TS16949 PPAP Trainingrev E课件.pptx
WELCOMEWhatistheintentofthisTraining?WhatistheintentofthisTraining?TheintentofthistrainingistocommunicateMotorolaPCSs,PPAPrequirementstothesuppliersandtraintheSDEEngineersandsuppliersonthesePPAPrequirementsforqualificationSUPPLIERDEVELOPMENTENGINEERINGTRAININGMODULESDE-VOLIIIBy:ZubairIqbalJuly16th2004WhatdoesPPAPstandfor?PRODUCTIONPPAPPARTAPPROVALPROCESSPPAPisaproductionpartapprovalprocessusedbyUSautoindustry(GM,Ford,andChrysler).TheProductionPartApprovalProcess(PPAP)outlinesthemethodsusedforapprovalofproductionandservicecommodities,includingbulkmaterials,uptoandincludingpartsubmissionwarrantintheAdvancedQualityPlanningprocess.ThepurposeofthePPAPprocessistoensurethatsuppliersofcomponentscomplywiththedesignspecificationandcanshowdocumentaryevidencethatthelevelcanbemaintainedduringthelifeoftheproduct.WhatistheProductionPartApprovalProcess?IsMotorolaPCSchangingthequalificationrequirements?MotorolaPCSisnotchangingqualificationrequirements,insteadMotorolaPCSisenhancing/addingthecurrentqualificationrequirementstomatchthePPAPrequirements.WhatarethePPAPrequirements?PPAPRequirementsInadditiontothesePPAPrequirements,PCShasaddedthisnewadditionalrequirementWhatisthePurposeofthesenewPPAPRequirements?ThePurposeofPPAPistodetermineifallcustomerengineeringdesignrecordsandspecificationrequirementsareproperlyunderstoodbythesupplierandthattheprocesshasthepotentialtoproduceproductmeetingtheserequirementsduringanactualproductionrunatthequotedrate.Iamnotfamiliarwithsomeoftheserequirements,wouldyoupleaseexplainwhatthesePPAPrequirementsare?(1)DesignRecordsDesign Records:Designrecordsareengineeringrequirementsforjudgingtheacceptabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsareconsideras,allcustomerandsupplierdesignrecords(e.g.:CAD,Pro-Efiles,partdrawing/prints,specifications)(2)EngineeringChangeDocuments(ifany)Engineering Change Documents:EngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchange(s)(authorizedbyMotoroladevelopmentengineering)notyetrecordedinthedesignrecordbutincorporatedintheproduct,partortooling.(3)CustomerEngineeringApproval(Ifrequired)Customer Engineering Approval:CustomerEngineeringapprovalistheprocessthatprovidesfortwowaycommunicationbetweenthecomponentsupplier&theresponsibleMotoroladesignengineeringactivityandthroughwhichthesupplierrequestsconcurrenceforcertaindesignandprocesschanges.OnceMotoroladesignengineeringdeterminesthatthechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillcompleteandsubmittheProcessChangeNotificationforapproval.(4)DesignFMEADesign FMEA:FMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.(5)ProcessFlowDiagramProcess Flow Diagram:Processisacombinationofpeople,equipment,method,Material,andenvironmentthatproducesoutput,foragivenproductorservice.ProcessFlowDiagramdepictstheflowofmaterialsthroughtheprocess,includinganyre-work,repairoperationsorcycletime.(6)ProcessFMEAFailure Modes and Effects Analysis(FMEA)FMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.(7)DimensionalResultsDimensional Results:Dimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool,mold,orset-up.Alldimensions(exceptreferencedimensions),Characteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.(8)Material,PerformanceTestResultsMaterial,Performance Test Results:MaterialtestsaretestthatspecifiedonMotorolaprintorspecificationsaschemical,physicalormetallurgicaltestse.g.MEK,abrasion,adhesion,etc.PerformancetestsaretestthatspecifiedonMotorolaprintorspecificationsasperformancetestse.g.numberofcycles,environmentaltesting,electricaltesting,Platingthickness,Paintthickness,Glossreadings,etc.