ncr-supplier-PPAP-Training-Presentation

ProductionPartApprovalProcess(PPAP)2NCRConfidentialWhatisPPAP?•ProductionPartApprovalProcess•Standardusedtoformallyreduceriskspriortoproductorservicerelease,inateamorientedmannerusingwellestablishedtoolsandtechniques•InitiallydevelopedbyAIAG(AutoIndustryActionGroup)in1993withinputfromtheBig3-Ford,Chrysler,andGM•AIAG’s4theditioneffectiveJune1,2006isthemostrecentversion•PPAPhasnowspreadtomanydifferentindustriesbeyondautomotive3NCRConfidentialPurposeofPPAP•Provideevidencethatallcustomerengineeringdesignrecordandspecificationrequirementsareproperlyunderstoodbytheorganization•TodemonstratethatthemanufacturingprocesshasthepotentialtoproduceproductthatconsistentlymeetsallrequirementsduringanactualproductionrunatthequotedproductionratePPAPmanageschangeandensuresproductconformance!4NCRConfidentialWhenisPPAPRequired?NewpartEngineeringchange(s)Tooling:transfer,replacement,refurbishment,oradditionalCorrectionofdiscrepancyToolinginactiveoneyearChangetooptionalconstructionormaterialSub-supplierormaterialsourcechangeChangeinpartprocessingPartsproducedataneworadditionallocationPPAPisrequiredwithanysignificantchangetoproductorprocess!5NCRConfidentialBenefitsofPPAPSubmissions•Helpstomaintaindesignintegrity•Identifiesissuesearlyforresolution•Reduceswarrantychargesandpreventscostofpoorquality•Assistswithmanagingsupplierchanges•Preventsuseofunapprovedandnonconformingparts•Identifiessuppliersthatneedmoredevelopment•Improvestheoverallqualityoftheproduct&customersatisfaction6NCRConfidentialProductionRun•PPAPdatamustbesubmittedfromaproductionrunusing:ProductionequipmentandtoolingProductionemployeesProductionrateProductionprocessAlldatareflectstheactualproductionprocesstobeusedatstart-up!7NCRConfidentialRun@Rate•ThepurposeofaRun@Rateistoverifythesupplier’smanufacturingprocessiscapableofproducingcomponentsthatmeetNCR’squalityrequirements,atquotedtoolingcapacity,foraspecifiedperiodoftime•VerificationoftheRun@RatewillbeattheSupplierQualityEngineer’s(SQE)discretion.ThesupplierwillbenotifiedoftheneedtoperformaRun@Rateasearlyintheprocessaspossible.•ThenumberofcomponentstobeproducedduringtheRun@RateshouldbesufficienttodemonstrateprocesscapabilityandwillbepredeterminedbytheSQEandthesupplier.Factorssuchasproductcomplexity,shelflife,storage,costandsingleshiftvs.multipleshiftoperationswillbetakenintoconsideration8NCRConfidentialOfficialPPAPRequirements1.DesignRecords2.AuthorizedEngineeringChangeDocuments3.CustomerEngineeringApproval,ifrequired4.DesignFailureModesandEffectsAnalysis(DFMEA)appliedinspecialsituations5.ProcessFlowDiagram6.ProcessFailureModesandEffectsAnalysis(PFMEA)7.ControlPlan8.MeasurementSystemsAnalysis(MSA)9.DimensionalResults10.RecordsofMaterial/PerformanceTestResults11.InitialProcessStudies12.QualifiedLaboratoryDocumentation13.AppearanceApprovalReport(AAR)14.SampleProductionParts15.MasterSample16.CheckingAids17.Customer-SpecificRequirements18.PartSubmissionWarrant(PSW)Now,let’stakeacloserlookatNCR’srequirements9NCRConfidentialNCR’sPPAPRequirements1.DesignRecords2.AuthorizedEngineeringChangeDocuments3.CustomerEngineeringApproval,ifrequired4.DesignFailureModesandEffectsAnalysis(DFMEA)appliedinspecialsituations5.ProcessFlowDiagram6.ProcessFailureModesandEffectsAnalysis(PFMEA)7.ControlPlan8.MeasurementSystemsAnalysis(MSA)9.DimensionalResults10.RecordsofMaterial/PerformanceTestResults11.InitialProcessStudies12.QualifiedLaboratoryDocumentation13.AppearanceApprovalReport(AAR)14.SampleProductionParts15.MasterSample16.CheckingAids17.Customer-SpecificRequirements18.PartSubmissionWarrant(PSW)–NCRcallsthisthe“ProductionWarrant”Suppliershallsubmitthese12itemsandretainacopyofrecordsatappropriatelocations10NCRConfidential1.DesignRecords2.AuthorizedEngineeringChangeDocuments3.CustomerEngineeringApproval,ifrequired4.DesignFailureModesandEffectsAnalysis(DFMEA)appliedinspecialsituations5.ProcessFlowDiagram6.ProcessFailureModesandEffectsAnalysis(PFMEA)7.ControlPlan8.MeasurementSystemsAnalysis(MSA)9.DimensionalResults10.RecordsofMaterial/PerformanceTestResults11.InitialProcessStudies12.QualifiedLaboratoryDocumentation13.AppearanceApprovalReport(AAR)14.SampleProductionParts15.MasterSample16.CheckingAids17.Customer-SpecificRequirements18.PartSubmissionWarrant(PSW)–NCRcallsthisthe“ProductionWarrant”Suppliershallretainthese6itemsatappropriatelocations,andmakereadilyavailableuponrequestNCR’sPPAPRequirements11NCRConfidentialLevel1ProductionWarrantandAppearanceApprovalReport(ifapplicable)submittedtoNCRLevel2ProductionWarrant,productsamples,anddimensionalresultssubmittedtoNCRLevel3ProductionWarrant,productsamples,andcompletesupportingdatasubmittedtoNCRLevel4ProductionWarrantandotherrequirementsasdefinedbyNCRLevel5ProductionWarrant,productsamplesandcompletesupportingdata(areviewwillbeconductedatthesupplier'smanufacturinglocation)PPAPSubmissionLevels12NCRConfidentialRequirementLevel1Level2Level3Level4Level51.DesignRecordsofSaleableProductRRR*Ra.Forproprietarycomponents/detailsRRR*Rb.Forallothercomponents/detailsRRR*R2.EngineeringChangeDocume