SAE AS 9145-2016 Aerospace Series C Requirements for Advanced Product Quality Planning and Production Part Approval Process.pdf

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1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref

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4、side USA)Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on thisTechnical Report, please visithttp:/standards.sae.org/AS9145AEROSPACESTANDARDAS9145Issued 2016-11Technically equivalent writings published in IAQG sectors.Aerosp

5、ace Series Requirements for Advanced Product QualityPlanning and Production Part Approval ProcessRATIONALEThis 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 aspec

6、ts of this standard define 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 pro

7、duct 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.FOREWORDTo assure customer satisfaction, the aviation, space, and d

8、efense industry organizations must produce and continually improve safe, reliable products that equal or exceed customer and regulatory authority requirements. The globalization of the industry and the resulting diversity of regional/national requirements and expectations have complicated this objec

9、tive. End-product organizations face the challenge of assuring the quality of and integration of product purchased from suppliers throughout the world and at all levels within the supply chain. Industry suppliers face the challenge of delivering product to multiple customers having varying quality e

10、xpectations and requirements.The aviation, space, and defense industry established the International Aerospace Quality Group (IAQG) for the purpose of achieving significant improvements in quality, delivery, safety, and reductions in cost, throughout the value stream. This organization includes repr

11、esentation from companies in the Americas, Asia/Pacific, and Europe.This document standardizes the requirements for the Product Development Process (PDP) through the use of APQP and PPAP methodologies. The establishment of common requirements, for use at all levels of the supply chain, should result

12、 in the elimination or reduction of organization unique requirements, and the resulting variation inherent in the multiple expectations.SAE INTERNATIONAL AS9145 Page 2 of 29TABLE OF CONTENTSRATIONALE . 1FOREWORD. 1INTRODUCTION. 30.1 General 30.2 Application. 41. SCOPE 51.1 Purpose. 51.2 Convention 5

13、2. REFERENCES 53. TERMS AND DEFINITIONS. 64. ADVANCED PRODUCT QUALITY PLANNING REQUIREMENTS 104.1 General Requirements 104.2 Advanced Product Quality Planning Project Management. 104.3 Phase 1 Requirements Planning . 114.4 Phase 2 Requirements Product Design and Development . 124.5 Phase 3 Requireme

14、nts Process Design and Development. 134.6 Phase 4 Requirements Product and Process Validation. 154.7 Phase 5 Requirements On-Going Production, Use, and Post-Delivery Service . 175. PRODUCTION PART APPROVAL PROCESS REQUIREMENTS . 175.1 Process Requirements for Production Part Approval Process . 175.2

15、 Production Part Approval Process File and Submission 185.3 Production Part Approval Process Disposition . 195.3.1 Production Part Approval Process Submission Disposition 195.3.2 Recording the Production Part Approval Process Disposition 195.4 Production Part Approval Process Resubmission 196. NOTES

16、 196.1 Revision Indicator 19APPENDIX A ACRONYM LOG. 20APPENDIX B ADVANCED PRODUCT QUALITY PLANNING PHASEACTIVITIES, DELIVERABLES, AND OUTPUTS 22APPENDIX C CONTROL PLAN 26APPENDIX D PRODUCTION PART APPROVAL PROCESS APPROVAL FORM 27FIGURE 1 PRODUCT DEVELOPMENT PROCESS AND ADVANCED PRODUCT QUALITY PLAN

17、NING (CONCEPTUAL ILLUSTRATION) . 4TABLE 1 ACCEPTANCE CRITERIA FOR PROCESS CAPABILITY STUDIES 16TABLE 2 PRODUCTION PART APPROVAL PROCESS FILE CONTENTS 18SAE INTERNATIONAL AS9145 Page 3 of 29INTRODUCTION0.1 General This standard specifies requirements in a structured framework to plan and complete act

