Scenario
During new vehicle model development, engineers in the design phase thought "this part should be fine" and did not conduct a complete DFMEA. After mass production, customers complained that the part would become brittle in low-temperature environments.
Recall cost: $800 per vehicle, 50,000 vehicles produced = $40,000,000.
If DFMEA and DVP&R validation had been performed during the design phase, the cost to find this material problem might have been only $50,000.
This is why APQP invests so much effort upfront.
What is APQP
APQP (Advanced Product Quality Planning) = Advanced Product Quality Planning
A five-phase quality gate system, ensuring quality confirmation at every stage from concept to mass production.
Exponential Increase in Design Change Costs:
| Phase | Design Change Cost Multiplier |
|---|---|
| Concept Design | 1x |
| Detailed Design | 10x |
| Process Design | 100x |
| Pilot Production | 1,000x |
| Customer Complaint After Mass Production | 10,000x+ |
The later a problem is discovered, the higher the cost. APQP aims to force problems to be discovered upfront.
Five Phases
Phase One: Plan & Define
Working Focus:
- QFD (Quality Function Deployment): Translating customer requirements into engineering specifications
- Preliminary BOM and Process Flow
- Design Quality Objectives
- Reliability, Quality, and Initial Life Objectives
Gate Criteria: Clear design objectives, approved resource plan
Phase Two: Product Design & Development
Working Focus:
- DFMEA: Identifying design-level failure risks
- DVP&R (Design Verification Plan and Report): What tests, how many pieces, when to complete
- Design Drawings Completed
- Engineering Samples (Prototypes) Production and Testing
Gate Criteria: High RPN items in DFMEA have countermeasures, DVP&R tests passed
Phase Three: Process Design & Development
Working Focus:
- Process Flow Diagram (Full Version)
- PFMEA: Identifying process-level failure risks
- Control Plan (Pre-launch Version)
- Measurement Devices and Equipment Plan
- Operator Training Plan
Gate Criteria: High RPN items in PFMEA have countermeasures, Control Plan completed
Phase Four: Product & Process Validation
Working Focus:
- Pilot Production (typically requires a significant batch size, e.g., 300 pieces)
- MSA: Confirming Measurement System
- Process Capability Study (Cpk ≥ 1.67 is a PPAP requirement)
- Packaging Confirmation
Gate Criteria: Cpk achieved, MSA qualified, PPAP documentation completed
Phase Five: Feedback, Assessment & Corrective Action
Working Focus:
- Quality Monitoring After Mass Production
- Customer Satisfaction Assessment
- Continuous Improvement Actions
- Documentation of Lessons Learned
Gate Criteria: No major customer complaints, continuous improvement mechanism established
Golden Quote
"The essence of APQP is to make you spend time in the right place. A DFMEA in the design phase can prevent a recall after mass production. Early quality investment is not a cost; it's the cheapest insurance."