P P A P
Production Part Approval Process
Presented by Robert M. Stolzman
Scope
?The class covers the generic requirements for production part approval for all production and service commodities, including bulk materials.
History of the PPAP
In the past, Chrysler, Ford and General Motors each had their own processes
for reviewing submissions for production parts.
Differences between these three processes resulted in additional demands on
supplier resources.
To improve this situation the Big 3 agreed to develop a procedure for
production part approvals. A PPAP group was organized made up of Quality
and Part Approval staffs from the Big 3. Over a period of a few years the PPAP
manual was developed and released along with the FMEA and APQP/CP
reference manual.
These manuals are distributed by AIAG (Automotive Industry Action Group
– https://www.doczj.com/doc/5215502744.html,)
Purpose
For the supplier to demonstrate
–all design records and specification requirements are properly understood
–the process has the capability to produce product that meets requirements
General
PPAP Submission
?If something has changed, the supplier MUST notify the customer who will determine the need for part submission
?Purpose is to identify changes that may affect direct customer or ultimate purchaser
?Suppliers are responsible for subcontracted materials and services
Methodology
?Customer enters the date of PPAP submission on the purchase order
?Customer determines submission level
–default level 3
?Supplier submits PPAP
–Electronic submission recommended (MS Excel preferred)
?Customer evaluates PPAP package
–Level 5 at supplier site
?Customer will determine part submission status
?Customer will notify the supplier of the status of acceptance
Methodology
?P roduction P art A pproval P rocess (PPAP)
?Production parts are manufactured at the production site using production tooling, gaging, equipment, operators, process settings, environment, etc
?Each part from multiple processes or multiple streams must be measured and tested independently
?Parts from production run are analyzed
?Test results and records from APQP are submitted with Part Submission Warrant
Methodology
?Parts taken from a significant run
?One hour to one shift
?300 parts minimum, normally
- lesser quantities needs customer approval (in writing)
?One part from each position for multiple cavity, die, mold, tool pattern to be measured
Formal Submission
?Always Required
?Prior to first production shipment of a new part or product
?When a discrepancy is corrected on a previously submitted part
?In case of an engineering change to:
- design records
- specifications
- m aterial
?Use of optional construction or material
?Production uses new or modified tools, dies, patterns, etc.
?Refurbishing or rearranging of existing tooling or equipment
?Changes in process or method of manufacture
?Tooling and equipment is transferred to/from a different location
Formal Submission
?Change in subcontractor source for:
- parts
- materials
- services (heat treating, plating, etc)
?Production resumes after being inactive for more than one year
?Customer requests shipments to be suspended due to a customer concern
?Customer may waiver or require partial submission (always get in writing)
?Applies to Tier 1, Tier 2 and Tier 3 suppliers. (Tier 1 = Direct Supplier; Tier 2 = Subcontractor of the Direct Suppler; Tier 3 = Subcontractor of the Subcontractor of the Direct Supplier)
Supplier Data Received
?***Warrant
?Appearance Approval Report (AAR), as required
?***Sample Parts
?***Print/Design Record
?Engineering Change Documents
?Check fixtures/aids
?***Process Flow Diagram
?***PFMEA
?***Dimensional Results
?DFMEA
?***Control Plan
?***Pre-Launch Control Plan
?***Process capability studies
?***Gage Measurement System Analysis (GR & R)
?***Lab Accreditation & scope
?***Restricted & Reportable Materials form (Material Safety Data Sheet)
PPAP Process
?Form an APQP Team (APQP = Advanced Product Quality Planning) Plan Quality into the Process – Not Inspect Quality into the Product! ?Review the Drawing to ensure that the company has the manufacturing capabilities, equipment, tools, gauges, and personnel to meet the requirements of the customer.
?Accept or reject the feasibility of the project.
–If No, turn down contract.
–If Yes, Continue
?Create Process Flow Diagram
–Create Characteristic Matrix
?List Processes Across the top of the Matrix
?List All Dimensions on the left side of the Matrix
?Indicate what operation the characteristic will be controlled or inspected.
PPAP Process
?Create PFMEA ( PFMEA = Process Failure Mode and Effects Analysis)
–All items listed on the Process Flow Diagram must be addressed for potential/failure modes including all product and process special/critical characteristics.
