Length: 3 Days
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AS9145, APQP, and PPAP Workshop, Applied Aerospace

Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP) are two aviation core tools regulated by aerospace standard AS9145.

APQP is an organized approach to product and process design. This approach is a standardized set of quality requirements designed for suppliers to allow them to design a product that meets customer’s needs.

APQP was designed to assure that the needs of the customer are clearly understood, translated into requirements, technical specifications and special characteristics. The APQP was developed to create a proactive structured approach for the product development processes used throughout the aviation, space and defense industries.

This process ensures that industries have fully integrated processes; extending from concept and design to manufacturing process, into product use, service and customer feedback.

PPAP on the other hand, defines the approval process for new or revised parts, and also parts produced from new or revised production methods. PPAP is a standardized process in aerospace industries that helps manufacturers and suppliers communicate and approve production designs and processes before, during and after manufacture.

The International Aerospace Quality Group (IAQG) is a cooperative global organization of companies providing aviation, space and defense products and services. It established and deployed the AS9145 standard as a step to help achieve these objectives. The hope was also to reduce costs worldwide by enforcing these activities through the regional representatives: Americas (AAQG), Europe (EAQG) and Asia/Pacific (APAQG).

APQP begins with conceptual product needs and extends through product definition, production planning, product and process validation (i.e., PPAP), product use and post-delivery service. This standard integrates and collaborates with the requirements of the 9100, 9102, 9103, and 9110 standards.

The requirements specified in the AS9145 standard are complementary (not alternative) to contractual and applicable statutory and regulatory requirements. Should there be a conflict between the requirements of this standard and applicable statutory or regulatory requirements, the latter takes precedence.

The big difference between AS9145 and previous standards is section 8 regarding matters like contractor view, design and purchasing.

AS9145 is laid out in five distinct phases resulting in simultaneous processing between product and process. Those phases are:

  1. Planning – identify project scope with consideration of time, budget, quality and technical requirements.
  2. Product Design & Development – design products in accordance with requirements.
  3. Process Design & Development– design manufacturing processes in accordance with identified requirements and risks.
  4. Product & Process Validation– verify the ability of the processes to produce products at a given rate in conformance with the quality requirements.
  5. On-Going Production, Use & Post-Delivery Service Production– reduce variation with regular control checks, continuous improvement, and lessons learned to ensure ongoing customer satisfaction.

AS9145, APQP, and PPAP Workshop, Applied Aerospace course by Tonex

AS9145, APQP, and PPAP Workshop, Applied Aerospace is a 3 day hands-on workshop covering principles and application of AS9145, Advanced product quality planning (APQP), Production Part Approval Process (PPAP) applied to aerospace requirements. The AS9145 Aerospace standard is used to define the aviation, space, and defense process requirements for Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP).

Participants learn about Requirements for AS9145 Advanced Product Quality Planning and Production Part Approval Process. Principles of APQP including conceptual product needs, product definition, production planning, product and process validation (i.e., PPAP), product use, and post-delivery service are covered. Integration and collaborates with the requirements of the 9100, 9102, 9103, and 9110 standards are also discussed.

This three-day workshop walks participants through the AS9145 Aerospace standard, aviation, space, and defense process requirements for Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP).  The workshop covers APQP phases, Production Part Approval Process (PPAP)  required by aerospace industry that demand high quality, fast-turnaround and no deviation. Production Part Approval Process (PPAP) defines the requirements for production part approval, including production and bulk materials.

Participants learn how to apply APQP process and methodology to ensure that the product development processes deployed throughout the aviation, space, and defense industries are fully integrated phased processes including phases in concept and design through manufacturing process planning and execution, deployment, operation, maintenance and retirement.  The PPAP concepts are related to the output of APQP to confirm that production process leading products fulfill all requirements at the customer demand rate.

Applying AS9154, ASQP/PPAP to aerospace provides evidence that all aerospace engineering criteria, design records, and specification requirements are clearly understood by the supplying organization, along with processes to manufacture the part can consistently reproduce the part at stated production rates during routine production runs. The workshop also provides risk management, guidance on the Aerospace PPAP submission requirements and covering tools such as DFMEA, PFMEA, FMECA, Control Plans, MSA, and SPC.

Target Audience

AS9145, APQP, and PPAP Workshop, Applied Aerospace  is a three-day workshop designed for:

  • Product/process design managers
  • Quality managers
  • Product/process design engineers
  • Production engineers
  • Process development engineers
  • ISO/TS internal auditors
  • Outside and second-party auditors
  • All individuals interested in learning and pursuing AS9145, APQP/PPAP

Classroom Style

Instructor-led at your site or Learning Live can bring the classroom to you, virtually.

Training Objectives

Upon the completion of this workshop, attendees are able to:

  • Relate the concepts behind concepts of AS9145 standard
  • Learn about AS9145 definitions and aerospace requirements for Advanced Product Quality Planning (APQP) and
  • Production Part Approval Process (PPAP)
  • Appreciate and learn about the importance of a multi-disciplinary team in the planning process
  • Learn about aerospace products and processes development
  • Plan and develop the steps required to organize an APQP manual
  • Apply APQP 5 Phases within the aerospace sector
  • Conduct the Production Part Approval Process
  • Explain applicable frameworks and techniques to facilitate the process design
  • Learn about FMEAs (DFMEA/PFMEA) for process risk reduction
  • Learn about AS9145 control plan
  • Apply Process Flow Diagram (PFD)
  • Learn about Measurement System Analysis (MSA) and Statistical Process Control (SPC)
  • Describe Process Capability and First Article Inspection Report (FAIR)