(9)InitialProcessStudiesInitial Process Studies:ForBox-X Xandparameters,thesuppliershallprovideCp/Cpkstatisticstoensureanacceptableprocesscapability(Cp/Cpkof2/1.5orgreater).Asampleof35piecesisdeemedappropriatefornormallydistributeddatagatheredviaanacceptablemeasurementmethod(errorrate10%orlessunlessapprovedbyCTE).Forconditionsthatrequirereview(Cp/Cpkbelow1.5,supplierrequest,non-normaldistribution,ormeasurementissues),thesuppliermustnotifyMotorola.Motorolamustapproveanydeviation.(*)(10)MeasurementSystemAnalysis Measurement System Analysis:Measurementsystemanalysis(MSA)isanexperimentalandmathematicalmethodofdetermininghowmuchthevariationwithinthemeasurementprocesscontributestooverallprocessvariability.TherearefiveparameterstoinvestigateinanMSA:bias,linearity,stability,repeatabilityandreproducibility.(11)QualifiedLaboratoryDocumentationQualified Laboratory Documentation:AQualifiedlaboratoryisatestfacilitythatmayincludechemical,metallurgical,dimensional,physical,electrical,reliabilitytestingortestvalidation.QualifiedLaboratoryDocumentationisadocumentationortestresultsissuedbyaMotorolaqualifiedlaboratory(12)ControlplanControl plan:Controlplansarewrittendescriptionsofthesystemforcontrollingproductionpartsorbulkmaterialsandprocesses.Theyarewrittenbysupplierstoaddresstheimportantcharacteristicsandengineeringrequirementsoftheproduct.Eachpartmusthaveacontrolplan,butinmanycases,“family”controlplanscanapplytoanumberofpartsproducedusingacommonprocess.(13)PartSubmissionWarrantPart Submission Warrant:PartSubmissionWarrantisacertificateofcompliancerequiredForallnewlytooledorrevised(up-rev)productsinwhichsupplierconfirmsthatInspectionsandtestsonproductionpartsshowconformancetoMotorolaprintrequirements.(14)AppearanceApprovalReportAppearance Approval Report:MotoroladefinesAppearanceApprovalReportaslimitsamples.LimitsamplesarethepartsthatdonotmeetMotorolaPCScosmeticrequirements,butareapprovedbytheMotorola,PCSdevelopmentEngineeringandquality/CTE.Inadditionlimitsamplesaresetupforcolororfinishesranges(InlimitsamplesrangesaresetperGolden/Mastersample)(15)BulkMaterialRequirementsChecklistBulk Material Requirements:Bulkmaterialisasubstance(e.g.non-dimensionalsolid,liquid,gas)Suchasadhesives,sealants,chemicals,coating,fabrics,lubricants,etc.AbulkmaterialmaybecomeproductionmaterialifissuedaMotorolapartnumber.Bulkmaterialchecklistisdefinedasalistofqualificationrequirements(16)SampleproductionPartsSample production Parts:SampleproductionPartsaremanufacturedattheproductionsiteusingtheproductiontooling,gaging,process,materials,operators,environment,andprocesssetting.,feeds/speeds/cycletimes/pressures/temperatures.(17)MasterSampleMaster Sample:MasterSample(s)areconsideredasGoldensamplesGoldensamplesareforappearancepartsonly.MostofthetimeGoldensamplesaresetorapprovedForpaintcolor,anodizing,orsurfacefinishes(18)RecordofComplianceWithcustomerspecificRequirementsRecord of Compliance With customer specific Requirements:Motorola,PCSdefines“RecordofComplianceWithcustomerspecificRequirements”asPAFPrintAcceptanceForm(19)CheckingAidsChecking Aids:Checkingaids(fixtures,models,templates,mylars,etc.)Specifictothepartbeingsubmitted,usedininspectingortesting.