際際滷

際際滷Share a Scribd company logo

PPAP Awareness training.pptx

Download as PPTX, PDF
Neeraj Pandey
Neeraj Pandey

The document provides an overview of Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP). It describes: 1) APQP as a cross-functional planning process with 5 phases to ensure a product meets customer expectations. It involves tools like DFMEA, PFMEA, control plans. 2) PPAP is required when a product or process changes and validates that production meets requirements. There are 5 submission levels with varying documentation required. 3) Both APQP and PPAP aim to launch defect-free products and improve quality, customer satisfaction and cost savings through thorough upfront planning and validation of designs and manufacturing processes.

1 of 28
Downloaded 19 times
2019 1 APQP introduction APQP timing chart and phases APQP application APQP sum up & key take aways PPAP introduction When is PPAP required? PPAP submission level PPAP status application of PPAP PPAP sum up & key take aways Training Outline
What is APQP? 2019 2 Advanced Product Quality Planning Cycle Advanced Product Quality Planning method to assure that a product satisfies the customer (both internal and external) The goal of APQP is to: Plan before acting Anticipate and prevent issues Validate before moving forward Facilitate communication Each Advanced Product Quality Plan is unique and is a living document Particular emphasis should be placed on identifying critical path activities and ensuring those are fully resourced
APQP at 2019 3 PDP: Product Development Process Same approach: Plan, Do, Check, Act Phases: Portfolio, Project proposal, Feasibility till Project Closure Milestones: scope approval, tech solution approval Roles and Responsibilities: deliverables per project function
APQP Background 2019 Automotive and Non Automotive industries challenges: Innovation, product complexity Reduce NPD times (Time to Market!) Complicated Supply chain (Global presence) Increasing customer and quality requirements (Zero Defect!) Solution: Ford, GM, Chrysler APQP Task Force jointly developed in the late 80s to standardize their respective supplier quality systems. Continuous Improvement: Many industries outside the Automotive industry have embraced the AIAG APQP process to achieve similar benefits
APQP timing chart and phases - AIAG 2019 5 The Advanced Product Quality Planning process consists of four phases and five major activities and has some 20+ supporting tools (e.g. DFMEA, PFMEA, CTQ, Special Characteristics, Control Plan, SPC) along with ongoing feedback assessment and corrective action.
Voice of the Customer Market Research (ie IHS Markit) Historical Warranty and Quality Information Team Experience Business Plan/Marketing Strategy Product/Process Benchmark Data Product/Process Assumptions Product Reliability Studies Customer Inputs INPUTS: Design Goals Reliability & Quality goals CONC targets Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary list of Special Product and Process Characteristics Product Assurance Plan Management Support OUTPUTS: Assure that customer needs and expectations are clearly understood and assessed * The inputs and outputs applicable to the process may vary according to the product process and customer needs and expectations. Phase 1: Plan and Define Program 2019 6
Design Failure Mode and Effects Analysis (DFMEA) Design For Manufacturability and Assembly Design Verification Design Reviews Prototype Build Control plan Engineering Drawings (Including Math Data) Engineering Specifications Material Specifications Drawing and Specification Changes Design Goals Reliability & Quality goals Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary list of Special Product and Process Characteristics Product Assurance Plan Cont. next slide Phase 2: Product Design and Development 2019 7 INPUTS: OUTPUTS: Develop design into a near final form. Prototype and feasibility studies volumes, schedule, manufacturing.
New Equipment, Tooling and Facilities Requirements Special Product and Process Characteristics Gages/Testing Equipment Requirements Team Feasibility Commitment Management Support Design Goals Reliability & Quality goals Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary list of Special Product and Process Characteristics Product Assurance Plan 2019 8 Phase 2: Product Design and Development INPUTS: OUTPUTS: Develop design into a near final form. Prototype and feasibility studies volumes, schedule, manufacturing.
