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(APQP)
The purpose of this Workbook is to provide guidelines for ConMet suppliers for a
standardized process of Advanced Product Quality Planning (APQP), including
the specified Production Part Approval Process (PPAP) for new production
products or for process/product changes.
Scope
This Workbook applies to all ConMet suppliers. Suppliers shall comply with the
specific reporting requirements of this Workbook, Where a requirement or policy
is not specified, suppliers shall comply with the general requirements of the
AIAG APQP manual and the Truck Industry Specific Requirements (AIAG PPAP
manual), unless waived by ConMet Supplier Quality.
General Information
Suppliers should follow the format in this Workbook in reporting to ConMet their
project progress using APQP and also their PPAP development process. There are
tabs that precede each form that describes what to do.
Each major step in the APQP and PPAP process will require a notification to
ConMet so that the project can be mutually tracked and any problems are
es for ConMet suppliers for a
lanning (APQP), including
AP) for new production
require a notification to
nd any problems are
PROJECT TRACKER
Date Updated
Part # Next Meeting Date:
Part Name
NA-ST-054J
Page 4 of 35 Supplier Quality Assurance
Effective Date: 10/29/04
Initiate the APQP Checklist Color code this block
NA-ST-054J
Page 5 of 35 Supplier Quality Assurance
Effective Date: 10/29/04
OPEN ISSUES LOG
Date Issued:
Next Meeting Date:
Place:
Product Team:
NA-ST-054J
Page 6 of 35 Supplier Quality Assurance
Effective Date: 10/29/04
Issue Description Action To Be Taken Performance Metric
Issue # Part Number Date Status Category Description Action To Be Taken Initiator Person Date Due Percent Date 1-Complete
Opened Responsible Complete Completed On Time
NA-ST-054J
Page 7 of 35 Supplier Quality Assurance
Effective Date: 10/29/04
Supplier Team Feasibility Review Instructions
General Information
The guidelines below will assist in the completion of the Feasibility Review.
The supplier should assemble the project Team. A project Champion needs to be
identified and the name provide to ConMet SQA.
w Instructions
Feasibility Considerations
Our product quality planning team has considered the following questions, not intended to be all-inclusive in
performing a feasibility evaluation. The drawings and/or specifications provided have been used as a basis for
analyzing the ability to meet all specified requirements. All "no" answers are supported with attached comments
identifying our concerns and/or proposed changes to enable us to meet the specified requirements.
YES NO CONSIDERATION
Is product adequately defined (application requirements, etc. to enable
feasibility evaluation?
Can Engineering Performance Specifications be met as written?
Can product be manufactured to tolerances specified on drawing?
Can product be manufactured with Cpk's that meet requirements?
Is there adequate capacity to produce product?
Does the design allow the use of efficient material handling techniques?
Can the product be manufactured without incurring any unusual:
- Costs for capital equipment?
- Costs for tooling?
- Alternative manufacturing methods?
Is statistical process control required on the product?
Is statistical process control presently used on similar products?
Where statistical process control is used on similar products:
- Are the processes in control and stable?
- Are Cpk's greater than 1.33?
Conclusion
Sign-Off
General Information
The following are instructions for completing the APQP Checklist tab that
follows these instructions.
The APQP Checklist is designed to identify all the requirements to complete the
supplier’s APQP from Process Design and Development through PPAP
submission to ConMet.
Checklist
The supplier should notify ConMet when the Manufacturing Processes have been
identified. ConMet SQA will be tracking APQP progress on the Dashboard chart.
