APQP 23 ELEMENTS
What is APQP 23 Elements?
APQP 23 elements are documented sequence of processes that introduce each
element dedicated to advanced product quality planning.
List of APQP 23 Elements:
1. Customer order
When any order received by supplier from customers, all the planning,
schedules and investments are directly effects. The customers are explaining
those expectations and decisions of suppliers for particular order for further
documentation like nomination letters, APQP supporting documentation, and risk
levels for particular order or product / process.
2. Customer specifications
In along with customer's order, customer expecting some specific requirements
to related its end applications, where expected design and drawing, technical
sheets and other specific requirements enclosed for supplier understanding. The
technical sheet and drawings are most important for engineering segment hence
specifically needs to highlight and frequent communication required to comply all
the requirements accordingly.
3. Ability Appearance
The supplier must be aware requirements of customers, and should be important
to defined characteristics related auditability, handling and appearance
mentioned, and the characteristics must be verified, and characteristics set and
reference samples should be accessible with the customer.
4. Design FMEA
To prevent defects during product design & development phase, a design FMEA
needs to apply in the system to ensure potential design and development
defects and their root causes identification, measurements and preventive
actions. The cross functional team, conduct the design FMEA where all the
functions of the product and must take into account practices and concern. The
expectations from the design FMEA, is to all the problems related to product /
process layout can identify and resolved during initial stages so that mass
production schedule can be observed.
5. Design Review
The targets of the design review are to prevent confusions and problems,
observing the progress of processes and, to ensure that the purposes meet the
requirements and all the verification should be conducted according to design
verification plan. Reviews on potential improvements as concern product
reliability and manufacturing cost, quality costs and planning.
6. Design Verification plan
It is supplier responsibility to effectively implement design phase of the product
development, and planning of all inspection, and checking to ensure that the
product or design meets the customer's end applications.
7. Quality Planning
The organization must communicate with team to conduct detailed requirements
of APQP and verify the implementation, and provide detailed for APQP status
report. The quality planning should have managed to provide clear illustration of
the task program and conclude associated risk during planning phase at the
customer's specific request. Expectation from the quality planning element to
carry out a risk assessment and specify the extent of his team participation in the
advance quality planning processes.
8. Inspection Method, Inspection Equipment & Tools
The purpose of this element is to obtain inspection methods and used inspection
equipment and tools which is adequate for the measuring works. The equipment
& tools used for the inspection processes should be verified & evident of
equipment capability, process suitability and requirements must have discussed
with customers. The equipment & Tools are providing by planning team
according to operation requirements. The inspection methods, equipment & tools
used for inspection processes and inspection planning should be communicated
with customers.
9. Inspection Plan / Control plan for Prototype item
To secure the prototype quality, inspection plan carried out as the categorized
and scope of the inspection and consistent inspection equipment for prototypes
are defined and approved with customer. In case of customer having any special
requirements or special characteristics should be included in inspection plan,
and control plan and related documentation maintained and submission to
customer accordingly.
10. Prototype item's production & inspection
To maintain customer schedules and dispatch the product, prototypes must
meet quality requirements and cost competence. The expectations from this
section is to proper planning, monitoring and inspection should be maintained &
approved without any non-conformance with prototypes prior to delivery.
11. Design - Drawing & Specifications
When we talk drawing and specification that means includes all the technical
drawings and specifications, design data & information, material specifications
received / provided by customers & prepared at supplier end. The element
indicates the drawing and specifications and it related schedule management,
generally customer must be informing to supplier of schedules and changes
making in a drawing and specification on before real production to maintain
schedule of product. If the supplier had prepared drawing & specifications,
supplier responsible for agreed changes with customer.
