The flow of stages involved in the APQP are such that the output of one stage acts as input of subsequent stage.
In this stage supplier understanding the customer requirements and expectations.
Input
Output | |
|
Voice of Customer
|
Design goals |
| Business plan/marketing strategy | Reliability and quality goals |
| Product/process benchmark data | Preliminary Bills of Materials |
| Product reliability studies | Preliminary listing of special products and process characteristics |
| Customer inputs | Product assurance plan |
| Management support |
Stage 2 verifies design feasibility and compliance.
Inputs (from Stage 1 outputs)
Output | |
| Design goals | Design failure mode and effects analysis (DFMEA) |
| Reliability and quality goals | Design for manufacturability and assembly |
| Preliminary bill of materials | Design verification |
| Preliminary process flow chart | Design reviews |
| Preliminary listing of special products and process characteristics | Design reviews |
| Product assurance plan | Engineering drawings (including math drawing) |
| Management support | Material specifications |
| Drawing and specification changes |
Stage 3 verifies the manufacturing capability and measurement methods.
Inputs (from Phase 2 outputs)
Outputs | |
| Design failure mode and effects analysis (DFMEA) | Packaging standards and specifications |
| Design for manufacturability and assembly | Product/process quality system review |
| Design verification | Process flow chart |
| Design reviews | Floor plan layout |
| Prototype build – control plan | Characteristics matrix |
| Engineering drawings (including math drawing) | Process failure mode and effects analysis (PFMEA) |
| Material specifications | Process instructions |
| Drawing and specification changes | Measurement systems analysis plan |
| Preliminary process capability study plan | |
| Management support (including operator staffing and training plan) |
Stage 4 validates the complete manufacturing process and final product.
Inputs (from Phase 3 outputs)
Outputs | |
| Packaging standards and specifications | Significant production run |
| Product/process quality system review | Measurement systems evaluation |
| Process flow chart | Preliminary process capability study |
| Floor plan layout | Production part approval |
| Characteristics matrix | Production validation testing |
| Process failure mode and effects analysis (PFMEA) | Packaging evaluation |
| Process instructions | Product control plan |
| Measurement systems analysis plan | Quality planning sign-off and management support |
| Preliminary process capability study plan | |
| Management support (including operator staffing and training plan) |
Stage 5 closes the feedback loop.
Inputs (from Phase 4 outputs)
Outputs | |
| Significant production run | Reduced variation |
| Measurement systems evaluation | Improved customer satisfaction |
| Preliminary process capability study | Improved delivery and service |
| Production part approval | Effective use of lessons learned |
| Production validation testing | |
| Packaging evaluation | |
| Control plan | |
| Part submission warrant | |
| Quality planning sign-off and management support |
Learn more from our experts how to enhance your PPAP and APQP processes to derive the best results, today.
