Industry Forum

NEWS – AESQ and RM13145 Updates (APQP & PPAP):

The Aerospace Engine Supplier Quality (AESQ) strategy group created RM13145 supplemental material to offer guidance and good practise on the application of Advanced Product Quality Planning (APQP) & Production Part Approval Process (PPAP) in-line with the requirements of AS9145 and AS13100.

RM13145 aligns the general APQP and PPAP methodologies to the specific needs of aero-engine manufacturers, focusing on early risk mitigation and robustness of the introduction of change in the product development process, striving for Zero Defects.

RM13145 has recently been updated in August 2024. In addition to this supplemental material on the AESQ website, they have also added in October 2024, the PPAP Approval Form template, which supports RM13145 and is essential for confirming that suppliers meet the requirements of PPAP (AS13100). It serves to confirm that they have submitted the sufficient evidence based on the planned scope of the PPAP (submission level). The form also provides detail supporting the reason for the PPAP submission (supplied by the PPAP Co-ordinator) and also the disposition decision (supplied by the Customer Authorised Representative (CARe)).

This template has been standardised to promote consistency across the aero-engine supply chain, facilitating reduced complexity in the PPAP submission process.

The template includes the following sections:

  • Supplier Information: Details of the company submitting the PPAP, including supplier code and contact information.
  • Part Information: The specific part number, description, and revision level being approved.
  • Submission Level: Defines the level of PPAP submission required (ranging from Level 1 to Level 5) and the reason for submission
  • PPAP Submission Checklist and associated element acceptance (from customer).
  • Corrective Actions: Section for planned, dated and owned actions.
  • Signatures: From both the PPAP Co-ordinator and CARe, confirming that the PPAP has been reviewed and disposition.

At SMMT Industry Forum, our AESQ-endorsed 3-day PPAP Co-ordinator & CARe course fully covers the syllabus and qualification requirements for PPAP Co-ordinators or CARe’s as defined by AESQ Reference Manual RM13145. The training reflects the latest revision of RM13145 (August 2024) and contains the latest templates, including the PPAP Approval Form (October 2024). The course draws from AS13100 sections B and C and follows the APQP/PPAP model as defined within AS9145 and AESQ RM13145. This course is available virtually in different timezones and also may be flexibly delivered over 4-slightly shorter days to accommodate these timezone differences.

In this course, we cover in detail:

  • Essentials of PPAP Process Management
  • Explain the fundamentals of APQP
  • Evaluating the PPAP File
  • Preparing and evaluating the PPAP Submission
  • Disposition of the PPAP Submission and Approval Form

If you are interested in finding out more on this course, then please follow this link: https://industryforum.co.uk/courses/14-as13100-aligned-rm13145-ppap-co-ordinator-and-care-training-course/

By Joseph Dodd – Aerospace Quality Management Consultant SMMT Industry Forum

Introduction

Measurement is determining the extent, quality or value of something. So what is a measurement system?

A Measurement System is the overall combination of input factors that influence the output of that measurement, such as: people, equipment, measurand, methods and the environment.

Measurement Systems Analysis (MSA) is a statistical tool used to ensure we understand the sources of variation inherent in our measurement systems used to determine product quality and conformance.

 

Purpose of MSA in Aerospace

The primary purpose of MSA in the aerospace sector is to assess the capability and consistency of measurement systems. This analysis identifies the sources of variation such as that caused by appraiser’s, equipment and part variation, allowing Engineers to assess the systems overall gauge repeatability and reproducibility (GR&R) amongst other factors (e.g. NDC) against industry standard criteria. By doing so, aerospace companies can take action to ensure that their measurements are accurate, leading to better quality control, reduced waste, and increased safety in their products.

Key objectives of MSA include:

  • Evaluating Measurement Accuracy: Ensuring that measurement tools and systems provide true values without significant deviation. (E.g., Bias, Linearity, Stability).
  • Assessing Precision: Determining the repeatability and reproducibility of measurement systems (GR&R).
  • Identifying Sources of Variation: Pinpointing where variations occur in the measurement process to mitigate them effectively (ANOVA method).

 

Benefits of Applying MSA

A robust Measurement Systems Analysis (MSA) process can ensure that production data being collected is accurate and precise, and that the methods used for data collection are suitable for the process. Accurate, reliable data can save time, labour, and materials in manufacturing.

