Industry Forum

Category: News

The 2025 Midlands Aerospace Alliance annual conference held at RAF Cosford was a fantastic opportunity to hear the insights of the diverse Aerospace manufacturing supply chain from OEMs to lower Tiers and even tool manufacturers. It provided key insights into the industry’s current challenges and opportunities.

This article will discuss the main takeaways from the event, focusing on supply chain resilience, zero-defect manufacturing, and strategies for scaling production in a volatile global landscape.

The aerospace industry is undergoing a critical phase of ramp-up, with demand for commercial and defence aircraft surging. Airbus and Boeing’s backlog by the end of 2024 was 14,253 (ADS, 2024). One of the sectors biggest challenges is trying to navigate the current geopolitical landscape, rising demand and therefore the increased emphasis on the need for risk resilience in the supply chain.

Supply Chain Risk Resilience: A Pressing Concern

Aerospace supply chains are complex and globally interconnected, making them vulnerable to disruptions. The industry is still grappling with the lingering effects of pandemic-induced shortages, geopolitical tensions such as the introduction of US tariffs, and logistical constraints. Lead times for certain essential dependant components remain extended, acting as a bottleneck to the product development process. Additionally, the limited availability of raw materials has placed further strain on production schedules.
Manufacturers are increasingly adopting risk-mitigation strategies such as reshoring, dual-sourcing, and digital supply chain monitoring to enhance resilience. The integration of AI-driven predictive analytics is also helping firms anticipate disruptions and adjust procurement strategies in real time. Yet, despite these advancements, the industry continues to experience delays, impacting aircraft delivery schedules and customer commitments.
Airbus spoke at the conference on the need for Industrial Maturity. They proposed that in order to have a resilient supply chain there must be zero tolerance on non-quality and safety, innovation and an ongoing drive to remove waste in manufacturing in order to be competitive.
An Aerospace Supply Chain Resilience Report (Roland Berger, 2024) was presented which highlighted key challenges in ramping up production. Many companies face difficulties in scaling, due to the discussed reasons. Supply chain disruptions have worsened, with Tier-1 suppliers hit hardest. To address this, firms are restructuring supply chains, focusing on regionalisation and improved resilience. Recommendations from the report include tackling bottlenecks, enhancing long-term stability, and fostering collaboration to ensure consistent, high-quality production.

The Importance of Zero-Defect Tools for Ramp-Up

As production rates accelerate, ensuring product integrity is paramount. Aerospace components must meet stringent quality and safety standards (such as AS13100, if within the Aero-Engine supply chain), with defects posing severe risks to both operational performance, in-flight safety and regulatory compliance. To mitigate these risks, manufacturers are leveraging zero-defe ct frameworks, such as Advanced Product Quality Planning (APQP).
Adopting the Zero Defect tool kit will enable manufacturers to produce high-precision components with minimal waste, reducing the likelihood of defects that could cause costly rework or aircraft grounding. But it will also help with ramp-up.
APQP streamlines aerospace ramp-up by ensuring quality and consistency. It identifies risks early, standardises processes, and aligns suppliers. The Reference Manual RM13145 which is aligned to AS13100 discusses supply chain risk management and how risk factors relating to organisations and products can be mitigated (AESQ, 2024). Ultimately, the framework, when adopted effectively enhances supply chain resilience, reduces defects, and accelerates production scaling.

Striking the Balance Between Speed and Accuracy

While ramping up production is necessary to meet growing demand, the aerospace sector must strike a delicate balance between speed and precision. Supply chain fragility and quality concerns must be addressed through proactive risk management, investment in advanced manufacturing tools, and closer collaboration across the supply network.
By prioritising resilience and Zero Defect methodologies, aerospace manufacturers can navigate the challenges of supply chain uncertainty while ensuring that every aircraft component meets the highest standards of reliability and performance.

SMMT Industry Forum supports aerospace manufacturers and has training endorsed by AESQ member companies that provide expert support in these key areas where skill gaps exist: APQP, PPAP, Lean Manufacturing and Supply Chain Management.

If you would like to discuss how we could support helping with enhancing your organisations quality, reducing defects, and efficiently scaling production to meet rising demand, then please feel free to get in touch:

Joseph Dodd MSc CMgr MCMI Aerospace Quality Management Consultant

Email: [email protected] https://calendly.com/joseph-dodd-industryforum

tel: +44 (0)121 717 6600 | mob: +44 (0)7809522182 | web: www.industryforum.co.uk

Industry Forum were privileged to have the opportunity of attending a recent event at Rolls-Royce Derby arranged by the Midlands Aerospace Alliance. The event was well organised and there was no doubting the efforts taken by the Midlands Aerospace Alliance to make this event a success, with members of the Rolls-Royce senior management team being very generous with their time and approachability.

It was a pleasure to rub shoulders with likeminded individuals who share a passion for the growth and success of the Aerospace sector in the Midlands.

Attendees were given insights into strategic initiatives being taken at Rolls-Royce and treated to a plant tour.

It was interesting to hear from Craig Askew – Manufacturing Operations. Craig shared his pride and passion for the Rolls-Royce production system.

