🥇 Internal Motivation System: The APQP Method

The article presents the Advanced Product Quality Planning (APQP) method, whose goal is to create a product quality plan taking into account customer requirements. Initiated by the Big Three automakers – Chrysler, General Motors, and Ford – this method aims to reduce the number of production defects and streamline quality control.

Currently, in 2022, APQP consists of five phases leading to the creation of a solid quality plan. The first phase, Planning and Program Definition, involves gathering information and analyzing customer requirements, allowing for defining the new program and its quality goals. The result of this phase is the product design and setting quality goals.

In the second phase, Product Design and Development, we focus on analyzing technical and engineering requirements necessary for project implementation. Key actions in this phase include completing design verification, determining necessary materials and equipment, creating a control plan for prototypes, and identifying potential production problems.

The third phase, Process Design and Development, involves planning the production process that meets the requirements defined in the first and second phases. Production costs and quality are also considered here, as well as determining the production volume that will meet customer demand.

The fourth phase, Product and Process Validation, is a testing phase. It focuses on verifying the production process and evaluating final products. It includes performing trial series, assessing process performance, verifying product quality, and implementing required improvements.

The last phase, Launch, Feedback, and Continuous Improvement, starts full-scale production, in which performance is assessed and problems are identified. Main tasks include process improvement and analyzing customer feedback, leading to a smoother process and improved product.

The article also discusses the benefits of implementing APQP, such as product compliance with assumptions, shortening the time to introduce a new product to the market, better communication with suppliers, reducing project failure risk, and minimizing changes in late development stages. Additionally, when working with APQP, quality tools such as FMEA, SPC, and PPAP can be used.