PPAPProcedureSupplier要求实用教案

1、DefinitionOur Responsibility “Production Part Approval Process (PPAP) defines generic requirements for production part approval, including production and bulk materials. PPAP定义了生产件批准的一般要求，包括生产材料和散装材料。The purpose of PPAP is to determine if all customer engineering design records and specification req

2、uirements are properly understood by the supplier and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.”PPAP的目的是确定供应商是否(sh fu)正确理解了客户工程设计记录和规范的所有要求，以及在报价生产节拍下进行实际生产的过程中，是否(sh fu)能生产出能持续满足这些要求的产

3、品。Production Part Approval Process (PPAP) Fourth Edition, 2006第1页/共29页第一页，共30页。Quality Documentation Review 质量质量(zhling)文件评审文件评审The supplier is to generate a PPAP number and load all documents on SCC for the SQE to review while keeping the PPAP in the “New” status. 供应商要生成一个PPAP编号，并把所有文件(wnjin)放到SCC上

4、供SQE评审。将PPAP状态保持在 “New”的状态All documentation and layout results MUST be approved by the SQE prior to the supplier “Submitting” the PPAP on SCC. 在供应商在SCC上提交PPAP之前，所有文件(wnjin)和全尺寸报告必须得到SQE的批准。PPAP Approval Should be Quick, with Little Review Needed第2页/共29页第二页，共30页。PPAP Level Requirements PPAP等级等级(dngj)

5、要求要求Level 1: Warrant Sheet PSW Level 2:Warrant Sheet PSWDimensional 尺寸报告Material certification理化报告Level 3:Warrant Sheet PSWMaterial certification理化报告Dimensional尺寸报告Process capability study过程能力研究Measurement systems analysis MSAProcess Failure Mode and Effects Analysis PFMEADynamic Control Plan控制计划Pro

6、cess Flow Chart 流程图Run-at-Rate / Capacity study worksheet节拍生产(shngchn)报告Sample Parts 样件Level 4: Level 1 PPAP + additional customer requirements PSW+客户其他要求Level 5: Level 3 PPAP + additional customer requirements + on site audit第3等级PPAP提交文件+客户其他要求+现场审核 第3页/共29页第三页，共30页。Level 1 PPAP 等级等级(dngj)1 Require

7、ments 要求 Warrant Sign Off PSW的签署 Usage Applicable to note revisions, drawing revisions and other revisions which have no impact on the process or dimensions on the part print or specification 适用于备注修改、图纸(tzh)修改及其他修改，这些改动不会影响产品图纸(tzh)或规范上规定的过程或尺寸。第4页/共29页第四页，共30页。Level 2 PPAP等级等级(dngj)2 Requirements要求

8、 Warrant Sign Off PSW Material Certification 理化报告 Dimensional 尺寸报告 Usage Applicable to changes small changes when the process is unaffected and verification of a minor change is necessary 适用于一些较小的、不会影响(yngxing)过程的变更，而且这些变更有必要进行验证和确认。第5页/共29页第五页，共30页。Level 3 PPAP 等级等级(dngj)3 Requirements 要求 Warrant S

9、ign Off Material Certification Dimensional Process Capability Studies Measurement System Analysis Process Failure Mode and Effects Analysis Dynamic Control Plan Process Flow Chart Run Rate worksheet* Packaging Requirements Sample Part Usage This is the basic submission for all initial PPAPs, tool re

10、placements, and major changes to the process 适用情况：所有(suyu)首次PPAP提交、工装变更、过程发生重大变更第6页/共29页第六页，共30页。Level 4 PPAP 等级等级(dngj)4 Requirements 要求(yoqi) Warrant sign off PSW Additional customer requirements 客户其他要求(yoqi) See Customer / Performance Testing in the following slides 见客户/性能测试（后面的幻灯片） Usage Same as

11、 Level 1 with additional customer requirements 同等级1，增加了客户其他要求(yoqi)第7页/共29页第七页，共30页。Level 5 PPAP 等级等级(dngj)5 Requirements 要求 PPAP level 3 + customer specified requirements 等级3要求+客户规定的要求 On site process audit 现场过程审核 Form - 5414 On site Run Rate verification See Run Rate in the following slides 见节拍生产(

12、shngchn)（见幻灯片21） Usage Qualification of new products at new suppliers, “black box” components or high risk situations identified by Program Management or Supply Base 适用于：对新供应商生产(shngchn)的新零件的认证、黑盒子零件或在供应商项目管理中识别出的高风险情况第8页/共29页第八页，共30页。Warrant Sheet PSWMaterial Number* 材质号Part Revision Level*件号版本 Ver

