“Feedback is the compass on the path to excellence.”: Unknown
Introduction
During an academic year, typically three to four Parent–Teacher Meetings (PTMs) are held. The purpose of these meetings is to periodically evaluate the students’ performance and communicate the observations to their parents or guardians. Based on the feedback received, parents can assess their child’s progress and initiate appropriate corrective actions to help achieve the desired academic outcomes.
Content: APQP Phase 5
- What is APQP
- 5 Phases of APQP
- 8 Inputs for Phase 4
- Steps in Phase 5
- Key changes from APQP 2nd edition
- Possible benefits
- Key challenges
- Conclusion
Read More: bit.ly/APQP3rdedition2024 (APQP Overview)
Read More: https://bit.ly/APQPPhase1 (APQP Phase 1)
Objective
This phase is the final stage in the five-phase APQP structure, focusing on closing the loop: moving beyond product launch to validate, monitor performance, capture lessons learned, and continually improve. In the 3rd edition of APQP, this phase receives additional emphasis on metrics, change management, risk review, and knowledge transfer.
After reading the article, you will understand the meaning of APQP, details about Phase 5, preparation before proceeding, key industry challenges, key changes from the 2nd edition, and possible benefits.
Read More: https://bit.ly/APQPPhase2 (APQP Phase 2)
Read More: https://bit.ly/StatutoryRegulatory (Difference Between Statutory & Regulatory Requirements)
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-responsible organisation: organisation with authority to establish a new, or change an existing, product specification
Read More: https://bit.ly/OpportunityCostTradeOff (Opportunity Cost & Trade-off)
Read More: https://bit.ly/APQP3rdPhase (APQP Phase 3)
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.
Read More: https://bit.ly/APQPPhase4 (APQP Phase 4)
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)
Read More: https://bit.ly/PDCASDCA (Difference Between PDCA and SDCA)
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 4
As per the APQP manual, the following are the 8 key inputs (which are outputs from phase 4)
- Significant Production Run
- Measurement System Analysis, AIAG 4th Edition
- Preliminary Process Capability Study, AIAG 2nd Edition
- Production Part Approval (PPAP), AIAG 4th edition
- Production Validation Testing
- Packaging Evaluation
- Production Control Plan, AIAG 1st Edition
- Quality Planning Sign-off and Leadership Support
Read More: https://bit.ly/DiagramTurtleDiagram (What is a Turtle Diagram)
Read More: https://bit.ly/SWOTAnalysisEV (SWOT Analysis)
Purpose of Phase 5
This phase focuses on launching production, monitoring performance, and driving continuous improvement. It ensures that the product and process continue to meet customer requirements after production commences. The key points include
Production Launch:
- Begin full-scale production using the validated processes and controls established in earlier phases.
- Ensure that the product meets all quality, cost, and delivery targets.
Performance Monitoring:
- Continuously monitor product and process performance using tools like Statistical Process Control (SPC) and Measurement System Analysis (MSA).
- Track key performance indicators (KPIs) such as defect rates, customer complaints, and delivery performance.
Feedback Collection:
- Gather feedback from internal stakeholders and customers.
- Use this feedback to identify areas for improvement.
Evaluation and Corrective Actions:
- Analyse performance data to detect trends or issues.
- Implement actions to address the root causes of problems.
- Update documentation such as Control Plans, FMEAs, and Work Instructions as needed.
Continuous Improvement:
- Apply lessons learned to current and future projects.
- Foster a culture of ongoing improvement in quality and efficiency.
Phase 5: Feedback, Assessment and Corrective Action
In the 3rd Edition, these checkpoints aren’t just a “to-do list”, they’re formal gate deliverables. This phase is crucial for maintaining product quality and ensuring customer satisfaction throughout the product lifecycle. It also aligns with the Plan-Do-Check-Act (PDCA) cycle, reinforcing the importance of feedback loops and iterative improvement.
The input and output in this phase will vary depending on the customer and the organisation’s expectations. According to the APQP manual, for some, all key inputs and outputs will be relevant, while for many, only a few will be applicable.
| S. No. | Output | Description / Purpose | Typical IATF 16949 Clause Link |
| 1 | Reduced Variation | Consistent Quality: predictable and repeatable product quality. Example: In-process rejection<100 ppm in the assembly line.
Improved Process Capability: ensures processes stay within control limits. Example: Cpk>1.33 for the critical characteristics in the CNC machining process. Lower Defect Rates: Reduce scrap and rework. Example: COPQ <0.5% from the previous project. Standardised Workflows: minimise operator-induced variability. Example: Reduction in Poka-Yoke failures. |
Clause 9.1.1
Monitoring & measurement of manufacturing processes |
| 2 | Improved Customer satisfaction | Reliable Product Performance: Meeting or exceeding customer expectations. Example: Customer rejection <10 ppm.
Fewer Complaints: reduces field failures and warranty claims. Example: Zero complaints and warranty. Faster Response to Issues: Ensure quick resolution. Example: Response time to ECN <2 days. Customer Confidence: commitment to quality and continuous improvement. Example: CSI >95%. |
Clause 9.1.2
Customer Satisfaction |
| 3 | Improved customer service and delivery | On-Time Delivery: consistent scheduling and fulfilment. Example: 100% delivery compliance to the customer and supplier.
Reduced Lead Times: fewer disruptions speed up delivery. Example: SMED: Single Minute Exchange of Dies: Quick changeover of Dies in 8 minutes. Better Communication: Transparent reporting and feedback mechanisms. Example: Response time to customer <2 hours. Supply Chain Reliability: better coordination with suppliers and logistics. Example: Zero Premium Freight. |
Clause 10.3
Continual Improvement |
| 4 | Effective use of lessons learned/best practices | Knowledge Retention: Capturing insights from current projects helps future programs. Example: Updated Lesson learnt (TGR and TGW).
Process Optimisation: Continuous refinement based on real-world data and feedback. Example: High inventory turnover and low R&R% (MSA Study). Cross-Functional Learning: Sharing best practices across teams. Example: Improvement in FTR: First Time Right. Risk Mitigation: Reduce the likelihood of recurring issues. Example: Reduction is a statutory and Regulatory requirement failure. |
Clause 10.3
Continual Improvement |
Read More: https://bit.ly/OEECalculation (What is OEE?)
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 5 effectively is like “building the house on a solid foundation.”
- Ensures Product Quality in Mass Production
- Drives Continuous Improvement
- Monitors Performance Effectively
- Supports Corrective and Preventive Actions (CAPA)
- Improves Customer Satisfaction
- Captures Lessons Learned
Read More: https://bit.ly/PESTLEANALYSIS (What is PESTLE?)
Conclusion:
Phase 5 of APQP focuses on ensuring the product meets customer expectations during full-scale production and drives continuous improvement through feedback and corrective actions.
In essence, Phase 5 is getting the feedback from Phases 1 to 4, assessing what went right & wrong and taking corrective action where needed.
Read More: https://bit.ly/7ProblemSolvingTechnique (What is Problem Solving Technique?)
Read More: https://bit.ly/4MChanges (What is 4M change?)
Present Challenges:
- How often does top management involve itself in systematically reviewing the performance of each phase and taking corrective action?
- How often does the organisation have a robust system to record TGR (Things Gone Wrong) and TGR (Things Gone Right)?
- How often is the status of new development products at different phases reviewed in the management review?
References:
APQP 3rd Edition
IATF 16949
Industry Experts
This is the 241st 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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