--- title: APQP, PFMEA and Control Plan Software | FactoryQA description: Ballooned drawings, process flow, PFMEA, control plans, inspection sheets and PPAP, linked by the same characteristics so changes carry through. image: https://factoryqa.com/hubfs/fqa-og-quality-plans.png --- [![FactoryQA](https://factoryqa.com/hubfs/fqa-logo-white.png)](https://factoryqa.com/?hsLang=en) Features [**Platform overview**Every module, and how they connect](https://factoryqa.com/feature-overview?hsLang=en)[**AI features**Purpose-built AI in every module](https://factoryqa.com/ai-powered-quality-management?hsLang=en)[**Integrations**ERP connectors and imports](https://factoryqa.com/integrations?hsLang=en) [**Dashboard**Every module in one scorecard](https://factoryqa.com/products/qualitybi-dashboard?hsLang=en)[**Tasks**Every to-do, from every module](https://factoryqa.com/products/task-management?hsLang=en)[**Compliance**Readiness for your standard](https://factoryqa.com/products/compliance?hsLang=en)[**Quality Plans**Ballooning, PFMEA, control plans, PPAP](https://factoryqa.com/products/quality-plans)[**Documents**Revisions, approvals, sign-offs](https://factoryqa.com/products/document-control?hsLang=en)[**Issues**NCRs, CAPAs and SCARs](https://factoryqa.com/products/non-conformance-management?hsLang=en)[**Inspection**Sheets, first articles and SPC](https://factoryqa.com/products/inspection-sheets?hsLang=en)[**Calibration**Gages, due dates and Gage R&R](https://factoryqa.com/products/calibration-management?hsLang=en)[**Preventive Maintenance**Scheduled work orders and repairs](https://factoryqa.com/preventive-maintenance-factoryqa?hsLang=en)[**Supplier Quality**Approved suppliers, portal and SCARs](https://factoryqa.com/products/supplier-management?hsLang=en)[**Audits**Schedules, checklists and findings](https://factoryqa.com/products/audit-management?hsLang=en)[**Learning Management**Courses, quizzes and the training matrix](https://factoryqa.com/products/learning-management-system?hsLang=en)[**QMS Generator**Your manual from an interview](https://factoryqa.com/products/qms-generator?hsLang=en) Services [**Services overview**Certification, consulting and supplier quality](https://factoryqa.com/services?hsLang=en)[**Get Certified**Three paths to AS9100, ISO 9001 or ISO 13485: do it yourself, join a workshop, or work 1-1 with a consultant.](https://factoryqa.com/certification-services?hsLang=en)[**Certification Workshops**A 9-week, small-group program with 18 expert-led sessions and an AI-built document kit.](https://factoryqa.com/certification-cohorts?hsLang=en)[**QMS Consulting**A consultant on your team from training through implementation, internal audit and the registrar audit.](https://factoryqa.com/qms-consulting?hsLang=en)[**Supplier Quality Services**Qualification, management, training and security services for your whole supply base.](https://factoryqa.com/supplier-quality-services?hsLang=en) [Pricing](https://factoryqa.com/pricing?hsLang=en) [Log in](https://app.factoryqa.com/auth/login)[Book a demo](https://factoryqa.com/get-a-demo?hsLang=en)[Start free](https://app.factoryqa.com/auth/register) Features[**Platform overview**](https://factoryqa.com/feature-overview?hsLang=en)[AI features](https://factoryqa.com/ai-powered-quality-management?hsLang=en)[Integrations](https://factoryqa.com/integrations?hsLang=en)[Dashboard](https://factoryqa.com/products/qualitybi-dashboard?hsLang=en)[Tasks](https://factoryqa.com/products/task-management?hsLang=en)[Compliance](https://factoryqa.com/products/compliance?hsLang=en)[Quality Plans](https://factoryqa.com/products/quality-plans)[Documents](https://factoryqa.com/products/document-control?hsLang=en)[Issues](https://factoryqa.com/products/non-conformance-management?hsLang=en)[Inspection](https://factoryqa.com/products/inspection-sheets?hsLang=en)[Calibration](https://factoryqa.com/products/calibration-management?hsLang=en)[Preventive Maintenance](https://factoryqa.com/preventive-maintenance-factoryqa?hsLang=en)[Supplier Quality](https://factoryqa.com/products/supplier-management?hsLang=en)[Audits](https://factoryqa.com/products/audit-management?hsLang=en)[Learning Management](https://factoryqa.com/products/learning-management-system?hsLang=en)[QMS Generator](https://factoryqa.com/products/qms-generator?hsLang=en) Services[**Services overview**](https://factoryqa.com/services?hsLang=en)[Get Certified](https://factoryqa.com/certification-services?hsLang=en)[Certification Workshops](https://factoryqa.com/certification-cohorts?hsLang=en)[QMS Consulting](https://factoryqa.com/qms-consulting?hsLang=en)[Supplier Quality Services](https://factoryqa.com/supplier-quality-services?hsLang=en)More[**Pricing**](https://factoryqa.com/pricing?hsLang=en)[Log