9145 - ADVANCED PRODUCT QUALITY PLANNING (APQP) …

1 The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015) PRODUCT & SUPPLY CHAIN IMPROVEMENTSUPPLY CHAIN MANAGEMENT HANDBOOK (SCMH)9145 - ADVANCED PRODUCT QUALITY PLANNING (APQP) AND PRODUCT PART APPROVAL PROCESS (PPAP)AVIATION SPACE AND DEFENSE INDUSTRIESD eborah oberhausen -UTCBERLIN SUPPLIER FORUM18 OCTOBER 2019 The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)9145 APQP & PPAPThe purpose of this presentation is to: Introduce key concepts of APQP and PPAP and the benefits of application Implementation First steps Guidance material and trainingThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev.)

2 08-2015)3 Introduction to 9145 The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)What is 9145?APQPA dvancedProductQuality PlanningQualityrefers to Good, effective Enterprize-widePlanningAPQPThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)What is 9145?9145 applies ADVANCED PRODUCT QUALITY PLANNING (APQP) and Production Part Approval Process (PPAP) to PRODUCT Developmentin the Aviation Space And Defense (AS&D) industry5-Phase PRODUCT Development Design and Design and and Process Production, Use, and Post-Delivery ServiceSuccess Drivers Management commitment Integrated cross-functional teams Effective project management Defined deliverables & outputs for each phaseThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev.

3 08-2015)6 Why 9145? Prevention tools for risk reduction Early achievement of PRODUCT maturity Reduced overall life-cycle costs Provides foundation for successful work transfersImprove QUALITY and Reduce CostThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)7 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 QUALITY products that satisfy customer expectationsThe iceberg IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)89145 Benefits from Proactive ApproachUpfront costs are offset by reduction in failure and inspection costFailure externalFailure internalFailure internalInspectionInspectionPreventionPr eventionFailure external0102030405060708090100 BeforeAfter-Reactive to proactive approach-Improved PRODUCT QUALITY -Reduce failure costs throughprevention-Increased Customer satisfactionThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev.

4 08-2015)99145 Benefits from Proactive ApproachNon-conformances reduced through PPAP (actual AS&D example)Work TransfersFirst benefits of APQP can be achieved through PPAP deployment80 % ReductionProgram to program comparisonAcross programsNew PRODUCT introductionThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)10 APQP OverviewThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)11 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 risksThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev.

5 08-2015)Pillars of successCustomer Satisfaction On-Time, On- QUALITY , Shorter lead timesOrganizational Commitment & Management SupportCross Functional TeamEffective Project PLANNING APQP PRINCIPLESAPQP PrinciplesThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)Pillars of successCustomer Satisfaction On-Time, On- QUALITY , Shorter lead timesOrganizational Commitment & Management SupportCross Functional TeamEffective Project PLANNING APQP PRINCIPLESAPQP PrinciplesTop Management demonstrates commitment Completing APQP training Allocating and training resources Leading reviews Standardizing APQP practices Removing roadblocksManagement engagement & commitment from launch to closure is key!The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev.

6 08-2015)Pillars of successCustomer Satisfaction On-Time, On- QUALITY , Shorter lead timesOrganizational Commitment & Management SupportCross Functional TeamEffective Project PLANNING APQP PRINCIPLESAPQP PrinciplesCross functional teams enable effective communications and faster PRODUCT developmentTeams should consist Engineering Procurement Manufacturing QUALITY Sales Suppliers Customers Customer SupportThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)Pillars of successCustomer Satisfaction On-Time, On- QUALITY , Shorter lead timesOrganizational Commitment & Management SupportCross Functional TeamEffective Project PLANNING APQP PRINCIPLESAPQP PrinciplesEffective project PLANNING and Schedule tasks, assign responsibility and drive on-time completion Continually monitor plan, communicate risks and remove roadblocks The APQP plan cascades program key targets through the value streamCustomerInternalOperationsSupplier sCommitment to a firm APQP plan is a critical success factor!

7 The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)16 PDP and APQP Phase AlignmentPhase MilestonesAPQP has 5phases starting with PRODUCT concepts and extending through the PRODUCT life cycleProduction LaunchPhases of ADVANCED PRODUCT QUALITY PLANNING (APQP) PRODUCT DevelopmentProcess (PDP)Kick OffEnd of Concept(PDR) Initial Production ApprovalDesign Release(CDR) 1. Planning4 PRODUCT and Process Validation2 PRODUCT Design and Development3 ProcessDesign and Development5 On-going Production, Use and Post-delivery ServiceD1st Article Inspection (FAI)EProduction Part Approval Process (PPAP)CProcess validationProduction Readiness ReviewBDesign validation & verificationAPQP MilestoneAProduct concept The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev.)

8 08-2015)17 PPAP OverviewThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)18 PPAP OverviewPPAP is an aerospace APQP element finalizing PRODUCT and Process Validation 1. Planning4 PRODUCT and Process Validation2 PRODUCT Design and Development3 ProcessDesign and Development5 On-going Production, Use and Post-delivery ServicePPAP combines First Article Inspection and Process qualificationPPAPThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)19 What is Production Part Approval Process?PPAP the production process has demonstrated the potential to produce consistently fulfill all operating at the customer demand rateThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev.

9 08-2015)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 occurProducts used for PPAP are from initial production run(s)The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)21 PPAP Elements & Phase AlignmentPPAP elements are the output and evidence of APQP executionPPAP ELEMENTAPQP PHASE1. Design Records*22. Design Risk Analysis* Flow Diagram34. PFMEA35. Control Plan36. MSA47. Initial Process Capability Studies48. Packing, Preservation and Labeling Approvals39. FAIR410. Customer SpecificRequirements411. PPAP ApprovalForm (or equivalent)4* Responsibility of design responsible organizationThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev.

10 08-2015)Production Part Approval Process (PPAP)Compile the PPAP PackageSubmit to CustomerDisposition PPAP SubmissionApprovedInterim ApprovalRejectedPPAP Approval Form -9145 Appendix DMaintain the PPAP file throughout PRODUCT lifecycleThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)Aviation Space And Defense APQP & PPAPS ummary 9145 is the internationally harmonized Aerospace standard for APQP and PPAP APQP Principles are keys to success APQP has defined deliverables aligned to each of the 5 phases PPAP approval is the output of APQP APQP and PPAP apply throughout the life of the productThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev. 08-2015)24 ImplementationThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe andthe Asia Pacific Region (Rev.