aerospace advanced product quality planning (aerospace apqp) introduction

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1 Aerospace Advanced Product Quality Planning (Aerospace APQP) Introduction October 2013

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Aerospace Advanced Product Quality Planning (Aerospace APQP) Introduction. October 2013. 1. Purpose. Hint: Google: “ iaqg scmh ” and then Bookmark it!. The purpose of this presentation is to introduce Advanced Product Quality Planning to Aerospace Suppliers - PowerPoint PPT Presentation

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Page 1: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

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Aerospace Advanced ProductQuality Planning (Aerospace APQP)

Introduction

October 2013

Page 2: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

The purpose of this presentation is to introduce Advanced Product Quality Planning to Aerospace Suppliers

Note: The full APQP Introduction presentation is available to the public on the IAQG SCMH website (www.iaqg.org/scmh)

Page 2

Purpose

Hint: Google: “iaqg scmh” and then Bookmark it!

Page 3: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Supply Chain Management Handbook (SCMH)

Page 3

The APQP material is located in Chapter 8.4

www.iaqg.org/scmh

APQP Introduction

Page 4: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Document structure

Structure for Aerospace APQP guidance material content:1. Definition and Benefits2. Aerospace APQP Model - Pillars

A. Organizational commitment & Management supportB. Cross functional teamC. Effective project planning

3. Aerospace APQP model - PrinciplesA. Product orientedB. Structure

1. Phases 2. Elements3. Deliverables

C. ChecklistD. Production Part Approval Process (PPAP)

4. Implementation and customizationA. Assessments/ratingsB. ReportingC. Escalation

Page 4

Refer to the SCMH for more information

Page 5: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

What is APQP?

APQP is a structured method that deploys the necessary steps to assure that a product satisfies the customer

5-Phase Quality Planning Cycle (PDCA)Up-front planning (First 3 phases)Implementation (Last 2 phases)

Success DriversManagement commitmentIntegrated cross-functional teamsEffective project managementDefined deliverables & outputs for each phase

Page 5

Program Needs

PPAP

Phases

Elements

Deliverables

Aerospace APQP

Page 6: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

• The IAQG Guidance material on APQP and PPAP builds on the principles of quality planning as pioneered by Deming from the 1950s and the Automotive industry during the later decades of the 20th Century.- GM, Ford & Chrysler published the first combined APQP manual for the

automotive industry in June 1994

Page 6

Background

• IAQG recognizes that the Aerospace industry is different from other industries and has developed guidance material which is tailored to suit companies working in this industry.

• Low volumes• Long life cycles• High levels of regulation

Page 7: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Benefits

Products are successfully launched when all functions/disciplines work together to achieve common project objectives. Aerospace APQP encourages cross functional teamwork and early engagement of all functions and suppliers.

• The APQP approach helps satisfy the customer with:• Better product quality by reducing process variation and

anticipating risks and defects• Shorter lead time by reducing waste and reworks and better

manage capacity • Lower costs

Page 7

Page 8: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Aerospace APQP Model

Page 8

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

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APQP PRINCIPLES

Page 9: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Organizational commitment & management understanding and support• Aerospace APQP brings success when it is embraced by the

whole organization • Top management demonstrates commitment through:

- Completing specific APQP training- Allocating appropriate resources- Leading periodic reviews- Standardizing APQP practices- Removing Roadblocks

Page 9

Full engagement and commitment of top management from project launch is key.

Aerospace APQP main pillars

Page 10: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Cross functional team• Establish a cross functional team including: Engineering,

Procurement, Manufacturing, Quality, Sales, Field Service, and others as appropriate

• The team should consist of representatives from both the supplier and the customer

• Roles- Team leader (project management function) determines the team membership,

guides, assigns tasks, escalates issues to management- Members complete the required tasks and deliverables- Quality (APQP) management arranges for the meetings, ensures on-time and

on-quality of deliverables, documents and records

Page 10

Cross functional team approach ensures effective communication across the business & enables faster product development.

Aerospace APQP main pillars

Page 11: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Effective project planning• Schedule the tasks defined by the APQP elements and

monitor them in order to deliver a product conforming to quality, cost and delivery targets

• Aerospace APQP Planning cascades program key targets throughout the value stream; driven from final customer through internal operations and all sub-tiers

• This establishes a customer/supplier relationship throughout the value stream

Page 11

Aerospace APQP main pillars

Commitment of the project team to Aerospace APQP planning is key to the project success.

