PPAP trg.ppt

8/9/2019 PPAP trg.ppt

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Good Morning


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• Understanding APQP (Advanced ProductQuality Planning)

• Production Part Approval Process (PPAP)

• Purpose

• Benefts

•Standards• When is PPAP required?

• PPAP subission levels

• !leents o" PPAP and its iportance

• #esign $ecords• Process %lo& #iagra

• #%'!A P%'!A

• ontrol Plan

• 'SA• *nitial Process apability Study

Learning Objectives


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Advanced Product Quality

Planning (APQP)


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Advanced Product Quality Planning

accompanies the development of a product

and is intended to ensure that all of the

customer's requirements are met. The

objective is to provide a quality product at

the right time.



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Definition phaseDuring the definition phase, design or! is carried out on

products and processes and project planning ta!es place. The

quotation is then prepared on the basis of the results.

Prototype phase

During the prototype phase and or!ing from the product

design, the product function is developed and proven ith the

help of the Design "erification Plan #D"P$. A product design is

dran up and developed as far as the initial layout.



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*amp(up phase

The ramp(up phase,

hich follos the start ofproduction,forms a

transition from the

development phase to the

stable production phase.

The ramp(up of volume

production is

accompanied by a project

team. All measures that

are required in order toachieve the productivity

and cost objectives are

introduced.



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APQP 1 - Sourcing Decision

Formal commitment of the customer to work with the sulier !customer or"er#

$omination Letter etc%& so that investments can be effecte" on sche"ule%

APQP ' - (ustomer Secifications

)o avoi" misun"erstan"ings in (ustomer secifications inclu"e the "esign criteria an"

rogram re*uirements# e%g% "rawings# secifications !+$ote, if material orcoatinglating# etc% is not inclu"e" on the "rawing or in secifications# then there must

be a sign off between engineering# urchasing# an" sulier rior to issue of urchase

or"er& an" "esign re*uirements which are necessar. for the intro"uction of the

sulier/s APQP%

APQP 0 - (ontract eview

)o carr. out a commercial an" technical assessment of the "ocuments rovi"e" b. thecustomer to check that the. are comlete# u-to-"ate an" feasible%

APQP 2 - (raftsmanshi

)o "efine characteristics relating to aearance# te3ture# han"ling abilit.# noise an"

smell%

APQP +lements


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APQP 4 - Design-F56A

)o revent "efects "uring ro"uct "eveloment

APQP 7 - Design eview

)o revent misun"erstan"ings an" roblems8 to monitor the rogress of measures

an" to ensure that objectives are met

APQP 9 - Design :erification Plan D:P

)o rovi"e a clear illustration of the rogress that a subcontractor is making on aroject

APQP ; - Qualit. Planning for Subcontractor

)o rovi"e a clear illustration of the rogress that a subcontractor is making on a

roject

APQP < - Facilities# )ools

)o obtain caablerelease" oerating materials from initial samles onwar"s

APQP +lements


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APQP 1= - >nsection 5etho"s an" 6*uiment)o obtain caablerelease" insection e*uiment# which is suitable for the measuring task

re*uire" of it# from initial samling onwar"s8 lanning !monitoring of "ates& an" rovision

of all necessar. insection e*uiment8 accetance in accor"ance with the criteria of 5SA

!>SO


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APQP 14 - DrawingsSecifications !Design Freee&

)o rovi"e# on sche"ule !customersulier all "rawings an" secifications that

are nee"e" to observe the initial samle "atestart of ro"uction !SOP&%

APQP 17 - (onfirmation of 5anufacturing Feasibilit.

)o assess ro"uction feasibilit. !volume& relative to the inten"e" "esign

APQP 19 - Process Flow Diagram an" Pro"uction La.out

)o rovi"e a foun"ation for investment lanning# S.stem F56A Process Process

F56A# ro"uction lan# control lans an" visual ai"s

APQP 1; - LogisticsSul. (oncet

)o ensure "eliver. caabilit.

APQP 1< - Process Freee

)o ensure that there are no roblems at start of ro"uction

APQP '= - Process F56A

)o revent "efects "uring rocess "eveloment

APQP +lements


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APQP '1- 5easurement S.stems 6valuation an" >nsection 6*uiment (aabilit.

)o evaluate the suitabilit. !scatter& of insection e*uiment for the re*uire"

measurement task

APQP '' - Pre-ro"uction >nsection PlanPre-launch >nsection Plan

)o ensure that rocess an" ro"uct re*uirements are imlemente"

APQP '0 - Process >nstructions

)o ensure *ualit. an" *uantit.

APQP '0 - Packaging 5aterials an" Secifications

)o maintain the *ualit. achieve"

APQP '2 - Pro"uction )rial un

)o ensure that volume ro"uction starts without an. roblems an" that the re*ueste"

values are observe" !cost - rofitabilit.&

APQP '4 - Pro"uction (ontrol Plan

)o ensure that rocess an" ro"uct re*uirements are imlemente"

APQP +lements


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APQP '7 - Preliminar. Process (aabilit. Stu".

)o rovi"e statistical roof of caable rocesses

APQP '9 - )echnical )ests on Pro"uction Parts

)o confirm that the arts meet technical stan"ar"scustomer

re*uirements%

APQP '; - >nitial Samling >nsection

)o rovi"e roof of ro"uct an" rocess release%

APQP +lements


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APQP PROCESS FLOWPrepare for

APQP

Plan and Define Program Product Design

and Development

Product and

Process

"alidation

Process Design and

Development

eedbac!,

Assessment and

-orrective Action

• Organize the Team

• Define the Scope

• Establish Team-to-

Team Communication

• Provide Core Tools

Training

• Involve Customers

and Suppliers

• Implement

Simultaneous

Engineering

• Develop Control

Plan ormat

• Decide on Concern

!esolution

• Develop Product

"ualit# Timing Plan

• $oice of theCustomer

• %usiness

Plan&'ar(eting

Strateg#

• Product&Process

%enchmar( Data

• Product&Process

)ssumptions

• Product !eliabilit#

Studies

• Customer Inputs

• Design *oals

• !eliabilit# and

"ualit# *oals

• Preliminar# %ill of

'aterial

• Preliminar# Process

lo+ Chart

• Preliminar# ,istingof Special Product

and Process

Characteristics

• Product )ssurance

Plan

• 'anagement

Support

• Design ailure odeand +ffects Analysis

#D+A$

• Design for

'anufacturabilit# and

)ssembl#

• Design $erification

• Design !evie+s

• Prototype /uild 0

-ontrol Plan

• Engineering Dra+ings

Including 'ath Data.

