“Good design is good business.” — Thomas Watson Jr
Introduction
Before investing in a flat, buyers visit the site to assess the surroundings and infrastructure. Builders construct sample flats to help visualise the final product. This aids in understanding layout and design. Based on these observations and a thorough risk analysis, buyers make an informed decision about the purchase.
Content: APQP Overview
- What is APQP
- 5 Phases of APQP
- Inputs for Phase 2
- Steps in Phase 2
- 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
To develop and validate a robust product design that meets customer, regulatory, and functional requirements, while confirming its manufacturability, serviceability, and cost-effectiveness through cross-functional reviews, risk analysis, and prototype testing before moving into process design. 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 2, preparation before proceeding, key industry challenges, key changes from the 2nd edition, and possible benefits.
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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 Quality, Cost and Time (QCD) & blueprint the entire development process accordingly.
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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.
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Key Inputs from Phase 1
As per the APQP manual, 3rd edition, the following are the 11 key inputs (which are outputs from the planning phase 1)
- Design Goals
- Reliability and Quality Goals
- Preliminary Bill of Materials
- Preliminary Process Flow Chart
- Preliminary identification of special characteristics related to products and processes
- Product Assurance Plan
- Capacity Planning
- Leadership Support
- Change Management Implementation
- APQP Program Metrics
- Risk Assessment Mitigation Plan
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Purpose of Phase 2
- Meet production volume and schedule
- Ability to meet Quality, Reliability, Investment Cost, Weight, Unit Cost and Timing objectives
- Prioritise the characteristics that need special product and process controls
Key Risk Related to Phase 2
APQP Phase 2 risk management = “designing with foresight.”
The organisation must:
- Rigorously review requirements,
- Identify high-severity risks early (DFMEA, feasibility reviews),
- Systematic Prototyping,
- Plan resources (gauges, tooling, suppliers) ahead of time, and
- Control changes tightly.
Phase 2: Product 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 2, management must review and approve progress before moving into Phase 3 (Process Design & Development).
The input and outputs in this phase will vary depending on the customer and 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 | Design Failure Mode and Effects Analysis (DFMEA) | Analysis of possible design failures & their effects. Living document, Refer to the DFMEA checklist, Appendix A-1. Example: Low fuel efficiency. | 8.3.3.3 (Special characteristics, risk analysis) |
| 2 | Design for Manufacturability, Assembly and Service | Simultaneous engineering process to ensure that the design can be manufactured, assembled and serviced efficiently. Example: How to change the battery, how to open the bonnet | 8.3.3.1 (Manufacturing feasibility), 8.3.3.2 (Special characteristics) |
| 3 | Design Verification | Confirming the design meets requirements via tests, simulations, or calculations. “Did we design the product right?” Detect discrepancies between the intended requirements and the design results before launch. Example: Airbags designed as per the legal requirements | 8.3.4.3 (Design and development verification) |
| 4 | Design Review | Formal scheduled reviews of design progress, changes, and compliance. Example: QCD target met or not? | 8.3.4.1 (Design and development controls) |
| 5 | Prototype Build Control Plan | Plan for building prototypes, including how they are tested/controlled to meet Voice of the Customer (VOC). Example: Fitment of the bumper and its alignment. | 8.3.4.4 (Prototype program) |
| 6 | Engineering Drawings (including Math data) | Official blueprint for how a part is defined, built, and measured. A contract between design intent and manufacturing reality (CAD data). Example: Complex curves, geometry, mounting holes and interface with door skin (Door Handle). | 8.3.5 (Design and development outputs) |
| 7 | Engineering Specifications | What the product must do (performance/requirements). Example: For EV, how much will be the charging time and output | 8.3.5 (Design and development outputs) |
| 8 | Material Specifications | What the product must be made of. What materials must be used (grade, quality, etc.)? Example: Sheet thickness and grade of door panel. | 8.3.5 (Design and development outputs) |
| 9 | Drawing and Specification Changes | A formal process to manage changes to design documents. Example: Bulb not meeting the legal requirement of light intensity. | 8.3.6 (Design and development changes) |
| 10 | New Equipment, Tooling and Facilities Requirements | What will tooling, test equipment, etc., be required for design verification and future phases? Example: Clean room for the electronic components’ storage and assembly. | 8.3.5 (Design and development outputs), 7.1.3 (Infrastructure) |
| 11 | Special Product and Process Characteristics | Items that are critical for safety, fit, function, etc., require tighter control. Example: Wheel alignment can be a special characteristic for smooth vehicle running. | 8.3.3.3 (Special characteristics) |
| 12 | Gauges / Testing Equipment Requirements | Any new tooling or changes are needed to support the design. Example: How to check the sound of the horn (Decibels) | 7.1.5.1.1 (Measurement system analysis), 8.3.5 (Design outputs) |
| 13 | Team Feasibility Commitment & Management Support | Confirmation that teams (engineering, manufacturing, quality, etc.) are aligned, resources are committed to meet QCD and support from top management. Example: Government guidelines to mix 20% ethanol in gasoline. | 8.3.3.1 (Manufacturing feasibility), 5.1.1 (Leadership commitment) |
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Key Changes from Rules 2nd Edition
- Capacity Planning
- Risk Management
- Program Metrics
- Change Management
Key Benefits:
Managing Phase 2 effectively is like “building the house on a solid foundation.”
- Robust Design
- Manufacturability and assembly verified
- Risk Reduction Early On
- Efficient Resource Planning
- Improved Reliability & Quality
- Management Commitment
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Conclusion:
Phase 2 of APQP, Product Design and Development, lays the foundation for all downstream activities. When managed well, it ensures robust, manufacturable designs, early risk mitigation, supplier readiness, and clear documentation. Effective execution minimises costly changes, accelerates launches, and aligns teams and management, leading to higher quality, lower costs, and satisfied customers.
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Present Challenges:
- How often is the organisation clear whether they are design responsible or not? If yes, why and if not, why!
- How often is regular and updated feedback shared with top management as management review input?
- How often are prototypes manufactured to analyse design, manufacturability, assembly and service?
References:
APQP 3d Edition
IATF 16949
Industry Experts
This is the 238th 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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