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Revision 07/28/08
PPAP Training
3 Primary Training Sessions Available
Sessions
Duration
1 hour
Suggested Staff
Focus
Management
Manufacturing
2 Hours
Purchasing
Engineering
3-4 Hour
Suppliers
Quality
Developed by AIAG originally in 1993 for the Automotive Industry with input from the big
three OEM
OEMss.
Coopers
C
PPAP requirements
i
t are ttargeted
t d ttowards
d di
directt material
t i l suppliers
li
((external)
t
l)
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).
PPAP Requirements
AIAG
PSW
Cooper Requirements
1. Design Records
2 E
2.
Engineering
i
i Ch
Change D
Documents
t
3. Customer Engineering Approval, if required
4. Design Failure Modes & Effects Analysis (DFMEA)
5. Process Flow Diagram
6. Process Failure Modes & Effects Analysis (PFMEA)
7 Control Plan
7.
8. Measurement Systems Analysis (MSA)
9. Dimensional Results
10. Material, Performance Results
11. Initial Process Study
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Product
15. Master Sample
16. Checking Aids
17. Customer-Specific Requirements
18 Part Submission Warrant (PSW)
18.
2. D
2
Design
i R
Records
d
3. Engineering Change Documents
4. Customer Engineering Approval
5 DFMEA
6. Process Flow Diagram
7 PFMEA
7.
8. Control Plan
9. Measurement Systems Analysis (MSA)
10. Dimensional Results
11. Material, Performance Results
12. Initial Process Studyy
13. Qualified Laboratory Documentation
14. Appearance Approval Report (AAR)
15. Sample Product
16. Master Sample
17. Checking Aids
18 C
18.
Cooper-Specific
S
ifi Requirements
R
i
t
Tooling information Form
Packaging Form
Inspection Plan (ASC Only)
Specification Deviation
Supplier PPAP Worksheet
Cooper Requirements
Level 1
Full
Partial
Level 2
Level 3 Level 4
Level 5
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
AR
Shall Submit
Shall Retain
Critical Systems
Element Links
2. Design Records
Requirements
CTQs
7. PFMEA
Robust Process
8. Control Plan
9. MSA
Confirm Measurement
18 Cooper Specific
18.
Customer Requirements
DFMEA
Submit
Applied
to: Critical
products
critical fasteners, simple
Customer
hasBulk
discretion
to such
applyas
thePlastic/Paint/Chemicals,
specific application.
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-fitfit
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.
PPAP Requirements
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.
Submission must be received prior to the PPAP due date.
date
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.
PPAP KIT
PPAP Training
Presentation
All other
th requirements
i
t can b
be mett b
by using
i either:
ith
The additional forms in the kit (Preferred Method)
Forms consistent with AIAG guidelines
PPAP Manual
The approved PSW officially warrants the parts ready for production
E1 PSW
Reviewers Checklist
Reference prints
Sub-assembly prints
Component prints with a different part number
Applicable
pp
specifications
p
Print bubble number must correspond to the Item number on the Dimensional
Reviewers Checklist
This is a p
placeholder for all relevant information not covered in the p
part p
print.
ECNs
Specifications
Feasibility studies
Supplier Change Requests
Emails
Sub assembly drawings
Life or reliability testing requirements
Reviewers Checklist
DFMEA
A
DESIGN Failure Mode and Effects Analysis
PFMEA
PROCESS Failure Mode and Effects Analysis
AIAG FMEA
AIAG FMEA
Reviewers Checklist
The entire
Th
ti manufacturing
f t i process (receiving
(
i i th
through
h shipping)
hi i )
All key steps in the process
All offline activities (such as measurement, inspection and handling)
Should identify areas containing nonconforming material
Scrap, defective and rework parts
The process flow should clearly identify each step in the process
Reviewers Checklist
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 PFMEA Exercise
In class exercise For PFMEA
Reviewers Checklist
Address
allisCritical
to Quality
characteristics
Verify
there
a system
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
with AIAG
G that
guidelines
andprocess
scored within
reason.
Make
sure
high RPN
concerns
are
carried over into the control plan.
Make sure that action is being taken on higher RPN
line items
& the
actually
have
impact.
Make
sure that
allaction
criticalwill
failure
modes
are
addressed
Safety
Form, Fit, Function
Material concerns
E8 Control Plan
Purpose: A structured approach for the design, selection and implementation of
control methods used in producing a part.
All process must have a control plan that defines all methods used for process control
and complies with customer-specified requirements.
Can be on the Cooper supplied format or AIAG compliant.
Control Plan should list all operations used in the process.
process
Control Plans must address and include all print CTQs.
Suppliers should also include other details they know to be vital to the process.
CTQ Characteristic:
A critical PART requirement specified on a controlling document (typically an
engineering drawing or specification)
A critical PROCESS requirement identified by Customer or Supplier.
Directly represents the safety, regulatory, or primary functional performance
requirements by the end customer or business
Requires verification of part conformance during first production.
Requires documented evidence of process control to maintain part conformance
through the life of the product
E8 Control Plan
AIAG APQP
(contains the Control Plan
Methodology and concepts)
Reviewers Checklist
Control
t Control
l Pl
Plan requires
i addresses
hi
highest
h td
degree
off scrutiny!
ti !
C
Good
Plans
all testing
requirements
Dimensional
Must
define a robust level of process control!
Material
Performance
Address every Critical To Quality characteristic
Address all product and process characteristics at
Evaluation
must
conformity.
every step methods
throughout
theensure
process.
reaction
plans
that control
the on
process.
Effective
The Control
Method
should
be based
an effective
analysis of the process such as:
Must address
periodic performance
SPC
Inspection testing
Periodic
DimensionalSampling
confirmation
Error proofing
Plans.
