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AS9145 standard - American Society for Quality

AS9145 standardGideon Quality & RegulatoryCabiran (1991) LtdBackground advanced product Quality planning (APQP) is aprocess developed in the late 1980s by acommission of experts gathered around 'Big Three' US automobile industry: Ford, GM and Chrysler. The launch of the first APQP manualwas in June 1994. APQP is a structured method that deploysthe necessary Quality plan that willassure that a product or a servicesatisfies the customer Background In 1982 AIAG (Automotive Industry Action Group) developed Production Part Approval Process (PPAP) to affirm product Quality planning. The first manual on PPAP was published in February 1993. PPAP is a method that verifies that the supplier s production process has the capability toproduce parts at the rate and quantityspecified by the customer and that all thecustomer s engineering design record andspecification requirements are In Automotive industry both techniques are implemented and in use since the 80thof the 20thcentury In Aviation they are in use only in recent years.

• In 2016 a new standardAS9145 Aerospace Series – Requirements for Advanced Product Quality Planning and Production Part Approval Process was released • The standard was developed by a team nominated by IAQG. AS9145 team. Aerospace APQP Model. Introduction From the standard:

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Transcription of AS9145 standard - American Society for Quality

1 AS9145 standardGideon Quality & RegulatoryCabiran (1991) LtdBackground advanced product Quality planning (APQP) is aprocess developed in the late 1980s by acommission of experts gathered around 'Big Three' US automobile industry: Ford, GM and Chrysler. The launch of the first APQP manualwas in June 1994. APQP is a structured method that deploysthe necessary Quality plan that willassure that a product or a servicesatisfies the customer Background In 1982 AIAG (Automotive Industry Action Group) developed Production Part Approval Process (PPAP) to affirm product Quality planning. The first manual on PPAP was published in February 1993. PPAP is a method that verifies that the supplier s production process has the capability toproduce parts at the rate and quantityspecified by the customer and that all thecustomer s engineering design record andspecification requirements are In Automotive industry both techniques are implemented and in use since the 80thof the 20thcentury In Aviation they are in use only in recent years.

2 In 2016 a new standard AS9145 aerospace Series Requirements for advanced product Quality Planning and Production Part Approval Processwas released The standard was developed by a team nominated by IAQG. AS9145 teamAerospace APQP ModelIntroductionFrom the standard : This standard specifies requirements in a structured framework to plan and complete actions of the product realization cycle which are necessary to ensure Quality product (s)are delivered on time, while satisfying costperformance targets. IntroductionFrom the standard : Successful implementation of APQP requires: management commitment and support from the beginning of the product development cycle, multidisciplinary project teams integrating all stakeholders and delivering a committed timeline for executing planned activities.

3 IntroductionFrom the standard : APQP has five phases starting with conceptual product needs and extending throughout the product life cycle. The actual duration of each phase will differ depending upon the scope and timing of the specific product and/or production development project. The APQP phases:APQP phases1 -Planning2 - product Design & Development3 -Process Design & Development4 - product Process Validation5 -ProductionProduct DevelopmentProcessEnd of concept End of designProduct validationProduction readinessKick offABECDAPQP milestonesAPQP 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 Alignment with product Development Process (PDP)Cascade through product Breakdown Structure (PBS)

4 Sub-system levelSystem levelProduct DevelopmentProcessEnd of concept End of designProduct validationProduction readinessKick offComponents level1 -Cascade deliverables and align timing for each level2 -Bottom up status based on on-time on- Quality deliverablesNote: Compressed timeline to support program timing3 -Report APQP status at project levelTypical PBS: system sub-system component1 -Planning2 - product Design & Development3 -Process Design & Development4 - product Process Validation5 -Production1 -Planning2 - product Design & Development3 -Process Design & Development4 - product Process Validation5 -Production1 -Planning2 - product Design & Development3 -Process Design & Development4 - product Process Validation5 -ProductionAPQP 5 Phases 1 Planning: collect project inputs and set the project.

