Professional Documents
Culture Documents
Revision 07/28/08
Division PPAP Training Agenda
Supplier PPAP Training 3-4 Hour Suppliers Still more in depth with
Quality focus on key topics and
participation exercises
Benefits of PPAP Submissions
Developed by AIAG originally in 1993 for the Automotive Industry with input from the big
three OEM
OEM’ss.
Cooper’s
C ’ PPAP requirements
i t are ttargeted
t d ttowards
d di
directt material
t i l suppliers
li ((external)
t l)
What is the purpose of PPAP Submissions?
To provide the evidence that all customer engineering design record and specification
requirements are properly understood by the manufacturing organization.
To demonstrate that the manufacturing process has the potential to produce product
that consistently meets all requirements during an actual production run at the
quoted production rate
rate.
PPAP data must be submitted from a “significant production run”, which is identified by
AIAG as 300 consecutive pieces sampled randomly (unless otherwise agreed upon by the
customer and supplier).
AIAG
Submission requirements are called Elements
PSW
Level 1 Warrant
PPAP Standard is a Framework
only and Appearance Standard
Approval Report as requested submitted to the customer.
Atto:
Applied the"Non-critical" parts, "non
customer’s discretion critical" to
(Cooper) raw/bulk material
define the or within
picture catalog/
thecommodity
frame parts for
electrical applications and re-certification of existing parts previously approved by Cooper at
levels 3, 4 or 5. Also used for Self Certification
Levels are defined by AIAG and the Customer
AIAG
Level 2 Warrant withhas
product samples the
pre-determined andgeneral
limitedapplication.
supporting data submitted to the customer.
Applied to: Critical
Customer hasBulk products
discretion to such
applyasthePlastic/Paint/Chemicals,
specific application. critical fasteners, simple
material
t i l changes,
h simple
i l revision
i i llevell only
l changes
h or simple
i l print
i t updates
d t nott affecting
ff ti fform-fit-
fit
function. This level can also be applied to low and medium risk parts within a product family.
Level 3 Warrant with product samples and complete supporting data submitted to customer.
Default Cooper
p Industries Submission Level Applied pp to: New p parts on Cooper
p p programs.
g
Changes affecting form-fit-function, reliability, or performance. All product resourced to new
suppliers, serial production parts, existing high risk parts undergoing a part number change.
Level 4 Warrant and other requirements as defined by the customer. This level is reserved for special
applications only.
only Applied to: This level can only be applied with prior approval from the
designated divisional Cooper Quality PPAP representative.
Level 5 Warrant with product samples and complete supporting data reviewed at the supplier's
manufacturing location. Applied to: On site review as requested by each Cooper Division.
Supplier Checklist for PPAP
U
Use off a paper or emailil submission
b i i must h
have prior
i approvall by
b the
h authorized
h i d
SQ or Quality representative.
Recommendation:
Review and Approval process will be managed by each Cooper division
division.
Each Cooper Division will determine how to apply “status” of a submission.
Purpose:
To document ppart approval
pp
To provide key information
To declare (warrant) that the parts meet specification
The approved PSW officially warrants the parts ready for production
Element 1 Part Submission Warrant
E1 PSW
Reviewer’s Checklist
Must be signed
g by
y the supplier
pp
Purpose:
To document & p provide a copy
py of the formal p
part p
print.
All part prints must have clearly defined CTQ’s
To provide any additional engineering records for reference.
Print bubble number must correspond to the “Item” number on the Dimensional
E2 Design Records and & Bubbled Part Prints
Reviewer’s Checklist
Purpose:
To p
provide any
yppertinent change
g information for reference
This is a p
placeholder for all relevant information not covered in the p
part p
print.
ECN’s
Specifications
Feasibility studies
Supplier Change Requests
Emails
Sub assembly drawings
Life or reliability testing requirements
Reviewer’s Checklist
Purpose:
To demonstrate p
pre-approval
pp by
y Cooper’s
p customers of a design
g
DFMEA
A
DESIGN Failure Mode and Effects Analysis
PFMEA
PROCESS Failure Mode and Effects Analysis
AIAG FMEA
E5 Design FMEA (DFMEA)
Purpose: To show evidence that potential failure modes and risk have been
addressed at the design
g level.
AIAG FMEA
E5 Design FMEA (DFMEA) Template
E5 Design FMEA (DFMEA) EXAMPLE
Reviewer’s Checklist
DFMEA is only required if designed by the supplier.
Purpose:
To document the entire manufacturing gpprocess for a p
part
To clarify the steps in manufacturing the part.
The process flow should clearly identify each step in the process
E6 Process Flow Diagrams Examples
E6 Process Flow Diagrams
Reviewer’s Checklist
Process Flow must identify each step in the process
s
Each Line item step in the flow numbered
Match both PFMEA and Control Plan
Process
P Flow
Fl must include
i l d allll phases
h off the
h process
Receiving of Raw Material
Part Manufacturing
Offline inspections and checks
Shipping
Assembly
E7 Process FMEA (PFMEA)
Purpose: To show evidence that failure mode and risk have been assessed at
the Manufacturing
g Process level.
