Production Part Approval Process(PPAP)

Transcription

1 Table of contents 1 Terms Resposibilities... Fehler! Tetmarke nicht definiert. 3 Details General Commitment for eecution of the PPA instruction Approvals of other MS sites Possible trigger events for a PPA Performing PPA Procedure Submission Level Period of archiving Result of approval Form of the documentation Preparing PPA Noncompliance State of the art of science and technology Zero defect strategy Traceability Other samples/ Submission level other Additional information Schedule of first article inspection Labeling of the samples Maturity workshop (supplier day) Process release Supply of sample parts and first article inspection documentation Attachments Attachment Parts History (eample) Attachment Evaluation Matri First Article Inspection Production and Part Approval Process (PPAP) page 1/10

2 1 Terms AIAG APQP PAA CAD Cpk PSW FMEA MS PPAP PPA Q QAA SOP VDA IMDS Automotive Industry Action Group Advanced Product Quality Planning Production Action Authorization Computer Aided Design Process capability parameter (see SPC Manual from AIAG) Part Submission Warrant Failure Mode and Effect Analysis Maschinenfabrik Spaichingen Production Part Approval Process Production Part Approval Quality Quality Assurance Agreement Start of series Production Verband der Automobilindustrie e.v. International Material Data System 2 Responsibilities Quality Management MS is responsible for updating this instruction and controlling of the compliance of its requirements. 3 Details The supplier is only authorized for delivering automotive series parts to MS Spaichingen hereinafter referred to as MS- after the official approval of the production process and the product. MS will approve the process and the product in the case the requirements of the following instruction are met. Additional attention should be paid to the QAA. Production and Part Approval Process (PPAP) page 2/10

3 3.1 General Commitment for eecution of the PPA instruction According to ISO TS the supplier is requested to perform a production process and product approval to achieve the release for series production. In general the requirements of APQP, PPAP according to AIAG is preferred. VDA Part 2 in its actual version is possible for use. For a whole scope of supply as well as for included single parts MS may require a warrant. While this document shows discrepancies to other customer requirements, the harder requirements are binding. The following matri is preferred, while content of this document shows no discrepancies: site MS Spaichingen GmbH MS Precision Components LLC. MS Industries LLC MS Powertec GmbH Procedure to be used VDA Document N 2 in its actual version APQP, PPAP according to AIAG requirements VDA Document N 2 in its actual version Approvals of other MS sites In the case the supplier has already performed a PPA process to other MS sites with a positive result, and there is no trigger for a new PPA, the supplier is not requested to perform the same PPA a second time. In such a case there is only a PPA according to VDA part 2, chapter 4.5 or PPAP level 1 required Possible trigger events for a PPA All changes made on the production process and the parts have to be reported to MS. As far as nothing different is already agreed, the following matri has to be used Trigger event Performing PPA PPF New part Product change Transfer of production Change of the production process Change of a test/ inspection Production stoppage, (over 12 months) Use of new, modified or spare tools (does not apply to machining tools) Change of supplier (MS 2nd tier). For parts with special characteristics (safety or homologation Information to purchase dep., supplier Management Production and Part Approval Process (PPAP) page 3/10

4 relevant) the above requirement does apply downwards until to the characteristic responsible supplier Change of buy parts of the supplier New first article inspection Requalification of parts and/ or processes anually Prototype parts Instruction for "other submision level Performing PPA Procedure In the case a PPA is triggered by the supplier, the supplier has to report this to MS 6 months before the planned implementation starts. In special cases a different proceeding can be agreed with the responsible MS site. The supplier will supply sample parts for PPAP according the mentioned schedule also without special production order and unpaid unless MS has waived the shipment of samples formally. The supplier is requested to supply dimensional test results for uncoated parts in the case coated parts require dimensional test results. For casting and forging parts the supplier is requested to create cuts and perform measurements referencing to the CAD model as defined to have evidence of required radii and wall thicknesses. The cutted parts have to be submitted with the sample parts. The supplier is requested to obtain a PAA from MS before shipping parts to MS site if parts don t comply with the required specifications. Before the PAA epires the supplier has to perform PPA again with an optimized version. In the case special characteristics are not defined by MS or the customer of MS the supplier is requested to define in minimum one characteristic autonomous. Special characteristics have to be analyzed with SPC during production. Process capability studies are required for prototype parts as well as for initial sample parts. Until the required capability values are met, all the parts have to be checked 100%. This is also required if the capability values are not achieved or differences are detected. As long as the required capability values are met, testing according control plan is essential. As minimum the following values are required for SPC, while nothing different is agreed by MS in writing form: -machine capability Cmk 2,00 -long term capability Cpk 1,67 -short term capability Ppk 1, Submission Level As long as nothing different is agreed between MS and the supplier, submission level 2 is required. For prototype parts submission level other is binding. N requirements (Characteristics specified according VDA) Submission Level Other Production and Part Approval Process (PPAP) page 4/10