• Engineering

Specifications

• 'aterial Specifications

• Dra+ing and

Specification Changes

• /e+ E0uipment1

Tooling and acilities!e0uirements

• Special Product and

Process Characteristics

• *ages&Testing

E0uipment

!e0uirements

• Team easibilit#

Commitment and

'anagement Support

• Pac(aging Standards

• Product&Process

"ualit# S#stem !evie+

• Process lo+ Chart

• loor Plan ,a#out

• Characteristics 'atri2

• Process ailure ode

and +ffects Analysis

#P+A$

• Pre(1aunch -ontrol

Plan

• Process Instructions

• easurement 2ystems

Analysis Plan

• Preliminary Process

-apability 2tudy Plan

• Pac(aging

Specifications• 'anagement Support

• Production Trial!un

• easurement

2ystems +valuation

• Preliminary

Process -apability

2tudy

• Production Part

Approval

• Production

$alidation Testing

• Pac(aging

Evaluation

• Production -ontrol

Plan

• "ualit# Planning

Sign-Off and

'anagement Support

• !educed $ariation

• Customer

Satisfaction

• Deliver# and Service

I / P 3 T

I / P 3 T

I / P 3 T

I / P 3 T

I / P 3 T

O 3 T P 3 T

O 3 T P 3 T

O 3 T P 3 T

O 3 T P 3 T

O 3 T P 3 T

'E)

)P"P

'S)

SPC

PP)P


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What is PPAP?

•Pro"uction Part Aroval Process

•Stan"ar" use" to formall. re"uce risksrior to ro"uct or service release#in a team oriente" manner using well

establishe" tools an" techni*ues

•>nitiall. "eveloe" b. A>AB !Auto >n"ustr.Action Brou& in 1


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The Purpose of PPAP

A) If all customer engineering design records and specificationrequirements are properly understood by the supplier(Customer and Supplier have a common understanding ofCustomer requirements)

B)The process has potential to produce parts consistently

meeting the requirements during an actual production run atthe quoted production rate (Is the process capable ofmeeting customer requirements during on going productionprocess)


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Applicability of PPAP• PPAP shall apply to Eternal and internal

suppliers sites of!"ul# $aterial

Production $aterial

Production Parts

Service Parts

%or "ul# material PPAP is not required unlessas#ed by the customer&

•A supplier of production parts ' service partsshall comply ith the PPAP requirements unlessthe same is formally aived by the Customer(documented evidences should be available)


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SomethingChanged

Application

A*A+ (Autootive*ndustry Action +roup)PPAP anual defnes&hen PPAP subission

is required – ,e& part

– orrection to discrepancyin previous subission

– #esign or process change

– hange in source o"subcontracted aterialsor services

– trans"er or


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Benefts o" PPAPsubission

• -elps to aintain design integrity• *dentifes issues early "or resolution

• $educes &arranty charges andprevents cost o" poor quality

• Assists &ith anaging supplierchanges

• Prevents use o" unapproved and

noncon"oring parts• *dentifes suppliers that need ore

developent

• *proves the overall quality o" theroduct custoer satis"action


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PPAP Process )equirements S*"$ISSI+, T+ C*ST+$E - .E/E.S +% E/I0E,CE

Submission .evels

The supplier shall submit the items and'or records specified bythe level as requested by the customer&

.evel 1 - 2arrant only (and for designated appearance items3 anAppearance Approval eport) submitted to the customer&

.evel 4 5 2arrant ith product samples and limited supportingdata submitted to the customer&

.evel 6 - 2arrant ith product samples and complete supporting

data submitted to the customer&

.evel 7 - 2arrant and other requirements as defined by thecustomer&

.evel 8 5 2arrant ith product samples and complete supportingdata available for revie at the supplier9s manufacturing location&

PPAP 1 l f 2 b i i d * t ti


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PPAP 1evels for 2ubmission and *etention


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#efnition o" $is. • -igh $is.

Parts associated &ith ultiple critical "eatures/ cople0design/ or high end technology that is not yetestablished in the general anu"acturing environent

Supplier1s quality syste and2or quality per"orance isnot to ustoer1s satis"action

• 'ediu $is.

Parts that have at least one critical "eature

• 3o& $is.

Parts that have no critical "eatures and can beanu"actured by any anu"acturer in the cooditycategory

Supplier1s quality syste and quality per"orance areacceptable• ,e& Parts,e& Parts

3evel 4 is required "or 3o& $is. Parts

3evel 5 is required "or 'ediu and -igh $is. Parts

• Part hangesPart hanges

3evel 5 is required "or Parts produced at a ne& or additional location

Supplier Quality !0cellence &ill defne the level required "or all other changes


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PPAP Status66667• Approved8he part eets all ustoer

requireents

Supplier is authori9ed to ship

production quantities o" the part• *nteri ApprovalPerits shipent o" part on a

liited tie or piece quantity basis• $e:ected8he part does not eet custoer

requireents/ based on theroduction lot "ro &hich it &as


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Official PPAP e*uirements

1% Design ecor"s'% Authorie" 6ngineering (hange Documents

0% (ustomer 6ngineering Aroval# if re*uire"

2% Design Failure 5o"es an" 6ffects Anal.sis !DF56A& applied in

special situations

4% Process Flow Diagram

7% Process Failure 5o"es an" 6ffects Anal.sis !PF56A&

9% (ontrol Plan;% 5easurement S.stems Anal.sis !5SA&


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;7 #esign $ecords

Design ecor"s an" @ubble" Part Prints Purose?

