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PPAP for the automotive industries its usage
- 1. Process Flow Diagram Failure Mode Effect Analysis Control Plan Production Part Approval
- 3. Training Program on Process Flow Diagram WHY? To understand all the processes involved from the Incoming stage to the final product despatch. BENIFITS  Can able to see at once all the processes  Allows each operation to questioned  Exposes source variations  Highlights Non Value Added activities involved in the process ºÝºÝߣ 01 of 09
- 4. Training Program on Process Flow Diagram ºÝºÝߣ 01A of 09 Understand the Process Critical Failure Points Where to Control Exercise the Control Good Product Process Flow FMEA Control Plan Work Instruction
- 5. Training Program on Process Flow Diagram INPUTS OF PFD (Process Flow Diagram)  Customer Drawings  In-process Drawings  Plant Layout  Design FMEA outputs  FMEA for Similar Products ºÝºÝߣ 02 of 09
- 6. Training Program on Process Flow Diagram HOW to prepare the PFD To prepare PFD following to be taken into,  Operation sequences  What is the output of each process/operation  What are the Input characters which affect the Output of the process/operation  What are the Process characters which affect the Output of the process/operation  What is the symbols to be used for Process Flow Diagram ºÝºÝߣ 03 of 09
- 7. Training Program on Process Flow Diagram Oper.no Operation Description Incomming Source Variation PFD Product Characteristics / Desired Outcome Process Characteristics 1 2 4 6 3 5 As per the above sequence only Process Flow should be filled ºÝºÝߣ 04 of 09
- 8. Training Program on Process Flow Diagram OPERATION No. & DESCRIPTION Following guide line shall be followed to provide the Operation nos for the processes. Category Operation Nos. 1 One Machine -One operation OP 10, OP 20, OP 30... 2 One Machine-Multi Operations In this Component cannot be checked stage wise by manually or automatically till the operation completed. OP 10, OP 20, OP 30... 3 One Machine-Multi Operations In this Cccomponent can be checked stage wise by manually or automatically. OP 10, OP 10A, OP 10B, OP 10C,..., OP 20, OP30,... ºÝºÝߣ 05 of 09
- 9. Training Program on Process Flow Diagram Incoming Source Variations (ISV) This could be due to  Raw Material If it is due to Raw Material variation Check the Supplier FMEA,Process Flow, etc.  Any Previous Operation’s out comes If it is due to any Previous operations, clearly specify the operation/machine from where this Variation occurred. Also note that these ISVs are not the outcome of this particular operation ºÝºÝߣ 06 of 09
- 10. Training Program on Process Flow Diagram Product Characteristics/Desired Outcome These are the characters which to be obtained from the particular operation. This Desired outcome shall be one or more of the below mentioned.  Blue Print (BP)  Engineering Specifications (ES)  In process Characteristics (IP)  Functional Characteristics (FC)  Regulatory ºÝºÝߣ 07 of 09
- 11. Training Program on Process Flow Diagram Process Characteristics  These are also the Characters which affects the Desired Outcome during the particular operation.  These can be from one or more of the below mentioned  Men  Machine  Method  Process Materials  Environment ºÝºÝߣ 08 of 09
- 12. Training Program on Process Flow Diagram Process Flow Diagram  Process Flow Diagram identifies  Where the inspection is carried out  Where the Operator involvement is required  Where the Delay is occurred during the process This process flow Diagram (with the symbols) indicates, where ever the Non Value Added actives are there in the process ºÝºÝߣ 09 of 09
- 13. Failure Mode Effect Analysis
- 14. WHY FMEA Tool for 6 SIGMA Catch the cause before the problem occurs Prevent the failure Easy understanding of Process Reducing the cost of poor quality Customer Satification Optimize the controls
- 15. PROCESS FMEA 1 EFFECT ANALYSIS 2 CAUSAL ANALYSIS 3 CONTROL ANALYSIS opposite negative desired isv,process outcome char. OPN OPERATION/ POTENTIAL POTENTIAL SEV CLASS POTENTIAL OCCUR CURRENT PROCESS CURRENT PROCESSDECT. RPN NO. DESCRIPTION FAILURE EFFECT NO CAUSE NO CONTROL PREV. CONTROL DETECT. NO MODE next process assy customer field feed speed skill Tool wear
- 16. Special Characteristics Critical Characteristics Severity number 10 & 9 Significant Characteristics Severity number is 8& 7 Potential Failure Mode It is opposite of the desired outcome in the PFD Potential Effects what are the effects of the failure at 1 Next Process 2 Assembly 3 Customer 4 Field EFFECT ANALYSIS
