Duration: 3 days – 21 hrs
Overview
This course delves into the updated methodologies and practices in the Second Edition of APQP and Control Plans, guiding participants through the structured phases of product quality planning for new product introduction and process improvement. The training emphasizes best practices for reducing product development risks and enhancing customer satisfaction through effective planning and control strategies.
Objectives
• Gain an in-depth understanding of APQP’s phases and its implementation in product development.
• Learn to create and manage effective Control Plans to monitor critical processes.
• Understand the Second Edition updates and how they impact the APQP process.
• Improve product quality and consistency by applying APQP and Control Plan techniques.
• Mitigate risks and ensure product readiness for launch.
Audience
• Quality assurance professionals and engineers.
• Product and process engineers involved in new product development.
• Project managers and production managers.
• Automotive industry professionals adhering to IATF 16949 standards.
Prerequisites
• Participants should have a basic understanding of quality management systems and familiarity with APQP principles.
Course Content
Introduction to APQP and Control Plans
• Overview of APQP principles and objectives
• Importance of Control Plans in quality management
• Key updates in the APQP and Control Plan Second Edition
Phase 1: Plan and Define Program
• Defining customer requirements and expectations
• Initial risk assessment and feasibility analysis
• Developing the project scope and quality targets
Phase 2: Product Design and Development
• Design Failure Mode and Effects Analysis (DFMEA)
• Design verification and validation activities
• Engineering specifications and compliance with standards
Phase 3: Process Design and Development
• Process flow chart creation
• Process Failure Mode and Effects Analysis (PFMEA)
• Developing robust production processes for quality consistency
Phase 4: Product and Process Validation
• Production Part Approval Process (PPAP) requirements
• Developing and implementing Control Plans
• Production trial runs and capability studies
Phase 5: Feedback, Assessment, and Corrective Action
• Monitoring customer feedback and performance metrics
• Root cause analysis and continuous improvement
• Corrective actions and their integration into the APQP cycle
Developing and Implementing Effective Control Plans
• Key elements of Control Plans and documentation standards
• Control plan structure for monitoring key product/process characteristics
• Practical exercise: drafting a Control Plan based on case studies
APQP and Control Plan Documentation Best Practices
• Documenting quality planning processes for audit readiness
• Ensuring alignment with IATF 16949 requirements
• Best practices for cross-functional team collaboration in APQP
Case Studies and Real-World Applications
• Examining APQP and Control Plan applications in various industries
• Group exercise: applying APQP phases to a hypothetical product
Wrap-Up and Q&A
• Review of key APQP and Control Plan takeaways
• Open Q&A session to address participant questions and challenges
