Production Part Approval Process CONTENTS APPENDICES …...CTQ Features: Reference HSC16199 for...

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No.: HT1000 Revision: 0 Effective Date: 01OCT2011 HOW TO PROCEDURE Title: Production Part Approval Process COPYRIGHT © HAMILTON SUNDSTRAND CORPORATION. THIS DOCUMENT IS THE PROPERTY OF HAMILTON SUNDSTRAND CORPORATION (HS). YOU MAY NOT POSSESS, USE, COPY OR DISCLOSE THIS DOCUMENT OR ANY INFORMATION IN IT, FOR ANY PURPOSE, INCLUDING WITHOUT LIMITATION, TO DESIGN, MANUFACTURE OR REPAIR PARTS, OR OBTAIN ANY GOVERNMENT APPROVAL TO DO SO, WITHOUT HS’S EXPRESS WRITTEN PERMISSION. NEITHER RECEIPT NOR POSSESSION OF THIS DOCUMENT ALONE, FROM ANY SOURCE, CONSTITUTES SUCH PERMISSION. POSSESSION, USE, COPYING OR DISCLOSURE BY ANYONE WITHOUT HS’S EXPRESS WRITTEN PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY. THIS DOCUMENT CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Page 1 of 18 1.0 POLICIES AND DEFINITIONS 1.1 Scope This procedure defines and establishes instructions for implementing the requirements of ASQR-09.2, “UTC Production Part Approval Process (UPPAP). The roles and responsibilities described within this procedure apply to the manufacturing of production hardware. 1.2 Policies This procedure defines the process for validating manufacturing processes that produce HS hardware in meeting all engineering, quality and delivery requirements. Assessments required for the purpose of completing a PPAP (Production Part Approval Process) Review have detailed instructions defined in HT0990, “Manufacturing Process Reviews”. Minimum PPAP training requirements are described in Appendix 1. The term “Control Build Review” is synonymous with the PPAP process described here in this procedure, utilizing the same checklists, forms and protocols. CONTENTS Policies and Definitions....................................................………………….. 1.0 Procedure……………….............................................……………………… 2.0 APPENDICES Change Notification ……………………….....................................……….. Training Requirements ……………………….....................................…….. 1 2 Procedure Administration..................................................…………………. 3

Transcript of Production Part Approval Process CONTENTS APPENDICES …...CTQ Features: Reference HSC16199 for...

Page 1: Production Part Approval Process CONTENTS APPENDICES …...CTQ Features: Reference HSC16199 for definition of Critical-to-Quality Features. Engineered Item (Buy Parts): A product that

No.: HT1000

Revision: 0 Effective Date: 01OCT2011

HOW TO PROCEDURE

Title: Production Part Approval Process

COPYRIGHT © HAMILTON SUNDSTRAND CORPORATION. THIS DOCUMENT IS THE PROPERTY OF HAMILTON SUNDSTRAND

CORPORATION (HS). YOU MAY NOT POSSESS, USE, COPY OR DISCLOSE THIS DOCUMENT OR ANY INFORMATION IN IT, FOR ANY

PURPOSE, INCLUDING WITHOUT LIMITATION, TO DESIGN, MANUFACTURE OR REPAIR PARTS, OR OBTAIN ANY GOVERNMENT

APPROVAL TO DO SO, WITHOUT HS’S EXPRESS WRITTEN PERMISSION. NEITHER RECEIPT NOR POSSESSION OF THIS DOCUMENT

ALONE, FROM ANY SOURCE, CONSTITUTES SUCH PERMISSION. POSSESSION, USE, COPYING OR DISCLOSURE BY ANYONE

WITHOUT HS’S EXPRESS WRITTEN PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY.

