APQP and CONTROL PLAN Fundamentals

Course Summary

This new course provides valuable information and examples for the successful implementation of the APQP process, including the changes in the newly released 3rd Edition APQP Plan Reference Manual and 1st Edition Control Plan Reference Manual.

Event Details

8 hours
Combination lecture and classroom exercises
Available at QSG’s training facilities and on-site at your organization


The latest APQP – 3rd Edition & Control Plan- Version 1 manuals have been released by AIAG!

As you may be aware, AIAG has been working on the new APQP and Control Plan manuals for quite some time. The automotive industry OEMs and their supply base have been eagerly awaiting the new manuals, which will soon become mandatory requirements and be added to the US OEM CSR documents. Ford, GM, and Stellantis have already announced that they will accept the usage of these new manuals as soon as they are released, making way for international OEMs and a host of large Tier 1 suppliers to follow suit.

There are significant changes in both the APQP and the new Control Plan manuals, as indications have suggested. They not only address the needs of the latest ICE and hybrid vehicles but also the new electric vehicles. These developments emphasize the importance of new product development and process control more than ever before.

The QSG APQP Training course is taught in an engaging instructor-led format. The instructor will describe the best practices that have made APQP such a successful methodology for improving product quality. Participants will learn the proper course of action for each phase of APQP and will be able to identify the correct inputs and outputs to make the process work as designed.

Participants will have the opportunity to interact with all elements of the APQP process, as well as learn about the other Quality and Reliability Tools that are built into the methodology’s framework. Team activities, workshops and other exercises will be used to reinforce the best practices of this methodology to ensure that each participant will be able to put APQP into action for their company’s unique production needs.

Value-Add: An ever-growing number of companies must comply with Advanced Product Quality Planning (APQP) requirements. Even those that are not subject to a compliance mandate recognize the APQP process as a product development best practice that improves performance for new product introduction. To implement APQP effectively, companies must account for a series of key considerations that will determine the success of the initiative and ultimately the performance of future product launches.

Quality system requirements are intended to develop fundamentals that provide for continuous improvement, defect prevention, and the reduction of variation. APQP is at the heart of product development/project implementation and the prime element of successful project success, as it links the special characteristics identified in the project. It then integrates all of the prime tools of IATF 16949, such as FMEA, control plans, feasibility reviews, operator instructions, process flow diagrams, etc.

This course provides valuable information and examples for the successful implementation of the APQP process at companies of all sizes and across industries. It gives the participants the opportunity to work in teams and to implement APQP using actual case studies. Training includes discussions about the use of control plan and relevant data required to construct and determine control plan parameters, as well as the importance of the control plan in the continuous improvement cycle.

Who Should Attend

This course is appropriate for those with some APQP experience (APQP Rev.2), as well as for experienced individuals who would like to refresh their knowledge and learn the new Rev.3 requirements and Control Plan Rev.2. Program/product managers, design and manufacturing engineers, quality personnel, and other product design and manufacturing personnel will all benefit from participation in this course.

Learning Objectives

Upon successful completion of this course, participants will be able to:

  • Identify transitional information for applying the 3rd Edition APQP Reference Manual
  • Define the five phases of APQP for New Product Development and its relationship to program management, including
  • the knowledge and skills needed to participate in an APQP team
  • Learn how to apply the APQP Checklists during an APQP Program Launch
  • Align APQP phases with product development practices
  • Identify important product development deliverables
  • Achieve standardization and improvement using process flow diagrams, process FMEA, and process control plans
  • Measure Key Performance Indicators (KPI metrics) for Launch Performance
  • Demonstrate knowledge of APQP and how it relates to IATF 16949
  • Describe the importance of APQP to successfully implement the launch of a new product
  • Implement an APQP project planning system
  • Describe the importance of linkages and flow of special characteristics within a project
  • Be able to develop Control Plans (Per Rev.1) in each phase (Prototype, Pre-launch, Safe Launch, Production) efficiently and effectively
  • Describe the minimum information that should be entered in the Control Plan
  • Utilize information gathered from implementing APQP and completing a Process FMEA to construct a Control Plan
  • Identify and address changes that occur during and after development
  • Apply proven techniques for the effective use of Control Plans

Course Outline

Phase 1 (Plan and Define Program)
Determine customer needs, requirements, and expectations using tools such as Quality Function Deployment (QFD). Review the entire quality planning process to enable the implementation of a quality program. Define and set the inputs and the outputs.

  • Voice of the Customer
  • Design Goals
  • Customer Inputs
  • Benchmarking and development of the preliminary bill of material and process flow chart

Phase 2 (Product Design and Development)
Review the inputs and execute the outputs, which include:

  • FMEA
  • DFMA
  • Design verification
  • Design reviews
  • Material and engineering specifications
  • Team feasibility commitment and management support review process

Phase 3 (Process Design and Development)
Address features for developing manufacturing systems and related control plans.

  • Process flow charts
  • Floor plans
  • MSA plan and pre-launch control plans

Phase 4 (Product and Process Validation)
Validation of the selected manufacturing process and its control mechanisms through production run evaluation, outlining mandatory production conditions and requirements identifying the required outputs.

  • Production trial runs
  • Capability analysis
  • Production validation testing
  • Production control plans
  • Product quality planning
  • Sign off and PPAP submissions

Phase 5 (Feedback, Assessment, and Corrective Action)
Phase 5 focuses on reduced variation and continuous improvement, identifying outputs and links to customer expectations and future product program, as well as:

  • Customer satisfaction
  • Delivery
  • Service




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