TS16949 PPAP Trainingrev E课件.pptx

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1、WELCOMEWhatistheintentofthisTraining?WhatistheintentofthisTraining?TheintentofthistrainingistocommunicateMotorolaPCSs,PPAPrequirementstothesuppliersandtraintheSDEEngineersandsuppliersonthesePPAPrequirementsforqualificationSUPPLIERDEVELOPMENTENGINEERINGTRAININGMODULESDE-VOLIIIBy:ZubairIqbalJuly16th20

2、04WhatdoesPPAPstandfor?PRODUCTIONPPAPPARTAPPROVALPROCESSPPAPisaproductionpartapprovalprocessusedbyUSautoindustry(GM,Ford,andChrysler).TheProductionPartApprovalProcess(PPAP)outlinesthemethodsusedforapprovalofproductionandservicecommodities,includingbulkmaterials,uptoandincludingpartsubmissionwarranti

3、ntheAdvancedQualityPlanningprocess.ThepurposeofthePPAPprocessistoensurethatsuppliersofcomponentscomplywiththedesignspecificationandcanshowdocumentaryevidencethatthelevelcanbemaintainedduringthelifeoftheproduct.WhatistheProductionPartApprovalProcess?IsMotorolaPCSchangingthequalificationrequirements?M

4、otorolaPCSisnotchangingqualificationrequirements,insteadMotorolaPCSisenhancing/addingthecurrentqualificationrequirementstomatchthePPAPrequirements.WhatarethePPAPrequirements?PPAPRequirementsInadditiontothesePPAPrequirements,PCShasaddedthisnewadditionalrequirementWhatisthePurposeofthesenewPPAPRequire

5、ments?ThePurposeofPPAPistodetermineifallcustomerengineeringdesignrecordsandspecificationrequirementsareproperlyunderstoodbythesupplierandthattheprocesshasthepotentialtoproduceproductmeetingtheserequirementsduringanactualproductionrunatthequotedrate.Iamnotfamiliarwithsomeoftheserequirements,wouldyoup

6、leaseexplainwhatthesePPAPrequirementsare?(1)DesignRecordsDesign Records:Designrecordsareengineeringrequirementsforjudgingtheacceptabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsareconsideras,

7、allcustomerandsupplierdesignrecords(e.g.:CAD,Pro-Efiles,partdrawing/prints,specifications)(2)EngineeringChangeDocuments(ifany)Engineering Change Documents:EngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchange(s)(authorizedbyMotoroladevelopmentengineering)notyetrecordedinthedesignrecor

8、dbutincorporatedintheproduct,partortooling.(3)CustomerEngineeringApproval(Ifrequired)Customer Engineering Approval:CustomerEngineeringapprovalistheprocessthatprovidesfortwowaycommunicationbetweenthecomponentsupplier&theresponsibleMotoroladesignengineeringactivityandthroughwhichthesupplierrequestscon

9、currenceforcertaindesignandprocesschanges.OnceMotoroladesignengineeringdeterminesthatthechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillcompleteandsubmittheProcessChangeNotificationforapproval.(4)DesignFMEADesign FMEA:FMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,p

10、rioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.(5)ProcessFlowDiagramProcess Flow Diagram:Processisacombinationofpeople,equipment,method,Material,andenviron

11、mentthatproducesoutput,foragivenproductorservice.ProcessFlowDiagramdepictstheflowofmaterialsthroughtheprocess,includinganyre-work,repairoperationsorcycletime.(6)ProcessFMEAFailure Modes and Effects Analysis(FMEA)FMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminatekn

12、ownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.(7)DimensionalResultsDimensional Results:Dimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool

13、,mold,orset-up.Alldimensions(exceptreferencedimensions),Characteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.(8)Material,PerformanceTestResultsMaterial,Performance Test Results:MaterialtestsaretestthatspecifiedonMotorolaprintorspecificationsaschemi

