PRODUCT & SUPPLY CHAIN IMPROVEMENT

SUPPLY CHAIN MANAGEMENT HANDBOOK (SCMH)

AWARENESS WEBINAR

SCMH TOPIC: ADVANCED PRODUCT QUALITY

PLANNING (APQP) – 7 NOVEMBER 2018
Deborah Oberhausen P&W UTC
Jennifer Cox Spirit Aerosystem
Susan Parsons IAQG
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 Supply Chain Management Handbook Webinar
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 Product & Supply Chain Improvement
Webinar Agenda

Webinar Tips
Supply Chain Management Handbook (SCMH) Susan Parsons
– SCMH Focus
– IAQG Link to SCMH
– SCMH Access
– SCMH Content
Advance Product Quality Planning (APQP) and Deb Oberhausen
Product Part Approval Process (PPAP) & Jennifer Cox

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 SCMH Focus
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 Sections in progress
SCMH Content Recently published

Updated October 2018

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ADVANCED PRODUCT QUALITY PLANNING (APQP) AND PRODUCTION
PART APPROVAL PROCESS (PPAP)

DEBORAH OBERHAUSEN P&W UTC

JENNIFER COX SPIRIT AEROSYSTEMS

Nov 2018

© 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)
 9145 APQP & PPAP

The purpose of this presentation is to:

• Introduce the key concepts of APQP and PPAP and the
benefits of application
• Communicate availability of guidance material and
training
• Implementation – First steps

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 APQP and PPAP Webinar Series

Design Risk
Analysis
Webinar Objectives
Process Flow
• Provide high level understanding
PPAP
Diagram &
Process
• Introduce APQP and PPAP and
FMEA show relation to 9145
Advanced
Product Quality • Share benefits & best practices
Planning
Overview • Provide sources of additional
Process information
Capability & Control Plan
Control

Measurement
Systems
Analysis

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 Introduction to 9145

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 What is 9145?
9145 applies Advanced Product Quality Planning (APQP) and
Production Part Approval Process (PPAP) to Product Development in the
Aviation Space And Defense (AS&D) industry

5-Phase Product Development Process Success Drivers

1. Planning • Management commitment
2. Product Design and Development • Integrated cross-functional teams
3. Process Design and Development • Effective project management
4. Product and Process Validation • Defined deliverables & outputs for each phase
5. On-Going Production, Use, and Post-Delivery
Service

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 Why 9145?
Improve Quality and Reduce Cost
• Early achievement of product maturity
• Reduced overall life-cycle costs
• Prevention tools for risk reduction
• Provides foundation for successful work transfers

Progressive companies have incorporated APQP into their Product Development Process
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 Companies incorporating APQP into their PDP and
flowing these requirements to their suppliers
Airbus Group Honeywell Embraer
Boeing Hensoldt Oshkosh
GE Aviation Lockheed Martin Rolls Royce
Raytheon Safran Group Woodward
Spirit Aero UTC MHI
Rockwell Collins Bombardier Parker Aerospace
Textron Eaton

Not intended to be a comprehensive list

© 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015) 18
 Why 9145?
Improve Quality and Reduce Cost by eliminating:
• Visible Costs:
• Non Conformances
• Rework / Repairs
• Penalties

• Hidden Costs:
• Design changes
• Warranty costs
• Loss of productivity
• Field service costs
• The list goes on…
The iceberg effect…

Deliver quality products that satisfy customer expectations

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 What does 9145 do for AS&D?

Standardizes requirements for Product Development across AS&D

• Integrated multifunctional approach to ensure effective

collaboration

• Structured proactive life-cycle approach

• Phased/gated process to ensure on-time quality products

• Strengthens production verification process (PPAP)

Based on proven methodology for Product Development

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 How are 9145 Benefits achieved?