Page 12: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

1 - Planning

2 - Product Design & Development

3 - Process Design & Development

4 - Product Process Validation

5 - Production

Effective planning includes flow down of timing requirements throughout the value stream

Page 12

Customer APQP timeline

xxQRepresentative

DeliverableOwner

DeliverableOwner

DeliverableOwner

DeliverableOwner

Deliverables

xx QRepresentative

DeliverableOwner

DeliverableOwner

DeliverableOwner

DeliverableOwner

Deliverables

Supplier APQPtimeline

Aerospace APQP main pillars

1 - Planning

2 - Product Design & Development

3 - Process Design & Development

4 - Product Process Validation

5 - Production

Page 13: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Program Needs

PPAP

Phases

Elements

Deliverables

Aerospace APQP

Aerospace APQP model

Page 13

5 PHASES

ELEMENTS DEFINING

ACTIVITIES

KEY DELIVERABLES

Page 14: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Aerospace APQP enhances the product development process• Product Development Process (PDP) specifies activities across

functions and suppliers, with associated deliverables and interim approvals at defined points, e.g. gate reviews

• Aerospace APQP aligns with Product Development Process• Ensures that all activities are completed on-time and on-quality• Facilitates effective communication• Provides timely escalation and resolution of road blocks

Aerospace APQP model

Page 14

Page 15: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

APQP phases1 - Planning

2 - Product Design & Development

3 - Process Design & Development

4 - Product Process Validation

5 - Production

Product DevelopmentProcess

Aerospace APQP model alignswith PDP

Page 15

End of concept

End of design

Product validation

Production readiness

APQP supports Product Development Process (PDP)• Applies to each item of the product breakdown structure• Standardizes deliverables for each Aerospace APQP Phase• Evaluates maturity based on timing and quality of required deliverables

Kick off

A

BE

C

D

APQP milestones

Alignment with Product Development Process (PDP)

Page 16: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Sub-system level

System level

Product DevelopmentProcess

Cascade through Product Breakdown Structure (PBS)

Page 16

End of concept

End of design

Product validation

Production readinessKick off

Components level

1 - Cascade deliverables and align timing for each level

2 - Bottom up status based on on-time on-quality

deliverables

Note: Compressed timeline to support program timing

1 - Planning

2 - Product Design & Development

3 - Process Design & Development

4 - Product Process Validation

5 - Production

3 - Report APQP status at project level

Typical PBS: system→ sub-system→ component

Aerospace APQP model

1 - Planning

2 - Product Design & Development

3 - Process Design & Development

4 - Product Process Validation

5 - Production

1 - Planning

2 - Product Design & Development

3 - Process Design & Development

4 - Product Process Validation

5 - Production

Page 17: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

APQP Principles

PhasesElements

Deliverables

Page 17

Page 18: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Aerospace APQP principles

Aerospace APQP organized into 5 Phases• Logical steps to deliver a product from concept to production

that can be applied to any product at any level across the supply chain

• The 5 phases are:1. Planning2. Product design and development 3. Process design and development4. Product and process validation 5. Production

Page 18

Page 19: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

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 has decided what will be made in house

and what will be purchased/sub-contract • Provides an agreed timing for deliverables attached to each Aerospace

APQP elements

Output• The product concept is frozen (milestone A) and a pre-design is

available• Concurrent product design and process design can start

Page 19

Aerospace APQP principles

Page 20: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Phase 2 - Product design & development• Turns product specifications into a robust product definition• Provides a verified product design• Team commits to product manufacturability

Output• Specified prototype testing (e.g. simulation & functional testing) have

been completed • The product design is verified and validated (milestone B) by the

design organization

Page 20

Any design changes after this phase requires change management

Aerospace APQP principles

Page 21: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

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.

Page 21

Aerospace APQP principles

Page 22: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Phase 4 - Product & process validation:• Launches the significant 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:

- The product and process design is validated by the organization

- Production readiness evaluation

- Corrective actions taken for any issues identified to date

Page 22

Aerospace APQP principles

Page 23: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

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

Page 23

Aerospace APQP principles

Page 24: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Phase 5 - Production• Records Lessons Learned for continuous improvement

• Ensures robust product realization processes are in place

• Implements actions to reduce product and process variation in order to achieve quality goals

• Supports on-going Maintenance Repair and Overhaul (MRO) operations

• Performs capacity monitoring

Outputs• Project goals are achieved, including reliability, quality, and customer

satisfaction

• On-time, on-quality, on-cost production and servicePage 24

Aerospace APQP principles

Page 25: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Aerospace APQP principles

Elements • Describes key activities accomplished during each

Aerospace APQP phase• Assure the health of the project through monitoring on-

time,on-quality key deliverables• Encourages a standardized approach • Applicability evaluated for each project

Page 25

Page 26: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Aerospace APQP principles

Deliverables• Specific outputs defined for each element• Tangible outcomes of the cross functional team activities• Provides the base for assessing the on-quality of the

Aerospace APQP elements• Provides standardized content wherever possible (e.g.