Packaging Standards Product/Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis (PFMEA) Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Management Support Design Failure Mode and Effects Analysis (DFMEA) Design For Manufacturability and Assembly Design Verification Design Reviews Prototype Build Control Plan Engineering Drawings (Including Math Data) Engineering Specifications Material Specifications Drawing and Specification Changes New Equipment, Tooling and Facilities Requirements Special Product and Process Characteristics Gages/Testing Equipment Requirements Team Feasibility Commitment Management Support 2019 9 Phase 3: Process Design and Development INPUTS: OUTPUTS: Develop a manufacturing system and its related control plans to achieve quality products.
Measurement Systems Evaluation Significant Production Run Preliminary Process Capability Study Production Part Approval Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off - formal Management Support Packaging Standards Product/Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis (PFMEA) Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Management Support 2019 10 Phase 4. Product and Process Validation INPUTS: OUTPUTS: Validate manufacturing process through production trial run. Validate that the control plan and process flow chart are effective and that the product meets customer expectation.
Production Trial Run Measurement Systems Evaluation Preliminary Process Capability Study Production Part Approval Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off and Management Support Reduced Variation Improved Customer Satisfaction Improved Delivery and Service Effective use of best practice, lessons learned Maximum ROI Minimum Waste 2019 11 Feedback, Assessment, Corrective actions INPUTS: OUTPUTS: Evaluate outputs, effectiveness of the product quality planning efforts.
Application to Different Mfg. Environments 2019 12 High Volume APQP plans and activities are organized by part number and are very specific to the part Low Volume APQP plans may be specific to part families with activities focused on the parent part More limited validation would be done on child parts Family part differences should be understood and higher risk differences incorporated into APQP plans
Design Quality DFMEA / PFMEA / DFM/A Manufacturing Quality Control Plans Process Flows Measurement System Analysis Capability Analysis Process Validation Run at rate Supplier Qualification & Quality Requirements Product Qualification 1st Article Inspection PPAP Tooling & Gauges Testing What we do: Defect Free Launches Reduced Warranty Claims Zero Spills Customer Satisfaction Robust Products Greater Supplier Control Reduced supplier cost How we do it: APQP What we get: Leadership Engagement is Critical UP FRONT DETAILED QUALITY PLANNING 13 APQP Summary:
CONC APQP Benefits: 2019 14 Manufacturing process functions that are clearly planned, validated, documented and communicated that result in: Robust and reliable designs Reduced process variation Enhanced confidence in suppliers capabilities Better controlled process changes Defect free launches Improved Customer satisfaction Improved Delivery and Service Maximum ROI Minimum Waste Minimum Cost of Non-conformance Development Production Prevention through APQP Current state Time $$ Total Cost of Quality Redesign Re-qualifications Escape Investigations
Key Take Aways: 2019 APQP is cross-functional planning and execution to produce product that fully meets the customers expectations the first time AIAG APQP phases are Planning, Product Design, Process Design, Validation, Production Phase approach ensures activities are completed in the appropriate order Can be applied to different manufacturing environments High Volume, Low Volume Its cross-functional Marketing/Design/Manufacturing/SCM/Quality
Production Part Approval Process (PPAP) 2019 16
What is PPAP? 2019 17 Production Part Approval Process Standard used to formally reduce risks prior to product or service release, in a team oriented manner using well established tools and techniques Initially developed by AIAG (Auto Industry Action Group) in 1993 with input from the Big 3 - Ford, Chrysler, and GM AIAGs 4th edition effective June 1, 2006 is the most recent version PPAP has now spread to many different industries beyond automotive
PPAP at 2019 18 Aligned to AIAG PPAP Manual rev 4 Requirements set up during Technical Reviews (DPAR Process*) Continuous validation approach Embedded to our APQP (output of phase 4 Production Part Approval) *DPAR: Design, Process & Assembly Review you can refer to DPAR Training Material for further information
Production Run 2019 19 PPAP data must be submitted from a production run using: Production equipment and tooling Production employees Production rate Production process All data shall reflect the actual production process that will be used at start-up!
