Applied PPAP within a Process Approach, Including Fourth Edition Updates. Jim Collins

Transcription

1 Applied PPAP within a Approach, Including Fourth Edition Updates Jim Collins

2 Outline Applied PPAP within a Approach, Including Fourth Edition Updates Approach Review Model Example Measuring Performance PPAP, 4 TH Edition Developing Your Approach Questions

3 ISO 9001:2000 Model of a -Based Quality Management System Continual improvement of The quality management system s Management responsibility s Resource Management Measurement, analysis and improvement Satisfaction Requirements Input Product realization Product Output Value-adding activities Information flow

4 Defining es INPUT who has a need OUTPUT who has a need met Step Step Step Step N Input Output

5 Critical Elements of the Approach owner exists is defined is documented, as appropriate Linkages of process established monitored, analyzed and improved Records maintained

6 What: What are the Materials, Equipment and other Resources for the? Materials: Equipment (Production, test, inspection) Buildings: Who: Who applies the Resources? Owner (competence issues): Personnel (competence issues): Who is involved? Hardware/Software: Input: wants? Input Requirements What are the inputs that determine what the process should produce? Specifications: Governmental/ Regulatory: Other: Organization s Name/Description Output: need is fulfilled for? Output Requirements What output criteria are used to determine what should have been produced has been produced? How: How is this process controlled, including use of procedures, work instructions, and methods? Support es (Who helps and how?) Measure: Measurement/analysis of process effectiveness. Measurement and Metric Selection: Use of Data: Procedures/Control Documents

7 The Automotive Required Method for Identifying es There isn t one

8 How to Identify es The organization may use any method as long as: steps are identified The finished identity reflects the reality of the organization's system as defined by the organization The sequence and interaction of processes are clear The following slides show an example of one way to identify processes

9 Core es An Example of one Core s Subprocesses

10

11

12 Performance Meaningful in terms of customer satisfaction Tells how well organizational goals & objectives are being met through processes & tasks Simple, understandable, logical, & repeatable Shows a trend (measures over time) Defined in simple and certain terms Data economical to collect Timely Drives Appropriate Action

13 Metrics Success Factors management becomes more aware of their quantitative information requirements work centers become process driven metrics are integrated into daily practices measures are oriented to achieve objectives processes are managed from the numbers management uses the measures to improve capability

14 Products to Specification Specifications for Products s Critical Measures of Supplier Performance (Scorecard) OEM MEASURES C/100 & EPUS Advanced Quality Planning Corrective Action PPM Field Campaign / Containment Supplier s Alignment with the s Measures (Scorecard) C/100 & EPUS Advanced Quality Planning Corrective Action PPM Field Campaign / Containment Which internal performance measures contribute to the customer s Critical Measures? How will these measures be cumulated? Tier 1 Supplier Organization Management Review Additional Management es Owner Owner Owner Owner Sub/support processes Sub/support processes Sub/support processes Sub/support processes Measurement Flow and Interactions Core Core Owner Sub/support processes Core Owner Sub/support processes Core Core Core

15 The PPAP Model CUSTOMER Purchase Order / -Specific Requirements An Example ORGANIZATION CUSTOMER Record of Approved PSW Part Design Requirements Project Owner & Team Completion of PPAP Required Items Submission (or Resubmission) of PPAP Warrant Receipt and Approval of Submitted PSW Design Requirements Gather Information Completion of PSW Validated [PSO / Run at Rate] Specifications PPAP Table 4.1 Records Approved PSW Supplier Initiated Changes to Part / Initiated Changes to Part, Specifications, etc. Logistics Requirements Notes: 1. Activities shown will not always be present. 2. Records shown may be in various media and in various storage locations. Draft as of 1 Aug 05

16 PPAP s Purpose PPAP s purpose continues to be to provide the evidence that all customer engineering design record and specification requirements are properly understood by the organization and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. Draft as of 1 Aug 05

17 Applicability PPAP shall apply to internal and external organization sites (see Glossary) of bulk materials, production materials, production or service parts. For bulk materials, PPAP is not required unless specified by the authorized customer representative. Draft as of 1 Aug 05

18 Effective Date The PPAP Fourth Edition obsoletes the Third Edition effective January 1, 2006 unless otherwise specified by your customer. Draft as of 1 Aug 05

19 TABLE OF CONTENTS INTRODUCTION SECTION 1 GENERAL SECTION 2 PPAP PROCESS REQUIREMENTS SECTION 3 CUSTOMER NOTIFICATION AND SUBMISSION REQUIREMENTS SECTION 4 SUBMISSION TO CUSTOMER - LEVELS OF EVIDENCE SECTION 5 PART SUBMISSION STATUS SECTION 6 RECORD RETENTION Appendix A Completion of the Part Submission Warrant (PSW) Appendix B Completion of the Appearance Approval Report Appendix C Production Part Approval, Dimensional Results Appendix D Production Part Approval, Material Test Results Appendix E Production Part Approval, Performance Test Results Appendix F Bulk Material - Specific Requirements Appendix G Tires - Specific Requirements Appendix H Truck Industry - Specific Requirements GLOSSARY Draft as of 1 Aug 05

20 Changes in the 4 th Edition The Fourth Edition of PPAP includes the following changes, based upon demonstrated industry consensus on the need for these changes: Identified issues in the application of PPAP Removal of QS-9000 references Minor edits including typographical or grammatical corrections Draft as of 1 Aug 05

