Course overview
An emerging customer requirement is for their suppliers to implement APQP (Advanced Product Quality Planning) and PPAP (Production Part Approval Process) in full conformity with –
Aerospace: the 9145 standard (plus customer-specific requirements)
Aeroengine AESQ: AS13100 Chapter B (9145 + supplemental requirements)
Implementation of APQP and PPAP requires an in-depth knowledge of the essential processes and competency in the use of quality tools such DFMEAs, PFMEAs, MSA (Measurement Systems Analysis), Control Plans, Process Capacity Studies, SPC, etc.
TEC's unique 3-day “Master Class" incorporates Quizzes, Tests and ‘hands-on’ Exercises to empower participants in both the implementation of the APQP methodology and the use of all of the above ‘quality tools’ including the statistical software package Minitab®.
a downloadable (pdf) Delegate Workbook is included
Knowledge and skills are evaluated at each stage to guarantee successful new product introduction in full conformity with both aerospace and automotive requirements.
The course covers in detail everything that is needed to develop, document and implement 9145 and AS13100 (Chapter B) processes for APQP and PPAP
Course details
The course is delivered as an interactive 3-day course & workshop.
Within the course, the following topics are covered:
Preamble
Product Development Process (PDP)
APQP (PDP), PPAP and IAQG/SAE documents
Quiz: Does 9100 mandates a PDP?
9145 standardizes APQP and PPAP
Responsibilities, exclusions, support and competency
9145 – APQP structured requirements
Quiz: APQP, its application & AS9145 requirements
9145 scope, contractual requirement and conformity
Team exercise: APQP project management
APQP and PPAP overview and related standards, quality processes and quality tools
Team exercise: APQP project management
APQP phases for a ‘generic’ organization
Map and align your existing QMS processes
Organizations having design responsibility
APQP ‘cascade’ through PBS (Product Breakdown Structure)
Identifying your organization’s level in PBS
Individual exercise: What’s your organization’s level?
The ‘responsibility’ matrix
Project planning, monitoring and reporting
Interested party mapping (RACI)
Other related (mandated) IAQG/SAE standards
Exercise: Awareness of standards?
Mandated quality processes and tools
Team exercise: Identifying ‘skills gaps’
Developing the evidence – the PPAP file
Key ‘deliverables’ of PPAP
Team exercise: Customer PPAP requirements
APQP phase/activity checklists
Phase 1 ~ Planning
Product quality planning timeline chart
Phase 1 – Planning (Goal)
9145-mandated requirements
Producers (‘make-to-print’) interaction with design
Phase 1 elements
Project inputs
Quiz: Project inputs
Product design requirements
Producer product specification
Producer product specification
Preliminary listing of CIs and KCs
Quiz: Special requirements, CIs and KCs
Preliminary BOM (Bill-of-Material)
Preliminary PFD (Process Flow Diagram)
SOW (Statement of Work) review
Preliminary sourcing plan – supplier selection
Project (timeline) plan
Project planning – supply chain alignment
Key project planning elements
Summary of APQP and PPAP timeline plan
IAQG’s APQP timeline template
IAQG’s APQP timeline elements
Individual exercise: Identify your timeline elements
Phase 1 – activities, deliverables and outputs
Phase 1 – conformity checklist questions
Conformity with 9145 clause 4.3 – summary
Phase 2 ~ Product design, development and design validation
Product quality planning timeline chart
9145 mandated requirements
Phase 2 – Product design, development and design validation
Phase 2 elements
Exercise: Design and development planning
Preliminary design – early in the design phase!
DFMEA (Design Failure Modes and Effects Analysis)
Design risk analysis – preliminary design focus
Prerequisites for a DFMEA
Block (Boundary) Diagrams – examples
FMEA Interface Matrix – example
FMEA Interface Matrix – example
P-Diagram (Parameter Diagram)
P-Diagram – example
The DFMEA is conducted in logical order
Sequence of the DFMEA steps
DFMEA – Specimen template
Quiz video: Could a DFMEA have prevented this?
