PRODUCT & SUPPLY CHAIN IMPROVEMENT
SUPPLY CHAIN MANAGEMENT HANDBOOK (SCMH)
AWARENESS WEBINAR
SCMH TOPIC: PRODUCTION PART APPROVAL PROCESS
(PPAP) – 21 JANUARY 2020
Brian Murphy P&WC UTC
Larry Bennett GE Aviation
Susan Parsons IAQG
© 2020 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. 08-2015)
Product & Supply Chain Improvement
Webinar Agenda
Webinar Tips
Supply Chain Management Handbook (SCMH) Susan Parsons
–
–
–
–
SCMH Focus
IAQG Link to SCMH
SCMH Access
SCMH Content
Production Part Approval Process (PPAP)
© 2020 IAQG
Brian Murphy &
Larry Bennett
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)
2
APQP and PPAP Webinar Series
Webinar Objectives
Design Risk
Analysis
PPAP
Advanced
Product Quality
Planning
Overview
Process
Capability &
Control
Process Flow
Diagram &
Process
FMEA
Control Plan
• Provide high level understanding
• Introduce PPAP and show relation
to 9145
• Share benefits & best practices
• Provide sources of additional
information
Measurement
Systems
Analysis
© 2020 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. 08-2015)
3
Objectives
By the end of this webinar, participants will understand:
• the linkage of PPAP to APQP requirements
• key concepts and benefits of PPAP application including planning
• the requirement(s) of each element and when to complete them
• the relationship between elements
• FAI and PPAP – Production Runs
• when to submit and when to resubmit PPAP
• where to find reference materials
© 2020 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. 08-2015)
4
APQP Relationship
5. On-going Production
& Post Delivery
1. Planning
4. Product & Process Validation
2. Product Design & Development
3. Process Design & Development
Project
Inputs
Design
Risk
Analysis
Key Product
Characteristics
Feedback
Process
Flow
Diagram
Process
Capability
& Control
Control
Plan
PFMEA
Product &
Process Key
Characteristics
PPAP
Submission
& Approval
Measurement
Systems
Analysis
*Reference 9145 Table 2 – Production Part Approval Process file contents
© 2020 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. 08-2015)
5
Why PPAP?
P P A P
PRODUCTION
PA R T
A P P R O VA L
PROCESS
A standardized process that helps communicate and approve
production designs and processes before, during, and after
manufacture.
© 2020 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. 08-2015)
6
Aviation, Space & Defense is Different
IAQG recognizes that the AS&D 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
© 2020 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. 08-2015)
7
Aviation, Space & Defense is Different
Adapting PPAP for High Mix / Low Volume
and Engineer to Order Manufacturing
• Utilize Part & Process Family Approach
– What parts use the same manufacturing process flow?
– What parts have 90%+ features in common?
• Design and validate processes based on families
• Use planning and prevention tools such as PFMEA and Control
Plan by process
Utilize the Supply Chain Management Handbook (SCMH)
© 2020 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. 08-2015)
8
PPAP and APQP
© 2020 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. 08-2015)
9
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
© 2020 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. 08-2015)
10
PPAP Overview
Overview of PPAP application within APQP framework
Product
Development
Process
Kick Off
End of
Concept
(PDR)
Design
Release
(CDR)
Initial Production
Approval
5. Ongoing Production, Use and
Post Delivery Service
1. Planning
Phases of Advanced
Product Quality
Planning (APQP)
Production
Launch
4. Product & Process
Validation
2. Product Design & Development
3. Process Design & Development
FAIR
Production
Readiness
Review
Key PPAP
Events
PPAP Core
Element Timing
(Start)
Design
Records
DRA
PFMEA
Control
Process
Plan
Flow
MSA
Packaging,
Preservation
& Labelling
Production
Process Run(s)
PPAP Approval
Initial Process
Capability Studies
PPAP is an APQP element finalizing “Product and Process Validation”
© 2020 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. 08-2015)
11
Aerospace APQP & PPAP
Summary
• 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
© 2020 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. 08-2015)
12
Key Concepts of PPAP
© 2020 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. 08-2015)
13
Production Part Approval Process (PPAP)
Key aspects PPAP
• Collection of records completed from the previous phases of APQP
• Defines the standard deliverables for production part approval
• First Article Inspection (FAI) is the first milestone of Product Validation
• PPAP elements are updated as process and/or product changes occur,
resubmission is required when changes occur as per AS9102
Parts used for PPAP validation are from initial production run(s)
© 2020 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. 08-2015)
14
Production Part Approval Process (PPAP)
Compile the
PPAP Package
Submit to
Customer
Disposition
PPAP
Submission
Approved
Interim Approval
Rejected
• PPAP File data collection starts in Phase 2
• PPAP Package is submitted to the Customer in Phase 4
• A formal PPAP Approval is required for Shipment
Reference 9145 section 5.1 - Process Requirements for PPAP
PPAP Approval Form
9145 Appendix D
Maintain the PPAP file throughout product lifecycle
© 2020 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. 08-2015)
15
When should PPAP be applied?