18、ions of the product realization cycle which are necessary to ensure quality product(s) are delivered on time, while satisfying cost performance targets. APQP drives a quality focused approach to product development through the use of a phased planning process within which specific deliverables are e

19、stablished, monitored, and tracked to closure, while highlighting and mitigating risks as they are identified. PPAP is an output of APQP confirming that the production process has demonstrated the potential to produce products that consistently fulfill all requirements while operating at the custome

20、r demand rate.Successful implementation of APQP requires: management commitment and support from the beginning of the product development cycle, and multidisciplinary project teams integrating all stakeholders and delivering a committed timeline for executing planned activities. APQP has five phases

21、 (conceptually illustrated in Figure 1) starting with conceptual product needs and extending throughout the product life cycle. The actual duration of each phase will differ depending upon the scope and timing of the specific product and/or production development project. These phases are described

22、as follows:xPhase 1 PlanningThe goal of this phase is to capture customer inputs, benchmark data, lessons learned, regulatory requirements, technical specifications, company know-how, and strategy into a product concept and realization plan. This includes identification of the high-level technical,

23、quality, and cost targets.xPhase 2 Product Design and DevelopmentThe goal of this phase is to translate the technical, quality, and cost requirements into a controlled, verified, and validated product design. Design validation is achieved using prototype, development, or production parts in test env

24、ironments that can represent the customers installation and subject the product to extreme conditions required by contract or regulation.xPhase 3 Process Design and DevelopmentThe goal of this phase is to design and develop the production processes needed to produce product that consistently fulfill

25、 technical, quality, and cost requirements while operating at the customer demand rate. xPhase 4 Product and Process ValidationThe goal of this phase is to validate that product fulfills the design requirements and the production processes have demonstrated the capability to consistently produce con

26、forming product at the customer demand rate. Product validation is achieved using product produced from the defined production processes.xPhase 5 On-Going Production, Use, and Post-Delivery ServiceThe goal of this phase is to ensure customer requirements are continually fulfilled through the use of

27、process control, lessons learned, and continuous improvement.SAE INTERNATIONAL AS9145 Page 4 of 29Figure 1 Product development process and advanced product quality planning (conceptual illustration)0.2 ApplicationThis standard applies to new product development efforts, but can also be applied to pr

28、oducts currently in production where changes are planned. It can be applied to the final product or selected levels of parts (i.e., parts within an assembly as defined by the organization or customer). When this standard is flowed down as a general contractual requirement (i.e., not for a specific p

29、rogram or project), the scope of applicability is established between the organization and the customer.This standard is generally not applied to standard parts or Commercial-off-the-Shelf (COTS) items. Producers and their suppliers are responsible for flow down of the requirements of this standard,

30、 as appropriate, to suppliers who design and/or produce product.When this standard is invoked, APQP and PPAP shall continue to apply when previously approved products and processes undergo change (e.g., introduction of a new production process, change to existing production process, change of produc

31、tion source, addition to the existing production sources). SAE INTERNATIONAL AS9145 Page 5 of 291. SCOPEThis standard establishes requirements for performing and documenting APQP and PPAP. APQP begins with conceptual product needs and extends through product definition, production planning, product

32、and process validation (i.e., PPAP), product use, and post-delivery service. This standard integrates and collaborates with the requirements of the 9100, 9102, 9103, and 9110 standards. The requirements specified in this standard are complementary (not alternative) to contractual and applicable stat

33、utory and regulatory requirements. Should there be a conflict between the requirements of this standard and applicable statutory or regulatory requirements, the latter shall take precedence.1.1 PurposeThe purpose of this standard is to establish a uniform approach to product realization across the a

34、viation, space, and defense industry ensuring that quality products are delivered on time, while satisfying cost performance targets.1.2 ConventionThe following conventions are used in this standard:xThe word “shall” indicates a requirement.xThe word “should” indicates a recommended action (content