)o "ocument rovi"e a co. of the formal art rint%

All art rints must have clearl. "efine" ()QCs

)o rovi"e an. a""itional engineering recor"s for reference%

All submissions shoul" have one co. of the formal rint

@ubble rint that suorts the "imensional reort%

5ust have all notes an" secifications circle" an"

numbere"%

5ust be clear an" legible%

An. a""itional suorting information inclu"ing

eference rints

Sub-assembl. rints

(omonent rints with a "ifferent art number

Alicable secifications


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#esign $ecord < hec.3ist

5ust be a clean an" legible +@ubble, rint

5ust have correct Part $umber an" evision $o%

6ver. re*uirement must have a searate bubble

Dimensions$otes

()QCs are i"entifie"

eference" secifications

:erif. that no other rints nee" to be submitte"Sub-assemblies

(omonent level "etail


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47 !ngineering hange#ocuents

• 8he supplier shall provideauthori9ed change docuents"or those changes not yet

recorded in the design record/but incorporated in the product/part or tooling/ such as=

!,s (must be approved, not pending)

Specifcations %easibility studies < Advantages

Supplier change requests

Sub>assebly dra&ings

3i"e or reliability testing requireents

ustoer ng neer ng


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7 ustoer ng neer ngApprovals

Purose?

)o "emonstrate re-aroval b. (ustomer

to ro"uce a ro"uct

e*uire" onl. when customer "eman"s


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%'!A%ailure 'ode and !ects

AnalysisEhat we learnGEhat is itG

5otivation

F56A 5etho"s

63amle

F56A in-class e3ercise

at s


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at s%ailure 'ode !ect

Analysis#escription=• A procedure that e0aines each ite

in a syste/ considers ho& that itecan "ail and then deterines ho& that"ailure &ill aect the syste

A structured approach to3)dentifying the ays in hich a product or process can fail

+stimating ris! associated ith specific causes

Prioriti&ing the actions that should be ta!en to reduce ris!

+valuating design validation plan #product$ or current control plan #process$


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-istory o" %'!A

• %irst used in the ;@1s in theAerospace industry during the Apolloissions

• *n ;@CD/ the ,avy developed MIL-STD-

1629 regarding the use o" %'!A• *n the late ;@C1s/ the autootive

industry &as driven by liability coststo use %'!A

• 3ater/ the autootive industry sa&the advantages o" using this tool toreduce ris.s related to poor quality


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D7 #!S*+, %'!A(#%'!A)

• )he Design F56A is use" to anal.e ro"uctsbefore the. are release" to ro"uction%

• >t focuses on otential failure mo"es of ro"ucts

cause" b. "esign "eficiencies%

• Design F56As are normall. "one at three levels H s.stem# subs.stem# an" comonent levels

• )his t.e of F56A is use" to anal.e har"ware#functions or a combination


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7 P$E!SS %'!A (P%'!A)

• 8he Process %'!A is norally used toanaly9e anu"acturing and asseblyprocesses at the syste/ subsyste

or coponent levels7

• 8his type o" %'!A "ocuses onpotential "ailure odes o" the process

that are caused by anu"acturing orassebly process defciencies7

'ethod to onduct an


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'ethod to onduct an%'!A

– *denti"y all coponents or systes atgiven level o" the design hierarchy7

– 3ist the "unction o" each identifed

coponent or syste7 – *denti"y "ailure odes "or each

coponent2syste7 8ypically there&ill be several &ays in &hich a

coponent can "ail7 – #eterine the eect (both locally

and globally) on the syste7


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'ethod to onduct an%'!A

– lassi"y the "ailure by its eects onthe syste operation7

– #eterine the "ailure1s probability

o" occurrence7 – *denti"y ho& the "ailure ode can

be detected (ay point out &hatneeds to be inspected on a regularbasis)7

– *denti"y any copensatingprovisions or design changes to

itigate the "ailure eects7


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FMEA Form

Blank FMEA form

%'!A 8erinology


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%'!A 8erinology 'ethods

• Process Function e*uirements

– Simle Descrition of the rocess or oerations being anal.e"!eg% )urning# assembling# etc%#&

– Function comes from Functional Anal.sis# Functional

Decomosition

• Potential Failure 5o"e

– 5anner in which the "esign rocess coul" otentiall. fail to meetthe rocess or re*uirements

– Potential Failure 5o"e comes from things that have gone wrong in

the ast# concerns of "esigners# an" brainstorming% Possible

consi"erations are artial function# intermittent function# e3cess

function%

• Potential 6ffects of Failure

– )he effect of the failure mo"e on customer

– Potential 6ffects are conse*uences to the "esign# the user# an" the

environment% Safet. an" regulation noncomliance are critical

issues%

%'!A 8erinology


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%'!A 8erinology 'ethods

• Severit.

– Assessment of the seriousness of the effect of the otential failure

mo"e to the customer% Bive ranking between 1 1= as er the

gui"elines

• (lassification

– )o (lassif. an. secial characteristics such as critical# ke.# major#

significant# etc%#

• Potential (auses 5echanism of Failure

– Iow failure coul" occur H "escribe" in terms of how the failure

can be correcte" or can be controlle"%

– Potential (auses of failure shoul" be engineering relate" such as

incorrect material# corrosion# wear an" human relate" such asine3erience# misuse# etc%

• Occurrence

– Iow fre*uentl. the secific failure cause mechanism is rojecte"

to occur% Bive ranking between 1 1= as er the gui"elines

%'!A 8erinology


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%'!A 8erinology 'ethods• (urrent Process (ontrol

– (urrent rocess "esign control metho"s a"ote"

– (urrent Design (ontrols are things like insections# testing# oke

.oke# an" other "esign checks that are inten"e" to revent the

roblem%

• Detection

– Iow the e3isting control s.stem "etects the failure mo"e% Bive

ranking between 1 1= as er the gui"elines• *is! Priority 4umber #*P4$

– Assign values to 2everity, %ccurrence, and Detection using the tables.

