TS16949 PPAP Trainingrev E.ppt

WELCOME,TheintentofthistrainingistocommunicateMotorolaPCSs,PPAPrequirementstothesuppliersandtraintheSDEEngineersandsuppliersonthesePPAPrequirementsforqualification,WhatdoesPPAPstandfor?,PRODUCTION,PPAP,PART,APPROVAL,PROCESS,PPAPisaproductionpartapprovalprocessusedbyUSautoindustry(GM,Ford,andChrysler).TheProductionPartApprovalProcess(PPAP)outlinesthemethodsusedforapprovalofproductionandservicecommodities,includingbulkmaterials,uptoandincludingpartsubmissionwarrantintheAdvancedQualityPlanningprocess.ThepurposeofthePPAPprocessistoensurethatsuppliersofcomponentscomplywiththedesignspecificationandcanshowdocumentaryevidencethatthelevelcanbemaintainedduringthelifeoftheproduct.,WhatistheProductionPartApprovalProcess?,IsMotorolaPCSchangingthequalificationrequirements?,MotorolaPCSisnotchangingqualificationrequirements,insteadMotorolaPCSisenhancing/addingthecurrentqualificationrequirementstomatchthePPAPrequirements.,WhatarethePPAPrequirements?,PPAPRequirements,InadditiontothesePPAPrequirements,PCShasaddedthisnewadditionalrequirement,WhatisthePurposeofthesenewPPAPRequirements?,Iamnotfamiliarwithsomeoftheserequirements,wouldyoupleaseexplainwhatthesePPAPrequirementsare?,(1)DesignRecords,DesignRecords:Designrecordsareengineeringrequirementsforjudgingtheacceptabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsareconsideras,allcustomerandsupplierdesignrecords(e.g.:CAD,Pro-Efiles,partdrawing/prints,specifications),(2)EngineeringChangeDocuments(ifany),EngineeringChangeDocuments:EngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchange(s)(authorizedbyMotoroladevelopmentengineering)notyetrecordedinthedesignrecordbutincorporatedintheproduct,partortooling.,(3)CustomerEngineeringApproval(Ifrequired),CustomerEngineeringApproval:CustomerEngineeringapprovalistheprocessthatprovidesfortwowaycommunicationbetweenthecomponentsupplier&theresponsibleMotoroladesignengineeringactivityandthroughwhichthesupplierrequestsconcurrenceforcertaindesignandprocesschanges.,OnceMotoroladesignengineeringdeterminesthatthechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillcompleteandsubmittheProcessChangeNotificationforapproval.,(4)DesignFMEA,DesignFMEA:FMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.,(5)ProcessFlowDiagram,ProcessFlowDiagram:Processisacombinationofpeople,equipment,method,Material,andenvironmentthatproducesoutput,foragivenproductorservice.ProcessFlowDiagramdepictstheflowofmaterialsthroughtheprocess,includinganyre-work,repairoperationsorcycletime.,(6)ProcessFMEA,FailureModesandEffectsAnalysis(FMEA)FMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.,(7)DimensionalResults,DimensionalResults:Dimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool,mold,orset-up.Alldimensions(exceptreferencedimensions),Characteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.,(8)Material,PerformanceTestResults,Material,PerformanceTestResults:MaterialtestsaretestthatspecifiedonMotorolaprintorspecificationsaschemical,physicalormetallurgicaltestse.g.MEK,abrasion,adhesion,etc.PerformancetestsaretestthatspecifiedonMotorolaprintorspecificationsasperformancetestse.g.numberofcycles,environmentaltesting,electricaltesting,Platingthickness,Paintthickness,Glossreadings,etc.,(9)InitialProcessStudies,InitialProcessStudies:ForBox-XXandparameters,thesuppliershallprovideCp/Cpkstatisticstoensureanacceptableprocesscapability(Cp/Cpkof2/1.5orgreater).Asampleof35piecesisdeemedappropriatefornormallydistributeddatagatheredviaanacceptablemeasurementmethod(errorrate10%orlessunlessapprovedbyCTE).Forconditionsthatrequirereview(Cp/Cpkbelow1.5,supplierrequest,non-normaldistribution,ormeasurementissues),thesuppliermustnotifyMotorola.Motorolamustapproveanydeviation.