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May 30, 2022 Tags: importance of PPAP, Initial Process Studies for PPAP, PPAP, PPAP process
Initial Process Studies used for to measure the consistency of the process or product performance based
on specified design by reaching consistency of the product quality and performance. Initial Process
Studies helps to manufacturers to reduce wastages, reworks, over processing. Involvement of control chart
disclose the status of process performance and product quality to manufactures by real time consideration
of SPC (Statistical Process Control). Whether manufacture choosing real time Initial Process Studies can
avoid and control the special cause variation on process and product. Moreover can focus on process
improvements and defect free products.
PPAP Process Model with feedback:
Purpose is to determine if production process is likely to produce a product that meet customer
requirements
Initial process capability and performance to be determined for all special characteristics
designated by customer or organization
Customer concurrence to be obtained on Indices for estimating process capability prior to
submission ( Cpk, Ppk).
Initial studies focus on variables and not attribute data
May be replaced by long term historical data from similar process- customer concurrence needed
For bulk material – customer agreement required
Index>1.67-acceptable
For Index between 1.67 and 1.33, customer agreement needed
Index <1.33 currently not acceptable.
Initial process capability acceptance criteria is only one of a number of requirements that leads
to PPAP approval
Process Capability:
Calculate the appropriate statistical metrics in order to determine how the “Voice of the Process” compares
to the “Voice of the Customer.”
Capability Indices:
Cp – Relates short term (within subgroup) standard deviation to tolerance. Sometimes called
“Entitlement,” meaning it is the best the current process can do, if centered
Cpk – Relates short-term mean & short term (within subgroup) standard deviation to tolerance.
Only tells you about the nearest spec limit; doesn’t tell anything about the other side
Pp- Relates long term (overall) standard deviation to tolerance
Ppk – Relates mean & long term (overall) standard deviation to tolerance
Only tells you about the nearest spec limit; does not tell anything about the other side
Difference between Cp & Cpk:
The supplier is new to customer , but has already been manufacturing a part
The supplier is existing, but has produced a number of nonconforming parts