APQP AS9145

AS9145 / APQP-PPAP Workshop

Course Description
The AS9145 Aerospace standard was created to define the aviation, space, and defense process requirements for Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP). The APQP process defines a methodology for ensuring that the product development processes deployed throughout the aviation, space, and defense industries are fully integrated phased processes that extend from concept and design through manufacturing process planning and execution, and on into product use, service, and customer feedback. The PPAP is an output of APQP confirming that the production process has demonstrated the potential to produce products that consistently fulfill all requirements at the customer demand rate.

This AS9145 APQP Workshop is designed to provide participants with an understanding of how the risk management elements of APQP help ensure successful launches based on robust new product development processes and how to employ these tools to manage continual improvement in products and processes. This workshop also provides guidance on the Aerospace PPAP submission requirements and quality tools such as DFMEA, PFMEA, Control Plans, MSA, and SPC.

Product Development Process and APQP

Aerospace Quality Core Tools

  • Advanced Product Quality Planning (APQP) is a process that enables a manufacturer to demonstrate that it can design and manufacture a product in line with customer requirements. The main objectives of APQP are effective communication, timely completion of the tasks, reduction of quality issues, and minimization of quality-related risks during product launch. The steps in APQP are: planning, product design and development, process design and development, product and process validation, and finally, on-going production, use and post-delivery service.
  • Failure Mode and Effects Analysis (FMEA) is a method for identification and prioritization of different modes of failure and resulting effects. The risk represents a relationship between modes of failure, their potential effects, and causes of failure. FMEA has proven itself as a valuable risk assessment tool in the design (DFMEA) and production (PFMEA) process.
  • Measurement Systems Analysis (MSA) is a method of evaluating variability in the measurement process. It is primarily used to determine the viability of an evaluation or measuring methodology for use on a specific part characteristic. MSA looks at five distinct parameters: bias, linearity, stability, repeatability, and reproducibility, and guidelines for acceptance are “Percent Error to Tolerance” and “Percent Error to Variation.”
  • Statistical Process Control (SPC) is a statistical method applied in quality control, and it is primarily used to monitor and control processes.
  • Product Part Approval Process (PPAP) is a process of demonstrating that the produced part meets design intent and initial requirements, and that the production process can consistently provide such products. The result of PPAP is a set of documents called the “PPAP package,” which needs to be approved by the supplier and the customer to demonstrate that the client’s requirements are understood, the product meets the requirements, and the production process is capable of providing conforming product.

These core tools are used during the Product and Process Development phases of New Product Introduction (NPI) and during certain events such as failure investigation or engineering changes. The training methodology from QSG harmonizes and links the inputs and outputs of the core tools to one another. Linking tools increases their value to one another and reduces overall workload.

QSG’s AS9145 APQP Workshop is taught by seasoned aerospace industry professionals. It covers the requirements of each of the core quality tools and helps the student understand how to complete the necessary paperwork and forms.

Who Should Attend
This course is designed for:

  • Managers and individuals with direct responsibility for introducing new products or new manufacturing technologies
  • Anyone needing to plan, manage, and conduct APQP and/or PPAP for Aerospace and Defense customers

Learning Objectives
Through training, participants will learn the following:

  • Advance Part Quality Planning (APQP)
  • Production Part Approval Process (PPAP)
  • Failure Mode & Effect Analysis (FMEA), both Design and Process
  • Process Flow Diagram
  • Control Plan
  • Measurement System Analysis (MSA)
  • Statistical Process Control (SPC)
  • Process Capability
  • First Article Inspection Report (FAIR)

Course Outline
DAY 1

  • Agenda & Introductions
  • Introduction
  • Scope and purpose
  • APQP Planning Requirements
    • General requirements
    • Project management
    • Phase 1 requirements, activities, deliverables and outputs – Planning
      • Inputs
      • Requirements
      • Business plan
      • Design and quality goals
      • Review of contract
      • Project plan
      • Management support
    • Phase 2 requirements, activities, deliverables and outputs – Product design and development
      • Design risk analysis
      • Design records
      • Design for manufacturability and assembly
      • Special characteristics
      • Preliminary risk analysis of sourcing plan
      • Design review report
      • Product build plan
      • Drawings and specifications (Engineering, material, changes)
      • Design verification and validation plans
      • Feasibility assessment
    • Phase 3 requirements, activities, deliverables and outputs – Process design and development
      • Process flow diagram
      • Plan layout
      • Production preparation plan
      • PFMEA
      • Process Key Characteristics
      • Control plan
      • Capacity assessment
      • Process documentation
      • MSA plan
      • Supply chain risk management plan
      • Material handling, packaging, labelling

DAY 2

  • Phase 4 requirements, activities, deliverables and outputs – Product and process validation
    • Production process runs
    • MSA
    • Process capability studies
    • Control plan
    • Capacity verification
    • Packaging evaluation
    • Product validation results
    • PPAP file and approval form
    • Customer specific requirements
  • Phase 5 requirements, activities, deliverables and outputs – On-going production, use, and post-delivery service
    • Measuring performance
    • MRO KPIs and plans to reach the established targets
    • Continual improvement actions (reduced variation, improved customer satisfaction, improved delivery and service)
    • Lessons learned
  • PPAP Process
    • Submission of PPAP
    • Process requirements (production run)
    • PPAP requirements
  • Submission requirements
    • Customer notification
    • Submission to customer
  • Submission to customer
  • Part submission status
  • Record retention
  • Process disposition
  • Process resubmission
  • PPAP approval form

Prerequisites
n/a

Course Format
16 hours
Combination lecture and classroom exercises
A test will be administered, resulting in a certificate
Available at QSG’s training facilities, virtually, and on-site at your organization

Course instructors:
Laura Halleck – Senior Consultant, Quality Systems Auditing (Automotive, Aerospace)
Ed McFayden – Consultant, Quality Systems, Lean Six Sigma, Auditing

8:30am-4:30pm (EST) each day


Payment Type
Dates Attending
Name of Attendee(s)
Name of Company



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