‘Metalman Auto Pvt.Ltd. DAY 2: PPAP 26.03.2019 Shreoyash Consulting a CORE TOOLS Aeetas Shveoyast Consulting Shreeyash Consulting 24/03/2019Metalman Auto Pvt.Ltd. CORE TOOLS - PPAP rrectast Production Part Approval Process ( PPAP) defines generic requirement {or Production pat approval, inchising production andBulk Material . Purpose is 10 determine if all cusiomer Engineering design record and specification requirements are propery understood by the organsiation and the manutacturing process has the potential fo produce product consistently meeting these requirements during an actual prodvction run at the quoles production rate PPAP shall apply 12 intemal and extemal organisation sites supplying production arts , service parts ,\production material or bulk material, ~ For bulk materials, PPAP is not required unless specified by the authorised customer representative. For Catalogue products , PPAP unless formally waived by the authorised customer represeriative, “ Shreeyash Consulting é 3 CORE TOOLS - PPAP IPPAP's purpose contifues to be to provide the evidence & confidenée to Customer that all Customer engineering design record and specification requirements related to Product, Process & QMS are properly reviewed, understood & agreed by the Organization and that the Organization's manufacturing processes, QMS & Infrastructure has the ability to produce & Supply Parts as per Customer requirement which will consistently meet Quality, Delivery, QMS & Cost requirements of Customer for serial production : conditions. Sheceyash Consult Shreeyash Consulting, 24/03/2019Metalman Auto Pvt.ttd. 24/03/2019 PPAP PROCESS FLOW CHART. raeevat oes ‘Shreeyash Consulting 7 S ‘CORE TOOLS - PPAP ieetar? PAP Submission Criteria “Anew part . - Need of Re-PPAP if initial PPAP is rejected - = Change in Product Design ~ Change in Manulacturing Prasess Design - Noed of Re-PPAP dus to increased Customer Compiaint Trend . ‘ - Periodic Supplier Re-tvaluation requirement of Customer Shreeyosh Consulting . Shreeyash Consulting 3Metalman Auto Pvt.ltd. 24/03/2019 ‘CORE TOOLS - PPAP Drectat PPAP Submission Levels Level 1 : Only PSW tobe submited tothe Customer Level 2: PSW with product samples and limited supporting data (o be submitted to the Customer Level 3 : PSW with product samples and complete supporiing data to be submitted . {0 the Customer (Default Level of PPAP submission) Level 4 : PSW and othor requirements as defined by the Customer (CSR) Level 5 : PSW, PPAP cocumentation, Product samples & actual PPAP run will be witnessed & reviewed! by Cilstomer Representative at the Organization's manufacturing location . Shveoyash Consulting CORE TOOLS - PPAP Srnceras Significant Production Run * For production parts product for PPAP shall be taken from 2 ‘significant production run - * Significant Production Run = : 11 hour to 8 Hours of Production with specific production quantity to total a min. 300 consecutive parts unless other wise spocified by the customer. * Significant productior: run shalt be conducied at the production site at the production ‘ate using production tooling, production gauging, production process, production materia! and production material Shreeyash Consulting a Shreeyash Consulting 4, Metalman Auto Pvt.Ltd. 24/03/2019 CORE TOOLS - PPAP PAP Documentation Requirements Product Design Revors ‘Auborzed Enginewnng change documents Customer Enginearing Ag prov Design FMEA ( Organization it Product design responsi ) Press tow siagrams Process FMEA Control Plan MSA Surtes Dimensional Result Maton! tet rests Inia Process Studies (SC) Qualifies Laboratory Documentation Appearanov Aporoval Repon (lf Appice} Sample Prdcion Parts Maser sample & Lint Semple (it Appicabie} Checking Ais Custoiner Specie Requirements Part Sutmission Warrant Shieayash Consuiting CORE TOOLS - PPAP 1. DESIGN RECORDS + Part drawings, specifizations, CAD data or any documents referenced . = Asingle design recor! can represent multiple part or assembly configurations. For bulk materials + Raw material identification » Formulations Processing stéps & parameters, Final product specifications & acceptance criteria Shreayesh Consulting Shreeyash Consulting “ 5Metalman Auto Pvt.itd. 24/03/2019 CORE TOOLS - PPAP Dhneetar 1. DESIGN RECORDS + Part drawings, specifizations, CAD data or any documents referenced © Assingle design recon! can represent multiple part or assembly configurations, For bulk materials + Raw material identification + Formulations + Processing steps & parameters «+ Final product specifications & acceptance criteria Shreayash Consulting " a CORE TOOLS - PPAP Dreetan . 