[精选]TS16949 PPAP Trainingrev E.pptx

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1、WEL EWhatistheintentofthisTraining?WhatistheintentofthisTraining?TheintentofthistrainingistomunicateMotorolaPCSs,PPAPrequirementstothesuppliersandtraintheSDEEngineersandsuppliersonthesePPAPrequirementsforqualificationSUPPLIERDEVELOPMENTENGINEERINGTRAININGMODULESDE-VOLIIIBy:ZubairIqbalJuly16th2004Wha

2、tdoesPPAPstandfor?PRODUCTIONPPAPPARTAPPROVALPROCESSPPAPisaproductionpartapprovalprocessusedbyUSautoindustryGM,Ford,andChrysler.TheProductionPartApprovalProcessPPAPoutlinesthemethodsusedforapprovalofproductionandservicemodities,includingbulkmaterials,uptoandincludingpartsubmissionwarrantintheAdvanced

3、QualityPlanningprocess.ThepurposeofthePPAPprocessistoensurethatsuppliersofponentsplywiththedesignspecificationandcanshowdocumentaryevidencethatthelevelcanbemaintainedduringthelifeoftheproduct.WhatistheProductionPartApprovalProcess?IsMotorolaPCSchangingthequalificationrequirements?MotorolaPCSisnotcha

4、ngingqualificationrequirements,insteadMotorolaPCSisenhancing/addingthecurrentqualificationrequirementstomatchthePPAPrequirements.WhatarethePPAPrequirements?PPAPRequirementsInadditiontothesePPAPrequirements,PCShasaddedthisnewadditionalrequirementWhatisthePurposeofthesenewPPAPRequirements?ThePurposeof

5、PPAPistodetermineifallcustomerengineeringdesignrecordsandspecificationrequirementsareproperlyunderstoodbythesupplierandthattheprocesshasthepotentialtoproduceproductmeetingtheserequirementsduringanactualproductionrunatthequotedrate.Iamnotfamiliarwithsomeoftheserequirements,wouldyoupleaseexplainwhatth

6、esePPAPrequirementsare?1DesignRecordsDesign Records:Designrecordsareengineeringrequirementsforjudgingtheacceptabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsareconsideras,allcustomerandsuppli

7、erdesignrecordse.g.:CAD,Pro-Efiles,partdrawing/prints,specifications2EngineeringChangeDocumentsifanyEngineering Change Documents:EngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchangesauthorizedbyMotoroladevelopmentengineeringnotyetrecordedinthedesignrecordbutincorporatedintheproduct,p

8、artortooling.3CustomerEngineeringApprovalIfrequiredCustomer Engineering Approval:CustomerEngineeringapprovalistheprocessthatprovidesfortwowaymunicationbetweentheponentsupplier&theresponsibleMotoroladesignengineeringactivityandthroughwhichthesupplierrequestsconcurrenceforcertaindesignandprocesschange

9、s.OnceMotoroladesignengineeringdeterminesthatthechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillpleteandsubmittheProcessChangeNotificationforapproval.4DesignFMEADesign FMEA:FMEAisanEngineering“ReliabilityToolthathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfail

10、uresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.5ProcessFlowDiagramProcess Flow Diagram:Processisabinationofpeople,equipment,method,Material,andenvironmentthatproducesoutput,foragivenproductorservice.Pr

11、ocessFlowDiagramdepictstheflowofmaterialsthroughtheprocess,includinganyre-work,repairoperationsorcycletime.6ProcessFMEAFailure Modes and Effects Analysis FMEAFMEAisanEngineering“ReliabilityToolthathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufact

12、uringprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.7DimensionalResultsDimensional Results:Dimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool,mold,orset-up.Alldimensionsexceptreferencedimensions,Cha

13、racteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.8Material,PerformanceTestResultsMaterial,Performance Test Results:MaterialtestsaretestthatspecifiedonMotorolaprintorspecificationsaschemical,physicalormetallurgicaltestse.g.MEK,abrasion,adhesion,etc

