Aerospace Advanced Product Quality Planning (Aerospace APQP) Introduction. Date: April Section 7.2

Transcription

1 Aerospace Advanced Product Quality Planning (Aerospace APQP) Introduction Date: April Section 7.2

2 Purpose of this document The purpose of this document is to provide the key messages introduced in the Aerospace APQP guidance material. This document can be used as a base for communication sessions as well as a tutorial on Aerospace APQP. Page 2

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 3

4 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 20 th 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 4

5 Purpose of APQP Aerospace APQP is a structured method to guarantee the necessary steps are taken to assure new products satisfy customer needs and wants Aerospace APQP, as part of project management, provides effective early warning to support on-time and on-quality delivery of the product by monitoring key deliverables critical to quality Aerospace APQP drives a cross functional approach to product development avoiding the creation of functional silos Aerospace APQP implementation drives a proactive and preventative mindset Program Needs Aerospace APQP Phases Elements Deliverables PPAP Page 5

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 6

7 Organizational Commitment & Management Support Cross Functional Team Effective Project Planning Aerospace APQP Model Customer Satisfaction On-Time, On-Quality, Shorter lead times APQP PRINCIPLES Page 7

8 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. Page 8

9 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 whole business & enables faster product development. Page 9

10 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. Page 10

11 Aerospace APQP main pillars Effective planning includes flow down of timing requirements throughout the value stream xx Q Representative Deliverables Deliverable Owner Deliverable Owner Deliverable Owner Deliverable Owner Customer APQP timeline 1 - Planning 2 - Product Design & Development 3 - Process Design & Development 5 - Production 4 - Product Process Validation Supplier APQP timeline 1 - Planning 2 - Product Design & Development 3 - Process Design & Development 5 - Production 4 - Product Process Validation xx Q Representative Deliverables Deliverable Owner Deliverable Owner Deliverable Owner Deliverable Owner Page 11

12 Aerospace APQP model Program Needs Aerospace APQP PPAP Phases Elements Deliverables Phases Elements Aerospace APQP Deliverables 5 PHASES ELEMENTS DEFINING ACTIVITIES KEY DELIVERABLES Page 12

13 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 Page 13

14 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 Product Development Process Kick off End of concept End of design Production readiness Product validation APQP phases 1 - Planning A 2 - Product Design & Development B D 5 - Production E 4 - Product Process Validation 3 - Process Design & Development C APQP milestones Page 14

15 Aerospace APQP model Cascade through Product Breakdown Structure (PBS) Product Development Process Kick off End of concept 3 - Report APQP status at project level End of design Production readiness Product validation System level 1 - Planning 2 - Product Design & Development 5 - Production 4 - Product Process Validation 3 - Process Design & Development Sub-system level 1 - Planning 5 - Production 2 - Product Design & Development 4 - Product Process Validation 3 - Process Design & Development Components level 1 - Planning 2 - Product Design & Development 5 - Production 4 - Product Process Validation 3 - Process Design & Development Typical PBS: system sub-system component 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 Page 15

16 APQP Principles Phases Elements Deliverables Page 16

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 17

18 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 Page 18

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 Any design changes after this phase requires change management Page 19

20 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 20

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 21

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 22

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 Page 23 Project goals are achieved, including reliability, quality, and customer satisfaction On-time, on-quality, on-cost production and service

24 Aerospace APQP principles: phase alignment Product concept frozen Product Design Verified Production readiness assessment Start of production and FAI PPAP approval A B C D E 1 - Planning 2 - Product Design & Development 5 - Production 4 - Product Process Validation 3 - Process Design & Development Prototypes Development products Parts must be 100% certified PPAP run Production products Key milestones APQP phases Page 24 Parts status

25 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 Page 25

26 Elements Aerospace APQP principles 1 - Planning 5 - Production 2 - Product Design & Development 4 - Product Process Validation 3 - Process Design & Development Phase 1 Planning 1.01 Project Inputs 1.02 Technical Design Requirements 1.03 Reliability & Quality goals 1.04 Preliminary Listing of Critical Items & Key Characteristics 1.05 Product Specification 1.06 Preliminary Bill of Material 1.07 Preliminary Process Flow Chart 1.08 Statement of Work Review 1.09 Sub-tier Selection and Management Plan 1.10 APQP Timeline Page 26

27 Elements Aerospace APQP principles 1 - Planning 5 - Production 2 - Product Design & Development 4 - Product Process Validation 3 - Process Design & Development Phase 2 Product design and development 2.01 Design Failure Mode Effects Analysis Design for Manufacture and Assembly Design for Maintenance, Repair & Overhaul Product Key Characteristics New Packaging Specification 2.03 Design Reviews 2.04 Development Product/ Part Build Plan 2.05 Design Verification and Validation 2.06 Team Feasibility Commitment and Management Support Page 27