Requirements for PPAP Submission, Review and Approval are flowed
down from the Customer based on:
• Risk
• Complexity
• Contract terms
• Past quality performance “including past history of similar
product”
Reference 9145 Section 4.3.3
Risk based PPAPs focus attention on the right components
© 2020 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. 08-2015)
16
PPAP Element Requirements
© 2020 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. 08-2015)
17
PPAP Elements & Phase Alignment
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
4
10. Customer Specific Requirements
4
11. PPAP Approval Form (or equivalent)
4
9145 Table 2 – Production part approval process file contents
* Responsibility of design responsible organization
Utilize Phase 4 checklist to verify prior to submission
© 2020 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. 08-2015)
18
1. Design Records
What is It?
• A collection of the design documents typically including;
• CAD/CAM Math Data
• Part Drawings
• Specifications
• List of all characteristics and requirements
• If the customer is responsible for designing, this is a copy
of customer drawing that is sent together with the
Purchase Order (PO).
• If supplier is responsible for designing this is a released
drawing in supplier's release system.
Objective or Purpose
• Verification that the supplier has designed the product and
process according to Customer & Regulatory Requirements
When to Use It
• Anytime a product or service is being designed or redesigned
• Design Records must be confirmed early in APQP Phase 2/3
and be updated with any changes prior to submitting PPAP
© 2020 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. 08-2015)
19
2. Design Risk Analysis
What is It?
Analytical techniques used by the design responsible
organization to identify, to the extent possible, potential risks
related to product performance (i.e., fit, form, and function),
durability, manufacturability, and cost.
Noise Factors (Z)
1. Piece-to-Piece Variation
2. Other Systems
3. Customer Usage
4. Deterioration Over Time
5. Environment
P Diagram
Inputs (M)
Outputs (Y)
Material/Mass
Intended Results
Product Name
Energy
- Thermal
- Mechanical
- Chemical
- Pressure
Responses
Decision-Map
Function or Design Intent
m
Control Factors (X)c
Flight time
{Target& Cpk}
-3
+3
Rotor length
Failure Modes
Response
Descent Rate
Configuration
Un-intended Results
surface
Body length
Target time
,
Variance
Rev date 11-27-2013, UTC Proprietary
Failure Modes and Effects Analysis (FMEA)
Rotor width
This Workbook Contains No Technical Data Subject to the EAR or the ITAR
Design FMEA
COMPONENT _______________________________
Design Responsibility _________
FMEA Number _____________
Assembly ______
Prepared By:______________
Page ____ of _______
CORE Team ________
FMEA DATE (orig.)_____ (rev.)________
S
Potential
O
D
FMEA
Item's Potential Potential e
Cause(s)
c Current e
R.
DOE Plan
Type
Item FunctionDesign,
Failure all
Effect(s)
of v
(Failure
Controls t
P.
Central
Composite
dimensions
in
inches c
Modes
Failure Blocks
e Mechanisms)
u
e C Body
N.
StdOrder
RunOrder
PtType
A Rot Len B Rot W id
7
1
1
1
3
2
4.5
r
r
c 4.5
5
2
1
1
3
1
3
3
1
1
3
2
2.5
Design 2 Material: Structural
Too light, 1Unstable
10
Material 5 7 None1
10 2.5
700
4
1
6 paper
5
1
1
4.5
& Aeroinsufficien1Descent
selection 5
1
6
1
1
3
1
2.5
4 bond wt
7
1
2
2.5
dynamic
t rigidity 1
process 5
8
8
1
1
5
2
4.5
Stability
9
9
0
1
4
1.5
3.5
10
11
Design 12
16
17
18
15
13
19
14
20
Factorial DOE: RSM
10
11
0
0
12
0
Structural
Too
Fast
13
-1
-1
& 14
Aeroheavy/stiff
descent,
15
-1
16
-1
dynamic
Low flight
17
-1
18
0time
Stability
19
20
-1
0
© 2020 IAQG
1
1
1
2
2
2
2
2
2
2
2
7
4
4
Material 4
7
4
selection 4
4
4
process 2.367
4
5.633
4
1.5
1.5
1.5
None
2.3165 10
1.5
1.5
0.6835
1.5
1.5
1.5
1.5
3.5
3.5
3.5
3.5
1.867
5.133
3.5
3.5
3.5
3.5
3.5
490
Knowledge Space
Recommended
Action
Tave
Responsibility
& Target
Completion Date
Save
DOE
Design Team
DOE
Design Team
Action Results
S
Action
e
Taken
v
Full
10
factorial
complete
d
Full
factorial
complete
d
7
O
c
c
1
D
e
t
7
R.
