Advanced Product Quality Planning (APQP) Workshop     


I.D.# C0111Printable Description
Duration: 4 Days

This four-day workshop will provide you with fundamental knowledge and hands-on practice with the Advanced Product Quality Planning process and key tools. Topics addressed include the overview and application of the APQP process, Failure Mode and Effects Analysis, Control Plans, and Error Proofing. The program is designed for all levels of design and manufacturing personnel, as well as more experienced engineering and management personnel, especially for those involved in developing new products or processes.

Why All Four Topics Together? APQP, FMEAs, Control Plans, and Error Proofing are all interrelated and build on each other. Training that focuses only on one of these subjects at a time cannot show how these tools work together to minimize effort, improve quality, and complete programs more quickly with less headaches before, during, and after launch. Participants apply these key tools together to bring an actual product from concept to production during this comprehensive, start-to-finish workshop.

Learning Objectives
By attending this seminar, attendees will learn:

  • APQP phases, milestones, and deliverables
  • The relationship between APQP, PPAP, FMEAs, and Control Plans, and Error Proofing
  • Step-by-step instructions for completing Design and Process FMEAs
  • How to avoid some of the most common FMEA pitfalls
  • How to use FMEAs and other inputs to complete Control Plans easily and quickly
  • Error proofing and mistake proofing concepts, applications, and opportunities throughout the APQP process.

Who Should Attend
This course is designed for individuals with minimal experience with the APQP process and its related key tools. However, many experienced individuals attend the course to refresh their knowledge, gain advanced strategies, and practice development and application of these tools with an experienced facilitator. Program managers, design-responsible engineers or managers, potential APQP or FMEA team members such as operators and technicians, quality personnel, and other product design and manufacturing personnel who are interested in continuous improvement strategies will all benefit.

Attendees should have some previous experience with the APQP process and related tools.

Topical Outline

  • Advanced Product Quality Planning
    • Pre-Assessment
    • Product Quality Planning Responsibility Matrix
    • Fundamentals of Product Quality Planning
    • Product Quality Planning Timing Chart
    • Plan and Define Program
    • Voice of the customer -- Market research; Historical warranty and quality information; Team Experience
    • Business plan/marketing strategy
    • Product/process benchmark data
    • Product/process assumptions
    • Product reliability studies
    • Customer inputs
    • Design goals
    • Reliability and quality goals
    • Preliminary bill of materials
    • Preliminary process flow chart
    • Preliminary listing of special product and process characteristics
    • Product assurance plan
    • Management support
  • Product Design and Development
    • Design failure mode and effects analysis (DFMEA)
    • Design for manufacturability and assembly
    • Design verification
    • Design reviews
    • 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
    • Gages/testing equipment requirements
    • Team feasibility commitment and management support
  • Process Design and Development
    • Packaging standards
    • Product/process quality system review
    • Process flow chart
    • Floor plan layout
    • Characteristics matrix
    • Process failure mode and effects analysis (PFMEA)
    • Pre-launch control plan
    • Process instructions
    • Measurement systems analysis plan
    • Preliminary process capability study plan
    • Packaging specifications
    • Management support
  • Product and Process Validation
    • Production trial run
    • Measurement systems evaluation
    • Preliminary process capability study
    • Production part approval
    • Production validation testing
    • Packaging evaluation
    • Production control plan
    • Quality planning sign-off and management support
  • Feedback, Assessment and Corrective Action
    • Reduced variation
    • Customer Satisfaction
    • Delivery and service
    • Supplements
    • Post-Assessment


  • Failure Mode and Effects Analysis
    • Pre-assessment
    • Instructor-lead development of a sample FMEA
    • FMEA definition, questions, purpose, and benefits
    • Types of FMEAs, their focus, and their relationship with QS-9000
    • Timing of FMEA development and revisions
    • FMEA team composition and data inputs
  • Design FMEA Development
    • DFMEA Candidates, Timing, and Inputs
    • Prepare the Form for Traceability
    • Item/Function, Failure Modes, and DFMEA Assumptions
    • Effects and Severity: Worst Case Scenarios
    • Causes and Occurrence: Warranty Data vs. Test Data
    • Current Design Controls and Detection: Ranking Criteria Weaknesses
    • Risk Priority Number: One of several indicators
    • Recommended Action Do's and Don't's
    • DFMEA group exercises
  • Process FMEA Development
    • PFMEA Candidates, Timing, and Inputs
    • Process Requirements, Failure Modes, and PFMEA Assumptions
    • Effects and Severity: The Five Categories of Effects
    • Causes and Occurrence: The link with Cpk and the 5 Whys
    • Current Design Controls and Detection: The Case for Error Proofing
    • Risk Priority Number: Proper RPN Calculation
    • Recommended Action: What if there isn't one?
    • PFMEA group exercises
  • FMEA Application Workshop
    • Participant-lead Review of Day 1 Content
    • Brainstorming, Selection, and Practice on a Sample FMEA Project
    • Guided Small Group FMEA Development
    • Small Group FMEA Presentations


