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Production Part Approval Process(PPAP)

Table of contents

1 Terms ...................................................................................................... 2
2 Resposibilities ..................................................... Fehler! Textmarke nicht definiert.
3 Details ...................................................................................................... 2
3.1 General ....................................................................................................................... 3
3.1.1 Commitment for execution of the PPA instruction .........................................................3
3.1.2 Approvals of other MS sites .................................................................................... 3
3.1.3 Possible trigger events for a PPA ............................................................................. 3
3.1.4 Performing PPA Procedure ....................................................................................... 4
3.1.5 Submission Level ................................................................................................... 4
3.1.6 Period of archiving ................................................................................................. 5
3.1.7 Result of approval .................................................................................................. 5
3.1.8 Form of the documentation ...................................................................................... 6
3.1.9 Preparing PPA....................................................................................................... 6
3.1.10 Noncompliance ....................................................................................................... 6
3.1.11 State of the art of science and technology ................................................................. 6
3.1.12 Zero defect strategy ............................................................................................... 6
3.1.13 Traceability............................................................................................................ 6
3.1.14 Other samples/ Submission level other ................................................................... 7
3.1.15 Additional information .............................................................................................. 7
3.1.16 Schedule of first article inspection ............................................................................. 7
3.1.17 Labeling of the samples .......................................................................................... 7
3.1.18 Maturity workshop (supplier day) ............................................................................. 7
3.1.19 Process release ..................................................................................................... 7
3.1.20 Supply of sample parts and first article inspection documentation ....................................8

3.2 Attachments.................................................................................................................. 9
3.2.1 Attachment Parts History (example) ...................................................................... 9
3.2.2 Attachment Evaluation Matrix First Article Inspection ................................................. 10

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1 Terms
AIAG Automotive Industry Action Group
APQP Advanced Product Quality Planning
PAA Production Action Authorization
CAD Computer Aided Design
Cpk Process capability parameter (see SPC Manual from AIAG)
PSW Part Submission Warrant
FMEA Failure Mode and Effect Analysis
MS Maschinenfabrik Spaichingen
PPAP Production Part Approval Process
PPA Production Part Approval
Q Quality
QAA Quality Assurance Agreement
SOP Start of series Production
VDA Verband der Automobilindustrie e.V.
IMDS International Material Data System

2 Responsibilities

Quality Management MS is responsible for updating this instruction and controlling of the compliance of its
requirements.

3 Details
The supplier is only authorized for delivering automotive series parts to MS Spaichingen hereinafter
referred to as MS- after the official approval of the production process and the product. MS will approve
the process and the product in the case the requirements of the following instruction are met.
Additional attention should be paid to the QAA.

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3.1 General

3.1.1 Commitment for execution of the PPA instruction


According to ISO TS 16949 the supplier is requested to perform a production process and product
approval to achieve the release for series production. In general the requirements of APQP, PPAP
according to AIAG is preferred. VDA Part 2 in its actual version is possible for use.

For a whole scope of supply as well as for included single parts MS may require a warrant.
While this document shows discrepancies to other customer requirements, the harder requirements are
binding.

The following matrix is preferred, while content of this document shows no discrepancies:

site Procedure to be used


MS Spaichingen GmbH VDA Document N 2 in its actual version
MS Precision Components LLC. APQP, PPAP according to AIAG requirements
MS Industries LLC
MS Powertec GmbH VDA Document N 2 in its actual version

3.1.2 Approvals of other MS sites


In the case the supplier has already performed a PPA process to other MS sites with a positive result,
and there is no trigger for a new PPA, the supplier is not requested to perform the same PPA a second
time. In such a case there is only a PPA according to VDA part 2 , chapter 4.5 or PPAP level 1
required.

3.1.3 Possible trigger events for a PPA


All changes made on the production process and the parts have to be reported to MS. As far as nothing
different is already agreed, the following matrix has to be used

Trigger event Performing PPA Information to


PPF purchase dep.,
supplier
Management
New part x
Product change x
Transfer of production x x
Change of the production process x
Change of a test/ inspection x
Production stoppage, (over 12 months) x
Use of new, modified or spare tools (does not apply x x
to machining tools)
Change of supplier (MS 2nd tier). For parts with x x
special characteristics (safety or homologation

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relevant) the above requirement does apply


downwards until to the characteristic responsible
supplier
Change of buy parts of the supplier x x
New first article inspection x
Requalification of parts and/ or processes anually x
Prototype parts Instruction for x
"other submision
level

3.1.4 Performing PPA Procedure


In the case a PPA is triggered by the supplier, the supplier has to report this to MS 6 months before
the planned implementation starts. In special cases a different proceeding can be agreed with the
responsible MS site.