5 2 - product Design & Development: Design the product considering all identified requirements and risks 3 Process Design & Development: Design the manufacturing and assembly process considering all identified requirements and risks 4 Products & Process Validation: Validate that the process is producing the specified product at the required rate 5 Production: Reduce variation, manage any non-conformity, continuous improvement and feed lessons learned back into the new product development projectsPhase 1 PlanningAPQP phases1 -Planning2 - product Design & Development3 -Process Design & Development4 - product Process Validation5 -ProductionProduct DevelopmentProcessEnd of concept End of designProduct validationProduction readinessKick offAPQP milestonesPhase 1 Planning.

6 Activities Collect the technical and non-technical requirements applicable to the product and associated project Develop a Statement of Work (SOW) for the project Define the product and associated project targets Develop the product breakdown structure [ , high-level Bill of Material (BOM)] to support source selection Coordinate and communicate timing with all applicable stakeholders Schedule all key dates and deliverables in the project planPhase 1 Planning: Deliverables product design requirements Project targets safety, Quality /manufacturability, service life, reliability, durability, maintainability, schedule, and cost Preliminary listing of Critical Items (CIs) and Key Characteristics (KCs) Preliminary BOM Preliminary process flow diagram SOW review Preliminary sourcing plan Project planPhase 1 Planning: Outputs The product concept is frozen (milestone A) and a pre-design is available Concurrent product design and process design can start Phase 1 Planning: ChecklistsIn the IAQG/SCMHyou will find the following checklists.

7 Project Inputs Technical Design Requirements Reliability & Quality goals Preliminary Listings of Critical Items & KC product Specification Preliminary BOM Preliminary Process Flow Chart Statement of Work Review Sub-tier Selection & Management APQP TimelinePhase 1 Planning: Checklistexample#QuestionY*NN/ARYG1 Was a a cross-functional team used to gather project inputs including the following as applicable: Program Management, Quality , Design Engineering, Manufacturing Engineering, Marketing and Sales, Procurement?2 Are applicable regulatory requirements available?3 Are customer requirements available including:Project milestones and product delivery date Projected volumes Project lifecycleProduct and process assumptions4 Are all internal data to build product performance expectations available including: Historical problems internal and external Warranty Reliability requirements Quality requirements Technical Requriements5 Have lesson learned been conducted including: Best Practices Project management Quality issues product design guidelines Process design guidelines 6Is the company strategy available including.

8 Business plan Marketing strategy Industrial strategy Technical strategy7 Have the resulting project/ product requirements been referenced/recorded into a repository, including supporting data?Data is made available to be used by the project team?8Is there a process to keep formal requirements document up-to-date?9 Has (Have) any potential risk(s) not highlighted by previous question been identified? If no, describe this risks?1011X25%N/AIP50%Status (%):25% - Action Identified 50% - Owner Identified75% - Action in Progress 100% - Action Closed75%R100%YGDeliverable RYG RatingRed: Some questions have a negative answer and no recovery plan is in place or the plans identified will have an impact in program timing.

9 Support is required. When an item is highlighted Red an assessment on the impact to the WP timing needs to be : Some questions have a negative answer but a recovery plan is in place which will prevent impact on timingGreen: All questions have a positive answer (Y) and are ongoing normal program developmentEvidenceActions RequiredTable 1 Questions Marking Evidence Rating The following slides show the principle of the SCMH phase has it s own checklistsPhase 1 Planning: Checklistexample questions sectionTable 1 QuestionY*Was a a cross-functional team used to gather project inputs including the following as applicable: Program Management, Quality , Design Engineering, Manufacturing Engineering, Marketing and Sales, Procurement?

10 Are applicable regulatory requirements available?Are customer requirements available including:Project milestones and product delivery date Projected volumes Project lifecycleProduct and process assumptionsAre all internal data to build product performance expectations available including: Historical problems internal and external Warranty Reliability requirements Quality requirements Technical RequriementsHave lesson learned been conducted including: Best Practices Project management Quality issues product design guidelines Process design guidelines Is the company strategy available including: Business plan Marketing strategy Industrial strategy Technical strategyHave the resulting project/ product requirements been referenced/recorded into a repository, including supporting data?