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9145 Guidance
9145 Guidance
Aerospace Standard
Advanced Product Quality Planning (APQP)
and Production Part Approval Process (PPAP)
Guidance Material
November 2016
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Rationale and Foreword
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Contents
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Introduction
APQP has five phases starting with product concept and extending throughout
the product life cycle.
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Purpose
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Purpose
Phase 4 – Product and Process Validation - validate that product fulfills the design
requirements and the process has demonstrated the capability to constantly produce
conforming products at the customer demand rate. Product validation is achieved using
product produced from the final production process.
Phase 5 – On-going Production, Use, and Post-delivery Service - ensure customer
requirements are continuously met through the use of process control, lessons learned,
and continuous improvement.
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General Terms
Control Plan tem Measurement Systems Analysis (MSA) Production Readiness Review (PRR)
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4.1 General Requirements
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4.2 Project Management
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4.3 Phase 1 - Planning
Phase Output
Activities Deliverables Key Milestones
• Collect the technical and non- • Product design requirements • The product concept is finalized and a pre-
technical requirements applicable to • Project targets – safety, design is available
the product and associated project quality/manufacturability, service
• Develop a Statement of Work life, reliability, durability, maintainability,
(SOW) for the project schedule, and cost
• Define the product and associated • Preliminary listing of Critical Items (CIs)
project targets and Key Characteristics (KCs)
• Develop the product breakdown • Preliminary BOM
structure [i.e., high-level Bill of • Preliminary process flow diagram
Material(BOM)] to support source • SOW review
selection • Preliminary sourcing plan
• Coordinate and communicate timing • Project plan
with all applicable stakeholders
• Schedule all key dates and
deliverables in the project plan
Phase 1 Outputs
• Finalization Product Concept
• Availability of Preliminary Bill of Material (BOM)
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4.4 Phase 2
Product Design & Development
Phase Output
Activities Deliverables Key Milestones
• Turning product specifications into • Design risk analysis* • Design record and BOM
robust product definition • Design records and BOM* addressing the • Design verification and validation plans,
- Design risk analysis findings of the design risk analysis and associated results
- Design for Manufacture and • DFMA, tolerance, stack-up analysis, etc.
Assembly (DFMA) • Special requirements, including product
- Design for Maintenance, Repair, and KCs and CIs listings
Overhaul (DFMRO) • Preliminary risk analysis of sourcing plan
- Identification of product KCs • Packaging specification
- Product error proofing • Design review report
• Create BOM • Development product build plan
• Conduct design reviews • Design verification and validation plans,
• Validate and verify product design and associated results
• Conduct design record review at • Feasibility assessment
production sources to evaluate
manufacturing feasibility
“Bold” text indicates requirements defined in this standard * Indicates PPAP requirement
Phase 2 Outputs
• Release of Design Records
• Completion of Design Verification, Validation Plan
• Initiation of Sourcing Plan risk analysis
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4.5 Phase 3
Process Design & Development
Phase Output
Activities Deliverables Key Milestones
• Complete source selection • Process flow diagram* • Production process defined and
and establish a supply chain risk • Floor plan layout deployed
management plan • Production preparation plan • Successful completion of the PRR
• Create a process flow diagram
• Operator staffing and training plan
• Conduct Process Failure Mode and Effects (Human Resources)
Analysis (PFMEA) on the proposed
• PFMEA*
process(es) and identify process KCs
• Process KCs
• Update the process based on the • Control plan*
PFMEA risk mitigation plans, focusing on • Preliminary capacity assessment
process KCs
• Work station documentation
• Create the control plan including results of
• Measurement Systems Analysis
the PFMEA and KCs identification
(MSA) Plan
• Create process manufacturing instructions
• Supply Chain Risk Management Plan
and documentation
• Material handling, packaging, labelling, and
• Evaluate production readiness
part marking approvals*
