PPAPPG1.doc

Course TitlePPAP/Run-at-Rateart Production Approval ProcessThe subject matter contained herein is covered by a copyright owned by:FORD MOTOR COMPANYCORPORATE QUALITY DEVELOPMENT CENTERDEARBORN, MICopyright 2001 Ford Motor CompanyThis document contains information that may be proprietary. The contents of this document may not be duplicated by any means without the written permission of Ford Motor Company.All rights reservedTable of ContentsIntroduction3How This Course Relates to Other Courses3Agenda3Purpose5Goal5Objectives7Roles and Responsibilities9STA Engineer9Supplier11Sub-Supplier11PPAP Requirements13Impact (legal)1319 Elements13When PPAP Is Required17Activity, continued21Signing Control Plans23Manage the Change25Introduction25Purpose of Manage the Change27Using Manage the Change27Types of Change29Change and the SREA Process31Manage the Change Roles and Responsibilities33Role of the STA Engineer33Activity Practice Performance35Role-play Exercise35Responsibilities of the STA Engineer37Activity: Supplier Checklist and SREA Form Review39Supplier Checklist/SREA Form Review39Manage the Change Indicators of Change45Flags and Triggers45Process Change47Miscellaneous49Manage the Change Flowchart for External Suppliers51Performing PPAP53Communicate Requirements53Number of Parts to Run53Timing Ford Product Development System (FPDS)55Run-at-Rate55Validating PPAP57Review Techniques57The PPAP Package57Documentation Flow59Asking Probing Questions59Validate Outcomes61Engineering and Supply Information System (EASI)63Phased PPAP65Summary67Review of Answers to Pre-Test and Post-Test69Introduction3How This Course Relates to Other Courses3Agenda3Purpose5Goal5Objectives7Roles and Responsibilities9STA Engineer9Supplier11Sub-Supplier11PPAP Requirements13Impact (legal)1319 Elements13When PPAP Is Required18Activity, continued22Signing Control Plans24Manage the Change26Introduction26Purpose of Manage the Change28Using Manage the Change28Types of Change30Change and the SREA Process32Manage the Change Roles and Responsibilities34Role of the STA Engineer34Activity Practice Performance36Role-play Exercise36Responsibilities of the STA Engineer38Activity: Supplier Checklist and SREA Form Review40Supplier Checklist/SREA Form Review40Manage the Change Indicators of Change46Flags and Triggers46Process Change48Miscellaneous50Manage the Change Flowchart for External Suppliers52Performing PPAP54Communicate Requirements54Number of Parts to Run54Timing Ford Product Development System (FPDS)56Run-at-Rate56Validating PPAP57Validating PPAP58Review Techniques58The PPAP Package58Documentation Flow60Asking Probing Questions60Validate Outcomes62Engineering and Supply Information System (EASI)64Phased PPAP66Summary68Review of Answers to Pre-Test and Post-Test70Review of Answers to Pre-Test and Post-Test70Introduction33Welcome33Agenda773Goal885Objectives885Roles and Responsibilities997STA997Supplier11119Sub-Supplier11119PPAP Requirements131311Impact (legal)13131119 Elements131311When PPAP Is Required181815Performing PPAP525221Communicate Requirements535321Capacity Verification (Run-at-Rate)555523Use Forms565625Exercise565625Validating PPAP575727Review Techniques575727The PPAP Package575727Documentation Flow595929Asking Probing Questions595929Validate Outcomes616131Engineering and Supply Information System (EASI)636333Summary676735Phased PPAP676735Summary676735This PageIntentionallyLeft BlankACTIVITY/MEDIACONTENT/INSTRUCTOR NOTESxx minutes2 slidesEstimated time for this section.Display: Slides: PPAP./Run-at-Rate Welcome the class Introduce yourself.Display: Slide: How This Course Relates Tto Other Courses.Discuss:where this course fits in the curriculum by referring to the curriculum map. Indicate other courses in the curriculum that relate specifically to PPAP.Fit with Curriculum.Note: The Curriculum Map should be displayed at the front of the room. Refer to this map and point to the current course/place “You Are Here” sticky-note arrow to illustrate where the course fits in relation to the curriculum. Learners will have previously participated in other courses. This course is taught in relationship with the other