P.
N.
70
1
7
49
Design Space
Objective or Purpose
• Document the design risks, mitigations needed, actions
taken, and results obtained.
• Support identification of Critical Items (CI’s) and product
Key Characteristics (KC’s)
• Provide input and flow-down of Product CI’s and KC’s to
APQP phase 3 and the PFMEA
When to Use It
• Anytime a product or service is being designed or redesigned
• Elements of DRA can and should be started in APQP Phase
1 (Lessons Learned, for example)
• DRA should be updated as new learnings occur throughout
the PDP and execution of the APQP phases
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)
20
2. Design FMEA
What is It?
• A structured approach used to identify and prioritize
potential risks in a new or changed design
Objective or Purpose
• Per 9145 the DFMEA methodology can be used as a record
of the DRA
• Identifies potential failure modes, the resulting effects, and
prioritizes actions based on the expected severity,
likelihood of occurrence, and ability to detect the failure
mode during design
• Enables collaborative identification of risk and associated
risk mitigation actions
When to Use It
• Started during initial design, updated as the design
matures and throughout the product lifecycle as the
product is updated
• As an input to the next product development cycle
© 2020 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. 08-2015)
21
3. Process Flow Diagram
Operator
Separate Cutting
Tags
(31)
Evaluate for
Corrective Action
What is It?
• Representation of sequential steps of a process
Yes
Operator
Get Traveler and
Nest from Holding
Shelf
(26)
Operator
Prints Cut Tags
(27)
Operator
Load Machine with
Blanket
(28)
Operator
Download Cutting
Infomation
(2s to 2m)
(29)
Operator
Program
Command
"Ready to Cut"
(30)
Operator
Observe Cutting
Operation for
Errors
(32)
Cutting Error?
(33)
No
Operator
Remove Small
Plies from the
Cutting Table
(36)
Operator
Move to Kitting
Table
(37)
Operator
Tag Small Plies
(38)
No
Small Plies
Operator
Cutting Operation
Complete
(34)
Operator
Large
Tag while Laying
Large or Small Plies Piies
on the Cutting
or Test Coupons?
Table
And
(35)
(39)
Coupons
Operator
Remove Plies
from the Cutting
Table
(40)
Operator
Move Plies to
Kitting Table
(41)
Traveler
Complete?
(42)
Yes
Operator
Stamp Traveler
(43)
Objective or Purpose
• To help “see” the real process
• To understand the following characteristics of a process:
• Step-by-step process linkage
• Inputs and outputs of each process step
• Offline activities (measurement, inspection, handling)
• Planned vs. non-planned rework
• Assist in identification of needed resources (equipment,
tooling, facilities people)
When to Use It
• Once the preliminary design is released
• Prior to initiating the PFMEA
• To evaluate changes to the process
© 2020 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. 08-2015)
22
4. Process FMEA
What is It?
• A structured method for identifying all possible failures & impacts of the
process under review
• “Failure modes” is the description of the non-conformance to the
requirements
• “Effects analysis” refers to studying the consequences of those failures
• Failure modes are prioritized according to how serious their consequences,
how frequently they occur, and how easily they can be detected
• Reaction plan to eliminate or reduce failure modes with high severity, reduce
occurrence, and improve detection
Process FMEA
Potential Failure Modes and Effects Analysis
Process
Information
Date
(Origin
al):
Date
(Revisi
on):
Part/Dwg
Number:
Part/Dwg
Revision:
Part/Dwg
Name:
What is
the
severit
y of the
worse
case
effect
on the
proces
s
output
and/or
stakeh
olders?
Step
Require
ment
What
is the
likelih
ood
that
the
cause
will
result
in the
failure
mode
?
