ADVANCED PRODUCT QUALITY PLANNING ... - SAE …

1 ADVANCED PRODUCT QUALITY PLANNING (APQP) AND PRODUCTION. PART APPROVAL PROCESS (PPAP). JENNIFER COX - SPIRIT AEROSYSTEMS. ELIZABETH WALTERS THE BOEING CO. July 2019. 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 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) 2. APQP and PPAP Webinar Series Design Risk Analysis Webinar Objectives Process Flow Provide high level understanding PPAP.

2 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 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) 3. Introduction to 9145. 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) 4. 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.

3 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 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) 5. 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 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.)

4 08-2015) 6. 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) 7. 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).

5 Based on proven methodology for PRODUCT Development 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) 8. 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) 9. 9145 Benefits from Proactive Approach Non-conformances reduced through PPAP.

6 (actual AS&D example). Work Transfers New PRODUCT Introduction 40 % reduction Defective items per items received 80 % reduction 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016. Program to program comparison Across programs First benefits of APQP can be achieved through PPAP deployment 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) 10. APQP Overview 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) 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 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.)

7 08-2015) 12. 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 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) 13. 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.

8 08-2015) 14. 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 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) 15. 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 &.

9 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 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) 16. 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.

10 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 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) 17. 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 A.