(*),(10)MeasurementSystemAnalysis,MeasurementSystemAnalysis:Measurementsystemanalysis(MSA)isanexperimentalandmathematicalmethodofdetermininghowmuchthevariationwithinthemeasurementprocesscontributestooverallprocessvariability.TherearefiveparameterstoinvestigateinanMSA:bias,linearity,stability,repeatabilityandreproducibility.,(11)QualifiedLaboratoryDocumentation,QualifiedLaboratoryDocumentation:AQualifiedlaboratoryisatestfacilitythatmayincludechemical,metallurgical,dimensional,physical,electrical,reliabilitytestingortestvalidation.QualifiedLaboratoryDocumentationisadocumentationortestresultsissuedbyaMotorolaqualifiedlaboratory,(12)Controlplan,Controlplan:Controlplansarewrittendescriptionsofthesystemforcontrollingproductionpartsorbulkmaterialsandprocesses.Theyarewrittenbysupplierstoaddresstheimportantcharacteristicsandengineeringrequirementsoftheproduct.Eachpartmusthaveacontrolplan,butinmanycases,“family”controlplanscanapplytoanumberofpartsproducedusingacommonprocess.,(13)PartSubmissionWarrant,PartSubmissionWarrant:PartSubmissionWarrantisacertificateofcompliancerequiredForallnewlytooledorrevised(up-rev)productsinwhichsupplierconfirmsthatInspectionsandtestsonproductionpartsshowconformancetoMotorolaprintrequirements.,(14)AppearanceApprovalReport,AppearanceApprovalReport:MotoroladefinesAppearanceApprovalReportaslimitsamples.LimitsamplesarethepartsthatdonotmeetMotorolaPCScosmeticrequirements,butareapprovedbytheMotorola,PCSdevelopmentEngineeringandquality/CTE.Inadditionlimitsamplesaresetupforcolororfinishesranges(InlimitsamplesrangesaresetperGolden/Mastersample),(15)BulkMaterialRequirementsChecklist,BulkMaterialRequirements:Bulkmaterialisasubstance(e.g.non-dimensionalsolid,liquid,gas)Suchasadhesives,sealants,chemicals,coating,fabrics,lubricants,etc.AbulkmaterialmaybecomeproductionmaterialifissuedaMotorolapartnumber.Bulkmaterialchecklistisdefinedasalistofqualificationrequirements,(16)SampleproductionParts,SampleproductionParts:SampleproductionPartsaremanufacturedattheproductionsiteusingtheproductiontooling,gaging,process,materials,operators,environment,andprocesssetting.,feeds/speeds/cycletimes/pressures/temperatures.,(17)MasterSample,MasterSample:MasterSample(s)areconsideredasGoldensamplesGoldensamplesareforappearancepartsonly.MostofthetimeGoldensamplesaresetorapprovedForpaintcolor,anodizing,orsurfacefinishes,(18)RecordofComplianceWithcustomerspecificRequirements,RecordofComplianceWithcustomerspecificRequirements:Motorola,PCSdefines“RecordofComplianceWithcustomerspecificRequirements”asPAFPrintAcceptanceForm,(19)CheckingAids,CheckingAids:Checkingaids(fixtures,models,templates,mylars,etc.)Specifictothepartbeingsubmitted,usedininspectingortesting.,(20)RunatRatedSpeed,RunatRatedSpeed:Runningthetool/processatthevelocity/outputitisexpectedtoberunatduringproduction.ForExample:Ifatoolormoldisratedtoproducetrueproductionpartsatarateof300parts/hrorXXhundredparts/hr,suppliermustrunthetrueproductiontool/moldorprocesstothatspeedforsomeperiodoftimetoensureprocessstability,thenselectrandompartsforqualification.,ArentsomeofthesePPAPrequirementsthesameaswhatPCSrequiresalready?,Yes!Youareright,someofthesePPAPrequirementsarecoveredundercurrentqualificationrequirements.Thereareonlyafewthatarenotcovered.,CurrentQualificationRequirements*,*Abovementionedrequirementsareforatypicalcommodity,foranyspecificcommodityqualificationrequirementscontactyourlocalCTE,QualificationRequirementsthatarenotcoveredunderPPAP*,*Abovementionedrequirementsareforatypicalcommodity,foranyspecificcommodityqualificationrequirementscontactyourlocalCTE,ThereareNineteen(19)PPAPrequirements,butMotorolaPCSwillrequireonly13outofthose19requirementsfromtheirsupplierstosubmitwithqualificationpackage(s).Sinceall19requirementsarerequired,suppliersarerequiredtokeeptherestoftheitemsonfileforfuturereference.,HowmanyofthePPAPrequirementswillberequiredforqualificationandwhichones?,PCSPPAPREQUIREMENTS,Soasasupplier,whatshouldIsubmitforqualification?,FollowingitemsneedtobesubmittedforMotorolaPCSqualificationrequirements.Suppliermayneedtosubmitadditionalrequirementsbasedonthespecificcommodity.RefertoyourlocalSDEorCTEforadditionalrequirementsforaspecificcommodity.,DesignRecordsProcessFlowDiagramProcessFMEADimensionalResultsMaterialperformanceTestResultsInitialProcessStudiesMeasurementSystemAnalysisControlPlanPartSubmissionWarrant(PSW)AppearanceApproval(Forappearanceitemsonly)SampleProductionPartsMastersample(Forappearanceitemsonly)RecordofCompliancewithCustomerspecificRequirementsRunatratedSpeedControlledandReportableMaterialsDisclosure(W18),AcopyofacurrentMotorolaPrint/SpecificationAdetailedPFDoftheproductionprocessAdetailedprocessFMEACompletedimensionaldata(5-onfiveproductionparts).AmaterialCofCforallmaterials,PerformancetestresultsandmaterialtestresultsCpandCpkmeasurementson35-samples(perA78)GaugeR&Rresultsforequipmentusedtomeasurequalificationsamples.AdetailedqualitycontrolPlan.ASignedMotorolaCertificateofComplianceSubmitMotorolaapprovedStoryboards/limitsamplesSubmitfiveproductionsamplesSubmitMotorolaapprovedGoldensamplesAsignedandcompletelyfilledoutPAFAllqualificationsamplesandmeasurementsmustbetakenafterthetool/mold/assemblyprocessisrantoitsratedspeed.,QUALIFICATIONREQUIREMENTSFORPCS,IunderstandthesePPAPrequirements,butwhatexactlydoesMotorolaPCSwanttoseefortheserequirements?Alittlemoreexplanationwouldbehelpful.,(1)DesignRecords,Designrecordsareengineeringrequirementsforjudgingtheacceptabilityofapartcharacteristic.Forqualification,everyfeatureoftheproductasidentifiedbyengineeringspecificationsorpartdrawing/printmustbemeasured.Designrecordsareconsideras,allcustomerandsupplierdesignrecords(e.g.:CAD,Pro-Efiles,partdrawing/prints,specifications),Inthisrequirement,MotorolaPCSrequiressupplierstosubmitacurrentcopyoftheMotorolaPrint/specification.Print/specificationmusthavethesamerevisionasthequalificationpackage.,(2)EngineeringChangeDocuments(ifany),EngineeringChangeDocumentsaredefinedasanyauthorizedengineeringchange(s)(authorizedbyMotoroladevelopmentengineering)notyetrecordedinthedesignrecordbutincorporatedintheproduct,partortooling.,Inthisrequirement,MotorolaPCSrequiressuppliertoresolvealldesignorprocessissuesbeforesubmittingthequalificationpackage.IfforanyreasonthesupplierdecidestochangetheprocessfromtheOriginalqualification,aPCN(ProcessChangeNotification)mustbeapprovedbyPCS.IfMotoroladecidestochangethedesignaftertheQualification,suppliersarerequiredtore-submitthequalificationpernewPrint/specificationrevision.MotorolaexpectsitssupplierstoretainallengineeringChangedocumentsforfuturereference.