14、.PerformancetestsaretestthatspecifiedonMotorolaprintorspecificationsasperformancetestse.g.numberofcycles,environmentaltesting,electricaltesting,Platingthickness,Paintthickness,Glossreadings,etc.9InitialProcessStudiesInitial Process Studies:ForBox-X Xandparameters,thesuppliershallprovideCp/Cpkstatist

15、icstoensureanacceptableprocesscapabilityCp/Cpkof2/1.5orgreater.Asampleof35piecesisdeemedappropriatefornormallydistributeddatagatheredviaanacceptablemeasurementmethoderrorrate10%orlessunlessapprovedbyCTE.ForconditionsthatrequirereviewCp/Cpkbelow1.5,supplierrequest,non-normaldistribution,ormeasurement

16、issues,thesuppliermustnotifyMotorola.Motorolamustapproveanydeviation.*10MeasurementSystemAnalysis Measurement System Analysis:MeasurementsystemanalysisMSAisanexperimentalandmathematicalmethodofdetermininghowmuchthevariationwithinthemeasurementprocesscontributestooverallprocessvariability.Therearefiv

17、eparameterstoinvestigateinanMSA:bias,linearity,stability,repeatabilityandreproducibility.11QualifiedLaboratoryDocumentationQualified Laboratory Documentation:AQualifiedlaboratoryisatestfacilitythatmayincludechemical,metallurgical,dimensional,physical,electrical,reliabilitytestingortestvalidation.Qua

18、lifiedLaboratoryDocumentationisadocumentationortestresultsissuedbyaMotorolaqualifiedlaboratory12ControlplanControl plan:Controlplansarewrittendescriptionsofthesystemforcontrollingproductionpartsorbulkmaterialsandprocesses.Theyarewrittenbysupplierstoaddresstheimportantcharacteristicsandengineeringreq

19、uirementsoftheproduct.Eachpartmusthaveacontrolplan,butinmanycases,“familycontrolplanscanapplytoanumberofpartsproducedusingamonprocess.13PartSubmissionWarrantPart Submission Warrant:PartSubmissionWarrantisacertificateofpliancerequiredForallnewlytooledorrevisedup-revproductsinwhichsupplierconfirmsthat

20、InspectionsandtestsonproductionpartsshowconformancetoMotorolaprintrequirements.14AppearanceApprovalReportAppearance Approval Report:MotoroladefinesAppearanceApprovalReportaslimitsamples.LimitsamplesarethepartsthatdonotmeetMotorolaPCScosmeticrequirements,butareapprovedbytheMotorola,PCSdevelopmentEngi

21、neeringandquality/CTE.InadditionlimitsamplesaresetupforcolororfinishesrangesInlimitsamplesrangesaresetperGolden/Mastersample15BulkMaterialRequirementsChecklistBulk Material Requirements:Bulkmaterialisasubstancee.g.non-dimensionalsolid,liquid,gasSuchasadhesives,sealants,chemicals,coating,fabrics,lubr

22、icants,etc.AbulkmaterialmaybeeproductionmaterialifissuedaMotorolapartnumber.Bulkmaterialchecklistisdefinedasalistofqualificationrequirements16SampleproductionPartsSample production Parts:SampleproductionPartsaremanufacturedattheproductionsiteusingtheproductiontooling,gaging,process,materials,operato

23、rs,environment,andprocesssetting.,feeds/speeds/cycletimes/pressures/temperatures.17MasterSampleMaster Sample:MasterSamplesareconsideredasGoldensamplesGoldensamplesareforappearancepartsonly.MostofthetimeGoldensamplesaresetorapprovedForpaintcolor,anodizing,orsurfacefinishes18RecordofplianceWithcustome

