PPAP-Training-PresentationPPAP专业培训资料课件

ProductionPartApprovalProcess(PPAP)ProductionPartApprovalProce2NCRConfidentialWhatisPPAP?ProductionPartApprovalProcessStandardusedtoformallyreduceriskspriortoproductorservicerelease,inateamorientedmannerusingwellestablishedtoolsandtechniquesInitiallydevelopedbyAIAG(AutoIndustryActionGroup)in1993withinputfromtheBig3-Ford,Chrysler,andGMAIAGs4theditioneffectiveJune1,2006isthemostrecentversionPPAPhasnowspreadtomanydifferentindustriesbeyondautomotiveWhatisPPAP?ProductionPartA3NCRConfidentialPurposeofPPAPProvideevidencethatallcustomerengineeringdesignrecordandspecificationrequirementsareproperlyunderstoodbytheorganizationTodemonstratethatthemanufacturingprocesshasthepotentialtoproduceproductthatconsistentlymeetsallrequirementsduringanactualproductionrunatthequotedproductionratePPAPmanageschangeandensuresproductconformance!PurposeofPPAPProvideevidenc4NCRConfidentialWhenisPPAPRequired?NewpartEngineeringchange(s)Tooling:transfer,replacement,refurbishment,oradditionalCorrectionofdiscrepancyToolinginactiveoneyearChangetooptionalconstructionormaterialSub-supplierormaterialsourcechangeChangeinpartprocessingPartsproducedataneworadditionallocationPPAPisrequiredwithanysignificantchangetoproductorprocess!WhenisPPAPRequired?Newpart5NCRConfidentialBenefitsofPPAPSubmissionsHelpstomaintaindesignintegrityIdentifiesissuesearlyforresolutionReduceswarrantychargesandpreventscostofpoorqualityAssistswithmanagingsupplierchangesPreventsuseofunapprovedandnonconformingpartsIdentifiessuppliersthatneedmoredevelopmentImprovestheoverallqualityoftheproduct&customersatisfactionBenefitsofPPAPSubmissionsHe6NCRConfidentialProductionRunPPAPdatamustbesubmittedfromaproductionproduction run using:ProductionequipmentandtoolingProductionemployeesProductionrateProductionprocessAlldatareflectstheactualproductionprocesstobeusedatstart-up!ProductionRunPPAPdatamustb7NCRConfidentialRunRateThepurposeofaRunRateRunRateistoverifythesuppliersmanufacturingprocessiscapableofproducingcomponentsthatmeetNCRsqualityrequirements,atquotedtoolingcapacity,foraspecifiedperiodoftimeVerificationoftheRunRatewillbeattheSupplierQualityEngineers(SQE)discretion.ThesupplierwillbenotifiedoftheneedtoperformaRunRateasearlyintheprocessaspossible.ThenumberofcomponentstobeproducedduringtheRunRateshouldbesufficienttodemonstrateprocesscapabilityandwillbepredeterminedbytheSQEandthesupplier.Factorssuchasproductcomplexity,shelflife,storage,costandsingleshiftvs.multipleshiftoperationswillbetakenintoconsiderationRunRateThepurposeofaRun8NCRConfidentialOfficialPPAPRequirements1.DesignRecords2.AuthorizedEngineeringChangeDocuments3.CustomerEngineeringApproval,ifrequired4.DesignFailureModesandEffectsAnalysis(DFMEA)applied in special situations5.ProcessFlowDiagram6.ProcessFailureModesandEffectsAnalysis(PFMEA)7.ControlPlan8.MeasurementSystemsAnalysis(MSA)9.DimensionalResults10.RecordsofMaterial/PerformanceTestResults11.InitialProcessStudies12.QualifiedLaboratoryDocumentation13.AppearanceApprovalReport(AAR)14.SampleProductionParts15.MasterSample16.CheckingAids17.Customer-SpecificRequirements18.PartSubmissionWarrant(PSW)Now,letstakeacloserlookatNCRsrequirementsOfficialPPAPRequirementsDesi9NCRConfidentialNCRsPPAPRequirements1.DesignRecords2.2.AuthorizedEngineeringChangeDocumentsAuthorizedEngineeringChangeDocuments3.3.CustomerEngineeringApproval,ifrequiredCustomerEngineeringApproval,ifrequired4.DesignFailureModesandEffectsAnalysis(DFMEA)applied