THIS DOCUMENT CONTAINS NO TECHNICAL DATA. ECCN: EAR99

Page 1 of 18

1.0 POLICIES AND DEFINITIONS

1.1 Scope This procedure defines and establishes instructions for implementing the requirements of

ASQR-09.2, “UTC Production Part Approval Process (UPPAP)”. The roles and

responsibilities described within this procedure apply to the manufacturing of production

hardware.

1.2 Policies This procedure defines the process for validating manufacturing processes that produce

HS hardware in meeting all engineering, quality and delivery requirements.

Assessments required for the purpose of completing a PPAP (Production Part Approval

Process) Review have detailed instructions defined in HT0990, “Manufacturing Process

Reviews”.

Minimum PPAP training requirements are described in Appendix 1.

The term “Control Build Review” is synonymous with the PPAP process described here

in this procedure, utilizing the same checklists, forms and protocols.

CONTENTS Policies and Definitions....................................................………………….. 1.0

Procedure……………….............................................……………………… 2.0

APPENDICES Change Notification ……………………….....................................………..

Training Requirements ……………………….....................................……..

1

2

Procedure Administration..................................................…………………. 3

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1.3 Definitions Catalog Part: A supplier of standard parts (e.g., MS, AN, AS, etc) does not need to

comply with UPPAP requirements unless formally required to, by the member.

Control Build Review: A part process review that was the precursor to the PPAP

review.

CTQ Features: Reference HSC16199 for definition of Critical-to-Quality Features.

Engineered Item (Buy Parts): A product that is designed and built by a Producer.

The Producer maintains design authority and configuration control for the product.

Engineered Item Supplier: A supplier who designs and manufactures components

and/or end items (LRUs) based on an HS specification. Also known as Suppliers of

Designed Equipment (SDE).

FSP: Reference HSC16199 for definition of Flight Safety Part.

IPD Team: An Integrated Product Development Team, also known as a Design-to-

Build Team, is responsible for the overall coordination of a new program from

development, into production and finally through field service. Typically, the IPD

Team is composed of a Design Engineer, Project Engineer, Enterprise Quality

Engineer, Supplier Development Engineer, Manufacturing Engineer, Procurement

Buyer, Producibility Engineer and Service Engineer.

Make Part: Parts that are designed by Hamilton Sundstrand and produced by HS or

supplier.

Manufacturing Process Reviews: A series of assessments designed to validate

Hamilton Sundstrand products meet Customer requirements and company

commitments relating to quality, capability, capacity and overall readiness. Process

Certification requirements per this procedure are assessed as part of the MPR

(Manufacturing Process Review) system. The governing MPR document is HT0990.

Member Focal Point: Main technical interface supporting UTC PPAP activities as

defined in ASQR-09.2.

Objective Evidence Package: The collection of all PPAP documentation and

supporting evidence.

Process Control Plan: The Process Control Plan follows the PFMEA and Process

Flow steps, and provides step by step details on how the process is controlled to

product specification and how to respond to potential issues in the event of non-

conformances. Process Readiness Study: Reference HT0990 for definition. PPAP Element: The 19 sections listed in the PPAP submission requirements. The

elements of PPAP submission depends on the required submission level.

PPAP1 Review: Reference HT0990 for definition.

PPAP2 Review: Reference HT0990 for definition.

Producer: An HS Operating unit and/or Supplier who provides goods and services.

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Supplier Tracking & Analysis Tools: An HS web based system used to manage

PPAP schedules, assessments and action item tracking.

Transition Coordinator: The person assigned to the transition team to coordinate

PPAP requirements with the PEG Group.

Transition Team: A team assigned to manage specific product sourcing changes.

