PPAP Procedure Supplier 要求学习教程.pptx

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1、DefinitionOur Responsibility“Production Part Approval Process(PPAP)defines generic requirements for production part approval,including production and bulk materials.PPAP定义了生产件批准的一般要求，包括生产材料和散装材料。The purpose of PPAP is to determine if all customer engineering design records and specification requirem

2、ents are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.”PPAP的目的是确定供应商是否正确理解了客户工程设计记录和规范的所有要求，以及在报价生产节拍下进行实际生产的过程中，是否能生产出能持续满足这些要求的产品。Production Part A

3、pproval Process(PPAP)Fourth Edition,2006第1页/共29页Quality Documentation Review 质量文件评审质量文件评审The supplier is to generate a PPAP number and load all documents on SCC for the SQE to review while keeping the PPAP in the“New”status.供应商要生成一个PPAP编号，并把所有文件放到SCC上供SQE评审。将PPAP状态保持在“New”的状态All documentation and la

4、yout results MUST be approved by the SQE prior to the supplier“Submitting”the PPAP on SCC.在供应商在SCC上提交PPAP之前，所有文件和全尺寸报告必须得到SQE的批准。PPAP Approval Should be Quick,with Little Review Needed第2页/共29页PPAP Level Requirements PPAP等级要求等级要求Level 1:Warrant Sheet PSW Level 2:Warrant Sheet PSWDimensional 尺寸报告Mater

5、ial certification理化报告Level 3:Warrant Sheet PSWMaterial certification理化报告Dimensional尺寸报告Process capability study过程能力研究Measurement systems analysis MSAProcess Failure Mode and Effects Analysis PFMEADynamic Control Plan控制计划Process Flow Chart 流程图Run-at-Rate/Capacity study worksheet节拍生产报告Sample Parts 样件L

6、evel 4:Level 1 PPAP+additional customer requirements PSW+客户其他要求Level 5:Level 3 PPAP+additional customer requirements+on site audit第3等级PPAP提交文件+客户其他要求+现场审核 第3页/共29页Level 1 PPAP 等级等级1Requirements 要求Warrant Sign Off PSW的签署Usage Applicable to note revisions,drawing revisions and other revisions which ha

7、ve no impact on the process or dimensions on the part print or specification适用于备注修改、图纸修改及其他修改，这些改动不会影响产品图纸或规范上规定的过程或尺寸。第4页/共29页Level 2 PPAP等级等级2Requirements要求Warrant Sign Off PSWMaterial Certification 理化报告Dimensional 尺寸报告UsageApplicable to changes small changes when the process is unaffected and ver

8、ification of a minor change is necessary适用于一些较小的、不会影响过程的变更，而且这些变更有必要进行验证和确认。第5页/共29页Level 3 PPAP 等级等级3Requirements 要求Warrant Sign OffMaterial CertificationDimensionalProcess Capability StudiesMeasurement System AnalysisProcess Failure Mode and Effects AnalysisDynamic Control PlanProcess Flow ChartRu

9、n Rate worksheet*Packaging RequirementsSample PartUsage This is the basic submission for all initial PPAPs,tool replacements,and major changes to the process适用情况：所有首次PPAP提交、工装变更、过程发生重大变更第6页/共29页Level 4 PPAP 等级等级4Requirements 要求Warrant sign off PSWAdditional customer requirements 客户其他要求See Customer/P

10、erformance Testing in the following slides 见客户/性能测试（后面的幻灯片）UsageSame as Level 1 with additional customer requirements同等级1，增加了客户其他要求第7页/共29页Level 5 PPAP 等级等级5Requirements 要求PPAP level 3+customer specified requirements 等级3要求+客户规定的要求On site process audit 现场过程审核Form-5414On site Run Rate verificationSee

11、Run Rate in the following slides见节拍生产（见幻灯片21）UsageQualification of new products at new suppliers,“black box”components or high risk situations identified by Program Management or Supply Base适用于：对新供应商生产的新零件的认证、黑盒子零件或在供应商项目管理中识别出的高风险情况第8页/共29页Warrant Sheet PSWMaterial Number*材质号Part Revision Level*件号版

12、本 Verify latest revision in PDMDrawing Revision Level图纸版本Plant number*工厂代码Mexicali Turbo:7905Mexicali Thermal:7975Gross Weight*毛重Prod.Rate/8Hr*生产节拍/8小时Based on PPAP levelHoneywell Tool Number 联信工装编号Buyer Assigned 客户指定Tooling/Mold/Cavity工装/模号/腔号PPAP Level*PPAP等级Submission Reason*提交原因Submission Result

