Advanced Quality Planning for Low Production Volume with QRL (Quality Readiness Level) prioritization and optimization of Quality resources

The aim of this paper is to present a prioritization and optimization of quality resources by introducing the concepts of QRL (Quality Readiness Level) and PPAP (Production Part Approval Process) together with system or subsystem safety level and customer impact. The automotive industry has used APQP (Advanced Product Quality Planning) as the basis for product development to ensure its Quality for over 30 years. The question developed in the work is how to adapt the APQP for the low volume industry (in the case of aerospace industry) and, due to the amount of PNs (Part Numbers), how to create a prioritization for its use. For product development, the work proposes the use of APQP by the AS9145 standard and adapted with the 13 items of PPAP (Production Part Approval Process) listed as: project or design, modification control, engineering approval, Failure Mode and Effects Analysis (FMEA), measurement system analysis, First Article Inspection (FAI) report, accelerated test results, composite approval, workforce training, visual criteria, customer-specific requirements, approval of special processes, and management of sub-suppliers. In order to use all the items in the different systems of a project and to optimize the Quality resources, a prioritization is proposed with the QRL that evaluates the readiness based on the TRL (Technological Readiness Level), MRL (Manufacturing Readiness Level), product or process change, quality performance in the production line and reliability performance in the field. It is also considered the system or sub-system safety level, based on FAA (Federal Aviation Administration) category classification and the customer impact (how visible the system is to the final customer). A case study is shown using APQP in conjunction with QRL prioritization. In conclusion, an optimization greater than 99% of the Quality resources is observed, and a result of reduction of 6 years in the cost of poor quality curve in the production line and improvement of 2 years in the reliability of the product in the field.