WIXLIB

9145 - ADVANCED PRODUCT QUALITY PLANNING (APQP)AND PRODUCT PART APPROVAL PROCESS (PPAP)AVIATION SPACE AND DEFENSE INDUSTRIESBERLIN SUPPLIER FORUM18 OCTOBER 2019PRODUCT & SUPPLY CHAIN IMPROVEMENTSUPPLY CHAIN MANAGEMENT HANDBOOK (SCMH)Deborah Oberhausen - UTCThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

9145 APQP & PPAPThe purpose of this presentation is to: Introduce key concepts of APQP and PPAP and thebenefits of application Implementation – First steps Guidance material and trainingThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

Introduction to 9145The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)3

What is 9145?A AdvancedP ProductQ QualityP PlanningQuality refers toGood, effectiveEnterprize-wide PlanningThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

What is 9145?9145 applies Advanced Product Quality Planning (APQP) andProduction Part Approval Process (PPAP) to Product Developmentin the Aviation Space And Defense (AS&D) industrySuccess Drivers5-Phase Product Development Process1.2.3.4.5.PlanningProduct Design and DevelopmentProcess Design and DevelopmentProduct and Process ValidationOn-Going Production, Use, and Post-DeliveryService Management commitmentIntegrated cross-functional teamsEffective project managementDefined deliverables & outputs for each phaseThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

Why 9145?Improve Quality and Reduce Cost Prevention tools for risk reduction Early achievement of product maturity Reduced overall life-cycle costs Provides foundation for successful work transfersThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)6

Why 9145?Improve Quality and Reduce Cost by eliminating: Visible Costs: Hidden Costs: Non ConformancesRework / RepairsPenaltiesDesign changesWarranty costsLoss of productivityField service costsThe list goes on The iceberg effect Deliver quality products that satisfy customer expectationsThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)7

9145 Benefits from Proactive Approach-Reactiveto proactive approach-Improved product quality-Reduce failure costs through prevention-Increased Customer satisfaction10090Pre ve ntion8070Ins pe ction605040Failure inte rnalPre ve ntion3020Ins pe ctionFailure e xte rnal10Failure inte rnalFailure e xte rnal0BeforeAfterUpfront costs are offset by reduction in failure and inspection costThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)8

9145 Benefits from Proactive ApproachNon-conformances reduced through PPAP(actual AS&D example)New Product introductionWork Transfers80 %ReductionProgram to program comparisonAcross programsFirst benefits of APQP can be achieved through PPAP deploymentThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)9

APQP OverviewThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)10

What is Advanced Product Quality Planning?APQP is a structured phased Product Development methodology that assuresCustomer satisfaction by: Ensuring that all activities are completed on-time and on-quality Facilitating effective communication Providing timely escalation and resolution of delays and risksThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)11

APQP PrinciplesCustomer SatisfactionEffective ProjectPlanningCross FunctionalTeamOrganizationalCommitment &ManagementSupportOn-Time, On-Quality, Shorter lead timesAPQP PRINCIPLESPillars of successThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

APQP PrinciplesTop Management demonstratescommitment by On-Time, On-Quality, Shorter lead timesEffective ProjectPlanningManagement engagement &commitment from launch toclosure is key!Customer SatisfactionCross FunctionalTeamCompleting APQP trainingAllocating and training resourcesLeading reviewsStandardizing APQP practicesRemoving roadblocksOrganizationalCommitment &ManagementSupport APQP PRINCIPLESPillars of successThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

APQP PrinciplesCross functional teams enableeffective communications and fasterproduct developmentTeams should consist of Customer SatisfactionEffective ProjectPlanningCross FunctionalTeamOrganizationalCommitment &ManagementSupportOn-Time, On-Quality, Shorter lead times pliersCustomersCustomer SupportAPQP PRINCIPLESPillars of successThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