• Early understanding of Customer Expectations

• Reduce overall cost by identifying & eliminating risks
• Achieve robust Product and Process Designs
• Minimize required changes
• Effective implementation through program management
• Cross-functional teams collaborate on all aspects of the program
• Meet Customers requirements
• Achieve reliability and cost targets

© 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015) 21
 9145 Benefits from Proactive Approach

-Reactive to proactive approach

-Improved product quality
-Reduce failure costs through prevention
100
-Increased Customer satisfaction
90 Pre ve ntion

80
70
Ins pe ction
60
50
Pre ve ntion
Failure inte rnal
40
30
Ins pe ction
20 Failure e xte rnal
10 Failure inte rnal
Failure e xte rnal
0
Before After

Upfront costs are offset by reduction in failure and inspection cost

© 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015) 22
 9145 Benefits from Proactive Approach
Non-conformances reduced through PPAP
(actual AS&D example)
New Product Introduction Work Transfers

40 % reduction

80 % reduction

Program to program comparison Across programs

First benefits of APQP can be achieved through PPAP deployment

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 APQP Overview

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 What is Advanced Product Quality Planning?
APQP is a structured phased Product Development methodology that assures
Customer satisfaction by:
• Ensuring that all activities are completed on-time and on-quality
• Facilitating effective communication
• Providing timely escalation and resolution of delays and risks

Customer
Satisfaction

© 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015) 25
 APQP Principles

Customer Satisfaction
On-Time, On-Quality, Shorter lead times

Cross Functional

Effective Project
Commitment &
Organizational

Management

Planning
Support

Team
APQP PRINCIPLES

Pillars of success
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 APQP Principles
Top Management demonstrates
commitment by…

− Completing APQP training

− Allocating and training resources Customer Satisfaction
− Leading reviews On-Time, On-Quality, Shorter lead times

− Standardizing APQP practices

− Removing roadblocks

Cross Functional

Effective Project
Commitment &
Organizational

Management

Planning
Support

Team
Management engagement &
commitment from launch to
closure is key!

APQP PRINCIPLES

Pillars of success
© 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015) 27
 APQP Principles
Cross functional teams enable
effective communications and faster
product development

Customer Satisfaction Teams should consist of…

On-Time, On-Quality, Shorter lead times
− Engineering
− Procurement
− Manufacturing

Cross Functional

Effective Project
Commitment &
Organizational

Management
− Quality

Planning
Support
− Sales

Team
− Suppliers
− Customers
− Customer Support

APQP PRINCIPLES

Pillars of success
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 APQP Principles
Effective project planning and management…

− Schedule tasks, assign Commitment to a firm APQP plan

responsibility and drive on- Customer Satisfaction is a critical success factor!
time completion On-Time, On-Quality, Shorter lead times

− Continually monitor plan,

Cross Functional

Effective Project
Commitment &
communicate risks and
Organizational

Management
remove roadblocks

Planning
Support

Team
− The APQP plan cascades
program key targets
through the value stream
Customer

Internal Operations APQP PRINCIPLES

Suppliers

Pillars of success
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 PDP and APQP Phase Alignment
Phase Milestones
APQP has 5 phases starting with product concepts and extending through the product life cycle
Initial Production
End of Concept Design Production Launch
Kick Off Approval
(PDR) Release
(CDR)

Product Development
Process (PDP)

A 5 – On-going Production, Use and Post-

1. Planning delivery Service
Phases of Advanced Product B
D
4 – Product and Process
Quality Planning (APQP) 2 – Product Design and Development
Validation E
C

APQP Milestone 3 – Process Design and Development

Product concept 1st Article Inspection

(FAI)
Design validation & verification Production Part Approval
Process (PPAP)
Process validation
Production Readiness Review
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 APQP – Phase 1
Phase 1 –Planning
• Identifies and gathers all the inputs applicable to the product
• Collects the technical and non-technical requirements applicable to the project/product
• Defines the product and project goals
• Ensures that the organization makes the key make-buy decisions
• Establishes timing for deliverables for each APQP element

Output
• The product concept is finalized (milestone A) and a pre-design is available
• Concurrent product design and process design can start

APQP Milestone

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 APQP – Phase 2

Phase 2 –Product design & development

• Turns product specifications into a robust product definition
• Design risk analysis (DFMEA)
• Provides a verified product design
• Team commits to product manufacturability

Output
• Design record and BOM are available
• The product design is verified and validated (milestone B) by the design organization
•

A
B

APQP Milestone

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 APQP – Phase 3

Phase 3 –Process design & development

• Creates a robust manufacturing process that meets requirements in terms of quantity and quality of
product
• Defines the means to control the manufacturing process and its outputs

Output
• The process is defined, established, verified (Production Readiness Review - milestone C) and ready for
•
validation.