(Referto“MotorolaPCSProcessChangeNotificationProcedure12M09192A78”),(3)CustomerEngineeringApproval(Ifrequired),CustomerEngineeringapprovalistheprocessthatprovidesfortwowaycommunicationbetweenthecomponentsupplier&theresponsibleMotoroladesignengineeringactivityandthroughwhichthesupplierrequestsconcurrenceforcertaindesignandprocesschanges.,OnceMotoroladesignengineeringdeterminesthatthechangeisfeasibleandanengineeringapprovalisrequired,thesupplierwillcompleteandsubmittheProcessChangeNotificationforapproval.,WherespecifiedbytheMotorolaprint/specification,thesuppliershallhaveevidenceofMotorolaengineeringapproval.Suppliersdonotneedtosubmitthisrequirementwithqualification,butshouldkeepitforfuturereference.,(4)DesignFMEA,FMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.,ThesuppliershallhaveaDesignFMEAdevelopedforpartsormaterialforwhichtheyaredesign-responsible.DFMEAisarequirementforqualification.SuppliersdonotneedtosubmittheDFMEAwithqualification,insteadtheyneedtoretainitforfuturereference.,(5)ProcessFlowDiagram,ThesuppliershallhaveaPFD(ProcessFlowDiagram)forallpart(s)requiringqualification.SuppliermustsubmitadetailedPFDwitheachqualificationpackage.Inadditiontotheflowofmaterialsthroughtheprocess,includeallreworkorrepairoperationsandcycletimeinyourflowchart,VerificationofalloyRawmat.CompositionHardness,ShelfLifeHumidityOxidationWaterleakage(rain.etc),YouneedtoidentifyallthepotentialfailuremodesforyourPFMEAtobeeffective.Acrossfunctionalteam(teamshouldincludemembersfromoperatorstoqualitymanagers)shouldbedevelopedforaneffectivePFMEA.,(6)ProcessFMEA,ThesuppliershallhaveadetailedPFMEAdevelopedandsubmittedwitheveryqualificationpackage.SuppliermusttakecorrectiveactiontoitemswithaRPN60,Reviewprocessflowdiagramandidentifycriticalstepsintheprocessflow.VerifythatallthecriticalstepsarecoveredunderPFMEA,(7)DimensionalResults,Dimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool,mold,orset-up.Alldimensions(exceptreferencedimensions),Characteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.,Thesuppliershallprovideevidencethatdimensionalverificationsrequiredbytheprint/specificationhavebeencompletedandresultsindicatecompliancewithspecifiedrequirements.Dimensionalmeasurementmustbedoneonallcavities,mold,tools,ordies.Alldimensions,characteristics,andspecificationsasnotedontheprint/specificationandnotesshouldbemeasuredandlistedinaconvenientformatwiththeactualresultsrecorded.,(8)Material,PerformanceTestResults,Materialtestsmustbeperformedforallpartsandproductmaterialswhenchemical/physical/metallurgicalrequirementsarespecifiedontheprint.Thesuppliermustperformthetestsrequiredbythematerialspecificationsandthecontrolplan.Ifthesuppliercannotperformtherequiredtest,servicesmustbeprocuredfromanoutsidequalifiedsource.WhenthirdpartyLabservicesareused,theresultsmustbesubmittedontheirletterhead.Thenameofthelaboratorythatperformedthetestsmustbeindicated.Testreportmustindicatetherevisionlevelofthepartstested,andthedateandrevisionlevelofthespecifications.Inadditionsuppliermustsubmitamaterialcertificateofcomplianceforallthematerialinthepart(e.g.plasticpaintedpartmusthavebothmaterialCofCplasticandpaint.MaterialCofCmustbeonrawmaterialsupplierletterhead.Thenameoftherawmaterialsupplierthatsuppliedthematerialmustbeindicated.,(9)InitialProcessStudies,ForBox-XXandparameters,thesuppliershallprovideCp/Cpkstatisticstoensureanacceptableprocesscapability(Cp/Cpkof2/1.5orgreater).Asampleof35piecesisdeemedappropriatefornormallydistributeddatagatheredviaanacceptablemeasurementmethod(errorrate10%orless).Forconditionsthatrequirereview(Cp/Cpkbelow1.5,supplierrequest,non-normaldistribution,ormeasurementissues),thesuppliermustnotifyMotorola.Motorolamustapproveanydeviation.