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AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage

AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

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Page 1: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

AS9145 APQP and PPAP : Delivering

effective New Product Introduction

and Competitive Advantage

Page 2: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

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

Page 3: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile 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

Page 4: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

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

Page 5: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

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

Page 6: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

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

Page 7: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

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

Page 8: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

NPI Route to Success

Common Challenge Route to Success

OTIF failure caused by resource bottleneck Measure NPI pipeline

Page 9: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

NPI Route to Success

Common Challenge Route to Success

Erratic NPI QCD performance Build in Quality for NPI

Page 10: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

AS standards – Choice to make

Page 11: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

AS standards – Choice to make

Page 12: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

Aerospace APAP/PPAP

AS9145 Defines

The Output:

Production

Part

Approval

Process

PPAP

The Process:

Advanced Product Quality Planning = APQP

Page 13: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

Overview of APQP

* PDR – Preliminary Design Review, CDR – Critical Design Review

* *

Page 14: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

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

Page 15: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

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.

Page 16: AS9145 APQP and PPAP : Delivering effective New Product ... · AS9145 APQP and PPAP : Delivering effective New Product Introduction and Competitive Advantage. Profile Industry Forum

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