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Aerospace Advanced Product Quality Planning

(Aerospace APQP)

Introduction

Date: April 2014


www.iaqg.org/scmh Section 7.2
Purpose of this document

The purpose of this document is to


provide the key messages introduced in
the Aerospace APQP guidance material.
This document can be used as a base for
communication sessions as well as a
tutorial on Aerospace APQP.

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Document structure

Structure for Aerospace APQP guidance material content:


1. Definition and Benefits
2. Aerospace APQP Model - Pillars
A. Organizational commitment & Management support
B. Cross functional team
C. Effective project planning
3. Aerospace APQP model - Principles
A. Product oriented
B. Structure
1. Phases
2. Elements
3. Deliverables
C. Checklist
D. Production Part Approval Process (PPAP)
4. Implementation and customization
A. Assessments/ratings
B. Reporting
C. Escalation

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Background

• 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

• 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
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Purpose of APQP

• Aerospace APQP is a structured method to guarantee the


necessary steps are taken to assure new products satisfy
customer needs and wants
• Aerospace APQP, as part of project management, provides
effective early warning to support on-time and on-quality delivery
of the product by monitoring key deliverables critical to quality
• Aerospace APQP drives a cross functional
approach to product development Aerospace APQP
avoiding the creation of functional silos Program
Needs
• Aerospace APQP implementation drives a Phases

proactive and preventative mindset Elements

Deliverables

PPAP

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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

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

Cross Functional

Effective Project
Commitment &
Organizational

Management

Planning
Support

Team

APQP PRINCIPLES

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Aerospace APQP main pillars

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

Full engagement and commitment of top management from project


launch is key.

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

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

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Aerospace APQP main pillars

Effective planning includes flow down of timing


requirements throughout the value stream xx Q
Representative

Deliverables
Deliverable Deliverable Deliverable Deliverable
Owner Owner Owner Owner

1 - Planning 5 - Production
Customer 4 - Product Process
2 - Product Design & Development
APQP Validation

3 - Process Design & Development


timeline

1 - Planning 5 - Production

Supplier 2 - Product Design & Development


4 - Product Process
Validation

APQP 3 - Process Design & Development

timeline
xx Q
Representative

Deliverables
Deliverable Deliverable Deliverable Deliverable
Owner Owner Owner Owner

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Aerospace APQP model

5 PHASES
Aerospace APQP
Program Phases
Needs
Phases ELEMENTS
DEFINING
Elements Elements ACTIVITIES

Deliverables

PPAP Aerospace APQP KEY


Deliverables DELIVERABLES

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Aerospace APQP model

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

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Aerospace APQP model aligns
with PDP
Alignment with Product Development Process (PDP)

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
End of End of Production Product
Kick off design readiness validation
concept

Product Development
Process

APQP phases
1 - Planning D 5 - Production
A
E
4 - Product Process
2 - Product Design & Development B
Validation

3 - Process Design & Development


C

APQP milestones

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Aerospace APQP model

Cascade through Product Breakdown Structure (PBS)


3 - Report APQP
status at project level
End of End of Production Product
Kick off design readiness validation
concept

Product Development
Process

System level 1 - Planning 5 - Production

4 - Product Process
2 - Product Design & Development
Validation

3 - Process Design & Development

Sub-system level 1 - Planning 5 - Production

4 - Product Process
2 - Product Design & Development
Validation

3 - Process Design & Development

Components level 1 - Planning

2 - Product Design & Development


5 - Production

4 - Product Process
Validation

3 - Process Design & Development

1 - Cascade Note: Compressed timeline


deliverables and align to support program timing
timing for each level
2 - Bottom up status based
Typical PBS: on on-time on-quality
system→ sub-system→ component deliverables
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APQP Principles
Phases
Elements
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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Aerospace APQP principles

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

Any design changes after this phase requires change management

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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 service
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Aerospace APQP principles:
phase alignment

A B C D E

Production readiness assessment

Start of production and FAI


Product Design Verified
Product concept frozen

1- 5 - Production

PPAP approval
Planning
2 - Product Design & 4 - Product
Development Process
Validation

3 - Process Design & Development

Development products PPAP run Production


Prototypes products
Parts must be 100% certified

Key milestones APQP phases


Parts status
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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
Phases

Elements

Deliverables

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Aerospace APQP principles

Elements
1 - Planning 5 - Production

4 - Product Process
2 - Product Design & Development
Validation

3 - Process Design & Development

Phase 1 – Planning
1.01 Project Inputs 1.06 Preliminary Bill of Material
1.02 Technical Design Requirements 1.07 Preliminary Process Flow Chart
1.03 Reliability & Quality goals 1.08 Statement of Work Review
1.04 Preliminary Listing of Critical Items & 1.09 Sub-tier Selection and Management Plan
Key Characteristics 1.10 APQP Timeline
1.05 Product Specification

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Aerospace APQP principles

Elements
1 - Planning 5 - Production

4 - Product Process
2 - Product Design & Development
Validation

3 - Process Design & Development

Phase 2 – Product design and development


2.01 Design Failure Mode Effects Analysis 2.03 Design Reviews
2.02.1 Design for Manufacture and Assembly 2.04 Development Product/ Part Build Plan
2.02.2 Design for Maintenance, Repair & 2.05 Design Verification and Validation
Overhaul 2.06 Team Feasibility Commitment and
2.02.3 Product Key Characteristics Management Support
2.02.4 New Packaging Specification

