Introduction to APQP. This manual provides guidelines designed to produce a product quality plan, which will support the development of a product or service that will satisfy the customer see Section 1. The following terms, used in this edition are used to describe the supply chain. Second Edition. Ensure your suppliers understand the processes required to produce parts with consistent quality during an actual production run at production rates. Aiag Spc Reference Manual for Mac.
The term "organization" refers to the unit to which these guidelines. Aiag Ppap. This document identifies PPAP requirements for all service parts. Aiag Spc Reference Manual for Mac Ppap manual aiag, aiag ppap manual 4th edition forms including control plan. Aiag Pfmea Manual Pdf Ebooks - ebooktake. All books are in clear copy here, and all files are secure so don't worry about it. This site is like a library, you could find million book here by using search box in the header.
Product Code: PPAP-4 Pricing Ensure your suppliers understand the processes required to produce parts with consistent quality during an actual production run at production rates. PPAP is the industry standard for defining the production part approval process to ensure engineering design record and specification requirements are consistently met. Aiag Fmea Manuals. Try QI Macros software today with a 30 day trial.
For example, some parts do not have appearance requirements, others do not have color requirements, and plastic parts may have polymeric part marking requirements.
In order to determine with certainty which items intlst be included, consult the design record, e. Where the design record is in electronic format, e.
NOTE 1: For any saleable product, part or component, there will only be one design record, regardless of who has design-responsibility. The design record may reference other documents making them part of the design record. NOTE 2: A single design record can represent multiple part or assembly configurations, e. NOTE 3: For parts identified as black box see Glossary , the design record specifies the interface and performance requirements.
NOTE 4: For parts identified as catalog parts, the design record may consist only of a fimctional specification or a reference to a recognized industry standard. NOTE 5: For bulk materials, the design record may include identification of raw materials, formulations, processing steps and parameters, and final product specifications or acceptance criteria.
NOTE: For bulk materials, this requirement is satisfied by a signed 'Engineering Approvaly line item on the Bulk Material Requirements Checklist see Appendix F andlor inclusion a customer maintained list of approved materials. NOTE: Process flow diagrams for 'families' of similar parts are acceptable if the new parts have been reviewed for commonality by the organization.
NOTE 1: Control Plans for "families" of parts are acceptable if the new parts have been reviewed for coinmonality by the organization. The organization shall have applicable Measurement System Analysis studies, e.
Customer agreement should be obtained on actual requirements. The organization shall have dimensional results for each unique manufacturing process, e. The organization shall record, with the actual results: all dimensions except reference dimensions , characteristics, and specifications as noted on the design record and Control Plan. The organization shall indicate the date of the design record, change level, and any authorized engineering change document not yet incorporated in the design record to which the part was made.
The organization shall record the change level, drawing date, organization name and part number on all auxiliary documents e. A tracing shall be included when an optical comparator is necessary for inspection. The organization shall identify one of the parts measured as the master sample see 2. NOTE 2: Dimensional results typically do not apply to bulk materials. NOTE: Material test results may be presented in any convenient format. An example is shown in Appendix D. For products with customer-developed material specifications and a customer-approved supplier list, the organization shall procure materials andlor services e.
Performance test results shall indicate and include: 0 the design record change level of the parts tested; 0 any authorized engineering change documents that have not yet been incorporated in the design record; the number, date, and change level of the specifications to which the part was tested; 0 the date on which the testing took place; 0 the quantity tested; the actual results. NOTE: Performance test results may be presented in any convenient format.
An example is shown in Appendix E. The organization shall obtain customer concurrence on the index for estimating initial process capability prior to submission. The organization shall perform measurement system analysis to understand how measurement error affects the study measurements. NOTE 2: The purpose of this requirement is to determine if the production process is likely to produce product that will meet the customer's requirements.
