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APQP & PPAP 3 Day Master Class (9145) - Face to Face

Our face-to-face training can be provided at our training venue or in-company at your site.
Enquire for in-company training

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 3-day course, the following topics are covered:

Day #1

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

Day #2

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

Day #3

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!

Upcoming courses

APQP & PPAP 3 Day Master Class (9145)

Face to Face
16 Sep - 18 Sep 25
£1,350.00

Enquire

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