Professional Documents
Culture Documents
P P A P Manual
P P A P Manual
Ralf Glner
PPAP
+49-8131-53595, www.glaessner.de
PPAP_engl.PPT vom
13.01.2007
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PPAP
+49-8131-53595, www.glaessner.de
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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
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PPAP
Contents
1.
Introduction
2.
PPAP
General
PPAP Process Requirements
Customer Notification and Submission Requirements
Submission to Customer - Levels of Evidence
Part Submission Status
Record Retention
3.
4.
5.
Summary
6.
Internet Links
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PPAP
1. Introduction
it is the purpose of advanced quality management
to prevent that unreliable designs or processes
are used in serial production
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PPAP
EXPENSES
...saves the
major part of
the cost!
PROJECT TIME
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PPAP
errors
over
production
stock
muda
in the process
muda
Design ignoring
the customers
expectations
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PPAP
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PPAP
lower
stocks
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PPAP
no scrap, no rework
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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,
PPAP
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PPAP
Contents
1.
Introduction
2.
PPAP
1.
General
2.
3.
4.
5.
6.
Record Retention
3.
4.
5.
Summary
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2.
PPAP
PPAP
Introduction
Section 1
General
Section 2
Section 3
Section 4
Submission Levels
Section 5
Section 6
Record Retention
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PPAP
Appendicies
Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
Appendix F
Appendix G
Appendix H
Glossary
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PPAP
Contents
1.
Introduction
2.
PPAP
General
PPAP Process Requirements
Customer Notification and Submission Requirements
Submission to Customer - Levels of Evidence
Part Submission Status
Record Retention
3.
4.
5.
Summary
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PPAP
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PPAP
Applicability (
PPAP, Introduction)
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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
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PPAP
Contents
1.
Introduction
2.
PPAP
1.
General
2.
3.
4.
5.
6.
Record Retention
3.
4.
5.
Summary
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PPAP
(2.) 2.
2.1
2.2
PPAP Requirements
2.2.1
2.2.2
2.2.18
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PPAP
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PPAP
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PPAP
Warrant
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PPAP
4. Design-FMEA
6. Process-FMEA
7. Control Plan
9. Dimensional Results
17. Customer-Specific
Requirements
18. Part Submission Warrant
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PPAP
Paperwork or EDP?
PPAP?
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PPAP
Contents
1.
Introduction
2.
PPAP
1.
General
2.
3.
4.
5.
6.
Record Retention
3.
4.
5.
Summary
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PPAP
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.
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PPAP
2.
production from new or modified tools (except perishable tools), dies, molds,
patterns, etc., including additional or replacement tooling
3.
4.
5.
6.
product produced after tooling has been inactive for volume production for
twelve months or more
7.
product and process changes that impact fit, form, function, performance,
and/or durability of the salable product
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PPAP
2.
3.
4.
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PPAP
Contents
1.
Introduction
2.
PPAP
1.
General
2.
3.
4.
5.
6.
Record Retention
3.
4.
5.
Summary
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PPAP
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PPAP
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PPAP
I want
I need
I wish
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PPAP
S = submit
retain a copy at an
appropriate
location, (including
manufacturing)
R = retain at
appropriate locations
(including manufacturing)
has to be made
readily available to
the customer
representative upon
request
* = retain at
appropriate locations
submit upon
request
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PPAP
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PPAP
Contents
1.
Introduction
2.
PPAP
General
PPAP Requirements
Customer Notification and Submission Requirements
Submission Levels
Part Submission Status
Record Retention
3.
4.
5.
Summary
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PPAP
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PPAP
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PPAP
Approved
Interim Approval
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Rejected
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PPAP
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PPAP
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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
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PPAP
Contents
1.
Introduction
2.
PPAP
1.
General
2.
3.
4.
5.
6.
3.
4.
5.
Summary
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PPAP
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PPAP
Contents
1.
Introduction
2.
PPAP
General
PPAP Requirements
Customer Notification and Submission Requirements
Submission Levels
Part Submission Status
Record Retention
3.
4.
5.
Summary
+49-8131-53595, www.glaessner.de
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PPAP
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PPAP
Time frame:
Preparation 15 min.
2007 by R.Glner, D-85221 Dachau,
+49-8131-53595, www.glaessner.de
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PPAP
Contents
1.
Introduction
2.
PPAP
General
PPAP Requirements
Customer Notification and Submission Requirements
Submission Levels
Part Submission Status
Record Retention
3.
4.
5.
Summary
+49-8131-53595, www.glaessner.de
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PPAP
Warrant
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PPAP
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PPAP
4. Design-FMEA
6. Process-FMEA
7. Control Plan
9. Dimensional Results
17. Customer-Specific
Requirements
18. Part Submission Warrant
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PPAP
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PPAP
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PPAP
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PPAP
4.4
Design-FMEA
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PPAP
see QS-9000
APQP
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4.6
PPAP
Process-FMEA
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4.7
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PPAP
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
QM-Plan
according to
QS-9000
APQP
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PPAP
4.8 Measurement
System Analysis
Studies
the organization shall have applicable Measurement System
Analysis Studies (e.g. Gage R & R) for all new or modified
gages, measurement, and test equipment
See QS-9000
MSA (Measurement System Analysis
reference manual.
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PPAP
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PPAP
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PPAP
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PPAP
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PPAP
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PPAP
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PPAP
PPAP
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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,
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4.11
PPAP
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PPAP
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
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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)
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SPC (Statistical
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PPAP
Turning
Point
Mean Value x
Standard Deviation s
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PPAP
under control
capable
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PPAP
Example
Process
Capability
Index
Comment
No capability
High amount of
scrap
No capability
If centered pretty
exact, just about no
scrap
Statistically no scrap
No capability
Not centered
Scrap
Index
Good capability
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Process is centered
enough
Little scrap
Example 1 to 3
Process adjusted
exactly to center
of tolerance
interval
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PPAP
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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,
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PPAP
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PPAP
examine capability
continue with 4.11.3
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PPAP
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PPAP
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PPAP
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PPAP
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PPAP
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PPAP
PPAP, appendix B
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PPAP
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PPAP
PPAP
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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.
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PPAP
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PPAP
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PPAP
Warrant
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PPAP
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PPAP
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PPAP
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PPAP
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PPAP
Contents
1.
Introduction
2.
PPAP
General
PPAP Requirements
Customer Notification and Submission Requirements
Submission Levels
Part Submission Status
Record Retention
3.
4.
5.
Summary
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PPAP
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PPAP
Summary
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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
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