“Design is not just what it looks like and feels like. Design is how it works.”
– Steve Jobs
Introduction
Imagine two students working hard and competing with each other.
One studies every page of every book without thinking about what’s most important.
The other checks the syllabus, reviews past exam papers, and examines the latest class notes to select and focus on the key topics.
It’s not hard to guess which student will score higher marks.
Content: APQP Overview
- What is APQP
- 5 Phases of APQP
- 13 Inputs for Phase 3
- 10 Steps in Phase 3
- Key changes from APQP 2nd edition
- Possible benefits
- Key challenges
Read More: bit.ly/APQP3rdedition2024 (APQP Overview)
Read More: https://bit.ly/APQPPhase1 (APQP Phase 1)
Objective
Phase 3 in APQP (Advanced Product Quality Planning) focuses on designing and developing a manufacturing process that consistently produces parts meeting all customer requirements. The key objective is to translate the product design into a robust, capable, and controlled manufacturing process with all necessary documentation, controls, and readiness for validation in the next phase. In short, “Design it right, prove it works, and make sure it can be built reliably.”
After reading the article, you will understand the meaning of APQP, details about Phase 3, preparation before proceeding, key industry challenges, key changes from the 2nd edition, and possible benefits.
Read More: https://bit.ly/APQPPhase2 (APQP Phase 2)
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Definition: IATF 16949 Clause 3.1
APQP: product quality planning process that supports development of a product or service that will satisfy customer requirements; APQP serves as a guide in the development process and also a standard way to share results between organizations and their customers; APQP covers design robustness, design testing and specification compliance, production process design, quality inspection standards, process capability, production capacity, product packaging, product testing and operator training plan, among other items.
Control plan: a documented description of the systems and processes required for controlling the manufacturing of the product.
Design for assembly (DFA): a process by which products are designed with ease of assembly considerations. (e.g., if a product contains fewer parts, it will take less time to assemble. thereby reducing assembly costs).
Design for manufacturing (DFM): integration of product design and process planning to design a product that is easily and economically manufactured.
Design for manufacturing and assembly (DFMA): combination of two methodologies: Design for Manufacture (DFM), which is the process of optimizing the design to be easier to produce, have higher throughput, and improved quality; and Design for Assembly (DFA), which is the optimization of the design to reduce risk of error, lowering costs, and making it easier to assemble.
Design for Six Sigma (DFSS): systematic methodology, tools, and techniques with the aim of being a robust design of products or processes that meets customer expectations and can be produced at a six-sigma quality level.
Design-responsible organisation: organisation with authority to establish a new, or change an existing, product specification
Embedded Software: Embedded Software is a specialised programme stored in an automotive component (typically a computer chip or other non-volatile memory storage) specified by the customer, or as part of the system design, to control its function(s). To be relevant in the scope of IATF 16949 certification, the part that is controlled by embedded software must be developed for an automotive application (i.e., passenger cars, light commercial vehicles, heavy trucks, buses, and motorcycles; see Rules for achieving and maintaining IATF Recognition, 5th Edition, Section 1.0 Eligibility for Certification to IATF 16949, for what is eligible for “Automotive”).
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Detailed Information
In March 2024, AIAG (Automotive Industry Action Group) released the 3rd Edition of APQP. This new version brings updates that make the process more practical, more aligned with today’s business challenges, and easier to integrate with other quality tools.
This new edition reflects the latest industry trends like electric vehicles (EVs), autonomous driving, and digital manufacturing.
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What is APQP?
APQP is a structured way of planning and controlling product development. It ensures that customer needs are integrated into the design, development, and manufacturing process from the outset.
It is widely used in the automotive industry but is equally useful in other manufacturing sectors. Think of APQP as a roadmap that connects customer requirements, product design, process design, and final delivery.
APQP ensures the Voice of the Customer (VOC) is clearly understood and translated into specific requirements, technical specifications, and unique features.
APQP focuses on proactive measures to embed product and process benefits through prevention. The key intent is to understand the end objective in terms of Productivity, Process Capability, Timing, and Cost & blueprint the entire development process accordingly.