Design FMEA – Checklist questions
Maintenance FMEA
Team exercise: Design FMEA
DFM and DFA – example
Engineering BOM (Bill-of-Material)
Parts obsolescence
Part obsolescence issues and interventions
PLM (Product Lifecycle Management)
Individual exercise: Understanding terminology – Special requirements, KCs and CIs
Exercise: Types of design characteristics
Finalized design – engineering documents
Tolerance, assemblies and interchangeability
Geometric Dimensioning & Tolerancing (GD&T)
GD&T definition and benefits
Exercise: Design records (design outputs)
Sourcing, packing, design reviews and verification and validation activities
Preliminary risk analysis of sourcing plan
Packaging and labelling specification
Design review report (PDR and CDR)
Development product build plan
Design verification and validation plans – and associated results
Feasibility assessment
Individual exercise: Basic APQP requirements?
Phase 2 – activities, deliverables and outputs
Phase 2 – conformity checklist questions
Conformity with clause 4.4 – summary
Phase 3 ~ Process design and development
Product quality planning timeline chart
Phase 2 outputs ~ Phase 3 inputs
9145 summary requirements for Phase 3
Phase 3 – Process design and development
Phase 3 elements
Review product information – design output
Exercise: Inputs from (design) Phase 2
PFMEA (Process Failure Modes and Effects Analysis)
Process Flow Diagram (PFD)
Exercise: Process Flow Diagram (PFD) - variants
Floor plan layout
Exercise: Floor plan layout
Production preparation plan (PPP)
PFMEA (Process Failure Mode & Effect Analysis)
PFMEA – Specimen template
Ranking criteria (scoring)
Specimen S, O, D ranking criteria
Exercise: Process FMEA
Key characteristics and Control plan
Quiz: Process Key Characteristics (KCs)
Control plan – specimen example
Control Plan prerequisites
Control Plan (CP)
Control Plan – generic elements
Content of the 9145 Control Plan
Control Plan – methodology
Control plan – reaction plan
Exercise: Control plan
Using ‘groups or families of parts’
Preliminary capacity assessment and Workstation documentation
Preliminary capacity assessment
Workstation documentation
Quiz: Workstation documentation
Designed to be used by operators!
Measurement Systems Analysis Planning
MSA (Measurement Systems Analysis) plan
Components of measurement variation
Gauge selection – resolution (discrimination)
Resolution and ‘accuracy ratio’
Exercise: Determining gauge resolution
Visualizing measurement system errors
Accuracy
Illustration: Gauge bias and linearity
Interpret the results: Gauge bias and linearity
Assessing stability (consistency)
Illustration: Assessing stability
Supply chain, packaging and Production Readiness Review
Supply chain risk management plan
Material handling, packaging, labelling and part marking approvals
Exercise: Material handling, packaging, labelling and part marking approvals
Production Readiness Review (PRR)
Quiz: Production Readiness Review (PRR)
Phase 3 – activities, deliverables and outputs
Phase 3 – conformity checklist questions
Conformity with clause 4.5 – summary
Phase 4 ~ Product and process validation
Product quality planning timeline chart
9145-mandated requirements
Phase 4 – Product and process validation
Phase 4 Product and process validation elements
Quiz: PPRs (Production Process Runs)
Significant production process runs
Quiz: Significant production process runs
MSA (Measurement Systems Analysis)
Type 1 Gauge Study – gauge variation study
Understanding measurement consistency
Exercise: Type-1 Gauge Study
Basic test for normality – recommend first check
Type 1 Gauge Study – Minitab® dialogue boxes
Type 1 Gauge Study – Minitab® graphs & analysis
MSA (Measurement Systems Analysis)
Understanding a GR&R Study
Steps in an effective GR&R Study
Understanding GR&R acceptability criteria
Pre-requisites for an effective MSA study
Planning and conducting a GR&R study
Typical ‘team’ for undertaking a GR&R study
Illustration: Creating a Minitab® data worksheet
Illustration: Measure the parts in random order
Exercise: Diameter measurement Gauge R & R study
Analysis: Variance components
Analysis: Gauge Evaluation
Exercise: AS13003 Gauge R & R study
Illustration: Recording results on a Minitab® worksheet
Illustration: Gauge run chart – by Part and Operator
Illustration: Setting up the Minitab® GR&R study
Illustration: The Minitab® gauge evaluation – % tolerance
Interpreting the MSA results
Interpreting the MSA results
Exercise: Interpreting the MSA results
Understanding process variation
Case Study: Creating the shaft diameter on an old lathe
Exercise: Visualizing the ‘voice of the data’
Run Chart and Dot-Plot (Histogram)
Quiz: what did you make of the data?