Reviewer’s Checklist
Verify
Address allisCritical
there a systemto Quality characteristics
for prioritizing risk of CTQ.
failure such as top 25 or 33% of RPN numbers.
Show evidence of an objective process evaluation.
Discourage suppliers from setting RPN thresholds
Evidence of cross functional participation.
Arbitrary
Scoring becomes biased
Severity, Occurrence and Detection must be compliant
Make
with AIAGG that
sure guidelines
high RPN andprocess
scored within reason.
concerns are
carried over into the control plan.
Make sure that action is being taken on higher RPN
Make
line items & the
sure that allaction
criticalwill actually
failure modeshave impact.
are addressed
Safety
Form, Fit, Function
Material concerns
E& PFMEA Exercise
Over estimating
g the effectiveness of a “Recommended Action”
Applying thresholds.
Not recognizing
g g all p
potential failures.
Misapplication
pp of ranking
g scales.
Allowing
g the PFMEA to turn into a design
g review.
E8 Control Plan
All process must have a control plan that defines all methods used for process control
and complies with customer-specified requirements.
Suppliers should also include other details they know to be vital to the process.
Specifically
Specifically, the control plan should address the following:
Methods of production
Identification of CTQ characteristics’ controls
Secondary or outsourced operations
Materials and their physical and chemical characteristics
Types of process equipment at each operation
Types of test equipment used to measure each characteristic
Specifications,
S ifi ti sampling
li strategy,
t t control
t l and d reaction
ti methods
th d used
d
Periodic conformance testing and product verification
CTQ Characteristic:
AIAG APQP
(contains the Control Plan
Methodology and concepts)
E8 Cooper Control Plan
Reviewer’s Checklist
C
Control
Goodt Control
l Pl
Plan requires
i addresses
Plans hi
highest
h td degree off scrutiny!
all testing ti !
requirements
Dimensional
Must
Material
define a robust level of process control!
Performance
Address every Critical To Quality characteristic
Address all product and process characteristics at
Evaluation
every step methods must
throughout theensure
process.conformity.
Effective reaction
The “Control plans
Method” that control
should the on
be based process.
an effective
analysis of the process such as:
Must address
SPC periodic performance
Inspection testing
Periodic DimensionalSampling
Error proofing confirmation
Plans.
Performance testing
Can and should reference other documentation
Cannot
Specifications
S be ifi excessively
ti dependent on visual inspection
inspection.
Tooling
E9 Measurement System Analysis (MSA)
Importance:
Ensures we are using the right measurement system for running production. There
are two fundamental questions:
Are we using the right gage?
Are we using it correctly?
Measurement variation can make our processes look worse then they really are with
respect to capability.
Reduces the opportunity for passing a bad part & rejecting a good part
E9 Measurement System Analysis (MSA)
Detail on MSA is found in the AIAG manual (3rd Edition) which defines
guidelines for:
g
Stability
Bias
Linearity
Repeatability and Reproducibility.
Ideal Inspector A
Process
Target
2
2 o
g Inspector B
Inspector B
E9 (MSA) Gage R&R Study
Reviewer’s Checklist
IfAll
thegages
gage/inspection
and t affects
d systems th quality then
thatt measure GRR
GRR.
CTQ’
CTQ’s mustt
have a Gage R&R.
Make sure the study is recent , less than 1 year
Keyey gages & inspection
spect o pprocesses
ocesses tthat
at a
are
e pa
partt o
of
Compare control plan
the manufacturing gages against
processes shouldactual GRRs
also have GRR.
IfGage
you question the gage,
R&R results must then
followask
thequestions
approval %
Question the technique
> 30% must and part
have corrective sampling
action
Ask for additional studies
Request
Should Bias, Linearity
encourage suppliers&toStability
use Total Tolerance
Make surequality
Consult discrimination
if there isvs toleranceon
a question makes sense.
the need for a
Rule:
GRR. 1 level MORE
Generally than tolerance
the answer is yes if the gage:
Tolerance=.01,
Measures aThe CTQgage should be .001
Measures the part
Must look at all of
Controls the process
a key followingstep
GRR study results
%GRR, %EV and
Performs %AV.
a functional test
E9 (MSA) Gage R&R Study Example
Cooper requires a full dimensional layout of the part on all PPAP submissions
except level 1.
Reviewer’s Checklist
Ensure
E “M
“Method”
th d” iis on every measurementt
Cooper requires results for all print requirements that require testing
1. “Notes” that specify a requirement (tensile strength)
2. “Specifications” detailed on a print. (ex: NEMA, CSA or UL specifications)
Cooper does not require any specific format for test results.