35、or path), but not mandatory application.xWords “typical”, “example”, “for reference”, or “e.g.” indicate suggestions given for guidance only.x“NOTES” are used for additional clarification.xWords or phrases with specific meaning pertaining to this document are defined in Section 3.2. REFERENCESThe fo

36、llowing publications form a part of this document to the extent specified herein; referenced documents are supportive for the application of this standard. For dated references, only the edition cited applies. For undated references, the latestedition of the referenced document, including any amendm

37、ents, applies.9100 Quality Management Systems Requirements for Aviation, Space, and Defense Organizations9102 Aerospace First Article Inspection Requirement9103 Aerospace Series Quality Management Systems - Variation Management of Key Characteristics9110 Quality Management Systems Requirements for A

38、viation Maintenance OrganizationsNOTE: Equivalent versions (e.g., AS, EN, JISQ, SJAC, NBR) of the IAQG standards listed above are published internationally in each sector.IAQG Supply Chain Management Handbook (SCMH) http:/www.sae.org/iaqg/.xAdvanced Product Quality Planning (APQP)xAerospace Advanced

39、 Product Quality Planning (APQP) ManualAdvanced Product Quality Planning and Control Plan; APQP Second Edition; Automotive Industry Action Group (AIAG); www.aiag.org.SAE INTERNATIONAL AS9145 Page 6 of 29ASTM E 2782 Standard Guide for Measurement Systems Analysis (MSA)IEEE 1490:2011 Guide Adoption of

40、 the Project Management Institute (PMI) Standard; “A Guide to the Project Management Body of Knowledge (PMBOK Guide)” Fourth Edition; www.ieee.org.ISO 9000 Quality management systems Fundamentals and vocabularySAE J1739 Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential F

41、ailure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA)3. TERMS AND DEFINITIONSDefinitions for general terms can be found in ISO 9000 and the IAQG International Dictionary (located on the IAQG website). An acronym log for this document is presented in Appendix A. For

42、the purpose of this standard, the following definitions apply:3.1 Bill of Material (BOM)List of components and materials contained in the design record(s) of a product.3.2 Commercial off-the-Shelf (COTS)Commercially available applications, defined by industry recognized specifications and standards,

43、 sold through public catalog listings. 3.3 Control PlanA documented description linking manufacturing process steps to key inspection and control activities. The intent of a control plan is to control the design characteristics and the process variables to ensure product quality.3.4 Critical Item (C

44、I)Those items (e.g., functions, parts, software, characteristics, processes) having significant effect on the product realization and use of the product; including safety, performance, form, fit, function, producibility, service life, etc.; that require specific actions to ensure they are adequately

45、 managed. Examples include: safety CIs, fracture CIs, mission CIs, Key Characteristics (KCs), and maintenance tasks critical for safety (reference 9103 standard).3.5 CustomerOrganization, legal entity, or person that receives a product or service (e.g., consumer, client, end-user, retailer, benefici

46、ary, purchaser).3.6 DeliverablesItems (outputs) completed as part of the APQP process.3.7 Demand RateThe quantity of products required to be produced by the production organization over a specified period of time to fulfill the delivery schedule.SAE INTERNATIONAL AS9145 Page 7 of 293.8 Design Charac

47、teristicThose dimensional, visual, functional, mechanical, and material features or properties, which describe and constitute the design of the article, as specified by drawing or Digital Product Definition (DPD) requirements. These characteristics can be measured, inspected, tested, or verified to

48、determine conformance to the design requirements. Dimensional features include in-process locating features (e.g., target-machined or forged/cast dimensions on forgings and castings, weld/braze joint preparation necessary for acceptance of finished joint). Material features or properties may include

49、 processing variables and sequences, which are specified by the drawing or DPD (e.g., heat treat temperature, fluorescent penetrant class, ultrasonic scans, sequence of welding and heat treat). These provide assurance of intended characteristics that could not be otherwise defined (reference 9102 standard).3.9 Design RecordsThe records of the engineering definition/specification, which