  • Increased reliability in measurement data
  • Allows organisations to make better, data-driven decisions in production
  • Helps reduce rework and scrap
  • Gives confidence to customers in measurement capabilities and therefore product control
  • Enables organisations to understand sources of variation

 

Challenges in the Aerospace Industry

Despite its importance, the implementation of MSA in the aerospace industry faces several challenges:

  1. Resource: The aerospace industry is highly regulated, with stringent standards such as AS13100 and supplemental material such as RM13003 that dictate quality management and MSA requirements. Compliance with these standards requires rigorous MSA processes, which can be resource-intensive.
  2. Supply Chain: Ensuring that all suppliers adhere to the same measurement standards and practices can be difficult. Variations in measurement practices across the supply chain can lead to discrepancies and quality issues. AS13100 aims to harmonise requirements for Aero Engine Suppliers & Customer Specific Requirements should be considered when conducting APQP/PPAP.
  3. Skills: There are global skill gaps within the Aerospace Industry in certain areas such as supplier development and APQP/PPAP. Alignment of quality management systems to Industry Standards (AS9145 & AS13100) requires cross-functional, competent teams. This gap is particularly evident in emerging markets and smaller suppliers.

 

Conclusion

Measurement Systems Analysis is an essential practice in the aerospace industry, critical for ensuring the accuracy and reliability of measurement systems that underpin product quality and safety. Despite the challenges, the benefits of MSA in terms of improved quality, safety, and cost savings are undeniable. Addressing the skill gaps and ensuring robust MSA processes can significantly enhance the overall performance and reliability of aerospace products, fostering a Zero Defect culture.

Leveraging Advanced Product Quality Planning (APQP) for Unparalleled Product Safety and Zero Defects and understanding the how the Production Part Approval Process (PPAP) supports APQP.

Introduction:

In today’s aerospace industry, where safety and quality are paramount, the adoption of Advanced Product Quality Planning (APQP) is crucial. This article explores how APQP drives unparalleled product safety and zero defects by integrating proactive risk management, stringent quality standards, continuous improvement, and customer focused strategies.

Additionally, it examines the potential drawbacks and challenges associated with APQP implementation to provide a balanced viewpoint.

Proactive Risk Management:

Benefits:
APQP enables aerospace companies to proactively identify and mitigate risks throughout the product lifecycle. Companies that implement APQP can experience up to a 35% reduction in product development cycle time and a 25% decrease in the number of defects compared to those that do not utilize APQP (Source: Frost & Sullivan, & Advanced Product Quality Planning: The Cornerstone of Aerospace Excellence”, 2023).

Drawbacks:
However, the process of identifying and mitigating risks can be resource intensive.
Smaller companies might find the upfront investment in time and resources prohibitive, potentially outweighing the benefits in the short term.

Stringent Quality Standards:

Benefits:
APQP emphasizes the establishment of stringent quality standards and specifications. The Aerospace Industries Association (AIA) reports that companies adhering to APQP guidelines can achieve a 20% improvement in first time right yield rates and a 30% reduction in scrap and rework costs (Source: Aerospace Industries Association, & Best Practices in Advanced Product Quality Planning," 2022).

Drawbacks:
Implementing stringent quality standards and specifications requires a significant commitment to training and continuous education, which can be costly. Furthermore, rigid standards might stifle innovation and flexibility, making it difficult for companies to adapt to unforeseen changes quickly.

Continuous Improvement:

Benefits:
APQP fosters a culture of continuous improvement. Companies that embrace APQP can report a 15% increase in operational efficiency and a 20% reduction in warranty costs over a three-year period (Source: Deloitte,”Driving Excellence through Advanced Product Quality Planning,” 2021).

Drawbacks:
The continuous improvement process necessitates a long-term commitment and may not yield immediate results. This long-term horizon can be challenging for companies looking for quick wins or operating under tight budget constraints.

Effective Problem Solving:

Benefits:
With structured problem-solving methodologies, APQP empowers companies to address issues effectively. Research indicates that companies utilising APQP can achieve a 25% reduction in customer complaints and a 30% increase in customer satisfaction scores within two years of implementation (Source: McKinsey & Company, “Unlocking Value through Advanced Product Quality Planning,” 2020).

Drawbacks:
Structured problem-solving methodologies can sometimes lead to over-reliance on processes and documentation, potentially slowing down decision-making and responsiveness in dynamic situations.

