Upload
others
View
257
Download
8
Embed Size (px)
Citation preview
AS9145 APQP and PPAP : Delivering
effective New Product Introduction
and Competitive Advantage
Profile
Industry Forum supports manufacturing organisations to become more competitive
20 years multi-sector consulting experience
Management of all Industry Forum Aerospace activity
Master Assessor and lead author National Manufacturing Competitiveness Levels (NMCL)
Assessment - SC21 C&G
Andy Spence
General Manager, Aerospace
SMMT Industry Forum
IF NPI model for Launch Excellence
Product Launch Excellence
Production Part Approval Process (PPAP)
NP
I P
roc
es
s
Pro
jec
t M
an
ag
em
en
t
Des
ign
Ex
ce
lle
nc
e
Ma
nu
fac
turi
ng
Pro
ce
ss D
es
ign
Pro
du
ct
an
d P
roc
es
s V
ali
da
tio
n
Su
pp
ly C
ha
in R
ea
din
es
s
Advanced Product Quality Planning (APQP)
Product and
Technology Roadmap
Product Costing and
Portfolio AnalysisS&OP link with NPI
Product Launch Right First Time, On Time In Full and at Target cost
Output
Process PillarsAS standard
support
Stable
Foundations
NPI – Common challenges
Common challenges Route to success
Low win percentage for bids Bid / No bid strategy
One size fits all NPI process Map NPI process to fit business needs
OTIF failure caused by resource bottleneck Measure NPI pipeline
Erratic NPI QCD performance Build in Quality for NPI
Common Challenge Route to Success
Low win percentage for bids Bid / No bid strategy
NPI Ref. No. Customer
Date Platform
Assessment Scoring
Strategy Operations Technical CommercialBid
Preparation
Score 25% 15% 4% 19% 4%
Target 25% 25% 20% 20% 12%
0%
5%
10%
15%
20%
25%
30%
Percentage
66%
0%10%20%30%40%50%60%70%80%90%100%
NPI Route to Success
Driving strategy
NPI Route to Success
WHAT tasks and decision points are required?
WHO owns the task and decision making?
HOW do we present output of task?
WHEN will the task complete?
Common Challenge Route to Success
One size fits all NPI process Map NPI process to fit business needs
1
2
3
4
Timing
(When) -
hours
No. NameEvidence required to meet
gate
Gate purpose Commitment made at gate
Pro
ject
man
ag
er
Fin
an
ce
Co
mm
erc
ial
Su
pp
ly c
hain
En
gin
eeri
ng
Op
era
tio
ns
Qu
ali
ty
HS
E
Lo
gis
tics
Pla
nn
ing
R C
A I
0.2 1.1 Receive RFQ and log AR
0.5 1.2 Initiate project AR
0.5 1.3Complete outline business
case pro-formaAR
0.5 1.4 Plan bid resources for stage 2 AR C C
Gate 1 Decision to bidOutline business case
RFQ TrackerDo we bid for this work?
Commit resource to prepare
bidAR
Standard Work (How)
Tasks (What)
(on blue)
Consulted (provide
input)
Bid / No Bid decision matrix
Accountable (ultimately
answerable)
Responsible (doers)
Informed (require
output)
Stage 1.
Opportunity
evaluation
Initial
evaluation of
potential new
work
RFQ tracker
Project summary (incl. business
base)
Project summary (incl. business
base)
Project summary (incl. business
base)
NPI Route to Success
WHAT? WH0? HOW?WHEN?
Common Challenge Route to Success
One size fits all NPI process Map NPI process to fit business needs
NPI Route to Success
Common Challenge Route to Success
OTIF failure caused by resource bottleneck Measure NPI pipeline
NPI Route to Success
Common Challenge Route to Success
Erratic NPI QCD performance Build in Quality for NPI
AS standards – Choice to make
AS standards – Choice to make
Aerospace APAP/PPAP
AS9145 Defines
The Output:
Production
Part
Approval
Process
PPAP
The Process:
Advanced Product Quality Planning = APQP
Overview of APQP
* PDR – Preliminary Design Review, CDR – Critical Design Review
* *
AS9145 PPAP Elements
delivered by the APQP Process
Design record Design risk analysis (DFMEA)
Process flow Process FMEA Control planMSA
Part Number Gage Name Appraiser A
NUMBERPart Name Gage Number Appraiser B
NAME
Characteristic Gage Type Appraiser C
Characteristic Classif ication Trials Parts Appraisers Date Performed
3 10 3
Measurement Unit Analysis % Tolerance (Tol)
Repeatability - Equipment Variation (EV)
EV = R x K1 Trials K1 % EV = 100 (EV/Tol)
= 0.008 x 0.5907 2 0.8865 = 100(0.005/0.167)
= 0.005 3 0.5907 = 2.72
Reproducibility - Appraiser Variation (AV)
AV = {(xDIFF x K2)2 - (EV2/nr)}1/2
% AV = 100 (AV/Tol)
= {(0.011 x 0.5236) 2̂ - (0.005 2̂/(10 x 3))} 1̂/2 = 100(0.006/0.167)
= 0.006 = 3.42
A ppraisers 2 3
n = parts r = trials K2 0.7087 0.5236
Repeatability & Reproducibility (GRR) % GRR = 100 (GRR/Tol)
GRR = {(EV2 + AV2)}1/2Parts K3 = 100(0.007/0.167)
= {(0.005 2̂ + 0.006 2̂)} 1̂/2 2 0.7087 = 4.37
= 0.007 3 0.5236 Gage system O.K
Part Variation (PV) 4 0.4464
PV = RP x K3 5 0.4032 % PV = 100 (PV/Tol)
= 0.172 x 0.3145 6 0.3745 = 100(0.054/0.167)
= 0.054 7 0.3534 = 32.50
Tolerance (Tol) 8 0.3378
Tol = Upper - Lower / 6 9 0.3247 ndc = 1.41(PV/GRR)
= ( 15.5 - 14.5 ) / 6 10 0.3145 = 1.41(0.054/0.007)
= 0.167 = 10
Gage discrimination acceptable
Initial process capability studies
Packaging, preservation &
labelling
First article inspection (FAIR)
APQP PROCESS
1 2 3 4 5 6
7 9 108
Customer PPAP
Requirements
PPAP Confirms
Engineering requirements are
properly understood and verified
Manufacturing quality and rate
potential exists
All customer design definition and specification
requirements are properly understood, accounted
for, verified and recorded by the production supply
organisation.
The manufacturing process / tool / facility have
the potential to produce product consistently,
meeting these requirements during an actual
production process run, at a quoted production
rate.
All customer design record and specification
requirements are properly understood,
accounted for, verified and recorded by the
product supplier
The manufacturing process / tool / facility
have the potential to produce product
consistently meeting these requirements
during an actual production process run at a
quoted production rate.
Our Service Offerings
Visit www.industryforum.co.uk for details or Stand R20
Aerospace Management Systems
• AS9145 APQP & PPAP
• AS13000 8D Problem Solving
• AS13003 Measurement Systems Analysis
(MSA)
• AS13004 Process FMEA and Control Plan
(PFMEA)
• AS9103 Statistical Process Control (SPC)
• AS13006 Process Control
• Design FMEA (DFMEA)
• Implementation support
New Product Introduction
• NPI gap assessment
• New Product Launch eXcellence
(NPLX)
• Gated process development
• Project management techniques
• Design process Improvement
• Manufacturing process development
• Supplier readiness assessment