ppap

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Presentation on PPAP

PRODUCTION PART APPROVAL PROCESS

(PPAP)

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Presentation on PPAPProduction Part Approval Process

• Understanding ISO/TS 16949:2002 Basic requirements

• Overview of PPAP requirements • Understanding of

– Submission Level– Process Flow– Process FMEA – Capability Study– MSA

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C

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Continual Improvement of theQuality Management System

REQUIREMENTS

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SATISFACTION

Model of a process-based qualitymanagement system

© ISO 2000

FIGURE 1

ResourceManagement

Measurement,Analysis,

Improvement

ProductInput Output

ManagementResponsibility

ProductRealization

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Presentation on PPAPProduction Part Approval Process Objectives:

Understand when PPAP submissions are required

Understand requirements for PPAP submissions

Understand the different PPAP submission levels

Understanding of the forms used for PPAP submissions

Understanding where the PPAP submission fits into the APQP cycle

http://www.eaglegroupusa.com/APQP.htm

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Presentation on PPAPThe Purpose of PPAP

• is to determine A) If all customer engineering design

records and specification requirements are properly understood by the supplier (Customer and Supplier have a common understanding of Customer requirements)

B)The process has potential to produce parts consistently meeting the requirements during an actual production run at the quoted production rate (Is the process capable of meeting customer requirements during on going production process)

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Applicability of PPAP• PPAP shall apply to External and internal suppliers

sites of:Bulk Material Production MaterialProduction Parts Service Parts For Bulk material PPAP is not required unless asked

by the customer.• A supplier of production parts / service parts shall

comply with the PPAP requirements unless the same is formally waived by the Customer (documented evidences should be available)

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Something

Changed

Application AIAG PPAP manual defines when

PPAP submission is required – New part– Correction to discrepancy in previous

submission– Design or process change– Change in source of subcontracted

materials or services– transfer or rearrangement of tooling &

equipment

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Presentation on PPAPWHEN A PPAP IS REQUIRED ? A PPAP is required to be submitted in the following conditions also :

Requirement1. Use of otherconstruction ormaterial than was usedin the previouslyapproved part orproduct2. Production f romnew or modified tools(except perishabletools), dies, molds,patterns, etc.,including additional orreplacement tooling.

For example, other construction as documented on a deviation (permit) or included as a note on the design record and not covered by an engineering change

only applies to tools which due to their unique form or function, can be expected to influence the integrity of the final product. It is not meant to describe standard tools (new or repaired)., such as standard measuring devices, drivers (manual or power), etc.

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WHEN A PPAP IS REQUIRED ?

3. Production f ollowingrefurbishment or rearrangementof existing tooling or equipment

Refurbishment means the reconstruction and/or modification of a tool or machine or to increase the capacity, performance, or change its existing function (Not normal maintenance, repair etc..)

Rearrangement is defined as activity which changes the sequence of product/process flow from that documented in the process flow diagram (including the addition of a new process). minor changes to add to safety requirements can be made with out customer approval, provided these changes does not lead to a change in the process flow sequence

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Production process tooling and/or equipment transferred between buildings or facilities in one or more locations.

Suppliers are responsible for approval of subcontracted material and services that do not affect customer fit, form, function, durability, or performance requirements.

4. Production f rom tooling andequipment transferred to adiff erent plant location or f rom anadditional plant location.

5. Change of subcontractor f orparts, non-equivalent materials, orservices (e.g.: heat-treating,plating) that aff ect customer fi t,f orm, function, durability, orperformance requirements.

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WHEN A PPAP IS REQUIRED ?For product that has been produced after tooling has been inactive for twelve months or more, Notification is required when the part has had no active purchase order and the existing tooling has been inactive for volume production for twelve months or more. The only exception is when the part has low volume e.g. service or specialty vehicles. However, a customer may specify certain PPAP requirements for service parts.

6. Product producedaf ter the tooling hasbeen inactive f or volumeproduction for twelvemonths or more

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WHEN A PPAP IS REQUIRED ?Any change after, which affects customer requirements for fit, form, function, performance, and/or durability requires notification to the customer.

NOTE: The fit, form, function, performance, and/or durability requirements should be part of customer specifications as agreed on during contract review.