–Many processes will have multiple failure modes.
–All high risk factors must be addressed with corrective action.
?Acquire Packaging Specifications
–Create packaging standard.
–Create packaging work instructions
?Prepare Pre-Launch Control Plan
?Pilot Run / Sample Run / Trial Lot / PPAP Run
?Review Material Certifications
?Perform Gage R & R on all gages used to accept the product. ( 10 - 1 Rule to be followed, Gage R & R must be within 10% )
?Conduct Short Term Process Capability Study (Ppk 1.67 min)
?Evaluate Packaging
PPAP Process
?Balloon Drawing (Number sequentially starting upper left hand corner – clockwise)
?Dimensional Inspection Report (ISIR = Initial Sample Inspection Report)
?Does Pilot Run (PPAP Run/Trial Run/Sample Run) meet all specifications?
–No, Another run is required after corrective action has taken place. Review all PPAP documents, PFMEA, Control Plan, Flow Diagram, etc.)
–Yes, Continue
?Prepare Production Control Plan
?Prepare Operator Work Instructions
?Submit all the required PPAP documents along with:
–Signed PSW (Part Submission Warrant)
–Sample Parts
–Lab Scope
–Material Safety Data Sheets
–Special checking Aids if Used
Part Submission Warrant
Part Submission Warrant
?All areas of the Warrant must be completed. If there is an area that is not applicable then that section must be identified by filling it in as follows: N/A
?The person who is responsible for signing the Warrant is accountable for the submission and must be: –Knowledgeable of part and manufacturing process
–Knowledge of package contents
–Able to answer customer questions
Submission Levels
There are 5 different levels of submission:
?Level 1 – Warrant only and for designated appearance items, an Appearance Approval Report submitted to the customer.
?Level 2 – Warrant with product samples and limited supporting data submitted to the customer.
?Level 3 – Warrant with product samples and complete supporting data submitted to the customer.
?Level 4 – Warrant (no product samples) with complete supporting data submitted to the customer.
?Level 5 –Warrant with product samples and complete supporting data reviewed at the supplier’s manufacturing location.
Level 3 is the default level to be used for all submissions
unless specifically advised otherwise by the customer’s part
approval authority.
Part Weight
?Determine part weight without packaging or shipping material
?Report weight in kilograms to 3 decimal places
?Weight determination:
–Weigh 10 parts randomly selected and report the average weight
–Parts less than .100 kilogram, weigh 10 parts together and report the average weight
Appearance Approval Report
?Not applicable to all parts - Customer will specify
?Not all items must be completed – Customer will specify
?Appearance evaluation
?Color evaluation – 1 for each color
?Separate AAR for each part or series of parts when designated “Appearance Item”
?Submit to customer with representative sample of parts
?Send completed form and representative production parts to the customer for approval before full PPAP submittal.
?Send the signed AAR with the Warrant at the time of final submission.
Note: Currently not applicable to any product produced at this facility.
Samples
?Two sample parts – or as agreed to
?Master samples retained by supplier for the length of part approval
?Identified and show approval date
?May be modified by customer
Customer and Supplier Design Records
?Must be maintained
?Includes CAD/CAM math data
?Part(s) prints and latest revisions
?Material specifications and latest revisions
?Detail drawings
?Any authorized engineering changes incorporated in the part but not in the design record
Engineering Changes
?Any authorized engineering changes incorporated in the part but not in the design record
?Inspection and testing requirements are determined by the extent of the changes
?If certain dimensions are changes, the dimensional evaluation may be limited to those areas affected by the change
?Always contact the customer for guidance
Dimensional Results
?All parts and products with dimensional requirements.
? 3 pieces from each cavity, fixture or tool position to be evaluated dimensionally.
?One part from each cavity, fixture or tool position must be identified and maintained as a MASTER SAMPLE.
?Must identify by specific cavity for each part submitted
?Referenced to part drawing
?On a marked drawing (ballooned)
?Includes:
–Cross sections
–Tracings from optical comparator
–Sketches
?DO NOT submit PPAP if there are dimensions out of specification without prior written customer approval.
Dimensional Results
?All dimensions (except reference) and notes are to be recorded on the inspection form with the results. ?GD & T actual results must be recorded NOT recorded as “OK” or left blank.