1.4 Abbreviations And Acronyms ASQR: Aerospace Supplier Quality Requirement

CTQ: Critical-to-Quality

DFMEA: Design Failure Modes Effects Analysis

DQR: Designated Quality Representative

EC: Engineering Change

EQE: Enterprise Quality Engineer

FPRB: Frozen Process Review Board

FSC: Flight Safety Characteristic

FSP: Flight Safety Part

HS: Hamilton Sundstrand

IPD: Integrated Product Development

MPR: Manufacturing Process Review

OQE: Operations Quality Engineer

PCP: Process Control Plan

PD: Procurement Data

PEG: Preparation & Execution Group

PFMEA: Process Failure Modes Effects Analysis

PO: Purchase Order

SDE: Supplier Development Engineer

SPC: Statistical Process Control

SQA: Supplier Quality Assurance

STAT: Supplier Tracking & Analysis Tools

UPPAP: UTC Production Part Approval Process

1.5 Environment, Health and Safety Policy

Hamilton Sundstrand is committed to conducting its operations in such a manner

as to protect the health and safety of its employees, its neighbors and the natural

environment.

Each employee plays an important role in improving performance, not only by

understanding and following established procedures, but also by recommending

improved practices, where appropriate.

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There are no specific precautions associated with this Standard Procedure; however

associates are encouraged to bring unsafe conditions and practices to the attention

of supervision to ensure prompt resolution of potential hazards.

2.0 PROCEDURE

2.1 PPAP Strategy

Appling UPPAP at Hamilton Sundstrand is comprised of four specific strategic categories,

as described below.

1. NEW PROGRAMS. UPPAP will be applied on new programs, either driven by

Customer contract, or based on management directive. Parts will be selected utilizing

a risk based approach including criteria such as supplier performance, part criticality,

and producer maturation with the product or processes used in the manufacture of the

product.

2. TRANSITIONS: Manufacturing source transitions represent an inherent level of risk,

thus UPPAP will be applied as a risk mitigation tool. The new source will have to

demonstrate process readiness and adequacy prior to serial production.

3. ENGINEERING CHANGES: Engineering changes that meet the level of a Class I

change can utilize UPPAP as a means to assure key aspects of the production process

have been addressed that have a positive impact relative to the change.

4. ESCAPE MITIGATION: Depending on the nature of the escape, UPPAP may be

applied as a means of assuring any changes resulting from the root cause corrective

action plan have been properly implemented to prevent future occurrences.

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2.2 Document Flowdown

L1(Policy)

DP400QMS

L2

(Requirements Flowdown)

HSC16199 Management &

(Published)

PR9103 Manufacturing Process Control

(Published)L3

(Requirements Implementation;

(EPD: 3/28/06)

HT0990 Manufacturing

Process Reviews (currently in ballot)

(EPD: 3/28/06)

1(Requirements)

ASQR-09.2

UTC PPAP

2

(Implementation & Assessment)

HT1000

HS PPAP(Internal Implementation

Procedure)

3

(Key Flowdown Documents)

HT0990

Manufacturing Process Reviews(Assessments)

HSM17

HS SupplierProduct Release

(DQR Instructions)

HSC16199 Management & Control of

CTQ’s(Process Control Elements)

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2.3 PPAP Overview – The Four Key Milestones

The HS Production part Approval Process will be implemented in a structured manner

utilizing the Four Key Milestones as summarized below. Sections 2.4 thru 2.7 will define

the detailed roles & responsibilities for each sub-milestone.

