Aerospace Advanced Product Quality Planning (Aerospace APQP) Introduction

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
C. Escalation
Page 4
Refer to the SCMH for more information
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
Management commitment
Integrated cross-functional teams
Effective project management
Defined deliverables & outputs
for each phase
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Aerospace APQP
Program
Needs
Phases
Elements
Deliverables
PPAP
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
APQP PRINCIPLES
Page 8
Effective Project
Planning
Cross Functional
Team
Organizational
Commitment &
Management
Support
On-Time, On-Quality, Shorter lead times
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 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
Owner
Customer
APQP
timeline
Deliverable
Owner
Deliverable
Owner
Deliverable
Owner
1 - Planning
5 - Production
4 - Product Process
Validation
2 - Product Design & Development
3 - Process Design & Development
1 - Planning
Supplier
APQP
timeline
5 - Production
4 - Product Process
Validation
2 - Product Design & Development
3 - Process Design & Development
xx Q
Representative
Deliverables
Deliverable
Owner
Page 12
Deliverable
Owner
Deliverable
Owner
Deliverable
Owner
Aerospace APQP model
5 PHASES
Aerospace APQP
Phases
Program
Needs
Elements
ELEMENTS
DEFINING
ACTIVITIES
Aerospace APQP
Deliverables
KEY
DELIVERABLES
Phases
Elements
Deliverables
PPAP
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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
Kick off
End of
concept
End of Production
design readiness
Product
validation
Product Development
Process
APQP phases
1 - Planning
D
A
4 - Product Process
Validation
2 - Product Design & Development B
3 - Process Design & Development
C
APQP milestones
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5 - Production
E
Aerospace APQP model
Cascade through Product Breakdown Structure (PBS)
3 - Report APQP
status at project level
Kick off
End of
design
End of
concept
Production
readiness
Product
validation
Product Development
Process
System level
1 - Planning
5 - Production
4 - Product Process
Validation
2 - Product Design & Development
3 - Process Design & Development
Sub-system level
1 - Planning
5 - Production
4 - Product Process
Validation
2 - Product Design & Development
3 - Process Design & Development
Components level
1 - Planning
5 - Production
2 - Product Design & Development
4 - Product Process
Validation
3 - Process Design & Development
1 - Cascade
deliverables and align
timing for each level
Typical PBS:
system→ sub-system→ component
Page 16
Note: Compressed timeline
to support program timing
2 - Bottom up status based
on on-time on-quality
deliverables
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.
2.
3.
4.
5.
Page 18
Planning
Product design and development
Process design and development
Product and process validation
Production
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
Elements
• Describes key activities accomplished during each
Aerospace APQP phase
• Assure the health of the project through monitoring ontime,on-quality key deliverables
• Encourages a standardized approach
• Applicability evaluated for each project
Phases
Elements
Deliverables
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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.)
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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
Description:
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
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
but still has not reached completion
#
Question
1
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?
2
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
Definition , Value Stream Mapping Analysis, Inbound /
Outbound Logistics Flow, H&S and environmental
rules, Plant Lay Out Blue Print and plan, existing
facility utilities …)?
3
Have Material Flow, Storage and Buffer areas been
considered when defining the plant (facility) lay out?
4
Have People Flow (e.g., spaghetti charts) been
considered when defining the lay out?
5
Is the floor layout optimised to remove waste
(overproduction, movement, inventory, waiting,
overprocessing, rework and transportation) from the
process?
6
Have H&S and ergonomics, environmental and
Facilities requirements been validated in the
proposed lay out?
7
Is plant (facility) lay out implementation plan and its
readiness in line with program schedule?
8
Have Capital expenditure targets been considered by
the lay out? Has Capital Expenditure been approved?
9
Is the floor plan layout up-to-date and managed in
configuration? Is it consistent with the latest process
flow chart?
Y*
N
N/A
RAG
Evidences
Note: If planned review is delaid by more than two weeks item to be highlighted
as RED and escalated.
Actions Required
Responsible
Open
Date
12
13
14
15
N/A
X
CTQ RAG Rating
25%
Location: / Site:
R
Status (%):
25% - Action Identified
75% - Action in Progress
50% - Owner Identified
100% - Action Closed
Actual End
Date
Phases
Deliverables
11
Page 27
Status
%
Elements
Have all potential risks affecting the CTQ been
identified?
10
Due
Date
A
G
Red: Some questions have a negative answer and no recovery plan is in place or the plans
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.
Amber: Some questions have a negative answer but a recovery plan is in place which will
prevent
impact
on timing
Green: All
questions
have a positive answer (Y) and are ongoing normal program
development
Rewiewed by:
Reviewed with:
Date :
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
Linkage of DFMEA  PFMEA Control Plan
Process Capability validation
Product verification (FAI)
Process Validation
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Aerospace APQP
Program
Needs
Phases
Elements
Deliverables
PPAP
Summary
• Advance Product Quality Planning (APQP) is taking
hold in the Aerospace Industry
• APQP ensures the delivery of product on-time, onquality, 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
Elements
• More information on this topic will be
available in November 2013
Deliverables
Phases
PPAP
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