生产件批准控制程序(1).doc

1 目的Objective1.1 确保公司提供生产件符合顾客批准的工程设计记录和规范的所有要求，并在实际生产过程中按规定的生产节拍来生产，满足顾客要求。Ensure that the production parts supplied by AICQ can meet all customer engineering design record and specification requirements and that AICQ process have the potential to produce products that meet the customers requirements during an actual production run at the quoted production rate.1.2 确保分供方提供生产件符合本公司工程设计记录和规范的所有要求，并在实际生产过程中按 规定的生产节拍来生产，满足本公司要求。Ensure that the production parts supplied by the suppliers can meet all AICQ engineering design record and specification requirements and that the suppliers process have the potential to produce products that meet AICQs requirements during an actual production run at the quoted production rate.2 适用范围Applicable Scope 2.1 适用于本公司生产的所有产品。Applicable to all the products produced by AICQ.2.2 适用于本公司采购的主要原物料。Applicable to the main raw materials purchased by AICQ.3 职责Responsibility3.1 横向协调项目组负责新品生产件批准过程的实施和所需资料的准备。The Cross Function Team is responsible for implementation of production part approval process and preparation of the required information.3.2 各相关部门配合横向协调项目组工作。Other related departments shall cooperate with the Cross Function Team.3.3 技术工程部负责生产件批准的记录和标准样品的保存。The Engineering & Technical Department is responsible for recording the production part approval and maintaining the standard samples.3.4 质量部负责生产件批准资料向顾客提交。The Quality Department is responsible for submitting the Production Part Approval Data to the customer. 4 工作程序Work Procedures 4.1 定义Definition生产件批准提交（PPAP）从一个有效的生产过程中(该过程必须是1小时到8小时的生产，且规定的生产数量至少为300件连续生产的部件，除非顾客授权的质量代表另有规定)提取的零件和相关文件交顾客审批，且这个生产过程是由生产现场使用的工装、工艺过程来进行的。对于散装材料：零件没有具体数量要求；如果要求提交样品，那么样品的选取应能保证代表“稳定”的加工过程。Production part approval submission (PPAP): It refers to the submission of the parts and the relevant documents that are picked up during an effective production process to the customers for approval (this process must be of production from 1 to 8 hours, and the specified production quantity must reach at least 300 pieces of components during a continuous production, unless otherwise specified by customer authorized quality representative). And in addition, this production process is carried out by using the tools and processes available at the production site. For bulk materials, the parts have no quantity requirements. If it is required to submit samples, ensure the selected samples can represent the “stable” production process.4.2 生产件批准提交时机Production Part Approval Submission Time4.2.1 供方必须对下列情况获得顾客产品批准部门的完全批准：a. 一种新的零件或产品（如：从前未曾给某个顾客的某种零件、材料或颜色）；A new part or product (e.g. some kind of part, material or color never supplied to a customer before).b. 对以前提交零件不合格的纠正；Correction of nonconforming parts submitted before.c. 由于设计记录、规范或材料方面的工程更改而发生的产品变化；Product change due to the engineering revision of design records, specifications and materials.d. 只对散装材料：对于供方来讲，在产品上采用了以前未曾用过的新的过程技术。Only to bulk materials: The supplier has adopted a new process technology that was never used before. e. 第4.2.2章节要求的任一种情况。Any one of the situations required in Clause 4.2.2.4.2.2 本公司必须将下列的任何设计和过程更改通知给顾客产品批准部门。顾客可能因此会决定要求提交PPAP批准。如果顾客放弃提交正式的生产件批准，但是横向协调项目组仍应进行PPAP所有项目，以反映当前有关过程的状况：AICQ must notify any of the following design and process revisions to the customer product approval department. The customers might therefore decide to require the submission of PPAP approval. If the customers give up the submission of official product part approval, the Cross Function Team shall still keep performing all PPAP projects, so as to reveal the present process status.a. 相对于以前批准过的零件，使用其它可选择的加工方法或材料；Comparable to the parts approved before, other optional machining methods or materials are used.b. 