A
B
C
APQP Milestone

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 APQP – Phase 4

Phase 4 –Product & process validation:

• Launches the initial production run
• Collects data to demonstrate the manufacturing and assembly processes can produce conforming product
at the required rate
• Management determines process readiness for entry into serial production by reviewing the results of:
– Product and process design as validated by the organization
– Production readiness evaluation
•
– Corrective actions taken for any issues identified to date

A
B
C
APQP Milestone

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 APQP – Phase 4

Phase 4 –Product & process validation:

Output
• Start of production & FAI (milestone D) verify that the initial product made using all full production means
conforms to specified requirements
• First Article Inspection (FAI) is compiled, approved and available for customer review
• Production Part Approval Process (PPAP) (milestone E) is compiled, approved and available for customer
review

D
A
B E
C
APQP Milestone

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 APQP – Phase 5

Phase 5 –Production
• Evaluate if project objectives have been achieved
• Record Lessons Learned to drive robust product realization processes
• Implement actions to increase customer satisfaction

Output
• Project goals are achieved, including reliability, quality, and customer satisfaction
• On-time, on-quality, on-cost production and service

D
A
B E
C

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 PPAP Overview

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 PPAP Overview

PPAP is an aerospace APQP element finalizing “Product and Process Validation”

5 – On-going Production, Use

1. Planning and Post-delivery Service

2 – Product Design and 4 – Product and

Development Process Validation PPAP
3 – Process Design and Development

PPAP combines First Article Inspection and Process Validation

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 What is Production Part Approval Process?

PPAP confirms...
that the production process has demonstrated the potential to
produce products…..
that consistently fulfill all requirements…..
while operating at the customer demand rate

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 PPAP Elements & Phase Alignment
PPAP elements are the output and evidence of APQP execution
PPAP ELEMENT APQP PHASE
1. Design Records* 2
2. Design Risk Analysis* 2
3. Process Flow Diagram 3
4. PFMEA 3
5. Control Plan 3
6. MSA 4
7. Initial Process Capability Studies 4
8. Packing, Preservation and Labeling Approvals 3
9. FAIR 4
* Responsibility of design 10. Customer Specific Requirements 4
responsible organization 11. PPAP Approval Form (or equivalent) 4

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 Production Part Approval Process (PPAP)
Disposition Approved
Compile the Submit to
PPAP Interim Approval
PPAP Package Customer
Submission Rejected

PPAP Approval Form - 9145 Appendix D

Maintain the PPAP file throughout product lifecycle

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 Production Part Approval Process (PPAP)
Key aspects PPAP
• Follows successful completion of the first 4 phases APQP
• Defines the standard deliverables for production part approval
• First Article Inspection (FAI) is the first milestone of Production
Validation
• PPAP elements are updated as process and/or product changes occur

Products used for PPAP are from initial production run(s)

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 Aerospace APQP & PPAP
Summary
• 9145 is the internationally harmonized Aerospace standard for APQP
and PPAP
• APQP Principles are keys to success
• APQP has deliverables & milestones aligned to each of the 5 phases
• PPAP approval is the output of APQP
• APQP and PPAP apply throughout the life of the product

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 Guidance Material & Training

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 9145 Aerospace APQP & PPAP
AS Standard Published Nov 2016
SJAC 9145 June 21, 2017

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 Aerospace APQP SCMH Section 7.2

SCMH 7.2.3
SCMH 7.2.2

Introduction Presentation APQP Manual

NEW NEW
Phase Checklists Tools & Templates Maturity Assessment
SCMH 7.2.14
7.2.9 Process Flow Diagram
7.2.10 DFMEA
7.2.11 PFMEA
7.2.12 Element Applicability
7.2.13 Control Plan

SCMH 7.2.4-7.2.8
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 Self Assessment - Maturity Matrix
1.0 Philosophy: Management Awareness and Commitment
Item Content
Advance Product Quality
Level 1
(1 pt)
No knowledge of APQP. Not
Planning (APQP) Philosophy & integrated into product
Level 2
(2 pt)
Basic knowledge and
awareness of APQP and
Level 3
(3 pt)
Implementation plan in place
for integrating APQP into
Level 4
(4 pt)
APQP is defined and fully
integrated in product
Level 5
(5 pt)
Organizational structure and
systems in place to support
Weight Score Comment / Evidence
What is It?
Knowledge of the development process. basic understanding of Product Development development process. APQP. Continuous