in special situations5.5.ProcessFlowDiagramProcessFlowDiagram6.6.ProcessFailureModesandEffectsAnalysis(PFMEA)ProcessFailureModesandEffectsAnalysis(PFMEA)7.7.ControlPlanControlPlan8.8.MeasurementSystemsAnalysis(MSA)MeasurementSystemsAnalysis(MSA)9.9.DimensionalResultsDimensionalResults10.10.RecordsofMaterial/PerformanceTestResultsRecordsofMaterial/PerformanceTestResults11.InitialProcessStudies12.12.QualifiedLaboratoryDocumentationQualifiedLaboratoryDocumentation13.13.AppearanceApprovalReport(AAR)AppearanceApprovalReport(AAR)14.14.SampleProductionPartsSampleProductionParts15.MasterSample16.CheckingAids17.Customer-SpecificRequirements18.18.PartSubmissionWarrant(PSW)NCRcallsthisthe“ProductionWarrant”PartSubmissionWarrant(PSW)NCRcallsthisthe“ProductionWarrant”Suppliershallsubmitthese12itemsandretainacopyofrecordsatappropriatelocationsNCRsPPAPRequirementsDesign10NCRConfidential1.1.DesignRecordsDesignRecords2.AuthorizedEngineeringChangeDocuments3.CustomerEngineeringApproval,ifrequired4.4.DesignFailureModesandEffectsAnalysis(DFMEA)DesignFailureModesandEffectsAnalysis(DFMEA)applied in special situationsapplied in special situations5.ProcessFlowDiagram6.ProcessFailureModesandEffectsAnalysis(PFMEA)7.ControlPlan8.MeasurementSystemsAnalysis(MSA)9.DimensionalResults10.RecordsofMaterial/PerformanceTestResults11.11.InitialProcessStudiesInitialProcessStudies12.QualifiedLaboratoryDocumentation13.AppearanceApprovalReport(AAR)14.SampleProductionParts15.15.MasterSampleMasterSample16.16.CheckingAidsCheckingAids17.17.Customer-SpecificRequirementsCustomer-SpecificRequirements18.PartSubmissionWarrant(PSW)NCRcallsthisthe“ProductionWarrant”Suppliershallretainthese6itemsatappropriatelocations,andmakereadilyavailableuponrequestNCRsPPAPRequirementsDesignRecordsSuppliershallr11NCRConfidentialLevel1ProductionWarrantandAppearanceApprovalReport(ifapplicable)submittedtoNCRLevel2ProductionWarrant,productsamples,anddimensionalresultssubmittedtoNCRLevel3ProductionWarrant,productsamples,andcompletesupportingdatasubmittedtoNCRLevel4ProductionWarrantandotherrequirementsasdefinedbyNCRLevel5ProductionWarrant,productsamplesandcompletesupportingdata(areviewwillbeconductedatthesuppliersmanufacturinglocation)PPAPSubmissionLevelsLevel1ProductionWarrantand12NCRConfidentialPPAPSubmissionLevelTableS=SuppliershallsubmittoNCR&retainacopyofrecordsordocumentationitemsatappropriatelocationsR=SuppliershallretainatappropriatelocationsandmakereadilyavailabletoNCRuponrequest*=Suppliershallretainatappropriatelocations,andsubmittoNCRuponrequest.NCRwillidentifywhatisneededforsubmission.PPAPSubmissionLevelTableS=13NCRConfidentialDefinitionofRiskHighRiskPartsassociatedwithmultiplecriticalfeatures,complexdesign,orhighendtechnologythatisnotyetestablishedinthegeneralmanufacturingenvironmentSuppliersqualitysystemand/orqualityperformanceisnottoNCRsatisfactionMediumRiskPartsthathaveatleastonecriticalfeatureLowRiskPartsthathavenocriticalfeaturesandcanbemanufacturedbyanymanufacturerinthecommoditycategorySuppliersqualitysystemandqualityperformanceareacceptableDefinitionofRiskHighRisk14NCRConfidentialSubmissionLevelRequirements NewPartsNewPartsLevel2isrequiredforLowRiskPartsLevel3isrequiredforMediumandHighRiskParts