APQP is a highly structured and controlled method of defining and establishing the necessary process steps to assure that a product satisfies the aerospace/defence customer.
APQP ensures that the necessary planning and communication will take place between all interested parties with the commitment and support of top management – and that everything is completed on time and at cost.
The five phases are sequenced to represent planned timing to execute the functions described. Emphasis is on –
APQP methodology – up-front planning and the act of implementation
Defect Prevention Quality Tools/Techniques
PPAP file – the accumulation of objective evidence
The PPAP is an 'output' of APQP confirming that the production process has demonstrated the potential to produce products that consistently meet all requirements at the customer demand rate.
The end of each phase is defined by the accomplishment of specific outputs (milestones) that support the overall success of the project.
The requirement for APQP & PPAP has been given a major boost by the AESQ with the publication of their AS13100 standard which incorporates AS9100 and AS9145 with supplemental requirements plus mandatory ‘core’ Defect Prevention Quality Tools.
Implementation of APQP & PPAP requires an in-depth knowledge of the essential staged processes and competency in the use of quality tools including, as a minimum –
DFMEAs
PFMEAs
MSA
Control Plans
Process Capacity Studies
SPC, etc.
APQP can be applied to the final product or selected levels of parts (i.e. parts within an assembly as defined by the organization or customer).
APQP ‘flow-down’ will be mandated as a general contractual requirement (not programme-specific) and the scope of applicability will be established between the organization and their customer.