12. Confirmation of manufacturing feasibility
If the customer provided all the design and specification, the supplier must
assess the manufacturing feasibility of the products, from the planning stages to
production processes. A supplier cross functional team is responsible for
evaluate the manufacturing feasibility of the proposed product within the
structure of the documentation / sales control review. The cross functional team
must be committed that the product meet end application requirements and can
produced, review, inspect, packed and shipped to the customer in time manner
with expected quality.
13. Process flow chart & Mass Production Layout
A real production or mass production layout, or process flow chart of production
is a visual representation of planned sequences of processes for particular
product and its specification. The purpose of the establishment for planning,
FMEA of process, quality control plan, production plan and visual data structure
is to ensure that the process sequences of production stages and related, in-
process, and incoming materials in production inspection.
14. Process FMEA
A process FMEA is systematic procedures or method conducted for identify and
account potential defects in production processes, and to analyze root causes to
tracing real causes of defects occurred in processes. The method used before
the product development, to prevent defects during process development. To get
the better results all production and inspection stages should be involved for
analyze. The PFMEA helps to detect potential defect modes, describe causes to
easier for team to define necessary corrective measures and monitoring to
evaluate control for appropriate location.
15. Inspection Equipment Capability
The purpose of this element is to maintain and improvement of the measuring
system, capability study and inspection equipment accuracy. For the achieving
the goal of the standard element requirement needs to conduct capability studies
in direction to verify the suitability of the inspection equipment. The inspection
and measurement methods should be verified & approved by customers for
appropriate requirements, in case of the any modification are made in
measurement equipment of method of inspection, it is necessary to capability
study must be conducted.
16. Pre-production / Pre-release control plan
It is important that the process & product specification requirements should meet
during the pre-production, to achieve the standard specification needs to
increase inspection frequency and additional inspection characteristics. All the
inspection equipment, inspection methods and it scope should defined and
approved by customer before the production start.
17. Process Instructions
The process instruction is one of the important documents for the maintain and
improve product quality & increase performance of appropriate site, all the
instruction like production plan, work instructions, maintenance plan and
schedules, process parameters etc., are used at the workplace should be easier
for each people working at appropriate location, and should be accessible.
18. Logistics Concept includes Packaging materials
The purpose of the process is to ensure that the delivery capability in the
contract or agreement with the relevant customer communication. In the concept
all the logistics including packaging materials should be used suitable and
maintain quality of product during logistics. The packaging specifications and
corrosion protection for shipments to the customer, packaging specifications
must be observed & approved by customer.
19. Production First Trial Run
The purpose of the process is to verify of the mass production process. The
advanced production quality planning expecting from this element is to use of
machinery, tools, inspection equipment and location and manpower managed
accordingly. In the production first trial, process & product verification of product
quality as per planned, and the product quality must consist of each batch
measurements as per standards.
20. Mass Production Inspection Plan / Control plan
To ensure that mass production i.e. samples collected from production are met
the product & process specification requirements. Inspection related processes,
methods, inspection equipment etc., should be documented and verified,
approved by customer.
21. Initial Process Capability Study
To ensure the product can be manufactured as requirement of product and
process specifications are prove by process capability studies. The process
capability study uses statistical method to prove of process is capable, to
standard requirements of process & processes i.e. specifications. In the initial
process capability study all the required pp/ppk values, machine capability at
cm/cmk values should be maintained and controlled, in case of values or
deviation identified that corrective measures must be introduced in order to
achieve process capability.
22. Technical tests on Production Items
The process verification is structural planning document prove that the product
meets customer requirements and all the technical requirements are conducted
through technical test with product from the production trial run, if defined in the
design verification plan / or in product - process specification.
23. Initial Sampling Inspection
Initial sampling inspection is process that prove the product manufactured under
the production condition meets the customer's requirements as well as customer
provided technical, product & process specifications. In the sampling inspection,
qualified inspector collects the samples from running production lines and
inspect the sample according to standards and specification requirements.
The purposes, expectations and requirements associated with documenting the
individual elements of advanced product quality planning (APQP) status report.
Bibliografia:
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