FMEA, Control plan etc.)

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Elemen

t

Descri

ptions

coming so

on!

Page 27: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Description:

Deliverables:

* In the Y column use IP (In progress) when the CTQ is progressing as planned but still has not reached completion

# Question Y* N N/A RAGOpen Date

Due Date

Status%

Actual End Date

1

Was the Floor plan layout created by a cross functional team including Process Engineering, Production Manager, Quality, Facilities Management, Maintenace and Health, Safety & Environment Representatives?

2

Have all the necessary inputs, in the development of the plant lay out, been taken into account and they are frozen at the right stage (e.g., Build Process Definition , Value Stream Mapping Analysis, Inbound / Outbound Logistics Flow, H&S and environmental rules, Plant Lay Out Blue Print and plan, existing facility utilities …)?

3 Have Material Flow, Storage and Buffer areas been considered when defining the plant (facility) lay out?

4 Have People Flow (e.g., spaghetti charts) been considered when defining the lay out?

5Is the floor layout optimised to remove waste (overproduction, movement, inventory, waiting, overprocessing, rework and transportation) from the process?

6Have H&S and ergonomics, environmental and Facilities requirements been validated in the proposed lay out?

7 Is plant (facility) lay out implementation plan and its readiness in line with program schedule?

8 Have Capital expenditure targets been considered by the lay out? Has Capital Expenditure been approved?

9Is the floor plan layout up-to-date and managed in configuration? Is it consistent with the latest process flow chart?

10 Have all potential risks affecting the CTQ been identified?

11

12

131415

XN/A

25% Location: / Site:

RRewiewed by:

Status (%): 25% - Action Identified 50% - Owner Identified A Reviewed with:75% - Action in Progress 100% - Action Closed G Date :

The floor plan layout should be developed to clearly show the position and layout for all processes to be covered by the control plan. The plan should identify each process which affects the quality characteristics of the part. Synchronous material flow and floor usage optimisation should be taken into account when performing the lay out in an effort to economise space usage increasing the value added of floor space and minimising the travel and handling of materials, parts and assemblies following lean principles. Value Stream Mapping (VSM) and Spaghetti diagram techniques can be used in support of this. Deliverable is a plant layout plan approved by the Production manager and the Quality Manager.

Note: If planned review is delaid by more than two weeks item to be highlighted as RED and escalated.

Evidences Actions Required Responsible

Green: All questions have a positive answer (Y) and are ongoing normal program development

CTQ RAG Rating

Red: Some questions have a negative answer and no recovery plan is in place or the plans identified will have an impact in program timing. Support is required. When an item is highlighted Red an assessment on the impact to the WP timing needs to be provided.Amber: Some questions have a negative answer but a recovery plan is in place which will prevent impact on timing

Checklist• Standardized tool to evaluate on-quality of deliverables and

elements• Short set of simple, clear questions which will deliver closed

answers (Y/N)– Provides document references as evidence and records

deviations– Collects corrective actions to recover deviations– Establishes the first level of Red/Yellow/Green rating

Page 27

Aerospace APQP principles

Checklists

coming soon!

Page 28: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Aerospace APQP key milestones

Production Part Approval Process (PPAP) PPAP validates that the manufacturing process has the potential to produce product that consistently meets all requirements at the intended production rate.

Success DriversCompletion of key requirements at the right time during planning process (PPAP is an output of APQP)Risk mitigation and improved process control

Linkage of DFMEA PFMEA Control Plan

Process Capability validationProduct verification (FAI)Process Validation

Page 28

Program Needs

PPAP

Phases

Elements

Deliverables

Aerospace APQP

Page 29: Aerospace Advanced Product Quality Planning   (Aerospace APQP) Introduction

Summary

• Advance Product Quality Planning (APQP) is taking hold in the Aerospace Industry

• APQP ensures the delivery of product on-time, on-quality, on cost

• PPAP validates the production process• The full APQP Introduction presentation

is available in Chapter 8.4 of the SCMH• More information on this topic will be

available in November 2013

Page 29

Program Needs

PPAP

Phases

Elements

Deliverables

Aerospace APQP