13、s*提交结果Deviation Notes 偏离备注Required PCD values*要求的PCD数据*Mandatory Fields on the PSW 第9页/共29页Material Certification 理化报告理化报告Controlled by part IDM 受控于产品IDMHoneywell material specification 联信材质规范Located on PDM 按图纸上的材质要求规定Chemical Properties 化学性能Mechanical Properties 机械性能Microstructure (If required by I

14、DM)金相组织（如果IDM有要求的话）Compliance to IDM,mandatory 第10页/共29页Dimensional Layout 全尺寸报告全尺寸报告Verify that every dimension is on the layout and conforms to the drawing,notes and specifications检查每个尺寸是否都在报告中，是否符合图纸、备注和规范要求Request PPAP sample parts PPAP样件Layout must be approved by Honeywell 全尺寸必须得到联信认可Volute pro

15、files 流道轮廓GOM scans,etc.Any dimensional discrepancies must be approved by application engineering 任何不符合尺寸必须得到应用工程部门的认可Part prints should be changed to reflect actual part 应更改零件图纸来反映实际零件状况See required signature summary in the following sections 参见相关人员签字要求（见幻灯片29）Verify All Print and Specification Dim

16、ensions Comply第11页/共29页Process Control and Capability Requirements 过程控制和能力要求过程控制和能力要求Controlling Document 受控文件Specification:QCI 9310 190Bilateral KCCs 双边KCCCpk=1.67Estimated performance,calculated from subgroup mean Unilateral KCCs Cpm=1.30 单边KCCSee QCI 9310 190 appendix B,Calculation method 参见QCI 9

17、310 190 附录B，计算方法Customer Interface Characteristics,CICPoke Yoke/Mistake Proof 防呆Cpk=1.33 See QCI 9310 190 appendix A,Classification matrix 参见QCI 9310 190 附录A，分类矩阵表All non-conforming dimensions must be inspected 100%第12页/共29页Measurement Systems Analysis 测量系统分析测量系统分析Controlling Document 受控文件Specificat

18、ion:QCI 9310-190Requirements 要求Measurement discrimination 10%of tolerance range测量分辨率 公差范围的10%Repeatability 10%of total variation重复性 整个变差的10%Repeatability+Reproducibility 30%(Gage R&R)重复性+再现性 总变差的30%Gage R&R only necessary for KCCs and CICs 仅适用于KCC和CIC第13页/共29页Potential Failure Mode and Effects Analy

19、sis PFMEAControlling Document 受控文件Potential Failure Mode and Effects Analysis(FMEA)3r d edition PFMEA第三版Severity ratings must comply with DFMEA 严重度打分必须符合DFMEAControl plan and flow chart must coincide in both operation and dimension 控制计划和流程图必须与工序和尺寸对应Severity 严重度All KCCs and CICs(7)所有KCC 和CIC（7分）KCCs

20、 and CICs must be identified on PFMEA and DCP KCC 和CIC必须在PFMEA和控制计划中体现出来Tabulated on pg.43 参见PFMEA第43页Occurrence 频度Tabulated on pg.49 参见PFMEA第49页Detection 探测度Multiple visual inspection(7)多重目视检查（7分）SPC only=(6)仅SPC来控制（6分）100%attribute inspection or variable gaging=(5)100%计数检查或计量检查（5分）Automatic gaging

21、 with machine stop feature=(2)自动测量并自动停机（2分）Tabulated on pg.53 参见PFMEA第53页Suppliers must comply with PFMEA standards 供应商必须符合PFMEA标准PFMEAs are living documents 第14页/共29页PFMEA Example(cont.)PFMEA样表第15页/共29页Dynamic Control Plan,DCP 动态的控制计划动态的控制计划Controlling Document 受控文件 Advanced Product Quality Plannin

22、g&Control Plan (APQP),1st edition APQP，第一版PFMEA and flow chart must coincide with both operation number and dimension PFMEA和流程图必须和工序编号以及尺寸对应All CICs and KCCs must be identified in“Type Class”所有CICs和KCCs必须注明“等级类型”Reaction Plans must be robust and include non-conforming part containment 反应计划必须完善，要包含对不

23、合格件的遏制对策Sample sizes and frequencies should coincide with initial process studies or historical quality data样本大小和取样频率应该和首次过程研究或历史质量数据一致All quality documents must comply with each other 第16页/共29页DCP Example(cont.)控制计划样表第17页/共29页Process flow charts must identify:必须指明：Operations工序Machines设备Workers人员Sto

24、rage units存储区域Delays within the process过程中的延迟Flow charts must coincide with the PFMEA and DCP!必须和PFMEA和控制计划对应！Benchmark flow charts will contain:标准的流程图要包括Incoming sources of variation偏差的源头Completed dimensions 全部尺寸Traceability information 追溯信息Process Flow Chart 过程流程图过程流程图第18页/共29页Process Flow Chart(c