Utilize in-house
in house documents
Utilize the AIAG forms
Make sure the need for a test plan has been evaluated
E11 Examples of Material Test Results
C11 Examples of Performance Test Results
E11 Material, Performance Test Results
Reviewer’s Checklist
Utilize
P f this section
Performance should
h told get
iinclude
l more
d confirming:
fi i
information that could
Any formal
become specification
a significant referenced
quality issue at a later date.
Any formal life testing
Any specific functional test
Most parts have some type of material requirement so
make suppliers
Sometimes prove theyishave
performance a system
not directly for checking.
addressed via
the part print and therefore.
Material results should
Reference g be
through pcompared against a known
a specification
standard.
t d Referenced
d DDo nott assume th
the ttestt result
through Note lt spec is
i correct.
t
Verify
Impliedthe correct
through specification (ex:ASTM xxxx)
a requirement
Verify the composition breakdown
The resource for pperformance and functionalityy is
Verifying composition
Cooper design is not JUST for PPAP, it should
engineering.
be a periodic check that is identified in the CP.
Always probe for the need to demonstrate performance
if it is not on the print.
E12 Initial Process Study (Cpk/Ppk)
Capability studies are critical for verifying that processes are in control!
E12 Initial Process Study (Cpk/Ppk)
If testing
t ti involves
i l destructive
d t ti testst t off expensive
i parts,
t Cpk
C k by
b Moving
M i Range
R
can also be allowed.
Cp ≥ 1.67
1 67 Cp ≥ 1.67
1 67
Cpk ≥ 1.67 Cpk < 1.00
LS USL LS USL
L L
Capable, Centered Capable, Not Centered
Cp < 1.00
C 1 00 Cp < 1.00
C 1 00
Cpk < 1.00 Cpk < 0
LS USL LS USL
L L
Not Capable, Centered Not Capable, Not Centered
E12 Initial Process Study (Cpk/Ppk) – Good Process
Centered
Defects Defects
LSL USL
Lower Spec Upper Spec
Limit Limit
E12 Initial Process Study (Cpk/Ppk) – Bad Process
Results are not centered
Not
Centered
Defects Defects
LSL USL
Lower Spec Upper Spec
Limit Limit
E12 Initial Process Study (Cpk/Ppk)
Reviewer’s Checklist
Make
M k sure th
the results
lt are acceptable,
t bl process iis stable
t bl
and capable of producing a quality part.
Capability
p y is required
q for all CTQ’s
Q
Minimum Cpk, Ppk, is division specific
AIAG SPC
Statistical Process Control
E13 Qualified Lab Documentation
Purpose: To demonstrate that the inspection and testing for PPAP has been
performed by
p yaqqualified lab.
Reviewer’s Checklist
Third
Thi d party
t llabs
b th
thatt measure parts
t ffor performance,
f
material or dimensional should be accredited.
Reviewer’s Checklist
If no specification
ifi ti or print
i t reference
f exists,
i t ththe reviewer
i
should use requirement for more ‘print” definition.
Appearance Approval Report
Specific
p testing
g to a known standard
Defining limit samples
Purpose: To provide actual samples that reflect the parts documented in the PPAP.
Each Cooper Division should have a defined procedure for delivering & approving parts.
Minimum: Parts should be reviewed by both Quality and Engineering
Ideally: Sample parts are used in a functional part qualification procedure
Sample parts must reflect both the submission and actual production
E15 Sample Parts
Sample parts
E16 Master Sample
Purpose: The original intent was that a “Master” part must be maintained
throughout a products production life for all revision levels.
The
Th automotive
t ti industry
i d t relaxed
l d thi
this requirement
i t iin various
i ways.
Reviewer’s Checklist
Sample
S l PParts
t should
h ld bbe received
i d with
ith every PPAP
submission and examined thoroughly,
Purpose: To provide evidence that the checking aids used to verify product
exist and have been p
properly
p y validated.
Reviewer’s Checklist
If a fixture
fi t is
i used
d to
t check
h k physical
h i l print
i t di
dimensions
i
either in process or off line then it is a checking aid.
Purpose: Provide a placeholder for all customer specific requirements that are
not covered in the first 17 elements of PPAP
PPAP.
Purpose: Approve the packaging method and material for supplied product.
Suppliers
pp are required
q to p
provide p
packaging
g g to Cooper
p facilities that:
Meet all facility related requirements
Ensures the prevention of shipping and handling defects
Addresses any Hazmat related concern
Specification Deviations are not to be used for any purpose other than PPAP
non-conformances and does not replace “temporary deviation requests”
Supplier Checklist documents what has been submitted and all concerns
C18 Customer Specific Requirements
Reviewer’s Checklist
Must
M t be
b presentt if required
i db by L
Levell
!
Formal PPAP Dispositions
PPAPs can have unique division dispositions but these are universal!
!
Division PPAP Review and Approval Process
!
Recommendations – Application Priority