Purpose of PPAP 2019 20 Provide evidence that all customer engineering design record and specification requirements are properly understood by the organization To demonstrate that the manufacturing process has the potential to produce product that consistently meets all requirements during an actual production run at the quoted production rate
When is PPAP Required? 2019 21 New part Engineering change(s) Durable Tooling: transfer, replacement, refurbishment, or additional Tooling inactive > one year Correction of discrepancy Change to optional construction or material Sub-supplier or material source change Change in part processing Parts produced at a new or additional location PPAP is required with any significant change to product or process!
Benefits of PPAP Submissions 2019 22 Helps to maintain design integrity Identifies issues early for resolution Reduces warranty charges and prevents cost of poor quality Assists with managing supplier changes Prevents use of unapproved and nonconforming parts Identifies suppliers that need more development Improves the overall quality of the product & customer satisfaction
PPAP Submission Levels 2019 23 Level 1 Production Warrant and Appearance Approval Report (if applicable) submitted Level 2 Production Warrant, product samples, and dimensional results submitted Level 3 Production Warrant, product samples, and complete supporting data submitted Level 4 Production Warrant and other requirements as defined by Level 5 Production Warrant, product samples and complete supporting data (a review will be conducted at the supplier's manufacturing location)
PPAP Submission Requirements 2019 24 Requirement Level 1 Level 2 Level 3 Level 4 Level 5 1.Design Record R S S * R 2.Engineering Change Documents, if any R S S * R 3.Customer Engineering approval, if required R R S * R 4.Design FMEA R R S * R 5.Process Flow Diagrams R R S * R 6.Process FMEA R R S * R 7.Control Plan R R S * R 8.Measurement System Analysis studies R R S * R 9.Dimensional Results R S S * R 10.Material, Performance Test Results R S S * R 11.Initial Process Studies R R S * R 12.Qualified Laboratory Documentation R S S * R 13.Appearance Approval Report (AAR), if applicable S S S * R 14.Sample Product R S S * R 15.Master Sample R R R * R 16.Checking Aids R R R * R 17.Records of Compliance With Customer Specific Requirements R R S * R 18.Part Submission Warrant S S S S R 19.Bulk Material Checklist S S S S R S = The organization shall submit to the customer and retain a copy of records or documentation items at appropriate locations R = The organization shall retain at appropriate locations and make available to the customer upon request * = The organization shall retain at the appropriate location and submit to the customer upon request Note: For each level, full PPAP is required. The PPAP level simply indicates which elements you submit, and which you retain at your site.
PPAP Element 17: Requirements 2019 25 Depending on the specific business, may require: Measurement Agreement Gage Drawing Safe Launch Control Plan Annual layout Special Processes qualification Packaging Specification Data Sheet Submit Bar Code Label Packaging Approval Capacity R@R Worksheet MSDS
PPAP Status 2019 26 Approved The part meets all requirements Supplier is authorized to ship production quantities of the part Interim Approval Permits shipment of part on a limited time or piece quantity basis Rejected The part does not meet requirements, based on the production lot from which it was taken and/or accompanying documentation Production quantities shall not be shipped before Approval + Order!