Words of wisdom – Dr W Edwards Deming
Understanding ‘patterns’ of variation
Putting ‘properties’ into words
Quiz: Does the Case Study data look normal?
Estimating statistical parameters
Quiz: Which quadrant are we in?
Calculating the mean (Xbar)
Calculating the standard deviation StDev (σ)
Exercise: Calculating Xbar and StDev (σ)
Comparative calculations of Mean and StDev
Determining process capability
Quantifying process capability
A ‘non-capable’ process (centred)
A ‘capable’ process (centred)
Process capability – Cp (best case)
Process capability – Cpk (worse case)
Exercise: Cp and Cpk calculation (Case Study)
Illustration: Case Study Cp and Cpk using Minitab®
9145 requirements – Process improvement strategies
Benefits of centering a process (Cpk ~ Cp)
Exercise: Targets for process improvement
Summary report for shaft diameters – Improved
Finalized Control plan, Capacity verification, Product and process validation and FAI
Control plan – production control plan
Control plans – examples of different types
Capacity verification
Quiz: Capacity verification methodology
Product validation results
Product and process validation
FAI (First Article Inspection) ~ 9102
Types of data needed to satisfy a FAI
Exercise: Requirements for FAI
Production Part Approval Process (PPAP)
Reminder: The PPAP ‘evidence file’
PPAP file and (approval) form
PPAP process requirements
PPAP file contents – 9145 section references
Exercise: PPAP elements
Customer-specific PPAP requirements
Example: Customer-specific PPAP needs
Example: PPAP approval (submission) form
Phase 4 – activities, deliverables and outputs
Phase 4 – conformity checklist questions
Conformity with clause 4.6 – summary
Phase 5 ~ On-Going Production, Use and Post-Delivery Service
Product quality planning timeline chart
9145-mandated requirements and goals
Quiz: Monitoring performance
Examples: APQP performance measures
Optimizing process capability
MRO Services and MRO KPIs
Continuous improvement actions
Lessons learned (organizational knowledge)
Variation reduction actions
Phase 5 – activities, deliverables and outputs
Phase 5 – conformity checklist questions
Conformity with clause 4.7 – summary
Extended questions & answers session
Who should attend
Staff responsible for new product introduction and who need the knowledge/skills to implement an effective APQP system and create the contents of the PPAP file.
Deliverables & benefits
Attendees who successfully complete the course and actively participate in all of the exercises will receive Certificate demonstrating their knowledge/skills in operating the APQP and creating the PPAP document.
⚠ 𝗪𝗔𝗥𝗡𝗜𝗡𝗚 ⚠
⚠ Beware of organizations who lack internationally recognized aerospace/defence [A|S|D] certifications/approvals (e.g. CQI|IRCA, IAQG, Probitas AUTHENTICATION)
⚠ Avoid organizations who do not specialize in the A|S|D sector
⚠ Ensure detailed syllabi are provided for all courses for transparency
⚠ If the provider isn’t ISO 9001 certified themselves, ask why they promote third-party certification and related consulting and training!