Production Part Approval Process 4 Edition - …

1 Seite vom 2007 by ner, D-85221 Dachau, +49-8131-53595, Ralf Gl nerProduction part Approval Process Ralf Gl 2 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, to show you the basic content and the rules of theProduction part Approval Process and to explain the purpose and the background but this lecture willnotsave you from learninghow to practically use this systemIt s the goal of this lecture Ralf Gl 3 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, to This Lecture this lecture was created fortraining purposes only; it is not an extensive description, but azhelp for getting startedzview of contents, basic idea and goals The content of this lecture shall not be used as a reference for daily workzPlease 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!

2 Standards mentioned in this lecture can be obtained from the institutions listed insection6. Internet Ralf Gl 4 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, of the QS-9000 PPAP Process Notification and Submission to Customer - Levels of Submission of the Documentation and its Ralf Gl 5 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, Introduction it is the purpose of advanced quality managementto prevent that unreliable designs or processesare used in serial Production therefore it is necessary to have oneextensive, strict Approval processfor newor changeddesignsorprocesses inevitably this Process causes someadministration work but its worth while because it reduces theproduction of muda! Ralf Gl 6 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, TIMEEXPENSESS aving by taking advantage of the Rule Of The 10 : The cost of the remedy of a defect increasestenfold with every step, the project advances! Early identification of a themajor part ofthe cost!

3 Ralf Gl 7 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, by avoiding the 7+1 muda unnecessarymovementoverproductionwaiting timestockunnecessarytransportmudain the processerrorsDesign ignoringthe customer Ralf Gl 8 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, high take space raise assets employed require additional searching require additional administration require additional transport are a risk, because parts might exceed expiration date or becomeunsaleable are a risk, because parts might be damaged complicate the overview are often a consequence of a weak Process cover weak Ralf Gl 9 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, for low are controlled and capable processes and Total Productive Maintenance since all kind of Process problems will cause delivery stops,if the stocks are low! Ralf Gl 10 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, of controlled & capable Production processes satisfied customersby good quality and avoided muda no scrap, no rework constant flow of material low stocks Ralf Gl 11 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, to such an extensive and strict Process is an obligatory requirement(cp.)

4 QS-9000, main section I) the name of this Process isProduction part Approval Process its explanation is one QS-9000 reference manualQS-9000 PPAP Ralf Gl 12 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, of the QS-9000 PPAP Process Notification and Submission to Customer - Levels of Submission of the Documentation and its Ralf Gl 13 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, of the QS-9000 PPAP IntroductionSection 1 GeneralSection 2 PPAP Process RequirementsSection 3 Customer Notification and Submission RequirementsSection 4 Submission LevelsSection 5 part Submission StatusSection 6 Record RetentionManufacturer Specific Requirements Will not be discussed here! are to be found in internetOEM Homepages Ralf Gl 14 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, ACompletion of the part Submission Warrant Appendix BCompletion of the Appearance Approval Report Appendix CPPAP, Dimensional ResultsAppendix DPPAP, Material Test ResultsAppendix EPPAP, Performance Test ResultsAppendix FBulk Material - Specific RequirementsAppendix GTires - Specific RequirementsAppendix HTruck Industry - Specific Ralf Gl 15 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, of the QS-9000 PPAP Process Notification and Submission to Customer - Levels of Submission of the Documentation and its Ralf Gl 16 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, is, so to speak.

5 The goal of makes sure that all requirements are recognized before the ProductDevelopment is started that those special characteristics of the product are specifiedwhich influence these requirements that it is verified again and again that the planed design can safelymeet these requirements, if the special characteristics are withintolerance that only those Production processes are specified, which arecontrolled and capable according to SPCregarding thesecharacteristicsA test Production and PPAP are used to validate that all processes are under control and capable the produced parts fulfil all Ralf Gl 17 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, and ApplicabilityIt is the purpose of PPAP to define generic requirements for Production part Approval determine if all customer engineering design record and specificationrequirements are properly understood by the organization determine that the manufacturing Process has the potential to producethe product consistently meeting these requirements during an actualproduction run at the quoted Production rateApplicability( PPAP , Introduction) PPAP shall apply to internal and external organization sites supplyingproduction or service parts, Production materials or bulk bulk material PPAP is not required unless specified by the customer a supplier of standard catalogue Production or service parts shallcomply with PPAP unless formally waived by the Ralf Gl 18 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, of PPAPThe organization shall obtain full Approval from theauthorized customer product Approval activity for:1.

