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APQP & DFMEA Core Tools Training

APQP and Manufacturing Process Development

Seminar Content

This two or three day workshop addresses, in a hands on workshop, the elements of APQP for planning and developing the manufacturing process and system in preparation for product launch as well as the management of continual improvement. The workshop spans the entire process from planning and defining the program through process and product validation to launch.

Approaches discussed and employed are consistent with the guidelines in the APQP 2nd Edition, FMEA 4th Edition and PPAP 4th Edition Manuals issued by GM, Ford & Chrysler.

Who Should Attend


This seminar is designed for Quality Managers, Quality Engineers, Program Managers, Project Team Leaders, Manufacturing/Process Engineers, Product Design/Development Engineers, other APQP team members (Purchasing, Logistics, Tool Designers, Materials Management, Shop floor supervisors and/or team leaders, etc.)

Recommended Training and/or Experience


Seminar Materials

Each participant will receive extensive course material.

Seminar Goals

  • Understand APQP as a process from concept to launch in the manufacturing environment.
  • Manufacturing Process and System Design and Development
  • The Process Review Methodology establishing the linkages between Process flow, PFMEA, Control Plan and Work instruction
  • Developing the Process Flow, Process FMEA and Control Plan
  • How to derive Work instructions using APQP methodology
  • The process for product and process validation

Seminar Outline

Day One

  • APQP Overview
  • APQP Phase II Non-design Elements
  • APQP Phase III
  • Development and Use of the Process Flow Document

Day Two

  • APQP Phase III (Continued)
  • Conducting and Documenting the Process FMEA (Failure Mode and Effects Analysis)
  • Improvement Planning and Execution
  • Documenting and Implementing Effective Control Plans
  • Work Instructions Development

Day Three

  • APQP Phase IV: Verification and Validation
  • PPAP
  • Phase V: Continual Improvement


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