Read more: https://bit.ly/DifferenceCrandCSR (Difference Between Customer Requirement & Customer Specific Requirement)
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5 Phases of APQP
As per IATF 16949, Clause 8.3 and APQP manual (Advanced Product Quality Planning- 3rd edition 2024), there are 5 key phases. They are
- Plan and Define
- Product Design and Development
- Process Design and Development
- Product and Process Validation
- Feedback, Assessment and Corrective Action
The 3rd edition explains each phase in simpler, real-world terms. It helps teams focus on “what to do” and “why it matters” rather than just filling out forms.
Read More: https://bit.ly/LifeCycleAssesment (Life Cycle Assessment)
Key Inputs from Phase 2
As per the APQP manual, 3rd edition, the following are the 13 key inputs (which are outputs from phase 2)
- Design Failure Mode and Effects Analysis (DFMEA)
- Design for Manufacturability, Assembly and Service
- Design Verification
- Design Review
- Prototype Build Control Plan
- Engineering Drawings (including Math data)
- Engineering Specifications
- Material Specifications
- Drawing and Specification Changes
- New Equipment, Tooling and Facilities Requirements
- Special Product and Process Characteristics
- Gauges / Testing Equipment Requirements
- Team Feasibility Commitment & Leadership Support
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Purpose of Phase 3
The key purpose of Phase 3 in the Advanced Product Quality Planning (APQP) 3rd Edition – 2024 is to ensure that the manufacturing process is robust, capable, and aligned with product requirements before full-scale production begins. The key points include
- Translate Product Design into a Viable Manufacturing Process
- Meet targets related to Productivity, Process Capability, Timing, and Cost
- Identify and Mitigate Process Risks
- Establish Process Controls and Validation
- Ensure Readiness for Production
- Facilitate Cross-Functional Collaboration
- Support Continuous Improvement
Phase 3: Process Design and Development
In the 3rd Edition, these checkpoints aren’t just a “to-do list”, they’re formal gate deliverables. At the end of Phase 3, Leadership must review and approve progress before moving into Phase 4 (Product and Process Validation).
The input and output in this phase will vary depending on the customer and the organisation’s expectations. As per the APQP manual, for some, all the key inputs and outputs will be relevant, for many, only a few.
| S. No. | Output | Description / Purpose | Typical IATF 16949 Clause Link |
| 1 | Packaging Standards & Specifications | • Packaging design (including internal partitions) that protects product integrity in handling, storage, transit • Packaging must interface with material handling/logistics systems • Comply with customer packaging or industry standardsExample: Electronic components packaged in anti-static packaging. Chemicals should be stored away from sunlight. |
8.5.4 — Preservation; 8.5.5 / Post‑delivery |
| 2 | Product / Process Quality System Review | • Assess the existing quality management system against any additional controls needed • Update procedures, internal audits, and quality documentation • Use Product/Process Quality Checklist (Appendix A-4) to verify completenessExample: As per the Customer manual, special characteristics to have 100% testing or process capability study or error proofing. |
4.3.2 Customer-Specific Requirements
9.2: Internal audit |
| 3 | Process Flow Chart | • Create detailed flow diagrams capturing the sequence of operations, inspection points, and material flow • Include material logistics, rework, scrap, wait, movement • Cross-check against DFMEA and design input (Appendix A-6)Example: In the MIG welding process, reworking and re-inspection are an integral part of the process. |
8.3.5.2 Manufacturing Process Design Output |
| 4 | Floor Plan Layout | • Develop a layout showing workstation arrangement, material flow, and logistics paths • Ensure clear separation of operations, minimise waste • Include safety, ergonomic, and equipment clearance considerations (Appendix A-5).Example: Location to display the work instruction and its legibility. Whether the layout help to meet the Productivity target? |
8.3.5.2 Manufacturing Process Design Output
7.1.3.1 Plant Facility and Equipment Planning |
| 5 | Process Failure Mode & Effects Analysis (PFMEA)
AIAG/VDA 1st Edition |
• Identify failure modes, causes and effects for the manufacturing process • Assign severity, occurrence, and detection ratings • Derive corrective/preventive actions • Ensure linkage with design-level FMEA (DFMEA) and control plan • Capture lessons learned, update family/foundation PFMEAs where applicable (Appendix A-7).Example: How the past problems and lessons learnt are incorporated. All the special characteristics from the customer and DFMEA are incorporated. |
