When reading the APQP and Control Plan manual, bear in mind that it is written as if you are starting a new product rather than that which is most common - variations on an existing product.
One of the reasons I stress that every APQP is unique is that the fact that a company is typically going through a process they have gone through before. This means that the APQP Team will be drawing on ‘old’ data and information. For example, most companies do not empanel an entire FMEA team and start their FMEA (process or design) from ‘scratch’. More typically someone takes a copy of an FMEA for a similar existing product and reviews it. Many times few , if any, changes have to be made.
The probable failure modes will most often not change for a product ‘type’ or ‘family’. If you’re making a foundation brake currently, the probability is very high that the FMEA will not change, and if it does it will be based upon feedback from the customer in one way or another. There is a higher probability that current production will evoke changes to the FMEA in response to an engineering change arising out of one ‘problem’ or another during ‘this years’ production than a need for change being identified during the APQP process.
APQP - Advanced Product Quality Planning - In Consonance with the AIAG’s (QS-9000) APQP Manual
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