APQP / Advanced Product Quality Planning

Author: Maren Fichtner | June 16, 2025

APQP: Definition & Meaning

APQP is a systematic process for the early quality planning of products. Before the actual production phase - i.e. during the design and development process - measures are defined to ensure the desired product quality.

This quality management has its origins in the QS 9000 standard and its successor standard IATF 16949, both of which originate from the automotive industry, but this does not mean that APQP cannot also be used in medical technology, mechanical engineering or other industries.

APQP stands for Advanced Product Quality Planning, which literally translates as advance product quality planning. In German, the term Qualitätsvorausplanung - QVP for short - is also commonly used alongside APQP.

Summary

APQP = systematic advance quality planning before the start of production

Originated in the automotive industry, can now be used across all sectors

Goal: Ensure product quality through early measures

Prerequisite for APQP

The most important prerequisite for effective Advanced Product Quality Planning is cross-departmental cooperation. In order to plan for high product quality in advance, you need to bring the development department, production, quality assurance and supplier management together. The departments then work together to derive measures and options.

The 5 phases of the APQP project structure

APQP processes must be carefully planned in order to achieve the desired result. And they may have to be redefined for each new order. The best way to do this is to follow the 5 phases of the APQP project structure.

Phase 1: Planning & conception

This is what you need to do:

Record all customer requirements and expectations as completely and seamlessly as possible. Clarify the project requirements and framework conditions.

This is the result:

Typically, at the end of this phase, you will have specifications and concrete quality and reliability targets.

Phase 2: Product design & development

This is what needs to be done:

In this phase, the responsible departments develop a production-ready product design suitable for series production. You also plan all assembly and production processes.

This is the result:

At the end of this phase, you will have a failure mode and effects analysis (FMEA) for the design and the final product. You will have created a prototype and drawn up a production control plan.

Phase 3: Process design & development

This is what needs to be done:

You know what needs to be done. Now it's all about the "how". In phase 3, you work out efficient production processes and select the appropriate equipment, machines and systems.

This is the result:

You conclude phase 3 with a concrete process flow chart and a process FMEA.

Phase 4: Product & process validation

This is what you have to do:

In this step, you validate that all theoretical and prototype preparatory work stands up to the reality of production. In other words, you ensure that the production processes deliver reproducible products according to customer specifications.

That is the result:

Typically, at the end of this phase, you will have clear reports on the success or failure of your measures.

These can include

Test equipment capability analyses
Sampling in accordance with PPAP (Production Part Approval Process)
Initial sample test reports

Phase 5: Feedback, assessment, correction

This is what you need to do:

You have now established an APQP process and must collect feedback on it and continuously reassess the process steps. You keep your eyes open for deviations and initiate corrective measures where necessary.

This is the result:

Over time, you optimize and stabilize the established processes more and more. Statistical process control (SPC), for example, helps you to do this.

Another important tip: document all phases of an APQP project systematically in a status report and evaluate each phase separately before starting the next phase. This will help you to identify any need for action and avoid "follow-up errors" in later phases.

Summary

Phase 1: Clarify customer requirements and define quality objectives

Phase 2: Develop product design ready for series production, create prototype

Phase 3: Plan production processes and create process FMEA

Phase 4: Validate product and processes under real conditions

Phase 5: Evaluate feedback and optimize processes

Important: Document and evaluate each phase separately in order to identify errors at an early stage.

Advantages of APQP

Admittedly, APQP requires you to invest a considerable amount of time and "brainpower" in your production processes in advance. But the effort can be well worth it. Advanced Product Quality Planning helps you

identify and eliminate potential sources of error at an early stage
actively avoid errors instead of reworking them
establish targeted measures to avoid quality defects in series production
introduce structured planning and control processes to ensure compliance with defined quality requirements
continuously develop and optimize product quality
ensure that your products meet customer requirements and expectations
increase customer satisfaction

Summary

Early error prevention through structured planning

Sustainable quality assurance, even in series production

Higher customer satisfaction through targeted measures

Objectives of APQP

Let's keep it short: the overarching aim of APQP is to identify all the necessary steps and measures required for a high-quality end product before production begins. This enables lean, error-free production processes and a high level of customer satisfaction.

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