Suppliers should complete the plan and finish dates of each relevant checklist
PQP Checklist tab that
Project Leader:______________________
Plan Actual Approved
Comments
Start date Finish date Finish Supplier ConMet
Feasibility review
Can the part be made using existing equipment
Will equipment be added to manufacture given item
Is expertise to operate any new equipment available
Foundry processes
Initial gating system determined
Solidification models completed and approved
Gaging and inspections determined for production
Work instructions completed for all key operations
Trial casting runs
Material propety/microstructure checks
Gating system approved through process studies
Pour PPAP castings
Machining Processes
Numbered bubble drawings created for inspection
CNC programs
Chucks & fixtures design
Chucks and fixtures build
Trial runs - machine set up - initial capability studies
Capability study / PPAP machining
CMM Program - printout references numbered
features from bubble drawing
Gage design
Gage build
Gage R&R
Work/inspection instructions
Packaging
Pallet and container layouts
Special inspections processes determined
Special labelling determined
PPAP
Finalize PFMEA based on process trial results
Finalize Control plan based on process trial & final
FMEA results
Capability studies for all CCs show Cpk≥1.67 or
corrective action for all 1.0≤Cpk<1.67
Dimension Inspections with no OTOL
X-ray certs (send Xray film to ConMet SQA)
Material property / chemistry / microstructure certs
Approval of PPAP document package by ConMet
Ship PPAP samples and documents
PROCESS / INSPECTION FLOWCHART
Legend:
Operation Transportation Inspection Delay Storage
Page 14 of 35
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
Print # #REF! Rev. #REF! (PROCESS FMEA) FMEA Number: #REF!
Item: #REF! Process Responsibility #REF! Prepared by:
Model Year(s)/Vehicle(s) #REF! Key Date Date (Orig.)
Core Team: Date (Rev.)
C O D
Process S l Potential c Current Current e R. Responsibility Action Results
Potential Potential
Function/ e a Causes(s)/ c Process Process t P. Recommended & Target S O D R.
Failure Effect(s)
Require- v s Mechanism(s) u Controls Controls e N. Action(s) Completion Actions e c e P.
Mode of Failure
ments of Failure Prevention Detection Date Taken
s r c v c t N.
Page 15 of 35
KEY CHARACTERISTICS & GAUGES CHART
Part Number Engineering Change Level Part Name
DIMENSION
NUMBER DESCRIPTION TOLERANCE DESCRIBE THE GAUGE USED
Page 16 of 35
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
#REF!
Part Name Gage Number Appraiser B
#REF!
Characteristic Specification Gage Type Appraiser C
Lower Upper
Characteristic Classification Trials Parts Appraisers Date Performed
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.
Notes:
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
#REF!
Part Name Gage Number Appraiser B
#REF!
Characteristic Gage Type Appraiser C
For information on the theory and constants used in the form see MSA Reference Manual, Third edition.
CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)
#REF! #REF! 1/1/1996 1/1/1996
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
#REF! ###
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)
#REF!
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
#REF! #REF!
PART/ MACHINE, CHARACTERISTICS SPECIA METHODS
PROCESS NAME/
PROCES DEVICE L PRODUCT/PROCESS EVALUATION/ SAMPLE REACTION
OPERATION
S JIG, TOOLS CHAR. SPECIFICATION/ MEASUREMENT CONTROL PLAN
DESCRIPTION NO. PRODUCT PROCESS
NUMBER FOR MFG. CLASS SIZE FREQ. METHOD
TOLERANCE TECHNIQUE
Page 19 of 35
第 20 页,共 35 页
ConMet Buyer
coordinates w/SQA to
define PPAP
requirements on the
P.O. to the Supplier
* Supplier completes the APQP process per the ConMet APQP Workbook
requirements
* Supplier completes all process capability studies and inspections on samples Corrective
action
* Supplier prepares the PPAP package and samples for shipment
Supplier’s
electronic PPAP
documents
Plant QA
completes all
sample
verifications and
notifies SQA
Contact
Procurement/
Buyer for
production
release
Rev 12/12/07
Guidelines for PPAP Submissions
ConMet follows the general PPAP requirements specified in the latest AIAG
PPAP Manual for submission, unless waived by ConMet Supplier Quality:
Suppliers are also required to notify ConMet Supplier Quality when any of the
below situations are planned. Use the Product/Process Change Notification form
attached as a tab in this Workbook:
ConMet Procurement/Purchasing will issue the PPAP request per the above
submission requirements and maintain a network log of status that includes part
number, vendor, reason, due dates and approval status.
Suppliers will affix the orange PPAP sample labels on all PPAP sample shipments
(See tab in this Workbook, or download from www.conmet.com
PPAP documents are required to be submitted with the samples.
ubmitted part
ations or materials
sting tooling
ed
erials or services
ive for twelve months or
rnally or suppliers)
tion technique
Requirements (Page 57 -
plier Quality.