What is
the
ability
of the
current
control
s to
detect
the
failure
mode
before
experie
ncing
the
effect?
Action Results
Process
Typ
Potential
/
Potential
Operatio Proce
e
Effects of
Product
Failure
SEV
n
ss
Cla
Failure:
Charact
Modes
Sequenc Functi
ss
Severity (SEV)
eristic
e
on
Descrip
tion
Current
Current
Detectiv
Potential Preventativ
e
Cause of e Controls: OCC Control
Failure Occurrence
s:
(OCC)
Detectio
n (DET)
DET
Recom
Targ
RP
Respon
Ne Ne Ne Ne
mended
et
Effecti
N
sibility
Actions
w w w w
Actions
Date
ve
Taken
SE OC DE RP
Date
V C T N
0
0
0
0
0
0
0
0
0
0
0
0
0
0
IMPORTANT!
A cross-functional team is required
for completing a robust PFMEA
© 2020 IAQG
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Objective or Purpose
•
•
•
•
•
Identify potential product related process failure modes
Assess potential effect of the failures
Identify potential cause(s)
Plan for the prevention, mitigation and control of failures
Repository for Lessons Learned
When to Use It
• When launching a new product or service
• Design and development of new manufacturing process
• To improve an existing process
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)
23
5. Control Plan
What is It?
Key Contact/Phone
Date (Original)
Part Number/Latest Change Level
Core Team
Customer Engineering Approval/Date (If Required)
Part Name/Description
Supplier/Plant Approval/Date
Customer Quality Approval/Date (If Required)
Other Approval Date (If Required)
Other Approval/Date (If Required)
Prototype
Pre-launch
Production
Date (Revised)
Control Plan Number
Supplier/Plant
Supplier Code
Characteristics
Operation /
Process
Number
Process Name/
Operation Description
Tools for
Mfg
Product/Process
Characteristic ID
Product
Description
Methods
Process
Description
Special Chararcteristic
Classification
Product /
Evaluation
Process
Measurement
Specification/
Technique
Tolerance
Sample
Size
Frequency
Control
Method
Reaction
Plan
• 9145: A documented description linking manufacturing process steps to key
inspection and control activities. The intent of a control plan is to control the
design characteristics and the process variables to ensure product quality.
• It is a document that describes the measurement methods, tools and
procedures required at each significant phase of a process to control critical
inputs and assure product that will conform to pre-determined requirements.
Objective or Purpose
Control Plan (CP) Owner: Manufacturing
and Quality Engineering; typically led by
Manufacturing Engineering with a cross
functional team
NOTE:
The control plan is a living document that is revised
and updated in response to product/process changes
or new quality issues!
© 2020 IAQG
•
•
•
•
Implementation of new process
After risks identified in PFMEA have been mitigated
Following a process change
Evaluating processes with non-conformances after corrective action
When to Use It
• Monitors all product and process Key Characteristics (KCs) and Critical Items
(CIs) defined by the customer and organization.
• Manages process variation (input) to reduce product characteristic variation
(output).
• Defines reaction to out-of-control situations, and ensures process
improvements are sustained throughout the product lifecycle
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)
24
6. MSA
What is It?
• An MSA is a statistical tool used to determine if a
measurement system is capable of accurate/precise
measurements
Objective or Purpose
• Quantifies the variability/error added by the measurement
system
• To discover areas where:
• Training is needed
• Procedures are lacking
• Standards are not defined
IMPORTANT!
•An MSA addresses precision – whether the
answer is repeatable and reproducible – with
partial information on accuracy
•Calibration is critical to fully address accuracy
© 2020 IAQG
When to Use It
• When trying to understand the effectiveness of your
measurement system on its ability to measure both inputs
and outputs of a process
• Any new or modified process in order to ensure the quality
of the data
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)
25
7. Initial Process Studies
What is It?
• A collection of dimensional results on product and process
Key Characteristics identified in the control plan.
Objective or Purpose
• Initial process capability studies demonstrate that the
combination of people, machine, methods, material, and
measurements have the potential to produce product that
will consistently meet the design requirements.
9145 Table 1 – Acceptance criteria for process capability studies
When to Use It
• Products produced from the Production Run(s) are used to
provide data for determining initial process capability.
© 2020 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. 08-2015)
26
8. Packing, Preservation and Labeling Approvals
What is It?