使用新的或改进的工装（易损工具除外）、模具、铸模、模型等，包括附加的和可替换的工装进行的生产；Use new or revised tooling (exclusive of easily damaged tools), dies, moulds and models, including the production using attached and replaceable tools.c. 对现有工装或设备进行重新翻新或重新布置后进行的生产；The production after renewal or reallocation of present tooling or equipment.d. 把工装或设备转到其它生产场地或在另一生产场地进行的生产；The production at another production site or under the conditions that the tooling or equipment are relocated to other production sitee. 分承包方对零件、非等效材料或服务（如热处理、电镀）的更改，从而影响了顾客的装配、成型、功能、耐久性或性能的要求； The sub-contractors change of parts, non-equivalent materials or services (e.g. heat treatment, electroplating) has affected the customers requirements for assembly, molding, functions, durability or performance.f. 工装在停止批量生产达到12个月或更长时间后重新投入生产； The tooling are put back to production after they have been stopped of batch production for a period of 12 months or longer.g. 涉及由内部制造的或由分承包方制造的生产产品部件的产品和过程更改；The product and process change involving the product producing components internally manufactured or manufactured by the sub-contractors.h. 仅适用于散装材料Only applicable to bulk materials: 新的或现有的分承包方提供的具有特殊特性的原材料的新货源。New source of special characteristic raw materials provided by the new or present sub-contractors. 在没有外观规范的情况下，产品外观属性的更改。Change of product appearance under the conditions that there are no appearance specifications. 在相同的过程中变更了参数（属已批准产品的PFMEA参数以外部分，没有包装）。Change of parameters in the same process (the parts other than the PFMEA parameters of approved products, without packaging). 已批准产品的DFMEA（产品组成、成分等级）以外部分的更改。Changes of other parts excluding the DFMEA of approved products (product composition, composition grade).i. 试验/检验方法的更改-新技术的采用（不影响接受准则）。Change of test/inspection methods application of new technologies (not affecting the acceptance principles).4.2.3 顾客不要求通知的情况：本公司应该跟踪更改和/或改进，并更新PPAP文件。In case the customers do not require notification, AICQ shall trace the change and/or improvement and revise the PPAP documentations.a. 对部件级图纸的更改，内部制造或由分承包方制造，不影响到提供给顾客产品的设计记录；Revision of components drawings for internal manufacture or supplier manufacture does not affect the design records provided to the customers.b. 工装或设备在同一工厂内移动；Movement of tools or equipment in the same factory.c. 设备方面的更改；Change of equipmentd. 等同的量具更换；Change of the equivalent measuring instruments.e. 重新平衡操作工的作业含量，对过程流程不引起更改。Reevaluate the operation task of the operators and do not cause changes to the process flow.f. 只对散装材料Only applicable to bulk materials: 对批准产品DFMEA（配方范围、包装设计的更改）；Change of approved product DFMEA (prescription scope, package design). 对PFMEA（过程参数）的更改；Change of PFMEA (process parameters). 不会严重影响到特殊特性的更改；Changes that will not seriously affect the special characteristics. 对批准了的商品成分的更改和/或批准的分承包方的更改；Change of approved commodity composition and/or approved sub-contractors. 生产不涉及特殊特性的原材料的分承包方生产现场发生变化；Change of production site of raw material sub-contractor not involving special characteristics. 不涉及特殊特性的原材料的新货源；New source of raw materials not involving special characteristics. 加严的顾客/销售接受容差限值。Stricter acceptable tolerance limit values for customers/sales.4.3 PPAP保存/提交要求（见附件二）PPAP Retention/Submission Requirements (Appendix 2).4.4 PPAP提交等级PPAP Submission Level 本公司必须按照顾客要求的等级，提交该等级规定的项目和/或记录；如果顾客负责产品批准部门没有其他规定，则本公司必须使用等级3作为默认等级，进行提交。AICQ must submit the items and/or records in accordance with the levels required by the customers. If the customer product approval department has no other stipulations, AICQ must adopt Level 3 as the default level and make submission.4.5 生产件批准工作流程（见附件一）Work Flow of Production Part Approval (See Appendix 1)4.6 生产件批准记录和标准样品保存Retention of Production Part Approval Record and Standard Sample 所有生产件批准的记录和标准样品由技术工程部保存，生产件批准记录保存时间是该零件生产和服务活动所要求的时间再加上一个日历年时间，标准样品保存时间与生产件批准记录保存的时间相同，或直到顾客批准而生产出一个用于相同的零件号的新标准样品为止。