Quality Management, Tools & Certifications
APQP – Advanced Product Quality Planning & Control Plan
Plan quality into new products before launch. Participants work through the five APQP phases and their outputs – from design goals and DFMEA to PFMEA, control plans, MSA, capability and PPAP – aligned with the AIAG APQP 3rd edition and IATF 16949 expectations.
At a glance
Catalog codeB04
Duration
- 2 days
LevelAdvanced
Program typeTechnical
LanguageEnglish / Arabic
DeliveryIn-house · Public · Online
Who it's for
- Quality, design, process and supplier-quality engineers in automotive & manufacturing
Learning objectives
- Plan and run APQP across the five phases
- Produce phase outputs and link to PPAP
- Build control plans aligned to AIAG APQP 3rd ed. (2024) and AIAG-VDA FMEA
Detailed content
- Purpose of APQP and its link to IATF 16949
- Cross-functional team, timing plan and gateways
- Customer-specific requirements
- Overview of the core tools (FMEA, MSA, SPC, PPAP)
- Voice of the customer and business plan inputs
- Design and reliability goals
- Preliminary bill of materials and process flow
- Special product and process characteristics
- Product assurance plan and management support
- Design FMEA (AIAG-VDA)
- Design for manufacture and assembly
- Design verification and design reviews
- Prototype build and prototype control plan
- Engineering drawings, specifications and equipment needs
- Packaging standards and floor-plan layout
- Process flow chart and characteristics matrix
- Process FMEA and pre-launch control plan
- Work instructions
- MSA and preliminary capability study plans
- Significant production run
- MSA evaluation and preliminary capability (Ppk)
- PPAP submission
- Production validation testing
- Production control plan and quality planning sign-off
- Reducing variation and improving customer satisfaction
- Delivery and service performance
- Lessons learned and the effective use of the control plan
- Writing a control plan step by step
Day-by-day agenda
A typical schedule. In-company versions are tailored to your processes, data and timing.
- APQP framework
- Phase 1 – Plan and define
- Phase 2 – Product design and development
- Phase 3 – Process design and development
- Phase 4 – Product and process validation
- Phase 5 – Feedback and the control plan
- Case study, action plans and course assessment
Practice, tools and assessment
Hands-on practice
- Solve a real problem with 8D or A3 from containment to verification
- Fishbone and 5-Why workshop with evidence checks
- Mock regulatory inspection of a GMP area
- Deviation and CAPA case study with root cause
Tools and templates you keep
- 8D report and A3 templates
- Root-cause verification checklist
- Deviation, CAPA and change-control forms
- Validation master plan outline
How learning is assessed
- Pre- and post-course knowledge check
- Assessment of practical exercises by the trainer
- Action plan reviewed at the end of the course
Built on these standards and bodies of knowledge
- Ford 8D / VDA problem-solving guidance
- ASQ Quality Improvement tools
- EU GMP / PIC/S Guide; WHO GMP
How it is delivered
- Public courses in Cairo, in-company programs and live online training
- Practical exercises, case studies and examples from your sector
- Can also run as Train & Stay in Sharm El Sheikh, Hurghada or Cairo
Part of these career paths
- Automotive & Manufacturing Quality · Practitioner
FAQ
Frequently asked questions
How long is APQP – Advanced Product Quality Planning & Control Plan?
The program runs 2 days. In-company versions can be adapted to your needs.
Is the course taught in Arabic or English?
Sessions are usually delivered in Arabic with English technical terms and materials. Full English delivery is available for in-company groups.
Can you run it inside our company?
Yes. In-company programs use exercises built on your own processes. Tell us the group size and preferred timing and we will send a proposal.
Will I receive a certificate?
Participants who complete the program and its assessment receive a certificate from The Excellence Center, which can be verified online.
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Get dates, fees and the full outline.
Tell us whether you are joining as an individual or planning a program for your team.