Customer Satisfaction and Brand Reputation:

Benefits:
Through the consistent delivery of defect-free products, companies enhance customer satisfaction and brand reputation. A study published in the Journal of Quality Management found that companies practising APQP can experience a 10% increase in customer retention rates and a 15% improvement in brand loyalty compared to their counterparts (Source: Journal of Quality Management, “Impact of Advanced Product Quality Planning on Customer Satisfaction,” 2019).

Drawbacks:
While customer satisfaction is a key benefit, the initial implementation phase of APQP can disrupt existing workflows and impact short-term customer perceptions negatively if not managed carefully.

Pause for reflection:
The cumulative benefits of APQP implementation over a three-year period can be substantial, encompassing improvements in operational efficiency, cost reduction and customer satisfaction.

However, the process also comes with significant challenges, including resource-intensive implementation, potential rigidity in innovation, and high upfront costs.

More and more the requirement to adopt APQP and the supporting Production Part Approval Process (PPAP) is being driven by the customer and hence a company’s ability to weigh these factors carefully and consider their specific circumstances before adopting APQP is becoming limited.

A strategic approach, tailored to the company’s unique needs and capabilities, is essential for successful APQP implementation.

Having made the decision to implement APQP an organisation may be required to provide evidence of their APQP activities. Typically, this evidence is provided in the form of a PPAP submission.

Increasing the chances of successful PPAP.

To aid suppliers who supply Aero Engine manufacturers the AESQ have developed a common set of supplier requirements documented within AS13100 and guidelines for APQP/PPAP in reference manual RM13145.

Within organisations who are operating APQP and PPAP in an efficient and effective manner lies several roles, however two of these are key. These roles are PPAP Co-ordinator (the role of managing the supply organisations PPAP process and subsequent submission to the customer and CARe Customer approved representative (the role of reviewing and dis-positioning supplier PPAP submissions to the organisation).

In support of these two roles RM13145 defines essential skills and understanding required for the roles of PPAP Co-ordinator and CARe.

1 – Essentials of the PPAP Process Management

  • Understand the fundamentals of APQP and relationship between APQP and
    PPAP.
  • Appreciate the role of PPAP in various situations.
  • Navigate the APQP and PPAP Process Flow diagram and understand how
    this applies to PPAP.
  • Understand the how the PPAP Coordinator and CARe conduct their
    accountability.

2 – Evaluating the PPAP file

  • Understand what an acceptable standard is for each Element of the PPAP
    File.

3 – Preparing and evaluating the PPAP submission

  • Appreciated the meaning and use of Submission Levels.
  • Understand how to prepare and provide a PPAP Submission.
  • Understand when / how corrective action plan.

4 – Disposition of the PPAP submission and approval form

  • Be capable of conducting a disposition of the PPAP Submission.
  • Judge a PPAP Submission as Approved, Interim Approval and Reject.

The Industry Forum AS13100 aligned RM13145 PPAP Co-ordinator and CARe training course supports a strategic imperative for organisations committed to excellence in APQP and PPAP. By fostering a cross functional team of adept professionals equipped to navigate the complexities of APQP and PPAP and embrace the ethos of continuous improvement, this training program provides a shift towards operational excellence and enduring success.

Conclusion

The decision regarding implementing APQP is very much down to organisational culture, resource constraints and customer demand. The customer is seeking a reliable and predictable product launch process from suppliers. APQP and subsequent PPAP supports that customer goal.

Based on this customer goal, the skills and knowledge of the PPAP Co-ordinator and CARe are essential in ensuring the APQP process within an organisation delivers the required content for the PPAP file and PPAP submission, and that the PPAP process conforms to recognised best practice.

He joins us from his previous role working at an aerospace systems provider as a Principal Manufacturing Quality Engineer where he delivered training in APQP and PAPP, and the associated core tools, followed by in-house consultancy to assist in the implementation of such techniques, including the development of internal standards and procedures.

Before that role, Joseph was a metrologist at an automotive OEM, conducting

measurements to support the manufacturing process. He then moved to support the NPI phase of the business, before working as the metrology laboratory supervisor, including supporting warranty investigations and one-off specialist measurements.

Joseph participates in the National Metrology Skills Alliance, where he performs a voluntary role in the special interest group to offer manufacturing metrology expertise.

Welcome to the team Joseph.