[精选]TS16949 PPAP Trainingrev E.pptx

WEL EWhatistheintentofthisTraining?WhatistheintentofthisTraining?TheintentofthistrainingistomunicateMotorolaPCSs,PPAPrequirementstothesuppliersandtraintheSDEEngineersandsuppliersonthesePPAPrequirementsforqualificationSUPPLIERDEVELOPMENTENGINEERINGTRAININGMODULESDE-VOLIIIBy:ZubairIqbalJuly16th2004WhatdoesPPAPstandfor?PRODUCTIONPPAPPARTAPPROVALPROCESSPPAPisaproductionpartapprovalprocessusedbyUSautoindustryGM,Ford,andChrysler.TheProductionPartApprovalProcessPPAPoutlinesthemethodsusedforapprovalofproductionandservicemodities,includingbulkmaterials,uptoandincludingpartsubmissionwarrantintheAdvancedQualityPlanningprocess.ThepurposeofthePPAPprocessistoensurethatsuppliersofponentsplywiththedesignspecificationandcanshowdocumentaryevidencethatthelevelcanbemaintainedduringthelifeoftheproduct.WhatistheProductionPartApprovalProcess?IsMotorolaPCSchangingthequalificationrequirements?MotorolaPCSisnotchangingqualificationrequirements,insteadMotorolaPCSisenhancing/addingthecurrentqualificationrequirementstomatchthePPAPrequirements.WhatarethePPAPrequirements?PPAPRequirementsInadditiontothesePPAPrequirements,PCShasaddedthisnewadditionalrequirementWhatisthePurposeofthesenewPPAPRequirements?ThePurposeofPPAPistodetermineifallcustomerengineeringdesignrecordsandspecificationrequirementsareproperlyunderstoodbythesupplierandthattheprocesshasthepotentialtoproduceproductmeetingtheserequirementsduringanactualproductionrunatthequotedrate.Iamnotfamiliarwithsomeoftheserequirements,wouldyoupleaseexplainwhatthesePPAPrequirementsare?1DesignRecordsDesign Records:Designrecordsareengineeringrequirementsforjudgingtheacceptabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsareconsideras,allcustomerandsupplierdesignrecordse.g.:CAD,Pro-Efiles,partdrawing/prints,specifications2EngineeringChangeDocumentsifanyEngineering Change Documents:EngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchangesauthorizedbyMotoroladevelopmentengineeringnotyetrecordedinthedesignrecordbutincorporatedintheproduct,partortooling.3CustomerEngineeringApprovalIfrequiredCustomer Engineering Approval:CustomerEngineeringapprovalistheprocessthatprovidesfortwowaymunicationbetweentheponentsupplier&theresponsibleMotoroladesignengineeringactivityandthroughwhichthesupplierrequestsconcurrenceforcertaindesignandprocesschanges.OnceMotoroladesignengineeringdeterminesthatthechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillpleteandsubmittheProcessChangeNotificationforapproval.4DesignFMEADesign FMEA:FMEAisanEngineering“ReliabilityToolthathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.5ProcessFlowDiagramProcess Flow Diagram:Processisabinationofpeople,equipment,method,Material,andenvironmentthatproducesoutput,foragivenproductorservice.ProcessFlowDiagramdepictstheflowofmaterialsthroughtheprocess,includinganyre-work,repairoperationsorcycletime.6ProcessFMEAFailure Modes and Effects Analysis FMEAFMEAisanEngineering“ReliabilityToolthathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.7DimensionalResultsDimensional Results:Dimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool,mold,orset-up.Alldimensionsexceptreferencedimensions,Characteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.8Material,PerformanceTestResultsMaterial,Performance Test