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Automotive Safety Program Planning with APQP and Gates

30 Chapters
View Course Samples Online
01
Introduction to automotive safety program planning
APQP framework, gate reviews, and the product development lifecycle.
automotiveplanning
02
APQP phases and deliverables
from concept initiation through production validation and launch.
APQPdeliverables
03
Gate review fundamentals
purpose, timing, entry and exit criteria, and decision-making roles.
criteriadecision-making
04
Safety program planning integration
aligning APQP gates with functional safety and safety-of-the-intended-function requirements.
planningintegration
05
Phase 1 – Plan and define program
voice of customer, safety goals, and preliminary program timing.
customerpreliminary
06
Phase 2 – Product design and development
design FMEA, safety analysis, and design verification planning.
developmentFMEA
07
Phase 3 – Process design and development
process FMEA, control plans, and safety-critical process controls.
developmentFMEA
08
Phase 4 – Product and process validation
validation testing, safety confirmation, and production trial runs.
validationconfirmation
09
Phase 5 – Feedback, assessment, and corrective action
launch readiness, lessons learned, and continuous improvement.
Feedbackassessment
10
Gate 1 – Concept and program initiation review
safety case scoping, risk assessment, and resource commitment.
initiationassessment
11
Gate 2 – Design release review
design maturity, safety requirements traceability, and verification evidence.
maturityrequirements
12
Gate 3 – Process readiness review
manufacturing feasibility, safety-critical process capability, and operator training.
readinessmanufacturing
13
Gate 4 – Production validation review
validation results, safety performance, and launch authorization.
Productionvalidation
14
Gate 5 – Production launch and post-launch review
field monitoring, safety incident response, and corrective actions.
Productionpost-launch
15
Safety deliverables per gate
safety plan, hazard analysis and risk assessment (HARA), safety validation report, and safety case.
deliverablesanalysis
16
Cross-functional team roles and responsibilities
program manager, safety manager, design engineer, process engineer, and quality engineer.
Cross-functionalresponsibilities
17
Risk management throughout APQP gates
risk registers, mitigation plans, and escalation paths for safety-critical issues.
managementthroughout
18
Traceability and documentation
linking requirements, design, verification, validation, and safety evidence across gates.
Traceabilitydocumentation
19
Supplier safety program integration
APQP requirements for suppliers, gate reviews, and safety performance monitoring.
Supplierintegration
20
Change management and safety impact analysis
engineering change requests, safety re-assessment, and gate re-entry criteria.
managementanalysis
21
Tools and templates for gate reviews
checklists, scorecards, readiness matrices, and safety case templates.
templateschecklists
22
Metrics and key performance indicators for safety program planning
gate on-time delivery, safety defect density, and validation coverage.
performanceindicators
23
Case study 1
APQP and gate planning for an advanced driver assistance system (ADAS) program.
APQPplanning
24
Case study 2
safety program planning for an electric vehicle battery management system using APQP gates.
planningelectric
25
Case study 3
gate review challenges and resolutions in a global automotive safety-critical program.
challengesresolutions
26
Common pitfalls and best practices in APQP gate execution for safety programs.
Common pitfalls and best practices in APQP gate execution for safety programs.
pitfallspractices
27
Regulatory and standards alignment
ISO 26262, ISO 21434, IATF 16949, and APQP reference manuals.
Regulatorystandards
28
Agile and iterative approaches in APQP gate planning for automotive safety
hybrid models and continuous safety assurance.
iterativeapproaches
29
Practical workshop
designing a gate review package for a safety-critical automotive subsystem.
workshopdesigning
30
Capstone project
developing a complete APQP-based safety program plan with gate criteria for a selected automotive system.
Capstonedeveloping