MILESTONE 1MILESTONE 1MILESTONE 1

MILESTONE 1Definition

MILESTONE 1MILESTONE 1MILESTONE 1

MILESTONE 1Definition

MILESTONE 2MILESTONE 2MILESTONE 2

MILESTONE 2MILESTONE 2

MILESTONE 2MILESTONE 2

MILESTONE 2Preparation

MILESTONE 3MILESTONE 3MILESTONE 3

MILESTONE 3MILESTONE 3

MILESTONE 3MILESTONE 3

MILESTONE 3Validation

MILESTONE 4MILESTONE 4MILESTONE 4

MILESTONE 4MILESTONE 4

MILESTONE 4MILESTONE 4

MILESTONE 4Approval

Milestone 1: DEFINITION – Define PPAP parts

– Define PPAP elements

– Define PPAP levels

– Update Quality notes

– Issue Purchase Order

Milestone 2: PREPARATION

– HS PPAP package preparation

– Schedule PPAP1 Review

– PPAP training

– Conduct PPAP1 Review

– Producer prepares PPAP package

Milestone 3: VALIDATION

– Producer submits PPAP Package for approval

– Conduct PPAP2 Review

– Determine gaps

– Provide feedback to Producer

– Producer re-submits updated package

Milestone 4: APPROVAL – Sign off UPPAP Form 1

– Update PPAP database

– Forward Form 1 to Producer

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2.4 MILESTONE 1 - DEFINITION

OVERVIEW: Milestone 1 involves the identification of applicable part

numbers, elements, and oversight levels. Milestone 1 involves the upfront

planning for PPAP that includes training and scheduling of the reviews.

Actor Action

2.4.1 Define PPAP Parts

EQE

Transition

Coordinator

IPD/Transition

Team

PEG

OQE

PEG

EQE/OQE

New Program Parts/Transition Parts

Coordinate the following IPD Team PPAP actions.

Coordinate the following Transition Team PPAP actions.

Obtain bill of material (BOM) for the specific program

component responsible for.

Determine which parts from the BOM have PPAP

applicability. Recommended criteria is as follows:

Part complexity

New part design

New manufacturing process

Functionality

Previous failures, quality escapes on part or similar

designed part

Impact to safety

List all part numbers on Form QC-1000.1, PPAP Decision

Matrix Tool.

Submit QC-1000.1 form with PPAP part numbers to PEG

Group.

– Receive part number applications for PPAP:

– “Make” parts from OQE/Transition

Coordinator

– “Buy” parts from EQE

– Receive list of “Make” parts from EQE.

– Determine detail components requiring PPAP for the LRU

“make” component (e.g., fuel control).

– Forward list of “Make-Internal” (e.g., fuel control assembly)

and “Make-External” (e.g., valve, sleeve, housing, etc.) parts

to PEG.

Perform part risk assessment using the QC-1000.1 form to

determine the applicable PPAP Elements and oversight

levels.

Engineering Changes

Initiate PPAP implementation request to PEG Group for

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SDE/EQE/OQE

PEG

PEG

Buyer

2.4.2

2.4.3

Class I engineering changes.

Escape Mitigation

– Initiate PPAP implementation request to PEG Group for

major escapes where a PPAP2 Review would be beneficial.

Define PPAP Elements and Levels – Determine PPAP elements and levels using PPAP Decision

Tree.

Update Quality Notes and Issue PO

Add the PPAP requirement to the purchase order master

quality note as follows:

“The requirements of ASQR-09.2, UTC Production Part

Approval Process, are in effect for this part number”.

Notify corresponding Buyer that a quality note update exists

for the subject part number.

– Issue revised or new purchase order to supplier.

2.5 MILESTONE 2 – PREPARATION

OVERVIEW: Milestone 2 involves the preparation activities needed in

order to execute a successful PPAP review. These activities include

conducting a PPAP1 Review, training the Producer and finally creation

of the PPAP Objective Evidence Package.

Actor

Action

2.5.1 HS PPAP Package Preparation

PEG

PEG

SDE

2.5.2

Initialize PPAP Objective Evidence Package (Form QC-

0990.28) for the Producer from the appropriate parts list that

was submitted. The key actions to initialize the PPAP are:

– Fill out all the Producer identification and part

characterization data.

– Define which PPAP Elements are required.

– Define which PPAP Elements the Producer must submit

objective evidence back to HS if not a Level 1 PPAP

Review as defined in HT0990.

Forward to SDE/OQE to use with Supplier or plant site cell.

Initialize PPAP record for the part number and Producer in

the STAT Tool.

Schedule PPAP1 Review

Coordinate with the SDE, Supplier Quality Planning Group

and the OQE (for in plant PPAP applications) to schedule the

PPAP1 Review in the STAT Tool.

