Customer requirements for APQP & PPAP

An emerging aerospace/defence customer requirement is for their suppliers to be AS9100 certified and also deploy APQP & PPAP – which demands the use of essential ‘Core Defect Prevention Quality Tools’. The basic requirements are contained in AS9145.

AESQ & AS13100

The Aerospace Engine Supplier Quality (AESQ) Group have harmonized their supplier requirements to supplement those already defined in AS9100 and AS9145 in a single principal standard, AS13100 –

• AS13100 Chapter A ~ 9100 Quality Management Systems - Requirements for Aviation, Space and Defence Organizations - AESQ Supplemental Requirements

• AS13100 Chapter B ~ 9145 - Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP) - AESQ Supplemental Requirements

• AS13100 Chapter C ~ Core Defect Prevention Quality Tools to Support APQP and PPAP - Supplemental Requirements

APQP (Advanced Product Quality Planning)

APQP (Advanced Product Quality Planning) is a highly structured and controlled method of defining and establishing the necessary processes to assure that a new/revised product satisfies the aerospace and defence customer – and that everything is completed on time and at cost!

PPAP (Production Part Approval Process)

PPAP (Production Part Approval Process) is a documented 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.

Core Defect Prevention Quality Tools

Core Defect Prevention Quality Tools include –

🔅Design Failure Mode & Effects Analysis (DFMEA) – applying risk-based thinking and risk management to product design using DFMEA 'scoping tools’ including B-O-M, Block/boundary diagram, Interface matrix, Parameter diagram and Structure & Function Analysis.

🔅Process Failure Mode & Effects Analysis (PFMEA) & Control Plans – applying risk-based thinking and risk management to manufacturing and assembly processes and undertaking value-adding Process PFMEAs and creating effective Control Plans.

🔅Measurement Systems Analysis (MSA) – appreciating the nature and types of variation present in measurement systems and conducting measurement system analysis (MSA) studies on ‘variable’ and ‘attribute’ gauges (GR&R) including visual/workmanship inspection.

🔅First Article Inspection (FAI) ~ AS9102:2023 Rev C – interpreting and deploying the requirements of AS9102:2023 Rev C Aerospace First Article Inspection, completing the new FAI report forms while avoiding FAIR rejections!

🔅Process control methods & SPC – understanding the theory and practices of capability studies and designing/using process control charts (SPC – Statistical Process Control).

Organization responsibilities

Organizations must define the roles and responsibilities for managing and accomplishing APQP and PPAP elements, and allocate resources appropriately –

 ✔Demonstrable top management commitment and support

✔Assigned project owner for each APQP project

✔A committed timeline for executing planned APQP phases

✔A cross-functional team to assure effective product quality planning and execution

✔Staff competency in the use of the ’quality tools’

TEC's APQP & PPAP empowerment training

🔆 TEC’s Face-to-Face and e-Learning Aerospace/Defence APQP & PPAP + Quality Tools program has been developed over three decades and provides everything required for effective APQP & PPAP deployment 🔆

 Key questions to ask

• Are your customers demanding APQP & PPAP in conformity with AS9145 plus supplemental requirements?

• How would you fare if customers conducted an audit?

• Are your staff competent in the use of the ’quality tools’?