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How can you effectively use APQP in your product design process?

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APQP, or Advanced Product Quality Planning, is a structured approach to ensure that your product design meets customer expectations and requirements. It involves five phases that cover the entire product lifecycle, from planning and development to launch and feedback. In this article, you will learn how to effectively use APQP in your product design process and how it can benefit your quality management skills and career.

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Adriano Moura

Especialista em Qualidade | Melhoria Contínua | Indicadores | ISO 9001 | Mapeamento de Processos | Lean Manufacturing |…
Kirti Kumar Singh

LinkedIn Top Voice! I am an automobile professional with 20+ years of expertise in supplier management & vehicle build…
Waman Mhadeshwar

LinkedIn Top Voice | COO & Operational Excellence Executive | Supply Chain Innovator | Lean Six Sigma Master Black Belt…

1 Phase 1: Plan and Define

The first phase of APQP is to plan and define the scope, objectives, and deliverables of your product design project. You need to identify the customer needs, expectations, and specifications, as well as the regulatory and technical requirements. You also need to establish a cross-functional team, assign roles and responsibilities, and set a timeline and budget. This phase helps you to align your product design with the customer voice and set clear and measurable goals.

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Adriano Moura

Especialista em Qualidade | Melhoria Contínua | Indicadores | ISO 9001 | Mapeamento de Processos | Lean Manufacturing | Seis Sigmas | PDCA | Kaizen | Programa 5S | Controle Estatístico de Processos (CEP) | Treinamentos
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O planejamento bem feito ditará o sucesso do projeto. Invista tempo e recursos nessa fase, fa?a pesquisas de mercado, entenda o que os seus clientes precisam e o que os seus concorrentes est?o fazendo e deixando de fazer.

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?brahim Berksoy

Laboratuvar Akreditasyonu ve Y?netim Sistemi Dan??man?
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Before starting planning and defining the scope, objectives and deliverables of a product design project at least following questions should be answered: 1- Is "concept" of the project is essential, vital, genius and revolutionary? 2- What for? For complying a real, existing necessity or for complying a future necessity to be demanded in near future by "future" costumers as comfort standards increase? 3- What is the main difference(s) of this product design project as compared to existing product in respect of functionality and method of production. 4- What will be the "value" of this product in terms of usage and exchance?

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2 Phase 2: Product Design and Development

The second phase of APQP is to design and develop your product according to the customer requirements and specifications. You need to use various tools and techniques, such as design reviews, failure mode and effects analysis (FMEA), design verification and validation, and risk management, to ensure that your product design is feasible, reliable, and safe. You also need to document your design outputs, such as drawings, specifications, and test results, and communicate them to the relevant stakeholders. This phase helps you to optimize your product design and prevent potential failures.

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Kirti Kumar Singh

LinkedIn Top Voice! I am an automobile professional with 20+ years of expertise in supplier management & vehicle build quality. I help companies in sourcing, part development, improving & sustaining the vehicle quality.
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The second phase is critical from a product design point of view which deals in product design and development. DFMEA plays an important role in this as it tells about the DVP and reports.

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?brahim Berksoy

Laboratuvar Akreditasyonu ve Y?netim Sistemi Dan??man?
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Product design and development is a methodological process that needs to be used certain valid design tools. All these well known tools should be used effectively, correctively, practically and responsibly. Otherwise conventional design methods and mostly not too much productive manufacturing methods will be applied inevitably. When thinking on product design and development one should always keep in mind that every design process should be taken into account of manufacturing processes. It means a designer should keep in mind that next and essential (must) step of design is manufacture. Design for manufacture...

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3 Phase 3: Process Design and Development

The third phase of APQP is to design and develop the process that will produce your product. You need to define the process flow, the equipment, the materials, the methods, and the controls that will be used to manufacture your product. You also need to use tools and techniques, such as process FMEA, process capability analysis, control plans, and mistake proofing, to ensure that your process is capable, efficient, and robust. You also need to document your process outputs, such as process maps, instructions, and standards, and communicate them to the relevant stakeholders. This phase helps you to streamline your process and ensure its quality.

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4 Phase 4: Product and Process Validation

The fourth phase of APQP is to validate your product and process before launching them to the market. You need to conduct various tests and inspections, such as product testing, reliability testing, customer trials, and audits, to verify that your product and process meet the customer requirements and specifications. You also need to collect and analyze data, such as performance indicators, customer feedback, and defect rates, to evaluate the effectiveness and efficiency of your product and process. You also need to document your validation results, such as reports, certificates, and records, and communicate them to the relevant stakeholders. This phase helps you to confirm your product and process quality and readiness.

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?brahim Berksoy

Laboratuvar Akreditasyonu ve Y?netim Sistemi Dan??man?
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Product and process validation techniques are growing fast by supporting experimental methods. This is essential and vital step prior to release the product into market. On the other hand this step is very much essential to make convincing customers about the company and related product.

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5 Phase 5: Feedback, Assessment, and Corrective Action

The fifth and final phase of APQP is to monitor and improve your product and process after launching them to the market. You need to gather and review feedback from various sources, such as customers, suppliers, employees, and regulators, to assess the customer satisfaction and the product performance. You also need to identify and implement corrective and preventive actions, such as root cause analysis, problem solving, and continuous improvement, to address any issues or gaps that may arise. You also need to document your feedback and actions, such as surveys, reviews, and action plans, and communicate them to the relevant stakeholders. This phase helps you to enhance your product and process quality and customer loyalty.

APQP is a powerful tool that can help you to design and deliver high-quality products that meet customer expectations and requirements. By following the five phases of APQP, you can ensure that your product design process is systematic, comprehensive, and collaborative. You can also improve your quality management skills and career, as you will be able to demonstrate your ability to plan, execute, and improve your product design projects.

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Waman Mhadeshwar

LinkedIn Top Voice | COO & Operational Excellence Executive | Supply Chain Innovator | Lean Six Sigma Master Black Belt | Former WD & Flex Leader
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You of tool in APQP is best way to get your product design right - Most important to keep in mind generic designs rule - Focus on Function and fit feature using DFMEA and DFX -Feedback from PFMEA to make design manufacturing friendly - Use DFX to make product cost effective and manufacturing friendly

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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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How can you effectively use APQP in your product design process?

1

2

3

4

5

6

1 Phase 1: Plan and Define

2 Phase 2: Product Design and Development

3 Phase 3: Process Design and Development

4 Phase 4: Product and Process Validation

5 Phase 5: Feedback, Assessment, and Corrective Action

6 Here’s what else to consider

Quality Management

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How can you effectively use APQP in your product design process?

1

2

3

4

5

6

1 Phase 1: Plan and Define

2 Phase 2: Product Design and Development

3 Phase 3: Process Design and Development

4 Phase 4: Product and Process Validation

5 Phase 5: Feedback, Assessment, and Corrective Action

6 Here’s what else to consider

Quality Management

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