Results:MaterialtestsaretestthatspecifiedonMotorolaprintorspecificationsaschemical,physicalormetallurgicaltestse.g.MEK,abrasion,adhesion,etc.PerformancetestsaretestthatspecifiedonMotorolaprintorspecificationsasperformancetestse.g.numberofcycles,environmentaltesting,electricaltesting,Platingthickness,Paintthickness,Glossreadings,etc.9InitialProcessStudiesInitial Process Studies:ForBox-X Xandparameters,thesuppliershallprovideCp/CpkstatisticstoensureanacceptableprocesscapabilityCp/Cpkof2/1.5orgreater.Asampleof35piecesisdeemedappropriatefornormallydistributeddatagatheredviaanacceptablemeasurementmethoderrorrate10%orlessunlessapprovedbyCTE.ForconditionsthatrequirereviewCp/Cpkbelow1.5,supplierrequest,non-normaldistribution,ormeasurementissues,thesuppliermustnotifyMotorola.Motorolamustapproveanydeviation.*10MeasurementSystemAnalysis Measurement System Analysis:MeasurementsystemanalysisMSAisanexperimentalandmathematicalmethodofdetermininghowmuchthevariationwithinthemeasurementprocesscontributestooverallprocessvariability.TherearefiveparameterstoinvestigateinanMSA:bias,linearity,stability,repeatabilityandreproducibility.11QualifiedLaboratoryDocumentationQualified Laboratory Documentation:AQualifiedlaboratoryisatestfacilitythatmayincludechemical,metallurgical,dimensional,physical,electrical,reliabilitytestingortestvalidation.QualifiedLaboratoryDocumentationisadocumentationortestresultsissuedbyaMotorolaqualifiedlaboratory12ControlplanControl plan:Controlplansarewrittendescriptionsofthesystemforcontrollingproductionpartsorbulkmaterialsandprocesses.Theyarewrittenbysupplierstoaddresstheimportantcharacteristicsandengineeringrequirementsoftheproduct.Eachpartmusthaveacontrolplan,butinmanycases,“familycontrolplanscanapplytoanumberofpartsproducedusingamonprocess.13PartSubmissionWarrantPart Submission Warrant:PartSubmissionWarrantisacertificateofpliancerequiredForallnewlytooledorrevisedup-revproductsinwhichsupplierconfirmsthatInspectionsandtestsonproductionpartsshowconformancetoMotorolaprintrequirements.14AppearanceApprovalReportAppearance Approval Report:MotoroladefinesAppearanceApprovalReportaslimitsamples.LimitsamplesarethepartsthatdonotmeetMotorolaPCScosmeticrequirements,butareapprovedbytheMotorola,PCSdevelopmentEngineeringandquality/CTE.InadditionlimitsamplesaresetupforcolororfinishesrangesInlimitsamplesrangesaresetperGolden/Mastersample15BulkMaterialRequirementsChecklistBulk Material Requirements:Bulkmaterialisasubstancee.g.non-dimensionalsolid,liquid,gasSuchasadhesives,sealants,chemicals,coating,fabrics,lubricants,etc.AbulkmaterialmaybeeproductionmaterialifissuedaMotorolapartnumber.Bulkmaterialchecklistisdefinedasalistofqualificationrequirements16SampleproductionPartsSample production Parts:SampleproductionPartsaremanufacturedattheproductionsiteusingtheproductiontooling,gaging,process,materials,operators,environment,andprocesssetting.,feeds/speeds/cycletimes/pressures/temperatures.17MasterSampleMaster Sample:MasterSamplesareconsideredasGoldensamplesGoldensamplesareforappearancepartsonly.MostofthetimeGoldensamplesaresetorapprovedForpaintcolor,anodizing,orsurfacefinishes18RecordofplianceWithcustomerspecificRequirementsRecord of pliance With customer specific Requirements:Motorola,PCSdefines“RecordofplianceWithcustomerspecificRequirementsasPAFPrintAcceptanceForm19CheckingAidsChecking Aids:Checkingaidsfixtures,models,templates,mylars,etc.Specifictothepartbeingsubmitted,usedininspectingortesting.20RunatRatedSpeedRun at Rated