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 AS9145 standard (and the AS13100 supplementary requirements)
Aeroengine AESQ: AS13100 Chapter B (AS9145 + supplemental requirements)
Automotive: the IATF 16949 standard and AIAG's manual "Advanced Product Quality Planning (APQP) and Control Plan"
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. etc.
TEC's unique 3-day “Master Class" incorporates Quizzes, Tests, ‘hands-on’ Exercises and Personal assignments 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 AS9145, AS13100 (Chapter B) and IATF 16949 conforming 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:
Introduction
Download (pdf) Delegate Workbook
Understanding APQP & PPAP and AS9145
Definition of APQP
Definition of PPAP
Test: Purpose of APQP and PPAP
Understanding AS9145 and related IAQG standards
The AS9145 standard
The AS13100 (Chapter B) supplementary requirements
Related IAQG standards
Understanding customer demands for AS9145 conformity
Personal assignment
APQP & PPAP applicability and application
APQP & PPAP applicability
APQP & PPAP (AS9145) application
Quiz: APQP, its application & AS9145 requirements
APQP primary objective and essential risk-based thinking
Understanding the primary APQP objective
Risk-based thinking process stages
Test: Risk-based thinking
Systematic risk management (FMEA)
Introduction to FMEA
Overview of FMEA methodology
Example of a ‘generic’ FMEA worksheet
Quiz: FMEA purpose and ‘deliverables’
FMEA terminology explained
Test: FMEA terminology
Evaluating and scoring the ‘elements’ of failure modes
Test: The scoring ‘elements’ of failure modes
FMEA evaluation criteria
Quiz: Sources of FMEA scoring criteria
Risk Priority Number (RPN)
Exercise: Calculating RPM
Reducing risks to an acceptable level
Reasons for risk management and mitigation
Personal assignment
Understanding AS9100 & AS9145 purpose and applicability
AS9100 standardizes QMS requirements
Basic AS9100 requirements
AS9145 standardizes APQP and PPAP requirements
Test: AS9100 and AS9145 requirements for APQP
APQP requirements for ‘flow-down’, exclusions & conformity
Quiz: Customer demands for AS9145 conformity
Understanding essential APQP ‘success factors’
Quiz: Essential APQP ‘success factors’
Product Development Process & Product Breakdown Structure
Product Development Process (PDP)
Product Breakdown Structure (PBS)
Exercise: Defining your organization’s PBS level, products, APQP plan and activity scope
APQP ‘cascade’ through PBS & PDP
AS9145 – structured APQP requirements
AS9145 and the APQP phases
APQP phase constituents
Test: AS9145 – structured APQP requirements
Applicability of APQP phases
Personal assignment
Overview of the APQP phases and their goals
Phase 1 – Planning
Phase 2 – Product design, development and design validation
Phase 3 – Process design and development
Phase 4 – Product and process validation
Phase 5 – On-going production, use and post-delivery service
Quiz: The APQP phases and their goals
Phase 1 – Planning
Product design requirements
Producer product specification
Project targets
Quiz: Product design/specification/target requirements
Understanding characteristics
Quiz: Types of characteristics
Preliminary Bill of Material (BOM)
Preliminary process flow diagram (PFD)
Test: Preliminary BOM and PFD
Statement of Work (SOW) review
Preliminary sourcing plan
Quiz: Statement of Work and Preliminary sourcing plan
Project plan
Personal assignment
Phase 2 – Product design and development
Turning product specifications into robust product definition
DFMRO (Design for Maintenance, Repair and Overhaul)
DFMA (Design for Manufacturing & Assembly)
Aligning AS9100 controls with AS9145 reviews
Quiz: Understanding design considerations and reviews
Design risk analysis
DFMEA (Design Failure Mode and Effects Analysis)
Test: Sequence of the DFMEA steps
Design records (design outputs) and BOM*
Special requirements, including product KCs and CIs listings
Quiz: Design records (outputs)
Preliminary risk analysis of sourcing plan
Quiz: Risk analysis of Sourcing plan
Packaging specification
Development product build plan
Design verification and validation plans, and associated results
Feasibility assessment
Personal assignment: DFMEA
Phase 3 – Process design and development
Translating product design into the production processes
Review product information – design output
Quiz: Product design information
Process flow diagram
Floor plan layout
Production preparation plan
PFMEA (Process Failure Mode & Effect Analysis)
Test: Sequence of the PFMEA steps
Product/Process Key Characteristics (KCs)
Control plan
Test: Control plan
Using ‘families of parts’
Preliminary capacity assessment
Work station documentation
Measurement Systems Analysis (MSA) Plan
Quiz: Understanding measurement systems errors
Determining gauge Accuracy
Case study: Studying gauge linearity and bias
Exercise: Measuring gauge linearity and bias
Studying gauge stability
Case study: Studying gauge stability
Exercise: Studying gauge stability
Supply Chain Risk Management Plan
Material handling, packaging, labelling, and part marking approvals*
Production Readiness Review (PRR) results
Personal assignment: PRR results
Phase 4 – Product and process validation
Product from production process run(s)
Measurement Systems Analysis (MSA)
Type 1 Gauge Study
Case Study: testing gauge for consistency
Exercise: Testing gauge for consistency
Gauge Repeatability & Reproducibility (GR&R) study
Case Study: Gauge R & R study
Exercise: Full R & R study
Initial process capability studies
Exercise: Normality check, Mean and Standard deviation
Process Capability
Exercise: Process capability
Benefits of centring a process
Case study: Centring the process
Exercise: Centring the process
Control plan
Capacity verification
Quiz – Capacity verification
Product validation results
Product and process validation
Quiz: Process capability for KCs
First Article Inspection Report (FAIR)
Quiz: FAI applicability?
PPAP file and approval form*
Quiz: PPAP required elements
PPAP File
Customer specific requirements
Personal assignment: PPAP requirements
Understanding the PPAP submission procedure
Phase 5 – On-going production, use and post-delivery service
Phase 5 activities
Monitor product and process performance (KPIs)
Examples of APQP & quality performance measures
Continuous improvement actions
Case study: Improving process capability
Exercise: Improving process capability
Lessons learned
Promoting the benefits of APQP & PPAP
Identifying the potential benefits
Dealing with the ‘dissenters’
Personal assignment: creating an APQP & PPAP Management Orientation Session
Auditing considerations
The need for ongoing auditing
APQP Auditing
Layered Process Audits (LPA)
Further development of your knowledge & skills
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 the all of the exercises will receive Certificate demonstrating their knowledge/skills in operating the APQP and creating the PPAP document.