– Determine the *is! Priority 4umber #2everity5 %ccurrence 5 Detection$

• Develop an action plan

• *ecommended Actions

– -orrective actions to be first arrived for highest ran!ed *P4• *esulting *P4

• ollo up

G id li f S it


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Guidelines for SeverityRanking

!ect $an. riteria

None 1 No eect

Very Sligt ! Negligi"le eect on #erformance$ Some usersmay notice$

Sligt % Sligt eect on &erformance$ Non vital faults 'ill"e noticed "y many users

Minor ( Minor eect on &erformance$ )ser is sligtlydissatis*ed$

Moderate + Reduced &erformance 'it gradual &erformancedegradation$ )ser dissatis*ed$

Severe , -egraded &erformance. "ut safe and usa"le$ )serdissatis*ed$

/ig Severity 0 Very &oor &erformance$ Very dissatis*ed user$

Very /igSeverity

2no&era"le "ut safe$

E3treme Severity 4 #ro"a"le failure 'it a5ardous eects$6om&liance 'it regulation is unlikely$

Ma3imumSeverit

17 )n&redicta"le failure 'it a5ardous eectsalmost certain$ Non8com liant 'it re ulations$

G id li f 9


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Guidelines for 9ccurrenceRanking

Eccurrence $an. riteria

E3tremely)nlikely

1 :ess tan 7$71 &er tousand

Remote :ikeliood ! ≈7$1 &er tousand rate of occurrence

Very :o'

:ikeliood

% ≈7$+ &er tousand rate of occurrence

:o' :ikeliood ( ≈1 &er tousand rate of occurrence

Moderately :o':ikeliood

+ ≈! &er tousand rate of occurrence

Medium:ikeliood

, ≈+ &er tousand rate of occurrence

Moderately /ig:ikeliood

0 ≈17 &er tousand rate of occurrence

Very /igSeverity

≈!7 &er tousand rate of occurrence

E3treme Severity 4 ≈+7 &er tousand rate of occurrence

Ma3imum 17 ≈177 &er tousand rate of occurrence

G id li f - t ti


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Guidelines for -etectionRanking

#etection $an

.

riteria

E3tremely :ikely 1 6an "e corrected &rior to &rototy&e; 6ontrols 'illalmost certainly detect

Very /ig:ikeliood

! 6an "e corrected &rior to design release;Very /ig&ro"a"ility of detection

/ig :ikeliood % :ikely to "e corrected;/ig &ro"a"ility of detectionModerately /ig:ikeliood

( -esign controls are moderately eective

Medium :ikeliood + -esign controls ave an even cance of 'orking

Moderately :o':ikeliood

, -esign controls may miss te &ro"lem

:o' :ikeliood 0 -esign controls are likely to miss te &ro"lem

Very :o':ikeliood

-esign controls ave a &oor cance of detection

Remote :ikeliood 4 )n&roven. unrelia"le design;&oor cance for detection

E3tremely )nlikely 17 No design tecni


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%ailure 'odes and!ects

• 8he relationship bet&een "ailure odesand eectsis not al&ays ; to ;7

Failure Mode 1

Failure Mode 2

Effect 1

Effect 2

Failure Mode 1

Failure Mode 2

Effect 1

Failure Mode 1

Effect 1

Effect 2

Process %'!A < hec.


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Process %'!A < hec.3ist

Feri"y there is a syste "orprioriti9ing ris. o" "ailure such as$P, nubers o" ;4G or above

'a.e sure that high $P,process concerns are carriedover into the control plan

'a.e sure that all critical "ailure

odes are addressed


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%'!A !H!$*S!

G P %l


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G7 Process %lo&#iagras

Ehat is >tG• A visual "iagram of the entire rocess from receiving

through shiing# inclu"ing outsi"e rocesses an"

services

)o hel eole +see, the real rocess% Process mas

can be use" to un"erstan" the following characteristics

of a rocess?• Set-b.-ste rocess linkage• Offline activities !measurement# insection#

han"ling&

• ework# scra

Objective or Purose

Wh t U %l h t


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When to Use a %lo&chart

• =o develo& understanding of o' a &rocess isdone$

• =o study a &rocess for im&rovement$

• =o communicate to oters o' a &rocess is done$

• >en "etter communication is needed "et'een&eo&le involved 'it te same &rocess$

• =o document a &rocess$

• >en &lanning a &ro?ect$


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Process %lo& #iagras

Ehen to Jse >t G• )o un"erstan" how a rocess is "one• Prior to comleting the PF56A

• J"ate" after ro"uction trial run%

• $ee" to in"icate secial characteristics generate" at

each ste%• (omlete" Along with (ontrol Plan !APQP Process&%

Process %lo #iagra


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Process %lo& #iagra!0aple

Process %lo& #iagras


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Process %lo& #iagras <hec. 3ist

Process Flow must identify each step in the process

Should include abnormal handling processes

Scrap

Rework

Process Flow must include all phases of the process

Receiving of raw material

Part manufacturing

Offline inspections and checks Assembly

Shipping


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6hat e learn7

6hat is it7

6hen to use7

6hy *equired7

%ver vie

+ample of -ontrol Plan

-ontrol Plan Process

-lass +ercise

8. -%4T*%1 P1A4


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ontrol plan types


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Ehat >s A (ontrol PlanG

>t is a management tool to i"entif. an" monitor the activit. re*uire"

to control the critical inuts or ke. oututs for a rocess so the

rocess will continuall. meet its ro"uct or service goals%

(ontrol lans are usuall. monitore" at least b. Qualit. Assurance#

"eartments using insection roce"ures an" sometimes using*ualit. function "elo.ment metho"s%

(ontrol charts are t.icall. use" in a control lan to monitor items%

Ehen >s >t Jse"G>t is use" in the control hase to i"entif. an" recor" controls#

targets# an" secification limits for Ke. Process >nut :ariables an"