(*),Thesuppliermustfollow“MotorolaInc.SupplierMaterialQualityControl“spec(12M80967A78)forthisitem.,(10)MeasurementSystemAnalysis,MSAisarequirementforqualification.Forqualification,suppliermustsubmitandfollowthefollowing:AllmeasuringequipmentsandGaugesarecalibrated%R&Riscompletedonallgaugesthatareusedon-lineorinlabs.Allgaugeshaveanacceptable%R&R(10%).If%R&Risbetween11%to30%,SDEorCTEapprovalisrequired.AnANOVAmethodshouldbeusedtocalculate%R&R,notAverage&Rangemethod.Anyequipmentsorgaugethatisnotmeetingthe%R&Rshouldnotbeusedandmusthaveaplantofixitorreplaceit.,(11)QualifiedLaboratoryDocumentation,AQualifiedlaboratoryisatestfacilitythatmayincludechemical,metallurgical,dimensional,physical,electrical,reliabilitytestingortestvalidation.QualifiedLaboratoryDocumentationisadocumentationortestresultsissuedbyaMotorolaqualifiedlaboratory,SinceMotoroladoesnothavealistofqualifiedlaboratories.Thesuppliershouldacquireanapprovalpriortosendingthetestmaterialtoanylab.ThelaboratorymustbeapprovedbyMotorolaSDE,CTEorthePersonqualifyingthepartpriortothequalificationtesting.,(12)Controlplan,Controlplansarewrittendescriptionsofthesystemforcontrollingproductionpartsorbulkmaterialsandprocesses.Theyarewrittenbysupplierstoaddresstheimportantcharacteristicsandengineeringrequirementsoftheproduct.Eachpartmusthaveacontrolplan,butinmanycases,“family”controlplanscanapplytoanumberofpartsproducedusingacommonprocess.,ThesuppliershallhaveaControlPlanThatdefinesallcontrolsusedforprocesscontrolandcomplieswiththeMotorolaspecifications.Controlplansfor“families”ofsimilarpartsareacceptableifthenewpartshavebeenreviewedforcommonality.,(13)PartSubmissionWarrant,PartSubmissionWarrantisacertificateofcompliancerequiredForallnewlytooledorrevised(up-rev)productsinwhichsupplierconfirmsthatInspectionsandtestsonproductionpartsshowconformancetoMotorolaprintrequirements.,Motorolarequiresallsuppliertosubmitasignedandcompletedcertificateofcompliancewitheachqualificationpackage.Thecertificatemustincludetheaddressandthevendorcodeforthesitepursuingqualification.,(14)AppearanceApprovalReport,MotoroladefinesAppearanceApprovalReportaslimitsamples.LimitsamplesarethepartsthatdonotmeetMotorolaPCScosmeticrequirements,butareapprovedbytheMotorola,PCSdevelopmentEngineeringandquality/CTE.Inadditionlimitsamplesaresetupforcolororfinishesranges(InlimitsamplesrangesaresetperGolden/Mastersample),Ifapplicable,suppliersarerequiredtosubmitstoryboard/limitsamplesforcolororfinishvariations.Inadditionifthelimitsamples/storyboardsaredevelopedforpartsthatarenotmeetingMotorolaA97cosmeticrequirementsmustbesubmitted.Suppliermustcreatetwosetsoflimitsamples,oneforqualificationandthesecondshouldbekeptforsuppliersreference.(ifrequiredbyCTEmoresamplesshouldbecreatedforMotorolafactoryor3rdparty).AlllimitsamplesmustbeapprovedandsignedbyMotorola.,(15)BulkMaterialRequirementsChecklist,Bulkmaterialisasubstance(e.g.non-dimensionalsolid,liquid,gas)Suchasadhesives,sealants,chemicals,coating,fabrics,lubricants,etc.AbulkmaterialmaybecomeproductionmaterialifissuedaMotorolapartnumber.Bulkmaterialchecklistisdefinedasalistofqualificationrequirements,BulkMaterialQualificationChecklist:AcopyofacurrentMotorolaPrint/Specif