(20)RunatRatedSpeedRun at Rated Speed:Runningthetool/processatthevelocity/outputitisexpectedtoberunatduringproduction.ForExample:Ifatoolormoldisratedtoproducetrueproductionpartsatarateof300parts/hrorXXhundredparts/hr,suppliermustrunthetrueproductiontool/moldorprocesstothatspeedforsomeperiodoftimetoensureprocessstability,thenselectrandompartsforqualification.ArentsomeofthesePPAPrequirementsthesameaswhatPCSrequiresalready?Yes!Youareright,someofthesePPAPrequirementsarecoveredundercurrentqualificationrequirements.Thereareonlyafewthatarenotcovered.CurrentQualificationRequirements*Abovementionedrequirementsareforatypicalcommodity,foranyspecificcommodityqualificationrequirementscontactyourlocalCTEQualificationRequirementsthatarenotcoveredunderPPAP*Abovementionedrequirementsareforatypicalcommodity,foranyspecificcommodityqualificationrequirementscontactyourlocalCTEThereareNineteen(19)PPAPrequirements,butMotorolaPCSwillrequireonly13outofthose19requirementsfromtheirsupplierstosubmitwithqualificationpackage(s).Sinceall19requirementsarerequired,suppliersarerequiredtokeeptherestoftheitemsonfuturereference.HowmanyofthePPAPrequirementswillberequiredforqualificationandwhichones?PCSPPAPREQUIREMENTSSo as a supplier,what should I submit for qualification?FollowingitemsneedtobesubmittedforMotorolaPCSqualificationrequirements.Suppliermayneedtosubmitadditionalrequirementsbasedonthespecificcommodity.RefertoyourlocalSDEorCTEforadditionalrequirementsforaspecificcommodity.qDesign Records qProcess Flow DiagramqProcess FMEAqDimensional ResultsqMaterial performance Test ResultsqInitial Process StudiesqMeasurement System AnalysisqControl PlanqPart Submission Warrant(PSW)qAppearance Approval(For appearance items only)qSample Production PartsqMaster sample(For appearance items only)qRecord of Compliance with Customer specific Requirements qRun at rated SpeedqControlled and Reportable Materials Disclosure(W18)qA copy of a current Motorola Print/SpecificationqA detailed PFD of the production processqA detailed process FMEAqComplete dimensional data(5-on five production parts).qA material C of C for all materials,Performance test results and material test resultsqCp and Cpk measurements on 35-samples(per A78)qGauge R&R results for equipment used to measure qualification samples.qA detailed quality control Plan.qA Signed Motorola Certificate of ComplianceqSubmit Motorola approved Story boards/limit samplesqSubmit five production samplesqSubmit Motorola approved Golden samplesqA signed and completely filled out PAFqAll qualification samples and measurements must be taken after the tool/mold/assembly process is ran to its rated speed.QUALIFICATIONREQUIREMENTSFORPCSIunderstandthesePPAPrequirements,butwhatexactlydoesMotorolaPCSwanttoseefortheserequirements?Alittlemoreexplanationwouldbehelpful.(1)DesignRecordsDesignrecordsareengineeringrequirementsforjudgingtheacceptabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsareconsideras,allcustomerandsupplierdesignrecords(e.g.:CAD,Pro-Efiles,partdrawing/prints,specifications)Inthisrequirement,MotorolaPCSrequiressupplierstosubmitacurrentcopyoftheMotorolaPrint/specification.Print/specificationmusthavethesamerevisionasthequalificationpackage.(2)EngineeringChangeDocuments(ifany)EngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchange(s)(authorizedbyMotoroladevelopmentengineering)notyetrecordedinthedesignrecordbutincorporatedintheproduct,partortooling.Inthisrequirement,MotorolaPCSrequiressuppliertoresolvealldesignorprocessissuesbeforesubmittingthequalificationpackage.IfforanyreasonthesupplierdecidestochangetheprocessfromtheOriginalqualification,aPCN(ProcessChangeNotification)mustbeapprovedbyPCS.IfMotoroladecidestochangethedesignaftertheQualification,suppliersarerequiredtore-submitthequalificationpernewPrint/specificationrevision.MotorolaexpectsitssupplierstoretainallengineeringChangedocumentsforfuturereference.