14、cal,physicalormetallurgicaltestse.g.MEK,abrasion,adhesion,etc.PerformancetestsaretestthatspecifiedonMotorolaprintorspecificationsasperformancetestse.g.numberofcycles,environmentaltesting,electricaltesting,Platingthickness,Paintthickness,Glossreadings,etc.(9)InitialProcessStudiesInitial Process Studi

15、es:ForBox-X Xandparameters,thesuppliershallprovideCp/Cpkstatisticstoensureanacceptableprocesscapability(Cp/Cpkof2/1.5orgreater).Asampleof35piecesisdeemedappropriatefornormallydistributeddatagatheredviaanacceptablemeasurementmethod(errorrate10%orlessunlessapprovedbyCTE).Forconditionsthatrequirereview

16、(Cp/Cpkbelow1.5,supplierrequest,non-normaldistribution,ormeasurementissues),thesuppliermustnotifyMotorola.Motorolamustapproveanydeviation.(*)(10)MeasurementSystemAnalysis Measurement System Analysis:Measurementsystemanalysis(MSA)isanexperimentalandmathematicalmethodofdetermininghowmuchthevariationwi

17、thinthemeasurementprocesscontributestooverallprocessvariability.TherearefiveparameterstoinvestigateinanMSA:bias,linearity,stability,repeatabilityandreproducibility.(11)QualifiedLaboratoryDocumentationQualified Laboratory Documentation:AQualifiedlaboratoryisatestfacilitythatmayincludechemical,metallu

18、rgical,dimensional,physical,electrical,reliabilitytestingortestvalidation.QualifiedLaboratoryDocumentationisadocumentationortestresultsissuedbyaMotorolaqualifiedlaboratory(12)ControlplanControl plan:Controlplansarewrittendescriptionsofthesystemforcontrollingproductionpartsorbulkmaterialsandprocesses

19、.Theyarewrittenbysupplierstoaddresstheimportantcharacteristicsandengineeringrequirementsoftheproduct.Eachpartmusthaveacontrolplan,butinmanycases,“family”controlplanscanapplytoanumberofpartsproducedusingacommonprocess.(13)PartSubmissionWarrantPart Submission Warrant:PartSubmissionWarrantisacertificat

20、eofcompliancerequiredForallnewlytooledorrevised(up-rev)productsinwhichsupplierconfirmsthatInspectionsandtestsonproductionpartsshowconformancetoMotorolaprintrequirements.(14)AppearanceApprovalReportAppearance Approval Report:MotoroladefinesAppearanceApprovalReportaslimitsamples.Limitsamplesarethepart

21、sthatdonotmeetMotorolaPCScosmeticrequirements,butareapprovedbytheMotorola,PCSdevelopmentEngineeringandquality/CTE.Inadditionlimitsamplesaresetupforcolororfinishesranges(InlimitsamplesrangesaresetperGolden/Mastersample)(15)BulkMaterialRequirementsChecklistBulk Material Requirements:Bulkmaterialisasub

22、stance(e.g.non-dimensionalsolid,liquid,gas)Suchasadhesives,sealants,chemicals,coating,fabrics,lubricants,etc.AbulkmaterialmaybecomeproductionmaterialifissuedaMotorolapartnumber.Bulkmaterialchecklistisdefinedasalistofqualificationrequirements(16)SampleproductionPartsSample production Parts:Sampleprod

23、uctionPartsaremanufacturedattheproductionsiteusingtheproductiontooling,gaging,process,materials,operators,environment,andprocesssetting.,feeds/speeds/cycletimes/pressures/temperatures.(17)MasterSampleMaster Sample:MasterSample(s)areconsideredasGoldensamplesGoldensamplesareforappearancepartsonly.Most

24、ofthetimeGoldensamplesaresetorapprovedForpaintcolor,anodizing,orsurfacefinishes(18)RecordofComplianceWithcustomerspecificRequirementsRecord of Compliance With customer specific Requirements:Motorola,PCSdefines“RecordofComplianceWithcustomerspecificRequirements”asPAFPrintAcceptanceForm(19)CheckingAid