2 ANY AUTHORISED ENGG. CHANGE DOCUMENT ‘+ Authorized change documents provided by customer incorporated in the part not incorporated in the drawing é 2. CUSTOMER ENGINEERING APPROVAL «* As required by design record + For bulk materials, signature of customer on bulk material approval check list or inclusion of supplier's name in customer list of approved materials ‘Shreayash Consulting 2 Shreeyash Consulting 6\ Metalman Auto Pvt.ltd. a CORE TOOLS - PPAP Dreeetas 4. DESIGN FMEA ‘Applicable to design responsible suppliers ~ for bulk materials, Design Matrix & Design FMEA are prepared as required by bulk material requirements checklist . + Single Design may be applied toa family or similar parts or materials 5. PROCESS FLOW DIAGRAM * As per APQP manual + For bulk materials process flow description satisfies the requirement + Family concep! is acceptable. Shreayash Consulting « = CORE TOOLS - PPAP Dneetah 6 PROCESS FMEA * Compliance to customer requirements (use current version of FMEA Manual) + Process FMEA for faraily of parts - 7. CONTROL PLAN . * As per APP manual & ISO/TS requirement and Customer specific requirement. Family Control Plans are acceptable if the new parts have been reviewed for ‘commonality by the Crganization. Control Pian approval may be required by some Customers, Shreeyash Consulting “ Shreeyash Consulting 24/03/2019Metalman Auto Pvt.Ltd. CORE TOOLS - PPAP aera 8. MEASUREMENT SYSTEMS ANALYSIS STUDIES Compliance to MSA studies as per current version of the reference Manual or as required by Customer, 9. DIMENSIONAL RESULTS Compliance {o control plan & Design Record and all characteristics (except ref Dimensions) « Dimensional results for each production tines, each cavities, molds, patlems, dies Indicate design reocrd, change fevel, authorized engineering. Change document ref. On all reports Identify master sariple which is measured Tracing is required when optical comparator is required Shraayesh Consulting 3 CORE TOOLS - PPAP 10. RECORDS OF MATERIAL / PERFORMANCE TEST RESULTS ~ Complanee to design record / control pian + Record of aly ested on each esis Engineering. Change level o authorized engineering. Change Date of testing Material supplii’s name und ther code ((rom customer approved List) Shreeyash Consuiting 6 Shreeyash Consulting 24/03/2019Metalman Auto Pyt.ltd. 24/03/2019 CORE TOOLS - PPAP 1, INITIAL PROCESS STUDIES + Prior to submission, acceptable level of initial process capability or performance shall be determined with customer. + MSA prior fo intial process studies + For special Characteristics of variabie data + Where there are no special characteristics identified, the Customer reserves the ‘ight to require demorstration of initial process capabilty on other characteristics Shreeyash Consulting a CORE TOOLS - PPAP ‘nrectast + Cpk or Ppk can be as per customer agreement. + Control charts are preferred, # X bar — R charts used, Min, 25-sub groups, frin 100 nos. from significant production run. ~ Use Cpk or Pp + Where historical Cpk data is available for similar parts of same process, Cpk can be capiured. + For chvonivaly unstable processes (within specification) use Ppk * Index valve 2 1.67, Ese CA plan is road. Shroeyash Consulting * Shreeyash ConsultingMetalman Auto Pvt.Ltd. CORE TOOLS - PPAP 12. QUALIFIED LABORATORY DOCUMENTATION + Tin house laboratory és only used for testing / calibration, add laboratory scope + outside laboratory fs used for testing calibration, add .NABL certificate or ‘equivalent of that laboratory * Add scope of accreditation of that tab + Quatiied outside laboratory must be as defined by the Customer. Shreeyesh Consuting CORE TOOLS - PPAP Sa 13. APPEARANCE APPROVAL REPORT (AAR) * Separate report for ‘each part or series of parts, if part has the appearance requirements on design record. + Record af AAR with complete information : AAR applies only for parts with color, grain, or surtace appearance requirements. * Certain customers may not require entries in all AAR fields. 14. SAMPLE PRODUCTICN PARTS: = As per customer nsquest. 24/03/2019 Shreeyash Consulting Shreeyash Consulting a 10Metalman Auto Pvt.Ltd. ~ 24/03/2019 CORE TOOLS- PPAP Srreetesh 4S, MASTER SAMPLE Reiain til new master sample is produced or as per design record requirement for inspection criteria, - For each position of @ multiple cavity, die, tool, mould or pattem, fine Retention period :an be waived or motified by customer 46. CHECKING AIDS Inspection Fixtures, gages. models, templates. elc. specific o the part ~ if more than ane , prspare & refer the kt in PSW including its change level. 2 + Submit ifroquited by customer + Centication of checking aid wrt part dimensions + Demonstration of engg. Change in gauge change + Appropriate MSA studies | Shreeyash Consulting n CORE TOOLS - PPAP . 17 CUSTOMER SPECIFIC REQUIREMENTS Compliance records tc all specific requirements of customer. 48. PART SUBMISSION WARRANT + Separate PSW for each part 0, : . Identity Mould / cavily Tine no, in PSW Part weight shall be rounded off to four decimals derived out of 10 randomly selected parts 10 parts represent ail moulds, cavities. ines as appropriaie. =, Shreayash Consulting: 7 Shreeyash Consulting 1Metalman Auto Pvt.ttd. a CORE TOOLS - PPAP Dredian CUSTOMER NOTIFICATION AND SUBMISSION REQUIREMENTS Shall notily the customer of any planned changes tothe design . process or site. Organisation is responsible Upon notification ans approval of the proposed change by the authorised customer representative and after change implementation . PPAP submission is required unless otherwise spectiod. “Examples of changes requiring notification + Use of other construction or material than was wed in the previously approved ar or product + Production from new or modified tools, dies , molds pattems etc + Production following upgrade oF rearrangement of existing ooking oF equipment + Production from tooling and equipment transferred to a diferent plant ste or from an additional plant site + Change of supplier for pars non equivalent material, bervices |: Sieeyash Consulting CORE TOOLS - PPAP Srreevass ‘SUBMISSION TO CUSTOMER : * Shall submil for PPAP approval prior to the first production shipment * Change of supplier for parts . non equivalent material services * Shall review and upilate al applicable items in the PPAP file to reflect the production process Shreeyash Consulting * Shreeyash Consulting 24/03/2019Metalman Auto Pvt.itd. CORE TOOLS.- PPAP Sareevan PPAP Submission Levels . Level 1 : Only PSW to be submitted to the Customer Level 2 : PSW with product samples and limited supporting data fo be submitted to the Customer Level 3: PSW with product samples and complete supporting data to be submitted to the Customer (Detaull Level of PPAP submission) Level 4» PSW and othar requirements as defined by the Customer (CSR) Level 5 : PSW, PPAP ciocumentation, Product samples & actual PPAP run will be witnessed & reviewed by Customer Representative at the Organization's manufacturing location Shreoyash Consulting ws " GORE TOOLS - PPAP Sovccitash PART SUBMISSION STATUS = * Upon approval of submission, the organisation shall assure thal the future production contiques: {o mee! all customer requirements. CUSTOMER APPROVAL, STATUS * APPROVED : Approves indicates thal the pan of material , including all sub-contractors, meets allcustomer requirements + INTERIM APPROVAL “Permits shipment of material for prod oF piece quantity basis, ion requirements on filed time * REJECTED : Means FPAP submission does nol meet customer requirement based on the [production lot from whch it was taken . In such vases . the submission and for process as ‘appropriate , shall be corrected to meet customer cequitements . The submission shall be approved before produrlion quantities may be shipped. Shreeyash Consuting = Shreeyash Consulting 24/03/2019Metalman Auto Pvt.Ltd. rectant Y CORE TOOLS - PPAP PPAP Submission Levels Level 1: Only PSW to be submitted to the Customer Level 2 : PSW with product samples and limited supporting data to be submitted to the Customer Level 3 : PSW with product samples and complete supporting data to be submitied to the Customer (Default Level of PPAP submission) Level 4 : PSW and other requirements as defined by the Customer (CSR) Level 5 : PSW, PPAP documentation, Product samples & actual PPAP run wil be winessed & reviewec by Customer Representative athe Organization's manufacturing focation Shreeyash Consulting af CORE TOOLS - PPAP Greets ‘Shreeyash Consulting Shreeyash Consulting 24/03/2019Metalman Auto Pvt.Ltd. QUESTION SiStayaynstt Genuniigg Shreeyash Consulting 24/03/2019 15