Quality Tools courses.Write:The course agenda on the flip chart. Include approximate times for sections. Introduction: xx min. Roles and Responsibilities: xx min. PPAP Requirements: xx min. Manage the Change: xx min Manage the Change- Roles and Responsibilities: XX mins. Manage the Change- Indicators of Change: XX mins. Manage the Change- Flowchart for External Suppliers: XX min Performing PPAP: xx min. Validating PPAP: xx min. Documentation Flow: xx min Summary: xx min. Additional Resources: xx min Include breaks as appropriate. Approximately 10 minutes every 2 hours Approximately 30 minutes for lunchIntroductionWelcome to the Part Production Approval Process course, part of the Corporate Quality Development Center curriculum. This course is part of the Quality Tools module, which is designed to provide STA Engineers with practical knowledge of the tools required to successfully accomplish their jobs.How This Course Relates to Other CoursesThis course is taught in relationship with the other Quality Tools curriculum courses: High Mileage Reliability Craftsmanship Design Concepts DVP & PV FMEA Control Plans Global 8D Global 8D Analysis SPC DOE Lean Value Stream MappingWelcomeFit with CurriculumThis course is taught in relationship with the other Quality Tools curriculum courses: Conducting an On Site Assessment Q1 2001 Advanced Product Quality Planning (APQP)AgendaIntroductionRoles and ResponsibilitiesPPAP RequirementsManage the ChangeManage the Change Roles and ResponsibilitiesManage the Change Indicators of ChangeManage the Change Flowchart for External SuppliersPerforming PPAPValidating PPAPDocumentation FlowSummaryAdditional ResourcesACTIVITY/MEDIACONTENT/INSTRUCTOR NOTESDisplay:Slide: Purpose.Review:This course focuses on providing detailed information about PPAP, including the roles and responsibilities of STA engineers.Display:Slide: Goal.Review:The goal of this course is to prepare participants to: iImplement the requirements of the PPAP process effectively and consistently, cConduct PPAP Reviews independently with Suppliers, vValidate that the PPAP was performed correctly. PurposeThis course focuses on providing detailed information about PPAP, including the roles and responsibilities of STA Engineers. Instruction will include inputs and outputs for PPAP. The identification of links to other processes, common failure modes, and strategic questions will be integrated throughout the course.GoalThe goal of the PPAP (Production Part Approval Process) course is to prepare participants to implement the requirements of the PPAP process effectively and consistently, to conduct PPAP Reviews independently with Suppliers, and to validate that the PPAP was performed correctly.ACTIVITY/MEDIACONTENT/INSTRUCTOR NOTES4 slides5 minutesDisplay:Slides: Objectives 1. Objectives 2. Objectives 3. Objectives 4.Review:the objectives for this course.Instruct:Participants participants to remove the Pre-Test from Appendix A and write their names on the test.Explain:That that the Pre-Tests are not being recorded but will be reviewed for prior knowledge and compared to the postPost-tests Tests for knowledge gained.Allow:Five five minutes for participants to complete the Pre-Test.Collect: the completed Pre-Tests. Do not review the answers with the class. During a break, make copies of the completed Pre-Tests for use by the instructor and/or developers.Do not return the Pre-Tests until after the Post-Test is taken.Write:The course agenda on the flip chart. Include approximate times for sections. Introduction: xx min. Getting Started: xx min. Purpose, Goal, Objectives: xx min. Roles and Responsibilities: xx min. Requirements of PPAP: xx min. Performing PPAP: xx min. Validating PPAP: xx min. Summary: xx min.ObjectivesUpon completion of this course, the participant will be able to: Define the requirements of PPAP and state the outcomes of those requirements Describe roles and responsibilities Consult with the supplierSupplier regarding PPAP performance Describe how to manage the PPAP process for a part with an alertAlert in the system Process a supplierSuppliers PSW (Part Submission Warrant) in the Ford