5 1 Warrant X X 2 Test results (e.g. dimension, function (approval from Daimler), material (e.g. resistance, physical characteristics), process capability, weight, etc.) 3 Sample (numbers per cavity; for color samples differing only 2 parts) 4 documents (e.g. blue prints and CAD-Data, Specs, released design changes, etc.) 5 Design- development releases of the supplier in the case of design responsibility X X X E X X 6 System FMEA Product E E 7 System FMEA Process E E 8 Process flow chart (production and inspection steps) X 9 Control Plan E E 10 Test/ inspection equipment X 11 MSA, Gage R&R, there appropriate (results) X X 12 Evidence of requirements by law, as far as agreed with MS (e.g. environment, safety, recycling) 13 Material data sheet per IMDS (ID-Nr. has to be shown on the warrant) and paper form E E E E X 14 Software test report, it applicable Bill of material, if required by MS with blueprint List of all worker instructions and test instructions with release level 17 Tooling list (with quantity / numbers of cavities and tooling quality) 18 Evidence of achieving the required cycle time, e.g. production test results 19 Overview of buy parts and inbound parts of the supplier with release level for part and process 20 Approval in writing form according characteristic matri maturity degree part and process E E E E X 21 Parts history for quality 22 Parts labeled as PPAP parts X X X X 23 Approval of paint system by MS if applicable - - X = requirement for submission level, E = only available for inspection at suppliers site, documentation stays at supplier site Period of archiving All documents of the PPA process have to be archived in a readable version for a period of 15 years starting after ending of series production If required by, the documentation has to be made available for MS Result of approval The result of the approval will be reported to the supplier in the form of a report (e.g. signed warrant) If the IMDS System is used, the evaluation of the IMDS pages will be performed by the IMDS-System Production and Part Approval Process (PPAP) page 5/10

6 3.1.8 Form of the documentation The documentation has to be submitted in electronically form (e.g. pdf). MS has the authorization to inspect all product and process related documents regarding design or production of the product in the manner of analysis Preparing PPA In front of and respectively during PPA process MS performs maturity evaluations for special chosen parts in cooperation with the supplier Noncompliance If the agreed first article inspections (per maturity degree) do not end in a release and the supplier has to represent the negative result, the supplier has to cover all cost caused by an additional PPA (cost which are in direct contet with the PPA) State of the art of science and technology The supplier has to make evidence meeting the requirements of product liability law and that the products/ services are state of the art of science and technology Zero defect strategy The special regulations of the QAA-document have higher priority for Zero defect strategy as regulations below: The supplier has the responsibility for supplying parts without defects. The zero defect strategy has to be secured by quality assurance and documented evidence of conformity. Are offenses against Zero defect strategy foreseeable, the supplier has the responsibility to inform MS immediately. The analysis and evaluation of the Machine and process capability is based on VDA Part 4, MSA according VDA part 5 or MSA 4 th edition while anything different is agreed (e.g. QAA or APQP, PPAP is binding). In the case the supplier is responsible or has a share of responsibility for design of the scope of supply, the vendor has to define special characteristics for safety relevance and homologation relevance by himself, all products and/ or documents have to be marked correct. The marking has to be done according MS or other customer requirements. In the case no requirements are available, the supplier shall use his own requirements. For all countermeasures which are derived from marking the supplier is responsible for implementation. All related documents have to be archived according to the requirements of this document Traceability For traceability of parts the supplier is requested to label all special defined parts with a consecutive number or a batch number and respectively with the production date, cavity number. The scope of parts and the way of marking/ labeling will be defined by MS or its customers. Production and Part Approval Process (PPAP) page 6/10