PartChangesPartChangesLevel3isrequiredforPartsproducedataneworadditionallocationSupplierQualityExcellencewilldefinethelevelrequiredforallotherchangesNCRreservestherighttoredefinethesubmissionlevelrequiredSubmissionLevelRequirementsN15NCRConfidentialPPAPStatusApprovedThepartmeetsallNCRrequirementsSupplierisauthorizedtoshipproductionquantitiesofthepartInterimApprovalPermitsshipmentofpartonalimitedtimeorpiecequantitybasisRejectedThepartdoesnotmeetNCRrequirements,basedontheproductionlotfromwhichitwastakenand/oraccompanyingdocumentationProductionquantitiesmaynotbeshippedbeforeNCRApprovalPPAPStatusApproved16NCRConfidentialElectronicSubmissionRequirementsNCRrequiresthatallPPAPsbesubmittedelectronicallyUseofpapersubmissionmusthavepriorapprovalbytheSQESubmissionmustbereceivedon or prior tothePPAPduedateReviewandApprovalProcess:NCRwillattempttoreviewandprovidefeedbackwithin2businessdaysNCRrequiresallsubmissionstobeelectronicElectronicSubmissionRequirem17NCRConfidentialNCRPPAPPlaybookWhatistheNCRPPAPPlaybook?AnExcelspreadsheetcontainingtemplatesofthedocumentssuppliersarerequiredtosubmittoNCRWhyusethePPAPPlaybook?Simplifiestheprocessforsuppliersbyservingasa“checklist”ofwhatneedstobesubmittedtoNCRReducesthenumberoffilestomanageEnablestheSQEtoquicklyseeifanythingismissingShowPPAPPlaybookNCRPPAPPlaybookWhatistheN18NCRConfidentialPRODUCTIONWARRANTPRODUCTIONWARRANT19NCRConfidentialProductionWarrantNow,letstakeacloserlookWhatisIt?DocumentrequiredforallnewlytooledorrevisedproductsinwhichthesupplierconfirmsthatinspectionsandtestsonproductionpartsshowconformancetoNCRrequirementsUsedto:documentpartapprovalprovidekeyinformationdeclarethatthepartsmeetspecificationObjectiveorPurposeWhentoUseItPriortoshippingproductionpartsProductionWarrantNow,letst20NCRConfidentialProductionWarrantPartName/NCRPartNumberEngineeringreleasedfinishedenditempartnameandnumberSafetyand/orGovernmentRegulation“Yes”ifsoindicatedbytheDesignRecord,otherwise“No”EngineeringChangeLevel&DateShowthechangelevelanddateoftheDesignRecordAdditionalEngineeringChangesListallauthorizedEngineeringchangesnotyetincorporatedinthedesignrecordbutwhichareincorporatedinthepartShownonDrawingNumberThedesignrecordthatspecifiesthecustomerpartnumberbeingsubmittedCheckingAidNumber,ChangeLevel,&DateEnterifrequestedbythecustomerPurchaseOrderNumberEnterthisnumberasfoundonthecontract/purchaseorderSupplierPartNumberPartnumberdefinedbythesupplier,ifanyProductionWarrantPartName/21NCRConfidentialProductionWarrantNCRLocationShowthelocationwherepartswillbeshippedtoBuyer/BuyerCodeEnterthebuyersnameandcodeRestrictedSubstancesEnter“Yes”or“No”ModelName/NumberEnterthemodelnameandnumberPartsIdentifiedwithAppropriateMarkingCodesULUL=UnderwritersLaboratoriessafetystandardsCECE=ConformiteEuropeenne(EuropeanConformity)CertifiesthataproducthasmetEuropeanconsumerSafety,health,orenvironmentalrequirementsISO=InternationalOrganizationforStandardizationEnter“Yes”or“No”SupplierManufacturingInformationShowthenameandcodeassignedtothemanufacturingsiteonthepurchaseorder/contractProductionWarrantNCRLocation22NCRConfidentialProductionWarrantReasonForSubmissionChecktheappropriatebox(es)RequestedSubmissionLevelIdentifythesubmissionlevelrequestedbyNCRSubmissionResultsChecktheappropriateboxesMold/Cavity/ProductionProcessIfproductionpartswillbeproducedfrommorethanonemold,cavity,tool,die,pattern,orproductionprocess,thesuppliershallcompleteadimensionalevaluationononepartfromeach.Thespecificmolds,lines,etc.shallthenbeidentifiedhere.ProductionWarrantReasonForS23NCRConfidentialProductionWarrantTheapprovedProductionWarrantofficiallywarrantsthepartsreadyforproductionDeclarationEnterthenumberofpiecesmanufacturedduringthesignificantproductionrunandthetime(inhours)takenforthesignificantproductionrunExplanation/CommentsProvideanyexplanatorycommentsonthesubmissionresultsoranydeviationsfromtheDeclaration.Attachadditionalinformationasappropriate.SupplierAuthorizedSignatureAresponsiblesupplierofficial,afterverifyingthattheresultsshowconformancetoallNCRrequirementsandthatallrequireddocumentationisavailable,shallapprovethedeclarationForNCRUseOnlyTobecompletedbyappropriateNCRSupplierQualityEngineerDeclarationAffirmationthatthesamplesrepresentedbythewarrantarerepresentativeandweremadebyaprocessthatmeetsNCRsPPAPrequirementsPPAPWarrantDispositionApproved,Rejected,OtherNCRSignatureSignedbyNCRSupplierQualityEngineerProductionWarrantTheapproved24NCRConfidentialReviewersChecklistMustbecompletelyfilledoutMustbesignedbythesupplierP/NmustmatchthePOSubmittedatthecorrectrevisionlevelSubmittedatthecorrectsubmissionlevelSpecifythereasonforsubmissionProductionWarrantReviewersChecklistProduction25NCRConfidentialAUTHORIZEDENGINEERINGCHANGEDOCUMENTSAUTHORIZEDENGINEERINGCHANGE26NCRConfidentialAuthorizedEngineeringChangeDocumentsThesuppliershallprovideauthorizedchangedocumentsforthosechangesnotyetrecordedinthedesignrecord,butincorporatedintheproduct,partortooling,suchas:ECNs(must be approved,not pending)SpecificationsFeasibilitystudiesSupplierchangerequestsSub-assemblydrawingsLifeorreliabilitytestingrequirementsAuthorizedEngineeringChange27NCRConfidentialPROCESSFLOWDIAGRAMPROCESSFLOWDIAGRAM28NCRConfidentialProcessFlowDiagramWhatisIt?Avisualdiagramoftheentireprocessfromreceivingthroughshipping,includingoutsideprocessesandservicesTohelppeople“see”therealprocess.Processmapscanbeusedtounderstandthefollowingcharacteristicsofaprocess:Set-by-stepprocesslinkageOfflineactivities(measurement,inspection,handling)Rework,scrapObjectiveorPurposeWhentoUseItTounderstandhowaprocessisdonePriortocompletingthePFMEAProcessFlowDiagramWhatisIt29NCRConfidentialProcessFlowDiagramsTheprocessflowdiagramutilizesthesesymbolstoclearlyidentifyeachstepintheprocessProcessFlowDiagramsTheproce30NCRConfidentialProcessFlowDiagram-ExampleProcessFlowDiagram-Example31NCRConfidentialStarExerciseDivideintoteamsDistributesuppliesPaperforStarsInstructionsformakingStarsScissorsUsingtheinstructionshandedoutinclass,make10ShurikenStarsThisexercisewillprepareyourteamtocompletefutureexercises45MinutesStarExerciseDivideintoteams32NCRConfidentialProcessFlowDiagramStarExercise05Incoming Inspection10Paper Folding15Cutting20Star Folding2535Tucking30Final InspectionPacking40ShippingInspection as per Operation layoutIf rework possibleRework100%InspectionScrapNext OperationNot OKOKPatrol Insp ReportProcessFlowDiagramStarEx33NCRConfidentialReviewersChecklistProcessFlowmustidentifyeachstepintheprocessShouldincludeabnormalhandlingprocessesScrapReworkProcessFlowmustincludeallphasesoftheprocessReceivingofrawmaterialPartmanufacturingOfflineinspectionsandchecksAssemblyShippingProcessFlowDiagramsReviewersChecklistProcessFlo34NCRConfidentialPROCESSFMEAPROCESSFMEA35NCRConfidentialProcessFMEA(PFMEA)WhentoUseItAftercompletionoftheprocessflowdiagram.PriortotoolingforproductionWhatisIt?Atoolusedtoidentifyandprioritizeriskareasandtheirmitigationplans.The