“The bitterness of poor quality remains long after the sweetness of low price is forgotten.”: Unknown
Introduction
Before travelling abroad, we always double-check our passports, flight tickets, foreign currency, and other essentials. Missing even one important item can disrupt the entire trip. That’s why, even at the airport, we check everything once again—just to be sure.
Content: APQP Phase 4
- What is APQP
- 5 Phases of APQP
- 10 Inputs for Phase 3
- Steps in Phase 4
- 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 4 is the stage where the organisation “prove” that both the product and the manufacturing/assembly process can consistently meet customer requirements under production-like conditions. It includes pilot or trial production, validation testing of both product and process, packaging validation, and submission of approval documentation.
After reading the article, you will understand the meaning of APQP, details about Phase 4, 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 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”).
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.
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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)
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 3
As per the APQP manual, 3rd edition, the following are the 10 key inputs (which are outputs from phase 3)
- Packaging Standards & Specifications
- Product / Process Quality System Review
- Process Flow Diagram
- Floor Plan Layout
- Process Failure Mode & Effects Analysis (PFMEA)
- Pre-Launch Control Plan
- Process Instructions / Work Instructions
- Measurement Systems Analysis (MSA) Plan
- Preliminary Process Capability Study Plan
- Leadership Support
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Read More: https://bit.ly/SWOTAnalysisEV (SWOT Analysis)
Purpose of Phase 4
This phase validates that both the product design and the manufacturing process can consistently produce products that meet all customer requirements under actual production conditions. The key points include
- Verify Production Capability: Confirm that the manufacturing process can produce parts at the required rate and quality.
- Validate Product Performance: Ensure the product meets all functional, durability, and regulatory requirements through testing.
- Approve Production Parts: Submit and gain customer approval via the Production Part Approval Process (PPAP).
- Confirm Measurement Systems: Validate that all measurement systems are accurate and repeatable (MSA).
- Establish Control Plans: Finalise the Production Control Plan to maintain quality during mass production.
- Evaluate Packaging: Ensure packaging protects the product and meets customer logistics requirements.
- Mitigate Risks: Address any remaining risks identified in the PFMEA or during trial runs.
Phase 4: Product and Process Validation
In the 3rd Edition, these checkpoints aren’t just a “to-do list”, they’re formal gate deliverables. At the end of Phase 4, Leadership must review and approve progress before moving into Phase 5 (Feedback, Assessment and Corrective Action).
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 | Significant Production Run | · Data from initial production runs using production tooling, equipment, environment, Facility, gauges, operators and production rate to validate process stability and capability.
· Refer to AIAG PPAP Manual, 4th edition Example: Trial run report showing 300 parts produced with 98% yield and no major defects. Whether the customer production can be met or not (Productivity). |
8.5.1.1 Control Plan |
| 2 | Measurement System Analysis
AIAG 4th Edition |
· Verification that measurement systems (vernier, micrometer, hardness tester, etc.) are capable (e.g., Gage R&R, bias, linearity).
· Alignment of the measurement system at the supplier, organisation and customer end. Example: Gage R&R study showing 90% acceptable repeatability and reproducibility. Validation of the right selection of measuring system and inspector competence (Capability). |
7.1.5.1.1 Measurement System Analysis |
| 3 | Preliminary Process Capability Study
AIAG 2nd Edition |
· Initial Cp/Cpk values are special characteristics to assess process capability.
Example: Cp = 1.67 and Cpk = 1.45 for critical dimension X, Capable of matching with the mating part (Capability) |
9.1.1.2 Identification of Statistical Tools |
| 4 | Production Part Approval (PPAP)
AIAG 4th edition |
· The purpose is to provide evidence that all customer engineering design records and specifications requirements are properly understood.
· Complete PPAP documentation submitted to the customer for approval. · Ensure the software is protected against unauthorised access, data breaches, and tampering (Cybersecurity) Example: Level 3 PPAP submission including dimensional results, material certificate, and control plan (Productivity, Capability, Timing and Cost). |
8.3.5.2 Manufacturing Process Design Output
|
| 5 | Production Validation Testing | · Results from functional, durability, and performance testing to confirm the product meets requirements.
· Confirm software installation and functionality during final product testing. · Effective implementation of ADAS (Advanced Driver Assistance Systems) to assist the driver and enhance safety, comfort, and convenience while driving. Example: Test report showing product passed all vibration and thermal cycling tests. Qualified in shade variation as per the limit sample. Validation of Euro VI Emission norms (Capability). |
8.3.5.2 Manufacturing Process Design Output |
| 6 | Packaging Evaluation | · Validation of packaging for protection, handling, adverse environment, and logistics. Additionally, any required backup packaging.
· Validate that the correct software version is installed and documented. Example: Packaging test results confirming no damage after drop and vibration tests. How returnable packaging is managed. How shelf-life items are packaged (Capability). |
8.5.1.1 — Control Plan |
| 7 | Production Control Plan
AIAG 1st Edition |
· A detailed plan for controlling product and process characteristics during production.
· May include ‘Safe Launch’ period to ensure containment of potential non-conformities. Example: Control plan listing process steps, control methods, and reaction plans for each key characteristic (Productivity, Capability, Timing and Cost). |
8.5.1 — Control of production & service provision |
| 8 | Quality Planning Sign-off and 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). · Refer to Appendix E Example: Participation in gate review (quality risk, cost, lead time, critical path), periodic management review, and Effective implementation of any statutory/regulatory requirement (Productivity, Capability, Timing and Cost). |
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 4 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 4 of APQP focuses on validating that the product and manufacturing process can consistently meet customer requirements. It includes production trial runs, measurement system analysis, capability studies, PPAP submission, product and packaging validation, and final control plan. This phase ensures readiness for full-scale production and customer approval.
In essence, Phase 4 is the final checkpoint before full-scale production, ensuring that everything, from tooling and processes to quality systems and packaging, is fully validated and aligned with customer expectations.
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Present Challenges:
- How often are the key input parameters, like productivity, cost, timing and capability are validated?
- How often is embedded software validated to ensure that the software performs reliably within the product and meets all customer and regulatory requirements?
- In phase 4, we need to validate both product and process. In the majority of cases, the focus is only on product validation (meeting the drawing). What about process validation?
References:
APQP 3rd Edition
IATF 16949
Industry Experts
This is the 240th 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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