25、sChecking Aids:Checkingaids(fixtures,models,templates,mylars,etc.)Specifictothepartbeingsubmitted,usedininspectingortesting.(20)RunatRatedSpeedRun at Rated Speed:Runningthetool/processatthevelocity/outputitisexpectedtoberunatduringproduction.ForExample:Ifatoolormoldisratedtoproducetrueproductionpart

26、satarateof300parts/hrorXXhundredparts/hr,suppliermustrunthetrueproductiontool/moldorprocesstothatspeedforsomeperiodoftimetoensureprocessstability,thenselectrandompartsforqualification.ArentsomeofthesePPAPrequirementsthesameaswhatPCSrequiresalready?Yes!Youareright,someofthesePPAPrequirementsarecovere

27、dundercurrentqualificationrequirements.Thereareonlyafewthatarenotcovered.CurrentQualificationRequirements*Abovementionedrequirementsareforatypicalcommodity,foranyspecificcommodityqualificationrequirementscontactyourlocalCTEQualificationRequirementsthatarenotcoveredunderPPAP*Abovementionedrequirement

28、sareforatypicalcommodity,foranyspecificcommodityqualificationrequirementscontactyourlocalCTEThereareNineteen(19)PPAPrequirements,butMotorolaPCSwillrequireonly13outofthose19requirementsfromtheirsupplierstosubmitwithqualificationpackage(s).Sinceall19requirementsarerequired,suppliersarerequiredtokeepth

29、erestoftheitemsonfuturereference.HowmanyofthePPAPrequirementswillberequiredforqualificationandwhichones?PCSPPAPREQUIREMENTSSo as a supplier,what should I submit for qualification?FollowingitemsneedtobesubmittedforMotorolaPCSqualificationrequirements.Suppliermayneedtosubmitadditionalrequirementsbased

30、onthespecificcommodity.RefertoyourlocalSDEorCTEforadditionalrequirementsforaspecificcommodity.qDesign Records qProcess Flow DiagramqProcess FMEAqDimensional ResultsqMaterial performance Test ResultsqInitial Process StudiesqMeasurement System AnalysisqControl PlanqPart Submission Warrant(PSW)qAppeara

31、nce 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

32、 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 s

33、amples.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 ta

34、ken after the tool/mold/assembly process is ran to its rated speed.QUALIFICATIONREQUIREMENTSFORPCSIunderstandthesePPAPrequirements,butwhatexactlydoesMotorolaPCSwanttoseefortheserequirements?Alittlemoreexplanationwouldbehelpful.(1)DesignRecordsDesignrecordsareengineeringrequirementsforjudgingtheaccep

35、tabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsareconsideras,allcustomerandsupplierdesignrecords(e.g.:CAD,Pro-Efiles,partdrawing/prints,specifications)Inthisrequirement,MotorolaPCSrequiressu

36、pplierstosubmitacurrentcopyoftheMotorolaPrint/specification.Print/specificationmusthavethesamerevisionasthequalificationpackage.(2)EngineeringChangeDocuments(ifany)EngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchange(s)(authorizedbyMotoroladevelopmentengineering)notyetrecordedinthede

37、signrecordbutincorporatedintheproduct,partortooling.Inthisrequirement,MotorolaPCSrequiressuppliertoresolvealldesignorprocessissuesbeforesubmittingthequalificationpackage.IfforanyreasonthesupplierdecidestochangetheprocessfromtheOriginalqualification,aPCN(ProcessChangeNotification)mustbeapprovedbyPCS.

