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Aerospace Advanced ProductQuality Planning (Aerospace APQP)
Introduction
October 2013
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)
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Purpose
Hint: Google: “iaqg scmh” and then Bookmark it!
Supply Chain Management Handbook (SCMH)
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The APQP material is located in Chapter 8.4
www.iaqg.org/scmh
APQP Introduction
Document structure
Structure for Aerospace APQP guidance material content:1. Definition and Benefits
2. Aerospace APQP Model - PillarsA. Organizational commitment & Management support
B. Cross functional team
C. Effective project planning
3. Aerospace APQP model - PrinciplesA. Product oriented
B. Structure
1. Phases
2. Elements
3. Deliverables
C. Checklist
D. Production Part Approval Process (PPAP)
4. Implementation and customizationA. Assessments/ratings
B. Reporting
C. Escalation
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Refer to the SCMH for more information
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 Drivers
Management commitment
Integrated cross-functional teams
Effective project management
Defined deliverables & outputs for each phase
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Program Needs
PPAP
Phases
Elements
Deliverables
Aerospace APQP
• 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
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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
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
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Aerospace APQP Model
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Customer Satisfaction On-Time, On-Quality, Shorter lead times
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APQP PRINCIPLES
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
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Full engagement and commitment of top management from project launch is key.
Aerospace APQP main pillars
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
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Cross functional team approach ensures effective communication across the business & enables faster product development.
Aerospace APQP main pillars
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
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Aerospace APQP main pillars
Commitment of the project team to Aerospace APQP planning is key to the project success.
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
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Customer APQP timeline
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Supplier APQPtimeline
Aerospace APQP main pillars
1 - Planning
2 - Product Design & Development
3 - Process Design & Development
4 - Product Process Validation
5 - Production
Program Needs
PPAP
Phases
Elements
Deliverables
Aerospace APQP
Aerospace APQP model
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5 PHASES
ELEMENTS DEFINING
ACTIVITIES
KEY DELIVERABLES
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
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APQP phases1 - Planning
2 - Product Design & Development
3 - Process Design & Development
4 - Product Process Validation
5 - Production
Product DevelopmentProcess
Aerospace APQP model alignswith PDP
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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)
Sub-system level
System level
Product DevelopmentProcess
Cascade through Product Breakdown Structure (PBS)
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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
APQP Principles
PhasesElements
Deliverables
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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. Planning
2. Product design and development
3. Process design and development
4. Product and process validation
5. Production
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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
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Aerospace APQP principles
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
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Any design changes after this phase requires change management
Aerospace APQP principles
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.
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Aerospace APQP principles
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
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Aerospace APQP principles
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
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Aerospace APQP principles
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
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
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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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Elem
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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
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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?
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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?
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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
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Aerospace APQP principles
Checklists
coming soon!
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 Drivers
Completion of key requirements at the right time during planning process (PPAP is an output of APQP)
Risk mitigation and improved process controlLinkage of DFMEA PFMEA Control Plan
Process Capability validation
Product verification (FAI)
Process Validation
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Program Needs
PPAP
Phases
Elements
Deliverables
Aerospace APQP
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
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Program Needs
PPAP
Phases
Elements
Deliverables
Aerospace APQP