  • FMEA and Control Plans
  • FMEA Summary and Advanced Strategies
    • Characteristics of Good FMEAs
    • Concurrent Development of PFMEAs and DFMEAs: Benefits and Sources of Confusion
    • Data-Gathering Strategies and Related Quality Tools
    • Cost/Benefits Analysis and Cost of Changes
    • Potential Problems, Pitfalls, and Areas of Confusion: Beware of RPN Threshholds
    • FMEA Maintenance and Control Plan Links
    • Mining for Gold using FMEAs
    • Group Summary Exercises
    • Post-Assessment
  • Control Plans
    • Pre-Assessment
    • What is a Control Plan?
    • How is a Control Plan Developed?
    • The Benefits of a Control Plan
    • Control Plans and the Product Life Cycle
    • Control Plan Inputs
    • The Control Plan Team (Process Team)
  • Process Flow and Characteristics
    • Operation Flow
    • Characteristics
    • Control Methods
    • Determining Sources of Variation
    • Table of Controls
    • Evaluation Methods/Measurement Technique
    • Sample Size/Frequency
    • Reaction Plans
  • Standardization and Continuous Improvement
    • Standardizing the Control Plan
    • Typical Instructions
    • Document Maintenance
    • Periodic Assessment
    • Process Review Flow Chart
    • Supplemental Information
    • Post-Assessment


  • Error Proofing and Workshop Summary
    • Pre-assessment
    • The philosophy of process-focused quality
    • What is Error Proofing and Mistake Proofing?
    • Everyday examples of Error Proofing
    • Manufacturing examples of Error Proofing
    • Purpose and Benefits of Error Proofing
  • The Key Elements of Error Proofing
    • Inspection Strategies
    • Feedback Categories
    • Intervention Levels
  • Error Proofing Case Studies
    • Conduct the following steps on three manufacturing case studies: Analyze Process Data; Brainstorm Error Proofing Solutions; Conduct Cost/Benefits Analysis; Recommend Solutions; Peer Analysis
  • Error Proofing, QS-9000, and the APQP process
    • QS-9000 Error Proofing requirements
    • Error Proofing strategies for each APQP phase
    • The role of Product Design Error Proofing
    • The link between Process FMEA and Error Proofing
    • Error Proofing at the Plant Level
  • Error Proofing Case Study Workshop
    • Each team will be assigned a process and supporting data, and will work together to do the following: Create a process flow diagram; Conduct a root cause analysis and problem solving worksheet; Brainstorm Error Proofing Solutions; Conduct cost/benefits analysis; Complete an Error Proofing worksheet; Present the case before the group
  • Error Proofing Summary and Advanced Strategies
    • Timing is everything: designing in Error Proofing
    • Choosing your Error Proofing battles
    • Resisting the temptation to inspect and rework
    • Data-Gathering Strategies and Related Quality Tools
    • Cost/Benefits Analysis Methods
    • Potential Problems, Pitfalls, and Lessons Learned
    • Additional Resources
    • Post-Assessment

Instructor(s): Daniel P. Bauer, Jr.
Mr. Bauer, an ASME Certified Senior GD&T Professional who holds a Master of Science in Industrial Operations and is fluent in Spanish, serves as president and principal consultant with ITR. With experience supporting over 20 automotive component and vehicle programs in the past 10 years in the U.S., Europe, and China, he specializes in providing training and engineering services in the areas of design engineering, quality, performance improvement, and productivity. In the early '90s Mr. Bauer spent three years designing and implementing training and quality programs for six Ford Motor Company launches. Programs included electrical, fuel handling, and powertrain components, including the 60oV6 Vortec Launch. Over the past three years he has worked to develop a comprehensive error proofing system for Chrysler Corp. He has worked with Chrysler to implement the system on several vehicle programs: the 1998 Dodge Durango, the 1999 Jeep Grand Cherokee, the 2000 Dakota Quad Cab, the 2001 Minivan, and the 2002 Ram Pickup. Most recently Mr. Bauer served as a visiting professor at Shanghai Jiao Tong Univ. where he conducted a certification program in Geometric Dimensioning and Tolerancing and Reading Engineering Drawings. The train-the-trainer program certified university professors and GM engineers who support the GM China training curriculum in both Shanghai and Beijing. He serves as an adjunct instructor and consultant for the Society of Manufacturing Engineers, DaimlerChrysler Quality Institute, General Motors Univ., General Physics Training Institute, and other post secondary institutions. He provides training and consulting services on topics including Failure Mode and Effects Analysis (FMEA), Control Plan Development, Problem Solving, Statistical Process Control (SPC), Capability Analysis, Blueprint Reading, Geometric Dimensioning and Tolerancing (GD&T), Project Management, and Error Proofing. Mr. Bauer has authored publications on Geometric Dimensioning and Tolerancing, Tolerance Stackup Analysis, Product Design Error Proofing, Failure Mode and Effects Analysis, Lean Plant Layout, Standardized Work, Blueprint Reading, Program Management, Advance Product Quality Planning, Control Plan Development, and Team Building. He has additionally worked with General Motors Distance Learning to pilot a series of interactive television broadcasts on Project Management. Mr. Bauer holds a B.A. from Eastern Michigan Univ. and an M.S. in Industrial Operations with distinction from Lawrence Technological Univ.

Fees: $1655.00 ; SAE Members: $1324.00 - $1490.00

2.6 CEUs
You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

For additional information, contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at

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