24、rspecificRequirementsRecord of pliance With customer specific Requirements:Motorola,PCSdefines“RecordofplianceWithcustomerspecificRequirementsasPAFPrintAcceptanceForm19CheckingAidsChecking Aids:Checkingaidsfixtures,models,templates,mylars,etc.Specifictothepartbeingsubmitted,usedininspectingortesting

25、.20RunatRatedSpeedRun at Rated Speed:Runningthetool/processatthevelocity/outputitisexpectedtoberunatduringproduction.ForExample:Ifatoolormoldisratedtoproducetrueproductionpartsatarateof300parts/hrorXXhundredparts/hr,suppliermustrunthetrueproductiontool/moldorprocesstothatspeedforsomeperiodoftimetoen

26、sureprocessstability,thenselectrandompartsforqualification.ArentsomeofthesePPAPrequirementsthesameaswhatPCSrequiresalready?Yes!Youareright,someofthesePPAPrequirementsarecoveredundercurrentqualificationrequirements.Thereareonlyafewthatarenotcovered.CurrentQualificationRequirements*Abovementionedrequi

27、rementsareforatypicalmodity,foranyspecificmodityqualificationrequirementscontactyourlocalCTEQualificationRequirementsthatarenotcoveredunderPPAP*Abovementionedrequirementsareforatypicalmodity,foranyspecificmodityqualificationrequirementscontactyourlocalCTEThereareNineteen19PPAPrequirements,butMotorol

28、aPCSwillrequireonly13outofthose19requirementsfromtheirsupplierstosubmitwithqualificationpackages.Sinceall19requirementsarerequired,suppliersarerequiredtokeeptherestoftheitemsonfileforfuturereference.HowmanyofthePPAPrequirementswillberequiredforqualificationandwhichones?PCSPPAPREQUIREMENTSSo as a sup

29、plier,what should I submit for qualification?FollowingitemsneedtobesubmittedforMotorolaPCSqualificationrequirements.Suppliermayneedtosubmitadditionalrequirementsbasedonthespecificmodity.RefertoyourlocalSDEorCTEforadditionalrequirementsforaspecificmodity.qDesign Records qProcess Flow DiagramqProcess

30、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 specif

31、ic 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

32、 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 produ

33、ction 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,butwhatexactlydoesMotorola

34、PCSwanttoseefortheserequirements?Alittlemoreexplanationwouldbehelpful.1DesignRecordsDesignrecordsareengineeringrequirementsforjudgingtheacceptabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsar

35、econsideras,allcustomerandsupplierdesignrecordse.g.:CAD,Pro-Efiles,partdrawing/prints,specificationsInthisrequirement,MotorolaPCSrequiressupplierstosubmitacurrentcopyoftheMotorolaPrint/specification.Print/specificationmusthavethesamerevisionasthequalificationpackage.2EngineeringChangeDocumentsifanyE

36、ngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchangesauthorizedbyMotoroladevelopmentengineeringnotyetrecordedinthedesignrecordbutincorporatedintheproduct,partortooling.Inthisrequirement,MotorolaPCSrequiressuppliertoresolvealldesignorprocessissuesbeforesubmittingthequalificationpackage

37、.IfforanyreasonthesupplierdecidestochangetheprocessfromtheOriginalqualification,aPCNProcessChangeNotificationmustbeapprovedbyPCS.IfMotoroladecidestochangethedesignaftertheQualification,suppliersarerequiredtore-submitthequalificationpernewPrint/specificationrevision.Motorolaexpectsitssupplierstoretai

38、nallengineeringChangedocumentsforfuturereference.Referto“MotorolaPCSProcessChangeNotificationProcedure12M09192A783CustomerEngineeringApprovalIfrequiredCustomerEngineeringapprovalistheprocessthatprovidesfortwowaymunicationbetweentheponentsupplier&theresponsibleMotoroladesignengineeringactivityandthro

