By Bill May and Staff
Product quality should be a paramount concern for manufacturers. Manufacturing companies of all sizes manage multiple processes internally and operate within complex supply chains, making consistent product quality a challenge.
How do manufacturers prioritize and achieve consistent and acceptable product quality?
As industries evolved and global competition intensified, the need for systematic approaches to quality management became increasingly apparent. One such approach that has significantly influenced modern manufacturing practices is Advanced Product Quality Planning (APQP).
However, the principles of APQP are only meaningful and effective if applied correctly. Members of the High Value Manufacturing team are knowledgeable of quality principles and highly experienced with implementing quality processes in client facilities. In our observations, APQP is not always practiced.
Here is the backstory.
APQP as a solution
The roots of APQP can be traced back to the early 1980s when the automotive industry struggled to meet consumer increasing quality expectations. Technological advancements during that time also complicated manufacturers’ ability to fully integrate new technologies into production, to quickly equip its workforce with new skills, and to simultaneously keep pace with growing demand.
In response, a collaborative effort between major automotive manufacturers and suppliers led to the development of APQP as a proactive quality planning methodology. Leading the charge for establishing APQP were General Motors, Ford, and Chrysler (Stellantis).
A focus on quality by OEMs has required that suppliers also demonstrate compliance with quality principles for components delivered. High Value Manufacturing has worked within supplier facilities to implement a Roadmap for Compliance that increases efficiency, lowers costs, and improves product quality before delivering to the customer. A commitment to quality is necessary throughout the supply chain to meet consumer expectations.
Quality collaboration
Recognizing the need for a standardized approach to quality planning and assurance, industry stakeholders worked together to establish common frameworks, tools, and guidelines that would later form the foundation of APQP. The Automotive Industry Action Group (AIAG) was formed to spearhead the collaborative effort. AIAG continues to educate, advocate, and document standardized quality practices for manufacturers.
APQP is a “structured method of defining and establishing the
steps necessary to ensure that a product satisfies the customer
and meets all performance and quality requirements.”
Timing and phases
APQP is founded on several key principles, including early planning, cross-functional collaboration, risk management, and continuous improvement. Its methodology consists of the following interrelated components:
- Plan and Define Program: Setting quality objectives, establishing timelines, and defining project scope.
- Product Design and Development: Conducting feasibility studies, design reviews, and ensuring product specifications meet customer requirements.
- Process Design and Development: Developing manufacturing processes, identifying potential failure modes, and implementing preventive measures.
- Product and Process Validation: Conducting prototype testing, verifying product performance, and validating manufacturing processes.
- Feedback, Assessment, and Corrective Action: Gathering feedback from production processes, assessing performance against targets, and implementing corrective actions as needed.
Quality for automotive and beyond
While APQP initially gained prominence in the automotive sector, its principles and methodologies proved applicable to a wide range of industries beyond automotive, including aerospace, electronics, and healthcare. Over the years, organizations worldwide embraced APQP as a foundational element of their quality management systems, adapting its principles to suit their specific contexts and requirements.
Over our ten years of supporting U.S. manufacturers, High Value Manufacturing’s clients have ranged from Automotive to Aerospace/Defense to Industrial Goods. In each client project, our team maintains a focus on quality products and quality processes. Whatever the original project objective – efficiency, cost control, throughput, on-time delivery, expansion, workflow – the corresponding result will also be consistent and sustainable quality products.
Today’s focus on quality
APQP serves as a guiding framework for organizations striving to deliver high-quality products while mitigating risks and reducing costs. As industries embrace digitalization, automation, and Industry 4.0 technologies, APQP continues to evolve. Organizations are integrating advanced analytics, predictive modeling, and real-time data insights into their quality planning and assurance processes.
APQP remains relevant today, especially during the development and introduction of Battery Electric & Hybrid Vehicles and Autonomous Vehicles. The High Value Manufacturing team has worked hands-on in battery manufacturing and BEV assembly facilities, in some cases to address and correct quality issues – related to scrap/rework requirements, FMEA documentation standardization, and BEV technologies training coordination.
Today’s emphasis on speed to market strains the need for strict adherence to quality principles, particularly during the critical learning cycles. Because APQP is a strategic, thorough, well-documented approach to quality management, the outcome demands patience and intention.
The key to Quality Focus by Leadership: DISCIPLINE, DISCIPLINE, DISCIPLINE
A legacy for quality excellence
APQP sets the standard for quality excellence in manufacturing. From its collaborative beginnings to its widespread adoption across industries, APQP is a testament to the power of proactive quality planning, cross-functional collaboration, and continuous improvement.
As manufacturing landscapes evolve and new challenges emerge, APQP remains a beacon of best practices, guiding organizations on their quest for quality, innovation, and customer satisfaction. By embracing the principles and methodologies of APQP, organizations can navigate the complexities of modern manufacturing with confidence, ensuring that every product delivered meets the highest standards of quality and reliability.
For manufacturers that struggle to deliver products that meet customer quality expectations, or for manufacturers that want to incorporate APQP principles into existing processes, the High Value Manufacturing team is available to help. How about a free consultation?
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