QUALITY MANAGEMENT
Presentation No 7:
PPAP
Production Part Approval Process
Silvia Rapp VU 7
Production Parts Approval Process
INDEX
1. PPAP 3
1.1 What is PPAP? 3
1.2 Who introduced PPAP? 3
1.3 The generał idea of PPAP 4
1.4 Development of PPAP 4
2. PPAP Process 5
2.1 When is PPAP required? 5
2.3 Design records 10
2.4 The 5 Submission Levels 16
3. PART SUBMISSION STATUS 18
3.1 Fuli Approval 18
3.2 Interim Approva1 18
3.3 Rejected 18
4. RECORD RETENTION 19
5. PPAP - PROCESS at the example of Siemens VDO Automotive .... 20
6. LITERATURĘ / SOURCES 21
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SiMa Rapp
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1. PPAP
1.1 What is PPAP?
Production Part Approval Process (PPAP) defines generic requirements for production part approval, including production and bulk materials (bulk materiał is a substance, e.g. non-dimensional, solid, liquid or gas, such as adhesive, sealants, chemicals, coatings, fabrics, etc. A bulk materiał may become production materiał if issued a customer production part number). The purpose of PPAP is to determine if the supplier understood all customer engineering design record and specification requirements properly and that the process has the potential to procedurę product consistently meeting these requirements during an actual production run at the quoted production ratę.
PPAP has to apply to internal and external supplier sites of bulk materials, production materials, production or service parts. Unless requested by the customer, PPAP is not required for bulk materials.
Unless formally waived by the customer, a supplier of standard catalogue production or service parts must comply with PPAP. As long as the items are offered or stated as being available, tooling has to be maintained for standard catalogue items.
1.2 Who introduced PPAP?
This Procedurę was developed by the Quality and Part Approval staffs at Chrysler, Ford and Generał Motors, working under the auspices of the Automotive Division of the American Society for Quality Control (ASQC) and the Automotive Industry Action Group (AIAG).
PPAP manuał is a required document for the U.S. automotive industry and is being used throughout the supplier base at all levels. With the formation of DaimlerChrysler, U.S.
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PPAP Production Part Approval Process
OEMs started looking at the international scenę and, with the International Organization for Standardization (ISO), began working on an international automotive sector-specific quality management system (QMS). This standard became known as ISO/TS 16949, and the U.S. group replacing the SO.RTF for the new effort is the International Automotive Task Force (IATF).
1.3 The general idea ot PPAP
1. For every component or component assembly print a documented PPAP approval at the products revision level per the released drawing is required. PPAP requirements are defined and communicated to the supplier by the Purchasing department. A component review or a PPAP Approval Requirements form is used to document the PPAP requirements, depending on the complexity of the part and/ or the change of the part covered by the PPAP.
2. A supplier cannot ship without Full or Interim PPAP Approval unless a deviation is in place.
3. Interim PPAP Approval permits the supplier to ship material for production on a limited time or quantity basis.
1.4 Development of PPAP
Historically, the automotive industry has asked suppliers to plan for the design, development and manufacture of products to be used in producing cars and trucks and, at the same time, to meet any number of quality-related issues. Between 1964 and 1994, each of the four U.S. OEMs-American Motors, Chrysler, Ford and General Motors-required unique processes for suppliers to plan production and submit samples of future parts prior to the start of a new assembly process.
By the early 1990s, the burden imposed by what then had become the Big Three was continuously growing. At an American Society for Quality (ASO.) Automotive Division meeting in the early 1990s, executives from a number of suppliers challenged the OEMs to devise a method to reduce the paperwork burden on the supply base. The executives
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of the OEMs opened the floor to a brainstorming session and devised a plan for a set of common quality-related standards that laid the initial groundwork for QS-9000. This, in turn, gave importance to PPAP.
2. PPAP Process
2.1 When is PPAP required?
Full approval from the customer product approval activity must be obtained by the supplier for:
> A new part or product (i.e., a specific part, materiał, or color not previously supplied to the specific customer).
> Correction of a discrepancy on a previously submitted part.
> Product modified by an engineering change to design records, specifications, or material.
> Any situations required by customer.
2.2 PPAP Process Requirements
The product for PPAP for production parts must be taken from a significant production run. This production run has to be from one hour to eight hours of production, and with the specific production quantity to total a minimum of 300 consecutive parts, unless otherwise specified by the authorized customer quality representative.
This run must be manufactured at the production site using the tooling, process materials, gaging and operators from the production environment. Parts from each unique production process, e.g. duplicate assembly line and/ or work cell, each position
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of a multiple cavity mold, die, tool or pattern, has to be measured and representative parts tested.
No specific numbers of “parts” is required to be submitted for bulk materials, it must be taken in a way as to assure that it represents “steady-state” operation of the process. The supplier has to meet all specific requirements, e.g. design record, specification, and for bulk materiał, the Bulk Materiał Requirement Checklist. Any results that are outside specification are cause for the supplier not to submit the parts, documentation and/ or records. Every effort has to be madę to correct the process so that all design record requirements are met. If the supplier is unable to meet any of these requirements, the customer must be contacted to determine appropriate corrective actions. All inspections and testing for PPAP must be performed by a qualified laboratory. The supplier must have the applicable items and records, regardless of the submission level.
2.2.11nitial Process Studies
For all Special Characteristics designated by the customer or supplier, the level of initial
process capability or performance must be determined to be acceptable prior to
submission.
Measurement system analysis must be performed by the supplier, to understand how a
measurement error is affecting the study measurements.
The purpose of this requirement is to determine if the production process is likely to procedurę a product that will meet the customer’s requirements. The initial process study is focused on variables not attributes data. Test failures, assembly errors, surface defects are examples of “count” time data, which is important to understand, but is not covered in this initial study. To understand the performance of characteristics monitored by attribute data will require morę data collected over time.
Initial process studies are short-term and will not predict the effects of time and variation in people, materials, methods, equipment, measurement systems and environment. Even for these short-term studies, it is important to collect and analyse the data in the order produced using control charts.
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