Ke. Process Outut :ariables%

-%4T*%1 P1A4


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Iea"er information

6nter the Iea"er information as re*uire"

PartProcess $umber)his item number is usuall. reference" from the Process Flow (hart% >f

multile art numbers e3ist !assembl. list the in"ivi"ual art numbers

an" their rocesses accor"ingl.%

Process $ame Oeration Descrition

All stes in the manufacturing of a comonent are "escribe" in a rocess

flow "iagram% >"entif. the rocessoeration name from the flow "iagramthat best "escribes the activit. being a""resse"%

5achine# Device# ig# )ools for 5anufacturing

For each oeration that is "escribe"# name the rocessing e*uiment as

aroriate%

$umber

6nter a cross reference number from all alicable "ocuments such as#

but not limite" to# rocess flow "iagram# numbere" blue rint# F56As#

an" sketches !comuter generate" or otherwise if re*uire"%



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Pro"uct

Pro"uct (haracteristics are the features or roerties of a art#

comonent or assembl. that are "escribe" on "rawings or other rimar.engineering information%

)he (ore )eam shoul" i"entif. the Secial Pro"uct (haracteristics that

are a comilation of imortant Pro"uct (haracteristics from all sources%

All Secial (haracteristics must be liste" on the (ontrol Plan% >n a""ition#

the manufacturer ma. list other Pro"uct (haracteristics for which

rocess controls are routinel. tracke" "uring normal oerations%

Process

Process (haracteristics are the rocess variable !inut variables& that

have a cause an" effect relationshi with the i"entifie" Pro"uct

(haracteristic%

A Process (haracteristic can onl. be measure" at the time it occurs%

)he (ore )eam shoul" i"entif. Process (haracteristics for which

variation must be controlle" to minimie ro"uct variation%

)here coul" be one or more Process (haracteristics liste" for each

Pro"uct (haracteristic% >n some rocesses one Process (haracteristic

ma. affect several Pro"uct (haracteristics%



60/102

Secial (haracteristic (lassification

Jse the aroriate classification to "esignate the t.e of secial

characteristic or this fiel" can be left blank for other un"esignate"characteristics% Please refer to the Danaher 5otion Qualit. 5anual to see

the "escritive terms an" s.mbols%

Pro"uct Process Secification )olerance

Secificationtolerance ma. be obtaine" from the engineering

"ocuments%

6valuation 5easurement )echni*ue

)his columns i"entifies the measurement s.stem being use"% )his coul"

inclu"e gages# fi3tures# tools# an"or test e*uiment re*uire" to measure

the artrocessmanufacturing e*uiment% An anal.sis of the

rero"ucibilit.# reeatabilit. an" accurac. of the measurement s.stem

shoul" be "one rior to rel.ing on a measurement s.stem an"

imrovements ma"e accor"ingl.

Samle SieFre*uenc.

Ehen samling is re*uire" list the correson"ing samle sie an"

fre*uenc.%




61/102

(ontrol 5etho"

)his column contains a brief "escrition of how the oeration will be

controlle"# inclu"ing roce"ure numbers where alicable%

)he control metho" utilie" shoul" be base" on effective anal.sis of the

rocess%

)he control metho" is "etermine" b. the t.e of rocess that e3ists%

Oerations ma. be controlle" b.# but are not limite" to# StatisticalProcess (ontrol# insection# attribute "ata# mistake-roofing#

!automate"non-automate" an" samling lans%

)he (ontrol Plan "escritions shoul" reflect the lanning an" strateg.

being imlemente" in the manufacturing rocess%

>f elaborate control roce"ures are use"# the lan will t.icall. reference

the roce"ure "ocument b. a secific i"entification name an"or number%

)he metho" of control shoul" be continuall. evaluate" for effectiveness

of rocess control% For e3amle# significant changes in the rocess or

rocess caabilit. shoul" lea" to an evaluation of the control metho"%



62/102

eaction Plan

)he reaction lan secifies the corrective actions necessar. to avoi"ro"ucing nonconforming ro"ucts or oerating out of control%

)he actions shoul" normall. be the resonsibilit. of the eole closest to

the rocess# the oerator# job setter# or suervisor# an" be clearl.

"esignate" in the lan%

Provisions shoul" be ma"e for "ocumenting%

>n all cases# susect an" nonconforming ro"ucts must be clearl.

i"entifie" an" *uarantine"# an" "isosition ma"e b. the resonsible

erson "esignate" in the reaction lan%

)his column ma. also refer to a secific reaction lan number an"

i"entif. the erson resonsible for the reaction lan%


-


63/102

Au"it Plans

• Au"it lans shoul" be inclu"e" in the control lan as a searate line%• Au"iting is an imortant tool for control%

• Process au"iting shoul" be a ke. element of the *ualit. s.stem of a

business%

• Au"its generall. cover?

6ffectiveness of controls(ontrol lan !sa.& vs% what is actuall. "one

!"o&• Au"its shoul" be objective !"one b. internal or e3ternal thir" arties if

ossible&%

• Au"it fre*uencies shoul" be base" on balancing level of risk !F56A&

an" cost%


- l Pl -h ! 1i


64/102

Jse rocess flow "iagram an" PF56A to buil" the control lan8 kee

them aligne"

(ontrols must be use" to be effective% Kee it simle%

6nsure that the control lan is in the "ocument control s.stem of thebusiness

Boo" control lans a""ress?

All testing re*uirements - "imensional# material# an" erformanceAll ro"uct an" rocess characteristics at ever. ste throughout

the rocess

)he control metho" shoul" be base" on an effective anal.sis of therocess

Such as SP(# 6rror Proofing# >nsection# Samling Plan (ontrol lans shoul" reference other "ocumentation

Secifications# tooling# etc%

-ontrol Plan -hec! 1ist

- l Pl -l + i


65/102

Prepare a control plan for the a drilling process on a rectangular bloc!