Course Outline

Overview of AS9145 Aerospace Standard

  • Aviation, space, and defense (ASD) process requirements
  • Aviation Core Tools
  • Aerospace APQP Solution in compliance to Aerospace PPAP and APQP (AS9145 & AS13004)
  • Fundamentals of AS9145 applied to Aviation, Space and Defense (ASD)
  • Aerospace Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP)
  • AS9145 requirements
  • Methodologies for risk management
  • New product launch
  • Characteristics and other aerospace requirements
  • AS9102 First Article Inspection
  • AS9103 variation management

Principles of APQP/PPAP

  • What is APQP
  • APQP as a Quality Framework
  • APAQ versus Design for Six Sigma (DFSS)
  • APAQ versus Voice of the Customer (VOC)
  • How APQP works
  • Identified process and product parameters
  • Product Conformity
  • Product Part Approval Process (PPAP)
  • Requirements to obtain part approval of supplier manufactured parts
  • Consistent part review and approval process

Application of APQP Processes

  • Inputs and outputs for each of the five phases
  • APQP linkages to Other Processes
  • Failure Modes and Effects Analysis (FMEA)
  • Statistical Process Control (SPC)
  • Measurement System Analysis (MSA)
  • Production Part Approval Process (PPA)
  • APQP Control Plan

Apply APQP 5 Phases

  • Planning
  • Collect project inputs and set the project
  • Product Design & Development
  • Design the product considering all identified requirements and risks
  • Process Design & Development
  • Design the manufacturing and assembly process considering all identified requirements and risks
  • Products & Process Validation
  • Validate that the process is producing the specified product at the required rate
  • Production
  • Reduce variation, manage any nonconformity, continuous improvement and feed lessons learned back into the new product development projects

PPAP Requirements

  • Element Requirements
  • Element 1 – Design Records
  • Element 2 – Design Risk Analysis (DRA)
  • Element 3 – Process Flow Diagram (PFD)
  • Element 4 – Process Failure Mode and Effects Analysis (PFMEA)
  • Element 5 – Control Plan
  • Element 6 – Measurement System Analysis (MSA)
  • Element 7 – Initial Process Capability Studies
  • Element 8 – Packaging, Preservation, and Labeling Approvals
  • Element 9 – First Article Inspection Report (FAIR)
  • Element 10 – UTC PPAP Requirements
  • Element 10.1 – Part Marking Approval
  • Element 10.2 – Production Process Run(s)
  • Element 11 – PPAP Approval

PPAP Approval Process

  • Part Submission Warrant (PSW)
  • The control plan
  • Process Failure Mode and Effect Analysis (PFMEA)
  • Records of Material/Performance
  • Tests and PPAP submittal

APQP/PPAP Project Management

  • Streamlining the entire Project Management Lifecycle
  • Task Definition for projects
  • Time schedule for different tasks
  • Delegation of various duties
  • Resource Allocation for the tasks
  • Reminders for tasks
  • Confirming Task Assignments
  • Establishing Baseline
  • Implementing APQP with PPAP
  • Core Tools
  • Developing flow charts, process instructions and control plans
  • Implementing APQP and Control Plan

Workshop 1: Plan and develop the steps required to organize an APQP manual

Phase 1: Plan and Define

  • Compiling sufficient data to make a business case
  • Defining what product should be studied

Phase 2: Developing and Designing Product

  • Finalizing the product design
  • Building a prototype, developing the features and specifying the inputs for the process

Phase 3: Developing and Designing Process

  • Designing the production process
  • Developing the process flow diagrams

Phase 4: Validating Product and Process

  • Validating the product design and process
  • Evaluating the measurement system and the process capability

Phase 5: Feedback, Assessment and Corrective Actions

  • Initiate an algorithm to improve the process constantly
  • Create charts to keep track of variations and their potential causes
  • Studying the system capability and applying the DOE to reduce common failures
  • Making sure the product completely satisfies customers
  • Controlling the Plan
  • Determine the control factors, points, and methods for the product and the process
  • Developing a comprehensive control plan
  • Review some examples of control plan

Workshop 2: Working with Production Part Approval Process (PPAP) Requirements

    • Bill of Materials (BOM) Inspection/Test Plan Production Part Approval Process (PPAP) File
    • Commercial off-the-Shelf (COTS)
    • Key Characteristic (KC)
    • Production Preparation Plan
    • Control Plan
    • Measurement Systems Analysis (MSA)
    • Production Readiness Review (PRR)
    • Critical Item (CI) Phase Special Requirements
    • Customer Post Delivery Service Stakeholder
    • Deliverables Pre-Design Standard Part
    • Demand Rate Preliminary BOM Supplier
    • Design Characteristics Preliminary Capacity Assessment Validation (Design, Process, Product)
    • Design Records Preliminary Capacity Study Verification
    • Design Risk Analysis Product Breakdown Structure (High-level BOM)
    • Failure Mode & Effects Analysis FMEA)
    • Product Development Process (PDP)

Workshop 3: Checksheets & Work Instructions

  • Manage Voice of Customer (VOC) Requirements
  • Build Block Diagrams
  • P-Diagram
  • DFMEA and Test Plans (V&V)
  • Automate Process Flow
  • Design Risk Analysis (Design Failure Modes and Effects Analysis DFMEA)
  • Process Flow Diagram (PFD)
  • Process Failure Modes and Effects Analysis (PFMEA)
  • PFMEA and Control Plan
  • Measurement Systems Analysis (MSA)

AS9145, APQP, and PPAP Workshop, Applied Aerospace

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