Overview of the New 3rd Edition Advanced Product Quality Planning (APQP) and 1st Edition Control Plan Manuals

Course Duration: 2 Days

This two-day course focuses on the changes in the newly released 3rd Edition APQP Plan Reference Manual and 1st Edition Control Plan Reference Manual.

The first day of class addresses all the elements of APQP, plus the changes from the 3rd Edition Reference Manual, and defines it as a process in your organization. It provides an overview of the five phases of APQP and how it is managed as a process in the planning, development and launch of new products and processes. Information on the transition to the 3rd Edition Reference Manual will also be included.

The approaches discussed and employed in this course are consistent with the intent and guidelines in the APQP 3rd Edition.

The second day of the course will focus on the development, implementation and improvement of Control Plans according to the Control Plan 1st Edition Reference Manual. The second day will identify all the concepts and best practices which were retained in the 1st Edition as well as expanded strategies and added concepts and best practices.

Join the writers of the Core Tools: Michael Down , Gregory Gruska , and Mary Rowzee .

Learning Objectives

Seminar Goals (APQP)

  • Identify transitional information for applying the 3rd Edition APQP Reference Manual
  • Define the five phases of APQP for New Product Development and its relationship to program management, including the knowledge and skills needed to participate in an APQP team
  • Learn how to apply the APQP Checklists during an APQP Program Launch
  • Define Management Gate Reviews and how best to perform them
  • Describe the Role of Leadership and application of APQP Metrics

Seminar Goals (Control Plan)

  • Be able to develop Control Plans in each phase (Prototype, Pre-launch, Safe Launch, Production) efficiently and effectively
  • Describe the minimum information that should be entered in the Control Plan
  • Utilize information gathered from implementing APQP and completing a Process FMEA to construct a Control Plan
  • Identify and address changes that occur during and after development
  • Utilize forms and checklists
  • Control Plan Checklist
  • Special Characteristic Worksheet
  • Apply proven techniques for the effective use of Control Plans
  • Reverse PFMEA
  • Using software to develop and manage Control Plans
  • Layered Process Audits (LPA)
  • Using Family and Foundation FMEAs
  • Control Plans in highly automated processes
  • Reaction Plans and CAPA
  • Control of storage and handling related risks
  • Management of abnormalities in relation to Control Plans

Course Outline

Course Competencies and Learning Objectives – APQP

  • Competency 01: Describe the Advanced Product Quality Planning (APQP) Process Model
  • LO 01: Describe the APQP Model
  • LO 02: List the five phases of APQP
  • LO 03: Explain the importance of concurrent engineering
  • LO 04: Relate APQP to IATF 16949
  • Competency 02: Identify the Key Inputs/Outputs of the Five Phases of APQP and Describe the Importance of Each
  • LO 05: Identify the inputs and outputs of the five APQP phases
  • LO 06: Describe some of the commonly used methods, tools and techniques that may be used during APQP
  • Competency 03: Use of APQP Checklists (Appendix A – Product Quality Planning Checklists)
  • LO 07: Customizing your APQP Checklist
  • LO 08: Linkage to the APQP Plan, i.e., deliverable
  • LO 09: Rating an APQP Checklist
  • Competency 04: Use of Gated Management (Appendix B – Gate Reviews)
  • LO 10: Importance of Gate Reviews and who should attend
  • LO 11: Creating an agenda and preparing for a Gate Review
  • LO 12: Conducting a Gate Review
  • Competency 05: Use of Role of Leadership and APQP Metrics (Appendix C – Analytical Techniques)
  • LO 13: Role of Leadership in APQP
  • LO:14 APQP Metrics and use of GYR from Checklists
  • LO 15: Use of various analytical techniques

Seminar Outline - APQP

  • APQP Overview
  • Getting Started with APQP Program Launch (Phase 0)
  • The Five APQP Phases and Related Inputs/Outputs
  • Breakout Exercise: Integration of the Process Model with the V-Model (for Electric or Hybrid Vehicles) or Integration with AIAG-VDA FMEA
  • APQP Checklists and Linkages to the APQP Plan
  • Gate Management
  • Breakout Exercise – Gate Management
  • Role of Leadership and APQP Program Metrics
  • Breakout Exercise – Program Metrics and the GYR Checklists
  • Risk Assessment Mitigation Plan
  • OEE - Overall Equipment Effectiveness
  • Traceability

Course Competencies and LOs – Control Plan

  • Competency 01: Explain the Purpose of a Control Plan
  • LO 01: Understand the purpose of a Control Plan
  • Competency 02: Populate a Control Plan
  • LO 02: Identify the minimum information required in a Control Plan
  • LO 03: Identify sources of information for the CP columns
  • Competency 03: Linkage of DFMEA/PFMEA and Special Characteristics
  • LO 04: Assign classifications to characteristics
  • Competency 04: Deriving a Control Plan linked to a PFMEA
  • LO 05: Understand the interrelationship between the PFMEA and CP

Seminar Outline – Control Plan

  • Fundamentals of Control Plan Development and Implementation
  • Definitions, Concepts and Key Linkages to APQP and FMEA
  • Using Family and Foundation FMEAs
  • How to Handle Directed Supply
  • Process Owners for APQP and Control Plans
  • Control Plan Information Development
  • Using Software to Develop and Manage Control Plans
  • Rework and Repair Control Plans
  • Control Plans and Bi-directional Traceability
  • Pass-through Characteristics
  • 9 or 10 Rating in the FMEA as Critical Characteristics
  • Breakout Exercise: Complete a Control Plan (from a sample PFMEA)
  • Control Plan Phases (Prototype, Pre-launch, Safe Launch, Production)
  • Breakout Exercises: Differences Between Production Control Plan and Safe Launch
  • Effective Use of Control Plans
  • Reverse PFMEA
  • Layered Process Audits (LPA)
  • Control Plans in Highly Automated Processes
  • Reaction Plans and CAPA
  • Control of Storage and Handling Related Risks
  • Management of Abnormalities in Relation to Control Plan

Who Should Attend

  • Program Managers
  • Design, Quality, and Manufacturing Engineers
  • Persons who have direct responsibility for preparation, assembly or review of PPAP components or packages
  • Auditors and those responsible for subcontractor PPAP documentation

Course Materials

Each participant will receive a seminar manual that includes breakout exercises.

Note: Omnex does not provide copies of standard(s) during training courses, but clients are encouraged to have their own copy.


Participants should possess a general knowledge of quality systems and have experience with APQP and Control Plans.

Upcoming Training