In today’s aerospace supply chain, quality planning is no longer reactive. Major OEMs such as Boeing, Lockheed Martin, RTX, and Gulfstream expect suppliers to demonstrate structured, risk-based planning before the first chip is cut.
AS9145 adapts the automotive APQP model for aerospace and aligns it with AS9100 requirements, adding the rigor needed for safety-critical products, configuration control, and complex supply chains.
What Is APQP in Aerospace?
Advanced Product Quality Planning (APQP) is a structured method used to ensure customer requirements are understood, risks are identified early, processes are capable, validation occurs before production, and escapes are prevented.
It complements AS9100 by providing the execution model for Clauses 8.1, 8.3, 8.5, and 8.6.
The 5 Phases of APQP per AS9145
Aerospace APQP includes Phase 0 – Planning, which focuses on risk management and contract readiness.
Phase 0 – Planning
Goal: Define the program and identify risks before design or manufacturing begins.
Key activities include contract review, risk assessment, make/buy decisions, resource planning, and preliminary process flow.
Outputs include the program plan, risk register, and quality plan.
Phase 1 – Design & Development
Goal: Ensure the design is producible and risks are mitigated.
Activities include design reviews, DFMEA, special characteristic identification, DVP&R, and configuration control.
Outputs include the released design baseline and DFMEA with mitigation actions.
Phase 2 – Process Design (Industrialization)
Goal: Build a capable and controlled manufacturing process.
Activities include Process Flow, PFMEA, Control Plan, work instructions, tooling validation, MSA planning, and supplier APQP flow-down.
Outputs include an approved process definition and risk-based control plan.
Phase 3 – Production Process Validation
Goal: Prove the process can repeatedly produce conforming parts.
Activities include FAIR per AS9102, capability studies, MSA execution, validation runs, and PPAP preparation.
FAIR validates the product; capability validates the process.
Phase 4 – Production
Goal: Maintain control and drive continuous improvement.
Activities include SPC monitoring, on-time delivery tracking, nonconformance and RCCA, and risk updates.
Core APQP Tool Linkage
Process Flow → PFMEA → Control Plan → Work Instructions → Inspection/SPC
DFMEA → Special Characteristics → PFMEA → Control Plan → FAIR
PPAP in Aerospace
PPAP proves the design is understood, the process is controlled, risks are mitigated, and the process is capable.
Typical elements include FAIR, ballooned drawing, Process Flow, DFMEA, PFMEA, Control Plan, capability studies, MSA results, and certifications.
Common APQP Gaps
PFMEA not tied to Control Plan, key characteristics not flowed down, no Phase 0 review, supplier APQP not required, FAIR done before validation, and risks not mitigated.
Benefits of Implementing AS9145 APQP
Fewer NCRs, reduced rework and scrap, faster ramp-up, improved on-time delivery, stronger customer confidence, and easier AS9100 audits.
How to Start Implementing APQP
Add Phase 0 risk review to contract review, standardize PFMEA to Control Plan linkage, define key characteristics, perform capability before FAIR, flow APQP to suppliers, and train cross-functional teams.
Final Thoughts
AS9145 APQP is a risk prevention system that protects margin, schedule, and customer trust. Organizations that integrate it into daily operations achieve right-first-time production and predictable launches.
Need Help Implementing APQP?
QMS Innovations helps aerospace manufacturers build AS9145-compliant APQP procedures, develop PFMEA and Control Plan templates, prepare for audits, and train teams.
