CWP-700 Composite Wing Panel Production Program

Scope, success criteria, budget, and governance for the CWP-700 Composite Wing Panel Production Program.

The actual kickoff presentation — success criteria, scope, the full 25-person program team across both phases, milestone timeline, budget, working agreement, risks, and next steps.

One-time kickoff meeting notes — agenda, attendees, key discussion points, and the decisions that shaped the program's stage-gate approach. See the Kickoff Deck for the actual presentation.

The quality-investment case, weighed against the cost of a prevented field escape.

3-year cost scenario including the steady-state production option.

The benefit register behind the CBA and TCO — what the program is worth, why each of the six benefits resists measurement for a different reason, the leading indicators substituted for unmeasurable cost avoidance, and who owns measurement after the program closes.

The strategy that connects the QMS, First Article and MRB — verification architecture from material through process, coupon, part and acceptance; incoming prepreg and special-process control; the ultrasonic NDT strategy and its capacity bottleneck; destructive, dimensional and measurement-system verification; and the earned transition from 100% inspection to statistical sampling at rate.

The AS9145 control plan enumerating every controlled characteristic on the CWP-700 — 6 Key Characteristics (100%, never sampled), 5 critical process parameters, 3 standard characteristics — each tied to the process step that creates it, its control & verification method, and its Phase-2 sampling intensity. The requirements baseline the test strategy, FAI and MRB all reference.

Traces every controlled characteristic in the Control Plan — 6 Key Characteristics, 5 critical process parameters, 3 standard characteristics — through its verification method and First Article Inspection evidence record to its acceptance path. A production RTM: it terminates in acceptance, not completion, and carries no priority column because nothing on a flight structure is optional.

How the AS9100 QMS governs this program and maps to specific program artifacts.

Implements AS9100 §8.4 (Control of Externally Provided Processes, Products & Services) for the CWP-700. Classifies the supply base by how far conformity can be verified after delivery, qualifies suppliers via PPAP/NADCAP, flows down requirements in the purchase order, and monitors performance on the quarterly D-04 cadence — grounded in dependency DEP-02 and the I-05 incomplete-PPAP incident.

The instrument behind the plan — issued under purchase order, not as a standalone agreement. Four qualification phases before production: flow-down and sub-tier declaration, PPAP, NADCAP accreditation, first-lot acceptance. What is bought is a qualified process, not parts, because a cured laminate does not reveal an out-of-spec resin batch on a caliper.

Full FAI checklist and results, including the nonconformance dispositioned through MRB.

MRB composition, disposition process, and the full nonconformance log.

Who does what across 50 people on an AS9100 build-to-print program — what the Material Review Board may and may not decide, and the long list of things nobody in the plant can waive.

The integrated plan tying scope, schedule, cost, quality, resources, risk, supplier, and configuration management together across the whole suite.

Interactive Gantt-style schedule — 79 line items across 2 phases, with live % complete and a "Today" marker. Exports as Excel or a genuine Microsoft Project file.

Allocation-aware resource loading of the CWP-700 WBS — 68 loaded work packages, 50 named resources, 312 assignments, split by program phase. Every person's effort and cost reconcile exactly to their Resource Plan line: Phase 1 8,216 h / $755,000 and Phase 2 92,352 h / $7,216,000, totaling $7,971,000 at $0 variance to the Program Budget. Owners are engineers; contributors are the technicians whose hands are on the part.

Named delivery roster with FTE%, blended rates, reconciled to the Program Budget.

Reporting structure across program, quality, and phase-specific roles, plus the customer source-inspection relationship.

Labor, tooling/NRE, materials, travel, and management reserve — $2,500,000 total.

Internal and customer-facing communication cadence, including mandatory nonconformance notification.

RACI, review cadence, part traceability, and escalation path.

Full RACI covering program, quality, tooling, MRB, and supplier-quality decisions.

Risks, assumptions, issues, decisions, and dependencies, tracing forward to Lessons Learned.

Every formal change against the engineering baseline or internal process — Engineering Change Notices, tooling/process changes, and documentation corrections — filterable by category, with a full detail page per change.

The worked change requests behind the log — engineering justification, impact across tooling, qualification, first article and production rate, disposition, and the approval record.

At-a-glance RAG status, budget, and MRB disposition breakdown.

Weekly status snapshot: schedule, budget, and quality health during production ramp.

Leadership briefing summarizing program health, quality performance, and financials.

Final performance vs. charter, budget reconciliation, and handoff to steady-state production.

10 entries, each traced to a specific risk, issue, or MRB nonconformance.

How AS9100/FAI/MRB governs an aerospace production program, illustrated with this program's real numbers.

AS9100, FAI, MRB, PPAP, NDT and other terms used across this suite.