PRODUCT & SUPPLY CHAIN IMPROVEMENT SUPPLY CHAIN MANAGEMENT HANDBOOK (SCMH) AWARENESS WEBINAR

Transcription

1 PRODUCT & SUPPLY CHAIN IMPROVEMENT SUPPLY CHAIN MANAGEMENT HANDBOOK (SCMH) AWARENESS WEBINAR SCMH TOPIC: ADVANCED PRODUCT QUALITY PLANNING (APQP) 7 NOVEMBER 2018 Deborah Oberhausen P&W UTC Jennifer Cox Spirit Aerosystem Susan Parsons IAQG 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev )

2 Supply Chain Management Handbook Webinar Webinar Tips Closing as many application running in the background as possible to eliminate lag time between slides could improve viewing. Once the webinar starts you are placed on mute, to communicate please use the Question box on the control panel. Feel free to type a question at anytime during the presentation. Time permitting we will respond to some of the questions at the end of the presentation. The Presentation and a Q&A specific to the subject will be posted in the appendix section of SCMH. There will be no certificates provided for this webinar. If you have more than one person connecting to the webinar from one line please send note the number attending in the question box IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 2

3 Product & Supply Chain Improvement Webinar Agenda Webinar Tips Supply Chain Management Handbook (SCMH) SCMH Focus IAQG Link to SCMH SCMH Access SCMH Content Advance Product Quality Planning (APQP) and Product Part Approval Process (PPAP) Susan Parsons Deb Oberhausen & Jennifer Cox 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 3

4 SCMH Focus Focus on How through SCMH 91XX Requirements Inputs for new revision of 91XX 91xx SCMH Guidance material, tools, training Providing guidance material and best practices on how to meet requirements and achieve objectives 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 4

5 IAQG Link to SCMH: Click Supply Chain Management Handbook (SCMH) 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 5

6 SCMH Access Terms and Conditions 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 6

7 SCMH Access Click to login or register User Registration First Time ONLY) Allows for the generation of a User roster, Project Launches, Future Topic Survey s and announcement or invitations at the SCMH opening. (in place since 2014) After registration, just log in using address and password IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 7

8 SCMH Access A quick look at the SCMH. Get there fast; Search Engine: IAQG 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 8

9 SCMH Access Detailed content and direct access to free guidance, training presentations, templates, forms, etc 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 9

10 SCMH Content Sections in progress Recently published Updated October IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 10

11 ADVANCED PRODUCT QUALITY PLANNING (APQP) AND PRODUCTION PART APPROVAL PROCESS (PPAP) DEBORAH OBERHAUSEN P&W UTC JENNIFER COX SPIRIT AEROSYSTEMS Nov IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev )

12 9145 APQP & PPAP The purpose of this presentation is to: Introduce the key concepts of APQP and PPAP and the benefits of application Communicate availability of guidance material and training Implementation First steps 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 12

13 APQP and PPAP Webinar Series PPAP Process Capability & Control Design Risk Analysis Advanced Product Quality Planning Overview Process Flow Diagram & Process FMEA Control Plan Webinar Objectives Provide high level understanding Introduce APQP and PPAP and show relation to 9145 Share benefits & best practices Provide sources of additional information Measurement Systems Analysis 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 14

14 Introduction to IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 15

15 What is 9145? 9145 applies Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP) to Product Development in the Aviation Space And Defense (AS&D) industry 5-Phase Product Development Process 1. Planning 2. Product Design and Development 3. Process Design and Development 4. Product and Process Validation 5. On-Going Production, Use, and Post-Delivery Service Success Drivers Management commitment Integrated cross-functional teams Effective project management Defined deliverables & outputs for each phase 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 16

16 Improve Quality and Reduce Cost Why 9145? Early achievement of product maturity Reduced overall life-cycle costs Prevention tools for risk reduction Provides foundation for successful work transfers Progressive companies have incorporated APQP into their Product Development Process 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 17