PPAP Sum up & Take Aways 2019 27 PPAP is a result of a good APQP! DPAR* is an important activity to determine PPAP expectations! Commitment on part and process feasibility We plan a good Control Plan: Measurement Agreement on key characteristics determines PPAP level based on component risk Submission requirements are increased for higher risk components Requirements are defined and agreed during DPAR phase provides a standard PPAP workbook with all necessary tools Supplier can use their own templates and tools if they meet the AIAG requirements Lets be Smart! Going through PPAP process as a routine Identifying opportunities: Master PFMEA, Master CP *: refer to DPAR Training DPAR = Design Process & Assembly Review
Thanks 2019 28

More Related Content

PPAP Awareness training.pptx

  • 1. 2019 1 APQP introduction APQP timing chart and phases APQP application APQP sum up & key take aways PPAP introduction When is PPAP required? PPAP submission level PPAP status application of PPAP PPAP sum up & key take aways Training Outline
  • 2. What is APQP? 2019 2 Advanced Product Quality Planning Cycle Advanced Product Quality Planning method to assure that a product satisfies the customer (both internal and external) The goal of APQP is to: Plan before acting Anticipate and prevent issues Validate before moving forward Facilitate communication Each Advanced Product Quality Plan is unique and is a living document Particular emphasis should be placed on identifying critical path activities and ensuring those are fully resourced
  • 3. APQP at 2019 3 PDP: Product Development Process Same approach: Plan, Do, Check, Act Phases: Portfolio, Project proposal, Feasibility till Project Closure Milestones: scope approval, tech solution approval Roles and Responsibilities: deliverables per project function
  • 4. APQP Background 2019 Automotive and Non Automotive industries challenges: Innovation, product complexity Reduce NPD times (Time to Market!) Complicated Supply chain (Global presence) Increasing customer and quality requirements (Zero Defect!) Solution: Ford, GM, Chrysler APQP Task Force jointly developed in the late 80s to standardize their respective supplier quality systems. Continuous Improvement: Many industries outside the Automotive industry have embraced the AIAG APQP process to achieve similar benefits
  • 5. APQP timing chart and phases - AIAG 2019 5 The Advanced Product Quality Planning process consists of four phases and five major activities and has some 20+ supporting tools (e.g. DFMEA, PFMEA, CTQ, Special Characteristics, Control Plan, SPC) along with ongoing feedback assessment and corrective action.
  • 6. Voice of the Customer Market Research (ie IHS Markit) Historical Warranty and Quality Information Team Experience Business Plan/Marketing Strategy Product/Process Benchmark Data Product/Process Assumptions Product Reliability Studies Customer Inputs INPUTS: Design Goals Reliability & Quality goals CONC targets Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary list of Special Product and Process Characteristics Product Assurance Plan Management Support OUTPUTS: Assure that customer needs and expectations are clearly understood and assessed * The inputs and outputs applicable to the process may vary according to the product process and customer needs and expectations. Phase 1: Plan and Define Program 2019 6
  • 7. Design Failure Mode and Effects Analysis (DFMEA) Design For Manufacturability and Assembly Design Verification Design Reviews Prototype Build Control plan Engineering Drawings (Including Math Data) Engineering Specifications Material Specifications Drawing and Specification Changes Design Goals Reliability & Quality goals Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary list of Special Product and Process Characteristics Product Assurance Plan Cont. next slide Phase 2: Product Design and Development 2019 7 INPUTS: OUTPUTS: Develop design into a near final form. Prototype and feasibility studies volumes, schedule, manufacturing.
  • 8. New Equipment, Tooling and Facilities Requirements Special Product and Process Characteristics Gages/Testing Equipment Requirements Team Feasibility Commitment Management Support Design Goals Reliability & Quality goals Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary list of Special Product and Process Characteristics Product Assurance Plan 2019 8 Phase 2: Product Design and Development INPUTS: OUTPUTS: Develop design into a near final form. Prototype and feasibility studies volumes, schedule, manufacturing.
  • 9. Packaging Standards Product/Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis (PFMEA) Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Management Support Design Failure Mode and Effects Analysis (DFMEA) Design For Manufacturability and Assembly Design Verification Design Reviews Prototype Build Control Plan Engineering Drawings (Including Math Data) Engineering Specifications Material Specifications Drawing and Specification Changes New Equipment, Tooling and Facilities Requirements Special Product and Process Characteristics Gages/Testing Equipment Requirements Team Feasibility Commitment Management Support 2019 9 Phase 3: Process Design and Development INPUTS: OUTPUTS: Develop a manufacturing system and its related control plans to achieve quality products.