The supplier will supply sample parts for PPAP according the mentioned schedule also without special
production order and unpaid unless MS has waived the shipment of samples formally.
The supplier is requested to supply dimensional test results for uncoated parts in the case coated parts
require dimensional test results.
For casting and forging parts the supplier is requested to create cuts and perform measurements
referencing to the CAD model as defined to have evidence of required radii and wall thicknesses. The
cutted parts have to be submitted with the sample parts.
The supplier is requested to obtain a PAA from MS before shipping parts to MS site if parts dont comply
with the required specifications. Before the PAA expires the supplier has to perform PPA again with an
optimized version.
In the case special characteristics are not defined by MS or the customer of MS the supplier is requested
to define in minimum one characteristic autonomous. Special characteristics have to be analyzed with SPC
during production. Process capability studies are required for prototype parts as well as for initial sample
parts. Until the required capability values are met, all the parts have to be checked 100%. This is also
required if the capability values are not achieved or differences are detected. As long as the required
capability values are met, testing according control plan is essential.
As minimum the following values are required for SPC, while nothing different is agreed by MS in writing
form:

-machine capability Cmk 2,00


-long term capability Cpk 1,67
-short term capability Ppk 1,33

3.1.5 Submission Level


As long as nothing different is agreed between MS and the supplier, submission level 2 is required.
For prototype parts submission level other is binding.

N requirements (Characteristics specified according VDA) Submission Level


1 2 3 Other

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1 Warrant x x X X
2 Test results (e.g. dimension, function (approval from X x X
Daimler), material (e.g. resistance, physical
characteristics), process capability, weight, etc.)
3 Sample (numbers per cavity; for color samples differing 5 5 5 1
only 2 parts)
4 documents (e.g. blue prints and CAD-Data, Specs, x X E
released design changes, etc.)
5 Design- development releases of the supplier in the x X X
case of design responsibility
6 System FMEA Product E E
7 System FMEA Process E E
8 Process flow chart (production and inspection steps) X x
9 Control Plan E E
10 Test/ inspection equipment X
11 MSA, Gage R&R, there appropriate (results) x X X
12 Evidence of requirements by law, as far as agreed with E E E E
MS (e.g. environment, safety, recycling)
13 Material data sheet per IMDS (ID-Nr. has to be shown x x x X
on the warrant) and paper form
14 Software test report, it applicable - - - -
15 Bill of material, if required by MS with blueprint - - -
16 List of all worker instructions and test instructions with E E
release level
17 Tooling list (with quantity / numbers of cavities and x x
tooling quality)
18 Evidence of achieving the required cycle time, e.g. E E
production test results
19 Overview of buy parts and inbound parts of the supplier x x
with release level for part and process
20 Approval in writing form according characteristic matrix x x X
maturity degree part and process
21 Parts history for quality x x x
22 Parts labeled as PPAP parts X X X X
23 Approval of paint system by MS if applicable - -

X = requirement for submission level, E = only available for inspection at suppliers site, documentation
stays at supplier site

3.1.6 Period of archiving


All documents of the PPA process have to be archived in a readable version for a period of 15 years
starting after ending of series production
If required by, the documentation has to be made available for MS.

3.1.7 Result of approval


The result of the approval will be reported to the supplier in the form of a report (e.g. signed warrant)
If the IMDS System is used, the evaluation of the IMDS pages will be performed by the IMDS-System

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3.1.8 Form of the documentation


The documentation has to be submitted in electronically form (e.g. pdf). MS has the authorization to
inspect all product and process related documents regarding design or production of the product in the
manner of analysis.

3.1.9 Preparing PPA


In front of and respectively during PPA process MS performs maturity evaluations for special chosen parts
in cooperation with the supplier.

3.1.10 Noncompliance
If the agreed first article inspections (per maturity degree) do not end in a release and the supplier has
to represent the negative result, the supplier has to cover all cost caused by an additional PPA (cost
which are in direct context with the PPA)

3.1.11 State of the art of science and technology


The supplier has to make evidence meeting the requirements of product liability law and that the products/
services are state of the art of science and technology.

3.1.12 Zero defect strategy


The special regulations of the QAA-document have higher priority for Zero defect strategy as regulations
below:
The supplier has the responsibility for supplying parts without defects. The zero defect strategy has to be
secured by quality assurance and documented evidence of conformity. Are offenses against Zero defect
strategy foreseeable, the supplier has the responsibility to inform MS immediately.
The analysis and evaluation of the Machine and process capability is based on VDA Part 4 , MSA
according VDA part 5 or MSA 4th edition while anything different is agreed (e.g. QAA or APQP, PPAP is
binding).

In the case the supplier is responsible or has a share of responsibility for design of the scope of supply,
the vendor has to define special characteristics for safety relevance and homologation relevance by himself,
all products and/ or documents have to be marked correct. The marking has to be done according MS
or other customer requirements. In the case no requirements are available, the supplier shall use his own
requirements. For all countermeasures which are derived from marking the supplier is responsible for
implementation. All related documents have to be archived according to the requirements of this document.

