Documente Academic
Documente Profesional
Documente Cultură
Ralf Glner
PPAP
+49-8131-53595, www.glaessner.de
PPAP_engl.PPT vom
13.01.2007
Seite 1
PPAP
PPAP
The content of this lecture shall not be used as a reference for daily work
Please make sure that you are working only with original latest level documents
Creating this lecture, the valid standards of Dec 2006 were used This lecture does not refer to customer specific requirements, nor to special PPAP rules/requirements for bulk materials, tires, nor truck industry! Standards mentioned in this lecture can be obtained from the institutions listed in section 6. Internet Links
+49-8131-53595, www.glaessner.de
Seite 3
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6.
PPAP
General PPAP Process Requirements Customer Notification and Submission Requirements Submission to Customer - Levels of Evidence Part Submission Status Record Retention
3. 4. 5. 6.
Summary of the Process The Documentation and its Preparation Summary Internet Links
+49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 4
PPAP
1. Introduction
it is the purpose of advanced quality management to prevent that unreliable designs or processes are used in serial production
therefore it is necessary to have one extensive, strict approval process for new or changed designs or processes inevitably this process causes some administration work
PPAP
Saving by taking advantage of the Rule Of The 10: The cost of the remedy of a defect increases tenfold with every step, the project advances!
Early identification of a defect
EXPENSES
PROJECT TIME
+49-8131-53595, www.glaessner.de
Seite 6
PPAP
errors
stock
muda
+49-8131-53595, www.glaessner.de
Seite 7
PPAP
PPAP
lower stocks
+49-8131-53595, www.glaessner.de
Seite 9
PPAP
no scrap, no rework
+49-8131-53595, www.glaessner.de
Seite 10
PPAP
According to QS-9000...
such an extensive and strict process is an obligatory requirement (cp. QS-9000, main section I) the name of this process is
QS-9000
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de
PPAP
PPAP_engl.PPT vom 13.01.2007 Seite 11
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6. General PPAP Process Requirements Customer Notification and Submission Requirements Submission to Customer - Levels of Evidence Part Submission Status Record Retention
PPAP
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 12
PPAP
2.
PPAP
Customer Notification and Submission Requirements Submission Levels Part Submission Status Record Retention
PPAP
Appendicies
Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F Appendix G Appendix H Glossary Completion of the Part Submission Warrant Completion of the Appearance Approval Report PPAP, Dimensional Results PPAP, Material Test Results PPAP, Performance Test Results Bulk Material - Specific Requirements Tires - Specific Requirements Truck Industry - Specific Requirements
+49-8131-53595, www.glaessner.de
Seite 14
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6.
PPAP
General PPAP Process Requirements Customer Notification and Submission Requirements Submission to Customer - Levels of Evidence Part Submission Status Record Retention
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 15
PPAP
PPAP
Applicability (
PPAP, Introduction)
PPAP shall apply to internal and external organization sites supplying production or service parts, production materials or bulk materials.
For bulk material PPAP is not required unless specified by the customer
a supplier of standard catalogue production or service parts shall comply with PPAP unless formally waived by the customer
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 17
PPAP
Submission of PPAP The organization shall obtain full approval from the authorized customer product approval activity for:
1. a new part or product 2. correction of a discrepancy on a previously submitted part 3. product modified by an engineering change to
design records specifications materials
4. any situations required by section 3 Note: If there is any question concerning the need for PPAP, contact the authorized customer representative.
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 18
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6. General PPAP Process Requirements Customer Notification and Submission Requirements Submission to Customer - Levels of Evidence Part Submission Status Record Retention
PPAP
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 19
PPAP
PPAP Process Requirements Significant Production Run PPAP Requirements 2.2.1 2.2.2 2.2.18
Requirements describing the details of documentation to be attached Will be discussed in chapter 4 of this presentation!
