Project Management

The APQP process forms the foundation of our manufacturing philosophy and is used to ensure that robust and reliable solutions are identified for every aspect of a new product introduction. Even after our products and processes have exceeded pre-production requirements, our engineering and manufacturing teams continue to run product and process durability studies. We use this ongoing information to refine and update our product and process FMEA’s and to optimize our existing and future designs.

Plan & Design

The team captures the customer’s system design intent by working together with their engineering and manufacturing team to establish robust design and process solutions. This process is used to define the product specification and establish preliminary product and process assumptions. Historic warranty, quality and durability information is also reviewed.


Product Design & Development Verification

Transform the collaborative inputs from the plan and define stage into a product design solution which is refined and optimized through joint FMEAs, material reviews, cross functional design reviews, technical specifications, etc.



Process Design & Development Verification

HUSCO’s capabilities in this phase of the APQP process have been recognized by both on and off road original equipment manufacturers as best in class. Our manufacturing engineering team is made up of experienced engineers with hands-on expertise in the design and operation of automated equipment. They work hand-in-hand with a small group of key automation equipment suppliers to produce cost effective solutions which enable us to meet our stringent quality and delivery standards of less than 50 ppm. We develop cross-functional PFMEA’s whose outputs drive solutions that extensively vet the complete production process. Capability studies on all processes prior to PPAP confirm solutions are reliable and robust against our customer’s requirements.

Product & Process Validation

Using our own state-of-the-art environmental chambers and durability test stands complemented by outside laboratories (as required), our production intent product solutions are exercised over all operational and environmental extremes defined by our customer. Fully capable production equipment is validated using production intent components, pre-production control plans, shop floor operators, etc. Results from these pre-production runs further validate the processes, run-at-rate requirements, etc. and provide hands on training for our operators. Our design and manufacturing engineers are also significant participants in the ‘run-at-rate’ experience.

Launch, Feedback, Assessment & Corrective Action

At HUSCO, PPAP sign-off is not the finish line. In fact, we do not believe a program should have a finish line. Our production cells provide ongoing opportunities for improvement and learning centers for our design, manufacturing, and quality engineers. Performance and quality metrics from each cell are used as drivers for our Six Sigma trained organization. Coupled with customer feedback and ongoing HUSCO product durability and reliability testing, we identify opportunities for improvements across both product and process. We work closely with our customers to re-engage our APQP process as appropriate for the introduction of these improvements.


Each program is regularly reviewed by our senior management personnel. HUSCO’s senior managers have all been program leaders over the course of their careers and are active participants in the APQP process.
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