Speed:Runningthetool/processatthevelocity/outputitisexpectedtoberunatduringproduction.ForExample:Ifatoolormoldisratedtoproducetrueproductionpartsatarateof300parts/hrorXXhundredparts/hr,suppliermustrunthetrueproductiontool/moldorprocesstothatspeedforsomeperiodoftimetoensureprocessstability,thenselectrandompartsforqualification.ArentsomeofthesePPAPrequirementsthesameaswhatPCSrequiresalready?Yes!Youareright,someofthesePPAPrequirementsarecoveredundercurrentqualificationrequirements.Thereareonlyafewthatarenotcovered.CurrentQualificationRequirements*Abovementionedrequirementsareforatypicalmodity,foranyspecificmodityqualificationrequirementscontactyourlocalCTEQualificationRequirementsthatarenotcoveredunderPPAP*Abovementionedrequirementsareforatypicalmodity,foranyspecificmodityqualificationrequirementscontactyourlocalCTEThereareNineteen19PPAPrequirements,butMotorolaPCSwillrequireonly13outofthose19requirementsfromtheirsupplierstosubmitwithqualificationpackages.Sinceall19requirementsarerequired,suppliersarerequiredtokeeptherestoftheitemsonfileforfuturereference.HowmanyofthePPAPrequirementswillberequiredforqualificationandwhichones?PCSPPAPREQUIREMENTSSo as a supplier,what should I submit for qualification?FollowingitemsneedtobesubmittedforMotorolaPCSqualificationrequirements.Suppliermayneedtosubmitadditionalrequirementsbasedonthespecificmodity.RefertoyourlocalSDEorCTEforadditionalrequirementsforaspecificmodity.qDesign Records qProcess Flow DiagramqProcess FMEAqDimensional ResultsqMaterial performance Test ResultsqInitial Process StudiesqMeasurement System AnalysisqControl PlanqPart Submission Warrant PSWqAppearance Approval For appearance items onlyqSample Production PartsqMaster sample For appearance items onlyqRecord of pliance with Customer specific Requirements qRun at rated SpeedqControlled and Reportable Materials Disclosure W18qA copy of a current Motorola Print/SpecificationqA detailed PFD of the production processqA detailed process FMEAq plete 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 A78qGauge R&R results for equipment used to measure qualification samples.qA detailed quality control Plan.qA Signed Motorola Certificate of plianceqSubmit Motorola approved Story boards/limit samplesqSubmit five production samplesqSubmit Motorola approved Golden samplesqA signed and pletely 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.1DesignRecordsDesignrecordsareengineeringrequirementsforjudgingtheacceptabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsareconsideras,allcustomerandsupplierdesignrecordse.g.:CAD,Pro-Efiles,partdrawing/prints,specificationsInthisrequirement,MotorolaPCSrequiressupplierstosubmitacurrentcopyoftheMotorolaPrint/specification.Print/specificationmusthavethesamerevisionasthequalificationpackage.2EngineeringChangeDocumentsifanyEngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchangesauthorizedbyMotoroladevelopmentengineeringnotyetrecordedinthedesignrecordbutincorporatedintheproduct,partortooling.Inthisrequirement,MotorolaPCSrequiressuppliertoresolvealldesignorprocessissuesbeforesubmittingthequalificationpackage.IfforanyreasonthesupplierdecidestochangetheprocessfromtheOriginalqualification,aPCNProcessChangeNotificationmustbeapprovedbyPCS.IfMotoroladecidestochangethedesignaftertheQualification,suppliersarerequiredtore-submitthequalificationpernewPrint/specificationrevision.MotorolaexpectsitssupplierstoretainallengineeringChangedocumentsforfuturereference.Referto“MotorolaPCSProcessChangeNotificationProcedure12M09192A783CustomerEngineeringApprovalIfrequiredCustomerEngineeringapprovalistheprocessthatprovidesfortwowaymunicationbetweentheponentsupplier&theresponsibleMotoroladesignengineeringactivityandthroughwhichthesupplierrequestsconcurrenceforcertaindesignandprocesschanges.OnceMotoroladesignengineeringdeterminesthatthechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillpleteandsubmittheProcessChangeNotificationforapproval.WherespecifiedbytheMotorolaprint/specification,thesuppliershallhaveevidenceofMotorolaengineeringapproval.Suppliersdonotneedtosubmitthisrequirementwithqualification,butshouldkeepitforfuturereference.4DesignFMEAFMEAisanEngineering“ReliabilityToolthathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.ThesuppliershallhaveaDesignFMEAdevelopedforpartsormaterialforwhichtheyaredesign-responsible.DFMEAisarequirementforqualification.SuppliersdonotneedtosubmittheDFMEAwithqualification,insteadtheyneedtoretainitforfuturereference.5ProcessFlowDiagramCustomersiteStopPROCESSFLOWDIAGRAMFORAMETALSMSHIELDIncomingMaterialStorageFinalInspectionPlatingDe-greasingStamping/FormingDe-burringoperationStorageTransportationStartThesuppliershallhaveaPFDProcessFlowDiagramforallpartsrequiringqualification.SuppliermustsubmitadetailedPFDwitheachqualificationpackage.Inadditiontotheflowofmaterialsthroughtheprocess,includeallreworkorrepairoperationsandcycletimeinyourflowchartIncomingMaterialStorageFinalInspectionPlatingDe-greasingStamping/FormingDe-burringoperationStorageTransportationCustomersiteVerificationofalloyRawmat.positionHardnessShelfLifeHumidityOxidationWaterleakagerain.etcYouneedtoidentifyallthepotentialfailuremodesforyourPFMEAtobeeffective.AcrossfunctionalteamteamshouldincludemembersfromoperatorstoqualitymanagersshouldbedevelopedforaneffectivePFMEA.6ProcessFMEAThesuppliershallhaveadetailedPFMEAdevelopedandsubmittedwitheveryqualificationpackage.SuppliermusttakecorrectiveactiontoitemswithaRPN60Reviewprocessflowdiagramandidentifycriticalstepsintheprocessflow.VerifythatallthecriticalstepsarecoveredunderPFMEA7DimensionalResultsDimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool,mold,orset-up.Alldimensionsexceptreferencedimensions,Characteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.Thesuppliershallprovideevidencethatdimensionalverificationsrequiredbytheprint/specificationhavebeenpletedandresultsindicatepliancewithspecifiedrequirements.Dimensionalmeasurementmustbedoneonallcavities,mold,tools,ordies.Alldimensions,characteristics,andspecificationsasnotedontheprint/specificationandnotesshouldbemeasuredandlistedinaconvenientformatwiththeactualresultsrecorded.8Material,PerformanceTestResultsMaterialtestsmustbeperformedforallpartsandproductmaterialswhenchemical/physical/metallurgicalrequirementsarespecifiedontheprint.Thesuppliermustperformthetestsrequiredbythematerialspecificationsandthecontrolplan.Ifthesuppliercannotperformtherequiredtest,servicesmustbeprocuredfromanoutsidequalifiedsource.WhenthirdpartyLabservicesareused,theresultsmustbesubmittedontheirletterhead.Thenameofthelaboratorythatperformedthetestsmustbeindicated.Testreportmustindicatetherevisionlevelofthepartstested,andthedateandrevisionlevelofthespecifications.In addition supplier must submit a material certificate of plianceforallthematerialintheparte.g.plasticpaintedpartmusthavebothmaterialCofCplasticandpaint.MaterialCofCmustbeonrawmaterialsupplierletterhead.Thenameoftherawmaterialsupplierthatsuppliedthematerialmustbeindicated.9InitialProcessStudiesForBox-X Xandparameters,thesuppliershallprovideCp/Cpkstatisticstoensureana