in](https://app.factoryqa.com/auth/login)[Book a demo](https://factoryqa.com/get-a-demo?hsLang=en) [Features](https://factoryqa.com/feature-overview?hsLang=en)/Quality Plans # APQP, PFMEA and control plan software Quality Plans is FactoryQA's APQP module: ballooned drawings, process flow, PFMEA, control plans, inspection sheets and PPAP, linked through the same characteristics, so a change in one shows up in the others. [Start free](https://app.factoryqa.com/auth/register)[Book a demo](https://factoryqa.com/get-a-demo?hsLang=en) Included on Pro **Linked end to end**Balloons, flow steps, PFMEA rows and control plan lines stay tied together. **Ratings do the math**Action priority and RPN are calculated for you. **Gaps block release**Rule checks stop a release with missing pieces. How it works ## One drawing, one linked plan. Ballooning ### Ballooned drawings that build your inspection sheets Upload the customer drawing and Auto-Balloon numbers every characteristic. Each balloon becomes a row with its limits, gage and sampling, and ticking an inspection phase builds that sheet. - Auto-Balloon reads every dimension - Each balloon is a row with limits and gage - Inspection sheets from the phases you tick Drawing BRK-4471 · Rev C**Upper mounting bracket**5 dimensions found by Auto-Balloon 1 · 25.000 ±0.0052 · Ø12.700 ±0.0103 · R.250 ±0.0104 · 30° ±1°5 · 40.0 ±0.1 The APQP chain ## Follow one characteristic through every document. A ballooned dimension is tagged to its process step, rated on the PFMEA, controlled on the control plan, measured on every inspection sheet and reported in the PPAP. Special characteristics land in the Critical Item Registry. APQP chainBalloon**Drawing BRK-4471**Process flow**BRK-4471 machining**PFMEA**FMEA-001**Control plan**CP-001**Inspection sheets**FAI, In Process, Final**PPAP**Level 3** Balloon**Drawing BRK-4471 · Rev C** - *1*25.000 ±0.005 - *2*Ø12.700 ±0.010 - *3*R.250 ±0.010 Process flow**BRK-4471 machining** - *10*Saw cut blank - *20*CNC mill bracket - *30*Deburr edges PFMEA**FMEA-001** - *20*Flange over limit · AP M - *20*Bore undersize · AP H - *30*Burr on edge · AP L Control plan**CP-001** - *#1*Micrometer · 5 per lot - *#2*Bore gage · 5 per lot · SPC - *#3*Radius gage · 1 per lot Inspection sheets**FAI, In Process, Final** - *FAI*Row 2 · Ø12.700 - *IP*Row 2 · Ø12.700 - *AS9102C*Form 3 · row 2 PPAP**Level 3 · 18 elements** - *8*Measurement system analysis - *9*Dimensional results - *10*Material test results Critical Item Registry**Ø12.700 bore · special characteristic***1 flow step1 PFMEA row1 control plan line3 inspection sheetsPPAP element 9Controlled* APQP, connected ## Built to keep the chain intact. Plan a new part in one step, see everything a new drawing touches, and let shop-floor results improve the plan. Set up APQP ### A new part planned in one sitting Pick a part with a ballooned drawing and Set up APQP creates its missing process flow chart, PFMEA, control plan, inspection sheets and PPAP as linked drafts, modelled on a similar part, a family template or nothing. The lifecycle wizard does the same in eight guided steps. - Linked drafts in one step - Modelled on a part, a template or nothing - Undo the run, or re-run it on a new drawing revision Part**BRK-4471 · Upper mounting bracket**Drawing Rev C · 5 balloons Model onBRK-4470 (similar part)Family templateNothing Set up APQP **Process flow chart**3 operations · from BRK-4470*Draft* **PFMEA**6 failure modes · 2 marked by AI*Draft* **Control plan**5 lines · linked to balloons*Draft* **Inspection sheets**FAI, In Process, Final*Draft* **PPAP**Level 3 · 18 elements preset*Draft* Linked drafts only. Nothing is released or sent. Drawing revisions ### A new print shows everything it touches Start a drawing revision when a new print arrives. FactoryQA compares the balloons, lists every document the change affects on an impact board and tracks each one until it is updated. - Balloon-by-balloon comparison - An impact board of affected documents - Delta-FAI for changed characteristics Drawing revision**BRK-4471 · Rev C → Rev D** Balloon 2Ø12.700 ±0.010Ø12.690 ±0.008 1 changed · 4 unchanged Impact board · 5 documents **PFMEA**Bore undersize · Op 20*Needs updateUpdated* **Control plan**Line 2 · spec and limits*Needs updateUpdated* **Inspection sheets**FAI, In Process, Final*Needs updateUpdated* **AS9102C**Delta-FAI for balloon 2*Needs updateUpdated* **Work instruction**WI-212 · re-pin Rev D*Needs updateUpdated* 5 of 5 updated · Rev D in use Closed loop ### Your plan learns from the shop floor Inspection readings, SPC and nonconformances suggest new PFMEA ratings and failure modes, and tighter or less frequent control plan checks. Each suggestion waits in the