6 A new part or product2. correction of a discrepancy on a previously submitted part3. product modified by an engineering change tozdesign recordszspecificationszmaterials4. any situations required by section 3 Note:If there is any question concerning the need for PPAP,contact the authorized customer Ralf Gl 19 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, of the QS-9000 PPAP Process Notification and Submission to Customer - Levels of Submission of the Documentation and its Ralf Gl 20 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, (2.) 2. PPAP Process Significant Production PPAP describing the detailsof documentation to be attachedWill be discussedin chapter 4 of this presentation! Ralf Gl 21 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, (2.) Significant Production Run Products for PPAP shall be taken from a significant Production run This Production run shall be from one hour to eight hours ofproduction, and with the specific Production quantity to total aminimum of 300 consecutive parts, unless otherwise specified bythe authorized customer representative This significant Production run shall be conducted at theproduction, at the Production rate, using the Production tooling, Production gaging, Production Process , Production materials, andproduction operators.

7 Parts from each unique Production Process , duplicateassembly line and/or work cell, each position of a multiple cavitydie, mold, tool or pattern, shall be measured and representativeparts Ralf Gl 22 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, (2.) PPAP Requirements the supplier shall meet all specified requirementszas listed in this handbookzand all customer-specific requirements Production parts shall meet all customer engineering designrecord and specification requirementszincluding safety and regulatory requirements If any part specification cannot be met, the organization shalldocument their problem-solving efforts and shall contact theauthorized customer representative for concurrence indetermination of appropriate corrective Ralf Gl 23 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, over the documentations to be created(see chapter 4 of this presentation for details) Ralf Gl 24 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, of the documentation to be created1.

8 Design Record2. Authorized Engineering ChangeDocuments3. Customer Engineering Approval4. Design-FMEA5. Process Flow Diagram(s)6. Process -FMEA7. Control Plan8. Measurement System AnalysisStudies9. Dimensional Results10. Records of Material/ Performance Test Results11. Initial Process Studies12. Qualified LaboratoryDocumentation13. Appearance Approval Report14. Sample Production Parts15. Master Sample16. Checking Aids17. Customer-SpecificRequirements18. part Submission Ralf Gl 25 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, or EDP? all forms mentioned in this documentmay be replaced by identical computergenerated forms these documents have to be approvedby the customer product approvalactivity before first submission at Adare Carwin a floppy with all formscan be obtainedPPAP? Ralf Gl 26 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, of the QS-9000 PPAP Process Notification and Submission to Customer - Levels of Submission of the Documentation and its Ralf Gl 27 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, Customer Notification and SubmissionRequirements( PPAP , Section 3)1.

9 Customer Notification The organization shall notify the authorized customer representative of anyplanned changes to the design, Process or site. Examples are indicated inTable of all changes to desing nad Process is the the organization s resonsibility. Upon notification and Approval of the proposed change by the authorizedcustomer representative, and after change implementation, PPAP submissionis required unless otherwise specified2. Submission to Customer The organization shall submit for PPAP Approval prior to the first productionshipment in the following situations (seeTable ) unless the authorizedcustomer representative has waived this requirement. The organization shall review and update all applicable items in the PPAP file toreflect the Production Process ,zregardless of whether or not the customer requests a formal submission. The PPAP file shall contain the name of the authorized customer representativegranting the waiver and the Ralf Gl 28 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, : Customer Notification of other construction or material than was used in the previouslyapproved part or product2.

10 Production from new or modified tools (except perishable tools), dies, molds,patterns, etc., including additional or replacement following refurbishment or rearrangement of existing tooling from tooling and equipment transferred to a different plantlocation or from a additional plant of subcontractor for parts, non-equivalent materials or services ( :heat-treating, plating) that affect customer fit, form, function, durability, orperformance produced after tooling has been inactive for volume Production fortwelve months or and Process changes that impact fit, form, function, performance, and/or durability of the salable Ralf Gl 29 vom 2007 by ner, D-85221 Dachau, +49-8131-53595, : Submission to Customer1. a new part or product ( : a specific part , material, or color notpreviously supplied to this specific customer)2. correction of a discrepancy on a previously submitted part3. engineering changes to design records, specifications, ormaterials for Production product/ part number(s)4.