APQP Training

Lesson 1 • History and Industry Context

Traces APQP's origin in automotive quality initiatives and its adoption across industries. Connects historical drivers to the structured planning approach used today.

Lesson 2 • APQP and Related Quality Tools

Maps APQP to companion tools such as FMEA, control plans, and PPAP. Establishes how these tools integrate within the APQP framework.

Lesson 3 • Key Stakeholders and Roles

Identifies cross-functional team members and their responsibilities within APQP. Clarifies accountability structures that enable effective planning.

Lesson 4 • Core Objectives of APQP

Defines the primary goals of APQP: defect prevention, customer satisfaction, and on-time launch. Grounds learners in the 'why' before introducing the 'how.'

Lesson 1 • Voice of the Customer Capture

Techniques for gathering, organizing, and prioritizing customer requirements. Feeds directly into design targets and quality goals established in Phase 1.

Lesson 2 • Programme Timing and Milestones

Builds a master timing plan with phase gates, deliverable deadlines, and resource assignments. Ensures all team members align on launch schedule commitments.

Lesson 3 • Design Goals and Reliability Targets

Converts customer needs into specific, measurable design goals and equipment reliability metrics. Establishes the performance baseline for all subsequent APQP phases.

Lesson 4 • Preliminary Process Flow

Creates a high-level process flow diagram to anticipate manufacturing steps and constraints. Connects product design intent to early process planning.

Lesson 1 • Prototype Build and Testing

Plans and executes prototype builds to validate design assumptions under real conditions. Results feed back into DFMEA updates and design revisions.

Lesson 2 • Design FMEA Fundamentals

Introduces Design FMEA methodology to identify and mitigate potential design failures. Directly supports risk reduction before design is finalized.

Lesson 3 • Design Verification Planning

Develops a Design Verification Plan and Report to confirm design meets specifications. Establishes test methods, acceptance criteria, and responsible parties.

Lesson 4 • Engineering Drawing and Specification Review

Reviews engineering drawings and specifications for completeness, accuracy, and manufacturability. Ensures design documentation is production-ready before Phase 3.

Lesson 1 • Work Instructions and Visual Aids

Develops operator-level work instructions and visual aids aligned with the control plan. Ensures process knowledge is accessible and consistently applied on the floor.

Lesson 2 • Control Plan Creation

Builds prototype, pre-launch, and production control plans to manage process variables. Links control plan characteristics to PFMEA and process flow outputs.

Lesson 3 • Detailed Process Flow Diagrams

Expands the preliminary flow into a detailed, step-by-step manufacturing process map. Serves as the foundation for control plans and work instructions.

Lesson 4 • Process FMEA Development

Applies FMEA methodology to manufacturing processes to identify and control failure modes. Builds on DFMEA knowledge to address process-specific risks.

Lesson 1 • Defining Special Characteristics

Explains what makes a characteristic 'special' and why it requires elevated control. Establishes the criteria used to classify safety-critical and key product features.

Lesson 2 • Embedding Controls in FMEA and Plans

Integrates special characteristic controls into PFMEA, control plans, and work instructions. Ensures elevated monitoring and reaction plans are in place for critical features.

Lesson 3 • Supplier Communication of Special Characteristics

Establishes methods for flowing down special characteristic requirements to suppliers. Confirms supplier understanding and control capability before production.

Lesson 1 • Measurement System Analysis

Conducts MSA studies including Gage R&R to confirm measurement system adequacy. Ensures data collected during validation is reliable and actionable.

Lesson 2 • Production Trial Run Planning

Designs and executes a production trial run using production tooling, processes, and personnel. Validates that all Phase 3 outputs perform as intended at production rates.

Lesson 3 • Process Capability Studies

Calculates Cp, Cpk, and Ppk indices to confirm process capability meets customer requirements. Identifies processes needing improvement before production launch.

Lesson 4 • Production Part Approval Process

Compiles and submits PPAP documentation to demonstrate product and process conformance. Covers all submission levels and required elements for customer approval.

Lesson 1 • Post-Launch Monitoring Systems

Implements production monitoring using SPC charts, dashboards, and quality metrics. Connects real-time data to the control plan established in Phase 3.

Lesson 2 • Corrective Action and 8D Process

Executes the 8D corrective action process to contain, correct, and prevent recurrence of issues. Ensures corrective actions are verified for effectiveness.

Lesson 3 • Customer Feedback and Warranty Analysis

Collects and analyses customer complaints, warranty claims, and field returns systematically. Feeds findings back into FMEA and control plan updates.

Lesson 4 • Lessons Learned and APQP Closure

Documents lessons learned and updates organisational knowledge for future APQP programmes. Formally closes the APQP cycle and archives deliverables.

Lesson 1 • Cross-Functional Team Leadership

Develops skills to lead cross-functional APQP teams through planning, conflict, and decision-making. Addresses team dynamics unique to quality-driven product development.

Lesson 2 • Multi-Site and Global APQP Coordination

Addresses challenges of coordinating APQP across multiple plants, regions, and supply tiers. Establishes governance models that maintain consistency without stifling local execution.

Lesson 3 • APQP Timing Plan Management

Manages the master APQP timing plan across all phases, tracking deliverables and resolving delays. Connects timing management to overall programme launch success.

Lesson 4 • Risk Management in APQP

Applies structured risk identification, assessment, and mitigation within the APQP process. Enables proactive management of technical, supply chain, and schedule risks.