alan daniels moscow, russia may 23, 2013 apqp/ppap standard advance product quality planning (apqp)...

Alan Daniels Moscow, Russia May 23, 2013

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– Team Leadership – Strategy, Focus, Projects – Standard Status –  ISO Liaison – 9100 Series Revision Plan – Standard Proposal – APQP/PPAP - Debbie – 9101E Ballot Results - Masa – 9100 Usage Survey - Alain

2

IAQG Strategic Focus

Relationship Growth Strategy •  Civil Authorities - Production •  Space •  Defense •  Maintenance, Repair & Overhaul •  Trade Associations

Improvement Strategy

•  Requirements

•  People Capability

•  Product & Supply Chain Improvement

•  Performance

IAQG Operating Management System IAQG Other Party Management Team

Integration Team

3

5

Current State • Independent release

of standards

• Most OEM’s deploy 9100

• Limited supply chain eligible and required to deploy 9100

• Standards supported for deployment presentations

• Few measures in place

Strategic Focus   Project manage future

integrated standard releases   Collaborate with Strategy

Streams   IAQG 5 year strategy -

Lead 90% certification   Ensure standards are current

and relevant   Develop and maintain

document support materials and improve communications

  Engage in ISO activities and obtain liaison voting status

  Develop future QMS concepts and measures

Future State •  Integrated release of

future standards

•  All IAQG member companies use the 9100 series

•  All eligible supply chain use 9100 series

•  Standard support is easy to use

•  Measures drive improvements

IAQG Standards

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Oversight of Certification Scheme 9104-1 (organization) 9104-2 (surveillance/certs) 9104-3 (auditors)

Maintenance of stds issued by IA

QG

(IA

QG 103)

IAQG OWNERS Data Type DATA B

est practices

Prod

uct &

Su

pply

Cha

in

Stra

tegy

St

ream

People Capability documents (PCAP001) & structure (skills matrix) Peop

le

Cap

abili

ty

Stra

tegy

St

ream

Supply Chain Management Handbook (SCMH)

Sales & Scheduling

Requirement Flow down

Design & Developm’t

Plant, skills &

planning

Manufact. &

Inspection

Supplier Mgt.

Control of N/C mat’l

C/A & P/A

Order Mgt & logistics

Customer Support

Sourcing selection

Business Processes

1 2 3 4 5 6 7 8 9 10 11

9103 Key Char

9102 FAI

9107 DDA

9114 Direct ship

9131 N/C Doc

9132 Marking

9133 Sup.Qual.

9134 Sup risk

9162 Self Ver

9115 Software

9137 AQAP align.

ICO

P C

ertification Scheme

9120 (Distributors)

9100 (General)

9110 (Maintenance) 9101 Audit

Process

Quality Management System

REQ

UIR

EMEN

TS

Stra

tegy

Str

eam

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• 22 Standards in Portfolio – 14 Active Changes –  4 Review Standards in the ballot or publish

phase –  4 Development Standards in active team

development –  3 New Projects Standards in development –  4 Study Standards planning a revision or

past due for reaffirmation –  1 Questionnaire Proposal phase to assess support

for the development of a standard –  7 Sustain Standards that are published and in

sustain & maintenance phase

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Complete the ballot and publication process for 10 standards, and initiate the revision process for the 4 behind schedule

• Standards in Review (active ballots)   9101 “Quality Management Systems Audit Requirements for

Aviation, Space, and Defense Organizations” •  Ballot draft developed, comments incorporated and second ballot has

been completed and passed – Changes presentation available

  9114 “Direct Ship Guidance for Aerospace Companies” •  Ballot draft developed, comments incorporated and ballot has been

initiated. Ballot results in May.

  9116 “Notification of Change” •  Ballot draft developed, comments incorporated and ballot has been

initiated. Ballot results in May.

  9104-2 “Requirements for Oversight of Aerospace Quality Management” •  Ballot draft developed, comments incorporated and ballot has been

initiated.