17 Companies incorporating APQP into their PDP and flowing these requirements to their suppliers Airbus Group Honeywell Embraer Boeing Hensoldt Oshkosh GE Aviation Lockheed Martin Rolls Royce Raytheon Safran Group Woodward Spirit Aero UTC MHI Rockwell Collins Bombardier Parker Aerospace Textron Eaton Not intended to be a comprehensive list 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 18

18 Why 9145? Improve Quality and Reduce Cost by eliminating: Visible Costs: Non Conformances Rework / Repairs Penalties Hidden Costs: Design changes Warranty costs Loss of productivity Field service costs The list goes on The iceberg effect Deliver quality products that satisfy customer expectations 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 19

19 What does 9145 do for AS&D? Standardizes requirements for Product Development across AS&D Integrated multifunctional approach to ensure effective collaboration Structured proactive life-cycle approach Phased/gated process to ensure on-time quality products Strengthens production verification process (PPAP) Based on proven methodology for Product Development 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 20

20 How are 9145 Benefits achieved? Early understanding of Customer Expectations Reduce overall cost by identifying & eliminating risks Achieve robust Product and Process Designs Minimize required changes Effective implementation through program management Cross-functional teams collaborate on all aspects of the program Meet Customers requirements Achieve reliability and cost targets 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 21

21 9145 Benefits from Proactive Approach Prevention Inspection Failure inte rnal -Reactive to proactive approach -Improved product quality -Reduce failure costs through prevention -Increased Customer satisfaction Prevention Inspection Failure external Failure inte rnal Failure external Before After Upfront costs are offset by reduction in failure and inspection cost 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 22

22 9145 Benefits from Proactive Approach Non-conformances reduced through PPAP (actual AS&D example) New Product Introduction Work Transfers 40 % reduction 80 % reduction Program to program comparison Across programs First benefits of APQP can be achieved through PPAP deployment 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 23

23 APQP Overview 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 24

24 What is Advanced Product Quality Planning? APQP is a structured phased Product Development methodology that assures Customer satisfaction by: Ensuring that all activities are completed on-time and on-quality Facilitating effective communication Providing timely escalation and resolution of delays and risks Customer Satisfaction 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 25

25 Organizational Commitment & Management Support Cross Functional Team Effective Project Planning APQP Principles Customer Satisfaction On-Time, On-Quality, Shorter lead times APQP PRINCIPLES Pillars of success 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 26

26 Organizational Commitment & Management Support Cross Functional Team Effective Project Planning APQP Principles Top Management demonstrates commitment by Completing APQP training Allocating and training resources Leading reviews Standardizing APQP practices Removing roadblocks Customer Satisfaction On-Time, On-Quality, Shorter lead times Management engagement & commitment from launch to closure is key! APQP PRINCIPLES Pillars of success 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 27

27 Organizational Commitment & Management Support Cross Functional Team Effective Project Planning APQP Principles Cross functional teams enable effective communications and faster product development Customer Satisfaction On-Time, On-Quality, Shorter lead times Teams should consist of Engineering Procurement Manufacturing Quality Sales Suppliers Customers Customer Support APQP PRINCIPLES Pillars of success 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 28

28 Organizational Commitment & Management Support Cross Functional Team Effective Project Planning APQP Principles Effective project planning and management Schedule tasks, assign responsibility and drive ontime completion Customer Satisfaction On-Time, On-Quality, Shorter lead times Commitment to a firm APQP plan is a critical success factor! Continually monitor plan, communicate risks and remove roadblocks The APQP plan cascades program key targets through the value stream Customer Internal Operations Suppliers APQP PRINCIPLES Pillars of success 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 29

29 PDP and APQP Phase Alignment Phase Milestones APQP has 5 phases starting with product concepts and extending through the product life cycle Product Development Process (PDP) Kick Off End of Concept (PDR) Design Release (CDR) Initial Production Approval Production Launch Phases of Advanced Product Quality Planning (APQP) 1. Planning A 2 Product Design and Development B C D 4 Product and Process Validation 5 On-going Production, Use and Postdelivery Service E APQP Milestone 3 Process Design and Development Product concept Design validation & verification 1 st Article Inspection (FAI) Production Part Approval Process (PPAP) Process validation Production Readiness Review 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 30