• Production Readiness Review (PRR)
results
“Bold” text indicates requirements defined in this standard * Indicates PPAP requirement
Phase 3 Outputs
• Production Readiness Review (PRR)
• Completion of Applicable Activities/Deliverables
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4.6 Phase 4
Product and Process Validation
Phase Output
Activities Deliverables Key Milestones
• Conduct a First Article Inspection (FAI) and • Product from production process • Validation that intended manufacturing
assemble Production Part Approval Process run(s) process and the associated product
(PPAP) file • MSA* conforms to specified requirements
• Completion of a production product run(s) • Initial process capability studies* • Approved FAI
• Conduct a capacity analysis • Approved PPAP
• Control plan*
• Collect data to demonstrate the manufacturing and
assembly processes can produce conforming • Capacity verification
product at the customer demand rate • Product validation results
• Conduct the MSA per the MSA Plan • First Article Inspection
• Review the results of production process runs and Report (FAIR)*
determine corrective actions, as needed • PPAP file and approval
• Subsequent to corrective actions being form*
implemented, determine process readiness for • Customer specific requirements*
entry into serial production
“Bold” text indicates requirements defined in this standard * Indicates PPAP requirement
Phase 4 Outputs
• Product conforms to Specified Requirements
• Completion & Approval of PPAP
• Completion of FAI, Applicable Activities/Deliverables
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4.6 Phase 5
On-Going Production, Use &
Post Delivery Service
Phase Output
Activities Deliverables Key Milestones
• Monitor product and process performance • Quality indices [e.g., CpK, Parts Per Million
and compare to the defined (PPM), rejection rates] • Project closure
• Phase 1 targets, including: • Key Performance Indicators (KPIs) reflecting
- Reliability, quality, and customer product quality and reliability
satisfaction • Evidence that project targets have been
- Product post-delivery performance met
(including warranty) • On-time Delivery (OTD) and capacity KPIs
- Maintenance, Repair, and Overhaul • OTD and capacity improvement plan
(MRO) operations • MRO KPIs and plan(s) to reach the established
• Implement actions to reduce product and targets
process variation in associated production • Project closure recommendations
and MRO activities • Continuous improvement actions
• Document sources of variation in support • Lessons learned
of continual improvement efforts • Updated design risk analysis, PFMEA, and
• Capture lessons learned and integrate into control plans
other design activities, as appropriate
• Update FMEAs based on lessons learned
Phase 5 Output
• Project closure
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5.1 PPAP Requirements
Organizations are to :
Identify PPAP elements & customer specific requirements
Develop a PPAP file
Comply with PPAP submission requirements
Provide required PPAP documentation
Maintain the PPAP file including accessibility
Notify customer of product/process changes
Determine requirements for changes
Provide a revision plan to address unfulfilled submission requirements
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PPAP File
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5.2 PPAP File & Submission
Submission contents:
Applicable elements of PPAP file
Reference to alternate locations of elements (when applicable)
PPAP Approval Form or equivalent form containing required fields
Customer defined submission levels
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PPAP APPROVAL FORM
PPAP APPROVAL
1. Part Number: 6. Additional Changes:
2. Part Name:
3. Part Revision Level:
4. Drawing Number: 7. Customer Purchasing Representative:
5. Drawing Revision Level: 8.Purchase Order Number:
SUPPLIER INFORMATION
1. Organization Name: 10. Supplier/Vendor Code:
11. Address (Street, City, State, Country, Postal Code): Country:
1. Submission
ubmission ubmission
4. Process FMEA
5. Control Plan
15. Declaration
I, the supplier, submit this PPAP Approval form as declaration of having met all applicable requirements of the 9145 standard, except as noted above, including having implemented the requirements at the sub-tier level where applicable. I further certify that our production
process meets all defined product delivery, engineering and quality requirements. I understand that the approval of this form by the customer does not release me from responsibility or liability for any non-conformances.
Clearly Print Name and Sign Title Email Address Date
Customer Authorization: Clearly Print Name and Sign Title Email Address Date
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5.3 PPAP Disposition
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5.4 PPAP Resubmission
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