28 Elements Aerospace APQP principles 1 - Planning 5 - Production 2 - Product Design & Development 4 - Product Process Validation 3 - Process Design & Development Phase 3 Process design and development 3.01 Process Flow Chart 3.02 Floor Plan Layout 3.03 Production Preparation Planning 3.04 Operator Staffing and Training Plan 3.05 Process Failure Modes and Effects Analysis 3.06 Process Key Characteristics 3.07 Pre-Launch Control Plan 3.08 Measurement Systems Analysis Plan 3.09 Manufacturing Process Documentation 3.10 Supply Chain Risk Management 3.11 Production Readiness Review Page 28

29 Elements Aerospace APQP principles 1 - Planning 5 - Production 2 - Product Design & Development 4 - Product Process Validation 3 - Process Design & Development Phase 4 Product and process validation 4.01 Significant Production Run 4.02 Measurement System Analysis 4.03 Preliminary Process Capability Study 4.04 Packaging Evaluation 4.05 Production Control Plan 4.06 Capacity Verification 4.07 Product Validation Testing 4.08 First Article Inspection 4.09 Production Part Approval Process (PPAP) Page 29

30 Elements Aerospace APQP principles 1 - Planning 5 - Production 2 - Product Design & Development 4 - Product Process Validation 3 - Process Design & Development Phase 5 Production 5.01 Variation Reduction (Preventive Action) 5.02 Product Quality Assurance (Corrective Action) 5.03 Product Improvement 5.04 On-time delivery and Capacity Assurance 5.05 Maintenance Repair and Overhaul 5.06 Lessons Learned Page 30

31 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.) Phases Elements Deliverables Page 31

32 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 Phases Elements Page 32 Deliverables

33 Aerospace APQP key milestones Production Part Approval Process (PPAP) PPAP is an Aerospace APQP element of phase 4 finalizing product and process validation. PPAP combines First Article Inspection and process qualification. The purpose of PPAP is to demonstrate that the production process is consistently capable of producing product that meets customer requirements at the intended production rate. Page 33

34 Aerospace APQP key milestones Production Part Approval Process (PPAP) Key aspects Follows successful completion of the first 4 phases Aerospace APQP Defines the standard deliverables for production part approval Products that will be used for PPAP are from the significant production run All applicable PPAP elements must be updated by the producer any time the process or the product are changed Resubmission may be required by the customer FAI (9102) part approval, is the first step of PPAP Page 34

35 Page 35 Implementation and Customization

36 Aerospace APQP deployment Identify product (new or modified) APQP is applied to all new or modified products as well as existing products in new applications and those with repetitive performance issues Nominate team Identify project leader, APQP leader and task owners Check element applicability Identify Aerospace APQP element applicability based on initial risk assessment Identify the product breakdown and create SOW Breakdown the product into manageable subcomponents and formalize in a Statement Of Work (SOW) Decide make or buy Identify what will be made in-house and what will be outsourced Cascade requirements to producer Cascade timing, quality and technical requirements to all producers (internal/external) Page 36 A

37 Aerospace APQP Process A Update APQP element applicability Evaluate risk for the project considering product technical content, process requirements, lesson learnt and product criticality and supplier capabilities Update Statement of Work Get supplier feedback and agree on work to be done Agree on assesment timing based on risks or issues and create APQP timeline Perform assessments based on deliverables checklists Escalate issues and get management feedback and support Adjust APQP monitoring based on risk (frequency of assessment) Aerospace APQP timeline needs to be agreed between all team members (internal and external if any) Perform assessment based on agreed frequency and checklist. Record results on check sheets. Evaluate element status Red Yellow Green Consolidate reports combining element status and sub-components status. Escalate issues on a timely manner Page 37

38 Aerospace APQP reporting Regularly assess deliverables Apply Red/Yellow/Green (RYG) ratings to each deliverable considering: On-quality according to checklist criteria On-time according to APQP timing Red: Whenever a question cannot be answered with a clear yes, the deliverable owner should provide an action to recover on-time and on-quality. When an action plan cannot be provided or is not able to recover initial product timing, a red should be raised: IMPACT TO THE FINAL PRODUCT DELIVERY SCHEDULE Yellow: Yellows are highlighted when the answer to the question is no, but there is a robust action plan to recover situation: THERE IS NO IMPACT TO THE PRODUCT DELIVERY SCHEDULE Green: All questions have a positive answer (Y) and are ongoing as planned Page 38

39 Escalation Aerospace APQP Reports Reporting Product System Sub-system Component Page 39 Aircraft / Program Report APQP status at project level Bottom up status based on on-time & on-quality deliverables Assessments are compiled and subsequently reported through the project layers Impact of Red/Yellow status are evaluated from bottom up Top layer reviews impact on overall project and enables necessary actions to ensure ontime delivery