?When 3rd party inspection services are used, the results must be submitted on their letterhead or normal AIAG inspection report with the name of the inspection service indicated.
?3rd party inspection houses must be approved A2LA or ISO 17025 approved.
Checking Aids
?Fixtures
?Models
?Templates
?Submission of checking aids
–Specific to part being tested or inspected
–Requires a GR & R
–Must be identified with the current part revision level
–May be waived by customer
Test Results Specified on Design Record
?Material tests
–Chemical
–Physical
–Metallurgical
–Must perform tests required by material specifications and control plans
–If required, outside services must be performed by a “qualified” source or customer’s qualified laboratory by special arrangement
–3rd party laboratory services
?Results must be submitted on their letterhead
?Name of laboratory that performed the tests must be indicated
Test Results Specified on Design Record
?All tests required are to be listed in a convenient format with quantity tested and actual results of each test, indicating:
–Design record change level
–Specification designation number, date and change level of the test specification
–Testing date
–Material supplier name
–Subcontractor name for services
–When required by customer, code name for material from customer’s approved source list
Test Results Specified on Design Record
?Performance tests
–Reporting
?Indicate design record change level
?Indicate number, date and change level of specifications
?Indicate date that the testing took place
–Supplier’s responsi bility
?Meet all applicable specifications
?Do NOT submit if results are outside specification
?Take corrective action required to meet all design record requirements
?Contact customer if unable to meet all requirements
Flow Chart
Flow Chart
?Linkage of Product Characteristics from DFMEA to Operational Steps
?Operation numbers consistent with PFMEA, Control Plan, Operator Instructions
?Ensure identification of inspection and rework
?Use A-6 Process Flow Chart checklist in APQP manual to evaluate
Design FMEA
?When the supplier has design control responsibility, a DFMEA must be submitted
Note: Currently not applicable to any product produced at this facility.
DFMEA
?Assess feasibility, risk, design intent issues
?Confirm manufacturing process capability considered
?Focus on Critical Characteristics
?Lessons Learned incorporated
?Use A-1 Design FMEA checklist in APQP manual to evaluate
Process FMEA
?PFMEA is a systematic approach used by a manufacturing responsible team to assure that potential process related failure modes and their associated causes have been identified, addressed and resolved.
?Must follow flow of process flow diagram.
?Must include all special characteristics as a minimum
PFMEA
?Linkage with DFMEA, Process Flow, Control Plan, Operator Instructions, etc
?H igh RPN’s are addressed with preventive strategies
?Action Plans assigned, implemented, effectiveness assessed and RPN recalculated
?Use A-7 Process FMEA checklist in APQP manual
Pre-Launch Control Plan
Pre-Launch Control Plan requirements
–Additional controls included for proper duration or quantity
–PFMEA and statistical data used to determine what additional controls necessary ?short term capability
?long term capability on similar process
Control Plan
?Is a written description of the systems for controlling parts and processes during a full production run. ?Ensure Control Plan is aligned to, and correlates with, DFMEA, Process Flow, PFMEA
?Control Methods appropriate to variation type(s)
?Incorporates Lessons Learned, Statistical Data
?Use A-8 Control Plan checklist in APQP manual to evaluate
Control Plan
?Includes product and process special characteristics
?Includes SPC requirements
?May be for a “family” of parts if reviewed for commonality
?May require customer approval
?Customer must always be notified when there is a revision
MSA Studies
?Assesses the variation of the measurement system and determines whether the measurement system is acceptable for monitoring the process.
?Measurement uncertainty determined
–Gage R&R, Bias, Stability, and Linearity
?Gage R & R acceptance guidelines
< 10% acceptable
10-30% may be acceptable, evaluate total variation
>30% unacceptable, measuring system needs improvement
MSA Studies
?Required on all new or modified gages, measurement or test equipment
?Required for all special characteristics
?Required before performing a process capability study
Process Capability Studies
Process Capability Studies
An acceptable level of preliminary process capability must be
determined prior to submission for all characteristics designated by
the customer or supplier as Safety, Key, Critical or Significant that
can be evaluated for variable data.