当由于标准样品外形尺寸而使贮存比较困难时，则应由顾客零件批准的部门以书面形式修改或放弃样品保存要求。All production part approval records and standard samples shall be retained by Technical Department. The production part approval records shall be maintained for the length of time that the part is active for production and service requirements plus a calendar year. The standard samples shall be maintained for the same period of time as the production part approval records, or until a new standard sample used for the same part number has been produced and approved by the customers. If it is difficult to store the standard samples due to their dimensions, the customer part approval department shall revise or abandon the standard sample storage requirements in written form. 4.7 供方生产件批准要求：The requirement for authorizing suppliers parts 给公司提供原材料和零部件的供应商由技术部通知供应商向技术部提交PPAP，并由技术部进行批准，批准后方可批量供货。提交文件至少应包含以下内容，技术部可根据产品的特殊情况要求供应商提交其他资料。The supplier, which provides us with raw material and components, should present PPAP under the notice from engineering department. The supplier can provide his products botchily after engineering department authorizes PPAP. These documents should include following items. Engineering department can ask supplier to provide other documents needed in products special cases 4.7.1提交时机：参见4.2的要求；The time to provide : see 4.2 requirement4.7.2原材料供应商的生产件批准要求 The requirement for supplier raw material原材料供应商需提交以下资料：The supplier of raw material should provide the following documents.、材料/性能试验结果Material/performance testing result 负责提供公司要求或设计要求的材料/性能试验结果。Responsible to provide the material or performance testing result according to our companys requirement and design requirement.、生产件样品Part sample负责提交产品样品。Responsible to provide part samples. 、材料标准The standard of material4.7.3 提供关重零部件供应商按PPAP手册等级3提交，不适用条款除外。4.7.4 提供一般零部件供应商按PPAP手册等级5提交。Provide normal 5 相关文件Related Documents 5.1 AIAG生产件批准程序手册 AIAG “Production Part Approval Process Manual”6 质量记录Quality Records 6.1 AICQ/QR-0203-01 零件提交批准保证书AICQ/QR-0203-01 “Part Submission Approval Guaranty”6.2 AICQ/QR-0203-02 外观件批准报告AICQ/QR-0203-02 “Appearance Part Approval Report”6.3 AICQ/QR-0203-03 生产件批准尺寸结果AICQ/QR-0203-03 “Production Part ApprovalDimensional Results”6.4 AICQ/QR-0203-04 生产件批准材料试验结果AICQ/QR-0203-04 “Production Part ApprovalMaterial Test Results”6.5 AICQ/QR-0203-05 生产件批准性能试验结果AICQ/QR-0203-05 “Production Part ApprovalPerformance Test Results”附件一： PPAP工作流程图 Appendix 1: PPAP Flow Chart根据PPAP时间进度表及顾客要求提出PPAP时间进度Submit PPAP time schedule according to PPAP time table and customer requirements试生产物料准备Preparation of trial production materials整改后重新提交Resubmit after change 试生产实施Trial Production试生产输出产品进行初始能力研究、测量系统分析、“控制计划”的结果记录Initial capability studies, measuring system analysis and “Control Plan” resultant records for trial production output products根据顾客要求填写生产件批准的提交资料（包括提交等级及提交项目）Fill in submission data for production part approval according to customer requirements (including submission level and submission items).不通过(Not Pass) 顾客通知提交的 临时通过(Temporary pass)审批结果Submission of approval results 按顾客在临时通知上规定的要求准备Prepare according to customer requirements stated in temporary notice. 通过(Pass) 批量供货准备或节拍生产准备Batch supply preparation or rate production preparation附件二：PPAP保存/提交要求Appendix 2: PPAP Retention/submission Requirements要 求Requirements提交等级Submission Level 等级1Level 1等级2 Level 2等级3 Level 3等级4 Level 4等级5 Level 51. 可销售产品的设计记录 Design records of sellable products RSS*R对于专利部件/详细资料For patent parts/detail dataRRR*R对于所有其他部件/详细资料 For all other parts/detail detailRSR*R2. 工程更改文件，如果有Engineering Revision Documents, if any.RSR*R3. 顾客工程批准，如果要求Customer Engineering Approval, if requiredRRR*R4. 设计FMEA Design FMEARRR*R5. 过程流程图 Process Flow