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• IAQG standards in Development (revisions)   9100 “Quality Management Systems - Requirements for

Aviation, Space and Defense Organizations” •  Developed design specification, schedule, integrated schedule, etc.

  9104-3 “Requirements for Aerospace Auditor Competency and Training Courses” •  Team member transition resulted in a delay – New resources added and

progressing.

  9107 “Direct Delivery Authorization Guidance for Aerospace Companies” •  Revision is in work. Will work after 9114 is complete. Judy Lasley to be

engaged.

  9102 “Aerospace First Article Inspection Requirement” •  Draft complete and steps towards ballot initiated - IAQG Editor

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• IAQG standards in Development (new)  9117 “Delegated Product Release Verification (DPRV)”

•  Active and meeting regularly working on the new standard.

 9136 “Root Cause Analysis and Problem Solving” •  Ballot draft complete – Ballot process to begin in the next few

weeks.

 9138 “Statistical Product Acceptance” •  Standard number issued and meetings have begun on revision.

 91XX “Advance Product Quality Planning” (APQP) / “Production Part Approval Process” (PPAP) •  SWG approved - Council vote in Moscow.

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• IAQG standards in Study or Noncompliant   9132 “Data Matrix Quality Requirements for Parts Marking”

•  Noncompliant to review requirement – No IDR

  9133 “Qualification Procedure for Aerospace Standard Parts” •  Noncompliant to review requirement - Working draft complete and SDRs

are reviewing.

  9134 “Supply Chain Risk Management Guideline” •  Noncompliant to review requirement - Recommendation is to cancel

standard.

  9162 “Aerospace Operator Self-Verification Programs” •  Noncompliant to review requirement – Project plate to be complete.

IDR recommends it be revised.

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Measure Description Status Comments

Performance to budget allocation Forecast to actual Performing within budget.

Compliance to 5 Year Standard Assessment requirement

IDR compliance 9132, 9133, 9134 and 9162 all behind schedule (TBD, Feldsmann, Stock, Gordon)

Publish an updated Standard Register twice a year

Revision schedule Updated in April and is being published (Daniels)

Deploy and collect data for the 9100 Usage & Flow Down Survey

Sector data on 9100 usage

Data delayed 2012 results but is now complete, 2013 initiated

Track the identification and performance of Standard IDRs and SDRs

IDRs and SDRs assigned

SDR needed for 9120 (EAQG) IDR needed for 9132 (?) SDR needed for 9132 (EAQG) IDR Needed for 9103 (?) SDR needed for 9162 (EAQG) SDRs needed for 9138 (EAQG, APAQG)

9100 manage the initiative, project and revision process

Revision schedule Ahead of schedule, deliverables met (Daniels)

9101 manage the initiative, project and revision process

Revision schedule 2nd ballot complete. (Kawamoto)

Provide proactive ISO Liaison support to the ISO 9001 revision

Coordination IAQG comments accepted, early preview enabled (Daniels)

On Track / Target Behind Schedule Issues Identified 13

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Presenter: Alan Daniels (Boeing) Subject: Cancellation of the 9134 “Supply Chain Risk

Management Guideline”. Currently noncompliant to review requirement . This standards is more guidance type material and the topic is currently covered in the SCMH. IDR, SDR and Reqs Team endorse request.

Does the Council accept the proposal to:

Cancel the 9134 standard “Supply Chain Risk Management Guideline” standard.

A vote in favor means: Cancellation process begins.

Not voting in favor means:

No cancellation and revision will need to be initiated.