The purpose of conducting preliminary process capability studies is to
determine if the process is likely to produce product that will meet the
customer’s requir ements.
Gage R & R must be performed prior to conducting the study.
Process Capability Studies
Process Capability Studies
?Requires a minimum of 25 subgroups and 100 individual readings as a minimum.
?Processes must be stable and in control otherwise corrective action must be taken.
?Cpk data is useless data if the process is unstable.
?If stability is not achieved by submission date:
–Corrective action plan is required,
–Interim revised control plan with 100% inspection is required and must be approved by the customer.
Part Submission Status
?Full Production Approval
?Interim Approval
–Authorize shipment without Full Production Approval
–Corrective Action Plan is required
?Rejected
–Corrected submission required before production quantities may be shipped
Part Submission Status
?Full Production Approval
–Meets all customer specifications and requirements
–Supplier authorized to ship production quantities to customer releases
?Interim Approval
–Permits shipment on a limited time or piece quantity basis
–Granted when supplier has:
?Clearly identified root cause of nonconformance
?Prepared an interim action plan agreed to by the customer
?Resubmission is required unless customer revises drawings or specifications to agree with part
–Must meet agreed upon action plan by expiration date or be rejected
–No additional shipments authorized until approval
Part Submission Status
?Rejected
–Submission, parts and/or accompanying documentation do not meet customer requirements
–Product or documentation must be corrected
–New submission required
–No part shipments until approval
Interim Part Class
A parts from production tooling and meet specs, not all PPAP requirements have been met
B parts from production tooling and require rework to meet specs
C parts not from production tooling, parts meet specs
D parts do not meet specs
E parts do not meet specs and vehicles with class E parts require retrofit to make them saleable
Part Submission Status
?Never ship production quantities before receiving customer approval (Signed PPAP Approval!!)
?Supplier must ensure that all future production continues to meet all customer requirements
?“Self Certifying” suppliers send approved documentation unless customer advises otherwise
?NO production parts can be shipped until approval is received
Master Samples and Record Retention
?Supplier must retain a complete record of findings and master sample(s) for each submission, including SPC results and, where applicable, appearance approval.
?Records should show conformance to all test specifications, including:
–Dimensional
–Chemical
–Metallurgical
–Physical
–Other (as required by the customer)
?SPC Results
?Appearance Approval Report, if applicable
?Inspection Results
Master Samples and Record Retention
?Laboratory Test Results
?Preliminary Process Capability Results
?Preliminary Process Performance Results
?Measurement System Analysis Results
?Process Flow Diagrams