PFMEA should be completed using a cross-functional team!IMPORTANT!ObjectiveorPurposeIdentifiespotentialfailuremodes,causes,andeffects.Inputscomefromtheprocessflowdiagram.Identifieskeyinputswhichpositivelyornegativelyaffectquality,reliabilityandsafetyofaproductorprocess.ProcessFMEA(PFMEA)WhentoUs36NCRConfidentialFMEAOriginCreatedbyNASAfollowingApollo1missionfailureAllowsustotakeaproactiveapproachtowhatcangowronginaprocessandmanageourrisksbetterFMEAOriginCreatedbyNASAfol37NCRConfidentialProcessFMEA(PFMEA)ThisisincludedinthePPAPPlaybook!ProcessFMEA(PFMEA)Thisisin38NCRConfidentialTIPSThereshouldbeatleastonefailuremodeforeachinput.UsingthecompletedProcessFlowDiagram,entertheprocessstep.FailureModesForeachProcessInput,determinethewaysinwhichtheinputcangowrong.PFMEA-Step1TIPSUsingthecompletedFailur39NCRConfidentialTIPSThereshouldbeatleastonefailureeffectforeachfailuremode.Effectsshouldbespecific,clear,andleavenodoubttotheuninformedreviewer.PotentialFailureEffectsForeachFailureMode,determinewhateffectthespecificfailurecouldhaveontheprocessoutput.PFMEA-Step2TIPSPotentialFailureEffectsP40NCRConfidentialTIPSThereshouldbeatleastonepotentialcauseforeachfailuremode.PotentialCausesForeachFailureMode,determinethepossiblecauseofthefailure.PFMEA-Step3TIPSPotentialCausesPFMEA-St41NCRConfidentialTIPSThisstepintheFMEAbeginstoidentifyinitialshortcomingsorgapsinthecurrentcontrolplan.Ifaprocedureexists,enterthedocumentnumber.Ifnocurrentcontrolexists,listas“none.”CurrentControlsForeachpotentialcause,listthecurrentmethodusedforpreventingordetectingfailure.PFMEA-Step4TIPSCurrentControlsPFMEA-St42NCRConfidentialAssignSeverity,Occurrence,andDetectionratingsAssignSeverity(Howseriousistheeffectifitfails?)AssignOccurrence(Howlikelyisthecausetooccur?)AssignDetection(Howeasilycanthecauseorfailuremodebedetected?)Severity,OccurrenceandDetectionratingdetailsonnextslidePFMEA-Step5AssignSeverity,Occurrence,a43NCRConfidentialPFMEA-DefinitionofTerms SeveritySeverity(ofEffect)-severityoftheeffectontheCustomerandotherstakeholders(HigherValue=HigherSeverity)OccurrenceOccurrence(ofCause)-frequencywithwhichagivenCauseoccursandcreatesFailureMode.(HigherValue=HigherProbabilityofOccurrence)DetectionDetection(CapabilityofCurrentControls)-abilityofcurrentcontrolschemetodetectthecausebeforecreatingthefailuremodeand/orthefailuremodebeforesufferingtheeffect(HigherValue=LowerAbilitytoDetect)Caution:NoticethescaledifferenceforDetectionDetection!PFMEA-DefinitionofTermsSev44NCRConfidentialHigh10Low1RatingSeverityOccurrenceDetection*HazardouswithoutwarningVeryhighandalmostinevitableCannotdetectordetectionwithverylowprobabilityLossofprimaryfunctionHighrepeatedfailuresRemoteorlowchanceofdetectionLossofsecondaryfunctionModeratefailuresLowdetectionprobabilityMinordefectOccasionalfailuresModeratedetectionprobabilityNoeffectFailureunlikelyAlmostcertaindetection*If No Controls Exist,Detection=10Createaratingsystemthatmakessenseforthedefectsyouaretryingtoprevent.AnExampleofRatingDefinitionsHigh 10Low 1RatingSeverityOccu45NCRConfidentialTIPSTheRPNisusedtoprioritizethemostcriticalrisksidentifiedinthefirsthalfoftheFMEA.HighRPNs(125orabove)areflagstotakeefforttoreducethecalculatedrisk.RegardlessofRPN,high