30 APQP Phase 1 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 makes the key make-buy decisions Establishes timing for deliverables for each APQP element Output The product concept is finalized (milestone A) and a pre-design is available Concurrent product design and process design can start A APQP Milestone 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 31

31 APQP Phase 2 Phase 2 Product design & development Turns product specifications into a robust product definition Design risk analysis (DFMEA) Provides a verified product design Team commits to product manufacturability Output Design record and BOM are available The product design is verified and validated (milestone B) by the design organization A B APQP Milestone 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 32

32 APQP Phase 3 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. A B APQP Milestone C 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 33

33 APQP Phase 4 Phase 4 Product & process validation: Launches the initial 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: Product and process design as validated by the organization Production readiness evaluation Corrective actions taken for any issues identified to date A B APQP Milestone C 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 34

34 APQP Phase 4 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 A B D E APQP Milestone C 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 35

35 APQP Phase 5 Phase 5 Production Evaluate if project objectives have been achieved Record Lessons Learned to drive robust product realization processes Implement actions to increase customer satisfaction Output Project goals are achieved, including reliability, quality, and customer satisfaction On-time, on-quality, on-cost production and service A B D E C 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 36

36 PPAP Overview 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 37

37 PPAP Overview PPAP is an aerospace APQP element finalizing Product and Process Validation 1. Planning 2 Product Design and Development 3 Process Design and Development 4 Product and Process Validation 5 On-going Production, Use and Post-delivery Service PPAP PPAP combines First Article Inspection and Process Validation 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 38

38 What is Production Part Approval Process? PPAP confirms... that the production process has demonstrated the potential to produce products.. that consistently fulfill all requirements.. while operating at the customer demand rate 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 39

39 PPAP Elements & Phase Alignment PPAP elements are the output and evidence of APQP execution * Responsibility of design responsible organization PPAP ELEMENT APQP PHASE 1. Design Records* 2 2. Design Risk Analysis* 2 3. Process Flow Diagram 3 4. PFMEA 3 5. Control Plan 3 6. MSA 4 7. Initial Process Capability Studies 4 8. Packing, Preservation and Labeling Approvals 3 9. FAIR Customer Specific Requirements PPAP Approval Form (or equivalent) IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 40

40 Production Part Approval Process (PPAP) Compile the PPAP Package Submit to Customer Disposition PPAP Submission Approved Interim Approval Rejected PPAP Approval Form Appendix D Maintain the PPAP file throughout product lifecycle 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 41

41 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 Production Validation PPAP elements are updated as process and/or product changes occur Products used for PPAP are from initial production run(s) 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 42

42 Summary Aerospace APQP & PPAP 9145 is the internationally harmonized Aerospace standard for APQP and PPAP APQP Principles are keys to success APQP has deliverables & milestones aligned to each of the 5 phases PPAP approval is the output of APQP APQP and PPAP apply throughout the life of the product 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 43

43 Guidance Material & Training 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 44

44 9145 Aerospace APQP & PPAP AS Standard Published Nov 2016 SJAC 9145 June 21, IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 45

45 Aerospace APQP SCMH Section 7.2 SCMH SCMH Introduction Presentation APQP Manual Phase Checklists Tools & Templates NEW Maturity Assessment NEW Process Flow Diagram DFMEA PFMEA Element Applicability Control Plan SCMH SCMH IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 46

