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FORD Phased PPAP Process

FORD Phased PPAP Process

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Sunil Vijaiy
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2K views48 pages

FORD Phased PPAP Process

FORD Phased PPAP Process

Uploaded by

Sunil Vijaiy
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
  • Introduction
  • Phased PPAP Process
  • Ford Special Requirements to PPAP 18 Elements
EP A RSP Production Part Approval Process (PPAP) PPAP is to demonstrate supplier’s understanding of: Le cose a faa VAs ota st, 0 deed oUt = pursed Ga agr Sea css ea eek ie Se S beta L@sti te hia pS aCe) Production SOO NR) cscs er meee eat ithe ede ae ee gi ii Ses om Dice rua rhea ee uunscey yes pp 0 Ma possi Cae = Ue eS hy Sartore ied rts Sie siapile| panies Re rm renee Perret! Ba DY cS CA 1) ed ene Soe Acsuabis Phas Seco mE co Se Bete Certain a Characteristics | | Significant an ae Siuciurostitud STE ete Vea Cee Ten pei ae ar | E30) Gs Zia Ohae ns 4 Material aman WA D3 ct leper oe ee oa, Model Year (MY) bls fore Characteristics roan Verification eer Tere no) Wests te Syren Pass Through ene not Characteristics Pena seusd Application nS Dae aed Ci ded Veal 1001-0 (elem ole | malol a [Taal Crem (om lage. Ee oe Sam N Mac amceye)(-(0 0 oy-U RICE [0 aes eee y All new vehicle programs and "running changes" for vehicles ColWT ec UaT QYAIaM ecole Ute: oTA I Goi eit ep oe. G es ie i o-a 2) y Any change in supplier operating pattern (i.e. new shift) (4 copia Sane aed) y Any additional, modified or reconfigured production tooling, equipment or work streams C8 cae be Ve eens ed) v Revised customer DPV (Daily Production Volume) exceeding AY-Uelit=Xe RS] 9) \lt=Lmrer-T er (ell VA(=\/=)] MGe=i es MPtBID Content aes Cinta Lore ee ea) CR regia Oa ieiac a eua ai ibi ee + Ford special requirements to PPAP 18 elements. See Lchmt 0s ee ea Gite Ate S| Ee + VPP usage Ce idee Ot eaten Diez aaa REL OL caeg PHASED PPAP PROCESS What is the Phased PPAP? 4-4 #2Phased PPAP? + Phased PPAP is Ford’ s approach to PPAP process management atl Rd asa Ee Oma fees + Introduced to improve upon launch performance ib ea ai OSes en Gama 0LOLIKcooM- 10] 9) 9 AML Ca COM ANMTOLUSSULC] * Manufacturing capability (iif 77) + Product quality (7* Jat) + And production capacity (7 fiz) 5 felielm CN es: Merc en aba UD) Phased PPAP vs the old PPAP iM aed ees wwe a PP ia=0) + Phased PPAP organizes the process into four phases Sierra noe CCC) + Phase 1: Quality Verification + Phase 2: Production Verification + Phase 3: Capacity Verification Supplier Phased PPAP Process Map Re ace Neds 8 ie Ete rae ayy er) a Se Te tC eT Ui ery smn UtLy Ue eee acl ee ee Ce ete eee) Sec isak Ten ee eee) ferries Emenee Harada ase Quality Verification for all oe ie alae pete Panera fede are eer) Pea niscesti a tal ey Soo aoe Canes aaas Pac sa eee nn a cad eis ersten arene eae Peeve rege Scioto CIN Phase 0: Run-At-Rate G#i444Er*) iment ‘tenon oa ‘Copyright © 2000-2008 Ford Motor Company. Al rights teserved. Phase 1 Prerequisites (Phase 1fJckAt) = In order to begin Phase 1, the following are required: = SoitPhase 1, BABI PARE: Successful completion of Run-at-Rate (Phase 0) for at least one work stream Het Bb — RAPER OD TE eT Capacity Analysis Report completed for at least one Job1-intended production work stream YB Ab — RAE PER MTN TEP BEST OT Tier “X” successful completion of Phase 1 ar hi 7am Phase 1 PPAP. ‘Copyright © 2000-2008 Ford Motor Company. Al rights reserved. Continue Production Part Approval Process (PPAP) using parts trom Phase 0 + Appearance criteria #13} + Sample parts [#14] + Master samples [#15] + Customer-specitic requirements [#17] «As defined by PPAP. Important note: for supptors with only Return to ‘one production stream, completion of Phase 0 for Phase 1.4 20ccur atthe same time. | | corrective action ais Slee pay bBo ED What is required to get Phase 1 PSW approval? Hamas) iseadee Phase 0 PPAP Elements (Before R@R) Design Records (Released) Engineering Change Documents Phase 182 Continue Production Part Approval Process (PPAP) [#9] Dimensional measurements #10) MeteriauPetormance tests ‘Customer Engineering Approval #11) Statistical process nackege Process FMEA [#12] Cualitied Laboratory Documentation [215] Appearance criteria #14) Sample parts Contral Plans Measurement System Analysis ‘Capacty Analysis Report [#15] Master samples [#17] Customer-specifc requirements (other) 16. Checking Aids Specific Requrements - All AIM issues must be closed with €D. Packaging Approval (FAPI121) = Sub-suppller readiness + Supplement - CRT Agreement PPAP Package 1 Phase 182 PSW Input Requirements (Phase 26 ci7RA LE) = Phase 2 requires the following (Phase2ji ZLib AE) : — All Job 1 intended production work streams have successfully completed Run-at-Rate (SrA4e"2kab mse 7 sae) — Capacity Analysis Reports completed for all Job 1 intended production work streams (/)r4i4e "2B a Te Me Pe IED — Tier ‘X’ successful completion of Phase 2 (4> fii 7énkPhase 2 PPAP). Paget -Dale Te dae ae Sonoomannes > +t 2000 2004 Ford Motor Company. Al aghts reserved. Phase 2: Production Verification (4 (Phase 0_been ‘conducted and ‘Quay Vertications (Phase 1) boon Satisted for ALL steams? subnet ‘important note: Phase 2 and Phase 3 ‘Copyright © 2000-2004 Ford Motor Company. Al rights reserved. Phase 3: Capacity Verification Phase Warartii8) ‘scamacty ‘soaie epon cure and pan i - cere acon ae I Database Phase and dant ce SS ~ ‘Copyright © 2000-2004 Ford Motor Company. Al rights reserved. Ford Special Requirements to PPAP 18 Ta) pete mma: asides Ais 1. Design Record Bebe + The design must be released and authorized by Ford D&R. CaeE sop ie aoae ad eM De eae eee Oe AW ats) Pac + Where the design record is in electronic format, the organization shall produce a hard copy (e.g., GD&T drawing) to identify measurements taken. Came aam ees C7 BCE: Sing SHEE) yea meee EG: B) (fae AP 6 A et On oe Was I ae Ace EA DR Tas etal akes + Engineering change level properly indicates the latest design change. Cen ah ee Oe omee ce vias peat ee + For FSS, if the parts are identified as black box, the design record should at least specifies the interface and performance requirements. (e.g. Vehicle Assembly Position). Peed ea 0A Pei SOP sree NE ane ay mee as ca. GUNG a eae ieee 2. Engineering Change Documents Be eae + SREA signed by CFT. GNA Dae ean Cin) 15 toe OLe ie. 100 See Ras oO la tcy BLoerai isa) Ha DAGINZSUbON\a RCo lieth cia aad eo uA SOc oy SUL Le AALS E Eh Lite a WERS = World Engineering Release System 3. Customer Engineering Approval Ed aig + The organization shall obtain documented Ford Product Development engineering approval of DV (Design Verification) and PV (Production Validation) tests of the initial sample parts. Ma Dieu gioesa rol PsA a Ome tata + The organization shall conduct the PV testing on parts/products which were fedede (Ueto = Lamar) Mv Se Oe uae A aC) + Where appropriate, Ford Engineering records initial sample part approval on the ESER/ESO, iby ileal Spa esMh cise ee So] ol pea o ON Daa pa + WERS Alert for Interim-Approval. Ure te tue SA eA Sea 4. DFMEA ae Seen Ly + When developing FMEA, the requirements of Ford FMEA handbook (special characteristic definition) shall be met. tera Unt Eee Rat alla seepage aN + For parts with YC/CC, DFMEAs must be approved in writting by Ford D&R engineer. eae De naLe fe ea (07/0 One Ee eraecas Iba asec Dt ae ea SEL AL + Ford reserves the right to review and tle all organization-developed Py aa Coad hee Muciau aL amb wa NaS NDE eg + Over patent concerns, sometimes, supplier does not wanna share DFMEA, we could review it at the supplier site or have the supplier bring them to our Colo SOG Ieee aU Ne 5. Process Flow Diagram Weiies ict F222 ill Mapping the Manufacturing Process. Cae * Organize the team - HET Sao Wacol eP elt) ON pcs meee Ue ON cee) 33 Identify sources of variation in each process ea ol eee eee) a lepec ed besa iM Sly) Detainee kate) 5. Process Flow Diagram Weiies Ce) aay Op No. Deals ecetal Wee Baie eeriad peer aeul (ire) rea omic 7 RARE Part Characteristic PUR ire Celera cs de BU gl | =P General Procedure to develop PFMEA: #jiji3!