system using EASI, ELECT, and CMMS Track PPAP to FPDS timing and identify links to the FPDS process Explain the Part Submission Warrant Explain the relationship between PPAP and Run-at Rate Explain the Run-at Rate process, the STA Engineers role in Run-at-Rate, and the documentation required for the Run-at-Rate process Verify that adequate and required preparations and inputs to an effective Run-at-Rate event have been completed Describe the Phased PPAP process and explain the improvements over the current PPAP process Sign off on a PPAP process Pre-Test Please take a few moments and fill out the pre-test. This will give us a chance to check the effectiveness of the course and to help you realize what you have learned.AgendaIntroductionPurpose, Goal, and ObjectivesRoles and ResponsibilitiesRequirements of PPAPPerforming PPAPValidating PPAPSummaryACTIVITY/MEDIACONTENT/INSTRUCTOR NOTESDisplay:Slides: Goal. Objectives 1. Objectives 2. Objectives 3. Objectives 4.Discuss:Objectives.Roles and ResponsibilitiesGoalThe goal of the PPAP (Production Part Approval Process) course is to prepare participants to implement the requirements of the PPAP process effectively and consistently, to conduct PPAP Reviews independently with Suppliers, and to validate that the PPAP was performed correctly.ObjectivesUpon completion of this course, the participant will be able to: Define the requirements of PPAP and state the outcomes of those requirements Describe roles and responsibilities Consult with the supplier regarding PPAP performance Describe how to manage the PPAP process for a part with an alert in the system Process a suppliers PSW (Part Submission Warrant) in the Ford system using EASI, ELECT, and CMMS Track PPAP to FPDS timing and identify links to the FPDS process Explain the Part Submission Warrant Explain the relationship between PPAP and Capacity Verification Explain the Capacity Verification process, the STA role in Run-at-Rate, and the documentation required for the Run-at-Rate process Verify that adequate and required preparations and inputs to an effective Run-at-Rate event have been completed Describe the Phased PPAP process, and explain the improvements over the current PPAP process Sign off on a PPAP package Roles and ResponsibilitiesACTIVITY/MEDIACONTENT/INSTRUCTOR NOTESxx minutes2 slides2 slidesEstimated time for this section.Display: Slides: Roles and Responsibilities 1 Roles and Responsibilities 2DiscussAsk:“TAsk, those of you who have done PPAP approval in the past, are there any new responsibilities here?” Ask for examples from them.Display:Slides: PPAP Manual. Situations that May Require a Decision.Discuss:Ask:Ask for examples of parts or situation with supplierSuppliers that they know of that may require them to make a decision.Examples:A half-pennyhalfpenny washer. A small spring for a dash knob vs. an instrument panel or a transmission or a truck frame.Discuss:There are more than 10,000 supplierSuppliers to the automotive industry, more than 150,000 different parts.Roles and ResponsibilitiesSTA EngineerThe role of the STA Engineer with regards toconcerning PPAP isare to: Understand the requirements of PPAP, Capacity Verification, and the forthcoming Phased PPAP Coach the supplierSupplier on those requirements Know when a PPAP is required Assume the responsibility of “part approval activity” for the supplierSupplier (see PPAP page 24, II.2.1) Be able to review the PPAP package for accuracy and completeness Be able to approve all PPAP submissions from the supplierSupplierThe PPAP requirements manual is very clear about “when” a PPAP should be submitted, and “what” should be submitted when a submission is required. These requirements will cover 90% of all submission questions that a supplierSupplier may have. One of your roles asA role of an STA Engineer is to consult with the supplierSupplier and answer questions about the remaining 10% of situations that are different from the examples in the PPAP manual. The PPAP manual states the following:“If there is any question regarding the requirements of PPAP or the need for submission, the supplierSupplier shall contact the customer