Council Decision:

9100 Series Revision High Level Plan

• The 9100 is based on ISO 9001 and is thus affected by the ISO TC176 revision activity

• Several other IAQG standards are based on the IAQG 9100 standard, and will require revision in parallel with the 9100 standard revision activity

• The IAQG 9100-series standards are planned for publication in 2016

9100 Series Revision

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EAQG Leader: Brigitte CLAMENS

(Zodiac Aerospace)

Members: Roberto CIASCHI (ESA) Stuart ANTHONY (RR)

AAQG Leader: Buddy CRESSIONNIE

(Lockheed Martin)

Members:

James CLIFFORD (UTC) Mark COVERT (Honeywell)

APAQG Leader: Masahiro KAWAMOTO

(MHI)

Members: Chen ZHONGYUAN (AVIC) Tatsuya SHIRAI (KHI)

IAQG Leader: Alan DANIELS (Boeing)

IAQG Standards Representatives 9101 : Masahiro KAWAMOTO (MHI)

9110 : Agathe MOLL (Airbus)

9120 : Dale GORDON (Aerojet)

9115 : Raymond WRIGHT (Raytheon)

9137 : Juan Ignacio MARTIN (Airbus Military)

IAQG 9100 Series Team

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18

Companies certified to revised standards

Nagoya 10/2012

Moscow 05/2013

Montreal 10/2013

Preparing

San Antonio 05/2012

Ballots reviews and comments Publications

9100 revision START

For more information, see detailed schedule

END TBD

First Draft Ballot Draft

Brussels 04/2014

TBD 10/2014

2014

TBD 04/2015

TBD 10/2015

2015

TBD 04/2016

TBD 10/22016

2016 2012 2013

TBD 04/2017

TBD 10/2017

2017

Ready for Publish

9100 Series Revision Master Schedule

Coord. Draft

Plan & Stakeholders feedback

Transition Period

Internal Dependencies Standards & Training as needed for publication -  Required for 9100 publication

-  9100 Transition Plan -  9101 Update (as required) -  9100 Training (as required)

External dependencies ISO 9001 publications • CD : May 2013 • DIS : Feb. 2014 • FDIS : Feb. 2015 • Publish Sept. 2015

9110 & 9120 Series Revisions

9115, 9137 Cancel 6 mo. after 9100 is ready for

publication

Training Decision

Auditors training (as needed)

Development (OPMT) Recommended Schedule

to satisfy need date

Required for publication

9101 Audit – Revisions (as needed) 9104-1, -2, -3 – Revisions (as needed)

Required for publication

Stakeholder IAQG Leader 9100 Team Liaison External • Certif Bodies /Aero Auditors Tim LEE Alan / Masa • 9100 Certified Organizations Brian BLOUNT Brian GEER • Airline and aviation operators Alain GROS Isabelle VOUGAZ • Distributors Dale GORDON Dale GORDON • Deliverable software orgs Raymond WRIGHT Raymond WRIGHT

Internal • IAQG & sector member companies Alan/Buddy/Brigitte/Masa 9100 Leader, Sector Leaders • IAQG Strategy Streams/Teams

•  Requirements Alan DANIELS Alan DANIELS •  People Capability Jesse MANGUEL Stuart ANTHONY •  Product & SC Improvement Bernard LAURAS Jim CLIFFORD •  Performance Improvement Christian BUCK Mark COVERT •  OPMT & Certification Bodies Tim LEE Alan/Masa •  Integration Jim CLIFFORD Jim CLIFFORD Civil Aviation

• IAQG Relationship Growth •  MRO orgs Alain GROS Flavio IZZO •  Authorities Edward/Alain Alan DANIELS •  Defense / NATO Mike HAYWARD Juan Ignacio MARTIN •  Space Roberto CIASCHI Roberto CIASCHI •  Trade Associations (EAQG) Alain BONNARD Brigitte CLAMENS

Stakeholders and Liaisons

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Determine Methods to Request Stakeholder Input

Stakeholder Contact Method Data Collection Tool External •  Certification Bodies/Aerospace Auditors Email Leader 9100 Revision Survey •  9100 Certified Organizations Email Leader 9100 Revision Survey •  Airline and aviation operators Email Leaders 9100 Revision Survey •  Distributors Email Leader 9100 Revision Survey •  Deliverable software organizations Email Leader 9100 Revision Survey

