PPAP Training.rev D

nullnullnullnullThe intent of this training is to communicate Motorola PCS’s, PPAP requirements to the suppliers and train the SDE Engineers and suppliers on these PPAP requirements for qualificationnullWhat does PPAP stand for ??What does PPAP stand for ??null PRODUCTIONPPAPPARTAPPROVALPROCESSnullPPAP is a production part approval process used 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 PPAP 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 PCS changing the qualification requirements ??Is Motorola PCS changing the qualification requirements ??Motorola PCS is not changing qualification requirements, instead Motorola PCS is enhancing/adding the current qualification requirements to match the PPAP requirements.Motorola PCS is not changing qualification requirements, instead Motorola PCS is enhancing/adding the current qualification requirements to match the PPAP requirements.null What are the PPAP requirements ?? nullPPAP RequirementsIn addition to these PPAP requirements, PCS has added this new additional requirementnullnull I am not familiar with some of these requirements, would you please explain what these PPAP requirements are ?? (1) Design Records(1) Design RecordsDesign 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, all customer and supplier design records (e.g.: CAD, Pro-E files, part drawing/ prints, specifications) (2) Engineering Change Documents (if any) (2) Engineering Change Documents (if any) Engineering 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) (3) Customer Engineering Approval (If required) Customer 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 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(4) Design FMEADesign 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 before they reach the customer. The Goal of Design or Process FMEA is to eliminate the Failure modes or reduce their risk. null(5) Process Flow Diagram Process Flow Diagram: Process is a combination of people, equipment, 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(6) Process FMEA Failure Modes and Effects Analysis (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 before they reach the customer. The Goal of Design or Process FMEA is to eliminate the Failure modes or reduce their risk. (7) Dimensional Results(7) Dimensional ResultsDimensional 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 listed in a convenient format. (8) Material, Performance Test Results (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 on 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(9) Initial Process Studies 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 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, supplier request, non-normal distribution, or measurement issues), the supplier must notify Motorola. Motorola must approve any deviation. (*) null(10) Measurement System Analysis Measurement System Analysis: Measurement system analysis (MSA) is an experimental and mathematical method of determining how 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 (11) Qualified Laboratory Documentation Qualified Laboratory Documentation: A Qualified 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(12) Control planControl plan: Control plans 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 plans can apply to a number of parts produced using a common process.(13) Part Submission Warrant(13) Part Submission WarrantPart 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 production parts show conformance to Motorola print requirements. (14) Appearance Approval Report(14) Appearance Approval ReportAppearance Approval Report: Motorola defines Appearance Approval Report as limit samples. Limit samples are the parts that do not meet Motorola PCS cosmetic requirements, but are approved by the Motorola, PCS development 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(15) Bulk Material Requirements ChecklistBulk Material Requirements: Bulk material is a substance (e.g. non-dimensional solid, liquid, gas) Such 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(16) Sample production PartsSample production Parts: Sample production 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(17) Master SampleMaster Sample: Master Sample(s) are considered as Golden samples Golden samples 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(18) Record of Compliance With customer specific RequirementsRecord of Compliance With customer specific Requirements: Motorola, PCS defines “Record of Compliance With customer specific Requirements” as PAF Print Acceptance Form(19) Checking Aids(19) Checking AidsChecking Aids: Checking aids (fixtures, models, templates, mylars, etc.) Specific to the part being submitted, used in inspecting or testing.(20) Run at Rated Speed(20) Run at Rated SpeedRun at Rated Speed: Running the tool/process at the velocity/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 stability, then select random parts for qualification.nullAren’t some of these PPAP requirements the same as what PCS requires already??nullnullCurrent Qualification Requirements **** Above mentioned requirements are for a typical commodity, for any specific commodity qualification requirements contact your local CTEnullQualification Requirements that are not covered under PPAP **** Above mentioned requirements are for a typical commodity, for any specific commodity qualification requirements contact your local CTE How many of the PPAP requirements will be required for qualification and which ones ? How many of the PPAP requirements will be required for qualification and which ones ? There are Nineteen (19) PPAP requirements, but Motorola PCS 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 the items on file for future reference . PCS PPAP REQUIREMENTSPCS PPAP REQUIREMENTSSo as a supplier, what should I submit for qualification?So as a supplier, what should I submit for qualification?Following items need to be submitted for Motorola PCS qualification requirements. Supplier may need to submit additional requirements based on the specific commodity. Refer to your local SDE or CTE for additional requirements for a specific commodity. Following items need to be submitted for Motorola PCS qualification requirements. Supplier may need to submit additional requirements based on the specific commodity. Refer to your local SDE or CTE for additional requirements for a specific commodity. nullDesign Records Process Flow Diagram Process FMEA Dimensional Results Material performance Test Results Initial Process Studies Measurement System 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 copy 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) 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 filled out PAF All qualification samples and measurements must be taken after the tool/mold/assembly process is ran to it’s rated speed. QUALIFICATION REQUIREMENTS FOR PCSnull I understand these PPAP requirements, but what exactly does Motorola PCS want to see for these requirements?? A little more explanation would be helpful.(1) Design Records(1) Design RecordsDesign 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, all customer and supplier design records (e.g.: CAD, Pro-E files, part drawing/ prints, specifications) In this requirement, Motorola PCS requires suppliers to submit a current copy of the Motorola Print/specification. Print/specification must have the same revision as the qualification package. (2) Engineering Change Documents (if any) (2) Engineering 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 PCS requires supplier 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 PCS. If Motorola decides to change the design after the Qualification, 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 PCS Process Change Notification Procedure 12M09192A78”) (3) Customer Engineering Approval (If required) (3) Customer Engineering Approval (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 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.Where specified by the Motorola print/specification, the supplier shall have evidence of Motorola engineering approval. Suppliers do not need to submit this requirement with qualification, but should keep it for future reference. (4) Design FMEA(4) Design FMEAFMEA 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 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 submit the DFMEA with qualification, instead they need to retain it for future reference. null(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 of materials through the process, include all rework or repair operations and cycle time in your flow chart Review process flow diagram and identify critical steps in the process flow. Verify that all the critical steps are covered under PFMEA Review process flow diagram and identify critical steps in the process flow. Verify that all the critical steps are covered under PFMEA 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. A cross functional team (team should include members from operators to quality managers) should be developed for an effective PFMEA.(6) Process FMEAThe supplier shall have a detailed PFMEA developed and submitted with every qualification package. Supplier must take corrective action to items with a RPN >60 (7) Dimensional Results(7) Dimensional ResultsDimensional 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 listed in a convenient format. The supplier shall provide evidence that dimensional verifications required by the print/specification have been completed and results 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 recorded. (8) Material, Performance Test Results (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 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 revision 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 material supplier letterhead. The name of the raw material supplier that supplied the material must be indicated. (9) Initial Process Studies(9) Initial Process StudiesFor 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 35 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 must approve any deviation. (*) The supplier must follow “Motorola Inc. Supplier Material Quality Control “ spec (12M80967A78) for this item. null(10) Measurement System Analysis MSA is a requirement for qualification. For qualification, supplier must submit and follow the following: All measuring equipments 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 (11) Qualified Laboratory Documentation A Qualified 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 Since Motorola does not have a list of qualified laboratories. The supplier should acquire an approval prior to sending the test ma