Build quality in before the first part ships
The Advanced Product Quality Planning (APQP) toolset for new product introduction. Run a program through the five classic phases, plan, design the product, design the process, validate, and launch, with a live phase‑gate tracker, Design & Process FMEAs, and stage‑based control plans that link risk to the floor. Open a read‑only preview anytime; create an account to fill them in and save your work.
The five phases, end to end
Every deliverable the phase‑gate tracker watches, laid out across the five APQP phases. Tools that are live link straight through; the rest are on the way and already wired into the tracker.
- Voice of customer & requirements
- Design goals & quality targets
- Preliminary bill of material
- Preliminary process flow
- Preliminary special characteristics
- Program timeline & assurance plan
- Design FMEA, DFMEA
- Design for manufacturing & assembly
- Design verification, DVP&R
- Drawings & specs released
- Prototype control plan
- Tooling & gauge requirements
- Process flow diagram
- Process FMEA, PFMEA
- Pre‑launch control plan
- MSA plan, study
- Work instructions & training
- Packaging & logistics standards
- Production control plan
- SPC, control charts
- Safe‑launch / containment exit
- Variation reduction, capability
- Customer satisfaction & delivery
- Lessons learned, read‑across
Plan it, design it, prove it
Start from the phase‑gate tracker, the master view of the whole program, then work the deliverables it links to: process flow, FMEA, special characteristics, control plan, design verification, run‑at‑rate, PPAP and lessons learned. Every tool feeds the next, and the tracker keeps score.
APQP Phase‑Gate Tracker
One living view of the whole program. Set a status on every deliverable across the five APQP phases and watch each gate‑readiness % and the overall program score update live. Each deliverable links straight to its tool, and you sign off each gate at the bottom of its phase.
FMEA: Design & Process
One worksheet, two modes: toggle between DFMEA (design) and PFMEA (process). Rate Severity × Occurrence × Detection and the RPN calculates live, so the highest‑risk items rise to the top and flow into your control plan.
Control Plan
The living link from PFMEA risk to the floor. For each characteristic, capture the spec, measurement, sample & frequency, control method and reaction plan, in your choice of prototype, pre‑launch or production stage.
Process Flow Diagram
The step‑by‑step sequence that seeds everything downstream. Pick a flow symbol for each step, operation, inspection, transport, storage, delay, then capture inputs, outputs and characteristics.
Special Characteristics Matrix
The agreed list of what matters most. Classify each characteristic Critical, Significant or Standard, note its source, and point to where it’s controlled, so every CC and SC flows to the PFMEA and control plan.
Design Verification (DVP&R)
Plan every requirement and test up front, then record the results. Set each test Pass / Fail and the summary tallies pass‑rate automatically, the evidence the design meets its requirements before launch.
Run‑at‑Rate
Enter the required rate and what the trial actually produced. Achieved rate, first‑time‑through, scrap and a Pass / Conditional / Not‑met verdict calculate live, can the process hold demand at quality?
PPAP Element Tracker
The full 18‑element production part approval package. Pick a submission level (1–5) and the required elements update; set each status and watch approval readiness climb, finishing with the PSW sign‑off.
Lessons Learned & Read‑Across
Capture what the program taught you, then read it across: name the other parts, processes and programs that share the same risk and should adopt the same change, each with an owner and status.
Branded, watermarked, and yours to use
These aren't generic worksheets. Every page is built to the Vanguard standard.
One program, one thread
The phase‑gate tracker links every deliverable to its tool, so the FMEA, control plan and validation studies all hang off a single program view.
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