+49-8131-53595, www.glaessner.de
Seite 20
PPAP
PPAP
Production parts shall meet all customer engineering design record and specification requirements
including safety and regulatory requirements
If any part specification cannot be met, the organization shall document their problem-solving efforts and shall contact the authorized customer representative for concurrence in determination of appropriate corrective action.
+49-8131-53595, www.glaessner.de
Seite 22
PPAP
Warrant
+49-8131-53595, www.glaessner.de
Seite 23
PPAP
PPAP
Paperwork or EDP?
PPAP?
all forms mentioned in this document may be replaced by identical computer generated forms these documents have to be approved by the customer product approval activity before first submission at Adare Carwin a floppy with all forms can be obtained
+49-8131-53595, www.glaessner.de
Seite 25
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6. General PPAP Process Requirements Customer Notification and Submission Requirements Submission to Customer - Levels of Evidence Part Submission Status Record Retention
PPAP
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 26
PPAP
Upon notification and approval of the proposed change by the authorized customer representative, and after change implementation, PPAP submission is required unless otherwise specified
2. Submission to Customer
The organization shall submit for PPAP approval prior to the first production shipment in the following situations (see Table I.3.2) unless the authorized customer representative has waived this requirement. The organization shall review and update all applicable items in the PPAP file to reflect the production process,
regardless of whether or not the customer requests a formal submission.
The PPAP file shall contain the name of the authorized customer representative granting the waiver and the date.
+49-8131-53595, www.glaessner.de
Seite 27
PPAP
6. 7.
PPAP
+49-8131-53595, www.glaessner.de
Seite 29
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6. General PPAP Process Requirements Customer Notification and Submission Requirements Submission to Customer - Levels of Evidence Part Submission Status Record Retention
PPAP
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 30
PPAP
The content of the documentation to be generated is always the same! The supplier has to retain everything (e.g.. as a copy)! the Submission Level just indicates what has to be submitted to the customer!
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 31
PPAP
+49-8131-53595, www.glaessner.de
Seite 32
PPAP
...looking at:
the status of the supplier (Ford Q1, ...) his experience with earlier approval processes the know-how of the supplier concerning this product the importance of the part so the submission level might be different for every product
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 33
PPAP
S = submit
retain a copy at an appropriate location, (including manufacturing)
+49-8131-53595, www.glaessner.de
Seite 34
PPAP
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6.
PPAP
General PPAP Requirements Customer Notification and Submission Requirements Submission Levels Part Submission Status Record Retention
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 36
PPAP
namely at the responsible product approval activity the customer will inspect everything and notify the organization of the result using the Part Submission Status
+49-8131-53595, www.glaessner.de
Seite 37
PPAP
Upon approval of the submission, the organization shall assure that future production continues to meet all customer requirements For those organizations that have been classified as self-certifying by a specific customer (PPAP Submission Level 1), submission of the required organization-approved documentation will be considered as customer approval unless the organization is advised otherwise.
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 38
PPAP
A
Approved
B
Interim Approval
C
Rejected
+49-8131-53595, www.glaessner.de
Seite 39
PPAP
+49-8131-53595, www.glaessner.de
Seite 40
PPAP
The organization is responsible for implementing containment actions to ensure that only acceptable material is beeing shipped to the customer. PPAP re-submission is required to obtain a status of Approved material covered by an interim approval that fails to meet the agreed-upon action plan either by the expiration date or the shipment of the authorized quantity will be rejected. No additional shipments are authorized unless an extention of the interim approval is granted.
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 41
PPAP
Means that the PPAP submission does not meet the customer requirements, based on
the production lot from which it was taken, and/or accompanying documentation
In such cases, the submission and/or process (as appropriate) shall be corrected to meet the customer requirements. The submission shall be approved before production quantities may be shipped.
+49-8131-53595, www.glaessner.de
Seite 42
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6. General PPAP Process Requirements Customer Notification and Submission Requirements Submission to Customer - Levels of Evidence Part Submission Status Record Retention
PPAP
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 43
PPAP
+49-8131-53595, www.glaessner.de
Seite 44
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6.
