Shadowing Practice: APQP Phase 4 - Product & Process validation phase - Learn English Speaking with Video
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Welcome to Young Business Professionals.
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I'm Felix and I hope you are all fine today.
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We are taking a look today on APQP Phase 4, the Product and Process Validation Phase.
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This is already the fifth video of our APQP Playlist.
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This video will take you on a 10 minutes tour through this project phase.
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Make sure you're watching this until the end as we releasing
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important lessons learned of phase four at the end of the video.
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If you're interested in increasing your automotive knowledge, please feel to subscribe to my channel and like the video.
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You might also check out our Facebook page through
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which we would like to create a community that shall support each other growing everybody's knowledge.
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What is the purpose of the product and process validation phase?
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During that phase of the project, the pre-serial production is taking place.
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Production equipment and board components are being released through PPAP approvals and run-it rates at sub-suppliers.
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The pre-serial products are used for process validation tests.
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After that, these results are shared with the customer as a part of the PPAP documentation.
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Now, let's take a more detailed look on all single working packages that can be a part of APQB Phase 4.
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The product and process validation phase may be splitted into the following working packages.
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Tracking and approval of production equipment, approval of board components, process validation,
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product trainings, finalization of quality planning,
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approval of production and run at weights and a sampling according to PPAP
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or EMPB standard and finally a quality gate review of phase 4.
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Tracking and approval of production equipment.
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The status tracking process is of course already started in phase 3 of the project
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but it is continued in phase 4 as well.
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Nominated suppliers are monitored frequently in order to check the timing status of the production equipment.
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The target is to approve the equipment as soon as possible as the requirements
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that were given in specification sheets can be proven.
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Often a preliminary approval of the equipment is happening at the location of the supplier.
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Later a final approval in the production plant is taking place.
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Approval of board components.
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In parallel a similar process will be performed for the board components.
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Suppliers will be monitored as well.
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The supplier APQB process is being tracked.
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The supplier is providing the documentation on the customer as soon
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as requirements for the components can be proven under serial production conditions.
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For important components, a production approval and a round rate at the supplier may take place.
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It is common that also preliminary or conditional approved components will be used for pre-serial production in this phase.
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Process validation.
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As soon as the product and the equipment is achieving a certain readiness, the process validation may start.
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All tools should be approved and or at least no major changes should be performed anymore at the equipment.
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In addition, the team that assembles the components for validation should be trained.
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Components will be produced and provided for the test.
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This test plan is based on the design validation plan that was defined and performed already in phase two of the project.
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Sometimes tests can be skipped or shortened as they have been performed already in the product design phase.
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The duration of the test is depending on the specification
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and is the overall target to prove that the product requirements can be achieved
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or can be reached while simulating real situation through these tests.
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Typical tests can be temperature cycle tests, vibration tests, functional tests or durability tests.
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To perform product trainings according to the training plan.
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In phase 3 of the project a training plan for product and process trainings was defined.
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Trainings for a production team such as operators or shift leaders according to created work instructions should be done.
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As well as the logistic team should be trained according to the packaging instructions and further specifications.
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The quality team needs to be instructed according to the control plan and the test plan.
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Introductions into new test equipment needs to be given.
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it's important that all team members
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that are in touch with the product understand its main functions
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and the drawing as well as the special characteristics of the
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product finalization of quality planning within project phase 4 the quality planning process will be closed
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and all planned test equipment and method will be applied
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so procured test equipments are are being installed and first tests are being performed during the pre-seal production.
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Short-term capability studies can be performed and a special focus on fulfillment of special characteristics should be given.
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In addition, the measurement system analysis can be started for new test equipment.
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The target is to check if identified error pattern can be identified correctly with procured test equipment.
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In addition, the control plan is being finalized for the level of the serial production.
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Approval of production and run and wait.
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Once all adjustments of the production equipment are closed in order to reach the product requirements on a repeatable level,
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the time of the full production approval is getting closer.
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At this juncture, not just the cycle times of all production depths are compared versus the planned and calculated values,
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but also it is checked if all requirements can be met.
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If this is the case, the product can be produced at planned cost and also planned capacities,
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which have been promised to the customer previously can be kept.
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In order to reach the production approval, often a so-called run-at rate will be performed.
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The run-at rate is a final trial run at which the production at serial conditions is being simulated.
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It is recommended to perform a production trial that takes several days
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or at least a few shifts on all new equipments in order to identify downtimes,
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scrap, and NOK parts, as well as OK components output.
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The result of the run-and-rate is the statement if a production approval can be declared or not.
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Sometimes this is being performed in presence of the customer.
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Sampling according to PPAP or EMPP.
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Once the serial production process is installed and approved, the team can proceed with the sampling of the product.
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This is the approval that all product requirements can be achieved permanently with the installed production process.
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In order to reach that a bunch of documentation will be submitted to the customer.
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The scope of this documentation package is depending on agreements that have been made before.
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If the project has a smaller scope, typically the documentation package requires less information.
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The sampling can be performed according to different standards such as the VDA standard or the IAG standard.
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We will provide you further details about these different sampling levels in further videos on that channel.
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After received up the documentation from the customer it is basically his job to provide a feedback on
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that and this is to be done in phase 5 of the project.
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Quality gate phase 4.
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Once all these activities are done the project manager has the
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pleasure to present the progress of the process phase to the management and top management of the company.
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That may then decide, based on the recommendation of the project manager, to release APQB phase 4 and to move on with phase 5.
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During such a gate review, the project manager is presenting which activities have been performed and if they have been closed in time.
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In case there are still actions unfulfilled, this is the right time and place for the manager to escalate
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that to the management and ask for special attention and support of the management team.
