Sharing In Growth Teach Point

AS9145 – APQP & PPAP

Awareness & Overview

Copyright © 2013-2020 Sharing in Growth

What is APQP & PPAP?

AS9145

Inputs Processes Outputs

Program Needs Advanced Production

Product Part
Quality Approval
Planning Process
APQP PPAP

• Structured methodology with defined outputs to ensure new products

satisfy customer needs and wants

• Uses project management to drive delivery and quality performance to

targets

• Proactive and preventative approach through cross functional

collaboration.
Why Use APQP?

Discuss the benefits of using APQP

Safety: Proactively seeks to identify and mitigate risks to product and process safety

Quality: Concerned with building quality into product and process designs; Provides a toolset
and culture to achieve Zero Defects

Delivery: Drives on-time delivery of initial parts and ensures ongoing rate capability

Cost: Avoids the high costs associated with problems occurring during initial volume production

People: Uses a cross-functional team to capitalise on available skills, knowledge & experience

Discuss the reasons for applying APQP in your own areas

AS9145: The Standard

AEROSPACE AS9145
STANDARD
Issued 2016-11

Technically equivalent writings published in

IAQG sectors.

Aerospace Series – Requirements for Advanced Product Quality

Planning and Production Part Approval Process

RATIONAL
E
This standard was created to define the aviation, space and defence process requirements for Advanced Product Quality Planning (APQP) and
Productions Part Approval Process (PPAP). The APQP aspects of this standard define a methodology for ensuring that the product development
processes deployed throughout the aviation, space and defence industries are fully integrated phased processes that extend from concept and deign
through manufacturing process planning and execution and on into product use, service and customer feedback. The PPAP is an output of APQP
confirming that the production process had demonstrated the potential to produce products that consistently fulfil all requirements at the customer
demand rate.

The IAQG created a multi-member group to author AS9145. The standard is

issued under the authority of SAE international, as per all AS standards.
Associated Standards

The processes and supporting activities for achieving APQP and PPAP
should be embedded in the organisation’s quality management system to
ensure:

• The process is documented & controlled

• Documents are treated as quality records
• The process is subject to audits

• AS13003 Measurement Systems Analysis (MSA)

• AS13004 Process Failure Mode & Effects Analysis (PFMEA) and Control Plans
• AS9100 Requirements for Aviation, Space & Defence Organisations
• AS9102 Aerospace First Article Inspection Requirement
• AS9103 Variation Management of Key Characteristics
• AS9110 Requirements for Maintenance Organisations.
APQP Phases

Preliminary Critical
Design Design
Review Review
Initial Production
End of Concept Design Release Approval Production
Kick off
(PDR) (CDP) Launch

Product Development Process

(PDP)

1. Planning 5. On-going Production, Use and

Post-delivery Service
Phases of Advanced
Product Quality Planning 4. Product & Process
2. Product Design and Development
Validation
(APQP)
3. Process Design and Development

Production
Key Production Part FAIR PPAP Approval
Readiness
Approval Process (PPAP) Review
Production
Events Process Run

Product Status Prototype / test product

Production trial
Production products
products

Discuss: how does your gated NPI process fit around this?
APQP Phase 1: Planning

Purpose

• Compile customer inputs. Benchmark data, lessons learnt, regulatory requirements, technical specifications, company
know-how and strategy into product concept and realisation plan.
• Identify high level technical, quality and costs targets.

Objectives

• The Product concept is finalised and a pre-design is available.

Outcomes

• Product design requirements

• Project targets
• Preliminary listing of critical items and key characteristics
• Preliminary BoM
• Preliminary process flow diagram
• Statement of work
• Preliminary sourcing plan
• Project plan
APQP Phase 2: Product Design & Development

Purpose

• Translate technical, quality and cost requirements into a controlled, verified and validated product design

Objectives

• Generate design record and BoM

• Generate design verification and validation plans

Outcomes
1. Design records and BoM
2. Design risk analysis (DFMEA)
• Design for Manufacture and Assembly (DFMA) study outputs
• Design for Maintenance, Repair and Overhaul (DMRO) study outputs
• Listings of critical items and key characteristics
• Preliminary risk analysis of sourcing plans
• Packaging specification
• Design review report
• Development part production plan
• Design verification and validation plans
• Feasibility assessment
APQP Phase 3: Process Design & Development

Purpose

• Design and develop the production processes needed to produce a product that consistently fulfil technical, quality and
cost requirements while operating at the customer demand rate