PPAP
General PPAP Requirements Customer Notification and Submission Requirements Submission Levels Part Submission Status Record Retention
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 45
PPAP
the documentation consist of the Part Submission Certificate and the required attachments according to his Submission Level the supplier has to submit everything or just parts of it to the customer the customer checks the documentation and sets the Part Submission Status depending on that the supplier can start delivery or not
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 46
PPAP
Time frame:
Preparation 15 min.
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 47
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6.
PPAP
General PPAP Requirements Customer Notification and Submission Requirements Submission Levels Part Submission Status Record Retention
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 48
PPAP
Warrant
+49-8131-53595, www.glaessner.de
Seite 49
PPAP
Only English report forms have to be filled out and submitted to the customer!
+49-8131-53595, www.glaessner.de
Seite 50
PPAP
PPAP
including component drawings For parts identified as black box the design record specifies the interface and performance requirements The organization shall provide evidence that the Material/Substance Composition reporting has been completed and that reported data complies with all requirements
Reporting and requirements as prescribed by the customer Reporting may be entered into International Materials Data System (IMDS), www.mdsystem.com/index.jsp
+49-8131-53595, www.glaessner.de
Seite 52
PPAP
+49-8131-53595, www.glaessner.de
Seite 53
PPAP
where specified by the customer, the organization shall have evidence of customer engineering approval
+49-8131-53595, www.glaessner.de
Seite 54
PPAP
4.4
Design-FMEA
If the supplier is design responsible a Design-FMEA is required according to the customer-specific requirements e.g. QS-9000 FMEA (Potential Failure Mode and Effect Analysis)
+49-8131-53595, www.glaessner.de
Seite 55
PPAP
see QS-9000
APQP
+49-8131-53595, www.glaessner.de
Seite 56
PPAP
4.6
Process-FMEA
according to the customer-specific requirements e.g. QS-9000 FMEA (Potential Failure Mode and Effect Analysis)
+49-8131-53595, www.glaessner.de
Seite 57
PPAP
4.7
Control Plan
The Organization shall have control plan that defines all controls used for process control and complies with the customerspecified requirements, e.g. QS-9000 APQP control plans for families of similar parts are acceptable if the new parts have been reviewed for commonality Note: Certain customers require control plan approval e.g. customer signature on the control plan, prior to submission.
QM-Plan according to QS-9000
APQP
+49-8131-53595, www.glaessner.de
Seite 58
PPAP
+49-8131-53595, www.glaessner.de
Seite 59
PPAP
+49-8131-53595, www.glaessner.de
Seite 60
PPAP
on all auxiliary documents (e.g. supplementary layout results sheets, sketches, tracings, cross sections, CMM inspection point results, geometric dimensioning and tolerancing sheets, or other auxiliary drawings used in conjunction with the part drawing).
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 61
PPAP
+49-8131-53595, www.glaessner.de
Seite 62
PPAP
+49-8131-53595, www.glaessner.de
Seite 63
PPAP
+49-8131-53595, www.glaessner.de
Seite 64
PPAP
NOTE: Material test results may be presented in any convenient format. An example is shown in Appendix D.
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 65
PPAP
+49-8131-53595, www.glaessner.de
Seite 66
PPAP
+49-8131-53595, www.glaessner.de
Seite 67
PPAP
NOTE: Performance test results may be presented in any convenient format. An example is shown in Appendix E.
