Advanced Product Quality Planning / APQP


APQP is a defined process for product development that provides a common path (between supplier and customer) and synchronization of these development activities. It ensures that appropriate and timely communication occurs within your organization, as well as between your organization and your customer’s organization.

Originally developed by the automotive industry, this approach to planning ensures that nothing is left to chance, and that the Design and Development function is fully integrated with operations in meeting customer needs.

Scope And Deliverables

Phase 1 – Plan & Define Programme:

  • Determine customer needs, requirements & expectations using tools such as QFD.
  • Review the entire quality planning process to enable the implementation of a quality programme.
  • Define & set the inputs & the outputs.

Phase 2 – Product Design & Development:

  • Review the inputs & execute the outputs, including FMEA, DFMEA, design verification, design reviews, material & engineering specifications.

Phase 3 – Process Design & Development:

  • Address features for developing manufacturing systems & related control plans.
  • These tasks are dependent on the successful completion of phases 1 & 2.
  • Execute the outputs.

Phase 4 – Product & Process Validation:

  • Validation of the selected manufacturing process & its control mechanisms through production run evaluation.
  • Outline mandatory production conditions & requirements
  • Identify the required outputs.
  • Use Control Plan methodology & relevant data to construct & determine control plan parameters.

Phase 5 – Launch, Feedback, Assessment & Corrective Action:

  • Focus on reducing variation & continuous improvement.
  • Identify outputs & links to customer expectations.
  • Identify future product programmes.

What We Will Do

  • Provide training in APQP techniques as needed to all relevant personnel.
  • Participate in establishing Critical To Quality (CTQ) customer requirements.
  • Support the creation of the required Process Flow Diagrams.
  • Facilitate the creation of FMEA and DFMEA documentation.
  • Support the translation of these documents into Control Plans.
  • Create Work Instructions in ISO9000 format as required.

What We Need You To Do

  • Identify key relevant resources.
  • Ensure availability of these resources to participate in the APQP activities.
  • Provide an appropriate working area for the team.
  • Ensure timely review and approval of the team’s work.
  • Purchase required software (if identified by the team).


Consulting Overview

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SatiStar's Experience Makes The Difference!

  • . . . worked extremely well with the departmental and site managers . . . goal oriented and met the objectives set within the quoted budget and ensured the results were attained for the Company.

  • The guys from SatiStar did more in one week than we were able to do in 6 months.

  • Achieving ISO registration was far less onerous than we thought, our employees really rallied to the cause. The registration effort really brought us closer together as a team, and SatiStar really came through for us when we needed them.

  • We started this process a year ago with Mickey helping us create a spaghetti map of our processes on the whiteboard, and then his team guided us through their streamlining methodology and got us to where we are today. Our processes now look nothing like the spaghetti map – and we’re much more efficient today

  • This projected cycle time reduction of over 80% annual cost savings amounting to over 3% of sales, one-time savings of roughly $10 million, and working capital reduction of roughly $30 million really have us excited!

  • An outstanding success with Motorola’s vendor audit! What made this an exceptional achievement is that it typically takes 4 to 5 attempts to pass this audit. SatiStar’s expertise made it easy to avoid all the extra attempts.