25、ont.)过程流程图（样表）第19页/共29页Run Rate*节拍生产节拍生产Run Rate Audit Procedure节拍审核程序PDP 0630Run Rate Calculation Worksheet节拍计算表Form 5407Mandatory with every PPAP level 3 or 5 unless waived必须对等级3或5的PPAP作节拍计算，除非客户放弃这方面的要求Run Rate Review Worksheet节拍评审表Form-5408Run Rate mandatory for PPAP levels 3 or 5PPAP level 3:Su

26、pplier performed等级3：由供应商进行节拍审核PPAP level 5:Honeywell performed 等级5：由联信进行节拍审核*Run Rates Required for PPAP Levels 3 or 5第20页/共29页Process Capability Database,PCD 过程能力数据库过程能力数据库When requested by Honeywell,this field becomes mandatory and necessitates the completion of the Supplier Part Feature Mapping,S

27、PFM,tab.当联信有要求时，就必须要完成供应商零件特性图表（SPFM）PCD is a database for Key Critical Characteristics,KCCs,and is used to generate customer mandated product scorecards,track quality issues and verify permanent corrective actions,as well as provide feedback to the Honeywell design team for implementation of Design

28、 for Six Sigma.PCD是针对KCC能力的数据库，并用于生成客户专有的产品打分卡、追踪质量问题、验证永久对策以及向联信设计团队提供反馈，来实施Six Sigma设计。第21页/共29页Customer/Performance Testing 客户客户/性能测试性能测试Casting and Machining 铸造和加工Emission tests 排放测试Gas StandPrecision Components and Wheels 精密零件和车轮Emission testsEngine lug line PingGas standRaw Material原材料NASpecia

29、lty Components专用零件?Thermal热量NAPossible Additional Tests Required by the Customer 第22页/共29页Interim Approval Procedure 临时批准程序临时批准程序Use of the Interim Recovery Worksheet is mandatory and must be attached to each interim approved PPAP 要求使用 Interim Recovery 工作表，而且必须附在每个临时批准的PPAP后面 Future integration of t

30、his worksheet into SCC is planned,and is currently being developed 计划以后将Interim Recovery 工作表整合进SCC（供应链协调），目前正在进展中Classification is necessary for each interim approval reason and must abide by the new sign off procedure(see signature summary)有必要对每个临时批准的原因进行分类，而且必须遵守新的签字批准程序（参见幻灯片29）Use of Interim Rec

31、overy Worksheet,Mandatory第23页/共29页Interim Approval Class I 临时批准临时批准等级等级IParts meet design record specifications,but not all PPAP requirements have been met.零件符合设计记录规范，但不是所有PPAP要求都满足Examples:1)A capability study has not been competed 没有完成能力研究2)Quality documentation improvements are required质量文件有待提高3)

32、A tier 2 casting is out of spec,but will not effect form,fit or function of machine component tier 2供应商供应的铸件超出规范要求，但是不会影响加工件的形状、装配或性能 第24页/共29页Interim Approval Class II 临时批准等级临时批准等级II Parts meet drawing and specification requirements,but are not produced off of the production process 零件满足图纸和规范要求，但不是

33、在量产过程中生产的。Examples:举例如下1)Parts have not been manufactured completely at the production site 零件不是完全在量产的车间生产的2)Parts have been produced using interim machinery 零件是使用临时设备生产的3)Parts have been produced using additional,substitute,or soft tooling 零件是使用其它的、替代的或临时的工装第25页/共29页Interim Approval Class III 临时批准等

34、级临时批准等级IIIParts meet drawing and specification requirements,but Run Rate not completed 零件满足图纸和规范要求，但节拍生产没有完成。Examples:举例如下1)Onsite Run Rate planned,but not yet completed or has been unsuccessful 有现场Run Rate 计划，但是没有完成，或不成功第26页/共29页Parts do not meet design record/drawing specifications,but form,fit an

35、d function are not adversely effected 零件没有满足设计记录/图纸规范要求，但是对零件的形状、装配和性能没有影响。Examples:举例如下：1)Finished parts fall outside of drawing or specification tolerances 成品件超出图纸或规范公差。2)Performance testing has not yet been completed,but the usage of the parts do not pose a significant risk to customer satisfaction.没有完成性能测试，但是对零件的使用不会产生严重影响客户满意度的风险。3)An ECN is in process to resolve a drawing discrepancy 工程变更通知（Engineering Change Note)正在建立过程中，目的是解决图纸不一致的情况。Interim Approval Class IV 临时批准等级临时批准等级IV第27页/共29页Required Signature Summary 相关人员签字要求相关人员签字要求第28页/共29页谢谢您的观看！第29页/共29页