| xt #2 FMEA HN res reetee ns Ca Seca i ceeeta es aaa Deane Rees naan : 2 HEED Ia Ste alee mie CeltE Oe asd lorena gene de BU gl | =P eicn Ie Sa aE to develop PFMEA: 4ij ii! xt FEFMEA £4) — Sic tnt He (22) al peer ee eas gion POV OC Rukus ied Die agar d Pee uae cl tc ie esd SU CR URC 8 Ib a RUE e a acute tae ie Se Une Pa Meu Moloed de BU gl | =P Process FEMA Output is): FEMA ‘fii: a Seca eich Cee irate ced Mele iitcel Sis yal Tee BR ee | ee eae as dd Pera Rate Mun acs oe ey et i are ea cba + How to control these things de BU gl | =P Cae a Moca areca gee aC MC RT a Se = using the CRT approach. VE seal al =a is SE Aa tL Sabo ere acer ae Seco a rc Uneem a aS Ca eh de a eRe neh EU Wasco rea aes eae ate cet PLL VOE ia Seca eee Mae nun Ue a= Wu nates N ry Crore Un Ct ty NSS 7 cc reece se Seman a Rue Tease Deiter ee ecela StNiieed erees tat + PFMEA is living document. (8D, SREA...) PFMEA%! 4s! S87 7. Control Plan Eesti) PUM EC Owe (psi eaap ai pee =i + Documenting the logical order of processes, start to finish DA a eee ee Bee arc eecis ici faeces Cue cry Pn Atl iea cot ate ee oa Beano ag (Bipipriig wae epee cIC Eee Sa ear ke uo amt Cae A Bk, BA TAB + What to do, if all failed 7. Control Plan Eesti) * CC/SC list is properly cascaded in to CP. aE SiS St a/c cacdivi- cea) Seon cluneM umn uae SAS A aE Hl PU BSP + The Reaction Plan should be evaluated for effectiveness and use. aa (eO eas a cal ose ca + Lists all process parameters and part characteristics that require specific quality Peer econ Set ae eOM ne gia i sibel Gis baal F(a pic CRSP) 910) SM Si O00 Soa md BDSM Gi) Seek ota ee ziti] Bbrab [e et ae) 7. Control Plan Et lai Se ere ne + Government Regulations Spee + Fiold Actions SM Sete gece Potential Critical Characteristics and Significant Characteristics Identified cae aU! Pee Cie ORE EUR ee-Uled peered Sluis) — v v o v u 8. Measurement System Analysis CU em + All gauges (both general or dedicated) in Control Plan. Dae ae DESEO De LC eae TT eRe ee Pade er aiy Boe eee + MSA 3.0 based. 48FMSA3.0fiR4. + Associated % tolerance and % study variation. fee Meteo On eceete + To variable gages, the parts used for the Gauge R&R study must be within Design Record specifications. Sane ees oO SNe aaa acum aap Ree + The acceptance criteria for Gauge R&R as a percent of TOLERANCE is less than 10%. If %tolerance is over 10% customer approval is needed. The Gauge is unacceptable if % tolerance is over 30%. NDC more than 5. Cie OMIM -lalele f o-Uclec-re 71M IAI C= \o Mn Neo a eet Pe Uselare mately IE aay Dimensional Measurements to compare the actual part with the drawing (bubble prints). Default are 3 parts measured (5 pcs preferred). Gee mad es dE ea If production parts will be produced from more than one cavity, mold, tool, die, pattern or production process, a dimensional evaluation on one part from each should be completed. Be ee Ie ie bo eee cle as ceed Sioa asst sea oe ai im Make one of the parts measured as "Master Sample “ oe a ede 10. Material/Performance Test Results DUE UREA LR a-ae Si UES + Where Ford specifies that materials are to be purchased from an approved supplier. Ei aiever alan haa ua us baie Sa oes o fo De ee Oa CBE Tag tem ae Bree a + AILPV test requirements are clearly identified in the DVP&R. (PVP&R) PAV Guo PaCS ten eM eho Taare eae fuse PE eae Pee Cae reat a Stee UCR MU | aceueted to Uy (fully calibrated and certified), Senate ace NR aL zt De SMP itt cole tel elo Cp pe etm + MSA should be conducted before Ppk study. eu Uwe cal peal DAG hase amNY ISTAY + Ppk is required for Initial Process Study, SCs and CCs must meet at minimum 1,67 Ppk. ES gee) Pel ee ACY ALE a Cie oleMo RY: Ute oKel- lt ae ORO + If Ppk < 1.67, Error Proofing or 100% Inspection is required. UE NA eed Oe PAE eee | a ee iV Cpk or Ppk? Equation Definition Process