Week 0 1 2 3 4
Milestones
PO for tooling and PPAP ۩
tool build Week 1-6
Process flowchart Week 1
Control Plan - Preliminary Week 1
gage design & build Week 2-9
Casting/Machining trials Week 7-9
Control Plan - Production Week 8
Work instructions Week 9
Cast PPAP samples Week 10
Machine PPAP Samples Week 11
Inspect PPAP Samples Week 12
capability studies & MSA Week 12
document preparation Week 13
PPAP submission Week 14
5 6 7 8 9 10 11 12 13 14
☺
PPAP Checklist Instructions
General Information
The following are instructions for completing the PPAP Checklist tab that follows
these instructions.
The PPAP Checklist is designed to identify all the requirements to complete the
supplier’s PPAP package, including sample preparation.
Checklist
Suppliers should complete all the relevant Checklist items. Forms for completing
the Process Flow Chart, PFMEA. Control Plans, Key Characteristics/Gauges,
Gage R&R, Dimensional Reports, and Material Test Reports are provided in this
workbook. Suppliers may use their own or their contractor’s X-Ray Radiological
reports, Chemistry reports, and Microstructure reports.
Supplier capability reports can be of the application format of their choice but
must include histograms.
The supplier must notify ConMet when the PPAP Checklist is complete. ConMet
SQA will be tracking APQP progress on the Dashboard chart.
Suppliers should complete the plan and finish dates of each relevant checklist
Checklist
PPAP Checklist
for hub PPAP package
PPAP Project Team Leader: Part # Rev:
Comments:
Truck Industry Part Submission Warrant
Part Name #REF! Customer Part Number #REF! Rev.
If applicable
Tool PO Number Engineering Drawing Change Level #REF! Dated
###
Street Address Customer Contact
Note: Does this part contain any restricted or reportable substances? Yes No
Are plastic parts identified with appropriate ISO marking codes? Yes No
DECLARATION
I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer
drawings and specifications and are made from specified materials on regular production tooling with no operations other than the regular
production process. I also certify that documented evidence of such compliance is on file and available for review.
EXPLANATION/COMMENTS:
Title E-Mail
Print Name
March THE-1001
2006
PPAP Qualification Samples
Indicate a ConMet Plant shipping address:
oConsolidated Metco, Inc., 2709 Walkup Avenue, Monroe, NC 28110
oConMet de Mexico, Av.de las Americas #100, Parque Industrial Las Americas, Cienega de Flores, Nuevo Leon,
Mexico C.P. 65550
oConsolidated Metco, Inc. 10448 Highway 212, Clackamas, OR 97015
oConsolidated Metco, Inc. 1821 Highway 19S, Bryson City, NC 28713
oConsolidated Metco, Inc. 171 Great Oak drive, Canton, NC 28716
[ ] Initial [ ] Resubmission
ConMet ECN___________
Part Number___________________PO Number_____________
Part Name_____________________Qty ___________________
Engineering Change Level________Date___________________
1.Attach this label to the packaging when sending PPAP Submission to the Plant.
2.Enclose the PPAP documentation records with the PPAP sample(s).
Complete this form and e-mail to your customer organization whenever customer notification is required by
the PPAP Manual in Table 3.1. Your customer will respond back with an acknowledgement and may
request additional change clarification or PPAP submission requirements.
Customer Part Number: #REF! Engineering Revision Level: #REF! Dated: #REF!
Purchase Order Number: Safety and/or Government Regulation:
Application: #REF!
ORGANIZATION MANUFACTURING INFORMATION
DECLARATION:
I hereby certify that representative samples will be manufactured using the revised product and/or process
and verified, where appropriate, for dimensional change, appearance change, physical property change,
functionally for performance and durability. I also certify that documented evidence of such compliance is on
file and available for customer review.
Explanation/Comments:
NAME: TITLE:
E-MAIL: DATE:
NOTE: Please submit this notification at least 6 weeks prior to the planned change implementation!
Contact your customer to determine if this form is available in an electronic format or if this form should be faxed.
March THE-1220
2006