APQP PrinciplesEffective project planning and management Schedule tasks, assignresponsibility and drive ontime completionEffective ProjectPlanningOn-Time, On-Quality, Shorter lead timesCross FunctionalTeam The APQP plan cascadesprogram key targetsthrough the value streamCustomer SatisfactionOrganizationalCommitment &ManagementSupport Continually monitor plan,communicate risks andremove roadblocksCommitment to a firm APQP planis a critical success factor!CustomerInternal OperationsAPQP PRINCIPLESSuppliersPillars of successThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

PDP and APQP Phase AlignmentPhase MilestonesAPQP has 5 phases starting with product concepts and extending through the product life cycleKick OffEnd of Concept(PDR)Initial ProductionProduction LaunchApprovalDesignRelease(CDR)Product DevelopmentProcess (PDP)1. PlanningPhases of Advanced ProductQuality Planning (APQP)APQP MilestoneADB2 – Product Design and DevelopmentC5 – On-going Production, Use and Postdelivery Service4 – Product and ProcessValidationE3 – Process Design and DevelopmentProduct conceptDesign validation & verification1st Article Inspection(FAI)Production Part ApprovalProcess (PPAP)Process validationProduction Readiness ReviewThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)16

PPAP OverviewThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)17

PPAP OverviewPPAP is an aerospace APQP element finalizing “Product and Process Validation”5 – On-going Production, Useand Post-delivery Service1. Planning2 – Product Design andDevelopment4 – Product andProcess ValidationPPAP3 – Process Design and DevelopmentPPAP combines First Article Inspection and Process qualificationThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)18

What is Production Part Approval Process?PPAP confirms.that the production process has demonstrated the potential toproduce products .that consistently fulfill all requirements .while operating at the customer demand rateThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)19

Production Part Approval Process (PPAP)Key aspects PPAP Follows successful completion of the first 4 phases APQP Defines the standard deliverables for production part approval First Article Inspection (FAI) is the first milestone of ProductionValidation PPAP elements are updated as process and/or product changes occurProducts used for PPAP are from initial production run(s)The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

PPAP Elements & Phase AlignmentPPAP elements are the output and evidence of APQP executionPPAP ELEMENT* Responsibility of designresponsible organizationAPQP PHASE1. Design Records*22. Design Risk Analysis*23. Process Flow Diagram34. PFMEA35. Control Plan36. MSA47. Initial Process Capability Studies48. Packing, Preservation and Labeling Approvals39. FAIR410. Customer Specific Requirements411. PPAP Approval Form (or equivalent)4The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)21

Production Part Approval Process (PPAP)Compile thePPAP PackageSubmit toCustomerDispositionPPAPSubmissionApprovedInterim ApprovalRejectedPPAP Approval Form - 9145 Appendix DMaintain the PPAP file throughout product lifecycleThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

Aviation Space And Defense APQP & PPAPSummary 9145 is the internationally harmonized Aerospace standard for APQPand PPAP APQP Principles are keys to success APQP has defined deliverables aligned to each of the 5 phases PPAP approval is the output of APQP APQP and PPAP apply throughout the life of the productThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

ImplementationThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)24

Implementation Strategy Benchmark other companies Perform Self-Assessment (Maturity Assessment from SCMH)– Identify strengths and weaknesses Training– Determine what training is needed based off Maturity Matrix– Develop a plan to address training needs Incorporate 9145 into the Product Development Process––––Align infrastructure to support 9145Understand and incorporate customer requirementsDevelop/update internal proceduresEstablish conformance to the 9145 & customer requirementsThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)

Guidance Material & TrainingThe IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)26

Aerospace APQP SCMH Section 7.2Revised 2017SCMH7.2.2Standard PublishedNov 2016WebinarsIntroductionarePresentationlocated hereNEWPhase ChecklistsMaturity AssessmentTools & TemplatesSCMH7.2.3APQP ManualNEW7.2.9 Process Flow Diagram7.2.10 DFMEA7.2.11 PFMEA7.2.12 Element Applicability7.2.13 Control PlanSCMH 7.2.4-7.2.8SCMH 7.2.14The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev. 08-2015)