13、ify latest revision in PDMDrawing Revision Level图纸版本Plant number*工厂代码Mexicali Turbo: 7905Mexicali Thermal: 7975Gross Weight*毛重Prod. Rate / 8Hr*生产节拍/8小时Based on PPAP levelHoneywell Tool Number 联信工装编号Buyer Assigned 客户指定Tooling/Mold/Cavity工装/模号/腔号PPAP Level* PPAP等级Submission Reason*提交原因Submission Resul

14、ts*提交结果Deviation Notes 偏离备注Required PCD values* 要求(yoqi)的PCD数据*Mandatory Fields on the PSW 第9页/共29页第九页，共30页。Material Certification 理化理化(lhu)报告报告Controlled by part IDM 受控于产品IDMHoneywell material specification 联信材质规范Located on PDM 按图纸上的材质要求规定Chemical Properties 化学性能Mechanical Properties 机械性能Microstruc

15、ture (If required by IDM) 金相组织(zzh)（如果IDM有要求的话）Compliance to IDM, mandatory 第10页/共29页第十页，共30页。Dimensional Layout 全尺寸全尺寸(ch cun)报告报告Verify that every dimension is on the layout and conforms to the drawing, notes and specifications检查每个尺寸是否都在报告中，是否符合图纸、备注和规范要求Request PPAP sample parts PPAP样件Layout must

16、 be approved by Honeywell 全尺寸必须得到联信认可Volute profiles 流道轮廓GOM scans, etc. Any dimensional discrepancies must be approved by application engineering 任何不符合尺寸必须得到应用工程部门的认可Part prints should be changed to reflect actual part 应更改零件图纸来反映(fnyng)实际零件状况See required signature summary in the following sections

17、参见相关人员签字要求（见幻灯片29）Verify All Print and Specification Dimensions Comply第11页/共29页第十一页，共30页。Process Control and Capability Requirements 过程过程(guchng)控制和能力要求控制和能力要求 Controlling Document 受控文件(wnjin) Specification: QCI 9310 190 Bilateral KCCs 双边KCC Cpk = 1.67 Estimated performance, calculated from subgroup

18、 mean Unilateral KCCs Cpm = 1.30 单边KCC See QCI 9310 190 appendix B, Calculation method 参见QCI 9310 190 附录B，计算方法 Customer Interface Characteristics, CIC Poke Yoke / Mistake Proof 防呆 Cpk = 1.33 See QCI 9310 190 appendix A, Classification matrix 参见QCI 9310 190 附录A，分类矩阵表All non-conforming dimensions must

19、 be inspected 100% 第12页/共29页第十二页，共30页。Measurement Systems Analysis 测量测量(cling)系统分析系统分析Controlling Document 受控文件Specification: QCI 9310 - 190Requirements 要求(yoqi)Measurement discrimination 10% of tolerance range测量分辨率 公差范围的10% Repeatability 10% of total variation重复性 整个变差的10% Repeatability + Reproducib

20、ility 30% (Gage R&R)重复性+再现性 总变差的30%Gage R&R only necessary for KCCs and CICs 仅适用(shyng)于KCC和CIC第13页/共29页第十三页，共30页。Potential Failure Mode and Effects Analysis PFMEAControlling Document 受控文件Potential Failure Mode and Effects Analysis (FMEA) 3rd edition PFMEA第三版Severity ratings must comply with

21、 DFMEA 严重度打分必须符合(fh)DFMEAControl plan and flow chart must coincide in both operation and dimension 控制计划和流程图必须与工序和尺寸对应Severity 严重度All KCCs and CICs (7) 所有KCC和CIC （7分）KCCs and CICs must be identified on PFMEA and DCP KCC和CIC必须在PFMEA和控制计划中体现出来Tabulated on pg. 43 参见PFMEA第43页Occurrence 频度Tabulated on pg.

22、 49 参见PFMEA第49页Detection 探测度Multiple visual inspection (7) 多重目视检查（7分）SPC only = (6) 仅SPC来控制（6分）100% attribute inspection or variable gaging = (5) 100%计数检查或计量检查（5分）Automatic gaging with machine stop feature = (2) ) 自动测量并自动停机（2分）Tabulated on pg. 53 参见PFMEA第53页Suppliers must comply with PFMEA standards

23、 供应商必须符合(fh)PFMEA标准PFMEAs are living documents 第14页/共29页第十四页，共30页。PFMEA Example (cont.) PFMEA样表第15页/共29页第十五页，共30页。Dynamic Control Plan, DCP 动态的控制动态的控制(kngzh)计划计划Controlling Document 受控文件(wnjin) Advanced Product Quality Planning & Control Plan (APQP), 1st edition APQP，第一版PFMEA and flow chart must

24、 coincide with both operation number and dimension PFMEA和流程图必须和工序编号以及尺寸对应All CICs and KCCs must be identified in “Type Class”所有CICs和KCCs必须注明“等级类型”Reaction Plans must be robust and include non - conforming part containment 反应计划必须完善，要包含对不合格件的遏制对策Sample sizes and frequencies should coincide with initia