• Packaging and Labelling approvals are used to validate the process of delivering product and material to the
customer
Objective or Purpose
• To ensure that product or material is not physically damaged, nor will the packaging degrade in performance
through the normal course of transportation, delivery, and storage.
• Labelling approval is used to ensure that the correct product or material is received by the customer.
When to Use It
• Packaging should be considered early in the process design and completed in Phase 3.
• When required by Customer, a packaging evaluation is completed in phase 4 when product becomes available.
• The producer should confirm that labeling requirements are understood and can be executed as planned in
Phase 3. Customer approval is obtained when required.
© 2020 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. 08-2015)
27
9. First Article Inspection Report (FAIR)
What is It?
• First Article Inspection is a complete, independent, and documented physical and functional inspection
process to verify that prescribed production processes have produced an acceptable item as specified by
engineering drawings, purchase order, engineering specifications, and/or other applicable design documents.
This element must comply with the requirements of Aerospace Standard 9102 when contractually required by
the customer.
Objective or Purpose
• The purpose of the FAI is to provide objective evidence, based on an assessment of the first production article
produced during the initial production run, that all engineering, design, and specification requirements are
correctly understood, accounted for, recorded, verified, and fulfilled.
When to Use It
• FAI planning should begin in the early APQP phases to ensure that all customer requirements are clearly
understood and accounted.
• The FAI submission shall be completed using the initial production part produced during the first production
run.
© 2020 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. 08-2015)
28
The Role of FAI in PPAP
• FAI is a part of PPAP but may be approved prior to the PPAP
submission
• FAI is approval of the Part in regard to the product sample.
• PPAP is approval of the process in regard to future product.
Reference: 9102 Standard for Aerospace First Article Inspection (FAI) requirements
© 2020 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. 08-2015)
29
10. Customer Specific PPAP Requirements
What is It?
• The Customer may specify activities and/or artifacts that exceed those required in the International Aerospace
Standard 9145. These items are referred to as Customer Specific (PPAP) Requirements in the PPAP submission.
Objective or Purpose
• To ensure compliance to any addition Customer Requirements
When to Use It
• Specific Customer Requirements should be identified during the project-planning phase, with timing
established and assigned to the appropriate functional organization.
• Evidence is submitted with the PPAP as defined by the Customer in Phase 4.
© 2020 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. 08-2015)
30
11. PPAP Approval Form
What is It?
• The official record of part approval is 9145 Appendix D if not
specified by the Customer
• May contain records of sub-tier PPAP approval status
Objective or Purpose
• Phase 4 when submitting PPAP to the customer
• When any design change in product or process is completed
When to Use It
• To record the status of all PPAP requirements
• Official record of the status of part approval, including subcomponents as required
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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)
31
Submission, Review and Approval
© 2020 IAQG
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32
PPAP File and Submission
The PPAP File contains current copies of all PPAP Elements
The PPAP Submission contains the Elements as defined by the
Customer, these are usually defined as Submission Levels
PPAP Elements may be requested for submission at the time of
completion
PPAP may be requested prior to all Elements being completed
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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)
33
Approval Status
Full Approval
✓ The product and/or associated documentation meets all customer requirements
✓ The supplier may supply product as required
Interim Approval
✓ The product and/or associated documentation does not meet all customer requirements
✓ Root cause defined with interim action plan that is approved by the customer
✓ Product may be supplied for a specified period of time or piece quantity
✓ Re-submission is required
Rejected
ꭗ The product and/or associated documentation does not meet customer requirements
ꭗ Product is not to be shipped
ꭗ Re-submission is required
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Approval Status
Most Common Reasons for Interim Approval
➢ Customer required supporting documentation has not been completed
➢ Limited quantity of production parts produced
➢ Incomplete testing
➢ ‘Conditional’ FAIR with engineering approval for deviations
➢ Open actions from PFMEA with approved mitigation plan
Utilize Phase 4 checklist to verify prior to submission
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Approval Status
Most Common Reasons for Rejection
➢ Customer required documentation not submitted
➢ Quality of Documentation
➢ Does not account for all product and process characteristics / tolerances
➢ Variable data requirements are not provided with numerical results
➢ Missing or wrong information provided
Utilize Phase 4 checklist to verify prior to submission
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Approval States
Product is NOT to be
shipped unless Customer
approval is received in writing.
Verbal approval is unacceptable!