capability for two-sided Process performance for tvo- specification limits; does not take into specification limits; does not take (USL -LSL)6o J aecount where the process is centered ( into account where the process is cp tered (i.e, what the process (ie., what the process average (X) is), Process performance based on the USL-X Process capability based on the upper —— ea en upper specification specification limit 30 Procese performance based on the =LSL__ J Process capability based on the lower [elaine cpl vl 30 specification limit Cpl Process perf specification limits taking into where the process is Process eapability for two-sided specification limits taking into account| where the process is centered. Minimum of | Cpu, Cpl 12. Qualified Lab Documentation fae ane The qualified laboratory (internal or external) shall have a laboratory scope and documentation to show it is qualified to conducted the inspection and testing for PPAP. Bie DAZ i $e FEY eB FB) HEA ATE AC fF The external laboratory shall be in compliance with the latest ISO/IEC 17025 (or national equivalent). ed eS aiew re 110) Om NAO) DEL SUSI HE FI ALBESR 13. Appearance Approval Report PDR Rii aa + All parts/products having appearance criteria shall be reviewed and approved by the appropriate Ford activity (Design Quality). paca am es ale Ne Ses Sel ed a dime Me eae eG OO + Appearance approval includes, but is not limited to: overall appearance, surface quality, color, texture, and gloss. See yeaa ece a.) Veet eM a 2B eh + Visual "match-to-master" is the specified requirement for AAR sign-off. Numeric evaluations should only be used for on-going quality control after visually acceptable parts/products are attained. SUNS Yogic Lz Es eam ve (Rene Dea aR ea au ew yao bai SBR + AAR plan and Pre-AAR. ee) We cs 14. Sample Production parts id + Customer defines the quantity. Ce Seb Se mE ATEN eae + Sample Parts are needed for the parts functioning in the Vehicle or Letey Ua te LAAN Sie ie aie, cece eo ec WI ee Laas + Photos as evidence is acceptable. CRG atc seam (cose 15. Master Sample Dai + Master sample which is retained in the supplier’ s site for reference. Master sample has the same life as PPAP package. Ream ee eee eee en eam i eee Lh + Supplier shall retain a master sample from each position of a multiple cavity die, mold, tool or partern, or production process unless otherwise sepcified by the customer. . eR TR. a ieee Se See ices elaine + Dimensional Result is required form Master Sample ee ia die ace oa 16. Checking Aids Live iE ee + Gauge strategy and drawing approved by customer. See ie Le Cas + The gauges are to the latest design level. az Ree ara oes + MSA study to checking fixtures is required. Dereon cece a. LS .vn Ih SWART Olu ms) relies Ce amr ney eee Bre eel WN) ene male sing: + Expendable Package VS. Returnable Dunnage. nen Gia e a Ome eg Se eH - FoE&FAP: FORM 1121 (via FSBC) Sea e Gn een MPR AMO ps8) |B gS) 310 Las a) - NA: FORM 150E ci tc eel + Trial shipment that simulates the production logistics process. (Water Shipment Trial for exporting suppliers) See UE Sab OLE ep iS L UP Me Ug ce oD Ca: na Saal 17. Customer Specific Requirements Bx er-yey-Wot NANA Va ii (orl (Ce) Opel) + Measure the ability of a supplier to meet Ford Motor Company’ s Capacity Planning Volume (CPV) with quality parts, on time. eM eee calla) Peat ae fh + Capacity verification to each work station to identify the bottleneck process F PAL BET LAR AR L FF * CPV information should be ibade Lome 1a See SNM Ee tam oa alenok 17. Customer Specific Requirements - Supplement-K & IMDS Pa Go iS Ses Geto + Supp.K is used to demonstrate the linkage between the Drawing - FMEAs - Control Plans - Operator Instruction Sheets. Nba name Ese) al V7 saat =P etc AE Ue see + All material need to comply to requirement of WSS-M99P9999-A1. Cie bea UE Se seie el ae LA e Daan VPP Usage Nd) de seize) are T awn di aed tie or COMA] od soe A a1 eo =a Cad Cel [

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