38、IfMotoroladecidestochangethedesignaftertheQualification,suppliersarerequiredtore-submitthequalificationpernewPrint/specificationrevision.MotorolaexpectsitssupplierstoretainallengineeringChangedocumentsforfuturereference.(Referto“MotorolaPCSProcessChangeNotificationProcedure12M09192A78”)(3)CustomerEn

39、gineeringApproval(Ifrequired)CustomerEngineeringapprovalistheprocessthatprovidesfortwowaycommunicationbetweenthecomponentsupplier&theresponsibleMotoroladesignengineeringactivityandthroughwhichthesupplierrequestsconcurrenceforcertaindesignandprocesschanges.OnceMotoroladesignengineeringdeterminesthatt

40、hechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillcompleteandsubmittheProcessChangeNotificationforapproval.WherespecifiedbytheMotorolaprint/specification,thesuppliershallhaveevidenceofMotorolaengineeringapproval.Suppliersdonotneedtosubmitthisrequirementwithqualification,butshouldke

41、epitforfuturereference.(4)DesignFMEAFMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.Thesuppl

42、iershallhaveaDesignFMEAdevelopedforpartsormaterialforwhichtheyaredesign-responsible.DFMEAisarequirementforqualification.SuppliersdonotneedtosubmittheDFMEAwithqualification,insteadtheyneedtoretainitforfuturereference.(5)ProcessFlowDiagramCustomersiteStopPROCESSFLOWDIAGRAMFORAMETALSMSHIELDIncomingMate

43、rialStorageFinalInspectionPlatingDe-greasingStamping/FormingDe-burringoperationStorageTransportationStartThesuppliershallhaveaPFD(ProcessFlowDiagram)forallpart(s)requiringqualification.SuppliermustsubmitadetailedPFDwitheachqualificationpackage.Inadditiontotheflowofmaterialsthroughtheprocess,includea

44、llreworkorrepairoperationsandcycletimeinyourflowchartIncomingMaterialStorageFinalInspectionPlatingDe-greasingStamping/FormingDe-burringoperationStorageTransportationCustomersiteVerificationofalloyRawmat.CompositionHardnessShelfLifeHumidityOxidationWaterleakage(rain.etc)Youneedtoidentifyallthepotenti

45、alfailuremodesforyourPFMEAtobeeffective.Acrossfunctionalteam(teamshouldincludemembersfromoperatorstoqualitymanagers)shouldbedevelopedforaneffectivePFMEA.(6)ProcessFMEAThesuppliershallhaveadetailedPFMEAdevelopedandsubmittedwitheveryqualificationpackage.SuppliermusttakecorrectiveactiontoitemswithaRPN6

46、0Reviewprocessflowdiagramandidentifycriticalstepsintheprocessflow.VerifythatallthecriticalstepsarecoveredunderPFMEA(7)DimensionalResultsDimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool,mold,orset-up.Alldimensions(exceptreferencedimensions),Characteristics,s

47、pecificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.Thesuppliershallprovideevidencethatdimensionalverificationsrequiredbytheprint/specificationhavebeencompletedandresultsindicatecompliancewithspecifiedrequirements.Dimensionalmeasurementmustbedoneonallcavities,mold

48、,tools,ordies.Alldimensions,characteristics,andspecificationsasnotedontheprint/specificationandnotesshouldbemeasuredandlistedinaconvenientformatwiththeactualresultsrecorded.(8)Material,PerformanceTestResultsMaterialtestsmustbeperformedforallpartsandproductmaterialswhenchemical/physical/metallurgical

49、requirementsarespecifiedontheprint.Thesuppliermustperformthetestsrequiredbythematerialspecificationsandthecontrolplan.Ifthesuppliercannotperformtherequiredtest,servicesmustbeprocuredfromanoutsidequalifiedsource.WhenthirdpartyLabservicesareused,theresultsmustbesubmittedontheirletterhead.Thenameofthel

50、aboratorythatperformedthetestsmustbeindicated.Testreportmustindicatetherevisionlevelofthepartstested,andthedateandrevisionlevelofthespecifications.In addition supplier must submit a material certificate of complianceforallthematerialinthepart(e.g.plasticpaintedpartmusthavebothmaterialCofCplasticandp