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APQP / PPAP

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Advanced Product Quality Planning (from AIAG) (APQP / PPAP) provides the framework for the development and manufacturing of a product for a vehicle. The approach describes gathering customer input, developing the product; develop the process from which the product will be built at volume; validate the product and the processes; finally launch the product – production.

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APQP / PPAP
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Voice of Customer/Requirements

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The voice of the customer drives our product development endeavor. This is an understanding of the scope of the work and requirements are generated. The scope is refined to the level to which a strategy or approach to meet these customer demands can be identified and planned. This often entails the use of decision matrices (example: Pugh Matrix) and tools such as Quality Function Deployment (QFD).

Product Development

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The product is iteratively and incrementally developed in the product development portion of the process. This consists of building models and prototypes of varying degrees of complexity and fidelity to the proposed final product. During each build, the product is explored, something is learned and alterations and refinements are made to the design. A tool known as the Design Failure Mode Effects Analysis (DFMEA) will help us to learn from the product as progress is made.

Process Development

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In parallel with the development of the product comes the development of the processes that will ultimately produce the product at volume (Design for Manufacture and Assembly). This is often referred to as concurrent engineering. This shortens the product development cycle as well as limiting or greatly reducing rework. This work will entail setting up the manufacturing line, developing control plans, work instructions, poke yoke, DFMEA, process capability and much more.

Process/Product Validation

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The validation of the product and the process helps ascertain the abilities of both the product and the manufacturing processes to meet the expectation or defined project and business goals. This phase includes trial production runs, run at rate runs, Measurement System Evaluation, Production Part Approval, and much more.

Launch

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Quality management is the practices the organization employs to meet the customer quality expectation. There are techniques and tools used to deliver a cost effective quality product. This includes quality control, quality assurance, quality improvement, and quality planning. Product reliability is the quality of the product over time, and Total Quality Management is a comprehensive approach to continuous quality improvement.

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APQP – Advance Product Quality Planning – an approach to automotive product development and manufacturing which includes tools and techniques in addition to processes for designing and manufacturing a quality product at automotive production volumes.

    1. https://www.aiag.org/
    2. https://www.sae.org/
    3. https://vda-qmc.de/en/software-processes/automotive-spice/
    4. https://www.assemblymag.com/
    5. https://www.ai-online.com/
    6. https://tmc.trucking.org/

Project Management for Automotive Engineers

Spamcast 380 – Kim Robertson, The Big Picture of Configuration Management

https://spamcast.libsyn.com/category/Configuration+Management

SPaMCAST 346 – Configuration Management, An Interview With Jon M Quigley

https://open.spotify.com/episode/0yNV2BTLZh5KNkUxf1hzZF

SPaMCAST 477 – Silence: A Powerful Tool, Muddling Through, Monolithic Monolith

https://podtail.se/podcast/software-process-and-measurement-cast/spamcast-477-silence-a-powerful-tool-muddling-thro/

Spamcast 380 – Kim Robertson, The Big Picture of Configuration Management

https://spamcast.libsyn.com/category/Configuration+Management

SPaMCAST 346 – Configuration Management, An Interview With Jon M Quigley

https://open.spotify.com/episode/0yNV2BTLZh5KNkUxf1hzZF

Peterman Design Firm- Conscious Management, An Interview With Jon M Quigley

https://www.petermanfirm.com/blog/podcast/interview-with-jon-quigley-of-value-transformation-on-conscious-management/

Lab Testing vs. Real-World Testing: Understanding the Differences

Introduction We watch Air Disasters on The Smithsonian Channel. You should watch the program to understand the root cause analysis. It is not just about root cause analysis but also risks and how circumstances and events stack up to produce unwanted results. A recent episode I watched was about Atlantic Southeast Airlines Flight 2311, a […]

Mastering Project Risk Management

Understanding Risks In project management, “Russian Roulette Risks” perfectly encapsulates the high-stakes, unpredictable challenges project managers often face. In risk management, there lies a deceptive and often overlooked danger: the illusion of safety born from previous success. This fallacy can lead organizations and individuals to mistakenly believe that a course of action is low risk […]

Establishing a PMO – Beyond Dogmatic Approaches

Creating a PMO (Project Management Office) is often seen as a strategic endeavor to streamline organizational project management practices. However, adopting a dogmatic approach to this process can lead to rigidity and inefficiency. In this post, we explore why flexibility and adaptability are crucial in creating a PMO and outline the steps to set up […]

The Project Schedule – and Distraction

Not all schedule risks are equal. While we are playing with one set of conditions, another seemingly less important, may end up sinking the project schedule.

Emerging Risk – No Risk Register

Thinking about what can go wrong in the project and how to respond (risk register) is so that we know what to do when the event happens. From experience, the quickness of the response to an emerging event often reduces the risk impact on the project.  Ideally, we will have generated a list of the […]

Unveiling the Metrics Behind Achievement

Unveiling the Metrics Behind Achievement Jon M Quigley In the dynamic landscape of project management, success hinges not only on effective planning and execution but also on accurately measuring progress (metrics) and outcomes. Project metrics serve as the compass guiding teams through the complexities of project delivery, offering valuable insights into performance, efficiency, and overall […]

Its been Five Weeks

A Song As I wrote this, I kept getting that song by Barenaked Ladies, One Week, going through my head. I have been working on the bassline for that song. My kid introduced the song to me some years back and just recently I thought about learning it. I’m very close. Estimating I have a […]

The Product Development Hike.

The Product Development Hike. You won’t read far in product development, where product road map analogy (or actuality) is brought up. Recently, I saw a tweet (is it still called tweet, or is it an X) from @CGLambdin. I wish I had captured the tweet for posting here, but I recall it was about the […]

Off Topic: Jimmy Buffett is Dead

I usually have little problem writing. I write multiple columns at technical and business magazines per month; I have a book or books in the queue at any given time. This has taken much longer than I had hoped, but for days, my mind raced. I ran through many Jimmy Buffett experiences and have never […]

Projects are People

People are Human I realize this piece is likely, nearly certainly, to ruffle some feathers. That is not my intention for sure.  We have written on the impediments to us seeing things truly as it is.  There are many cognitive biases that may plague us. In fact, we dedicated an entire section in our latest […]

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Contact Value Transformation about APQP

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