  • 10. Measurement Systems Evaluation Significant Production Run Preliminary Process Capability Study Production Part Approval Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off - formal Management Support Packaging Standards Product/Process Quality System Review Process Flow Chart Floor Plan Layout Characteristics Matrix Process Failure Mode and Effects Analysis (PFMEA) Pre-Launch Control Plan Process Instructions Measurement Systems Analysis Plan Preliminary Process Capability Study Plan Packaging Specifications Management Support 2019 10 Phase 4. Product and Process Validation INPUTS: OUTPUTS: Validate manufacturing process through production trial run. Validate that the control plan and process flow chart are effective and that the product meets customer expectation.
  • 11. Production Trial Run Measurement Systems Evaluation Preliminary Process Capability Study Production Part Approval Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off and Management Support Reduced Variation Improved Customer Satisfaction Improved Delivery and Service Effective use of best practice, lessons learned Maximum ROI Minimum Waste 2019 11 Feedback, Assessment, Corrective actions INPUTS: OUTPUTS: Evaluate outputs, effectiveness of the product quality planning efforts.
  • 12. Application to Different Mfg. Environments 2019 12 High Volume APQP plans and activities are organized by part number and are very specific to the part Low Volume APQP plans may be specific to part families with activities focused on the parent part More limited validation would be done on child parts Family part differences should be understood and higher risk differences incorporated into APQP plans
  • 13. Design Quality DFMEA / PFMEA / DFM/A Manufacturing Quality Control Plans Process Flows Measurement System Analysis Capability Analysis Process Validation Run at rate Supplier Qualification & Quality Requirements Product Qualification 1st Article Inspection PPAP Tooling & Gauges Testing What we do: Defect Free Launches Reduced Warranty Claims Zero Spills Customer Satisfaction Robust Products Greater Supplier Control Reduced supplier cost How we do it: APQP What we get: Leadership Engagement is Critical UP FRONT DETAILED QUALITY PLANNING 13 APQP Summary:
  • 14. CONC APQP Benefits: 2019 14 Manufacturing process functions that are clearly planned, validated, documented and communicated that result in: Robust and reliable designs Reduced process variation Enhanced confidence in suppliers capabilities Better controlled process changes Defect free launches Improved Customer satisfaction Improved Delivery and Service Maximum ROI Minimum Waste Minimum Cost of Non-conformance Development Production Prevention through APQP Current state Time $$ Total Cost of Quality Redesign Re-qualifications Escape Investigations
  • 15. Key Take Aways: 2019 APQP is cross-functional planning and execution to produce product that fully meets the customers expectations the first time AIAG APQP phases are Planning, Product Design, Process Design, Validation, Production Phase approach ensures activities are completed in the appropriate order Can be applied to different manufacturing environments High Volume, Low Volume Its cross-functional Marketing/Design/Manufacturing/SCM/Quality
  • 16. Production Part Approval Process (PPAP) 2019 16
  • 17. What is PPAP? 2019 17 Production Part Approval Process Standard used to formally reduce risks prior to product or service release, in a team oriented manner using well established tools and techniques Initially developed by AIAG (Auto Industry Action Group) in 1993 with input from the Big 3 - Ford, Chrysler, and GM AIAGs 4th edition effective June 1, 2006 is the most recent version PPAP has now spread to many different industries beyond automotive
  • 18. PPAP at 2019 18 Aligned to AIAG PPAP Manual rev 4 Requirements set up during Technical Reviews (DPAR Process*) Continuous validation approach Embedded to our APQP (output of phase 4 Production Part Approval) *DPAR: Design, Process & Assembly Review you can refer to DPAR Training Material for further information
  • 19. Production Run 2019 19 PPAP data must be submitted from a production run using: Production equipment and tooling Production employees Production rate Production process All data shall reflect the actual production process that will be used at start-up!