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In such a case the team may of course also decide not to release the phase.
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Anyhow in case they release the phase the team is proceeding with activities of the next one.
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Important learnings of phase 4 are the following.
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In general high efforts are required in order to reach the approval and sampling timing.
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The reason therefore is typically that a lot of small adjustments need to be performed in a very short time.
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The team can prevent these things by giving the highest possible attention within phases one and two,
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three of the project.
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As more efforts it's spending before, as better it is prepared for the critical phase right now.
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The team is focused to reach a defined target date for the sampling,
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as with approval of the sampling documentation invoices for the production equipment can be raised to the customer.
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And of course also the sampling date is important to be kept for the customer.
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Another important fact is that all sampling requirements should be clarified as early as possible in the project.
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It is definitely too late to clarify them within phase 4.
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They should be discussed and fixed already in phase 0 or 1 of the project.
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Otherwise it may occur that massive changes of the project efforts are a result of insufficient clarification.
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Well, that was my short video about APQP Phase 4.
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Thanks to all of you for watching this video until the end.
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I hope you enjoyed the video.
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I'm looking forward for your likes and your feedback below.
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Please subscribe to the channel to not miss further APQP updates.
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Please feel free to join our Facebook community.
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You will find the link below the video.
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Have a great day.
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Vocabulary and speaking notes for this lesson
This C1 speaking lesson is built on the video “APQP Phase 4 - Product & Process validation phase”. The speaker keeps coming back to these words: phase, production, test, approval, equipment. This video has 119 sentences and 1562 words to shadow. The speech runs for 11:14. The speaker talks at a steady 139 words per minute, a comfortable pace for shadowing. 86% of the words are among the 3,000 most common in English; the rest is worth studying before you start.
Key vocabulary in this video
The 15 most advanced words in the video, with pronunciation and meaning:
| Word | Pronunciation | Meaning |
|---|---|---|
| validation noun | /ˌvæl.əˈdeɪ.ʃən/ | The act of validating something. |
| supplier noun | /səˈplaɪə/ | One who supplies; a provider. |
| documentation noun | /ˌdɑkjəmɛnˈteɪʃən/ | A documentary. |
| approve verb | /əˈpɹuːv/ | To officially sanction; to ratify; to confirm; to set as satisfactory. |
| specification noun | An explicit set of requirements to be satisfied by a material, product, or service. | |
| finalisation noun | The act or process of finalising. | |
| procure verb | /pɹəˈkjʊɹ/ | To acquire or obtain. |
| simulate verb | /ˈsɪm.jə.lət/ | To model, replicate, duplicate the behavior, appearance or properties of. |
| clarify verb | /ˈklæɹ.ɪ.faɪ/ | To make or become clear or bright by freeing from impurities or turbidity. |
| adjustment noun | /əˈd͡ʒʌst.mənt/ | The action of adjusting something. |
| characteristic noun | /ˌkæɹ(ə)ktəˈɹɪstɪk/ | A distinguishing feature of a person or thing, a part of mental or physical behavior. |
| subscribe verb | /səbˈskɹaɪb/ | To write (one’s name) at the bottom of a document; to sign (one's name). |
| anyhow adverb | /ˈɛn.i.haʊ/ | In any way or manner whatever. |
| downtime noun | /ˈdaʊnˌtaɪm/ | Time lost due to the failure of some system or machinery, such as a computer crash or power outage. |
| durability noun | /dəɹəˈbɪləti/ | The ability to last a long time by virtue of the power to resist stress or force. |
Phrasal verbs you will hear
| Word | Meaning |
|---|---|
| check out verb | To record the departure or withdrawal of someone or something (such as guests, employees, books, etc.). |
Grammar in this video
The structures the speaker uses most, with the exact words from the video:
| Structure | In the video |
|---|---|
| Passive voice be + past participle — the focus is on what happens, not who does it | being released · are shared · may be splitted |
| Present perfect have/has + past participle — a past action that still matters now | have been performed · have been promised · have been made |
Pronunciation to watch
The speaker uses 4 contractions and reduced forms, such as I'm, you're. Say them the short way, as you hear them.
- The “sh” and “zh” sounds: validation /ˌvæl.əˈdeɪ.ʃən/, documentation /ˌdɑkjəmɛnˈteɪʃən/, shorten /ˈʃɔɹtn̩/, clarification /ˌklæɹɪfɪˈkeɪʃən/, vibration /vaɪˈbɹeɪʃən/
- Long words — get the stress right: validation /ˌvæl.əˈdeɪ.ʃən/, documentation /ˌdɑkjəmɛnˈteɪʃən/, characteristic /ˌkæɹ(ə)ktəˈɹɪstɪk/, durability /dəɹəˈbɪləti/, repeatable /ɹɪˈpiːtəbəl/
How to practise with this video
- Listen to the whole video once without speaking and note the words you do not know.
- Shadow it sentence by sentence at normal speed, repeating each one until your rhythm matches the speaker.
- Record yourself and compare with the original, paying attention to words like validation, supplier, documentation.
What is the Shadowing Technique?
Shadowing is a science-backed language learning technique originally developed for professional interpreter training and popularized by polyglot Dr. Alexander Arguelles. The method is simple but powerful: you listen to native English audio and immediately repeat it out loud — like a shadow following the speaker with just a 1–2 second delay. Unlike passive listening or grammar drills, shadowing forces your brain and mouth muscles to simultaneously process and reproduce real speech patterns. Research shows it significantly improves pronunciation accuracy, intonation, rhythm, connected speech, listening comprehension, and speaking fluency — making it one of the most effective methods for IELTS Speaking preparation and real-world English communication.