What is APQP? The 5 phases explained
Advanced product quality planning explained: the five phases, the deliverables of each phase, gates, the role of FMEA, control plan, MSA and PPAP, and how long it takes.
Purpose
APQP (advanced product quality planning, AIAG) is a structured way to launch a new or changed product so that it meets the customer requirements on time. It brings together design, process engineering, quality, purchasing and the supplier in one plan with defined deliverables and gates.
The five phases
| Phase | Goal | Key deliverables |
|---|---|---|
| 1 Plan and define | Understand the customer and the project | Design and quality goals, preliminary BOM, process flow and special characteristics |
| 2 Product design and development | Make the design robust | DFMEA, design verification, drawings, prototype control plan, feasibility commitment |
| 3 Process design and development | Design the process to make it | Process flow, PFMEA, floor plan, pre-launch control plan, MSA plan |
| 4 Product and process validation | Prove it in series conditions | Significant production run, MSA, capability study, PPAP, production control plan |
| 5 Feedback and corrective action | Learn and improve after SOP | Reduced variation, customer satisfaction, lessons learned |
The golden thread
The core tools are linked: special characteristics from phase 1 appear in the DFMEA, the PFMEA, the control plan, the MSA plan and the capability studies, and finally in the PPAP. A characteristic that disappears along the way is a typical audit finding.
How long does it take?
For a new automotive component typically 18–36 months from nomination to SOP. Phases overlap; tool and equipment lead times usually drive the critical path.
Written by Ľubomír Blažek, automotive quality manager. Standards are summarised in our own words; use the official publications for formal work.