Objectives

• Production process designed and deployed

• Successful completion of the Production Readiness Review (PRR)

Outcomes
• MSA plan
3. Process flow diagram • Supply chain risk management plan
• Floor plan layout 6. Material handling, packaging, labelling and part
• Production preparation plan marking approvals
• Operator recruitment and training plan • PRR results
4. PFMEA
• Process key characteristics identified
• Pre-production control plan
• Preliminary capacity assessment
• Work station documentation
APQP Phase 4: Product & Process Validation

Purpose

• Validate that the product fulfils design requirements and that defined product processes have demonstrated capability to
achieve quality and rate

Objectives

• Approved FAIR
• Approved PPAP

Outcomes

• Product from production processes

5. Control plan
7. Documented MSA studies
8. Initial process capability studies
• Capacity verification
• Product validation results
9. FAIR
10. Customer specific PPAP requirements
11. PPAP file and approval form
APQP Phase 5: On-going Production, Use &
Post-delivery Service

Purpose

• Ensure that customer requirements are continually fulfilled through process control, lessons learnt and continuous
improvement.

Objectives

• Project closure

Outcomes

• Process capability and product quality indices (DPPM, Cpk, etc.)

• KPIs reflecting product quality and reliability
• Evidence that project targets have been fulfilled
• On time delivery and capacity KPIs
• MRO KPIs and actions to close gaps is applicable
• Project closure recommendations
• Continuous improvement action log
• Lessons learnt log
• Updated DFMEA, PFMEA and control plan documents
The Benefits of APQP

Without APQP

• Low initial resource • Late

• Differing approaches • Wasted resource
• Limited team involvement • Over budget
• Wait for problems to emerge • Customer dissatisfaction

With APQP

• High initial resource • On time

• Standardised approach • Lean resource management
• Cross-functional team involvement • On budget
• Proactive risk identification and mitigation • Customer satisfaction

Concerns found without

APQP

Concerns found with APQP

Cost of design change

Time Product Launch

 PPAP Elements

AS9145 Defined PPAP Elements Aero Engine Manufacturer PPAP Elements

1. Design records 1. Product Definition / Engineering Specification
2. Authorised Engineering Change Documents
3. Customer Engineering Approvals
2. Design Risk analysis (e.g DFMEA) 4. Design Failure Modes & Effects Analysis (DFMEA)
3. Process Flow Diagram 5. Process Flow Diagram
4. Process Failure Modes & Effects Analysis (PFMEA) 6. Process Failure Modes & Effects Analysis (PFMEA)
5. Control Plan 7. Control Plan

APQP PROCESS
8. Test / Inspection Criteria & Planning
9. Qualified Laboratory Documentation
6. Packaging, Preservation & Labelling Approvals 10. Packaging & Labelling Standards & Documentation
11. Sample Production Permit
7. Measurement Systems Analysis (MSA) 12. Measurement Systems Analysis (MSA) Studies
13. Dimensional Results
14. Records of Material / Performance Test Results
8. Initial Process Capability Studies 15. Initial Process Studies
16. Process Control Surveillance results
17. Initial Manufacturing Performance Studies
9. First Article Inspection Report (FAIR) 18. Customer Specific Requirements
10. Customer PPAP Requirements 19. First Article Inspection Report (FAIR)
20. Process Control Document (PCD)
11. PPAP Approval Form or equivalent 21. Production Submission Warrant (PSW)

Although specific PPAP requirements vary by customer, the standard AS9145 elements will always feature.

Discuss: does anything need adding to your NPI process to achieve PPAP?
 Who?

The team members involved will differ, dependant on manufacturing or transactional processes and involve:

• Project leader / manager to ensure process adherence

• Cross-functional team – that understands APQP phases and PPAP requirements
• PPAP co-ordinator
• Customer Authorised Representative (CARe) for PPAP

Team Scope of involvement

• Procurement CEO level
• Engineering SMT
• Quality Team Leads
• Logistics Operators
• Manufacturing
Summary

APQP is logical stepped process that:

• Appropriately resources the early phases of projects with cross functional teams to ensure quality, delivery and
budgetary targets are achieved
• Proactively identifies and mitigates risks to products and processes
• Ensures PPAP requirements are met
• Provides a base level of requirements for the organisation to build upon
• Provides a toolset and culture to achieve Zero Defects
• Has phases which can co-exist with and compliment a gated product introduction process

Gate Gate Gate Gate Gate

Achieving ‘efficient’ maturity for SiG product introduction lighthouse ensures APQP and PPAP capability.