7. Product and processchanges related tocomponents of the productionproduct manufacturedinternally or manufacturedby subcontractors thatimpact fi t, f orm, f unction ,performance, and / ordurability of the salableproduct. Additionally, thesupplier shall concur with anyrequests by a subcontractorbefore submission to thecustomer.

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These changes would normally be expected to have an effect on the performance of the product.

8. For bulk materials only:New source of raw material withspecial characteristics f rom new orexisting subcontractor.

Change in product appearanceattributes where there is noappearance specification.

Revised parameters in the sameprocess (outside PFEA parametersof the approved product, includespackaging).

Change outside of DFEA (productcomposition, ingredient levels) ofthe approved product.

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For change in test method, supplier should have evidence that the new method provides results equivalent to the old method.

9. Change intest/ inspectionmethod – newtechnique (noeff ect onacceptancecriteria).

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Presentation on PPAPMethodology

• Buyer enters PPAP submission date on purchase order

• Approver determines submission level– default level 3

– Supplier submits PPAP

• Approver determine part submission status

• Approver evaluates PPAP package

• Notify supplier and manufacturing of status

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PPAP Process RequirementsSUBMISSION TO CUSTOMER – LEVELS OF EVIDENCE

Submission LevelsThe supplier shall submit the items and/or records specified by the level as requested by the customer.Level 1 – Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to the customer.Level 2 - Warrant with product samples and limited supporting data submitted to the customer.Level 3 – Warrant with product samples and complete supporting data submitted to the customer.Level 4 – Warrant and other requirements as defined by the customer.Level 5 - Warrant with product samples and complete supporting data available for review at the supplier’s manufacturing location.

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Presentation on PPAPPPAP Process Requirements

SUBMISSION TO CUSTOMER – LEVELS OF EVIDENCESubmission Levels•The supplier shall use level 3 as the default level for all submissions unless specified otherwise by the responsible customer product approval activity. A supplier of bulk material only shall use level 1 as the default level for all bulk material PPAP submissions unless specified otherwise by the responsible customer product approval activity.•The customer will identify the submission level that will be used with each supplier, or supplier and customer part number combination. Different customer locations may assign different submission levels to the same supplier manufacturing location.•All of the forms referenced in this document may be replaced by computer-generated facsimiles is to be confirmed with the responsible part approval activity prior to the first submission.

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Requirement Submission Level

Level 1 Level 2 Level 3 Level 4 Level 5

1. Design Records of Saleable R S S * RProduct-for proprietary components/ R R R * RDetails- for all other component/details R S S * R

2. Engineering change documents, If any R S S * R

3. Customer Eng. Approval, if required R R S * R

4. Design FMEA (See 1.2.2.4) R R S * R

5. Process Flow Diagrams R R S * R

6. Process FMEA R R S * R

7. Dimensional Results R S S * R

8. Material, Performance Test results R S S * R

9. Initial Process Study R R S * R

10.Measurement System Analysis Studies R R S * R

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11. Qualified Lab. Documentation R S S * R

12. Control Plan R R S * R

13. Part Submission Warrant (PSW) S S S * R

14. Appearance Approval Report (AAR) S S S * R

15. Bulk Material Requirement Checklist R R R * R

16. Sample Product R R R * R

17. aster Sample (See 1.2.2.17) R R R * R

18. Checking Aids R R R * R

19. Records of compliance R R S * R With Customer-Specific Requirements

S = The supplier shall submit to designated customer product approval activity and retain a copy ofrecords or documentation items at appropriate locations, including manufacturing.

R = The supplier shall retain at appropriate locations, including manufacturing, and make readilyavailable to the customer representative upon request.

* = The supplier shall retain at appropriate locations, ad submit to customer upon request.

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• DFMEA• Control Plan• Early Production Containment Plan

(Pre-Launch Control Plan)• Process capability studies• Gage Measurement System Analysis• Lab Accreditation & scope• Restricted & Reportable Materials

form• Interim Worksheet, if required

Supplier Data Received• Warrant• Appearance Approval

Report (AAR), as required• Sample Parts• Print/Design Record• Engineering Change

Documents• Check fixtures/aids• Process Flow Diagram• PFMEA

ppap

Automotive

evidence submission levels

customer levels

twelve months

ppap requirements

product samples

default level

process

requirements