Risk Assessment and Prevention (in other words: APQP)


Murphy’s Law applies to most unless you plan to prevent failure by considering solutions before you encounter it.  Making snaps more flexible, creating a one way only assembly aid before the molding tool is built, or implementing a poke yoke to ensure screw torque are all examples of preventative actions spawned by the thoughtful organized disciplined brainstorming of product risk assessment and prevention.  In some industries, this is also known as advanced product quality planning (APQP).


WE use the AIAG tools of Process Flow, Process & Design Failure Mode and Effects Analysis, Control Plan, and Operator Instructions to ensure statistically the provision of the highest quality product and/or services.  Think of it as problem solving before the problems arise.  Think of it as saving money by avoiding the high cost of customer issues, tool changes, and revalidation costs to name a few.


Perhaps your company already practices APQP, however you still experience recurring issues and multiple launch set-backs.  Perhaps a refresher course in this method is right for your team.  No matter the size of your company, this disciplined method will ensure your design and manufacturing integrity.


Students who attend this training receive a thorough understanding of using product requirements as the foundation for building a successful launch and manufacturing cycle.  They receive in depth training of how to create and use the Process Flow, PFMEA, DFMEA, and Control Plan as well as how to write effective Operator Instructions.  They also receive a quick reference hand-out to aid in applying the risk assessment to future projects and small applying the lessons of the day using actual company products.


Participants of this training will be able to:


  • Effectively assess the risk and prevent with appropriate actions
  • Show the process of engineering decisions towards the final product design to your customers in an organized and disciplined way
  • Effectively explore causes and effects using the PFMEA and DFMEA
  • Facilitate an assessment meeting on their own
  • Find and analyze multiple resolutions quickly to determine best design actions


Client feedback on this training:

 I always used to copy prior APQP documents and never fully understood how I could solve problems in advance so quickly. – Ray


Using the positive expected product requirements made it a lot easier to understand potential failure modes.  I always used to get stuck in the failure/cause loop before and blaming my operators for something I really could’ve fixed up-front – Scott