(Referto“MotorolaPCSProcessChangeNotificationProcedure12M09192A78”)(3)CustomerEngineeringApproval(Ifrequired)CustomerEngineeringapprovalistheprocessthatprovidesfortwowaycommunicationbetweenthecomponentsupplier&theresponsibleMotoroladesignengineeringactivityandthroughwhichthesupplierrequestsconcurrenceforcertaindesignandprocesschanges.OnceMotoroladesignengineeringdeterminesthatthechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillcompleteandsubmittheProcessChangeNotificationforapproval.WherespecifiedbytheMotorolaprint/specification,thesuppliershallhaveevidenceofMotorolaengineeringapproval.Suppliersdonotneedtosubmitthisrequirementwithqualification,butshouldkeepitforfuturereference.(4)DesignFMEAFMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.ThesuppliershallhaveaDesignFMEAdevelopedforpartsormaterialforwhichtheyaredesign-responsible.DFMEAisarequirementforqualification.SuppliersdonotneedtosubmittheDFMEAwithqualification,insteadtheyneedtoretainitforfuturereference.(5)ProcessFlowDiagramCustomersiteStopPROCESSFLOWDIAGRAMFORAMETALSMSHIELDIncomingMaterialStorageFinalInspectionPlatingDe-greasingStamping/FormingDe-burringoperationStorageTransportationStartThesuppliershallhaveaPFD(ProcessFlowDiagram)forallpart(s)requiringqualification.SuppliermustsubmitadetailedPFDwitheachqualificationpackage.Inadditiontotheflowofmaterialsthroughtheprocess,includeallreworkorrepairoperationsandcycletimeinyourflowchartIncomingMaterialStorageFinalInspectionPlatingDe-greasingStamping/FormingDe-burringoperationStorageTransportationCustomersiteVerificationofalloyRawmat.CompositionHardnessShelfLifeHumidityOxidationWaterleakage(rain.etc)YouneedtoidentifyallthepotentialfailuremodesforyourPFMEAtobeeffective.Acrossfunctionalteam(teamshouldincludemembersfromoperatorstoqualitymanagers)shouldbedevelopedforaneffectivePFMEA.(6)ProcessFMEAThesuppliershallhaveadetailedPFMEAdevelopedandsubmittedwitheveryqualificationpackage.SuppliermusttakecorrectiveactiontoitemswithaRPN60Reviewprocessflowdiagramandidentifycriticalstepsintheprocessflow.VerifythatallthecriticalstepsarecoveredunderPFMEA(7)DimensionalResultsDimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool,mold,orset-up.Alldimensions(exceptreferencedimensions),Characteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.Thesuppliershallprovideevidencethatdimensionalverificationsrequiredbytheprint/specificationhavebeencompletedandresultsindicatecompliancewithspecifiedrequirements.Dimensionalmeasurementmustbedoneonallcavities,mold,tools,ordies.Alldimensions,characteristics,andspecificationsasnotedontheprint/specificationandnotesshouldbemeasuredandlistedinaconvenientformatwiththeactualresultsrecorded.(8)Material,PerformanceTestResultsMaterialtestsmustbeperformedforallpartsandproductmaterialswhenchemical/physical/metallurgicalrequirementsarespecifiedontheprint.Thesuppliermustperformthetestsrequiredbythematerialspecificationsandthecontrolplan.Ifthesuppliercannotperformtherequiredtest,servicesmustbeprocuredfromanoutsidequalifiedsource.WhenthirdpartyLabservicesareused,theresultsmustbesubmittedontheirletterhead.Thenameofthelaboratorythatperformedthetestsmustbeindicated.Testreportmustindicatetherevisionlevelofthepartstested,andthedateandrevisionlevelofthespecifications.In addition supplier must submit a material certificate of complianceforallthematerialinthepart(e.g.plasticpaintedpartmusthavebothmaterialCofCplasticandp
