1. Aerospace Advanced Product Quality Planning (Aerospace APQP) Introduction
October 2013 1

2. 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 (
Hint: Google: “iaqg scmh” and then Bookmark it!

3. Supply Chain Management Handbook (SCMH)
The APQP material is located in Chapter 8.4
APQP Introduction

4. Document structure
Structure for Aerospace APQP guidance material content:
Definition and Benefits
Aerospace APQP Model - Pillars
Organizational commitment & Management support
Cross functional team
Effective project planning
Aerospace APQP model - Principles
Product oriented
Structure
Phases
Elements
Deliverables
Checklist
Production Part Approval Process (PPAP)
Implementation and customization
Assessments/ratings
Reporting
Escalation
Refer to the SCMH for more information

5. What is APQP? 5-Phase Quality Planning Cycle (PDCA)
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

6. 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

7. 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
These steps will be summarized in a Quality Plan Timing that aids Program Management in tracking the development of the project to assure its goals are met at the time of launch (i.e. Maturity at Entry-Into-Service, EIS).
Keep in mind that change is risk and what we need to do is to minimise and manage risks.
It aids Program Management in tracking the development of a project to assure its goals are met at the time of launch. (ie. Maturity at Entry into Service, EIS) => This is what is important to the Work Package Leader.
APQP HISTORY
Advanced Product Quality Planning, or APQP, was developed by Chrysler, Ford and General Motors, during the 1980s as an attempt to regain domestic market share from their growing Asian competitors
In an effort to commonize requirements to the supply base a single standard was developed by the Automotive Industry Action Group (AIAG). It took 5 years to develop the standard, which was launched initially in 1994.
While it mainly remains in the automotive industry, the APQP framework is a viable solution for any production environment.

8. Aerospace APQP Model Cross Functional Effective Project Planning
Customer Satisfaction
On-Time, On-Quality, Shorter lead times
Organizational Commitment & Management Support
Cross Functional
Team
Effective Project Planning
APQP PRINCIPLES

9. Organizational commitment & management understanding and support
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.

10. 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.

11. Effective project planning
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
Quality Plan Timing Not to be confused with a Quality Timing Plan.
We need to set milestones and have a prevention mindset. What we are trying to achieve with timing & planning is trying to plan to ensure we are aiming to achieve right first time.
10 years ago we delivered an Aircraft on time. As Work Package Leader APQP is the framework to help us to deliver on Time and on Quality.
If we deliver on time and not on Quality, we are affecting the timing upstream Refer to the AC-Element structure.
The time plan needs to ensure that the systems engineering approach of decomposing the product into its constituent components will be considered by the various constituent components (product development layers) is taking into account the overall program timing (alignment).
Team members need to be convinced that the tasks can be accomplished in the assigned timing slot, unrealistic timing mindset has to be avoided. Issues should be highlighted and solutions ralentlessly found.
Commitment of the project team to Aerospace APQP planning
is key to the project success.

12. Aerospace APQP main pillars
Effective planning includes flow down of timing requirements throughout the value stream xx Q
Representative
Deliverable
Owner
Deliverables
Customer
APQP
timeline
Requirements
Progress reports
Supplier
APQP
timeline
Quality Plan Timing Not to be confused with a Quality Timing Plan.
We need to set milestones and have a prevention mindset. What we are trying to achieve with timing & planning is trying to plan to ensure we are aiming to achieve right first time.
10 years ago we delivered an Aircraft on time. As Work Package Leader APQP is the framework to help us to deliver on Time and on Quality.
If we deliver on time and not on Quality, we are affecting the timing upstream Refer to the AC-Element structure.
The time plan needs to ensure that the systems engineering approach of decomposing the product into its constituent components will be considered by the various constituent components (product development layers) is taking into account the overall program timing (alignment).
Team members need to be convinced that the tasks can be accomplished in the assigned timing slot, unrealistic timing mindset has to be avoided. Issues should be highlighted and solutions ralentlessly found. xx Q
Representative
Deliverable
Owner
Deliverables

13. Aerospace APQP Deliverables
Aerospace APQP model
Phases
Elements
Aerospace APQP Deliverables
5 PHASES
ELEMENTS DEFINING ACTIVITIES
KEY DELIVERABLES
The structure is based on phases and is a cascade:
Phases: Few (alignement with timing)
Elements: Many / the things we want to concentrate
Critical to Quality: Most (things are on Quality or not) - The things we want to measure

14. 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

15. 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 concept
End of design
Production readiness
Product validation
Kick off
Product Development
Process
APQP phases D A E B C
APQP milestones

16. Aerospace APQP model Cascade through Product Breakdown Structure (PBS)
3 - Report APQP status at project level
End of concept
End of design
Production readiness
Product validation
Kick off
Product Development
Process
System level
Sub-system level
Components level
1 - Cascade deliverables and align timing for each level
Note: Compressed timeline to support program timing
2 - Bottom up status based on on-time on-quality deliverables
Typical PBS:
system→ sub-system→ component

17. APQP Principles Phases Elements Deliverables

18. 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:
Planning
Product design and development
Process design and development
Product and process validation
Production

19. 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

20. 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

21. 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.

22. 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

23. 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

24. 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

25. 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

26. 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.)
Element Descriptions coming soon!

27. 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
Checklists coming soon!
Phases
Elements
Deliverables

28. 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

29. 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