#APQP4Nuclear

Advanced Product Quality Planning For the Nuclear Sector

New Product Introduction

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@AmeliasBrain

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APQP
4
Nuclear

The Midcal team have been applying APQP, PPAP and associated tools since the inception and roll out of QS9001 in the automotive industry during the 1990’s.

Our team members have 20 to30 year practical hands on experience across all business functions utilising the APQP tool set.

In 2012 We embarked on applying APQP to the nuclear sector.  Concentrating on repeat/volume manufactured products mainly associated with the storage and transportation of nuclear materials and waste. The Adoption of APQP to the nuclear industry formulated the creation of a nuclear specific set of tools. APQP4Nuclear is the culmination of a number of years of working within the Nuclear industry and supporting the development of volume products    

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COMPLETE NEW PRODUCT INTRODUCTION (NPI) PROCESS DESIGN

  • MidCal, in association with the NAMRC and Sellafield Ltd have developed a gateway driven NPI process specifically for the nuclear industry that incorporates APQP and based on best practices from the automotive and aerospace industries adapted.
  • This process enable the development of volume, repeat manufactured products from project inception through to volume manufacture.
  • The NPI process is gateway driven with clear roles and responsibilities.
  • Clear definition of content each stage that culminates in a gateway.
  • Definition of functional roles and responsibilities and content
  • The expected deliverables and outcomes at the end of each gateway.
  • A generic timing plan structure encompassing the gateway requirements and cycle.

APQP4NUCLEAR TRAINING

As we drive the adoption of a standard way of working across the UK Nuclear industry and supply chain we aim to work with the NDA, NAMRC and Sellafield to create an accredited standard that becomes nationally recognised.

As we drive the adoption of a standard way of working across the UK Nuclear industry and supply chain we aim to work with the NDA, NAMRC and Sellafield to create an accredited standard that becomes nationally recognised.
  • MidCal can provide training in the APQP for nuclear. methodologies
  • The training can be provided at a number of levels;
  • Appreciation training.
    • Aimed at senior management to provide and over view and application of the processes,
  • In depth APQP and NPI training
    • Aimed at Project Team Members executing APQP4Nuclear to deliver products.
  • Specific element training, for example –
    • DFM,
    • PFMEA,
    • MSA planning.
    • Factory layout for repeat manufacturing process
  • NPI process training.
  • Business System Application Of APQP4Nuclear

Program and project support

  • MidCal can support a project from the initial tender through to completion.
  • Our experienced team can provide project support in the following areas:
    • Bid support
    • Supplier management.  Supplier selection, contract creation,
    • Program and project management
    • Mentoring and Coach teams (Learn by doing)
  • Coaching, Mentoring and Training can be provided guiding client teams through the The New Product Introduction (NPI) process specifically developed for the Nuclear sector applying the APQP process framework.
  • Enabling Customers and  suppliers to plan and complete the tasks necessary to ensure that manufactured products are delivered on time, within budget, and meet quality standards.
  • This application of the APQP4Nuclear  process is designed to enhance cross-functional communication and aims to reinforce activities such as concurrent engineering, product quality planning, design, manufacturing, and supply chain management.

Introduction - Advanced Product Quality Planning (APQP)

  • APQP is a structured method of defining, establishing and delivering products that satisfies or exceeds the customer expectations.  
  • APQP accompanies the development of a product with the objective of manufacturing products repeatably to the required standards, at the required volume and to the correct cost.
  • APQP first started development in the1980’s by the Ford Motor Company and by the 1990’s Chrysler, GM and Ford had jointly developed the process into the form it is know today.  
  • Since the 1990’s APQP has become an established tool across the automotive industry and has expanded into industries outside of the Automotive sectors.
  • APQP is a framework of tools, procedures and techniques used to develop a product and sits as an integral part of a New Product Introduction (NPI) process.  
  • The emphasis is on continuous improvement, reduced risk and lowering the costs resulting from poor and inconsistent quality.

Automotive Industry

Launched in the 1990’s by Ford, GM and Chrysler to standardise mass manufacture approach across supply chain. Adopted by most OEMs across the world

Aerospace Industry

Common standard across aerospace sector that is now formalised under AS9145

Wind Turbine Industry

Launched 2016 by multiple wind turbine OEMs Industry body established Provide training, standards and accreditation

Objectives of APQP

  • Cross functional communication with all departments enabling effective product and project delivery.
  • Tools within APQP define the framework for quality requirements, capable manufacturing processes, delivery performance and control.
  • Executed correctly will improve
    • Timely completion of required goals.
    • Minimise product quality concerns
    • Reduced risks related to manufacturing, product quality and delivery.
  • Establishes aligned methods and procedures for all Suppliers and Sub Suppliers nationally and internationally.
  • The APQP process concludes with the Production Part Approval Process (PPAP) submission that evidences completion all the elements of APQP.
  • Enables the supplier / manufacturer to confirm readiness to produce and supply product consistently and repeatably.

Benefits of APQP

  • APQP is developed and composed to meet all the business aspects of an organisation, including its suppliers.
  • The tools of APQP are both far-reaching and more productive when implemented precisely.
  • Enhanced communication between the supplier organisation and the customer to build the ability to meet customer needs, requirements, and expectations.
  • Effective cross-functional collaborative working throughout the supplier and customer organisations, with clear concise status reporting and escalation.
  • Early detection of manufacturing capacity restraints, equipment capability and capacity, quality and design problems that reduce the propensity for costly mistakes.
  • Benchmarking standards from which the supplier and customer organisations can build and grow upon.
  • Effective communication between suppliers and customer organisations that improves the product and supply.
  • Opportunity for continual improvement.