ncr-supplier-PPAP-Training-Presentation.ppt

ProductionPartApprovalProcess(PPAP),WhatisPPAP?,ProductionPartApprovalProcessStandardusedtoformallyreduceriskspriortoproductorservicerelease,inateamorientedmannerusingwellestablishedtoolsandtechniquesInitiallydevelopedbyAIAG(AutoIndustryActionGroup)in1993withinputfromtheBig3-Ford,Chrysler,andGMAIAGs4theditioneffectiveJune1,2006isthemostrecentversionPPAPhasnowspreadtomanydifferentindustriesbeyondautomotive,PurposeofPPAP,ProvideevidencethatallcustomerengineeringdesignrecordandspecificationrequirementsareproperlyunderstoodbytheorganizationTodemonstratethatthemanufacturingprocesshasthepotentialtoproduceproductthatconsistentlymeetsallrequirementsduringanactualproductionrunatthequotedproductionrate,WhenisPPAPRequired?,NewpartEngineeringchange(s)Tooling:transfer,replacement,refurbishment,oradditionalCorrectionofdiscrepancyToolinginactiveoneyearChangetooptionalconstructionormaterialSub-supplierormaterialsourcechangeChangeinpartprocessingPartsproducedataneworadditionallocation,BenefitsofPPAPSubmissions,HelpstomaintaindesignintegrityIdentifiesissuesearlyforresolutionReduceswarrantychargesandpreventscostofpoorqualityAssistswithmanagingsupplierchangesPreventsuseofunapprovedandnonconformingpartsIdentifiessuppliersthatneedmoredevelopmentImprovestheoverallqualityoftheproductkeepthemalignedControlsmustbeusedtobeeffective.Keepitsimple.EnsurethatthecontrolplanisinthedocumentcontrolsystemofthebusinessGoodcontrolplansaddress:Alltestingrequirements-dimensional,material,andperformanceAllproductandprocesscharacteristicsateverystepthroughouttheprocessThecontrolmethodshouldbebasedonaneffectiveanalysisoftheprocessSuchasSPC,ErrorProofing,Inspection,SamplingPlanControlplansshouldreferenceotherdocumentationSpecifications,tooling,etc.,ReviewersChecklist,MeasurementSystemAnalysis(MSA),AttributeDataExamples:Count,Pass/fail,yes/no,red/green/yellow,timekeepingbucketsVariableDataExamples:Physicalmeasurement(length,width,area,)Physicalconditions(temperature,pressure)Physicalproperties(strength,load,strain)Continuousornon-ending,AttributeandVariableMSA,MeasurementSystemAnalysis(MSA),ProcessVariation,MeasurementSystemVariation,ObservedVariation,Theobservedvariationinprocessoutputmeasurementsisnotsimplythevariationintheprocessitself;itisthevariationintheprocessplusthevariationinmeasurementthatresultsfromaninadequatemeasurementsystem.,MeasurementSystemAnalysis(MSA),ProcessVariation,MeasurementSystemVariation,ObservedVariation,ObservedVariation,ObservedVariation,ProcessVariation,MeasurementSystemVariation,Reproducibility,Precision(Variability),Linearity,Bias,Stability,Resolution,Repeatability,Accuracy(CentralLocation),ObservedVariation,MeasurementSystemAnalysis(MSA),ObservedVariation,ObservedVariation,ProcessVariation,MeasurementSystemVariation,Precision(Variability),Linearity,Bias,Stability,Resolution,Repeatability,Reproducibility,Accuracy(CentralLocation),CalibrationAddressesAccuracy,MeasurementSystemAnalysis(MSA),MeasurementSystemAnalysis(MSA),ErrorinResolutionTheinabilitytodetectsmallchanges.PossibleCauseWrongmeasurementdeviceselected-divisionsonscalenotfineenoughtodetectchanges.,Resolution,MeasurementSystemAnalysis(MSA),ErrorinRepeatabilityTheinabilitytogetthesameanswerfromrepeatedmeasurementsmadeofthesameitemunderabsolutelyidenticalconditions.PossibleCauseLackofstandardoperatingprocedures(SOP),lackoftraining,measuringsystemvariablilty.,Repeatability,EquipmentVariation,MeasurementSystemAnalysis(MSA),ErrorinReproducibilityTheinabilitytogetthesameanswerfromrepeatedmeasurementsmadeundervariousconditionsfromdifferentinspectors.PossibleCauseLackofSOP,lackoftraining.,Reproducibility,AppraiserVariation,VariableMSAGageR&RStudy,GageR&RisthecombinedestimateofmeasurementsystemRepeatabilityandReproducibilityTypically,a3-personstudyisperformedEachpersonrandomlymeasures10markedpartspertrialEachpersoncanperformupto3trialsThereare3keyindicatorsEVorEquipmentVariationAVorAppraiserVariationOverall%GRR,VariableMSANCRsGageR&RForm,Select10itemsthatrepresentthefullrangeoflong-termprocessvariation.Identifytheappraisers.Ifappropriate,calibratethegageorverifythatthelastcalibrationdateisvalid.OpentheGageR&RworksheetinthePPAPPlaybooktorecorddata.Haveeachappraiserassesseachpart3times(trialsfirstinorder,secondinreverseorder,thirdrandom).InputdataintotheGageR&Rworksheet.Enterthenumberofoperators,trials,samplesandspecificationlimitsAnalyzedataintheGageR&Rworksheet.AssessMSAtrustlevel.Takeactionsforimprovementifnecessary.,VariableMSAGageR&RSteps,Steps1and2:VariableMSA-GageR&R,Select10itemsthatrepresentthefullrangeoflong-termprocessvariation.,Identifytheappraisers.Shoulduseindividualsthatactuallydotheprocessbeingtested.Canalsoincludeotherappraisers(supervisors,etc.).Shouldhaveaminimumof3appraisers.,Steps3and4:VariableMSAGageR&R,Ifappropriate,calibratethegageorverifythatthelastcalibrationdateisvalid.,OpentheGageR&RworksheetinthePPAPPlaybooktorecordthedata,Step5:VariableMSAGageR&R,Haveeachappraiserassesseachitem3times.Eachappraiserhastoworkindependently.Itemsshouldbeevaluatedinrandomorder.Aftereachappraisercompletesthefirstevaluationofallitemsrepeattheprocessatleast2moretimes.Donotlettheappraisersseeanyofthedataduringthetest!,Steps6and7:VariableMSAGageR&R,InputdataintotheGageR&Rworksheet,Enterthenumberofoperators,trials,samplesandspecificationlimits,Steps8and9:VariableMSAGageR&R,AssessMSATrustLevel.Red:30%(fail)Yellow:10-30%(marginal)Green:30%(fail)Yellow:10-30%(marginal)Green:QualityToolsCapabilityAnalysisNormal.ClickintheSingleColumnfield.DoubleclickTimetoProcessinthecolumnontheleft.ClickintheSubgroupSizefield.,Dependingonsubgroupinformationeither:a.Enter1ifthesubgroupsizeis1.b.DoubleclickIndivDates_1inthecolumnontheleft.c.Sincethesubgroupsizeisconstant(n=5)thenumber5couldbetypedinthesubgroupsizefield.,NormalCapabilityAnalysisinMinitab,Type20inLowerSpec.Type40inUpperSpec.SelectOptionsbutton.Addtargetvalue(ifapplicable).UnderDisplayselectPartspermillionorPercentsCapabilityStatsorBenchmarkZAddTitleifdesired.ClickOK.ClickOK.,NormalCapabilityAnalysisResults,NormalCapabilityAnalysisResults,Non-NormalCapabilityDistributionIdentification,ExerciseUsingthedata(Time_2)inaMinitabfileCapabilityExample.MTWdeterminethecapabilityofthePOprocessintermsofthetimethatisrequiredtoprocessthePOs.,A,Q,WhichCapabilityAnalysisapplies?,No,Non-normalTryIndividualDistributionIdentification,Yes,?,Non-NormalCapabilityDistributionIdentification,Isthedataattributeorvariable?Isthedatanormal?Arethereasonsfornon-normalityunderstood?Canthedatabedescribedbyanotherdistribution?,IndividualDistributionIdentificationinMinitab,OpentheworksheetCapabilityExample.MTW.ChooseStatQualityToolsIndividualDistributionIdentification.ClickintheSingleColumnfield.DoubleclickTime_2inthecolumnontheleft.ChooseUsealldistributions.ClickOK.,IndividualDistributionIdentificationinMinitab,OpentheworksheetCapabilityExample.MTW.ChooseStatQualityToolsCapabilityAnalysisNonnormal.ClickintheSingleColumnfield.DoubleclickTime_2inthecolumnontheleft.SelectFitdatawithDistribution.Usingpulldownmenuselect3-parameterWeibull.Type20inLowerSpec.Type40inUpperSpec.,UsingIndividualDistributionIdentification,SelectOptionsbutton.Addtargetvalue(ifapplicable).UnderDisplayselectCapabilityStatsBenchmarkZAddTitleifdesired.ClickOK.ClickOK.,UsingIndividualDistributionIdentification,UsingIndividualDistributionIdentification,Non-NormalCapabilityCentralLimitTheorem,ActivityUsingthedata(Time_3andTime3sub)inaMinitabfileCapabilityExample.MTWdeterminethecapabilityofthePOprocessintermsofthetimeisrequiredtoprocessthePOs.,A,Q,WhichCapabilityAnalysisapplies?,No,Non-normalTrysub-groupingthedata,Yes,Yes,No,?,Isthedataattributeorvariable?Isthedatanormal?Arethereasonsfornon-normalityunderstood?Canthedatabedescribedbyanotherdistribution?Canthedatabesub-grouped?Isthesub-groupeddatanormal?,Non-NormalCapabilityCentralLimitTheorem,OpentheworksheetCapabilityExample.MTW.ChooseStatQualityToolsCapabilityAnalysisNormal.ClickintheSingleColumnfield.DoubleclickTime_3inthecolumnontheleft.ClickintheSubgroupSizefieldDoubleclickIndividDates_3inthecolumnontheleft.Type20inLowerSpec.Type40inUpperSpec.,Thesub-groupshavetomakelogicalsense,suchasbyday,byshift,bymachine,Important!,Checksub-groupdataTime_3subfornormality.Ifthedataisnotnormalthenthismethodcannotbeused!,Caution!,UsingCentralLimitTheoremSub-Grouping,SelectOptionsbutton.Addtargetvalue(ifapplicable).UnderDisplayselectPartspermillionorPercentsCapabilityStatsorBenchmarkZAddTitleifdesired.ClickOK.ClickOK.,UsingCentralLimitTheoremSub-Grouping,UsingCentralLimitTheoremSub-Grouping,UsingCentralLimitTheoremSub-Grouping,Non-NormalCapabilityBox-CoxTransformation,ActivityUsingthedata(Time_4)inaMinitabfileCapabilityExample.MTWdeterminethecapabilityofthePOprocessintermsofthetimeisrequiredtoprocessthePOs.,A,Q,WhichCapabilityAnalysisapplies?,No,Non-normalTryBox-Coxtransformation,Yes,No,No,?,Non-NormalCapabilityBox-CoxTransformation,Isthedataattributeorvariable?Isthedatanormal?Arethereasonsfornon-normalityunderstood?Canthedatabedescribedbyanotherdistribution?Canthedatabesub-grouped?Candatabetransformed?,Box-CoxTransformation,OpentheworksheetCapabilityExample.MTWChooseStatControlChartsBox-Co