Internal •  IAQG & sector member companies Email Leaders Comments template •  IAQG Strategy Streams/Teams

•  Requirements Email, Presentation Comments template •  People Capability Email, Presentation Comments template •  Product & SC Improvement Email, Presentation Comments template •  Performance Improvement Email, Presentation Comments template •  OPMT & Certification Bodies Email, Presentation Comments template •  Integration Email Leader Comments template

•  IAQG Relationship Growth •  Maintenance, repair, and overhaul Email Leader Comments template •  Authorities Email Leader Comments template •  Defense / NATO Email Leader Comments template •  Space Email Leader Comments template •  Trade Associations Email Leader Comments template 20

• External Stakeholders • Due date for inputs on “Web survey”

28 February 2013 July 31, 2013

• Internal Stakeholders • Due date for inputs on “Comments template”

31 July 2013

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What is your Sector or Geographical Area?

Americas

Europe

Asia-Pacific

What is the size of your organization?

Small <50 employees

Medium 50-500 employees Large 501-5000 employees Extra Large >5000 employees

How does your customer flow down 9100/9110/9120 standard certification

requirement for your organization?

Mandatory

Recommended

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Data Mining: 458 Responses Web Survey Demographics

How valuable is certification to 9100/9110/9120 in the management of your organization?

Extremely Valuable

Fairly Valuable

Valuable

Somewhat Valuable

No Value

How valuable is receiving ISO 9001 certification as part of your 9100 series (9100, 9110 and 9120)

certification?

Extremely Valuable

Fairly Valuable

Valuable

Somewhat Valuable

No Value

82% viewed receiving ISO 9001

certification was valuable as part of

9100 series certification.

91% rated 9100 series certification

to be valuable in the management of

their organization.

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Data Mining: 458 Responses Web Survey Responses

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Overall 9100 standards clarity

Project Management – Clause 7.1.1

Risk Management -‐ Clause 7.1.2

ConfiguraHon Management – Clause 7.1.3

Work Transfer – Clause 7.1.4

Special Requirements/CriHcal Items

ProducHon Process VerificaHon

Customer Focus/SaHsfacHon – Product Conformity and On Time Delivery Focus

Yes

No

N/A -‐ Not Applicable

Are the new requirements added to the 9100/9110/9120 series clear?

83% thought new requirements were clear

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Opportunities

Implementing the 9100/9110/9120:2009 requirements has benefits for my organization

that outweight the cost.

Yes

No

The 9100/9110/9120 Deployment Support Material located on the IAQG website (http://

www.iaqg.org/) is helpful.

Yes

No

Over 73% of respondents believe

that 9100 series requirements has

benefits that outweigh the costs.

Need to better communicate deployment

support materials.

Those that knew of materials found them

helpful.

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Questions

26

APQP/PPAP - 101 Questionnaire Standard Proposal Alan Daniels Moscow, Russia May 23, 2013

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IAQG APQP/PPAP Standard Advance Product Quality Planning (APQP)

Production Part Approval Process (PPAP) Summary •  APQP is a phased planning process applied to product

introductions. -  Includes specific deliverables to ensure on-time, on-

quality, on-cost objectives are met •  PPAP is an output of the APQP process

-  Requires Suppliers to demonstrate that they have established a production process that will consistently produce product meeting customers requirements

•  Applies existing tools to ensure products are produced under controlled conditions with minimal variation

IAQG APQP/PPAP Standard Advance Product Quality Planning (APQP)

Production Part Approval Process (PPAP)

Proposal •  Establish a common approach thru an aerospace variant

of existing APQP & PPAP materials •  IAQG APQP/PPAP Standard to include a collection of

standardized methods for ensuring consistency and quality of APQP & PPAP requirements

Question EAQG APAQG AAQG IAQG

Number of answers 33 6 15 54

ln your opinion how much value would this initiative provide to the industry if it was implemented?