-ritical parameters

/ig 9ole diameter 0 :;.>;

2mall 9ole diameter 0 :>.>;

Distance beteen the holes 0 8> .:

-ontrol Plan -lass +ercise

J 'easureent Syste


66/102

J7 'easureent SysteAnalysis ('SA)

An 5SA is a statistical tool use" to "etermine if a

measurement s.stem is caable of recise measurement%

Ehat is >tG

Objective or Purose

• )o "etermine how much error is in the measurement "ue to

the measurement rocess itself%• Quantifies the variabilit. a""e" b. the measurement

s.stem%• Alicable to attribute "ata an" variable "ata%

Ehen to Jse >t

• On the critical inuts an" oututs rior to collecting "ata

for anal.sis%• For an. new or mo"ifie" rocess in or"er to ensure the

*ualit. of the "ata%

'easureent Syste


67/102

'easureent SysteAnalysis ('SA)

Measurement System Analysis isan analysis of the measurementprocess, not an analysis of thepeople!!

PORTANT! Who Shoul e "n#ol#e

E#eryone $ho measures an ma%esecisions aout these measurementsshoul e in#ol#e in the MSA&

– AttriuteAttriute 'ata E(amples)

Count, Pass*fail, yes*no, re*+reen*yello$,

time%eepin+ uc%ets

– arialeariale 'ata E(amples)

Physical measurement -len+th, $ith, area, ./

Physical conitions -temperature, pressure./

Physical properties -stren+th, loa, strain./

Continuous or non0enin+

Measurement System


68/102

easu e e Sys eAnalysis @MSA

Error in Repeataility1he inaility to +et the same ans$erfrom repeate measurements mae ofthe same item uner asolutely ienticalconitions&

Possile Cause Lac% of stanar operatin+ proceures-SOP/, lac% of trainin+, measurin+system #arialilty&

Repeatability

E2uipment ariationE2uipment ariation

easureen ys e


69/102

yAnalysis ('SA)

Error in Reprouciility1he inaility to +et the same ans$erfrom repeate measurements maeuner #arious conitions from ifferentinspectors&

Possile Cause Lac% of SOP, lac% of trainin+&

Reproducibility

Appraiser ariationAppraiser ariation

Varia"le MSA B Gauge RCR


70/102

Varia"le MSA Gauge RCRStudy

• +auge $$ is the cobinedestiate o" easureentsyste $epeatability$epeatability and

$eproducibility$eproducibility• 8ypically/ a 5>person study isper"ored !ach person randoly easures ; ar.ed parts per

trial !ach person can per"or up to 5 trials

• 8here are 5 .ey indicators !F!F or !quipent Fariation

AFAF or Appraiser Fariation

ar a e B auge


71/102

;7 Select ; ites that represent the "ull range o" long>terprocess variation7

47 *denti"y the appraisers7

57 *" appropriate/ calibrate the gage or veri"y that the lastcalibration date is valid7

D7 Epen the +auge $$ &or.sheet to record data7

G7 -ave each appraiser assess each part 5 ties (trials < frstin order/ second in reverse order/ third rando)7

7 *nput data into the +auge $$ &or.sheet7C7 !nter the nuber o" operators/ trials/ saples and

specifcation liits

J7 Analy9e data in the +auge $$ &or.sheet7

@7 Assess 'SA trust level7

;7 8a.e actions "or iproveent i" necessary7

gSte&s

Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step : Step 3;Step <

Tips and Lessons Learned'easureent Syste


72/102

>mortant? An 5SA is an anal.sis of the rocess# not an anal.sis of the

eole% >f an 5SA fails# the rocess faile"%

A :ariable 5SA rovi"es more anal.sis caabilit. than an Attribute 5SA%

For this an" other reasons# alwa.s use variable "ata if ossible%

)he involvement of eole is the ke. to success%

>nvolve the eole that actuall. work the rocess

>nvolve the suervision

>nvolve the suliers an" customers of the rocess

An 5SA rimaril. a""resses recision with limite" accurac. information%

p 'easureent SysteAnalysis ('SA)


73/102

'SA < hec. 3ist*" the gauge2inspection aects

quality/ then conduct a +auge $$

'a.e sure the study is recent >less than ; year

opare the control plan againstthe +auge $$s

*" you question that gauge/ then

−Question the technique and partsapling

−As. "or additional studies

@ #iension 8est


74/102

@7 #iension 8est$esults

6vi"ence that "imensional verifications have been comlete"

an" results in"icate comliance with secifie" re*uirements%

Ehat is >tG

Objective or Purose

• )o show conformance to the customer art on "imensions

an" all other note" re*uirements%

Ehen to Jse >t

• For each uni*ue manufacturing rocess !e%g%# cells or

ro"uction lines an" all mol"s# atters# or "ies


75/102

#iension 8est $esults

)hirt.-five critical "ata oints 4 non-critical "ata oints arere*uire" for art *ualification

(ritical an" non-critical "ata oints must be taken from thesame 04-iece samle

Five arts from a ro"uction run must be shie" to customer

for verification of form# fit# an" function )he same 4 arts will be use" to verif. both critical an" non-

critical "imensions

Sulier must clearl. i"entif. which of the 04 arts are beingshie"

Sulier shoul" make ever. effort to shi 4 arts that reresentboth the low an" high en"s of the secifications for non-critical

"imensions

(aabilit. must be greater than 1%79 for critical "imensions an"greater than 1%00 for non-critical "imensions

7 ecor s o'aterial2Per"orance 8est


76/102

'aterial2Per"orance 8est$esults

'aterial 8est $esults'aterial 8est $esults 8he supplier shall per"or tests "or all parts and product

aterials &hen cemica!, p"sica!, or meta!!urgica! requireents are specifed by the design record orontrol Plan

%or products &ith ,$>developed aterial specifcations and2oran ,$>approved supplier list/ the supplier shall procureaterials and2or services "ro suppliers on that list

Per"orance 8est $esultsPer"orance 8est $esults 8he supplier shall per"or tests "or all parts or productaterials &hen per#ormance or #unctiona! requireentsare specifed by the design record or ontrol Plan


