Professional Documents
Culture Documents
(Aerospace APQP)
Introduction
Page 2
Document structure
Page 3
Background
Deliverables
PPAP
Page 5
Benefits
Page 6
Aerospace APQP Model
Customer Satisfaction
On-Time, On-Quality, Shorter lead times
Cross Functional
Effective Project
Commitment &
Organizational
Management
Planning
Support
Team
APQP PRINCIPLES
Page 7
Aerospace APQP main pillars
Page 8
Aerospace APQP main pillars
Page 9
Aerospace APQP main pillars
Page 10
Aerospace APQP main pillars
Deliverables
Deliverable Deliverable Deliverable Deliverable
Owner Owner Owner Owner
1 - Planning 5 - Production
Customer 4 - Product Process
2 - Product Design & Development
APQP Validation
1 - Planning 5 - Production
timeline
xx Q
Representative
Deliverables
Deliverable Deliverable Deliverable Deliverable
Owner Owner Owner Owner
Page 11
Aerospace APQP model
5 PHASES
Aerospace APQP
Program Phases
Needs
Phases ELEMENTS
DEFINING
Elements Elements ACTIVITIES
Deliverables
Page 12
Aerospace APQP model
Page 13
Aerospace APQP model aligns
with PDP
Alignment with Product Development Process (PDP)
Product Development
Process
APQP phases
1 - Planning D 5 - Production
A
E
4 - Product Process
2 - Product Design & Development B
Validation
APQP milestones
Page 14
Aerospace APQP model
Product Development
Process
4 - Product Process
2 - Product Design & Development
Validation
4 - Product Process
2 - Product Design & Development
Validation
4 - Product Process
Validation
Page 16
Aerospace APQP principles
Page 17
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
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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Aerospace APQP principles
Output
• The process is defined, established, verified (production readiness
review - milestone C) and ready for validation.
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Aerospace APQP principles
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Aerospace APQP principles
Page 22
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
Page 23
Aerospace APQP principles:
phase alignment
A B C D E
1- 5 - Production
PPAP approval
Planning
2 - Product Design & 4 - Product
Development Process
Validation
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
Page 25
Aerospace APQP principles
Elements
1 - Planning 5 - Production
4 - Product Process
2 - Product Design & Development
Validation
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
Page 27
Aerospace APQP principles
Elements
1 - Planning 5 - Production
4 - Product Process
2 - Product Design & Development
Validation
Page 28
Aerospace APQP principles
Elements
1 - Planning 5 - Production
4 - Product Process
2 - Product Design & Development
Validation
Page 29
Aerospace APQP principles
Elements
1 - Planning 5 - Production
4 - Product Process
2 - Product Design & Development
Validation
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
Page 31
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
Page 32
Aerospace APQP key milestones
Page 33
Aerospace APQP key milestones
Page 35
Aerospace APQP deployment
Nominate team Identify project leader, APQP leader and task owners
Decide make or buy Identify what will be made in-house and what will be
outsourced
Page 36 A
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)
Escalate issues and get Consolidate reports combining element status and sub-components
management feedback and
support status. Escalate issues on a timely manner
Page 37
Aerospace APQP reporting
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
Page 38
Aerospace APQP Reports
Reporting
Report APQP status
at project level
Product Aircraft / Program
Escalation
Sub-system evaluated from bottom up
• Top layer reviews impact on
Component overall project and enables
necessary actions to ensure on-
time delivery