It was also interesting to hear from James Partington – Procurement.

James shared the key procurement priorities for Rolls-Royce

Having had the opportunity digest the activities and events of the day it is evident that there are several common themes running through Rolls-Royce with an expectation that the Rolls-Royce supply chain will follow suite.

One of these themes is the drive towards Zero defects.

Adopting a zero defects mentality and approach is essential for the long-term survival of the civil aerospace sector.

The Zero defects approach is a mindset that is underpinned by tools and techniques employed throughout the Design and Manufacture of Aerospace product.

In its simplest form it can be described by the diagram below:

When considering creating a structured process to support Zero Defects then Aerospace Standard AS9145 defines Aerospace requirements for Advanced Product Quality Planning (APQP) and Production Part Approval (PPAP). This standard provides a more comprehensive approach for planning for product quality with the benefit that it embeds the key elements of the Zero defects approach.

The message from Rolls-Royce seems to be clear. They are enjoying the benefits of Zero defects gained by implementing Advanced Product Quality Planning and they are promoting its use by the supply chain. APQP benefits the supply chain, it benefits Rolls-Royce, and it benefits the customers of Rolls-Royce.

Industry Forum can support your organisations drive towards Zero defects with training courses covering Design/Process FMEA & Control Plan, MSA, Process Control and Problem Solving. We also offer training and consultancy for AS9145.

This article was written by our Senior Aerospace Consultant Richard Hammond, to get in touch with Richard, please email [email protected]

 

The AIAG VDA Combined FMEA (Failure Mode and Effects Analysis) Course and Manual, released in 2019, represents a collaborative effort between OEMs (Original Equipment Manufacturers) and Tier 1 suppliers from both the AIAG (Automotive Industry Action Group) and VDA (Verband der Automobilindustrie) communities. After over three years of collaboration, this manual was introduced as a standardised approach for the industry, offering a unified framework for FMEA development. While it differs significantly from the widely used AIAG (Blue Book) method, OEMs are increasingly mandating this new combined methodology for their Tier 1 suppliers.

The transition from the well-established AIAG Blue Book format to the new AIAG VDA FMEA approach is not a simple process. One of the key challenges is that DFMEA (Design FMEA) and PFMEA (Process FMEA) often require cross-functional teams consisting of different specialists who may be located in separate areas. Recognising this, the SMMT Industry Forum has developed specialised training programs aimed at equipping professionals with the necessary skills to implement the new AIAG VDA FMEA methodology effectively.

AIAG VDA DFMEA & PFMEA Training

To facilitate this transition, SMMT Industry Forum offers a range of practitioner courses that provide participants with hands-on experience in both DFMEA and PFMEA processes, tailored to the new AIAG VDA format.

1-Day AIAG VDA FMEA Awareness
This course is designed for individuals already familiar with the AIAG (Blue Book) format for DFMEA and PFMEA. It introduces participants to the updated format for both DFMEA and PFMEA, while also covering FMEA-MSR (Failure Mode and Effects Analysis for systems dealing with functional safety in vehicles). The course offers practical exercises that highlight the key differences in the new approach, allowing attendees to consider how to implement these changes within their organisations.

2-Day AIAG VDA FMEA Practitioner
Aimed at those who will be responsible for creating either DFMEAs or PFMEAs using the new AIAG VDA methodology, this course provides a more in-depth exploration. It includes hands-on exercises where delegates can create their own FMEA models. Both DFMEA, PFMEA, and FMEA-MSR are covered, providing participants with comprehensive knowledge of the new framework.

1-Day AIAG VDA DFMEA Practitioner
Tailored for individuals focused on DFMEA creation, this course covers the new AIAG VDA DFMEA format in detail. Participants will be guided through the creation of their own DFMEA and introduced to FMEA-MSR.

1-Day AIAG VDA PFMEA Practitioner
This course is designed for professionals who need to develop PFMEAs using the new AIAG VDA format. Similar to the DFMEA practitioner course, delegates will create their own PFMEA during the session.

Training Delivery

These courses can be delivered in various formats, virtual, at our Training Hub in Birmingham or  tailored in-house at your offices. 

AIAG VDA DFMEA Practitioner

https://industryforum.co.uk/courses/64-aiag-vda-dfmea-practitioner/

AIAG VDA PFMEA Practitioner

https://industryforum.co.uk/courses/65-aiag-vda-pfmea-practitioner/

For more information please contact [email protected]

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/

  • July 23, 2024
  • News

 

The SMMT Industry Forum and the UK Battery Industrialisation Centre (UKBIC) have signed a Memorandum of Understanding (MoU) to help create a training infrastructure to support the UK’s emerging battery sector.

The collaboration between the SMMT Industry Forum – the commercial arm of the Society of Motor Manufacturers & Traders (SMMT) – and UKBIC, the UK’s national battery manufacturing development facility, is designed to better support the growing battery industry in the UK.

The partnership aims to foster a thriving ecosystem of innovation and growth within the UK’s electrified technology sector.

The MoU is expected to lead to an SMMT training programme designed to support suppliers at every stage, ensuring they are fully equipped with the knowledge and skills needed to navigate the complexities of electrified technology development and production.