19 High 3 Medium 1 Low 10 No answers




Would this initiative benefit your own Company?

29 Yes 2 No 1 No answer 1 Not involved

3 Yes 3 No

12 Yes 3 No


If the initiative was developed would you implement it in your Company?


3 Yes 3 No

9 Yes 6 No


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IAQG - APQP/PPAP 101 Questionnaire Summary

Question EAQG APAQG AAQG IAQG

If the initiative was developed would you implement it with your Suppliers?

29 Yes 2 No 1 No answer 1 not involved

3 Yes 3 No

10 Yes 5 No

42 Yes 10 No 1 No answer 1 not involved

If the initiative was developed would it benefit ail Sectors?

28 Yes 4 No 1 No answer

5 Yes 1 No

14 Yes 1 No

47 Yes 6 No 1 No answer

Would your Company like to nominate someone to join the Initiative Project Team?

15 /18 Yes 18 No

0 Yes 5 No 1 If approved

8 Yes 7 No

23/26 Yes 30 No 1 If approved

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IAQG - APQP/PPAP 101 Questionnaire Summary

•  101 Survey results very positive in support of the initiative •  Strategy Working Group endorsed

  Recommend vote of approval

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Presenter: Alan Daniels (Boeing) Subject: APQP/PPAP

Advance Product Quality Planning (APQP) / Production Part Approval Process (PPAP)

Does the Council accept the proposal to:

Develop an internationally harmonized standard on Advance Product Quality Planning (APQP) / Production Part Approval Process (PPAP).

A vote in favor means: Work begins developing a standard in accordance with presentation.

Not voting in favor means:

No harmonization activities will start and no international standard will be established.

Council Decision:

32

Questions

33

IAQG 9101 Team Masahiro Kawamoto

Moscow, Russia 23rd May, 2013

Actually, yes we can…

9101E – Re-Ballot Results

Sector Eligible to vote No Reply Approved Not Approved Approved Disapproved AAQG 27 8 19 0 100% 0% EAQG 34 11 21 2 91% 9%

APAQG 12 5 7 0 100% 0% Total 73 24 47 2 96% 4%

96%

4%

Overall Re-‐Ballot Vote Approved Disapproved

19 21

7

2

0

5

10

15

20

25

AAQG EAQG APAQG

Re-‐Ballot Vote Count by Sector

Not Approved

Approved

37 (86%)

47 (96%)

6

2

0

10

20

30

40

50

60

Ballot 1 Ballot 2

9101 Ballot Votes

Not Approved

Approved


44

70

101

29 38

5 0

20

40

60

80

100

120

Ballot 1 Ballot 2

9101 Ballot Feedback

Comments

Editorial

Technical

Summary:

-  Team has reviewed and dispositioned on all comments (Total: 104 comments) through F2F meeting (March 2013: hosted by PFW in Speyer, Germany) and WebEx meetings.

-  Re-Ballot started on 26th January 2013 and closed on 24th March.

-  Moscow/Chicago meeting (F2F & WebEx) was held for creating(revising) the guidance materials.

-  The final draft for publication will be submitted after AAQSC affirmation ballot.

-  As a result of review on comments, no technical change is needed. Team has completed a draft for final editing and publication.


Questions

38

Alain Bonnard EAQG Operations Manager

Final results

39

9100 Survey

Note

•  Preliminary results (APAQG & EAQG) presented during IAQG Nagoya October 2012 meeting (AAQG consolidated results not available at this time)

•  Final 2012 results with consolidation of the 3 sectors answers presented here after

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9100 Survey Summary

Number of 9100 Survey answers

Topic AAQG APAQG EAQG Total IAQG

Number of Answers

20** on 21*** (100 %)

12 on 12 (100 %)

35 on 35 (100 %)

67** on 68*** (100 %)

Number of answers provided

at 100 %*

18 on 20 (90 %)

11 on 12 (92 %)

33 on 35 (94 %)

62 on 67 (93 %)

