Advanced Product Quality Planning (APQP)
- Is a structured approach to process / product development in quality management, traditionally used in the Automotive industry.
- As a potential supplier to wind energy, where rapid growth and innovation forms an essential part of business.
- APQP guides in achieving the above objectives by ensuring reliability, safety, and high-quality performance in the Scada & Compact scada panels.
Purpose of APQP
To establish Quality assurance methodology for the Global wind energy.Key benefits
- Preventive approach to quality
- Shift from quality control to quality assurance
- Helps supplier chain to mature globally
- Supports standardization & simplification of processes to reduce time to market and increase efficiency
- Avoid last minute changes
- Provide quality product on time and at lower cost etc.
Product quality planning cycle
APQP4Wind consists of Seven product quality planning cycles designed to ensure,
- Clear path for planning
- Implementing & verifying product conformance to requirements
- Supply chain deliver right products with required quality level and quantity the first time and on time
Following are the product quality planning cycles
- Plan, Define and Scope Quality program
- Product Design and Development
- Product requirement fulfilment
- Process Design and Development
- Process requirement fulfilment
- Product and Process Validation
- Product & process approval
Above product quality planning cycle emphasizes a cross-functional approach to enhance communication, collaboration etc. in the entire cycle.
We at Gigahertz, have APQP4Wind specialists to apply APQP4Wind concepts.
1. Plan, Define and Scope Quality program
Describes requirements for initiating a quality program to
- Understand needs, requirements, expectations of the customer
- Define scope
- Plan activities
Expectations
- Understand customer expectations
- Identify potential constraints & risks in fulfilling customer requirements
- Identify cost & time line for on-time delivery
- Determine any assistance required from customer
- Identify supply chain & processes to fulfil requirements
2. Product Design and Development
Describes requirements in the design of products with a focus to ensure product meets objectives & requirements of customer.
Expectations
- Conduct in-depth review of engineering & technical requirements
- Identify potential issues & challenges ( DFMEA )
- Ensure product is feasible to manufacture
- Ensure product design fulfils customer requirements
- Identify special characteristics
- Develop plan to verify design characteristics
- Identify tooling, equipment & gauge requirements
3. Product requirement fulfilment
Focusses on demonstrating that the product requirements are fulfilled by a reliable product design.
Expectations
- Product design verification
- Prototype is built, tested and approved
- Prototype is built, tested and approved
4. Process Design and Development
Describes elements involved in developing a production process to comply with customer quality expectations & product requirements.
Expectations
- Ensure a preliminary process flow is developed
- Identify potential failures & mitigating actions ( PFMEA )
- Conduct preliminary analysis of process capability ( Cp, Cpk )
- Develop a plan for MSA study
5. Process requirement fulfilment
Focusses on demonstrating that the process requirements are fulfilled by a reliable process design.
Expectations
- Measurement system in the process is analysed and found capable for the intended use
- Control plan for initial production run is available
- Statistical analysis on process capability is carried on special characteristics
- Special characteristics for the process(es) is(are) controlled
6. Product and Process Validation
Describes major features of validating production process through an evaluation of a production trial run.
Expectations
- Production trial run is conducted
- Process performance is validated & documented
- Product validation is done against design requirements
- Relevant testing & certification reporting is completed
7. Product & process approval
This is the approval phase where customer requirements for product quality are validated & approved.
Expectations
- Ensure PPAP documentation is completed
- Submit PPAP documents as agreed to customer.
Conclusion
Adopting the APQP process in the wind energy sector provides a structured framework for ensuring the reliability, safety, and efficiency of components & wind turbines. By incorporating rigorous design reviews, process qualifications, and continuous feedback loops, manufacturers can deliver panels that are not only cost-effective but also built to last in the demanding conditions they face. APQP is, therefore, key to advancing the wind energy industry toward greater sustainability and innovation.
Category: APQP