The variety of products in companies with order-based production system is high but the amount of production of each product variety is low. Therefore, each product is considered as a new product (NP) and challenges of not only producing NPs but also changing market and competitive conditions are faced. In order to overcome these difficulties and sustain the market share, it is necessary to produce high quality products at one time with minimum cost in all stages from the receipt of the order to the after-sales services in the production of NPs. In an attempt to solve this critical problem, our study focuses on the application of advanced product quality planning (APQP) technique, which is one of the most effective methods used in new product development (NPD) process control to ensure survival and continuous improvement of company and reduce the cost, time, labor and customer losses in the process of new product development. In this study, first, the NPD process and the use of APQP in NPD were explained and then an example of APQP application in a factory producing heat exchangers with order-based production system was given. APQP has been completed in three sections; process design and development, product and process validation, feedback and corrective actions. Process management and control activities and tools such as establishment of team, selection of NP, feasibility studies, determination of workflow, reduction of risks, determination of process capability and measurement systems analysis, creation of control plan, production, dimensional and performance tests were performed. As a result of this study, it has been proved that NPs produced by following an NPD process that is continuously evaluated with APQP method, fully meet both customer and company requirements. By using APQP method in NPD, process is controlled and scrap rates, costs and customer complaints are reduced.
New product development, Advanced product quality planning, Order-based production system