39、ughwhichthesupplierrequestsconcurrenceforcertaindesignandprocesschanges.OnceMotoroladesignengineeringdeterminesthatthechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillpleteandsubmittheProcessChangeNotificationforapproval.WherespecifiedbytheMotorolaprint/specification,thesuppliershal

40、lhaveevidenceofMotorolaengineeringapproval.Suppliersdonotneedtosubmitthisrequirementwithqualification,butshouldkeepitforfuturereference.4DesignFMEAFMEAisanEngineering“ReliabilityToolthathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingproces

41、sbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.ThesuppliershallhaveaDesignFMEAdevelopedforpartsormaterialforwhichtheyaredesign-responsible.DFMEAisarequirementforqualification.SuppliersdonotneedtosubmittheDFMEAwithqualification,insteadtheyneedtor

42、etainitforfuturereference.5ProcessFlowDiagramCustomersiteStopPROCESSFLOWDIAGRAMFORAMETALSMSHIELDIncomingMaterialStorageFinalInspectionPlatingDe-greasingStamping/FormingDe-burringoperationStorageTransportationStartThesuppliershallhaveaPFDProcessFlowDiagramforallpartsrequiringqualification.Suppliermus

43、tsubmitadetailedPFDwitheachqualificationpackage.Inadditiontotheflowofmaterialsthroughtheprocess,includeallreworkorrepairoperationsandcycletimeinyourflowchartIncomingMaterialStorageFinalInspectionPlatingDe-greasingStamping/FormingDe-burringoperationStorageTransportationCustomersiteVerificationofalloy

44、Rawmat.positionHardnessShelfLifeHumidityOxidationWaterleakagerain.etcYouneedtoidentifyallthepotentialfailuremodesforyourPFMEAtobeeffective.AcrossfunctionalteamteamshouldincludemembersfromoperatorstoqualitymanagersshouldbedevelopedforaneffectivePFMEA.6ProcessFMEAThesuppliershallhaveadetailedPFMEAdeve

45、lopedandsubmittedwitheveryqualificationpackage.SuppliermusttakecorrectiveactiontoitemswithaRPN60Reviewprocessflowdiagramandidentifycriticalstepsintheprocessflow.VerifythatallthecriticalstepsarecoveredunderPFMEA7DimensionalResultsDimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpar

46、tsfromproductiontool,mold,orset-up.Alldimensionsexceptreferencedimensions,Characteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.Thesuppliershallprovideevidencethatdimensionalverificationsrequiredbytheprint/specificationhavebeenpletedandresultsindica

47、tepliancewithspecifiedrequirements.Dimensionalmeasurementmustbedoneonallcavities,mold,tools,ordies.Alldimensions,characteristics,andspecificationsasnotedontheprint/specificationandnotesshouldbemeasuredandlistedinaconvenientformatwiththeactualresultsrecorded.8Material,PerformanceTestResultsMaterialte

48、stsmustbeperformedforallpartsandproductmaterialswhenchemical/physical/metallurgicalrequirementsarespecifiedontheprint.Thesuppliermustperformthetestsrequiredbythematerialspecificationsandthecontrolplan.Ifthesuppliercannotperformtherequiredtest,servicesmustbeprocuredfromanoutsidequalifiedsource.Whenth

49、irdpartyLabservicesareused,theresultsmustbesubmittedontheirletterhead.Thenameofthelaboratorythatperformedthetestsmustbeindicated.Testreportmustindicatetherevisionlevelofthepartstested,andthedateandrevisionlevelofthespecifications.In addition supplier must submit a material certificate of pliancefora

50、llthematerialintheparte.g.plasticpaintedpartmusthavebothmaterialCofCplasticandpaint.MaterialCofCmustbeonrawmaterialsupplierletterhead.Thenameoftherawmaterialsupplierthatsuppliedthematerialmustbeindicated.9InitialProcessStudiesForBox-X Xandparameters,thesuppliershallprovideCp/Cpkstatisticstoensureana