Total of Answers accountable

18 on 20 (90 %)

11 on 12 (92 %)

33 on 35 (94 %)

62 on 67 (93 %)

*: Not complete at 100% Supplier figures not provided **: Eaton figures not requested (New Member) ***: Rolls-Royce figures consolidated within EAQG answer

41

9100 Survey Summary

Sector

Number of Members

Internal IAQG Companies Number of Companies

certified

Certification Average

Company Sites Average / Member

AAQG (20) 19/20 (95 %) 89,5 % 39

APAQG (12) 12/12 (100 %) 93,5 % 10

EAQG (35) 35/35 (100 %) 90,1 % 13

Total IAQG (67)

66/67 (99 %) 89,5 % 20

Internal IAQG Company Certification

42

9100 Internal Certification

Plot order: AAQG - APAQG – EAQG (From Left to Right)

0

40

80

120

160

200

0%

20%

40%

60%

80%

100%

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67

CerJficaJon Rate Number of Sites

9100 Certification - IAQG - Internal

Certification Average Company Sites Average

89,5 % 20

43

9100 Survey Summary

Sector

Number of Members

IAQG Supply Chain Supply Chain Certification

Mandatory Rate (1)

Certification Average

Supplier Sites Average / Member

(2)

AAQG (20) 8/20 (40 %) 68,0 % 1796

APAQG (12) 9/12 (75 %) 84,2 % 212

EAQG (35) 26/35 (74 %) 70,5 % 625

Total IAQG (67) 43/67 (64 %) 72,3 % 920

IAQG Suppliers Certification

(1): Ratio of Number of IAQG Members mandating 9100 Certification to their Suppliers (2): Average of Suppliers sites (Eligible Suppliers) per IAQG Company

44

0

4000

8000

12000

16000

20000

0%

20%

40%

60%

80%

100%

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67

CerJficaJon Rate Number of Suppliers

9100 Certification - IAQG - Suppliers Certification

9100 Supplier Certification

Certification Average Supplier Sites Average

72,3 % 920

Plot order: AAQG - APAQG – EAQG (From Left to Right)

Supply Chain Certification Mandatory Rate

43 IAQG Companies mandating 9100 Certification / 67 (64 %)

45

9100 Survey Summary

Sector Internal Suppliers

2010 2011 2012 2010 2011 2012

AAQG 83,4 % 84,3 % 86,0 % 71,5 % 70,8 % 68,0 %

APAQG 91,3 % 96,6 % 93,5 % 60,6 % 72,6 % 84,2 %

EAQG 93,5 % 90,4 % 90,1 % 69,5 % 68,5 % 70,5 %

% of answers

100 % 100 % 100 % 67 % 98 % 93 %

Total IAQG

90,2 % 89,9 % 89,5 % 68,7 % 69,9 % 72,3 %

Evolution of Certification Rates 2010 2012

46

Comments

Suppliers certification rate: •  2 identified bias:

–  AAQG: –  Effect of Member companies not mandating

suppliers to be 9100 certified ( 12 on 20 60 %): –  Rate at 60,2 % instead of 77,7 % for the others

(The 8 mandating certification) –  EAQG: –  EAQG Members with only Defense and Space

activities (6 on the total of 35): –  Rate at 42,3 % instead of 75,8 % for the others

(The 29 not limited to Space or/and Space activities)

47

Next

2013 Survey: •  Keep yearly periodicity •  (Matching the IAQG 90% Certification goal

monitoring) •  Keep goal to get 100% completion (100% answers

from IAQG Company Members) •  2013 Survey schedule:

–  Same questionnaire as 2012 –  Survey launched: May 6th, 2013 –  Survey due date: July 31st, 2013

•  2013 results to be presented during Montreal Autumn 2013 meeting

48

Thanks for your valuable contribution

50

Questions

alan daniels moscow, russia may 23, 2013 apqp/ppap standard advance product quality planning (apqp)...

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