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A product that fails in series production was almost always poorly anticipated at the design stage. APQP structures that anticipation.
Why APQP is a strategic issue
Nonconformities discovered in production cost ten times more than those dealt with at the design stage. Delays in ramp-up, failed First Article Inspections, incomplete process qualifications: these are not production problems. They are planning problems.
APQP and PPAP: what is the difference?
APQP (Advanced Product Quality Planning) is the approach that structures product quality planning, from the expression of customer needs through to validation of the manufacturing process. PPAP (Production Part Approval Process) is its evidence deliverable: the formal demonstration that the product and the process are capable of meeting customer requirements in series production.
In short, APQP is the path, and PPAP is the proof that you have arrived.
EN 9145: APQP for aviation and space
Born in the automotive industry (where it is one of the IATF 16949 core tools), the APQP approach has been adapted to the requirements of the aviation, space and defence supply chain through the EN 9145 standard.
EN 9145 formalises the APQP process in five phases: project planning, product design and development, process design and development, product and process validation, and ongoing production. At each milestone, teams must demonstrate that risks have been identified, verifications carried out and deliverables completed in compliance with requirements.
Within EN 9145, PPAP is the final validation file. It gathers the evidence that the product conforms to its definition, that the process is qualified, that measuring equipment is under control and that production is repeatable.
Key interfaces
Special processes: the qualification of special processes (welding, heat treatment, surface treatment, etc.) is an APQP deliverable. An unqualified special process blocks the PPAP.
FMEA: failure mode analysis is a core APQP tool. It feeds into the design of the control plan and the identification of key characteristics.
Metrology and ISO 10012: PPAP requires evidence that measuring equipment is suitable and under control. Measurement systems analysis (MSA) is a mandatory deliverable.
Management systems: APQP is integrated into the requirements of EN 9100 (clause 8.1, operational planning and control) and IATF 16949 (core tools).
Configuration management: control of the product definition is a prerequisite for successful APQP. Any untracked change invalidates the PPAP.
A process, not a form
APQP is not a file to fill in. It is a multidisciplinary steering process that involves engineering, quality, production, metrology and purchasing. When it is reduced to a paperwork exercise, it loses its purpose, and nonconformities reappear in series production.
Our support
Consulting and structuring: setting up the APQP process in your organisation, defining milestones, expected deliverables and gate criteria. Adaptation to the requirements of your customers.
Operational support: support for project teams on real programmes: building the PPAP file, conducting FMEAs, defining the control plan, preparing FAIs (First Article Inspection).
Audit: assessment of the maturity of your APQP practices. Product audits, process audits, milestone reviews.
Training: transfer of skills to your teams to make the approach self-sustaining and lasting.
Why QALIA?
APQP rarely fails for lack of method. It fails when teams do not cooperate, when milestones are bypassed for pragmatic reasons, when feedback from the shop floor is ignored, when schedule pressure wins out over technical rigour.
Our Q-SYNQ® approach builds the organisational dimension into APQP deployment. We identify the real dynamics that hinder or support cooperation between functions, and we build an APQP process that holds up in your context, not just on paper.
Related training courses
Training courses designed to give your teams the keys to product quality planning, from the standard to the shop floor:
🎓 APQP / PPAP training in line with EN 9145
Understand, structure and deploy product quality planning in your organisation.
Let's talk about your APQP challenges
Process structuring, PPAP support, audit or training: we tailor our approach to your programme and your requirements.