Ashley Fernihough, chief executive officer of SMMT Industry Forum, said: “This MoU represents a significant step forward in the drive towards sustainable and competitive manufacturing in the UK.

“The establishment of a comprehensive training infrastructure to cater for existing suppliers and new market entrants, guiding them through the entire journey from technology development to the establishment of robust supply chains and ultimately, OEM supply.” Sean Gilgunn, the managing director of UKBIC, added: “By combining the expertise of the SMMT Industry Forum and UKBIC, we’re poised to help deliver a more effective training programme to support the growing UK battery sector in the UK.”

SMMT were honoured to be invited to attend the 1st Meeting of the Chartered Quality Institute Council in July. Convened in central London we were privileged to input an automotive quality perspective to a fruitful and searching discussion featuring representatives from a variety of disciplines, across public and private sectors.

Focused topics included how to develop culture and capability for quality, improvement and excellence in our economies and organisations; and how to make quality management a strategic tool. The output themes for the day centred on actions to promote the profession map, and to move towards it’s use as a tool to assess team competence and inform capability development.

The CQI is the professional body for experts in improving product, project and service quality. They do so by championing professional standards for quality management in the UK and globally. The CQI was granted Royal Charter in 2006, having demonstrated pre-eminence, public interest, stability and permanence.

NEW COURSE INTRODUCTORY OFFER – ISO 45001:2018 Internal Auditor Training

This course will help auditors develop relevant skills in judgement, decision-making, audit planning, audit non-conformity writing and subsequent close-out related to the ISO 45001:2018 standard.

The ISO 45001:2018 Internal Auditor Training is an interactive course supported by group exercises and open discussion.

The practical emphasis of this course and high tutor-to-delegate ratio provides a great opportunity for individual guidance, support and learning.

Don’t miss this offer, book your place here…

We are thrilled to partner with HORIBA MIRA, a leader in automotive training. Their unparalleled expertise delivers exceptional scheduled and custom courses in Functional Safety, Electric Vehicles, and Cybersecurity.

Led by industry specialists, these courses connect the next generation of engineers with professionals setting the highest standards in vehicle R&D. With new options added regularly, explore their current offerings or contact them for personalised guidance.

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Together with Horiba Mira, we offer tailored training to tackle your unique challenges. Collaboratively, we design courses and materials focused on your team’s needs and growth areas, ensuring a learning experience that maximizes long-term success.

Contact us to discuss your training needs.

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.

As part of the SMMT Group, we are really proud that The Society of Motor Manufacturers and Traders (SMMT) has been recognised as one of Britain’s best places to work after gaining Gold accreditation from Investors in People (IIP), the international benchmark for workplace standards and people management.

The Gold accolade, which is achieved by just 17% of organisations seeking IIP accreditation, was awarded to SMMT Group – including SMMT, Industry Forum and The Motor Ombudsman – for its ‘advanced’ levels of organisational leadership, with an emphasis on transparency, recognition, wellbeing and empowerment to encourage innovation and collaborative working.

SMMT was recognised for its progressive people-focused policies, including all-staff engagement in decision-making, investment in career development, creating a culture that recognises high performance, developing flexible working practices, establishing an extensive network of employee support groups, and striving to ensure the workplace is diverse and inclusive of all needs.

In addition, as part of SMMT’s remit to represent the UK automotive sector, the organisation was recognised for its committed to promoting workplace best practice across the wider industry. In 2022, under the auspices of the Automotive Council, it established the sector’s first ever Diversity Charter, and it continues to support businesses in the sector with their own development, with a DE&I Toolkit, specialist workshops and events.

Katie Milbourn, Director of SMMT Group HR, said, “Every one of us at SMMT is essential to the Group’s success, so we support and develop everyone’s talents to help each other – and the wider sector – continue to thrive. As the voice of the automotive industry in the UK, it’s our duty and mission to set the highest standards, and we strive to ensure our people, with their expertise, experience and dedication, realise their full potential and support our members.”

Tim Little, Practitioner, Investors in People, said, “Following the Investors in People programme is a journey SMMT started quite a few years ago, and the organisation’s drive, foresight and determination have kept it on the path to success and achieving Gold. SMMT has embraced IIP as a force for growth and put it at the heart of what it does. It’s been an absolute pleasure working with SMMT and watching its successes over the years.”

IIP Gold status builds on SMMT Group’s previous Bronze and Silver awards in 2015 and 2022, and reflects the organisation’s long-standing commitment to the highest standards of people management. Such an approach is essential not just to attract and retain the best talent but to enhance mental health and wellbeing in the workplace – particularly important given that stress, anxiety and depression accounted for more than half of all workplace-related illness in the UK last year.

Investors in People was founded by the UK government in 1991 and has since become a globally recognised certification of best practice for modern, high performing workplaces. The scheme requires an organisation to work closely with a practitioner to review its ‘people strategy’ – or its policies to attract, develop, retain, inspire and engage employees – as well as its long-term progress plan. The review also requires anonymous employee feedback on the organisation’s people strategy through surveys and interviews.