Contact supplier to set up on-site or teleconference.

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SDE/OQE

SDE/OQE

DQR/OQE

DQR

OQE

OQE/DQR

PRO

2.5.3

2.5.4

2.5.5

Forward Producer PPAP Objective Evidence

Package.

PPAP Training

Provide the Producer with PPAP Training per App. 2.

Access PPAP training material via the HS Supplier Portal or

Learning Portal.

Conduct PPAP1 Review

Conduct PPAP1 Review with the Producer per HT0990 and

PPAP 215 training course number 996971.

Producer Prepares and Approves PPAP Package

Use PPAP Objective Evidence Package (Form QC-0990.28).

For supplier PPAP part, Producer DQR, per HSM17, required

to ensure package is reviewed using PPAP2 Review

Checklist, Form QC-0990.26.

For internally made PPAP part, OQE required to ensure

package is reviewed using PPAP2–FAI Review Checklist,

Form QC-0990.26.

Ensure for Element 8, Process Readiness Study, the

following:

– Form QC-0990.27 is used

– Only Tab 1 of QC-0990.27 need be submitted in Tab 8,

“PRS”. This is the PRS roll-up score.

Approve PPAP Objective Evidence Package

– Complete UTC Approval Form 1

– Sign UTC Approval Form 1 and submit per Section 2.6.1.

2.6 MILESTONE 3 – VALIDATION

OVERVIEW: At the heart of Milestone 3 is conducting a validation of the

PPAP2 Review package. Depending on the level of oversight established, this

review may be conducted at HS or on-sight with the Producer. Gap closure

plans will be established for any review that identifies incomplete or deficient

elements.

Actor Action

PRO

2.6.1

Producer Submits PPAP Package for Approval

PROCESS FOR “SUPPLIER PRODUCED” PARTS

Per HT0990, Supplier will forward their completed PPAP

Objective Evidence Package (Form QC-0990.28) to the

Supplier Development Engineer so they can conduct the

PPAP2 Review.

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SDE

OQE

PRO

2.6.2

PROCESS FOR “INTERNALLY PRODUCED” PARTS

Per HT0990, Internal Plant Site area will forward their

completed PPAP Objective Evidence Package (Form QC-

0990.28) to the supporting Operations Quality Engineer so

they can conduct the PPAP2 Review.

Conduct PPAP2 Review Per HT0990

PROCESS FOR “SUPPLIER PRODUCED” PARTS

- Receive completed PPAP Objective Evidence Package from

Supplier.

- Conduct the PPAP2 Review per HT0990 on the received PPAP

Objective Evidence Package.

- If required, provide gap analysis feedback to the Producer,

Buyer and EQE.

- Upload open PPAP2 Review action items into the STAT Tool.

- Archive PPAP Objective Evidence Package in STAT Tool.

PROCESS FOR “INTERNALLY PRODUCED” PARTS

- Receive completed PPAP Objective Evidence Package from

internal plant site cell.

- Conduct the PPAP2 Review per HT0990 on the received PPAP

Objective Evidence Package.

- If required, provide gap analysis feedback to the Producer and

EQE.

- Upload open PPAP2 Review action items into the STAT Tool.

- Archive PPAP Objective Evidence Package in STAT Tool.

Submit completed PPAP Objective Evidence Package to Customer

MFP.

Update PPAP Objective Evidence Package when action items are

established by the MFP performing the PPAP2 Review.

2.6.3 Determine Gaps

SDE/OQE Document any gaps and associated corrective actions (i.e.,

incomplete elements, deficiencies, etc.) on PPAP2-FAI Checklist

(Form QC-0990.26).

Summarize action items onto UTC Approval Form 1.

2.6.4 Provide Feedback to Producer

SDE/OQE

Follow instructions in HT0990, PPAP2 Review section.

2.6.5 Producer Re-Submits Updated Package

Follow instructions in HT0990, PPAP2 Review section.

