Aerospace Advanced Product

Quality Planning
(Aerospace APQP)

Introduction

October 2013

1
 Purpose

The purpose of this presentation is to introduce

Advanced Product Quality Planning to Aerospace
Suppliers

Note: The full APQP Introduction presentation is available to the public on

the IAQG SCMH website (www.iaqg.org/scmh)

Hint: Google: iaqg scmh and then Bookmark it!

Page 2
Supply Chain Management Handbook (SCMH)

The APQP material is

located in Chapter 8.4

www.iaqg.org/scmh

APQP Introduction
Page 3
 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
Refer to the SCMH for more information
C. Escalation

Page 4
 What is APQP?

APQP is a structured method that deploys the necessary

steps to assure that a product satisfies the customer
5-Phase Quality Planning Cycle (PDCA)
Up-front planning (First 3 phases)
Implementation (Last 2 phases)
Success Drivers
Aerospace APQP
Management commitment
Program
Needs
Integrated cross-functional teams Phases

Effective project management Elements

Defined deliverables & outputs Deliverables

for each phase PPAP

Page 5
 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
Page 6
 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

Page 7
 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 8
 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.

Page 9
 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 business & enables faster product development.

Page 10
 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.

Page 11
 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

Page 12
 Aerospace APQP model

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

Deliverables

PPAP Aerospace APQP KEY

Deliverables DELIVERABLES

Page 13
 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

Page 14
 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

Page 15
 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
Page 16
 APQP Principles
Phases
Elements
Deliverables

Page 17
 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

Page 18
 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
Page 19
 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

Page 20
 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.

Page 21
 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

Page 22
 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

Page 23
 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 24
 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

Page 25
 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.)

Page 26
 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
The floor plan layout should be developed to clearly show the position and layout for all processes to be covered by the control plan.
The plan should identify each process which affects the quality characteristics of the part.
Synchronous material flow and floor usage optimisation should be taken into account when performing the lay out in an effort to
Description: economise space usage increasing the value added of floor space and minimising the travel and handling of materials, parts and
assemblies following lean principles. Value Stream Mapping (VSM) and Spaghetti diagram techniques can be used in support of this.
Deliverable is a plant layout plan approved by the Production manager and the Quality Manager.

Deliverables:
* In the Y column use IP (In progress) when the CTQ is progressing as planned Note: If planned review is delaid by more than two weeks item to be highlighted
but still has not reached completion as RED and escalated.
Open Due Status Actual End
#

1
Question
Was the Floor plan layout created by a cross
functional team including Process Engineering,
Production Manager, Quality, Facilities Management,
Maintenace and Health, Safety & Environment
Representatives?
Y* N N/A RAG Evidences Actions Required Responsible Date Date % Date

Phases
Have all the necessary inputs, in the development of
the plant lay out, been taken into account and they
are frozen at the right stage (e.g., Build Process
2 Definition , Value Stream Mapping Analysis, Inbound /
Outbound Logistics Flow, H&S and environmental
rules, Plant Lay Out Blue Print and plan, existing

Elements
facility utilities )?

Have Material Flow, Storage and Buffer areas been

3 considered when defining the plant (facility) lay out?

Have People Flow (e.g., spaghetti charts) been

4 considered when defining the lay out?

Is the floor layout optimised to remove waste

(overproduction, movement, inventory, waiting,
5 overprocessing, rework and transportation) from the
process?

Have H&S and ergonomics, environmental and

6 Facilities requirements been validated in the
proposed lay out?

Is plant (facility) lay out implementation plan and its

7 readiness in line with program schedule?

Have Capital expenditure targets been considered by

8 the lay out? Has Capital Expenditure been approved?

Deliverables
Is the floor plan layout up-to-date and managed in
9 configuration? Is it consistent with the latest process
flow chart?
Have all potential risks affecting the CTQ been
10 identified?

11

12
13
14
15

Page 27 X
25%
N/A CTQ RAG Rating

Red: Some questions have a negative answer and no recovery plan is in place or the plans
Location: / Site:

Status (%): 25% - Action Identified
75% - Action in Progress
R identified will have an impact in program timing. Support is required. When an item is
highlighted Red an assessment on the impact to the WP timing needs to be provided. Rewiewed by:
50% - Owner Identified A Amber: Some questions have a negative answer but a recovery plan is in place which will Reviewed with:
100% - Action Closed G prevent impact
Green: All on timing
questions have a positive answer (Y) and are ongoing normal program Date :
development
 Aerospace APQP key milestones

Production Part Approval Process (PPAP)

PPAP validates that the manufacturing process has the
potential to produce product that consistently meets all
requirements at the intended production rate.
Success Drivers
Completion of key requirements at the right time during
planning process (PPAP is an output of APQP)
Risk mitigation and improved process control
Aerospace APQP
Linkage of DFMEA PFMEA Control Plan Program
Needs
Process Capability validation Phases

Elements

Product verification (FAI) Deliverables

Process Validation
PPAP
Page 28
Summary
Advance Product Quality Planning (APQP) is taking
hold in the Aerospace Industry
APQP ensures the delivery of product on-time, on-
quality, on cost
PPAP validates the production process Aerospace APQP

The full APQP Introduction presentation Program

Needs
is available in Chapter 8.4 of the SCMH Phases

More information on this topic will be Elements

available in November 2013 Deliverables

PPAP

Page 29