Advanced Product Quality Planning (APQP)Production Part Approval Process (PPAP) Failure Mode Effects Analysis (FMEA)Measurement Systems Analysis (MSA) Statistical Process Control (SPC) and

Root Cause Analysis and Reporting Methods2-Day Risk Management using FMEA

What is APQP & PPAP?APQP (Advanced Product Quality Planning) and PPAP (Production Part Approval Process) are methods used inthe automotive and some other industries. Their purpose is to ensure that the supplier understands thecustomer's requirements and is capable of providing the required quality and quantity of product on time.APQP sets out a clear path for planning, implementing and verifying a process.The APQP process has five phases. What phases a company has to complete depends on what they do. Thereare checklists provided in the back of the guide published by AIAG that are very helpful in keeping on the rightpath. They provide the organization and consistency needed to ensure a successful product and process launch.If I needed to boil the whole idea down to a few words, it would be "Matching the voice of the supplier'sprocess to the voice of the customer, VOP = VOC."PPAP is the hard proof that the supplier understood the customer's requirements. It principally involvesgathering all the data and information that was generated throughout the APQP stage and presenting inprescribed method and format to the customer for review and, hopefully, approval. The customer reviews thePPAP submission and renders one of three possible decisions:1) Product and process approved as submitted2) Interim approval with a request for additional information or samples3) Not approved - start over

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Difference Between APQP and PPAPCompanies acting as suppliers to other businesses use the quality management standards APQP and PPAP to ensure the quality of their products and the satisfaction of their customers. These standard procedures were

originated by the Big Three automakers in the early 1990s. Each has its own manual published by the AIAG, or Automotive Industry Action Group. Many other industries have since embraced these standards. APQP and PPAP are related, but not identical. In fact, PPAP is one part of APQP.

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Different Definitions

APQP stands for Advanced Product Quality Planning. It is a process of detailed planning for the design of a product and of the production process that will be used to make the product. It emphasizes satisfying all of the customer's requirements and anticipating any problems before they occur.

PPAP stands for Production Part Approval Process. It is a formal procedure the supplier goes through to get approval from the customer to begin production. The supplier submits samples from trial production runs to show that the product can be consistently manufactured to meet all of the customer's specifications.

PPAP Is One Part of APQP

APQP is the entire quality planning process that takes place before the product is manufactured and shipped. The first three of its five phases are devoted to preliminary planning, product design and manufacturing process design. The fourth phase includes the trial production runs, data collecting and the PPAP. The fifth phase is for assessment and for making any production changes that are necessary or that would improve the product.

Different Goals

The primary goal of APQP as a whole is to design a product and a process that will fulfill all the tasks the customer requested. A further part of this goal is to anticipate any problems before they happen and keep them from becoming the customer's problems. Although the ultimate goal of PPAP is the same, its immediate goal is to secure the approval from the customer to begin production. PPAP has related goals of proving that the supplier truly understands the customer's needs and can produce a part that meets or exceeds those needs. The supplier must demonstrate that the part can be produced at the same level of quality consistently at a particular rate of production.

PPAP Has Direct Customer Involvement

The supplier's personnel are responsible for carrying out most of the APQP process. The supplier's teams work with the information and specifications the customer provided up front and may occasionally contact the customer for clarification. But the supplier designs its own processes, deals with its own problems and tries to keep them from becoming the customer's headaches. The PPAP is the part of APQP during which the supplier sends the customer the samples, the customer sends feedback the other way and the two companies discuss possible changes for the product or its process.

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Many industrial companies require that their parts providers utilize PPAP processes. PPAP, or the Production Part Approval Process, is used by almost every industry that produces and services part commodities. It is the standard utilized to ensure quality and efficiency with regard to part production. PPAP is an effective way to monitor financial prudence as well; its effective audits include the measurement of performance, the analysis of the return on investment in any given parts production process and the business case analysis for the production process. Legal prudence and industry standard conformance are also measured.PPAP is a set of standards within a larger set of standards called APQP, which stands for Advanced Product Quality Planning. This umbrella term is used for formalized standard and defined step-by-step processes to providing quality parts for the end customer.

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History

In 1982 the management staff of General Motors, Chrysler and Ford Motors founded AIAG (Auto Industry Action Group). The group then created to Advanced Product Quality Planning & Control Plan (APQP), within these standards, the AIAG developed PPAP to advance the parts production approval process of quality planning.

Industries

Primarily, the automotive and semiconductor industries utilize PPAP standards and processes. However, any industry that implements ISO/TS 16949 also uses PPAP standards. ISO/TS 16949 are connected to the application of ISO 9000 standard sets, which are required for the legal international distribution of various parts.

Purpose

Ultimately the PPAP being utilized is required so that the customer can expect a zero-defects part. This is accomplished by production tooling analysis prior to actual mass part production. By using the PPAP, process testing reports are generated with every product, and the customer is ensured that their are expectations met every time, even though massive orders, constant transactions and global exchange complicate the parts business.

Process

During the phase of production for quality planning, a process flow chart is created. From this chart, a Process Failure Mode and Effects Analysis (PFMEA) is established. A control plan is then drawn up based upon the results of the PFMEA.The control plan is developed detailing how the processes are controlled and how any issues with noncompliance are handled. (Manufacturing process audits require control plans as a main portion of the documentation requirements.) A Gauge R&R, or Gauge Repeatability and Reproducibility Analysis, is then necessary.Next, a sample manufacturing utilizing the specified production run is required to prove out the processes. The results of this sampling production run are then analyzed and documented statistically to complete the PPAP.

Training

PPAP training is offered by itself or as part of the training provided within the APQP training courses. These training courses can be found on the AIAG website. The PPAP course costs $200.00, and the APQP course costs $995.00. Both are accredited. These courses teach documentation, parts production and quality control processes and requirements.

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How to Prepare PPAP FormsA preapproved payment plan, otherwise known as a PAPP, provides convenience to your customers as well as your billing department. By authorizing your company to transfer a specified amount of funds from a checking or savings account on a predetermined date, your customers don't have to deal with the hassle of making periodic payments. Similarly, the arrangement frees your billing department from issuing invoices and some payment processing. Because you need written authorization to access an account held by another customer, you must secure the access to the account in writing using a PAPP form.

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Instructions1.

o 1Collect basic customer information. Format sections on the form for customers to enter their name, company telephone number and billing address on the PAPP form. Include a field for all pieces of customer information your billing department maintains for each customer.

o 2Collect information on the checking account from which the customer authorizes payment. Collect the home bank's name and address, its routing number -- the first nine-digit number located in the bottom left-hand corner of a check -- and the bank account number -- the series of numbers that follow the routing number. Banks devise their own account numbering systems, so they may be of any length.

o 3Collect a voided check from the customer to confirm the checking account information.

o 4Provide a written statement that authorizes your company to make withdrawals from the specified account as needed. If the billing date and amount billed remain constant, leave blanks for the customer or billing agency to complete. A sample statement would read, "I hereby authorize (company name) to debit my account for $______ on the ______ of each month. I certify that I have the authority to authorize debits from the account listed above, and agree to the terms and conditions presented by this agreement."

o 5Provide a space for customers to sign and date the statement to authorize your account.

o 6Include any terms and conditions you may need in a "Terms and Conditions" section. These items may include provisions that require the customer to assume responsibility for any returned or denied fees and provide notification of change of account details a week in advance of the billing date, as well as outline provisions for your company or the customer to cancel the agreement with written notice.

Tips & Warnings

While you should maintain the original copy of the PAPP agreement, it should be kept in a secure location in order to keep your customers' financial information safe from those without authorization to use it.

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