  • 20. Purpose of PPAP 2019 20 Provide evidence that all customer engineering design record and specification requirements are properly understood by the organization To demonstrate that the manufacturing process has the potential to produce product that consistently meets all requirements during an actual production run at the quoted production rate
  • 21. When is PPAP Required? 2019 21 New part Engineering change(s) Durable Tooling: transfer, replacement, refurbishment, or additional Tooling inactive > one year Correction of discrepancy Change to optional construction or material Sub-supplier or material source change Change in part processing Parts produced at a new or additional location PPAP is required with any significant change to product or process!
  • 22. Benefits of PPAP Submissions 2019 22 Helps to maintain design integrity Identifies issues early for resolution Reduces warranty charges and prevents cost of poor quality Assists with managing supplier changes Prevents use of unapproved and nonconforming parts Identifies suppliers that need more development Improves the overall quality of the product & customer satisfaction
  • 23. PPAP Submission Levels 2019 23 Level 1 Production Warrant and Appearance Approval Report (if applicable) submitted Level 2 Production Warrant, product samples, and dimensional results submitted Level 3 Production Warrant, product samples, and complete supporting data submitted Level 4 Production Warrant and other requirements as defined by Level 5 Production Warrant, product samples and complete supporting data (a review will be conducted at the supplier's manufacturing location)
  • 24. PPAP Submission Requirements 2019 24 Requirement Level 1 Level 2 Level 3 Level 4 Level 5 1.Design Record R S S * R 2.Engineering Change Documents, if any R S S * R 3.Customer Engineering approval, if required R R S * R 4.Design FMEA R R S * R 5.Process Flow Diagrams R R S * R 6.Process FMEA R R S * R 7.Control Plan R R S * R 8.Measurement System Analysis studies R R S * R 9.Dimensional Results R S S * R 10.Material, Performance Test Results R S S * R 11.Initial Process Studies R R S * R 12.Qualified Laboratory Documentation R S S * R 13.Appearance Approval Report (AAR), if applicable S S S * R 14.Sample Product R S S * R 15.Master Sample R R R * R 16.Checking Aids R R R * R 17.Records of Compliance With Customer Specific Requirements R R S * R 18.Part Submission Warrant S S S S R 19.Bulk Material Checklist S S S S R S = The organization shall submit to the customer and retain a copy of records or documentation items at appropriate locations R = The organization shall retain at appropriate locations and make available to the customer upon request * = The organization shall retain at the appropriate location and submit to the customer upon request Note: For each level, full PPAP is required. The PPAP level simply indicates which elements you submit, and which you retain at your site.
  • 25. PPAP Element 17: Requirements 2019 25 Depending on the specific business, may require: Measurement Agreement Gage Drawing Safe Launch Control Plan Annual layout Special Processes qualification Packaging Specification Data Sheet Submit Bar Code Label Packaging Approval Capacity R@R Worksheet MSDS
  • 26. PPAP Status 2019 26 Approved The part meets all requirements Supplier is authorized to ship production quantities of the part Interim Approval Permits shipment of part on a limited time or piece quantity basis Rejected The part does not meet requirements, based on the production lot from which it was taken and/or accompanying documentation Production quantities shall not be shipped before Approval + Order!
  • 27. PPAP Sum up & Take Aways 2019 27 PPAP is a result of a good APQP! DPAR* is an important activity to determine PPAP expectations! Commitment on part and process feasibility We plan a good Control Plan: Measurement Agreement on key characteristics determines PPAP level based on component risk Submission requirements are increased for higher risk components Requirements are defined and agreed during DPAR phase provides a standard PPAP workbook with all necessary tools Supplier can use their own templates and tools if they meet the AIAG requirements Lets be Smart! Going through PPAP process as a routine Identifying opportunities: Master PFMEA, Master CP *: refer to DPAR Training DPAR = Design Process & Assembly Review