8.3.5.2 Manufacturing Process Design Output |
| 6 | Pre-Launch Control Plan
AIAG 1st edition |
• Define interim (pre-production) control plan elements: what to monitor, how often, methods, reaction plans • Link to PFMEA, set up triggers and corrective actions • As of the 3rd edition, the control plan is now a standalone manual, so your process design must interface closely with that document (Appendix A-10)Example: Frequent inspection, more in-process checks and higher sample size. All controls defined in PFMEA are included in CP. |
8.5.1.1 — Control Plan; 8.5.1 — Control of production & service provision |
| 7 | Process Instructions / Work Instructions | • Create clear, standardised instructions for each operation • Include key steps, tolerances, checkpoints, and safety cautions • Should reflect special/critical characteristics • Incorporate error-proofing (poka-yoke) where applicableExample: Language of work instruction, legibility, complexity, Safety instructions |
8.3.5.2 Manufacturing Process Design Output
8.5.1.2 Standardised Work -Operator Instructions and Visual Standards |
| 8 | Measurement Systems Analysis Plan: AIAG 4th edition | • Plan for gauge/test equipment needed • Define measurement method, sample size, frequency • Perform Gage R&R studies • Confirm calibration/accuracy capability • Document measurement system requirements in the control plan contextExample: Identification of instruments/operators used for critical and safety/Legal characteristics |
8.3.5.2 Manufacturing Process Design Output
7.1.5.1.1 Measurement System Analysis |
| 9 | Preliminary Process Capability Study Plan: AIAG 2nd edition | • Define plan for capability studies (Cp, Cpk) once process is stabilised • Include sampling plan, target tolerances • Set criteria for acceptability • If capability is poor, plan for mitigation/improvement actionsExample: Special characteristics identified by the customers’ drawing, DFMEA and PFMEA |
8.3.5.2 Manufacturing Process Design Output
9.1.1.2 Identification of Statistical Tools |
| 10 | Leadership Support | • Verify that leadership (management) is aligned, review and approve Gate 3 (Process Feasibility) • Provide resource commitments, timelines • Document open issues and action items (with owners and due dates)Example: Participation in gate review, periodic management review |
5.1 Leadership and Commitment |
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Key Changes from Rules 2nd Edition
- Control Plan separated as a standalone manual
- Expanded & explicit checklists
- Stronger change management controls
- Gate reviews & milestone check control
- More emphasis on supplier/sourcing integration
- Greater attention to risk, agility & iteration
- More traceability/lessons learned integration
Key Benefits:
Managing Phase 3 effectively is like “building the house on a solid foundation.”
- Enhanced Risk Management
- Standardised Global Practices
- Improved Supplier Collaboration
- Clear Deliverables and Checkpoints
Read More: https://bit.ly/PESTLEANALYSIS (What is PESTLE?)
Conclusion:
Phase 3 of APQP, Process Design and Development, lays the foundation for all downstream activities. When managed well, it
- Establish the manufacturing process flow
- Identify key process characteristics and control methods
- Develop process FMEA, control plans, work instructions
- Prepare for tooling, equipment, and operator training
- Ensure all quality, reliability, and regulatory requirements are built into the process
This phase lays the foundation so that in Phase 4 (Product & Process Validation), the process can be proven capable under real production conditions.
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Present Challenges:
- How often does CFT prepare the PFMEA and Control plan?
- How often is the intent of internal and external audit not to check the PPAP documents but to analyse how the CFT worked together during phase 3?
- How often is leadership involved in the status and performance of the new development process?
References:
APQP 3d Edition
IATF 16949
Industry Experts
This is the 239th article of this Quality Management series. Every weekend, you will find useful information that will make your Management System journey Productive. Please share it with your colleagues too.
In the words of Albert Einstein, “The important thing is never to stop questioning.” I invite you to ask anything about the above subject. Questions and answers are the lifeblood of learning, and we are all learning. I will answer all questions to the best of my ability and promise to keep personal information confidential.
Your genuine feedback and response are extremely valuable. Please suggest topics for the coming weeks.
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