product approval activity.”Situations that may require the STA to make a decision about the requirements of PPAP may be: Part complexity and expense Criticality of the part or assembly (SCs, CCs) Type of change to the part or process Depth of change to part or process Part sizeIt will be imperative as that an STA Engineer that you assists the supplierSupplier in these decisions. If all part supplierSuppliers that supply all numbers in all vehicles were to submit for PPAP every time there was a question about the part or change in the process and never consulted with the proper customer activity, it would be safe to say that the automotive industry would slow to a snails pace waiting for submissions and approvals of those submissions. ACTIVITY/MEDIACONTENT/INSTRUCTOR NOTESDisplay: Slide: Supplier Responsibilities.Discuss:The the first paragraph. Suppliers are required to be registered and PPAP is a requirement for that registration.Display:Slide: Sub-Supplier Responsibilities.Discuss:that the requirement comes from QS-9000 element 4.2.4Display:Slide: PPAP vs. PSW.Discuss:the change in language as an STA.SupplierAll supplierSuppliers of production parts and services directly to Ford are required to be registered to QS-9000 and/or TS-16949. One of the requirements of QS-9000 is full compliance with PPAP and the PPAP requirements manual. The PPAP manual is clear on the requirements of the supplierSupplier. All suppliers Suppliers shall prepare and submit all required information and data for submission of a new or changed part, or after the major change in the process. If suppliers Suppliers are not sure of the requirements or the need for PPAP, they are required to contact the appropriate customer approval activity. For them, that is their STA Engineer. All suppliers Suppliers that submit levels 2-5 are required to notify their STA Engineer to schedule a PSW. (See page 25 in PPAP.)Sub-SupplierSub-suppliers Suppliers are required to comply with any product approval process their customer sets for them. This requirement is stated in QS-9000 element 4.2.4. It states “Suppliers shall use a part approval process for all their sub-suppliers Suppliers as required.”It is recommended that suppliers Suppliers use the PPAP process as stated in the PPAP manual for their sub-suppliersSuppliers.PPAP vs. PSWThe terms PPAP and PSW are used interchangeably at Ford and throughout the automotive community. They are two completely different things. PPAP is the entire approval process that we will be discussing today. It includes documentation review, capability and capacity analysis via Run-at-Rate, and completion of a Part Submission Warrant (PSW) if required. Completion of the PSW is one small piece of the PPAP process. We will be discussing this in detail.In the future, STA Engineers should refer to this process and the dates that go with it as PPAP, not PSW.PPAP RequirementsACTIVITY/MEDIACONTENT/INSTRUCTOR NOTESxx minutes2 slidesEstimated time for this section.Display: Slide: Legal Impact.Discuss:Emphasize importance of this and provide an example.Display:Slides: 19 Elements of PPAP 1 19 Elements of PPAP 2 19 Elements of PPAP 3 19 Elements of PPAP 4Discuss:Most elements are requirements of QS-9000. These are not additional. These are the key documents and tasks that prove that the supplier Supplier process will attains and maintains the part quality.Discuss:Elements, ask for examples of formats. QS-9000 does not dictate specific formats.Suggest:STA Engineers should work with suppliers to identify what formats work best for them.PPAP RequirementsImpact (legal)The PSW is a legal document. It is your the responsibility as of an STA Engineer to monitor that the PPAP process is conducted properly and all required documents are completed. Special attention should be given to all special, government, and safety items. 19 ElementsThere are 19 elements or items listed in the PPAP manual that suppliers Suppliers shall either file or submit for PPAP approval when required. Most of these 19 elements are not additional requirements for suppliersSuppliers; they are requirements of QS-9000 that they need to do