Advances Product Quality Planning (APQP) & Production Part Approval Process (PPAP)

Course Outline:

Module 1: Introduction to APQP & PPAP

• Overview of APQP & PPAP
• Importance of APQP & PPAP in the automotive and manufacturing industries
• Key benefits and objectives

Module 2: Fundamentals of Advanced Product Quality Planning (APQP)

• APQP phases:
  • Phase 1: Plan and Define the Program
  • Phase 2: Product Design and Development
  • Phase 3: Process Design and Development
  • Phase 4: Product and Process Validation
  • Phase 5: Feedback, Assessment, and Corrective Actions
• APQP tools and templates
• Cross-functional team involvement

Module 3: Core Tools Used in APQP

• Failure Modes and Effects Analysis (FMEA)
• Measurement Systems Analysis (MSA)
• Statistical Process Control (SPC)
• Production Part Approval Process (PPAP)

Module 4: Understanding Production Part Approval Process (PPAP)

• Purpose and significance of PPAP
• When PPAP is required
• PPAP submission levels
• Key PPAP documents:
  • Part Submission Warrant (PSW)
  • Design Records
  • Process Flow Diagram
  • Control Plan
  • Dimensional Results
  • Material Performance Test Results
  • Initial Process Studies
  • Packaging Specifications

Module 5: Risk Management & Continuous Improvement in APQP & PPAP

• Identifying and mitigating risks
• Lessons learned and best practices
• Continuous improvement techniques in APQP and PPAP

Module 6: Case Studies & Practical Applications

• Real-world case studies of APQP & PPAP implementation
• Common challenges and solutions
• Group exercises and hands-on activities

Module 7: Assessment & Certification

• Final assessment (quiz, case study evaluation)
• Feedback session
• Course certification

Course Objectives:

By the end of this training, participants will be able to:

1. Understand the purpose, scope, and importance of APQP and PPAP.
2. Apply APQP methodologies to ensure product and process quality.
3. Utilize core quality tools (FMEA, SPC, MSA) in APQP.
4. Demonstrate knowledge of PPAP requirements and submission levels.
5. Implement risk management strategies to minimize defects.
6. Identify and apply best practices for continuous improvement.
7. Effectively communicate quality planning strategies across teams.

Learning Outcomes:

Upon successful completion of the course, participants will:

• Gain a comprehensive understanding of APQP & PPAP methodologies.
• Develop the ability to create and analyze key APQP & PPAP documents.
• Apply risk assessment techniques to prevent quality issues.
• Implement statistical tools for process validation and control.
• Confidently lead or contribute to APQP & PPAP initiatives in their organizations.

Training Methodology:

This course will use an interactive and practical approach, including:

• Instructor-led presentations with real-world examples
• Group discussions to encourage knowledge sharing
• Hands-on exercises using actual APQP & PPAP documentation
• Case studies to demonstrate real-life industry applications
• Quizzes & assessments to reinforce learning
• Q&A sessions for clarification of concepts
• Certification exam to evaluate participants' understanding