APQP Checklist (Product Design and Development)

• Project Name

• Company

• Location
  Address

• Project Manager

• Conducted on

  Date

Product Design and Development

• Is Reliability Growth instituted at this phase and is it measured by design review activities through the product development cycle?

  Yes

  No

• Are Design FMEAs generated for the system, and component level designs and do they reflect all Special Characteristics (product and process) derived from product level Design FMEA?

  Yes

  No

• Are Special Characteristics Lists utilized?

  Yes

  No

• Are Actions followed up and are Process FMEAs updated to reflect actions taken?

  Yes

  No

• Is a Mistake Proofing Strategy (Poke Yoke) utilized from FMEA output for Design and Process?

  Yes

  No

• What Team makeup exists for DFMEA development?

• Are surrogate problem solving results used in DFMEA development?

  Yes

  No

• Is Warranty Data used for Failure Modes and Effects on DFMEAs?

  Yes

  No

• Have Designs been optimized using Design for Manufacturing and Assembly (DFMA)?

  Yes

  No

• Are Design Verification Plans established and do they reflect Design FMEA outputs for product level system, and component level designs as appropriate?

  Yes

  No

• Have Design reviews been held at appropriate stages part of all levels of designs?

  Yes

  No

• Is there a formal design review process with design items identified (check sheet)?

  Yes

  No

• Are serviceability items included?

  Yes

  No

• Are records maintained?

  Yes

  No

• Are APQP Design Deliverables part of the design review process?

  Yes

  No

• Are Prototype Control Plans utilized and do they reflect Special Characteristics derived from Design FMEAs?

  Yes

  No

• Are tolerance studies and analyses performed at intersections of mating components prior to design sign-off, part of management design reviews/sign-offs, and based on manufacturing variability data?

  Yes

  No

• Take/attach photos of Geometric Dimensioning and Tolerancing (GD&T) and Engineering Drawings

  Media

• Is GD&T developed based on customer need and process capability?

  Yes

  No

• Do Engineering Drawings reflect Special Characteristics driven from Design FMEAs and GD&T requirements?

  Yes

  No

• Are Engineering Drawings confirmed on Process FMEAs?

  Yes

  No

• Are changes to Engineering Drawings and Specifications promptly communicated and properly documented to all affected areas and utilized Design FMEAs to determine change impacts?

  Yes

  No

• Do Engineering, Material and Performance specifications include sample size, frequency and acceptance criteria and contain special characteristics relating to physical properties, performance, environmental handling, and storage of Materials?

  Yes

  No

• Are new equipment, tooling, facility, gaging, and test equipment requirements identified from Design FMEAs and included in the project plan?

  Yes

  No

• Take/attach photos of the Manufacturing Process Sequence

  Media

• Is the Manufacturing Process Sequence finalized and includes Process Flow and Plant Scroll?

  Yes

  No

• Are Process Descriptions available that include written description of the assembly process and instructions by workstations?

  Yes

  No

• Are Potential Process Failure Modes identified with the use of Process FMEA’s at the product level, system, and component level designs?

  Yes

  No

• Are high-risk failure modes identified by station and are lists available?

  Yes

  No

• Are recommended Significant and Critical Characteristics from DFMEA failure modes on appropriate process steps?

  Yes

  No

• Take/attach photos of Prototype Builds

  Media

• Are Prototype Builds conducted that include components that have completed and passed all Design Verification Testing, were made from production intent processes and information on actions required to improve designs from builds?

  Yes

  No

• Is Product level, System and/or Component Design Verification Testing conducted that includes test results that include Pass / Fail criteria and identification of any test Failures on Design FMEAs?

  Yes

  No

• Have Test, Diagnostic, and Service Procedures been finalized?

  Yes

  No

Completion

• Additional Recommendations

• Name & Signature of Project Manager

  Sign