TS16949 PPAP Trainingrev E

WELCOMEWhatistheintentofthisTraining??WhatistheintentofthisTraining??TheintentofthistrainingistocommunicateMotorolaPCS’s,PPAPrequirementstothesuppliersandtraintheSDEEngineersandsuppliersonthesePPAPrequirementsforqualificationSUPPLIERDEVELOPMENTENGINEERINGTRAININGMODULESDE-VOLIIIBy:ZubairIqbalJuly16th2004WhatdoesPPAPstandfor??PRODUCTIONPPAPPARTAPPROVALPROCESSPPAPisaproductionpartapprovalprocessusedbyUSautoindustry(GM,Ford,andChrysler).TheProductionPartApprovalProcess(PPAP)outlinesthemethodsusedforapprovalofproductionandservicecommodities,includingbulkmaterials,uptoandincludingpartsubmissionwarrantintheAdvancedQualityPlanningprocess.ThepurposeofthePPAPprocessistoensurethatsuppliersofcomponentscomplywiththedesignspecificationandcanshowdocumentaryevidencethatthelevelcanbemaintainedduringthelifeoftheproduct.WhatistheProductionPartApprovalProcess??IsMotorolaPCSchangingthequalificationrequirements??MotorolaPCSisnotchangingqualificationrequirements,insteadMotorolaPCSisenhancing/addingthecurrentqualificationrequirementstomatchthePPAPrequirements.WhatarethePPAPrequirements??PPAPRequirementsRunatRatedSpeedMaterialPerformanceTestResultsInitialProcessStudiesControlPlanMeasurementSystemAnalysisStudiesPartSubmissionWarrant(PSW)QualifiedLaboratoryDocumentationDesignRecordsCustomerEngineeringApprovalEngineeringChangeDocuments(ifany)DesignFMEAProcessFlowDiagramsProcessFMEASampleProductionPartsBulkMaterialReq.Checklist(bulkmtl’only)MasterSampleRecordsofComplianceWithCustomerSpecificRequirementsCheckingAidsDimensionalResultsAppearanceApprovalReport/CosmeticStoryboardsInadditiontothesePPAPrequirements,PCShasaddedthisnewadditionalrequirementWhatisthePurposeofthesenewPPAPRequirements??ThePurposeofPPAPistodetermineifallcustomerengineeringdesignrecordsandspecificationrequirementsareproperlyunderstoodbythesupplierandthattheprocesshasthepotentialtoproduceproductmeetingtheserequirementsduringanactualproductionrunatthequotedrate.Iamnotfamiliarwithsomeoftheserequirements,wouldyoupleaseexplainwhatthesePPAPrequirementsare??(1)DesignRecordsDesignRecords: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)DesignFMEADesignFMEA:FMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.(5)ProcessFlowDiagramProcessFlowDiagram:Processisacombinationofpeople,equipment,method,Material,andenvironmentthatproducesoutput,foragivenproductorservice.ProcessFlowDiagramdepictstheflowofmaterialsthroughtheprocess,includinganyre-work,repairoperationsorcycletime.(6)ProcessFMEAFailureModesandEffectsAnalysis(FMEA)FMEAisanEngineering“ReliabilityTool”thathelpstodefine,identify,prioritize,andEliminateknownand/orpotentialfailuresofthesystem,design,ormanufacturingprocessbeforetheyreachthecustomer.TheGoalofDesignorProcessFMEAistoeliminatetheFailuremodesorreducetheirrisk.(7)DimensionalResultsDimensionalResults:Dimensionalresultsarethemeasurementsresultstakenoffthefiveproductionpartsfromproductiontool,mold,orset-up.Alldimensions(exceptreferencedimensions),Characteristics,specificationsasnotedontheprintandprintnotesshouldbemeasuredandlistedinaconvenientformat.(8)Material,PerformanceTestResultsMaterial,PerformanceTestResults:MaterialtestsaretestthatspecifiedonMotorolaprintorspecificationsaschemical,physicalormetallurgicaltestse.g.MEK,abrasion,adhesion,……etc.PerformancetestsaretestthatspecifiedonMotorolaprintorspecificationsasperformancetestse.g.numberofcycles,environmentaltesting,electricaltesting,Platingthickness,Paintthickness,Glossreadings,……etc.(9)InitialProcessStudiesInitialProcessStudies:ForBox-X[X]andSTparameters,thesuppliershallprovideCp/Cpkstatisticstoensureanacceptableprocesscapability(Cp/Cpkof2/1.5orgreater).Asampleof35piecesisdeemedappropriatefornormallydistributeddatagatheredviaanacceptablemeasurementmethod(errorrate10%orlessunlessapprovedbyCTE).Forconditionsthatrequirereview(Cp/Cpkbelow1.5,suppli