIMindtree
Ansuman Mohanty

B.tech In mechanical engineering with more than 9 years of experience in Quality in precision manufacturing and…

1 Define the scope and objectives

Before you start documenting risks and controls, you need to define the scope and objectives of your APQP project. This will help you establish the boundaries, deliverables, assumptions, and constraints of your product development. You should also align your scope and objectives with the customer needs, specifications, and standards, as well as the internal and external stakeholders. By defining the scope and objectives, you can set the direction and expectations for your risk and control documentation.

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Dr. RVS Praveen Ph.D

Director - Product Engineering at LTIMindtree
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1. Define project scope to establish boundaries, deliverables, assumptions, and constraints. 2. Align scope and objectives with customer needs, specifications, and standards. 3. Ensure alignment with internal and external stakeholders' expectations and requirements. 4. Set clear direction for risk and control documentation within the APQP project. 5. Establishing scope and objectives provides a framework for effective project planning and execution.

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Ansuman Mohanty

B.tech In mechanical engineering with more than 9 years of experience in Quality in precision manufacturing and automotive industry
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The Most important thing is Planning at the start of the project. Understanding The requirements of drawing. Define the plan to Achieve. If Fixtures are need to be developed that is taken into account sling with ETA. Second Most important thing is customer Communication. Get Clarity of the party and CTQs.

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2 Identify the risks and sources

The next step is to identify the risks and sources that may affect your product quality and performance. You can use various tools and techniques, such as brainstorming, checklists, FMEA, SWOT analysis, PEST analysis, and stakeholder analysis, to generate a comprehensive list of potential risks and sources. You should consider both internal and external factors, such as design, manufacturing, testing, supply chain, environment, regulation, and competition. You should also prioritize the risks based on their likelihood and impact, and assign them to the responsible owners.

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Ansuman Mohanty

B.tech In mechanical engineering with more than 9 years of experience in Quality in precision manufacturing and automotive industry
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Utilizing tools like FMEA Brain Storming with design and development team,Weekly review on the project with project engineers. Time management objectives to achive the project deadline.

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Dr. RVS Praveen Ph.D

Director - Product Engineering at LTIMindtree
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1. Utilize tools like brainstorming, FMEA, and SWOT analysis to identify potential risks and sources. 2. Consider internal and external factors including design, manufacturing, supply chain, and regulation. 3. Prioritize risks based on likelihood and impact, assigning responsibility to owners. 4. Generate a comprehensive list of risks using checklists, PEST analysis, and stakeholder analysis. 5. Ensure a thorough understanding of all factors that could impact product quality and performance.

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3 Document the risks and controls

Once you have identified the risks and sources, you need to document them in a clear and consistent format. You can use a risk register, a risk matrix, or a risk map to capture and organize the relevant information about each risk, such as its description, category, owner, probability, impact, severity, detection, occurrence, mitigation strategy, control plan, and status. You should also document the controls that are in place or planned to prevent or reduce the risks, such as design reviews, testing protocols, quality audits, contingency plans, and corrective actions.

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Dr. RVS Praveen Ph.D

Director - Product Engineering at LTIMindtree
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1. Document risks in a structured format, including description, category, probability, and impact. 2. Utilize tools like risk registers, matrices, or maps to organize relevant information. 3. Capture details such as risk owner, severity, detection, occurrence, and mitigation strategy. 4. Document controls in place or planned, such as design reviews, testing protocols, and contingency plans. 5. Maintain clear documentation of risks and controls to facilitate effective risk management.

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4 Monitor and review the risks and controls

Documenting risks and controls is not a one-time activity, but an ongoing process that requires regular monitoring and review. You should update your risk and control documentation as the product development progresses, and as new risks and changes emerge. You should also track the performance and effectiveness of your controls, and verify that they are implemented and followed properly. You should also communicate and report the status and results of your risk and control documentation to the relevant stakeholders, such as customers, suppliers, management, and team members.

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Chander Mohan Dhingra

OLA Electric|TATA Motors |RENAULT NISSAN| Quality Assurance| Supplier Quality | Project Management | Battery Electric Vehicle I Strategic Sourcing 20 + Years With TATA Motors, RENAULT NISSAN
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High Risk, Medium Risk and Low Risk part supplier combination must be defined in design stage based on New Technology, New Supplier and Severity and stage wise simulations and testing to be monitored and reviewed to mitigate Risk

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5 Learn and improve from the risks and controls

The final step is to learn and improve from your risk and control documentation. You should analyze the data and feedback that you collected from your monitoring and review, and identify the lessons learned, best practices, gaps, and opportunities for improvement. You should also document and share your findings and recommendations with the stakeholders, and incorporate them into your future APQP projects. By learning and improving from your risk and control documentation, you can enhance your product quality and performance, and increase your customer satisfaction and loyalty.

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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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What are the best practices for documenting risks and controls in APQP?

1

2

3

4

5

6

1 Define the scope and objectives

2 Identify the risks and sources

3 Document the risks and controls

4 Monitor and review the risks and controls

5 Learn and improve from the risks and controls

6 Here’s what else to consider

Product Engineering

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What are the best practices for documenting risks and controls in APQP?

1

2

3

4

5

6

1 Define the scope and objectives

2 Identify the risks and sources

3 Document the risks and controls

4 Monitor and review the risks and controls

5 Learn and improve from the risks and controls

6 Here’s what else to consider

Product Engineering

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