APQP/PPAP Roadmap & Documentation Builder
Generate APQP/PPAP documentation and phase-gate assessments aligned to AIAG standards
What You Can Do
This skill synthesizes complex automotive quality requirements into structured, AIAG-compliant APQP/PPAP deliverables. You can generate complete phase-by-phase roadmaps from concept through production, build PPAP submission packages (Levels 1-3) that meet OEM specifications, correlate process flows with control plans, and create risk assessments linked to FMEA. It accelerates documentation timelines while ensuring all quality gates, readiness criteria, and evidence mapping align to automotive industry standards.
Features
automatically structure Concept, Planning, Product Design, Process Design, Product & Process Validation, and Production phases with exit criteria
generate Level 1, 2, and 3 submission frameworks with required documentation checklists tailored to part complexity
create FMEA-linked risk analyses with process FMEA and design FMEA correlation to control plans
develop integrated process flowcharts and statistical control plans mapped to critical characteristics and process parameters
define quantifiable exit criteria, evidence requirements, and sign-off protocols for each APQP phase
generate supplier communication packages, design change notifications, and corrective action documentation frameworks
create executable launch schedules with gate reviews, resource allocation, and interdependency mapping
Example Output
Example 1: PPAP Level 2 Submission Package Structure
PPAP Submission Overview
├── Design Records (CAD, Drawings, Specifications)
├── FMEA Summary (Design & Process)
├── Control Plan (Parameters, Sampling, Acceptance Criteria)
├── Process Flow Diagram (with tooling/equipment detail)
├── Capability Study Results (Cpk ≥ 1.33 validation)
├── First Article Inspection Report (FAIR)
├── Lab Test Data (per specification requirements)
└── Supplier Quality Agreement Sign-off
Example 2: Phase-Gate Assessment Template
- Phase: Product Design (Gate 2)
- Exit Criteria: Design FMEA complete, Design Verification Plan approved, BOM finalized
- Evidence Required: Signed DFMEA, DVP&R sign-off, Supplier capability confirmation
- Timeline: Week 8-12 of program
- Responsible Parties: Design Engineering, Supplier Quality, Program Management
Example 3: Control Plan Fragment
- Product Characteristic: Bore Diameter (Critical)
- Process Parameter: Boring tool feed rate & spindle speed
- Measurement System: Coordinate Measuring Machine (CMM)
- Sample Size: n=5 per shift (first-run capability study)
- Control Limits: ±0.050mm (Design Tolerance ±0.100mm)
- Reaction Plan: Tool offset adjustment & SPC signal investigation
What's Included
- SKILL.md instruction file with APQP/PPAP methodology, phase definitions, and AIAG alignment reference:
- APQP Phase Roadmap Template: 6-phase structured plan with gate criteria, deliverables, timeline, and resource mapping
- PPAP Submission Package Checklist: Levels 1-3 documentation requirements, OEM-specific variations, and completeness verification
- FMEA-to-Control Plan Linkage Framework: risk-to-mitigation correlation matrix and critical characteristic mapping
- Production Readiness Gate Assessment Tool: exit criteria scoring, evidence requirements, and sign-off protocol templates
Who It's For
- Automotive Quality Engineers — building first-article approval packages and managing production launches
- Supplier Quality Managers — coordinating PPAP submissions and OEM compliance responses
- Program Managers — planning launch timelines with quality gate discipline and deliverable tracking
- Manufacturing Engineers — developing control plans linked to process FMEA and capability studies
- Quality System Auditors — reviewing APQP phase-gate execution and documentation completeness during internal/OEM audits
Best For
- New product program launches requiring end-to-end APQP planning with phase-gate discipline
- PPAP submissions to automotive OEMs (Tier 1, Tier 2, Tier 3 supplier tiers)
- Design or process changes requiring revalidation and PPAP resubmission
- Supplier qualification on complex critical parts with advanced product quality planning requirements
- Production readiness reviews and OEM approval assessments with documented evidence of quality gate completion
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