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2.7 MILESTONE 4 – APPROVAL

OVERVIEW: Milestone 4 is the final leg of the PPAP process where

the Producer’s PPAP Package is approved. The MFP will sign the

UTC Approval Form and communicate back to the Producer whether or

not the approval stands on its own or requires follow-up action.

Actor Action

SDE

SDE

OQE

SDE

SDE

OQE

SDE

SDE

OQE

2.7.1

Forward for Customer Review

If package is fully complete with no gaps:

– Forward to EQE if “Buy” part for PPAP approval.

– Forward to OQE if “Make” part for PPAP approval.

– Forward to EQE if “Make” part but at final LRU level for

PPAP approval.

If package is not fully complete but with acceptable gap

closure plan:

– Forward to EQE if “Buy” part for PPAP “Interim Class”

approval.

– Forward to OQE if “Make” part for PPAP “Interim Class”

approval.

– Forward to EQE if “Make” part but at final LRU level for

PPAP “Interim Class” approval.

If package is rejected outright upon initial review by

SDE/OQE then the following actions shall take place:

– Inform EQE/Buyer if “Buy” part and work with supplier

on a gap closure plan.

– Forward to OQE if “Make” part and work with supplier on

a gap closure plan.

– Forward to EQE if “Make” part but at final LRU level and

work with plant site area on a gap closure plan.

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EQE/OQE

EQE/OQE

EQE

OQE

EQE

SDE/OQE

PEG

SDE/OQE

2.7.2

2.7.3

2.7.4

Customer Interim Class Assignment and Dispositioning

Update UTC Approval Form 1 with the appropriate Interim

Class per Table 1 below:

Table 1 – Interim Approval per ASQR-09.2

Sign and date UTC Approval Form 1.

Forward UTC Approval Form 1 to SDE for “Buy” supplier

parts.

Forward UTC Approval Form 1 to SDE for “Make” supplier

parts.

Forward UTC Approval Form 1 to OQE for “Make”

internally made parts.

Update PPAP Database

Update STAT Tool with completed UTC Approval Form 1.

Update PPAP Objective Evidence Package (Form QC-

0990.28) in the STAT Tool when receiving additional and/or

modified Producer data supporting PPAP Elements that were

not closed out.

Upload completed PPAP Objective Evidence Package (Form

QC-0990.28) into STAT Tool Database.

Forward completed UTC Approval Form 1 to Producer.

Ongoing PPAP Maintenance

Monitor open PPAP action items in STAT Tool resulting

from Interim Class approvals and/or rejected PPAP2 Reviews.

Work to close open PPAP action items in STAT Tool.

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2.8 CHANGE CONTROL

OVERVIEW: This section describes the procedure for handling

process changes that may require a delta or ful-up PPAP Review to a

part that previously was approved.

Actor Action

Supplier Mgt.

and/or DQR

Plant Site Area

M.E./Cell

Leader

EQE/SDE

SDE/

PEG

SDE/OQE

SDE/OQE/EQE

2.8.1

2.82

2.83

Producer Notifies MFP of Changes that may Impact

Engineering Design, Quality or Delivery Requirements

WHEN PRODUCER IS AN EXTERNAL SUPPLIER

– Inform SDE and/or Buyer for any changes per Table 2,

Appendix 1. Note that changes reflected in Table 3,

Appendix 1, do not require notification.

– The supplier shall notify the SDE using the UPPAP

Notification, ASQR-09.2 Form 2 when any situation

described below occurs.

WHEN PRODUCER IS AN INTERNAL PLANT SITE

AREA

– Inform EQE for any changes per Table 2, Appendix 1.

Note that changes reflected in Table 3, Appendix 1, do

not require notification.

– The Plant Site Area shall notify the EQE using the

UPPAP Notification, ASQR-09.2 Form 2 when any

situation described below occurs.