The initial process study is focused on variables not attribute data. Assembly errors, test failures, surface defects are examples of attribute 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 more data collected over time. Unless approved by the authorized customer representative, attribute data are not acceptable for PPAP submissions. Other methods more appropriate for certain processes or products may be substituted with prior approval from an authorized customer representative.
NOTE 4: 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 analyze the data in the order produced using control charts. The initial process study data requirements inay be replaced by longer- term historical data from the same or similar processes, with customer concurrence.
For certain processes, alternative analytical tools such as individual and moving range charts inay be appropriate and permitted with prior approval from an authorized customer representative.
NOTE 1: The initial process study results are dependent on the purpose of the study, method of data acquisition, sampling, amount of data, demonstration of statistical control, etc. See the Statistical Process Control reference manual for additional information in understanding the basic principles of statistical stability and process measures indices.
For guidance on items listed below, contact the authorized customer representative. Cpk- The capability index for a stable process. CpIcis an indicator of process capability based on process variation within each subgroup of a set of data. CpI,does not include the effect of process variability between the subgroups.
Cplcis an indicator of how good a process could be if all process variation between subgroups was to be eliminated. Therefore, use of Cpkalone may be an incomplete indicator of process performance. For more information, see the Statistical Process Control reference manual. Ppk- The performance index.
The estimate of sigma is based on total variation all of individual sample data using the standard deviation [root mean square equation], "s". Pplcis an indicator of process performance based on process variation throughout the full set of data.
Unlike Cpk,Ppkis not limited to the variation within subgroups. However, Pplccannot isolate within subgroup variation froin between subgroup variation. When calculated from the same data set, Cplcand Ppkcan be compared to analyze the sources of process variation. Initial Process Studies. The purpose of the initial process study is to understand the process variation, not just to achieve a specific index value.
When historical data are available or enough initial data exist to plot a control chart at least individual samples , Cplccan be calculated when the process is stable.
NOTE 2: For Initial Process Studies involving more than one process stream, additional appropriate statistical methods or approaches may be required. NOTE 3: For bulk material, the organization should obtain customer agreement regarding the appropriate techniques for initial process studies, if required, in order to determine an effective estimate of capability.
Contact the authorized customer representative for a review of the study results. NOTE 1: Meeting the initial process study capability acceptance criteria is one of a number of customer requirements that leads to an approved PPAP submission. NOTE 2: See 2. The organization shall identify, evaluate and, wherever possible, eliminate special causes of variation prior to PPAP submission. The organization shall notify the authorized customer representative of any unstable processes that exist and shall submit a corrective action plan to the customer prior to any submission.
NOTE: For bulk materials, for processes with known and predictable special causes and output meeting specifications, corrective action plans may not be required by the customer.
NOTE: The above mentioned acceptance criteria 2. When this is not true, using this analysis may result in unreliable information. These alternate acceptance criteria could require a different type of index or some method of transformation of the data.
The focus should be on understanding the reasons for the non-normality e. Refer to the Statistical Process Control reference manual for further guidance. Variation reduction efforts shall continue until the acceptance criteria are met, or until customer approval is received. When an externallcoinmercial laboratory is used, the organization shall submit the test results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that performed the tests, the date s of the tests, and the standards used to run the tests shall be identified.
A separate Appearance Approval Report AAR shall be completed for each part or series of parts if the productipart has appearance requirements on the design record. Upon satisfactory completion of all required criteria, the organization shall record the required information on the AAR.
The completed AAR. AARs complete with part disposition and authorized customer representative signature shall then accompany the PSW at the time of final submission based upon the submission level requested. See customer-specific requirements for any additional requirements. The master sample shall be identified as such, and shall show the customer approval date on the sample. The organization shall retain a master sample for each position of a multiple cavity die, mold, tool or pattern, or production process unless otherwise specified by the customer.
NOTE When part size, sheer volume of parts, etc. The purpose of the master sample is to assist in defining the production standard, especially where data is ambiguous or in insufficient detail to fully replicate the part to its original approved state. The organization shall document all released engineering design changes that have been incorporated in the checking aid at the time of submission.
