WorksheetsAPQP 3rd Edition
Total questions: 40
Worksheet time: 14mins
How many phases are there in APQP 3rd Edition?
4
5
6
7
Which APQP phase includes development of the DFMEA?
Phase 1 - Planning and Definition
Phase 2 - Product Design and Development
Phase 3 - Process Design and Development
Phase 4 - Product and Process Validation
Which of the following is an input to Phase 4 (Product and Process Validation)?
Voice of the Customer
Prototype test reports
Warranty data analysis
Lessons learned report
Which deliverable is typically first drafted in Phase 3?
Control Plan (initial draft)
PPAP package
Final Control Plan
Appearance Approval Report (AAR)
True or False: "Run‑at‑Rate" is mandatory for a Level 3 PPAP submission.
True
False
What is the primary purpose of a Control Plan?
Identify customer requirements
Define process steps only
Document how key product/process characteristics are monitored and controlled
Record warranty claims
In which phase is the Process Flow Diagram (PFD) first detailed?
Phase 1
Phase 2
Phase 3
Phase 4
True or False: The supplier submits the PPAP package to an external certification body.
True
False
What does "VOC" stand for in APQP?
Validation of Controls
Voice of the Customer
Verification of Capacity
Value‑of‑Cost
Which APQP output captures project insights for future programs?
DFMEA
Lessons Learned report
Prototype build record
Initial Control Plan
Which activity typically occurs during the APQP Kick‑off Meeting?
Run‑at‑Rate trial
Root Cause Analysis
Team roles and timeline alignment
Warranty data collection
Which of these is not normally part of a PPAP Level 3 submission?
Part Submission Warrant (PSW)
DFMEA
Customer Feedback report
Measurement System Analysis (MSA)
MSA refers to:
Material Specification Analysis
Measurement System Analysis
Manufacturing Sequence Audit
Method and Sequence Assessment
The Prototype Build is a deliverable of which phase?
Phase 1
Phase 2
Phase 3
Phase 4
True or False: The Final Control Plan is released in Phase 4.
True
False
What does "AAR" stand for in PPAP?
Advanced Audit Report
Appearance Approval Report
Assembly Acceptance Record
Approval Action Request
A Process Flow Diagram (PFD) shows:
Failure modes and effects
Sequence of manufacturing steps
Control limits for key characteristics
Customer requirements
Which tool is used to identify causes of a nonconformance after it occurs?
DFMEA
5‑Why Root Cause Analysis
PPAP
Control Plan
What does QFD stand for?
Quality Function Deployment
Quality Failure Determination
Quantitative Flow Diagram
Quick Feedback Design
The Initial Sample Inspection Report (ISIR) is typically produced in which phase?
Phase 2
Phase 3
Phase 4
Phase 5
Which PPAP document formally indicates the supplier's commitment that all customer requirements are met?
Appearance Approval Report (AAR)
Part Submission Warrant (PSW)
Control Plan
Measurement System Analysis (MSA)
Which APQP deliverable is updated continuously throughout production to reflect current process controls and lessons learned?
DFMEA
Control Plan
Prototype Build Record
Project Closure Report
True or False: Lessons Learned from one program become inputs into Phase 1 of the next APQP project.
True
False
What is the primary purpose of the Gate Review introduced in APQP 3rd Edition?
To certify tooling readiness
To formally evaluate phase outputs before moving to the next phase
To conduct supplier audits
To finalize the PPAP package
True or False: In APQP 3rd Edition, a Gate Review is required at the end of every one of the five phases.
True
False
Which group typically participates in a Gate Review?
Only the project manager
Cross‑functional team members (Engineering, Manufacturing, Quality, Purchasing, etc.)
External auditors only
Marketing department only
At the end of Phase 2 - Product Design and Development, the Gate Review is commonly called the:
Design Validation Gate
Design Release Gate
Production Readiness Gate
Feedback & Corrective Action Gate
True or False: One outcome of a Gate Review can be a "Go/No‑Go" decision to proceed, hold, or rollback activities.
True
False
Which deliverable must be presented at the Phase 3 Gate Review to demonstrate process controls are in place?
Final Control Plan
Initial Control Plan and PFMEA with risk mitigations
Warranty Data Analysis
Lessons Learned report
The Phase 4 Gate Review is often referred to as the:
Production Launch Readiness Review
Feasibility Assessment Gate
Concept Approval Gate
Feedback Assessment Gate
True or False: Gate Reviews replace the need for a final PPAP submission.
True
False
Which of the following is not typically an agenda item at a Gate Review?
Review of phase deliverables vs. success criteria
Identification of open issues and action owners
Formal hand‑off of responsibility to the next phase team
Detailed line‑balancing studies (only covered in Phase 5)
What documentation should attendees sign off during each Gate Review?
Project Closure Report
Gate Review Checklist with "Go/No‑Go" decision recorded
Warranty Claims Log
Customer Feedback Form
Which new concept is emphasized throughout all APQP 3rd Edition phases to reduce failure likelihood?
Warranty tracking
Continuous improvement
Risk management
Process benchmarking
In APQP 3rd Edition, how is "Change Management" treated?
Optional and only needed in Phase 5
A core activity that should be applied across all phases
Only relevant to suppliers
Documented only after PPAP approval
Which project management tool is emphasized more in APQP 3rd Edition to monitor status and accountability?
Gantt chart or timeline tracking
SPC chart
Fishbone diagram
Control chart
Which of the following is an expected benefit of applying structured Lessons Learned?
Increased project cost
Duplication of design issues
Reduction in recurring problems
More frequent engineering changes
What is the main purpose of supplier risk assessment in APQP 3rd Edition?
Identify the most expensive suppliers
Evaluate supplier pricing strategies
Identify and mitigate potential delivery or quality issues early
Track order volume
Which of the following documents would most likely be updated as a result of a structured change management process?
Control Plan
Warranty Report
Lessons Learned Summary
Calibration Log
Which APQP 3rd Edition element helps ensure knowledge is captured and reused?
Prototype Build Report
Traceability Matrix
Lessons Learned System
DFMEA Review Form