Determine Change Impact and Take Appropriate Action

– Decide if contents of Change Notification merit a new

PPAP review (delta or full-up).

– Forward UTC Change Notification Form 2 to PEG Group

with request to schedule new PPAP.

Schedule New PPAP

– Follow instructions located in Section 2.5 for PPAP

scheduling.

– Follow instructions located in Section 2.6 for PPAP

execution.

– Follow instructions located in Section 2.7 for PPAP

disposition and approval.

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Appendix 1

Change Notification

TABLE 1 – When Change Notification is Required

Requirement Clarification or Examples

1. Use of other construction or material than was

used in the previously approved part or product.

For example, other construction as documented on a

deviation (permit) or included as a note on the designrecord and not covered by an engineering change as

described in Table I.3.2 #3.

2. Production from new or modified tools (except

perishable tools), dies, molds, patterns, etc., including additional or replacement tooling.

This requirement only applies to tools which due to

their unique form or function, can be expected toinfluence the integrity of the final product. It is not

meant to describe standard tools (new or repaired),such as standard measuring devices, drivers (manualor power), etc.

3. Production following refurbishment or

rearrangement of existing tooling or equipment.

Refurbishment means the reconstruction and/or

modification of a tool or machine or to increase thecapacity, performance, or change its existing function.

This is not meant to be confused with normalmaintenance, repair or replacement of parts, etc., forwhich no change in performance is to be expected and

post repair verification methods have beenestablished.

Rearrangement is defined as activity which changesthe sequence of product/process flow from that

documented in the process flow diagram (includingthe addition of a new process).

Minor adjustments of production equipment may berequired to meet safety requirements such as,

installation of protective covers, elimination ofpotential ESD risks, etc. These changes can be made

without customer approval unless the process flow ischanged as a result of this adjustment.

4. Production from tooling and equipment

transferred to a different plant location or from an additional plant location.

Production process tooling and/or equipment

transferred between buildings or facilities in one ormore locations.

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Appendix 1

Change Notification

TABLE 1 – When Change Notification is Required (continued)

Requirement Clarification or examples

5. Change of subcontractor for parts, non-equivalent

materials, or services (e.g.: heat-treating, plating) that affect customer fit, form, function, durability, or

performance requirements.

Suppliers are responsible for approval of subcontracted

material and services that do not affect customer fit form,function, durability, or performance requirements.

6. Production produced after the tooling has been

inactive for volume production for twelve months or more.

For product that has been produced after tooling has been

inactive for twelve months or more: Notification is required when the part has had no active purchase order and the

existing tooling has been inactive for volume production for twelve months or more. The only exception is when the part has low volume, e.g. service or specialty vehicles.

However, a customer may specify certain PPAP requirements for service parts.

7. Product and process changes related to components

of the production product manufactured internally or manufactured by subcontractors that impact fit,

form, function, performance, and/or durability of the salable product. Additionally, the supplier shall concur with any requests by a subcontractor before

submission to the customer.

Any change that affects customer requirements for fit, form,

function, performance, and/or durability requires notification to the customer.

NOTE: The fit, form, function, performance, and/or durability requirements should be part of customer

specifications as agreed on during contract review.

8. Change in test/inspection method – new technique

(no effect on acceptance criteria)

For change in test method, supplier should have evidence

that the new method provides results equivalent to the old method.

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Appendix 1

Change Notification

TABLE 2 – When Change Notification is Not Required

Requirement Clarification or Examples

1. Changes to component level

drawings, manufactured internally

or manufactured by subcontractors,

that do not impact the design record

for the product supplied to the

customer.

Changes do not affect customer fin,

form, function, durability or

performance requirements.

2. Tool movement within the same

plant (used in equivalent

equipment, no change in process

flow, no disassembly of the tool) or

equipment movement within the

same plant (same equipment, no

change in process flow).