SeveritySeverityscores(9or10)shouldbegivenspecialattention.CalculatetheRiskPriorityNumberRPNRPN=SeverityxOccurrencexDetectionPFMEA-Step6TIPSCalculatetheRiskPriorit46NCRConfidentialOncetheRPNNumbersaredetermined,theycanbeusedtoprioritizethemostsignificantfailuremodes.SorttheFMEAbytheRPNnumbers.Graphicalandstatisticaltoolscanhelptheteamselecta“cut-off”RPNforthenextsteps.RPNThresholdsWhenusinganRPNthreshold,DONOTforgettoaddresshighSeveritySeverityscoresPareto Chart?Howmanyitemsshouldbethefocusofthenextsteps?SortbyRPNtodeterminethemostsignificantfailuremodesAnalyzingthePFMEAOncetheRPNNumbersaredeter47NCRConfidentialPFMEARemediationGuidelines SeveritySeverity canonlybeimprovedbyadesignchangetotheproductorprocess OccurrenceOccurrence canonlybereducedbyachangewhichremovesorcontrolsacause.Examplesareredundancy,substitutingamorereliablecomponentorfunctionormistake-proofing.DetectionDetectioncanbereducedbyimprovingdetection.Examplesaremistake-proofing,simplificationandstatisticallysoundmonitoring.Ingeneral,reducingtheOccurrenceispreferabletoimprovingtheDetectionPFMEARemediationGuidelines48NCRConfidentialDetermineActionsRecommendedtoreduceHighRPNsForthehighRPNnumbers,determinetherecommendedactions.FMEAStep7DetermineActionsRecommended49NCRConfidentialNowrecalculateyourRPNsbasedonmitigationplans.TIPS:ContinueupdatingtheactionstakenandresultingRPNsuntilallrisksareatanacceptablelevel(below125).Resp(responsibility)Assignaspecificpersonwhowillberesponsibleforrecommendedactions.ActionsTakenAsactionsareidentifiedandcompleted,documentinthe“ActionsTaken”column.FMEASteps8and9SEV,OCC,DET,RPNAsactionsarecompletereassessSeverity,Occurrence,andDetectionandrecalculateRPN.NowrecalculateyourRPNsTIP50NCRConfidential1.ForeachProcessInput,determinethewaysinwhichtheProcessStepcangowrong(theseareFailureModes).2.ForeachFailureModeassociatedwiththeinputs,determineEffectsontheoutputs.3.IdentifypotentialCausesofeachFailureMode.4.ListtheCurrentControlsforeachCause.5.AssignSeverity,OccurrenceandDetectionratingsaftercreatingaratingskeyappropriateforyourproject.6.CalculateRPN.7.DetermineRecommendedActionstoreduceHighRPNs.8.TakeappropriateActionsandDocument.9.RecalculateRPNs.10.Revisitsteps7and8untilallthesignificantRPNshavebeenaddressed.SummaryStepsToCompleteaFMEAForeachProcessInput,determ51NCRConfidentialPFMEAExercise30MinutesInstructionsOpenthePPAPTrainingTemplates.xlsfile,thenselectthePFMEAworksheet.Usingprocesssteps20and25fromthecompletedStarProcessFlowDiagramhandout,complete2rowsofthePFMEA.UsethefilePPAPTrainingTemplates.xlsPFMEAExercise30MinutesInstru52NCRConfidentialCollaborativeEffort:Donottryalone,useagroupVerylaborious:Timeconsumingprocess.Takenecessarybreaks.ActionitemsarerequiredforcompletionTrainteamaheadoftimebyexplainingscoringcriteriaProperpreparationisneededformeetingsSummarizeoften:FMEAisalivingdocumentTipsandLessonsLearnedProcessFMEA(PFMEA)CollaborativeEffort:Donott53NCRConfidentialReviewersChecklistVerifythereisasystemforprioritizingriskoffailuresuchasRPNnumbersof125oraboveMakesurethathighRPNprocessconcernsarecarriedoverintothecontrolplanMakesurethatallcriticalfailuremodesareaddressedSafetyForm,fit,functionMaterialconcernsProcessFMEA(PFMEA)ReviewersChecklistProcessFME54NCRConfidentialCONTROLPLANCONTROLPLAN55NCRConfidentialControlPlanAdocumentthatdescribeshowtocontrolthecriticalinputstocontinuetomeetc