The organization shall provide for preventive maintenance of any checking aids for the life of the part see Glossary - "Active Part". Measurement system analysis studies, e. NOTE 2: Checking aids, etc. If checking aids are used for bulk materials, the organization should contact the authorized customer representative regarding this requirement. For bulk materials, applicable customer-specific requirements shall be documented on the Bulk Material Requirements Checklist.
A separate PSW shall be completed for each customer part number unless otherwise agreed to by the authorized customer representative. If production parts will be produced from more than one cavity, mold, tool, die, pattern, or production process, e.
The specific cavities, molds, line, etc. The organization shall verify that all of the measurement and test results show conformance with customer requirements and that all required documentation is available and, for Level 2, 3, and 4, is included in the submission as appropriate. A responsible official of the organization shall approve the PSW and provide contact information. NOTE 1: One warrant per customer part number can be used to summarize many changes providing that the changes are adequately documented, and the submission is in compliance with customer program timing requirements.
The weight shall not include shipping protectors, assembly aides, or packaging materials. To determine part weight, the organization shall individually weigh ten randomly selected parts, calculate and report the average weight.
At least one part shall be measured from each cavity, tool, line or process to be used in product realization.
NOTE: This weight is used for vehicle weight analysis only and does not affect the approval process. Where there is no production or service requirement for at least ten parts, the organization should use the required number for calculation of the average part weight. For bulk materials, the part weight field is not applicable. The organization shall notify the authorized customer representative of any planned changes to the design, process, or site.
Examples are indicated in the table below see Table 3. Upon notification and approval of the proposed change by the authorized customer representative, and after change implementation, submission is required unless otlienvise specified.
Use of other construction or material For example, other constsuction as documented on than was used in the previously approved a deviation permit or included as a note on the part product design record and not covered by an engineering change as described in Table 3. Production from new or modified tools This requirement only applies to tools, which due except perishable tools , dies, molds to their unique form or fimction, can be expected patterns, etc.
It is replacement tooling not meant to describe standard tools new or repaired , such as standard measuring devices, drivers manual or power , etc. Rearrangement is defined as activity that changes the sequence of productlprocess flow from that documented in the process flow diagram including the addition of a new process.
Production from tooling and equipment Production process tooling and lor equipment transferred to a different plant site or from transferred between buildings or facilities at one or an additional plant site. Change of supplier for pasts, non- The organization is responsible for approval of equivalent materials, or services e.
Product produced after the tooling has For product that has been produced after tooling been inactive for volume production for has been inactive for twelve months or more: twelve months or more. Notification is required when the part has had no change in active purchase order and the existing tooling has been inactive for volume production for twelve months or more.
The only exception is when the part has low volume, e. However a customer may specify certain PPAP requirements for service parts. Change in testlinspection method - new For change in test method, the organization should technique no effect on acceptance criteria have evidence that the new method has measurement capability equivalent to the old method.
Additionally, for bulk materials: These changes would normally be expected to have an effect on the performance of the product. New source of raw material from new or existing supplier. The organization shall review and update, as necessary, all applicable items in the PAP file to reflect the production process, regardless of whether or not the customer requests a formal submission.
The PPAP file shall contain the name of the authorized customer representative granting the waiver and the date. A new part or product i. Correction of a discrepancy on a previously Submission is required to correct any submitted part. A "discrepancy" can be related to: e The product performance against the customer requirements 0 Dimensional or capability issues 0 Supplier issues o Approval of a part replacing an interim approval Testing, including material, performance, or engineering validation issues 3.
Engineering change to design records, Submission is required on any engineering specifications, or materials for production change to the production productlpart design record. Additionally, for Bulk Materials: 4. Process technology new to the organization, not previously used for this product. Level 2 Wai-sant with product samples and limited supporting data submitted to the customer. Level 3 Warrant with product samples and complete suppoi-ting data submitted to the customer.
