Purpose
The purpose of the PPPP is to determine if all of the customer's engineering design and specification records are properly understood by the supplier and that the process has the potential to consistently produce in compliance with these requirements during a current production run.
Applicability
PPP will apply to sites of internal and external suppliers of production materials, production parts and service parts.
general
the supplier shall obtain full approval (see 5.2.1) of the product approval activity for the customer for:
- a new part or product (i.e. a specific part, material or color not foreseen) correction or discrepancy on a previously stocked part. product modified by engineering change that affects design, specification or material records, any situation required by the section 1.3
process ppap requirements
- significant production run
for production parts, the product for ppap should be taken from a significant production run. This production run should be from one hour to eight hours of production, and with the production quantity specified to a total of 300 consecutive parts, unless otherwise specified by the customer's quality representative.
- ppap requirement
the supplier will fulfill all the specified requirements, for example design records, specifications, etc. Any result that is out of specification will cause the supplier not to admit the parts, documentation and / or records.
Note 1: For any product, part, or component there will be only one design record specifying design responsibility.
Documents of any authorized engineering changes
the supplier shall have documents of any authorized engineering changes not registered in the design, but incorporated in the product, part or tool.
Engineering approval, when required
where specified by the design registration, the supplier shall have evidence of customer approval.
Failure mode and effect analysis (dfmea), if the supplier is responsible for the design. See the reference manual for effect analysis and failure mode.
The supplier must have a dfmea developed in accordance with and in compliance with the requirements of the qs-9000 third edition for parts or materials for which it is responsible for the design.
Process flow diagrams
the supplier shall have a process flow diagram in a format specified by the supplier that clearly describes the steps and sequence of the production process, which appropriately meets the requirements of the needs specified by the client (see the apqp and control reference manual plan).
Analysis of the effect and mode of the process failure (process fmea). See the reference manual for effect analysis and failure mode.
The supplier must have a process file developed in accordance with and in compliance with the requirements of the qs-9000 third edition.
note: a particular process line can be applied to a manufacturing process or a family of similar parts of materials.
Dimensional results
The supplier shall provide evidence that the dimensional checks required by the design record and the control plan have been completed and the results indicate conformance with the specified requirements. The supplier must have dimensional results for each unique manufacturing process.
The supplier shall indicate the date of the design registration, level change and any authorized engineering change document not incorporated into the design registration for which the part was made.
The supplier shall identify one of the measured parts as a master sample.
The supplier must record the change in level, part name and number on all auxiliary documents for example (. Copies of these auxiliary materials must accompany the dimensional results according to the retention / admission table.
recording of test results
the supplier shall have records and / or performance test results for testing
specified on the design record or control plan.
Initial process studies
- general
The initial capacity level of the process should be determined to verify whether it is acceptable prior to submission for all special features designed by the customer or supplier.
The supplier shall carry out a measurement system analysis to understand how measurement error is affecting measurement studies. See the measurement system manual (msa) for reference.
Note 1. The purpose of this requirement is to determine if the production process is acceptable to produce product that meets the customer's requirements. Initial process studies are focused on continuous variables and not on attributes. Assembly errors, test failures, surface defects are examples of counting data, which are important to understand, but are not covered in this initial study.
Note 2. The index to estimate the capacity of the process should be an agreement between the client and the supplier. The cpk and ppk will be described later.
Note 3. Initial process studies are short-term and do not predict the effects of time and variation on people, materials, methods, equipment, measurement systems, and the environment. Even for these short-term studies, it is important to collect and analyze the data in the order produced using control charts.
Note 4. For those characteristics that can be studied using x-bar charts and r charts, a short-term study may be based on a minimum of 25 subgroups that contain at least 100 consecutive readings of parts of a significant production run. The initial data requirements may be replaced by long-term results of the same or similar processes with the concurrence of the client.
- quality indices
Initial process studies may be summarized with capacity or performance indices, if these are applicable.
Note 1. The results of the initial process studies are dependent on the purpose of the study, the normality of the data, the method of obtaining, the sampling, the amount of data, the demonstration of statistical control, etc. review the spc manual.
cpk.- the capacity index for a stable process. sigma estimation is based on the variation of the process within the subgroups (r-bar / d ^ 2 or s-bar / c4).
ppk-. the performance index. the sigma estimate is based on total variation (all data from individual samples using the standard deviation "s").
term studies cut. the purpose of initial process studies is to understand process variation, not exactly to calculate a specific value of an index. When historical data is available or sufficient data exists to produce a control chart (at least 100 individual samples), the cpk can be calculated when the process is stable. For chronically unstable processes with out-of-spec parts and predictable models, ppk may be used. When there is not enough data available (1.67 the process meets the customer's requirements. After approving, start production and follow the control plan.
1.33 <(index value) <1.67 the process is stable, but requires some improvement. Contact your client and review study results. This will require changes in the control plan, if there is no improvement prior to the start of volume production.
index value <1.33 the process does not currently meet the acceptance criteria. contact your customer.
note: cpk can only be used for stable processes.
