PPAP Motorola Training(PPAP摩托罗拉培训资料)

1、WELCOME,The intent of this training is to communicate Motorolas, PPAP requirements to the suppliers and train the SDE Engineers and suppliers on these PPAP requirements for qualification,What does PPAP stand for ?,PRODUCTION,PPAP,PART,APPROVAL,PROCESS,PPAP is a production part approval process used

2、by US auto industry (GM, Ford, and Chrysler). The Production Part Approval Process (PPAP) outlines the methods used for approval of production and service commodities, including bulk materials, up to and including part submission warrant in the Advanced Quality Planning process. The purpose of the P

3、PAP process is to ensure that suppliers of components comply with the design specification and can show documentary evidence that the level can be maintained during the life of the product.,What is the Production Part Approval Process ?,Is Motorola changing the qualification requirements ?,Motorola

4、is not changing qualification requirements, instead Motorola is enhancing/adding the current qualification requirements to match the PPAP requirements.,What are the PPAP requirements ?,PPAP Requirements,In addition to these PPAP requirements, PCS has added this new additional requirement,What is the

5、 Purpose of these new PPAP Requirements?,I am not familiar with some of these requirements, would you please explain what these PPAP requirements are ?,(1) Design Records,Design Records: Design records are engineering requirements for judging the acceptability of a part characteristic. For qualifica

6、tion, every feature of the product as identified by engineering specifications or part drawing/print must be measured. Design records are consider as, all customer and supplier design records (e.g.: CAD, Pro-E files, part drawing/ prints, specifications),(2) Engineering Change Documents (if any),Eng

7、ineering Change Documents: Engineering Change Documents are defined as any authorized engineering change(s) (authorized by Motorola development engineering) not yet recorded in the design record but incorporated in the product, part or tooling.,(3) Customer Engineering Approval (If required),Custome

8、r Engineering Approval: Customer Engineering approval is the process that provides for two way communication between the component supplier & the responsible Motorola design engineering activity and through which the supplier requests concurrence for certain design and process changes.,Once Motorola

9、 design engineering determines that the change is feasible and an engineering approval is required, the supplier will complete and submit the Process Change Notification for approval.,(4) Design FMEA,Design FMEA: FMEA is an Engineering “Reliability Tool” that helps to define, identify, prioritize, a

10、nd Eliminate known and/or potential failures of the system, design, or manufacturing process before they reach the customer. The Goal of Design or Process FMEA is to eliminate the Failure modes or reduce their risk.,(5) Process Flow Diagram,Process Flow Diagram: Process is a combination of people, e

11、quipment, method, Material, and environment that produces output, for a given product or service. Process Flow Diagram depicts the flow of materials through the process, including any re-work, repair operations or cycle time.,(6) Process FMEA,Failure Modes and Effects Analysis (FMEA) FMEA is an Engi

12、neering “Reliability Tool” that helps to define, identify, prioritize, and Eliminate known and/or potential failures of the system, design, or manufacturing process before they reach the customer. The Goal of Design or Process FMEA is to eliminate the Failure modes or reduce their risk.,(7) Dimensio

13、nal Results,Dimensional Results: Dimensional results are the measurements results taken off the five production parts from production tool, mold, or set-up. All dimensions (except reference dimensions), Characteristics, specifications as noted on the print and print notes should be measured and list

14、ed in a convenient format.,(8) Material, Performance Test Results,Material, Performance Test Results: Material tests are test that specified on Motorola print or specifications as chemical, physical or metallurgical tests e.g. MEK, abrasion, adhesion, etc. Performance tests are test that specified o

15、n Motorola print or specifications as performance tests e.g. number of cycles, environmental testing, electrical testing, Plating thickness, Paint thickness, Gloss readings, etc.,(9) Initial Process Studies,Initial Process Studies: For Box-X X and parameters, the supplier shall provide Cp/ Cpk stati

16、stics to ensure an acceptable process capability (Cp/Cpk of 2/1.5 or greater). A sample of 35 pieces is deemed appropriate for normally distributed data gathered via an acceptable measurement method (error rate 10% or less unless approved by CTE). For conditions that require review (Cp/Cpk below 1.5

17、, supplier request, non-normal distribution, or measurement issues), the supplier must notify Motorola. Motorola must approve any deviation. (*),(10) Measurement System Analysis,Measurement System Analysis: Measurement system analysis (MSA) is an experimental and mathematical method of determining h

18、ow much the variation within the measurement process contributes to overall process variability. There are five parameters to investigate in an MSA: bias, linearity, stability, repeatability and reproducibility.,(11) Qualified Laboratory Documentation,Qualified Laboratory Documentation: A Qualified

19、laboratory is a test facility that may include chemical, metallurgical, dimensional, physical, electrical, reliability testing or test validation. Qualified Laboratory Documentation is a documentation or test results issued by a Motorola qualified laboratory,(12) Control plan,Control plan: Control p

20、lans are written descriptions of the system for controlling production parts or bulk materials and processes. They are written by suppliers to address the important characteristics and engineering requirements of the product. Each part must have a control plan, but in many cases, “family” control pl