Level 4 Warrant and other requirements as defined by the customer. Level 5 Warrant with product samples and complete supporting data reviewed at the organization's manufacturing location. See RetentiodSubmission Requirements Table 4. The organization shall use level 3 as the default level for all subinissions unless othenvise specified by the authorized customer representative. I: The authorized customer representative may identify a submission level, different from the default level, that is to be used with each organization, or organization and customer part number combiliation.
Different customer locations may assign different submission levels to the same organization manufacturing location. NOTE 2: All of the f o r m referenced in this document may be replaced by computer-generated facsimiles.
Acceptability of these facsimiles is to be confirmed with the authorized customer representative prior to the first submission. Upon approval of the submission, the organization shall assure that future production continues to meet all customer requirements.
NOTE: For those organizations that have been classified as "self certifying" PPAP submission level 1 by a specific customer, submission of the required organization-approved documentation will be considered as customer approval unless the organization is advised otherwise.
The organization is therefore authorized to ship production quantities of the product, subject to releases from the customer scheduling activity. Interim Approval will only be granted when the organization has: 0 clearly defined the non-compliances preventing approval; and, c prepared an action plan agreed upon by the customer. PPAP re-submission is required to obtain a status of "approved. Note 2: Parts with a status of "Interim Approval" are not to be considered "Approved. No additional shipments are authorized unless an extension of the interim approval is granted.
For bulk materials, the organization shall use the "Bulk Material Interim Approval" form, or its equivalent see Appendix F. The submission shall be approved before production quantities may be shipped. Part Name and 2a. Customer Part Number: Engineering released finished end item part name and number.
Org, Part Number: Part number defined by the organization, if any. Shown on Drawing Number: The design record that specifies the customer part number being submitted. Safety andlor Government Regulation: "Yes" if so indicated by the design record, otherwise "No. Weight: Enter the actual weight in kilograms to four decimal places unless otherwise specified by the customer. Checking Aid Number, Change Level and Date: If requested by the customer, enter the checking aid number, its change level and date.
Street Address, Region, Postal Code, Country: Show the complete address of the location where the product was manufactured. For "Region," enter state, county, province, etc. Customer NameIDivision: Show the corporate name and division or operations group. Application: Enter the model year, vehicle name, engine, transmission, etc.
If submitted via other customer format, enter the date customer confirmation was received. Check the appropriate box es. For bulk materials, in addition to checking the appropriate box, check "Other" and write "Bulk Material" in the space provided. Check the appropriate boxes for dimensional, material tests, performance tests, appearance evaluation, and statistical data. Check the appropriate box. If "no," enter the explanation in "comments" below. Enter the number of pieces manufactured during the significant production run.
Enter the time in hours taken for the significant production run. Attach additional information as appropriate. Part Name Cust. Part Number Shown on Drawing No. Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location.
I further affirm that these samples were produced at the production rate of 24 ours 1 also certify that documented evidence of such compliance is on file and available for review. FAX No. Weight kg I Checking Aid No. Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer. I also certify that documented evidence of such compliance is on file and available for review.
Drawing Number: Use the number of the drawing on which the part is shown if different from the part number. Part Name: Use the finished part name on the part drawing. Organization Name: Organization responsible for submission include supplier if applicable.
Manufacturing Location: Location where part was manufactured or assembled. SupplierNendor Code: Customer-assigned code for organization location where the part was manufactured or assembled. Reason for Submission: Check box es explaining the reason for this submission. Color Suffix: Use alphanumeric or numeric color identification. Tristimulus Data: List numerical colorimeter data of submission part as compared to the customer-authorized master. Master Number: Enter alphanumeric master identification not used by Ford.