7 Other samples/ Submission level other The supplier has to prepare PPAP type other samples (see PPAP) according to the requirements agreed between MS and the supplier or as shown above. All the tests and documentation required has to be done analogously for PPAP. Differences between the used production conditions and the serial production conditions have to be announced to have the possibility to evaluate them Additional information The supplier is requested to provide MS and its customers with information on responsibilities, contact persons, organization, technical documents, time schedule, tooling s, test equipments, process capability, Quality methods, sub-suppliers as well as PPAP in writing form. Changes have to be announced immediately Schedule of first article inspection The supplier has to develop a part specific test concept, define test characteristics and has to choose and to buy the test equipment. All planed activities to prepare the first article inspection have to be agreed with MS. The supplier shall document this in a time schedule. In special cases it may be agreed between MS and the supplier to reduce the scope for first article inspection. All changes on product and process have to be noted in the parts history (please see attachment) Labeling of the samples Beginning with the first delivery of sample parts the supplier is requested to label the products as sample parts according to the parts maturity level (mistake proofing). The carriers as well as the parts have to be clearly tagged with a label or an adhesive tag. The following shall be noted on the tag: the annotation sample parts, part number, change level, production date, order number, for electronic parts with a memory/ control unit or software additional the software release number and the hardware release number (this shall also be listed in the parts history) Maturity workshop (supplier day) If required MS and/ or its customers will arrange a maturity workshop with the goal to evaluate the achieved maturity level of the products and the linked processes of the supplier Process release On demand of MS or its customers, particularly for critical parts/ processes, the release of the production process shall be done on supplier site during the production trial run of the supplier. To achieve a process release only series tools and series production equipment with series processes (e.g. material, tools, processes, quantity, cycle time, personnel and production site) shall be used. The responsible person for quality and other departments shall be involved. MS has to be informed early enough to ensure the possibility to participate the production test. The process will be released, when evidence of fulfillment of all requirements is given. The all over release has to be done on the agreed deadline at latest. Production and Part Approval Process (PPAP) page 7/10

8 Process objectives restricted release release without restrictions deadline Production test 1 supplier, if more than one planed tools equipment, facilities, ok devices logistic chain conditionally ok ok cycle time, quantity conditionally ok ok personnel conditionally ok ok Process capability conditionally ok ok test devices, test benches conditionally ok ok Production process of vendor parts conditionally ok ok last production test supplier ok For the chosen scope of supply the supplier has to produce in minimum the quantity for one shift and in maimum the quantity for 3 production days during the last production test (variations can be agreed if required). The production test has to be carried out under peak production conditions. For comple or critical parts from sub suppliers the vendor has to carry out production releases in an analogous procedure, where applicable with participation of MS or its customers. The required scope has to be agreed with the Supplier Management of the goods receiving MS site Supply of sample parts and first article inspection documentation Capable parts for PPAP are meeting the objectives of the Evaluation Matri for First article inspection (see attachment). In general the supply of sample parts is free of charge. In the case the delivery of parts is in general as assembly, the vendor has to supply additional samples apart with separate documentation if required by MS. In special cases MS will agree with the vendor the supply of jigs, test devices and/ or models which are in possession of the vendor together with the samples. Production and Part Approval Process (PPAP) page 8/10

9 3.2 Attachments Attachment Parts History (eample) Parts History Quality Vendor: Part name: Consecuti ve number Inde Change Change inde drawing Vendor N.: Part number: Date of change date Sample parts Series start Production and Part Approval Process (PPAP) page 9/10

10 3.2.2 Attachment Evaluation Matri First Article Inspection tools dimension ok conditional ok (PAA required) not ok mass production tool dimensional ok, no rework required pre- mass production tool meets customer requirements and accepted by MS (durability in minimum until mass production tool released) dimensional ok after rework by the vendor or uncritical dimensions not ok eperimental tool dimensional not ok surface structure, color/ grain ok, no sink marks, no waviness just acceptable, conform to borderline part significant deviations/ compliance not proven material mass production material, material specs. met no mass production material or differences ins production process, material specs not met, But PAA available/ no material data sheet or incomplete no mass production material, material data sheet not available, not conform to material specs build ability can be used without ependiture of time or money can be used with ependiture of time or money not usable function function fulfilled, complies with spec. spec not met, but only marginal deviations, PAA available function not ok, does not comply with spec. vendor parts approved conditional approved rejected or not approved Production and Part Approval Process (PPAP) page 10/10