21、ans can apply to a number of parts produced using a common process.,(13) Part Submission Warrant,Part Submission Warrant: Part Submission Warrant is a certificate of compliance required For all newly tooled or revised (up-rev) products in which supplier confirms that Inspections and tests on product

22、ion parts show conformance to Motorola print requirements.,(14) Appearance Approval Report,Appearance Approval Report: Motorola defines Appearance Approval Report as limit samples. Limit samples are the parts that do not meet Motorola cosmetic requirements, but are approved by the Motorola, developm

23、ent Engineering and quality/CTE. In addition limit samples are set up for color or finishes ranges (In limit samples ranges are set per Golden/Master sample),(15) Bulk Material Requirements Checklist,Bulk Material Requirements: Bulk material is a substance (e.g. non-dimensional solid, liquid, gas) S

24、uch as adhesives, sealants, chemicals, coating, fabrics, lubricants, etc. A bulk material may become production material if issued a Motorola part number. Bulk material checklist is defined as a list of qualification requirements,(16) Sample production Parts,Sample production Parts: Sample productio

25、n Parts are manufactured at the production site using the production tooling, gaging, process, materials, operators, environment, and process setting., feeds/speeds/cycle times/pressures/temperatures.,(17) Master Sample,Master Sample: Master Sample(s) are considered as Golden samples Golden samples

26、are for appearance parts only. Most of the time Golden samples are set or approved For paint color, anodizing, or surface finishes,(18) Record of Compliance With customer specific Requirements,Record of Compliance With customer specific Requirements: Motorola, defines “Record of Compliance With cust

27、omer specific Requirements” as PAF Print Acceptance Form,(19) Checking Aids,Checking Aids: Checking aids (fixtures, models, templates, mylars, etc.) Specific to the part being submitted, used in inspecting or testing.,(20) Run at Rated Speed,Run at Rated Speed: Running the tool/process at the veloci

28、ty/output it is expected to be run at during production. For Example: If a tool or mold is rated to produce true production parts at a rate of 300 parts/hr or XX hundred parts/hr, supplier must run the true production tool/mold or process to that speed for some period of time to ensure process stabi

29、lity, then select random parts for qualification.,Arent some of these PPAP requirements the same as what MOT requires already?,Yes! You are right, some of these PPAP requirements are covered under current qualification requirements. There are only a few that are not covered.,Current Qualification Re

30、quirements *,* Above mentioned requirements are for a typical commodity, for any specific commodity qualification requirements contact your local CTE,Qualification Requirements that are not covered under PPAP *,* Above mentioned requirements are for a typical commodity, for any specific commodity qu

31、alification requirements contact your local CTE,There are Nineteen (19) PPAP requirements, but Motorola will require only 13 out of those 19 requirements from their suppliers to submit with qualification package(s). Since all 19 requirements are required, suppliers are required to keep the rest of t

32、he items on file for future reference .,How many of the PPAP requirements will be required for qualification and which ones ?,MOT PPAP REQUIREMENTS,So as a supplier, what should I submit for qualification?,Following items need to be submitted for Motorola qualification requirements. Supplier may nee

33、d to submit additional requirements based on the specific commodity. Refer to your local SDE or CTE for additional requirements for a specific commodity.,Design Records Process Flow Diagram Process FMEA Dimensional Results Material performance Test Results Initial Process Studies Measurement System

34、Analysis Control Plan Part Submission Warrant (PSW) Appearance Approval (For appearance items only) Sample Production Parts Master sample (For appearance items only) Record of Compliance with Customer specific Requirements Run at rated Speed Controlled and Reportable Materials Disclosure (W18),A cop

35、y of a current Motorola Print/Specification A detailed PFD of the production process A detailed process FMEA Complete dimensional data (5-on five production parts). A material C of C for all materials, Performance test results and material test results Cp and Cpk measurements on 35-samples (per A78)

36、 Gauge R&R results for equipment used to measure qualification samples. A detailed quality control Plan. A Signed Motorola Certificate of Compliance Submit Motorola approved Story boards/limit samples Submit five production samples Submit Motorola approved Golden samples A signed and completely fill

37、ed out PAF All qualification samples and measurements must be taken after the tool/mold/assembly process is ran to its rated speed.,QUALIFICATION REQUIREMENTS FOR MOT,I understand these PPAP requirements, but what exactly does Motorola want to see for these requirements? A little more explanation wo

38、uld be helpful.,(1) Design Records,Design records are engineering requirements for judging the acceptability of a part characteristic. For qualification, every feature of the product as identified by engineering specifications or part drawing/print must be measured. Design records are consider as, a

39、ll customer and supplier design records (e.g.: CAD, Pro-E files, part drawing/ prints, specifications),In this requirement, Motorola requires suppliers to submit a current copy of the Motorola Print/specification. Print/specification must have the same revision as the qualification package.,(2) Engi