46 Self Assessment - Maturity Matrix 1.0 Philosophy: Management Awareness and Commitment Item Content Level 1 Level 2 (1 pt) (2 pt) Advance Product Quality No knowledge of APQP. Not Basic knowledge and Planning (APQP) Philosophy & integrated into product awareness of APQP and Knowledge of the development process. basic understanding of Requirements requirements and skills 1.1 needed to deploy. 1.2 Organizational Support Limited support and no APQP Acknowledged and executive leadership directive. supported in isolated sectors of the organization. (e.g. driven by quality and/or engineering) Level 3 (3 pt) Implementation plan in place for integrating APQP into Product Development process. Key personnel trained in the APQP methodologies. Leaders of function roles (e.g. engineering, quality, operations, procurement, etc.) understand and support APQP. Organization trained and some use of tools & process is evident. Level 4 (4 pt) APQP is defined and fully integrated in product development process. Strategic communications and objectives driving the APQP philosophy. Buy-in at all levels and relevant functional organizations of the organization and working to achieve the tactical objectives. Level 5 (5 pt) Organizational structure and systems in place to support APQP. Continuous improvements plans to ensure the APQP philosophy continues to drive culture change. Leadership objectives met and tactical objectives implemented. Results analysis driving improvements and closing gaps. Weight Score Comment / Evidence 30% 2 70% 2 Raw Score Overall Weighted Category Score 40.0% 40.0% What is It? A tools used to visually represent an organizations strengths and weaknesses within APQP Objective or Purpose To evaluate and assess the maturity of an organizations Advanced Product Quality Planning philosophy Management awareness/commitment Organizational alignment and effective communication Project/risk management Use of tools Readiness of external suppliers When to Use It Prior to deployment within your organization Prior to deployment of your external suppliers As needed to monitor and develop continuous improvement 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 47

47 Implementation 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 48

48 First Steps in Deployment Benchmark other companies Perform the Self-Assessment (Maturity Matrix) Identify strengths and weaknesses Training Determine what training is needed based off Maturity Matrix Develop a plan to address training needs Incorporate APQP in the Product Development Process Conformance to the standard/customer requirements 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 49

49 1. Planning 2. Product Design & Development APQP Relationship Webinar Series 4. Product & Process Validation 5. On-going Production & Post Delivery 3. Process Design & Development Project Inputs Next Webinar Nov 14th Design Design Risk Analysis Risk Analysis Process Process Flow Diagram Diagram Nov 28th Key Product Characteristics PFMEA Product & Process Key Characteristics Dec 12th Control Plan Feedback Jan 16th Measurement Measurement Systems Analysis Analysis Feb 13th Process Capability & Process Capability & Control Control Mar 13th PPAP Approval PPAP *Reference 9145 Table 2 Production part approval process file contents 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe 50 and the Asia Pacific Region (Rev ) 50

50 Upcoming IAQG 9145, APQP & PPAP Webinar Series Webinar Topic Date & Time Who Should Attend Advanced Product Quality Planning (APQP) Overview Nov 7 th :00 PM GMT Design Risk Analysis Critical Items Nov. 14 th :00 PM GMT Process Flow/ Process Failure Modes and Effects Analysis (PFMEA) Process Characteristics Nov. 28 th :00 PM GMT Control Plan Dec. 12 th :00 PM GMT Measurement Systems Analysis MSA Jan. 16 th :00 PM GMT Process Capability & Control (Variation Management) Feb. 13 th :00 PM GMT Production Part Approval Process (PPAP) Mar. 13 th :00 PM GMT 2:00 PM GMT = 9:00AM EST = 11:00 PM KST(+9GMT) Top leadership and leaders of all function engaged in product development process Systems, Design, Manufacturing and Quality Engineers Design, Manufacturing and Quality Engineers, Operations Management Design, Manufacturing and Quality Engineers, Operations Management Design, Manufacturing and Quality Engineers, Calibration Management Manufacturing and Quality Engineers, Operations Management Manufacturing and Quality Engineers 2018 IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 51

51 Comments and Suggestions Do you have comments about the APQP Guidance? You may provide feedback via the SCMH, go to accept the terms and conditions then click on Contact Us or Take Survey IAQG The IAQG is a legally incorporated international not for profit association (INPA) with membership from the Americas, Europe and the Asia Pacific Region (Rev ) 52