review inbox with the evidence behind it. - Occurrence and detection from real data - Cpk suggests the check frequency - Nothing changes until a person accepts it **SPC**Ø12.700 · Cpk 2.1 over 90 days **NCRs**Bore undersize · 3 in 60 days **NCR-1077**Chatter marks on bore Review inbox**3 suggestions for BRK-4471** Control plan · line 2**Check every 3rd lot instead of every lot***From Cpk 2.1AcceptKeep mineAccepted* PFMEA · bore undersize**Occurrence 4 → 6***From 3 NCRsAcceptKeep mineAccepted* PFMEA · new failure mode**Chatter marks on bore · Op 20***AI match from NCR-1077AcceptKeep mineAccepted* Nothing changes until a person accepts it. PFMEA ### PFMEA in the AIAG-VDA layout Build a process FMEA seeded from your process flow. Ratings calculate action priority and RPN, and recommended actions show the risk going down. - Seeded from the process flow chart - Action priority and RPN calculated - Gaps block release PFMEA · BRK-4471 **Bore undersize**S7 · O4 · D3RPN 84*H* **Burr on flange edge**S5 · O3 · D5RPN 75*M* **Thread undersize**S7 · O3 · D2RPN 42*M* **Length out of tolerance**S4 · O3 · D4RPN 48*L* High AP row has a recommended action PPAP ### PPAP from package to customer decision Each submission gets a workspace with the 18 AIAG elements preset for its level. Link live records as evidence, and the PPAP AI Reviewer scores readiness before you submit. - 18 elements preset by level - Live records as evidence - AI readiness review 1-34-67-910-1213-1516-18Elements✓✓✓✓✓✓✕✓✓✓✓✓✓✓✓✓ CompleteMismatchMissingNot applicable In the app ## The Quality Plans hub. Ballooning, process flow, FMEA, control plans, PPAP, deviations and change management in one place. ![The FactoryQA Quality Plans hub with ballooning, process flow, FMEA, control plans and PPAP](https://factoryqa.com/hs-fs/hubfs/fqa-app-quality-plans.jpg?width=1440&height=900&name=fqa-app-quality-plans.jpg) Also in Quality Plans ## Everything else you'd expect. The full feature list, grouped by the job it does. ### Drawings and characteristics - Upload a drawing and run Auto-Balloon - Company standard tolerances for untoleranced dimensions - Dimension table with bulk edit of limits, gages and sampling - Drawing revisions with an impact board - Trace a characteristic and its spec across revisions - Critical Item Registry of special characteristics - FAI and AS9102 flags that build inspection sheets ### The planning chain - Process flow charts with AIAG symbols and swimlanes - PFMEA and DFMEA with RPN and AIAG-VDA action priority - Control plans linked to the PFMEA and drawing - Lifecycle wizard that drafts the whole chain from one drawing - AI drafts and a Deep Dive on any row - Part families, templates and row-by-row template updates - Approvals in sequence or parallel, with released revisions - Work instructions pinned to control plan lines - PFMEA and control plan suggestions from SPC and NCRs - Reverse FMEA and layered process audits ### Quality records - PPAP at levels 1 to 5 or Custom, with all 18 elements - Supplier PPAP portal with no login - Deviations and change requests with approvals - Quality alerts with a signed read-back - COTO log of risks and opportunities - Management reviews with AI-drafted sections - Quality objectives and customer surveys with NPS - Reports & Forms builder that files PDFs in Documents AI designed for quality ## AI in Quality Plans. Each tool drafts inside Quality Plans, on your records. A person approves every change. AI**Auto-Balloon** Every dimension with a confidence score. AI**Generate FMEA** A full FMEA with ratings. AI**Generate control plan** Characteristic lines tied to your gages and machines. AI**PPAP Reviewer** A readiness score, verdict and findings. AI**Change impact** Affected documents, training, FMEA, plans and issues. Works with ## Connected to every other module. [**Inspection** Sheets, first articles and SPC.](https://factoryqa.com/products/inspection-sheets?hsLang=en)[**Issues** NCRs, CAPAs and SCARs.](https://factoryqa.com/products/non-conformance-management?hsLang=en)[**Supplier Quality** Approved suppliers, portal and SCARs.](https://factoryqa.com/products/supplier-management?hsLang=en) [Previous module**← Compliance**](https://factoryqa.com/products/compliance?hsLang=en)[Next module**Documents →**](https://factoryqa.com/products/document-control?hsLang=en) ## See Quality Plans on your own parts and records. Free plan · Basic $40 · Pro $60 per standard user per month · 14 days of Pro to start [Start free](https://app.factoryqa.com/auth/register)[Book a demo](https://factoryqa.com/get-a-demo?hsLang=en) ![FactoryQA](https://factoryqa.com/hubfs/fqa-logo-white.png)Every quality tool. One connected system. 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