24 September, 2024 | Category: Aerospace Quality

Introduction to AS9145 APQP

In today’s aerospace industry, maintaining high levels of quality and safety is crucial. To achieve this, advanced quality planning processes have been adopted, including Advanced Product Quality Planning (APQP). In aerospace, AS9145 has become the standard for implementing APQP. But how did this standard come into existence? In this post, we’ll explore the origins of AS9145 and its transformation into the industry benchmark for Aerospace APQP.

What is AS9145?

AS9145 is the International Aerospace Standard that defines the application of APQP and the Production Part Approval Process (PPAP) within aerospace manufacturing. This standard outlines the methodology for planning and controlling product development to ensure that products meet safety, reliability, and regulatory standards throughout their lifecycle.

AS9145 was introduced by the International Aerospace Quality Group (IAQG) to streamline the product development process across the aerospace industry, making quality planning more robust and aligned with aerospace’s stringent demands.

The Origins of APQP

The concept of Advanced Product Quality Planning (APQP) originated in the automotive sector in the 1980s. Automotive giants like Ford, GM, and Chrysler developed the APQP methodology to enhance product quality, reduce risks, and ensure customer satisfaction during the product lifecycle. APQP was formalised by the Automotive Industry Action Group (AIAG) and quickly became the go-to standard for quality planning in the automotive industry.

This success in the automotive sector inspired other industries to adopt similar methodologies, including aerospace.

Why Aerospace Needed its Own APQP Standard

The aerospace industry faces unique challenges, including stricter regulatory requirements, longer product lifecycles, and a higher level of risk in both safety and performance. While APQP served the automotive industry well, aerospace organisations recognised the need for a more tailored approach to quality planning.

The International Aerospace Quality Group (IAQG) saw the value in adapting APQP to aerospace’s specific needs, and thus, AS9145 was developed. The goal was to ensure that the processes of product development, risk management, and quality assurance were as rigorous in aerospace as they were in automotive, but with added considerations for the complexities of aerospace products.

How AS9145 Became the APQP Standard for Aerospace

AS9145 was officially introduced in 2016, taking key elements of the APQP process and incorporating them into a framework suited for the aerospace industry. Here’s how the transformation occurred:

Customisation for Aerospace – While the core principles of APQP remained intact, AS9145 adapted these to address the higher complexity, risk, and regulatory scrutiny found in aerospace.

Integration with PPAP – AS9145 incorporated the Production Part Approval Process (PPAP), another automotive-originated process, to ensure that parts produced during aerospace manufacturing meet the required quality standards.

Focus on Risk Management – Given the high-risk nature of aerospace, AS9145 places a strong emphasis on risk management throughout the product development lifecycle, ensuring potential failures are addressed before they impact safety or performance.

Lifecycle Approach – AS9145 applies the APQP process not only to product design and development but also to manufacturing, assembly, and even service, offering a comprehensive quality management strategy from concept to decommissioning.

The Five Stages of APQP in AS9145

AS9145 integrates the core structure of Advanced Product Quality Planning (APQP), which is broken down into five distinct stages. These stages provide a systematic approach to ensuring quality throughout product development and manufacturing in the aerospace industry. Below is an overview of how these stages apply within the framework of AS9145.

1. Planning and Definition

The first stage focuses on understanding and defining the customer’s needs and regulatory requirements. In the aerospace sector, this includes stringent safety and performance standards. Key activities include:

  • Identifying customer and regulatory requirements.
  • Performing a risk analysis for potential failure modes.
  • Establishing project goals, timelines, and resource requirements.

For aerospace applications, the planning stage is critical in aligning development efforts with both customer expectations and strict industry standards, ensuring that every requirement is met from the outset.

2. Product Design and Development

During this stage, the focus is on designing a product that meets the defined requirements. AS9145 ensures that design outputs, including detailed drawings, specifications, and material selection, undergo rigorous reviews and validation.

  • Product designs are subjected to failure mode and effects analysis (FMEA) to predict and address any potential issues.
  • Design verification and validation are performed to ensure the product’s functionality and performance meet the aerospace standards.

In aerospace, design validation is especially important, given the need for components to withstand extreme conditions and long lifecycles.

3. Process Design and Development

This phase is about developing manufacturing processes that are capable of consistently producing the product to the required specifications. Under AS9145, it includes:

  • Designing production processes that ensure repeatability and compliance with aerospace regulations.
  • Identifying and mitigating risks in the manufacturing process through Process FMEA.
  • Establishing process controls and inspection plans to ensure continuous monitoring of quality.

By focusing on process robustness, this stage ensures that the aerospace components can be manufactured reliably at scale, without compromising quality.

4. Product and Process Validation

At this stage, both the product and the production process are tested to verify they meet the required standards before full-scale production begins. This stage is critical for aerospace due to the high level of risk involved. It includes:

  • Conducting prototype testing and pilot runs to validate both the product and its manufacturing processes.
  • Implementing the Production Part Approval Process (PPAP), which ensures that every part produced meets the set quality standards.
  • Verifying that the manufacturing processes can consistently deliver quality parts.

This validation stage in AS9145 is crucial in the aerospace industry, as it helps prevent costly failures by ensuring that all parts function correctly and are manufactured within specification.

5. Production, Feedback, and Continuous Improvement

The final stage of APQP in AS9145 focuses on full-scale production and the ongoing monitoring of both the product and processes to ensure consistent quality. Key activities in this stage include:

  • Implementing continuous monitoring and process improvement techniques.
  • Collecting customer feedback and performing regular audits to identify areas for improvement.
  • Ensuring that any production issues are quickly addressed and resolved to avoid disruptions in the supply chain.

In aerospace, this stage ensures the long-term reliability of products and manufacturing processes, while also adapting to new challenges and technological advancements through a cycle of continuous improvement.

Benefits of AS9145

Implementing AS9145 brings numerous benefits to aerospace manufacturers:

Enhanced Product Quality – By following the APQP methodology, aerospace companies can improve product quality, ensuring that the final product meets all requirements.
Reduced Risks – AS9145’s focus on risk management means potential issues are identified and mitigated early in the development process.
Increased Customer Satisfaction – By ensuring products meet customer and regulatory requirements, AS9145 fosters trust and reliability.
Improved Efficiency – Standardising processes across the industry reduces waste and improves efficiency in product development and production.

Conclusion

AS9145 represents the evolution of APQP from its automotive origins into a robust, aerospace-specific standard. It is a critical framework for ensuring product quality, reducing risk, and maintaining regulatory compliance in the highly complex aerospace industry.

At Hillscom, we understand the importance of adhering to AS9145 and similar standards to achieve the highest levels of quality and performance. If you’re looking to improve your aerospace manufacturing processes, implementing AS9145 is a step in the right direction.

FAQs

1. What is AS9145?
AS9145 is the standard for applying APQP and PPAP in the aerospace industry to ensure robust quality management throughout the product lifecycle.

2. How is AS9145 different from automotive APQP?
While the core principles of APQP are shared, AS9145 is specifically tailored to the unique risks, regulatory requirements, and complexities of the aerospace industry.

3. Why is AS9145 important?
AS9145 helps aerospace manufacturers improve quality, reduce risk, and ensure compliance with stringent safety regulations, which is essential for maintaining high standards in the industry.

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