Based on lean manufacturing initiatives,

some equipment is designed for

mobility, i.e. on wheels with quick

disconnects. Cell configurations or

location within a department may be

changed without affecting process flow.

No change made to process flow or

control plan.

3. Changes in equipment (same type

equipment for same process flow

with same basic technology or

methodology).

Examples are new equipment,

additional equipment, replacement, or

change in equipment size. New

equipment that combines processes

requires notification per table 2.

4. Identical gage replacement. Gages replaced as a part of a gage

maintenance or calibration system.

5. Rebalance of operator job content

with no change in process flow.

Lean manufacturing allows for

rebalancing job content to eliminate

bottleneck issues.

6. Changes resulting in reduced RPN

on PFMEA (with no change to

process flow).

Example include added controls,

increased sample size and frequency,

and error-proofing installation.

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Appendix 2

PPAP Training Requirements

Refer to the following matrix for Production Part Approval Process (PPAP) training courses

recommended for Enterprise Quality Engineers, Manufacturing Engineers, Operations Quality Engineers,

Design Engineers, Project Engineers, Supplier Development Engineers, Supplier Quality

Representatives, Purchasing Buyers, and Management.

COURSE NAME COURSE ID # WHO DESCRIPTION # HOURS

PPAP 101

Awareness 992797

Anyone needing a

general overview of

the UPPAP per

ASQR-09.2

What is PPAP?

Why is it being

implemented?

2.0

PPAP 201 Implementation

996411

Anyone deemed an

MFP per ASQR-09.2

or performing any of

the functions as

described in this

procedure

In-depth on Four Key

Milestones, use of all

forms & checklists,

conducting the PPAP

assessments, and roles

& responsibilities

8

PPAP 215 Supplier Implementation

996971

Specifically the

functions as described

in this procedure

In-depth on 4 Key

Milestones, use of all

forms & checklists, and

roles & responsibilities

4

PPAP 301 Process Certification -

Implementation

Reference the

UTC Learning

Portal

(Type in “PPAP

301”)

This training leads to

certifying HS

associates to take on

the role of the MFP

(per ASQR-09.2) who

will review and

approve PPAP

packages submitted to

HS by a Producer.

In-depth training on the

19 UPPAP elements

with a focus on

DFMEA and PFMEA.

The training discusses

what is acceptable

versus not acceptable

when the MFP is

reviewing a PPAP

element for compliance

to ASQR-09.2

24

PC 201 Process Certification -

Implementation

017157

Engineers (Design,

Manufacturing,

Quality, Project,

Supplier Quality)

In-depth on Four Key

Milestones, SPC

Charts, Gage & Process

Capability, Intro. To

DOE

24

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Appendix 3

Procedure Administration

1. Document Changes

Revision Description of Change Effective Date

0 Initial Release.

01OCT2011

2. Document Owner HSC Operations Quality Director,

HSC SQA Manager

3. Originally Written by P. Teti and J. DeFazio

4. Next Higher Document ASQR-09.2, “UTC Production Part Approval Process”

5. Superseded Document None

6. Applicability Includes all European Aerospace Companies (EAC) and North

American Aerospace (NAA) Hamilton Sundstrand business

entities. Excludes all Aerospace Maintenance Activities

(AMA), Industrial (IND) and Space Systems (SS) Hamilton

Sundstrand business entities.

7. Distribution Online

8. Documents Referenced HS15000, Flight Safety Parts

HSC16199, Management and Classification of Critical to

Quality Characteristics

HSM17, Supplier Product Release Programs

HT0990, Manufacturing Process Reviews

Manual #996411, PPAP 201 Training Manual

9. Forms Authorized QC-1000.1, “PPAP Decision Matrix”

10. Forms Referenced

All PPAP forms authorized by this procedure can be found in

Documentum.

11. Audit Requirements Procedure Requirement PR009, Aerospace Quality Audit

Program

12. Key Functional Responsibilities See Section 2.0, Procedure.

13. Equipment List None