?Process FMEA
?Design FMEA (where applicable)
?Control Plans
?Subcontractor Warrants
?Subcontractor Supporting Documents
?Subcontractor AAR (where applicable)
?Subcontractor Master Samples
General
?Suppliers are required to complete and retain copies of all documentation identified in “Requirements for Approval” regardles s of submission level.
?Records of PPAP are to be maintained for the life of the part plus one calendar year.
?Master Samples retained,
–Same as PPAP, or
–Until a new master sample is produced for the purpose of a customer approval
?Master Sample MUST be identified by:
–Part Number
–Drawing Level or Revision Level
–Customer Approval Date
?Sample Storage:
–Customer can modify retention for large parts
–May be waived (MUST be in writing)
Summary
?Refer to the AIAG manual for customer specific requirements
?AIAG PPAP manual defines requirements
?APQP Product and Process Validation
?Supplier submits PPAP to proper level
?PPAP package evaluated and status determined
?Supplier supplier manufacturing site notified of PPAP approval status
Reference Documents
?AIAG PPAP, SPC, MSA, APQP and Control Plan manuals
?GM 1411 Interim Approval Worksheet
?AIAG QS-9000 Manual
?Appendix 20: PPAP checklist
PPAP 生产件批准程序 A．目的 生产件批准程序(PPAP)规定了包括生产和散装材料在内的生产件批准的一般要求。PPAP的目的是用来确定供应商是否已经正确理解了顾客工程设计记录和规范的所有要求，以及其生产过程是否具有潜在能力，在实际生产过程中按规定的生产节拍满足顾客要求的产品。 B．适用范围 PPAP必须适用于提供散装材料、生产材料、生产件或维修零件的内部和外部供应商现场。对于散装材料，除非顾客要求，PPAP可不作要求 C．条文解释 本文中出现“必须”（shall）一词表示强制执行的要求。“应该”（should）一词表示强制执行的要求，但在执行方式上允许一些灵活性。 段落中标有“注”的词句是就所涉及的要求在理解方面和明确性上给予解释。标有“注”的语句中出现“应该”（should）一词表示仅供参考。 第一部分 I.1 总则 针对如下情况，供应商必须获得顾客产品批准部门的完全批准。 1．新零件或产品（以前从未提供给顾客的特殊零件、材料或颜色）。 2．对以前提交零件的不符合之处进行了纠正。 3．由于设计记录、技术规范或材料方面的工程更改所引起的产品更改。 4．第I.3节要求的任何一种情况。 I.2 PPAP的过程要求 I.2.1生产件：用于PPAP的产品必须取自有效的生产过程。 所谓有效的生产过程： l 一小时至八小时的生产。 l 且至少为300件连续生产的部件，除非顾客授权的质量代表另有规定。 l 使用与生产环境同样的工装、量具、过程、材料和操作工进行生产。 l 每一独立生产过程制造的零件，如相同的装配线和／或工作单元、多腔冲模、铸模、工装及仿形模的每一腔位的零件都必须进行测量，并对代表性的零件进行试验。 I.2.2 PPAP要求 l 供应商必须满足所有规定要求，如设计记录、规范，对于散装材料，还需要有散装材料要求的审核清单。 l 任何不符合要求的检测结果都会成为供应商不得提交零件、文件和／或记录的理由。 l PPAP的检验和试验必须由有资格的实验室完成。所使用的商业性／独立的实验室必须是获得认可的实验室机构。
生产件批准程序（PPAP）的理解与实施 天津久威质量技术咨询中心 2003年6月
生产件批准程序 一、什么是生产件批准程序 二、生产件提交的时机 三、PPAP所提交的文件及内容 四、生产件提交的等级 五、生产件提交的状态 六、提交程序 七、对供方产品批准的管理 散装材料的特殊要求 一、散装材料的特点 二、顾客工厂衔接 三、设计矩阵表 四、散装材料特殊特性的确定 五、FMEA的特殊要求 六、其他要求 生产件批准程序（PPAP）的理解与实施---------- 生产件批准程序
生产件批准程序（PPAP）的理解与实施 生产件批准程序 1.PPAP ?是顾客对供方的一种控制手段， ?是顾客对供方进行批量生产前的一种认可， ?生产件批准后，意味着批量生产可以进行。 2.生产件， ?在生产现场中使用与批生产相同的工装，过程、材料、量具, 操作 者，环境，过程参数等所生产的零件。 ?生产件所提交的零件应为1小时~1个班次的产量中选取，且规定产 量不少于300件。 3.PPAP的目的：对以下方面进行确认： ?供方已了解顾客工程设计和规范的所有要求； ?供方的过程在实际中能按规定的节拍生产满足要求的产品。 4.PPAP是产品批准的一种型式 ?顾客对供方实施产品批准均有共同的目的 ?不同顾客实施产品批准有不同的内容要求
?要符合顾客的产品批准要求 生产件批准程序（PPAP）的理解与实施---------生产件批准程序 二、生产件提交的时机 1.以下几种情况，必须进行生产件提交 ?新的零件或新的产品， ?曾经提交但未获批准，进行修正而重新提交； ?工程规范，材料规范改变，而发生的产品变化。 2.以下几种情况，由顾客决定是否需进行提交（必须通知顾客） ?曾经获批准，使用了不同的加工方法和材料； ?使用新的或改变了工装；（不包括易损工装更换） ?对现有工装及设备进行行了重新调整或翻新； ?内部或供方提供零件发生了产品及过程更改； ?易地生产； ?供方提供材料及服务发生了更改； ?工装长期停产后重新生产（12个月以上）； ?试验/检验方法更改一一新技术使用。 ?设计阶段所输出的各类技术文件：包括：顾客和组织的图纸, 各种设计记录，工程规范，材料规范等； ?未记入设计记录，但已在零件上体现，所进行的工程更改批准文件； ?顾客零件图或规范有要求时，提交顾客进行设计工程批准的文件；