Master Date: Enter the date on which the master was approved. Material Type: Identify first surface finish and substrate e. Material Source: Identify first surface and substrate suppliers. Example: RedspotIDow. Color Shipping Suffix: Color part number suffix or color number. Part Disposition: To be determined by customer approved or rejected. Comments: General comments by the organization or customer optional. Organization Signature, Phone No. Organizations are responsible for applying PAP to their suppliers of ingredients which have organization-designated special characteristics.
Any customer-specific requirements shall be documented on the Bulk Materials Requirements Checklist. Primary Responsibility - Customer: Identify by name or function the individual who will review and approve the element. Primary Responsibility - Organization: Identify by name or function the individual who will assemble and assure the completeness of the element to be reviewed. Approved by: Enter the initials of the authorized customer representative who has reviewed and accepted the element.
Plan agreed to by: Identify the individuals and their functions who made and agreed upon the project plan. Use of these suggestions will arsive at the same end point of a completed Design FMEA, but with greater applicability to bulk materials. The Design Matrix detennines the complex interactions of fomula ingredients, ingredient characteristics, product characteristics, process constraints, and conditions for customer use.
Along the vertical axis, list the design iteins as Potential Causes CategoryICharacteristics : Formula Ingsedients o Ingredient Characteristics Product Characteristics Process Constraints Conditions for Use customer process constraints For each design item, enter the current robust threshold range levels and units.
Correlate the potential causes to the potential failure modes using a number, letter, or symbol representing the impact or strength of the relationship. Ask what would happen if a potential cause item is allowed to go under or over its robust minilnuin or maximum, respectively. After completion of the ranlcings in the Design Matrix, review the categorylcharacteristics for a preliminary assessment of Special Characteristics.
Designate any Special Characteristics in colu1m 1. List Effects of Failure Consumer Effects - General teims identifying the loss experienced by the ultimate user of the product e. The following figure provides a guideline for severity rankings. If your situation only uses a small portion of the scale then develop your own scale to improve the differentiation. If yous situation is greater than two tiers back from the final consumer, then the guideline figure should be adjusted to reflect the effects that will be felt by your customer's customer.
Mechanisms are generally described as over or under a certain threshold. These thresholds define the boundaries of the product approval and subsequent requirements for change notification. The following step provides an alternate method for assigning Occurrence ratings. Rank Occurrence - the ranking scale in the Potential Failure ode and Effects Analysis manual difficult to relate to bulk materials and generally results in very low numbers with little differentiation the ultimate risk.
The following matrix is recommended as a replacement. It evaluates the frequency occurrence based upon observed evidence the formulator has in the design. Similar Experience: Based upon similar products or processes and the potential failure model. Assumption: Based upon a clear understanding of the chemical impact of the material and the potential failure mode. Frequency ranking clarifications: High is defined as - Repeated failures Moderate is defined as - Occasional failures Low is defined as - Relatively few failures F.
Variation of supplier specifications. Design controls identified by a number should be available so that the relevant content of that control cs be understood. The next step provides an alternate method for assigning Detection rankings. Rank Detection - the ranking scale in the Potential Failure Mode and Effects Analysis manual difficult to relate to bulk materials and generally results in very low numbers with little differentiation the ultimate risk. The following matrix may be used. It evaluates the Detection as the ability of tl.
AssuinptiodExperience: Infonnationldata based upon similar products or processes. May cause serious disruption to subsequent processing of the product or result in the product failing to meet its sales specifications. Will result in a customer complaint and product return.
Moderate: Failure causes some customer dissatisfactioii and may result in a customer complaint or limitation on shelf life. The customer may need to make modifications or adjustments to their process to accommodate the material. The problem is liltely to be detected as part of an incoming inspection or prior to use 4. The problem will be detected during processing 5. The problem will be detected in subsequent processing steps 6. Low: Failure causing only a slight customer annoyance.
Customer will notice only a slight deterioration or inconvenience with the product or processing of the product. Minor: Reasonable to expect that the minor nature of this failure would not cause any real effect on the product or its processing by the customer.
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