- unstable processes
Depending on the nature of the instability, an unstable process may not meet the customer's requirements. the provider shall identify, evaluate and, where possible, eliminate special causes of prior variation in ppap submission.
the supplier shall notify the customer of any unstable processes that exist and shall present a corrective action plan to the customer prior to any submission.
- processes with one-sided specifications or non-normal distributions
the supplier shall determine with the customer an alternative acceptance criterion for processes with single-sided specifications or non-normal distributions.
note 1: the aforementioned acceptance criteria assume normality and two-sided specifications (target in the center). when this is not true, the use of analysis may result in unreliable information. These alternative acceptance criteria may require a different type of index or some methods of data transformation. The focus should be on understanding the reasons for non-normality and managing variation.
- strategies when acceptance criteria are not met
the supplier should contact the client when the process cannot be improved. If the acceptance criteria cannot be met by the promised date of submission of the ppap, the supplier shall present to the customer the approval of a corrective action plan and a modified control plan, normally providing for 100% inspection. Continue efforts to reduce variance until a ppk or cpk of 1.33 or mayar is obtained, or until full customer approval is received.
- studies of the analysis of the measurement system qualified laboratory documentation
the supplier shall have a laboratory field and documentation showing that the laboratories meet the requirements of qs-9000.
- control plan and qs-9000 third edition)
The supplier must have a control plan that defines all the controls used to control the process and that complies with the requirements of QS-9000.
note 1: control plans for “families” of similar parts are acceptable if the new parts have been reviewed in a common way.
note 2: certain clients require that the control plan be approved, that is, signed by the client on the control plan, prior to acceptance.
- submission parts guarantee (psw)
In order to successfully complete all required measurements and tests, the supplier shall record the required submission parts warranty (psw) information.
a separate psw shall be prepared for each customer part number unless otherwise agreed with the customer. If the production parts must be produced from more than one cavity, mold, tool or production process, for example lines or cells, the supplier must complete a dimensional evaluation (see 1.2.2.7) on a part of each one.
the specific cavities, lines, molds, etc. They should then be identified in the line "mold / cavity / production process" on a psw.
The supplier shall verify that all test and measurement results show conformity with customer requirements and that all required documents are available (or for levels 2, 3 and 4 is included in the submission). An official supplier manager must approve the psw and provide the date, title and telephone number.
note 1: a warranty by customer part number can be used to summarize many changes providing that the changes are properly documented, and the submission is in compliance with the time requirements of the customer's program.
note 2: the psw can be submitted electronically in compliance with the client's requirements, if this is approved by the client.
- part weight (mass)
the supplier must record the weight of the part as shipped in psw, measured and expressed in kilograms to four significant decimal places (0.0000) unless otherwise specified by the customer. weight should not include shipping guards, assembly aids, or packing material. To determine the weight of the part, the supplier must individually weigh ten randomly selected parts, calculate and report the average weight.
at least a part must be measured from each cavity, tool, line or process to be used in the realization of the product.
note: this weight is used only to analyze vehicle weight only, and does not affect the approval process. Where there is no production or service requirement for at least ten parts, the supplier shall use the number required to calculate the average part weight.
- appearance approval report (aar)
A separate Appearance Approval Report (AAR) must be completed part or series of parts for which a submission is required if the part / product has appearance requirements in the design records.
Upon successful completion of all required criteria, the provider must record the required information in the aar. The completed and representative aar of the part / product must be submitted to the location specified by the client to receive disposition. the aar (complete with part provision and client signature) must then accompany the psw at the time of the last submission based on the level of submission required. Additional requirements can be recorded in specific customer requirements.
note 1: aar typically applies only to parts with color, grain, or surface appearance requirements.
note 2: certain clients do not require entries in all fields of the aar. See appendix b for detailed instructions or completion of the aar.
- production parts sample.
the supplier must provide sample of the product as required by the customer and as defined by the submission requirement.
- sample master or master.
the supplier must retain a master sample from the same period as the production part approval records, or a) until a new master sample is produced by the same customer part number for customer approval, or b) where a Master sample is required by design records, control plan or inspection criteria, to be used as standard or reference. the master sample must be identified as such, and must show the client's approval date on the sample. the supplier must retain a master sample for each position or multi-cavity die, mold, tool or pattern, or production process unless otherwise specified by the customer.
note 1: when the part size, the pure volume of the parts etc. makes it difficult to store a master sample, the sample retention requirements may be modified or waived in writing by the client responsible for the product approval activity.
The purpose of a master sample is to assist in defining the production standard, especially where the information is ambiguous or insufficient in detail to fully replicate the part to its original accepted state.
- verification aids
If required by the customer, the supplier must submit with the submission of the ppap the verification assistance of any specific part or component assembly.
the supplier must certify that all aspects of the verification aids are consistent with the part's dimensional requirements. the supplier must document all engineering design changes that have been incorporated into verification aids up to the time of submission. the supplier must provide preventive maintenance of any verification aid for the life of the part.
Measurement system analysis studies, eg r & r studies, accuracy, pathways, linearity, stability studies, should be conducted in compliance with customer requirements. (see 1.2.2.10 and the msa manual).