25、l process studies or historical quality data样本大小和取样频率应该和首次过程研究或历史质量数据一致All quality documents must comply with each other 第16页/共29页第十六页，共30页。DCP Example (cont.) 控制控制(kngzh)计划样表计划样表第17页/共29页第十七页，共30页。 Process flow charts must identify:必须指明： Operations工序 Machines设备 Workers人员 Storage units存储(cn ch)区域 De

26、lays within the process过程中的延迟 Flow charts must coincide with the PFMEA and DCP! 必须和PFMEA和控制计划对应！ Benchmark flow charts will contain: 标准的流程图要包括 Incoming sources of variation偏差的源头 Completed dimensions 全部尺寸 Traceability information 追溯信息Process Flow Chart 过程过程(guchng)流程图流程图第18页/共29页第十八页，共30页。Process Flo

27、w Chart (cont.) 过程过程(guchng)流程图（样表）流程图（样表）第19页/共29页第十九页，共30页。Run Rate*节拍节拍(jipi)生产生产 Run Rate Audit Procedure节拍审核程序 PDP 0630 Run Rate Calculation Worksheet节拍计算表 Form 5407 Mandatory with every PPAP level 3 or 5 unless waived 必须对等级(dngj)3或5的PPAP作节拍计算，除非客户放弃这方面的要求 Run Rate Review Worksheet节拍评审表 Form -

28、5408 Run Rate mandatory for PPAP levels 3 or 5 PPAP level 3: Supplier performed 等级(dngj)3：由供应商进行节拍审核 PPAP level 5: Honeywell performed 等级(dngj)5：由联信进行节拍审核* Run Rates Required for PPAP Levels 3 or 5第20页/共29页第二十页，共30页。Process Capability Database, PCD 过程过程(guchng)能力数据库能力数据库 When requested by Honeywell,

29、 this field becomes mandatory and necessitates the completion of the Supplier Part Feature Mapping, SPFM, tab. 当联信有要求时，就必须要完成供应商零件特性图表(tbio)（SPFM） PCD is a database for Key Critical Characteristics, KCCs, and is used to generate customer mandated product scorecards, track quality issues and verify p

30、ermanent corrective actions, as well as provide feedback to the Honeywell design team for implementation of Design for Six Sigma. PCD是针对KCC能力的数据库，并用于生成客户专有的产品打分卡、追踪质量问题、验证永久对策以及向联信设计团队提供反馈，来实施Six Sigma设计。第21页/共29页第二十一页，共30页。Customer / Performance Testing 客户客户/性能性能(xngnng)测试测试Casting and Machining 铸造

31、和加工Emission tests 排放测试Gas StandPrecision Components and Wheels 精密零件(ln jin)和车轮Emission testsEngine lug line PingGas standRaw Material原材料NASpecialty Components专用零件(ln jin)?Thermal热量NAPossible Additional Tests Required by the Customer 第22页/共29页第二十二页，共30页。Interim Approval Procedure 临时批准临时批准(p zhn)程序程序U

32、se of the Interim Recovery Worksheet is mandatory and must be attached to each interim approved PPAP 要求使用 Interim Recovery 工作表，而且必须附在每个临时批准(p zhn)的PPAP后面 Future integration of this worksheet into SCC is planned, and is currently being developed 计划以后将Interim Recovery 工作表整合进SCC（供应链协调），目前正在进展中Classific

33、ation is necessary for each interim approval reason and must abide by the new sign off procedure (see signature summary) 有必要对每个临时批准(p zhn)的原因进行分类，而且必须遵守新的签字批准(p zhn)程序（参见幻灯片29）Use of Interim Recovery Worksheet, Mandatory第23页/共29页第二十三页，共30页。Interim Approval Class I 临时批准临时批准(p zhn)等级等级IParts meet desi

34、gn record specifications, but not all PPAP requirements have been met. 零件符合(fh)设计记录规范，但不是所有PPAP要求都满足Examples:A capability study has not been competed 没有完成能力研究Quality documentation improvements are required质量文件有待提高A tier 2 casting is out of spec, but will not effect form, fit or function of machine c

35、omponent tier 2供应商供应的铸件超出规范要求，但是不会影响加工件的形状、装配或性能 第24页/共29页第二十四页，共30页。Interim Approval Class II 临时批准临时批准(p zhn)等级等级II Parts meet drawing and specification requirements, but are not produced off of the production process 零件满足图纸和规范要求，但不是在量产过程中生产的。Examples: 举例如下Parts have not been manufactured completely at the production site 零件不是完全在量产的车间生产的Parts have been produced using interim machinery 零件是使用临时设备生产的Parts have been produced using additional, substitute, or soft tooling 零件是