3.1.13 Traceability

For traceability of parts the supplier is requested to label all special defined parts with a consecutive
number or a batch number and respectively with the production date, cavity number.
The scope of parts and the way of marking/ labeling will be defined by MS or its customers.

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3.1.14 Other samples/ Submission level other


The supplier has to prepare PPAP type other samples (see PPAP) according to the requirements
agreed between MS and the supplier or as shown above.
All the tests and documentation required has to be done analogously for PPAP.
Differences between the used production conditions and the serial production conditions have to be
announced to have the possibility to evaluate them.

3.1.15 Additional information


The supplier is requested to provide MS and its customers with information on responsibilities, contact
persons, organization, technical documents, time schedule, toolings, test equipments, process capability,
Quality methods, sub-suppliers as well as PPAP in writing form.
Changes have to be announced immediately.

3.1.16 Schedule of first article inspection


The supplier has to develop a part specific test concept, define test characteristics and has to choose and
to buy the test equipment.
All planed activities to prepare the first article inspection have to be agreed with MS. The supplier shall
document this in a time schedule. In special cases it may be agreed between MS and the supplier to
reduce the scope for first article inspection. All changes on product and process have to be noted in the
parts history (please see attachment).

3.1.17 Labeling of the samples


Beginning with the first delivery of sample parts the supplier is requested to label the products as sample
parts according to the parts maturity level (mistake proofing).
The carriers as well as the parts have to be clearly tagged with a label or an adhesive tag. The
following shall be noted on the tag: the annotation sample parts, part number, change level, production
date, order number, for electronic parts with a memory/ control unit or software additional the software
release number and the hardware release number (this shall also be listed in the parts history).

3.1.18 Maturity workshop (supplier day)


If required MS and/ or its customers will arrange a maturity workshop with the goal to evaluate the
achieved maturity level of the products and the linked processes of the supplier.

3.1.19 Process release


On demand of MS or its customers, particularly for critical parts/ processes, the release of the production
process shall be done on supplier site during the production trial run of the supplier.
To achieve a process release only series tools and series production equipment with series processes
(e.g. material, tools, processes, quantity, cycle time, personnel and production site) shall be used. The
responsible person for quality and other departments shall be involved.
MS has to be informed early enough to ensure the possibility to participate the production test.
The process will be released, when evidence of fulfillment of all requirements is given. The all over
release has to be done on the agreed deadline at latest.

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Process objectives restricted release release without restrictions


deadline Production test 1 last production test
supplier, if more than supplier
one planed
tools equipment, facilities, ok ok
devices
logistic chain conditionally ok ok
cycle time, quantity conditionally ok ok
personnel conditionally ok ok
Process capability conditionally ok ok
test devices, test benches conditionally ok ok
Production process of conditionally ok ok
vendor parts

For the chosen scope of supply the supplier has to produce in minimum the quantity for one shift and in
maximum the quantity for 3 production days during the last production test (variations can be agreed if
required). The production test has to be carried out under peak production conditions.
For complex or critical parts from sub suppliers the vendor has to carry out production releases in an
analogous procedure, where applicable with participation of MS or its customers. The required scope has to
be agreed with the Supplier Management of the goods receiving MS site.

3.1.20 Supply of sample parts and first article inspection documentation


Capable parts for PPAP are meeting the objectives of the Evaluation Matrix for First article inspection
(see attachment). In general the supply of sample parts is free of charge.
In the case the delivery of parts is in general as assembly, the vendor has to supply additional samples
apart with separate documentation if required by MS. In special cases MS will agree with the vendor the
supply of jigs, test devices and/ or models which are in possession of the vendor together with the
samples.

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3.2 Attachments
3.2.1 Attachment Parts History (example)

Parts History
Quality

Vendor: Vendor N.:


Part name: Part number:
Consecuti date
Change
ve Date of
Change index
number change Sample parts Series start
drawing
Index

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3.2.2 Attachment Evaluation Matrix First Article Inspection

ok conditional ok (PAA required) not ok


pre- mass production tool meets
customer requirements and
tools mass production tool accepted by MS (durability in experimental tool
minimum until mass production tool
released)
dimensional ok after rework by the
dimensional ok, no vendor or uncritical dimensions not
dimension dimensional not ok
rework required ok

surface structure, color/


ok, no sink marks, no just acceptable, conform to significant deviations/
grain
waviness borderline part compliance not proven

no mass production material or no mass production


mass production material, differences ins production process, material, material data
material material specs. met material specs not met, sheet not available, not
But PAA available/ no material conform to material
data sheet or incomplete specs
can be used without
can be used with expenditure of
build ability expenditure of time or not usable
time or money
money
function not ok, does
function fulfilled, complies spec not met, but only marginal
function not comply with spec.
with spec. deviations, PAA available

rejected or not
vendor parts approved conditional approved
approved

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