Performance testing
Can and should reference other documentation
Cannot
dependent on visual inspection
inspection.
Specifications
S be
ifi excessively
ti
Tooling
Reduces the opportunity for passing a bad part & rejecting a good part
Stability
Bias
Linearity
Repeatability and Reproducibility.
Ideal
Process
Target
2
g
Inspector A
2
o
Inspector B
Inspector B
E9 (MSA)
Reviewers Checklist
thegages
gage/inspection
quality then
GRR
GRR.
IfAll
and
d systems
t affects
th
thatt measure
CTQ
CTQs
mustt
have a Gage R&R.
Make sure the study is recent , less than 1 year
Key
ey gages & inspection
spect o p
processes
ocesses tthat
at a
are
e pa
partt o
of
Compare
control plan
gages against
GRRs
the manufacturing
processes
shouldactual
also have
GRR.
you question
the gage,
IfGage
R&R results
must then
followask
thequestions
approval %
Question
the technique
and part
sampling
> 30% must
have corrective
action
Ask for additional studies
Request
Bias, Linearity
Stability
Should
encourage
suppliers&to
use Total Tolerance
surequality
discrimination
toleranceon
makes
sense.
Make
Consult
if there isvs
a question
the need
for a
Rule:
1 level MORE
than tolerance
GRR.
Generally
the answer
is yes if the gage:
Tolerance=.01,
Measures aThe
CTQgage should be .001
Measures the part
Must look
at all of
the process
followingstep
GRR study results
Controls
a key
%GRR,
%EV and
%AV.
Performs
a functional
test
All dimensions
All applicable notes that have variable dimensions (ex: tensile test)
Any dimensions contained on reference prints.
Tolerances that include bonus for Geometric Dimensioning & Tolerancing (GDT)
Reviewers Checklist
Ensure
E
M
Method
th d iis on every measurementt
Identify all methods make sense for the dimension
Make sure the dimensional report addresses all
print requirements.
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)
Make sure the need for a test plan has been evaluated
Reviewers Checklist
Utilize
P f this section
Performance
should
h to
ld get
iinclude
l more
d confirming:
fi i
information
that could
Any formal
specification
referenced
become
a significant
quality
issue at a later date.
Any formal life testing
Any specific functional test
Material
results should
Reference
through
g be
a specification
pcompared against a known
standard.
t d Referenced
d D
Do nott assume
th
the ttestt result
lt spec is
i correct.
t
through Note
Verify
correct
specification (ex:ASTM xxxx)
Impliedthe
through
a requirement
Verify the composition breakdown
The resource for pperformance and functionalityy is
Verifying
composition
is not JUST for PPAP, it should
Cooper design
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.
Capability studies are critical for verifying that processes are in control!
If testing
t ti involves
i
l
destructive
d t ti tests
t t off expensive
i parts,
t Cpk
C k by
b Moving
M i Range
R
can also be allowed.
Capability is preferred as follows unless otherwise defined:
1.67 or higher on all print CTQs
1.67 or higher on critical process characteristics
1.33 or higher as a default for all unspecified characteristics.
CPK
PPK
Cp 1.67
1 67
Cpk < 1.00
Cp 1.67
1 67
Cpk 1.67
LS
L
USL
USL
LS
L
Capable, Centered
Cp < 1.00
C
1 00
Cpk < 1.00
LS
L
USL
Cp < 1.00
C
1 00
Cpk < 0
LS
L
USL
Centered
Defects
LSL
Lower Spec
Limit
Defects
USL
Upper Spec
Limit
Not
Centered
Defects
Defects
LSL
Lower Spec
Limit
USL
Upper Spec
Limit
Reviewers 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 CTQs
Q
AIAG SPC
Statistical Process Control
Reviewers Checklist
Third
Thi d party
t llabs
b th
thatt measure parts
t ffor performance,
f
material or dimensional should be accredited.
Class A surfaces
Color definition
Grain and texture requirements
Surface appearance requirements
Reviewers Checklist
If no specification
ifi ti or print
i t reference
f
exists,
i t th
the reviewer
i
should use requirement for more print definition.
Appearance Approval Report
Specific
p
testing
g to a known standard
Defining limit samples
Sample parts must reflect both the submission and actual production
Date of Manufacture
Cooper Part Number
Revision Level
Supplier Name
Name of Product (Optional)
Product Serial and Batch Number (Required if applicable)
Supplier Part and Type (Optional)
Approval markings (CL, UL, etc) where applicable
Quantity of Sample (Indicate Partial Shipments)
Procurement Contact, Purchasing Representative, etc
Sample parts
Reviewers Checklist
Sample
S
l P
Parts
t should
h ld b
be received
i d with
ith every PPAP
submission and examined thoroughly,
Reviewers 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.
Used differently by every customer for all types of requirements!
Cooper Industries has 5 specific requirements defined for PPAP submissions.
Supplier Checklist documents what has been submitted and all concerns
Reviewers Checklist
Must
M t be
b presentt if required
i db
by L
Levell
Must be completely filled out and include pictures!
Must be signed if required.
Should be confirmed during on-site reviews!
Critical Systems
Element Links
2. Design Records
Requirements
CTQs
7. PFMEA
Robust Process
8. Control Plan
9. MSA
Confirm Measurement
12 Cooper Specific
12.
Customer Requirements
DFMEA
Submit
PPAPs can have unique division dispositions but these are universal!
!
Tier PPAP requirements based on overall risk and value to the business
In order to manage the risk we need to effectively manage resources
Maximize the value PPAP can bring to Cooper
Minimize
Mi i i th
the iimpactt off poorly
l d
developed
l
d and
d unapproved
d product
d t