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 68
PPAP
+49-8131-53595, www.glaessner.de
Seite 69
PPAP
4.11
4.11.1 General 4.11.2 Quality Indices 4.11.3 Acceptance Criteria for Initial Study 4.11.4 Unstable Processes 4.11.5 Processes With One-Sided Specifications or Non-Normal Distributions 4.11.6 Actions To Be Taken When Acceptance Criteria Are Not Satisfied
+49-8131-53595, www.glaessner.de
Seite 70
PPAP
4.11.1 General
the level of initial process capability or performance shall be determined to be acceptable prior to submission for all special characteristics designated by the customer or the organization (sc,cc) the organization shall perform measurement analysis to understand how measurement error is affecting the study measurements (see Measurement System Analysis reference manual) for explanations about Cpk or Ppk see Process Control manual) SPC (Statistical
+49-8131-53595, www.glaessner.de
Seite 71
PPAP
Turning Point
Mean Value x
Standard Deviation s
PPAP
under control
+49-8131-53595, www.glaessner.de
Seite 73
PPAP
Example
Process Capability Index
Comment
Example 1 to 3
Seite 74
PPAP
+49-8131-53595, www.glaessner.de
Seite 75
PPAP
The estimate of sigma is based on total variation (all of individual sample data using the standard deviation. Ppk is an indicator of process performance based on process variation throughout the full Set of data. Unlike Cpk, Ppk is not limited to the variation within subgroups. However, Ppk cannot isolate within subgroup variation from between subgroup variation.
When calculated from the same data set, Cpk and Ppk can be compared to analyze the sources of process variation. For more information, see QS-9000 Statistical Process Control.
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 76
PPAP
+49-8131-53595, www.glaessner.de
Seite 77
PPAP
+49-8131-53595, www.glaessner.de
Seite 78
PPAP
+49-8131-53595, www.glaessner.de
PPAP
+49-8131-53595, www.glaessner.de
Seite 80
PPAP
PPAP
+49-8131-53595, www.glaessner.de
Seite 82
PPAP
PPAP
+49-8131-53595, www.glaessner.de
Seite 84
PPAP
+49-8131-53595, www.glaessner.de
Seite 85
PPAP
+49-8131-53595, www.glaessner.de
Seite 86
PPAP
+49-8131-53595, www.glaessner.de
Seite 87
PPAP
The master sample shall be identified as such, and shall show the customer approval date on the sample. The organization shall retain a master sample for each position of a multiple cavity die, mold, tool or pattern, or production process unless otherwise specified by the customer.
+49-8131-53595, www.glaessner.de
Seite 88
PPAP
PPAP
+49-8131-53595, www.glaessner.de
Seite 90
PPAP
A separate PSW shall be completed for each customer part number unless otherwise agreed to by the authorized customer representative. If production parts will be produced from more than one cavity, mold, tool, die, pattern, or production process. e.g., line or cell, the organization shall complete a dimensional evaluation on one part from each. The specific cavities, molds, line, etc., shall then be identified in the Mold/Cavity/Production Process line on a PSW, or in a PSW attachment.
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 91
PPAP
A responsible official of the organization shall approve the PSW and provide contact information.
+49-8131-53595, www.glaessner.de
Seite 92
PPAP
+49-8131-53595, www.glaessner.de
Seite 93
PPAP
+49-8131-53595, www.glaessner.de
Seite 94
PPAP
PPAP
Contents
1. 2. Introduction Content of the QS-9000
1. 2. 3. 4. 5. 6.
PPAP
General PPAP Requirements Customer Notification and Submission Requirements Submission Levels Part Submission Status Record Retention
3. 4. 5.
+49-8131-53595, www.glaessner.de
Seite 96
PPAP
+49-8131-53595, www.glaessner.de
Seite 97
PPAP
The Production Part Approval Process is an extensive strict approval process for new or changed designs or processes.
Summary
It is very formalized, so it inevitably causes some administration work, but it doesnt demand anything that makes no sense from an engineers point of view! Later changes of the product or the process are expensive and take a lot of time. The prerequisite to fulfill PPAP demands is a carefully done quality planning according to QS-9000 APQP.
+49-8131-53595, www.glaessner.de
Seite 98
PPAP
6.
Internet Links
http://www.din.de http://www.iso.ch http://www.cenorm.be https://www.carwin.co.uk/qs/qs9000default.htm http://www.aiag.org http://www.iaob.org http:// www.vda-qmc.de
+49-8131-53595, www.glaessner.de
Seite 99