APQP IMPLEMENTATION AND IMPROVEMENT

 

Seminar Content

This five-day seminar addresses in depth all of the elements of the Advance Product Quality Planning (APQP) process, addressing the objectives, inputs and deliverables for each phase. There is significant hands-on focus regarding how DFMEA, DVP&R, Process Flows, Process Failure Modes and Effects Analysis (PFMEA), Control Plans and Shop Floor documentation can be used to achieve product and process standardization and improvement.

The seminar includes program management and status assessment and reporting for APQP Phases I and II, DFMEA, DVP&R and Prototype Management and, in particular, focuses on Process Flow, PFMEA, PPAP and PSW. The approaches discussed and employed in this course are consistent with the guidelines in the APQP 2nd Edition, FMEA 4th Edition and PPAP 4th Edition Manuals issued by GM, Ford & Chrysler.

Who Should Attend

Those who have direct responsibility for introducing new products and/or a new manufacturing processes and systems. Additionally, program/product managers, quality managers, design engineers, manufacturing engineers, APQP team members and others who have direct responsibility for process standardization and improvement can benefit from this seminar.

Pre-Requisites for Course

Participants should possess knowledge of product design & development and/or manufacturing and basic Quality Assurance concepts.

Seminar Materials

Each participant will receive a seminar manual and a workbook including all team breakout exercises.

Seminar Goals

  • Provide a hands-on approach to new product development and continual improvement using the APQP process; its relationship to program management and status reporting to provide the knowledge and skills needed to introduce new products and processes smoothly.
  • Focus on the use of Process Management to achieve improved design, verification & validation using DFMEA, as well as standardization and improvement using Process Flow Diagrams, Process FMEA and Process Control Plans.
  • Understand all major automotive industry approaches to FMEAs and Control Plans and the variations in current use.

Seminar Outline

  • Overview - the NPD/APQP Process
  • AIAG APQP Model
  • Program Management
  • Risk Assessment and Feasibility Analysis
  • Phase I: Plan and Define Program
  • Phase II: Design FMEA
  • Phase II: Post - Design FMEA Elements
  • Design for Manufacturability & Assembly
  • Phase III: Design and Develop Process
  • Phase III: Process Flow and Process FMEA
  • Phase III: Control Plan
  • Phase III: Work Instructions
  • Phase IV: Product and Process Validation
  • MSA, PPAP 4th Edition and PSW
  • Phase V: Process Review Management and Continuous Improvement