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37
PPAP Re-Submission Triggers
Interims Status
➢ Submission of incomplete elements
Rejection Status
➢ Submission of missing or discrepant elements
Product / Process Changes
➢ Re-submission of PPAP when an FAI is required as outlined by 9102
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38
Guidance Material & Training
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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)
39
9145 Aerospace APQP & PPAP
AS 9145 published Nov 2016
SJAC 9145 published June 2017
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40
Aerospace APQP SCMH Section 7.2
SCMH 7.2.3
SCMH 7.2.2
Introduction Presentation
Phase Checklists
Tools & Templates
APQP Manual
NEW
7.2.9 Process Flow Diagram
7.2.10 DFMEA
7.2.11 PFMEA
7.2.12 Element Applicability
7.2.13 Control Plan
SCMH 7.2.4-7.2.8
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NEW
Maturity Assessment
SCMH 7.2.14
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41
Self Assessment - Maturity Matrix
1.0 Philosophy: Management Awareness and Commitment
Item
Level 1
(1 pt)
Content
Advance Product Quality
No knowledge of APQP. Not
Planning (APQP) Philosophy & integrated into product
Knowledge of the
development process.
Requirements
1.1
Organizational Support
1.2
Level 2
(2 pt)
Basic knowledge and
awareness of APQP and
basic understanding of
requirements and skills
needed to deploy.
Limited support and no APQP Acknowledged and
executive leadership
supported in isolated sectors
directive.
of the organization. (e.g.
driven by quality and/or
engineering)
Level 3
(3 pt)
Level 4
(4 pt)
Level 5
(5 pt)
Implementation plan in place
for integrating APQP into
Product Development
process. Key personnel
trained in the APQP
methodologies.
APQP is defined and fully
integrated in product
development process.
Strategic communications
and objectives driving the
APQP philosophy.
Organizational structure and
systems in place to support
APQP. Continuous
improvements plans to
ensure the APQP philosophy
continues to drive culture
change.
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.
Buy-in at all levels and
relevant functional
organizations of the
organization and working to
achieve the tactical
objectives.
Leadership objectives met
and tactical objectives
implemented. Results
analysis driving
improvements and closing
gaps.
Weight
Score
30%
2
70%
2
Comment / Evidence
What is It?
• A tools used to visually represent an organizations strengths
and weaknesses within APQP
Objective or Purpose
Raw Score
Overall Weighted Category Score
40.0%
40.0%
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
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42
References
•
•
•
•
•
•
•
•
AS9145 Requirements for Advanced Product Quality Planning (APQP) and Production Part Approval Process
(PPAP)
AS9102 Aerospace First Article Inspection Requirement
Supply Chain Management Handbook (SCMH) www.iaqg.org/scmh
SAE J1739 Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential Failure Mode and
Effects Analysis in Manufacturing and Assembly Processes (Process FMEA)
AS13003 Measurement Systems Analysis Requirements for the Aero Engine Supply Chain
AS13004 Process Failure Mode and Effects Analysis (PFMEA) and Control Plans
AS13006 Process Control Methods
Automotive Industry Action Group (AIAG) – Blue Books
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Completed APQP Webinars
www.iaqg.org
Completed webinars
are available for
viewing from the
SCMH website.
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Q&A, Survey, and Comments
APQP Survey:
The IAQG is committed to ensuring a high level
of quality in the guidance material we provide.
As part of an ongoing improvement process, we
would appreciate your feedback regarding the
value of the SCMH material to your organization.
https://www.surveymonkey.com/r/8DKSD33,
you may also go to the announcement page of the SCMH
to find this link. (All submissions are anonymous.)
SCMH Comments: If you have comments about the APQP Guidance. You
may provide feedback via the SCMH, go to www.iaqg.org/scmh accept the
terms and conditions then click on “Contact Us” or “Take Survey”.
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SCMH Focus
Focus on “How” through SCMH
91XX
Inputs for new
revision of 91XX
91xx
9131
9103
Requirements
9102
SCMH Guidance
material, tools, training
Providing guidance material and best practices on how to meet
requirements and achieve objectives
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IAQG Link to SCMH:
Click “Supply Chain Management
Handbook (SCMH)”
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SCMH Access
Terms and
Conditions
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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 e-mail
address and password.
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SCMH Access
A quick look at the
SCMH.
Get there fast;
www.iaqg.org
www.iaqg.org/scmh
Search Engine: IAQG
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SCMH Access
www.iaqg.org
Detailed content and
direct access to free
guidance, training
presentations,
templates, forms, etc
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SCMH Content
Sections in progress
Recently published
Updated October 2018
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