77/102

'aterial 8est $esults

Material Results shall inclue) The name of the laboratory that conducted the test The type of test that was conducted The number, date, and specification to which the part was tested The actual test results

" l


78/102

Per"orance 8est $esults

Performance 1est Results shall inclue) The name of the laboratory that conducted the test The type of test that was conducted A description of the test The parameters tested The actual test results

i i l S d


79/102

;;7 *nitial Process Study

Ehen to Jse >t G

1% )o establish baseline caabilit.%

'% )o vali"ate rocess imrovements%

Ehat is >tGA set of tools use" to un"erstan" rocess caabilit.%

• )o evaluate the erformance of .our rocess as comare" to

secification limits%

• )o "etermine if the ro"uction rocess is likel. to ro"uce ro"uct

that will meet customer re*uirements

eps or e er n ngP bilit


80/102

p gProcess apability

Step 3 Step < Step 4 Step 5 Step 6 Step 7 Step 8

1$ -ecide on te &roduct or &rocesscaracteristic to "e assessed

!$ Validate te s&eci*cation limits

%$ Validate te measurement system

($ 6ollect data

+$ Assess data caracteristics

,$ Assess &rocess sta"ility

0$ 6alculate &rocess ca&a"ility

%ocus on Fariable #ata


81/102

%ocus on Fariable #ata• 8he initial process study should be "ocused

on variab!evariab!e/ not attribute data

Assebly errors/ test "ailures/ andsur"ace de"ects are e0aples o" attributedata/ &hich is iportant to understand/but is not covered in this initial study

Unless approved by an authori9edustoer representative/ attribute dataattribute data

are not acceptab!e #or $$%$ submissionare not acceptab!e #or $$%$ submission

apability *ndices


82/102

p y

Capability

IndexFormula hat it shows

p

Relates short term -$ithin su+roup/ stanar

e#iation to tolerance

Sometimes calle =Entitlement,> meanin+ it is the

est the current process can o, if centere

pk

Relates short term mean ? short term -$ithin

su+roup/ stanar e#iation to tolerance

Only tells you aout the nearest spec limit@ oesnt

tell anythin+ aout the other sie

PP Relates lon+ term -o#erall/ stanar e#iation totolerance

Ppk Relates mean ? lon+ term -o#erall/ stanar

e#iation to tolerance

Only tells you aout the nearest spec limit@ oesnt

tell anythin+ aout the other sie

3S, 4 ,S,.

56sshort-term

3S, 4 ,S,.

56slong-term

'in73S, 4 8.1 8 4 ,S,.9

:6sshort-term

:6slong-term

'in73S, 4 8.1 8 4 ,S,.9

(aabilit. >n"ices - (k


83/102

.

• (( predicts capability predicts capability @ase" on short term within subgrou variation

Does not measure how well the rocess "istribution off the

centre of limits%

• (k >n"e3 of of ((k >n"e3 of of (

meameasures the variation of p valuesures the variation of p value

between ! and " and consider thebetween ! and " and consider the

variation closest to Specification limit#variation closest to Specification limit#

apability *ndices > Pp.


84/102

p y p

Pk in"icatesPk in"icates past performance past performance

@ase" on long term total variation

Jnlike (k# Pk is not limite" to variation within subgrous

Ehen calculate" from the same "ata set# (k an" Pk canbe comare" to anal.e the sources of rocess variation

Pk shoul" be use" whenPk shoul" be use" when? – )he art are newl. "esigne"%

– )he sulier is new to (ustomer# but has alrea". beenmanufacturing a art

– )he sulier is e3isting# but has ro"uce" a number of

nonconforming arts

(omments On (# (k•(1 means the rocess variation e3cee"s


85/102

secification# an" a significant number of "efects are

being ma"e%

•(M1 means that the rocess is just meetingsecifications% A minimum of %0N "efects will be ma"e

an" more if the rocess is not centere"%•(1 means that the rocess variation is less than

the secification# however# "efects might be ma"e if

the rocess is not centere" on the target value•( M (k when rocess is centere"•(k ( alwa.s this situation•(k 1%== rocess ro"ucing rejects•(k M = ⇒ rocess center is at one of sec% limit !Jor L&•(k =⇒ i%e% H ve value# average outsi"e of limits•(k 1to 0 ⇒ i%e rocess cabable but normal!Samling insection re*uire"&

>nitial Process Stu". H (heck List


86/102

>nitial Process Stu". (heck List

6nsure that the results are accetable# an"that the rocess is stable an" caable of

ro"ucing a *ualit. art

PPAPs shoul" onl. be arove" if thecaabilit. is greater than 1%79 for critical

"imensions an" greater than 1%00 for non-

critical "imensions

;47 Qualifed 3aboratory# t ti


87/102

#ocuentation• *nspection and testing "or PPAP shall

be per"ored by a qualifedlaboratory as defned by ustoerrequireents (e7g7/ an accreditedlaboratory)7

• 8he qualifed laboratory (internal ore0ternal to the supplier) shall have alaboratory scope and docuentation

sho&ing that the laboratory isqualifed "or the type o"easureents or tests conducted

When an e0ternal laboratory is used/ the supplier shallsubit the test results on the laboratory letterhead or the

noral laboratory report "orat

Qualified 1aboratory Documentation 0 -hec! 1ist


88/102

)hir" art. labs that measure arts for erformance#

material or "imensional shoul" be accre"ite"%

>f an. testing is erforme" to measure or monitor

art *ualit. the. shoul" have?

Lab Scoe H internal labs

6vi"ence of (alibration- in rocess

Accre"itation? 5inimum thir" art. accre"itation

b.?