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Aerospace APQP principles

Elements
1 - Planning 5 - Production

4 - Product Process
2 - Product Design & Development
Validation

3 - Process Design & Development

Phase 3 – Process design and development


3.01 Process Flow Chart 3.06 Process Key Characteristics
3.02 Floor Plan Layout 3.07 Pre-Launch Control Plan
3.03 Production Preparation Planning 3.08 Measurement Systems Analysis Plan
3.04 Operator Staffing and Training Plan 3.09 Manufacturing Process Documentation
3.05 Process Failure Modes and Effects 3.10 Supply Chain Risk Management
Analysis 3.11 Production Readiness Review

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Aerospace APQP principles

Elements
1 - Planning 5 - Production

4 - Product Process
2 - Product Design & Development
Validation

3 - Process Design & Development

Phase 4 – Product and process validation


4.01 Significant Production Run 4.06 Capacity Verification
4.02 Measurement System Analysis 4.07 Product Validation Testing
4.03 Preliminary Process Capability Study 4.08 First Article Inspection
4.04 Packaging Evaluation 4.09 Production Part Approval Process (PPAP)
4.05 Production Control Plan

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Aerospace APQP principles

Elements
1 - Planning 5 - Production

4 - Product Process
2 - Product Design & Development
Validation

3 - Process Design & Development

Phase 5 – Production
5.01 Variation Reduction (Preventive Action) 5.04 On-time delivery and Capacity Assurance
5.02 Product Quality Assurance 5.05 Maintenance Repair and Overhaul
(Corrective Action) 5.06 Lessons Learned
5.03 Product Improvement

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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.)

Phases

Elements

Deliverables

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Aerospace APQP principles

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
Phases

Elements

Deliverables
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Aerospace APQP key milestones

Production Part Approval Process (PPAP)

PPAP is an Aerospace APQP element of phase 4 finalizing


product and process validation. PPAP combines First Article
Inspection and process qualification.

The purpose of PPAP is to demonstrate that the production


process is consistently capable of producing product that
meets customer requirements at the intended production
rate.

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Aerospace APQP key milestones

Production Part Approval Process (PPAP)


Key aspects
• Follows successful completion of the first 4 phases
Aerospace APQP
• Defines the standard deliverables for production part
approval
• Products that will be used for PPAP are from the significant
production run
• All applicable PPAP elements must be updated by the
producer any time the process or the product are changed
• Resubmission may be required by the customer
• FAI (9102) part approval, is the first step of PPAP
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Implementation
and
Customization

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Aerospace APQP deployment

Identify product (new or APQP is applied to all new or modified products as


modified) well as existing products in new applications and
those with repetitive performance issues

Nominate team Identify project leader, APQP leader and task owners

Check element applicability Identify Aerospace APQP element applicability based


on initial risk assessment

Identify the product Breakdown the product into manageable sub-


breakdown and create SOW components and formalize in a Statement Of Work
(SOW)

Decide make or buy Identify what will be made in-house and what will be
outsourced

Cascade requirements to Cascade timing, quality and technical requirements to


producer all producers (internal/external)

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Aerospace APQP Process

Update APQP element Evaluate risk for the project considering product technical content,
applicability process requirements, lesson learnt and product criticality and
supplier capabilities

Update Statement of Work Get supplier feedback and agree on work to be done

Agree on assesment timing Adjust APQP monitoring based on risk (frequency of assessment)
based on risks or issues and Aerospace APQP timeline needs to be agreed between all team
create APQP timeline
members (internal and external if any)

Perform assessment based on agreed frequency and checklist.


Perform assessments based
on deliverables checklists Record results on check sheets. Evaluate element status Red
Yellow Green

Escalate issues and get Consolidate reports combining element status and sub-components
management feedback and
support status. Escalate issues on a timely manner

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Aerospace APQP reporting

• Regularly assess deliverables


• Apply Red/Yellow/Green (RYG) ratings to each deliverable considering:
• On-quality according to checklist criteria
• On-time according to APQP timing

Red:
Whenever a question cannot be answered with a clear yes, the deliverable owner
should provide an action to recover on-time and on-quality. When an action plan
cannot be provided or is not able to recover initial product timing, a red should be
raised: IMPACT TO THE FINAL PRODUCT DELIVERY SCHEDULE
Yellow:
Yellows are highlighted when the answer to the question is no, but there is a robust
action plan to recover situation: THERE IS NO IMPACT TO THE PRODUCT
DELIVERY SCHEDULE

Green:
All questions have a positive answer (Y) and are ongoing as planned

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Aerospace APQP Reports

Reporting
Report APQP status
at project level
Product Aircraft / Program

• Assessments are compiled and


subsequently reported through
System the project layers
• Impact of Red/Yellow status are

Escalation
Sub-system evaluated from bottom up
• Top layer reviews impact on
Component overall project and enables
necessary actions to ensure on-
time delivery

Bottom up status based


on on-time & on-quality
deliverables
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