40、neering Change Documents (if any),Engineering Change Documents are defined as any authorized engineering change(s) (authorized by Motorola development engineering) not yet recorded in the design record but incorporated in the product, part or tooling.,In this requirement, Motorola requires supplier

41、to resolve all design or process issues before submitting the qualification package. If for any reason the supplier decides to change the process from the Original qualification, a PCN (Process Change Notification) must be approved by MOT. If Motorola decides to change the design after the Qualifica

42、tion, suppliers are required to re-submit the qualification per new Print/specification revision. Motorola expects its suppliers to retain all engineering Change documents for future reference. (Refer to “Motorola Process Change Notification Procedure 12M09192A78”),(3) Customer Engineering Approval

43、(If required),Customer Engineering approval is the process that provides for two way communication between the component supplier & the responsible Motorola design engineering activity and through which the supplier requests concurrence for certain design and process changes.,Once Motorola design en

44、gineering determines that the change is feasible and an engineering approval is required, the supplier will complete and submit the Process Change Notification for approval.,Where specified by the Motorola print/specification, the supplier shall have evidence of Motorola engineering approval. Suppli

45、ers do not need to submit this requirement with qualification, but should keep it for future reference.,(4) Design FMEA,FMEA is an Engineering “Reliability Tool” that helps to define, identify, prioritize, and Eliminate known and/or potential failures of the system, design, or manufacturing process

46、before they reach the customer. The Goal of Design or Process FMEA is to eliminate the Failure modes or reduce their risk.,The supplier shall have a Design FMEA developed for parts or material for which they are design-responsible. DFMEA is a requirement for qualification. Suppliers do not need to s

47、ubmit the DFMEA with qualification, instead they need to retain it for future reference.,(5) Process Flow Diagram,The supplier shall have a PFD (Process Flow Diagram) for all part(s) requiring qualification. Supplier must submit a detailed PFD with each qualification package. In addition to the flow

48、 of materials through the process, include all rework or repair operations and cycle time in your flow chart,Verification of alloy Raw mat. Composition Hardness,Shelf Life Humidity Oxidation Water leakage ( rain.etc),You need to identify all the potential failure modes for your PFMEA to be effective

49、. A cross functional team (team should include members from operators to quality managers) should be developed for an effective PFMEA.,(6) Process FMEA,The supplier shall have a detailed PFMEA developed and submitted with every qualification package. Supplier must take corrective action to items wit

50、h a RPN 60,Review process flow diagram and identify critical steps in the process flow. Verify that all the critical steps are covered under PFMEA,(7) Dimensional Results,Dimensional results are the measurements results taken off the five production parts from production tool, mold, or set-up. All d

51、imensions (except reference dimensions), Characteristics, specifications as noted on the print and print notes should be measured and listed in a convenient format.,The supplier shall provide evidence that dimensional verifications required by the print/specification have been completed and results

52、indicate compliance with specified requirements. Dimensional measurement must be done on all cavities, mold, tools, or dies. All dimensions, characteristics, and specifications as noted on the print/specification and notes should be measured and listed in a convenient format with the actual results

53、recorded.,(8) Material, Performance Test Results,Material tests must be performed for all parts and product materials when chemical/physical/metallurgical requirements are specified on the print. The supplier must perform the tests required by the material specifications and the control plan. If the

54、 supplier cannot perform the required test, services must be procured from an outside qualified source. When third party Lab services are used, the results must be submitted on their letterhead. The name of the laboratory that performed the tests must be indicated. Test report must indicate the revi

55、sion level of the parts tested, and the date and revision level of the specifications. In addition supplier must submit a material certificate of compliance for all the material in the part (e.g. plastic painted part must have both material C of C plastic and paint. Material C of C must be on raw ma

56、terial supplier letterhead. The name of the raw material supplier that supplied the material must be indicated.,(9) Initial Process Studies,For Box-X X and parameters, the supplier shall provide Cp/ Cpk statistics to ensure an acceptable process capability (Cp/Cpk of 2/1.5 or greater). A sample of 3

57、5 pieces is deemed appropriate for normally distributed data gathered via an acceptable measurement method (error rate 10% or less). For conditions that require review (Cp/Cpk below 1.5, supplier request, non-normal distribution, or measurement issues), the supplier must notify Motorola. Motorola mu

58、st approve any deviation. (*),The supplier must follow “Motorola Inc. Supplier Material Quality Control “ spec (12M80967A78) for this item.,(10) Measurement System Analysis,MSA is a requirement for qualification. For qualification, supplier must submit and follow the following: All measuring equipme

59、nts and Gauges are calibrated %R&R is completed on all gauges that are used on-line or in labs. All gauges have an acceptable %R&R (10%). If %R&R is between 11% to 30%, SDE or CTE approval is required. An ANOVA method should be used to calculate %R&R, not Average & Range method. Any equipments or gauge that is not meeting the %R&R should not be used and must have a plan to fix it or replace it.,(11) Qualified Laboratory Documentation,A Qualified laboratory is a test facility that may include chemical, metallurgical, dimensional, physi