- 17. Potential cause negative of incoming source of variation and process Characteristics 3 M's & 1 E men,material,machines,Environment GUIDELINES FOR OCCURRENCE NUMBER 1 Occurrence number is to be calculated for causes based upon actual data 2 If data is not there related to cause,calculate the occurrence no. of the failure mode data and same occurance number has to be transferred to the causes using engineering judgement 3 If you don't have data related failure mode & causes,calculate occurrence number based on the Cpk Value 4 If the above 3 is not available,use the occurrence number from similar product 5 None of these are available,use the "GUT FEEL"
- 18. 1 "A" TYPE OF CONTROL- It is detection of failure mode(Inspection) 2 "B" TYPE OF CONTROL- It is detection of cause 3 "C" TYPE OF CONTROL-Prevention of cause. "A" Type- Control Plan,Patrol Inspection,Layout Inspection "B" Type - if the tool is inspected and run "C" Type-Work Instruction,Service Training CONTROL
- 19. 1 RPN Calculation is to be done for failure mode as well as the cause 2 For calculating RPN for failure mode,we have to multiple max.severity number,occurrence number of the failure mode and "A" Type control detection number 3 For calculating RPN for failure mode,we have to multiple max.severity number,occurrence number that specified cause & min of detection number of "A" type control & "B" type control of that cause RPN At what Risk the customer is operating the job? RPN for failure mode -for customer's RPN for Causes-for the manufactures RPN can be high (if the detection number is high) RPN CALCULATION
- 20. 1 Make a pareto of RPN of failure mode and identify which failure mode is contributing 80% 2 After that,pareto of causes RPN which is contributing above 80% of failure mode to be done. 3 When ever that occurrence number of cause is greater than 3, we have to take recommended action. 4 Whenever the severity number is 7,8,9,10,we have to introduce "A" type of control. GUIDELINES FOR RECOMMENDED ACTION
- 21. Control Plan
- 22. What Is Control Plan • Is a written summary of the system for controlling the variation of all product and process characteristics, important quality and engineering requirements • Is a contract between the supplier and the customer • Is used as the basis for development of process work instruction • Identifies all customer and supplier specified special characteristics.
- 23. CONTROL PLAN Prototype prelanch production Control plan number TALOP 001 Latest change level - 01 Description : OP 475 ASSY Supplier / Plant PLANT -III Supplier code Key contact / Phone Mr.M.CHIDAMBARANATHAN 26272676 Core team TAL CFT Supplier / Part approval / Date Other approval / Date (If required) Date (Original) 15.06.03 Date (Revised) Page 1 of 3 Customer engineering approval date (If required) Customer quality approval date (If required) Other approval / Date (If required) Opn. Operation description Tool and/ or technique Characteristics No Product Process Class Method Product / Process Specification / Tolerance Evaluation / Measurement/ Technique Sample Size Frequency Responsibility Record Yes / No Reaction Plan Control Method 10 Idle shaft pressing with body Assy fixture No.33 Hy.press No.1 1 Out of Square ness 0.05 CMM 2 Every setting Cell leader / operator YES First of inspection report Stop the assy and findout the root cause A)Out of Square of press ram WRT to bed B)Over size of fixture bush ID C)Sudden press load 0.10 Dial stand with angle plate Monthly Maintenance Engineer YES History card Inform to mainten ance and bed scrapping to be done 20.0 + 0.01 Bore dial As per history card Development Engineer YES History card Bush to be replaced Ram should be moved gradually Visual 100% Operator No Work instruction On job training to be given One time
- 24. PPAP PRODUCTION PART APPROVAL PROCESS
- 25. 5 Levels of PPAP Level 1 Warrant Only Level 2 Warrant, Product Samples, Limited Data Level 3 Warrant, Product Samples, Complete data submitted Level 4 Warrant, Other requirements as defined by the Customer.(All other PPAP Documents) Level 5 Warrant, Product samples, Complete Data reviewed at Supplier End.
- 26. 1. Design records 2. Any Authorize engg. Change documents 3. Engineering Approval (If Reqd) 4. DFMEA 5. Process Flow Diagram 6. PFMEA 7. Dimensional Reports 8. Material Test reports & Performance test reports 9. MSA Study 10. SPC study & Cpk Status 11. Qualified calibration lab and testing lab details 12. Control Plan 13. PSW 14. Appearance Approval Report 15. Bulk material manufacturing check list 16. Checking Aids 17. Product Samples 18. Master Sample 19. Any Customer Specific Requirements 19 Requirement of PPAP
- 27. Thank you