1.1
Requirements requirements and skills
needed to deploy.
process. Key personnel
trained in the APQP
Strategic communications
and objectives driving the
improvements plans to
ensure the APQP philosophy 30% 2 • A tools used to visually represent an organizations strengths
methodologies. APQP philosophy. continues to drive culture
change.
and weaknesses within APQP
Organizational Support Limited support and no APQP Acknowledged and Leaders of function roles Buy-in at all levels and Leadership objectives met

executive leadership supported in isolated sectors
directive. of the organization. (e.g.
driven by quality and/or
engineering)
1.2
(e.g. engineering, quality,
operations, procurement,
etc.) understand and support
APQP. Organization trained
and some use of tools &
process is evident.
relevant functional
organizations of the
organization and working to
achieve the tactical
objectives.
Objective or Purpose
and tactical objectives
implemented. Results
analysis driving
improvements and closing
70% 2
gaps.
To evaluate and assess the maturity of an organizations
Raw Score
40.0%
Overall Weighted Category Score
40.0% Advanced Product Quality Planning philosophy
• Management awareness/commitment
• Organizational alignment and effective communication
• Project/risk management
• Use of tools
• Readiness of external suppliers

When to Use It
• Prior to deployment within your organization
• Prior to deployment of your external suppliers
• As needed to monitor and develop continuous improvement

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 Implementation

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 First Steps in Deployment
• Benchmark other companies

• Perform the Self-Assessment (Maturity Matrix)

– Identify strengths and weaknesses

• Training
– Determine what training is needed based off Maturity Matrix
– Develop a plan to address training needs

• Incorporate APQP in the Product Development Process

– Conformance to the standard/customer requirements

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 APQP Relationship
Webinar Series
5. On-going Production
1. Planning
& Post Delivery
2. Product Design & Development 4. Product & Process Validation

3. Process Design & Development

Design
Design
Design Risk
Risk
Project Key Product
Inputs Risk
Analysis
Analysis Characteristics
Analysis
Feedback

Dec 12th Feb 13th

Process
Next Webinar Process
Process
Flow
Flow PFMEA
PFMEA
Control
Control
Plan
Plan
Process
Capability
Capability
Control
&
Diagram
Diagram & Control
Nov 14th Nov 28th
Jan 16th Mar 13th
Measurement
Measurement
Product & Systems PPAP
Systems PPAP
Process Key Approval
Analysis
Analysis
Characteristics

*Reference 9145 Table 2 – Production part approval process file contents

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 Upcoming IAQG 9145, APQP & PPAP
Webinar Series
Webinar Topic Date & Time Who Should Attend
Advanced Product Quality Planning (APQP) Overview Nov 7th 2018 Top leadership and leaders of all function engaged
2:00 PM GMT in product development process
Design Risk Analysis – Critical Items Nov. 14th 2018 Systems, Design, Manufacturing and Quality
2:00 PM GMT Engineers
Process Flow/ Process Failure Modes and Effects Nov. 28th 2018 Design, Manufacturing and Quality Engineers,
Analysis (PFMEA) – Process Characteristics 2:00 PM GMT Operations Management
Control Plan Dec. 12th 2018 Design, Manufacturing and Quality Engineers,
2:00 PM GMT Operations Management
Measurement Systems Analysis MSA Jan. 16th 2019 Design, Manufacturing and Quality Engineers,
2:00 PM GMT Calibration Management
Process Capability & Control (Variation Management) Feb. 13th 2019 Manufacturing and Quality Engineers, Operations
2:00 PM GMT Management
Production Part Approval Process (PPAP) Mar. 13th 2019 Manufacturing and Quality Engineers
2:00 PM GMT

2:00 PM GMT = 9:00AM EST = 11:00 PM KST(+9GMT)

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 Comments and Suggestions

Do you have comments about the

APQP Guidance?

You may provide feedback via the SCMH,

go to www.iaqg.org/scmh accept the terms and conditions
then click on “Contact Us” or “Take Survey”.

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