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APQP Implementation and Improvement

APQP Implementation and Improvement

Seminar Content

This four or five-day seminar addresses in depth all of the elements of Advance Product Quality Planning (APQP) process, addressing the objectives, inputs and deliverables for each phase. There is significant, hands on focus on how DFMEA, DVP&R, Process Flows, Process Failure Modes and Effects Analysis (PFMEA), Control Plans and shop floor documentation can be used to achieve product and process standardization and improvement.

The seminar includes program management and status assessment and reporting for APQP Phases I and II, DFMEA, DVP&R and Prototype Management and, in particular, focuses on Process Flow, PFMEA, PPAP and PSW consistent with the requirements of ISO/TS 16949:2002 (Second Edition), the APQP 2nd Edition, FMEA 4th Edition and PPAP 4th Edition Manuals.

Who Should Attend

Those who have direct responsibility for introducing new products and/or a new manufacturing processes and systems. Additionally, program/product managers, quality managers, design engineers, manufacturing engineers, APQP team members and others who have direct responsibility for process standardization and improvement can benefit from this seminar.

Recommended Training and/or Experience

Knowledge of product design & development and/or manufacturing and basic Quality Assurance concepts is required.

Seminar Materials

Each participant will receive extensive course material including breakout exercises.

Seminar Goals

  • Provide a hands-on approach to new product development and continual improvement using the APQP process; its relationship to program management and status reporting to provide the knowledge and skills needed to introduce new products and processes smoothly
  • Focus on the use of Process Management to achieve improved design, verification & validation using DFMEA, as well as standardization and improvement using Process Flow Diagrams, Process FMEA and Process Control Plans
  • Understand all major automotive industry approaches to FMEAs and Control Plans and the variations in current use

Seminar Outline

  • Overview
    • APQP Process Model
    • The Five APQP Phases
    • Program Management
  • APQP Phase I – Plan and Define Program
    • Breakout Exercise 1: Program Planning
  • Product Design and Development – Design FMEA
    • FMEA Overview
    • Design FMEA
    • Developing the DFMEA
    • Breakout Exercise 2 Part A: Functions and Requirements
    • Breakout Exercise 2 Part B: Failure Modes
    • Breakout Exercise 2 Part C: Causes and Controls
    • Determining Risk and Criticality
    • Breakout Exercise 2 Part D: Developing an Action Plan
  • Post Design FMEA Items
  • Design and Develop the Manufacturing Process
    • APQP Team Approach
  • Process Flow Diagram and Process FMEA
    • PFMEA Inputs
    • Breakout Exercise 3: Creating a Process Flow Diagram
    • PFMEA Development
    • Breakout Exercise 4 Part A: Operation, Requirements and Failure Modes
    • Breakout Exercise 4 Part B: Causes and Controls
    • Breakout Exercise 4 Part C: Effects, Relative Risk and Action Plans
  • Control Plan
    • Breakout Exercise 5: Developing the Control Plan
    • Process Development
  • Work Instruction Development
    • Breakout Exercise 6: Work Instructions
  • Introduction to Production Part Approval Process
    • Assessing a PPAP Package
    • Breakout Exercise 7: PPAP
  • Process Review and Management of Continual Improvement
    • Breakout Exercise 8: Revising FMEA and Control Plan


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