Introduction to APQP and Phase 1 & 2
Session 1:
Introduction to APQP
- What is APQP?
- Why is APQP important?
- Relation to IATF 16949 and
customer-specific requirements
- Overview of 5 Phases of APQP
Session 2:
Phase 1 – Plan and Define Program
- Understanding customer needs
- Voice of the Customer (VOC)
- Business plan, program timing, and
feasibility
- Product and process assumptions
Session 3:
Phase 2 – Product Design and Development
- Design FMEA (DFMEA)
- Design for Manufacturing and
Assembly (DFMA)
- Design verification and validation
- Engineering drawings and
specifications
- Design reviews and tools (DFMEA,
QFD)
Process Design and Validation
Session 4:
Phase 3 – Process Design and Development
- Process Flow Diagram
- Process FMEA (PFMEA)
- Control Plan – Initial (Prototype)
- Work instructions and equipment
planning
- Special characteristics and key
control points
Session 5:
Phase 4 – Product and Process Validation
- Production Trial Runs
- Measurement Systems Analysis (MSA)
- Initial Process Studies (Capability
studies – Cp, Cpk)
- Preliminary Process Capability
- Packaging, labeling, and logistics
Session 6:
PPAP Overview (Part of Phase 4)
- Purpose and levels of PPAP
- Key elements: Part submission
warrant (PSW), Dimensional results, Material certification
- When and why to submit PPAP
- Customer approval process
Launch, Feedback, and Continuous Improvement
Session 7:
Phase 5 – Feedback, Assessment, and Corrective Action
- Monitoring production and quality
performance
- Lessons learned documentation
- Customer feedback and complaint
handling
- Problem-solving tools (8D, Root
Cause Analysis)
- Continual improvement culture
Session 8:
Cross-functional Team Collaboration
- Roles and responsibilities in APQP
- Internal and external communication
- Importance of documentation and
project tracking
- APQP timeline and milestone reviews
Session 9:
Final Assessment and Review
- Recap of 5 APQP Phases
- Assessment (quiz or case study)
- Open Q&A
Course
Closure:
- Feedback collection
- Certificate distribution
- Summary and next steps for
implementation