6ither >SO 19='4 or A'LA !A'LA-AmericanAssociation for Laborator. Accre"itation&

Lab Scoe? 5ake sure internal labs have a

+S.stem, "efining what can be measure"# metho"#

trainin etc%

Q y

A&&earance A&&roval


89/102

Re&ort

Ehen to Jse >t• Prior to tooling for production

Ehat is >tG

• A report completed by the supplier containingappearance and color criteria

Typically only applies for parts ith color, grain, or surface appearance requirements

Objective or Purose

• $o demonstrate that the part has met the appearanc

re%uirements on the design record

;D7 Saple Production


90/102

Actual samples that reflect the parts ocumente inthe PPAP&

What is "tB

Oecti#e or Purpose!Confirm cosmetic or functional part appro#al&

When to Dse "t

!Sample parts shoul e eli#ere W"1 the PPAPsumission

Parts

• The sample parts provided should be the same parts measured for the dimensional results

• Default quantity for all submissions is ? parts unless otherise requested

Saple Production Parts


91/102

• Saple production parts 'US8be properly identifed – *nclude the "ollo&ing in"oration on the

part label=

• #ate parts &ere pac.ed• ustoer part nuber

• Quantity

• Serial nuber

• Supplier part nuber (optional)

• Part description

• ountry o" origin

• Approval ar.ings (!/ etc7) &here

:;. aster 2ample


92/102

Purose? )he original intent was that a +5aster, art must be

maintaine" throughout a ro"ucts ro"uction life for all revision

levels% (oncet is goo" but "ifficult to maintain an" store arts%

)he automotive in"ustr. rela3e" this re*uirement in various

wa.s%

(ustomer "oes not re*uire 5aster Part maintenance e3cet

when?

A Level 4 PPAP is re*ueste"%

).icall. a high risk art

)he criticall. of the ro"uct warrante" on site review

)herefore 5aster Part maintenance is a useful tool

(ustomer re*uires 5aster Part maintenance as follows?

1 5aster art for ever. art number at the most recent

revision level%

5ust be maintaine" for the life of the ro"uct%

:;. aster 2ample

2ample Production Parts and


93/102

2ample Parts should be received ith every PPAP submission and

eamined thoroughly,

*evieer needs to determine if any value added analysis can be

gained using the 2ample Parts3

@et additional dimensional data

eedbac! and questions from engineering

Perform additional testing

unctional analysis

it Analysis

2ample Parts must be properly tagged, if not reject

)f aster samples are requested ma!e sure the supplier has a

system for maintaining the parts

p

aster 2amples 0 -hec! 1ist

:. -hec!ing Aids


94/102

Purose? )o rovi"e evi"ence that the checking ai"s use" to

verif. ro"uct e3ist an" have been roerl. vali"ate"%

)here are man. "ifferent t.es of checking ai"s%

(ertifie" (heck Fi3tures

Jn-certifie" check fi3tures

)emlates

(ustom Bauges >n-house "eveloe" test stan"s !e3? leak test&

(ustomer ma. re*uire the following for all checking ai"s%

(o. of a controlle" rint that "ocuments the "esign of the

checking ai" >f the ai" confirms form or fit# then there shoul" be a thir"

art. certification

6vi"ence that the checking ai" has been verifie"

successful%

63amle? Bage

-hec!ing Aids 0 -hec! 1ist


95/102

eviewerCs (hecklist

>f a fi3ture is use" to check h.sical rint "imensions eitherin rocess or off line then it is a checking ai"%

(hecking ai"s must be "ocumente" through a rint an"

submitte" with PPAP%

(heck Fi3tures

)emlates

Assembl. fi3tures that confirm fit

(hecking ai"s must have evi"ence of?

(onformance to the rovi"e" rint

eeatabilit.B for ()Q features

6ncourage suliers that utilie critical checking ai"s to get

thir" art. certification

-hec!ing Aids -hec! 1ist

:8. -ustomer 2pecific *equirements


96/102

Purose? Provi"e a lacehol"er for all customer secific

re*uirements that are not covere" in the first 17 elements of PPAP%

Jse" "ifferentl. b. ever. customer for all t.es of re*uirements

)here are 4 secific re*uirements "efine" for PPAP submissions%

)ooling >nformation Form Packaging Form

>nsection Plan

Secification Deviation Form

Sulier PPAP (hecklist

6ach customer ma. re*uest a""itional "ocuments on a case b.

case basis%

:8. -ustomer 2pecific *equirements

;J7 Parts Subission


97/102

Warrant• Upon satis"actory copletion o" all

required easureents and tests/ enterall required in"oration on the &arrant7

• A separate PSW is required "or eachpart nuber7

• $esponsible supplier oLcial verifes – 'easureents and tests con"or to custoer

requireents

– $equired docuentation is available "or propersubission level7

– Signs &arrant and provided date/ title andtelephone nuber7

Part Subission Warrant


98/102

Part Subission WarrantEhat is >tG• Document re*uire" for all newl. toole" or revise"

ro"ucts in which the sulier confirms that

insections an" tests on ro"uction arts show

conformance to (ustomer re*uirements

Jse" to ?• "ocument art aroval• rovi"e ke. information• "eclare that the arts meet secification

Objective or Purose

Ehen to Jse >t• Prior to shiing ro"uction arts

Part Subission Warrant


99/102

hec. 3ist

5ust be comletel. fille" out

5ust be signe" b. the sulier

5ust match the PO

Submitte" at the correct revision level

Submitte" at the correct submission level

Points to $eeber


100/102

Points to $eeber 677

• Sulier is resonsible for meeting all alicable secifications%

• Do not submit arts an" "ocumentation results if the. are

outsi"e secification%

• )ake corrective action to meet all "esign recor" re*uirements%

• (ontact customer if unable to meet all re*uirements

• (oml. with customer "eveloe" material secifications an"or

arove" source list%

• Suliers are re*uire" to comlete an" maintain coies of all

"ocumentation i"entifie" in +re*uirements for aroval,regar"less of submission level%

• ecor"s of PPAP are to be retaine" for the life of the art lus

one calen"ar .ear%


101/102


102/102

*eferences

PPAP BT9 +dition Quality Planning and Analysis by C..Curan ran!..@ryna

.citehr.com

Production %perations anagement 0 Dr./.2.@oel

6i!ipedia
http://www.citehr.com/http://www.citehr.com/

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