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 )www.iaqg.org/scmh Page 2 Purpose Hint: Google: iaqg scmh and then Bookmark it!
Supply Chain Management Handbook (SCMH) Page 3 The APQP material is located in Chapter 8.4 APQP Introduction
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 Page 5
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 20 th Century. - GM, Ford & Chrysler published the first combined APQP manual for the automotive industry in June 1994 Page 6 Background 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
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 Page 8 Customer Satisfaction On-Time, On-Quality, Shorter lead times Customer Satisfaction On-Time, On-Quality, Shorter lead times Organizational Commitment & Management Support Cross Functional Team Cross Functional Team Effective Project Planning APQP PRINCIPLES
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 Page 9 Full engagement and commitment of top management from project launch is key. 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 Page 10 Cross functional team approach ensures effective communication across the business & enables faster product development. 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 Page 11 Aerospace APQP main pillars Commitment of the project team to Aerospace APQP planning is key to the project success. is key to the project success.
Effective planning includes flow down of timing requirements throughout the value stream Page 12 Customer APQP timeline xxQ Representative Deliverable Owner Deliverable Owner Deliverable Owner Deliverable Owner Deliverables xxQ Representative Deliverable Owner Deliverable Owner Deliverable Owner Deliverable Owner Deliverables Supplier APQP timeline Aerospace APQP main pillars
Aerospace APQP model Page 13 5 PHASES ELEMENTS DEFINING ACTIVITIES KEY DELIVERABLESPhasesElements Aerospace APQP Deliverables
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 Aerospace APQP model Page 14
APQP phases Product Development Process Aerospace APQP model aligns with PDP Page 15 End of concept End of design Product validation Production readiness 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 A B E C D APQP milestones Alignment with Product Development Process (PDP)
Sub-system level System level Product Development Process Cascade through Product Breakdown Structure (PBS) Page 16 End of concept End of design Product validation Production readiness Kick off Components level 1 - Cascade deliverables and align timing for each level 2 - Bottom up status based on on-time on-quality deliverables Note: Compressed timeline to support program timing 3 - Report APQP status at project level Typical PBS: system sub-system component Aerospace APQP model
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
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 Page 20 Any design changes after this phase requires change management 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 Page 25PhasesElements Deliverables
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 Element Descriptions coming soon!
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 Page 27PhasesElements Deliverables Aerospace APQP principles Checklists coming soon!
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 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 The full APQP Introduction presentation is available in Chapter 8.4 of the SCMH More information on this topic will be available in November 2013 Page 29