21 Changes in the 4th Edition (Continued) Removal of Section II of PPAP 3rd Edition (DaimlerChrysler, Ford, and General Motors Specific Instructions will be available on OEM websites and on the IAOB website, The Truck OEM s are responsible for their common Industry Requirements, which were revised and moved to Appendix H Draft as of 1 Aug 05

22 Changes in the 4th Edition (Continued) Bulk Material retained in Section 1 and as Appendix F with some reorganization of the text PSW revised and re-organized Draft as of 1 Aug 05

23 PSW Revised and Reorganized Truck Industry Part Submission Warrant Part Name 1 Part Number 2 3 Rev. 4 Tool PO Number Additional Engineering Changes Dated Dated If applicable Shown on Drawing Number Purchase Order No. Weight (kg) Checking Aid Number 10 Engineering Change Level 11 Dated ORGANIZATION MANUFACTURING INFORMATION SUBMISSION INFORMATION Organization Name and Code Name/Division Street Address 13 Engineering Drawing Change Level Contact City State Zip Application Note: Does this part contain any restricted or reportable substances? Are plastic parts identified with appropriate ISO marking codes? 17 Yes Yes No No REASON FOR SUBMISSION (check at least one) 18 Initial Submission Engineering Change(s) Tooling: Transfer, Replacement, Refurbishment, or Additional Correction of Discrepancy Tooling Inactive > than 1 year Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part ing Parts Produced at Additional Location Other - please specify below SUBMISSION LEVEL (Check one) 19 Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer. Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer (check) Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. DECLARATION I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer drawings and specifications and are made from specified materials on regular production tooling with no operations other than the regular production process. I also certify that documented evidence of such compliance is on file and available for review. EXPLANATION/COMMENTS 20 List Molds / Cavities / Production es 21 Organization Authorized Signature 22 Date Print Name Phone No. Fax Title PPAP Warrant Disposition: Signature FOR CUSTOMER USE ONLY Approved Rejected Comment: Interim Approval Date Print Name August 2005 THE-1001 Draft as of 1 Aug 05

24 Changes in the 4th Edition (Continued) Appendices C, D, and E forms clarified and made common Tire Appendix revised Draft as of 1 Aug 05

25 Changes in the 4th Edition (Continued) notification and submission requirements modified to exclude situations where customer notifications are NOT required (I.3.3, PPAP 3rd removed) Glossary aligned, revised, and simplified to be consistent with the updates in the text Draft as of 1 Aug 05

26 Glossary Aligned, Revised, and Simplified Deleted: Agreement; Critical Characteristic (both Ford and GM definition); Product Approval Activity; Documentation; Environment; Full Approval Gage Repeatability & Reproducibility (Gage R&R); Initial Sample; Interim Approval; Draft as of 1 Aug 05

27 Glossary Aligned, Revised, and Simplified (continued) Deleted (continued) Key Characteristics (All four); MSA Studies; Rejected; Remote Location; Repeatability and Reproducibility; Safety Characteristics; Self Certifying Supplier; Subcontractor; Tooling Maintenance; Tooling Refurbishment Draft as of 1 Aug 05

28 Glossary aligned, revised, and simplified (continued) Revised: Approved Attribute Data Initial Study Part Submission Warrant ; Flow Diagram; Quality Indices; Saleable Product Draft as of 1 Aug 05

29 Glossary aligned, revised, and simplified (continued) Revised (continued): Significant Production Run; Site; Special Characteristics; Specification; Stable ; Suppliers; Statistical Control; Submission Level; Variables Data Draft as of 1 Aug 05

30 Glossary aligned, revised, and simplified (continued) Added: Authorized Representative(s); Black Box; Organization; Production Rate Draft as of 1 Aug 05

31 PPAP Requirements The organization shall also meet all customer-specific PPAP requirements. 1. Design Record 2. Engineering Change Documents, if any 3. Engineering approval, if required 4. Design FMEA 5. Flow Diagrams 6. FMEA 7. Control Plan 8. Measurement System Analysis Studies 9. Dimensional Results 10. Material, Performance Test Results 11. Initial Studies 12. Qualified Laboratory Documentation 13. Appearance Approval Report (AAR), if applicable 14. Sample Product 15. Master Sample 16. Checking Aids 17. Records of Compliance With -Specific Requirements 18. Part Submission Warrant (PSW) Draft as of 1 Aug 05

32 APQP

33 APQP processes as Core es Input Core Output Expectations / Specifications Engineering Purchasing Manufacturing Sales Marketing Planning Quality Shipping Product Assurance Plan Approved Product Assurance Plan Product Design Engineering Drawings and Specifications Approved Engineering Design Design Capability Studies Requirements / Changes Validation PPAP Approved Production Part Plan Returns, Complaints and Surveys Production / Delivery Feedback / Correction Product or Service Corrections to Product, and System

34 Step 1 Step 2 Step 3 Step 4 Step 5 Linkages Requirements Input Who Definition What Output Custmr Product and Decision Order / Request Product and Verification & Validation Product Production Organization and all Support and Management Bid / Tender Delivery Market Analysis / Req s Payment Warranty / ServiceCustmr Post Sales / Feedback Input Who How Definition What Output Analysis Custmr Product and Verification & Validation Organization and all Support Product and Decision and Management Order / Request Product Production Bid / Tender Delivery Market Analysis / Req s Payment Warranty / Service Custmr Post Sales / Feedback Quality Manual Input Measurement and Data Analysis?Linkages???Input??Measurement and Data Analysis? Organization s COP / Core Name / Description: O rganization s COP / Core Name / Description: Output Management?Requirements??Output?? Management? How Analysis 5 Steps to achieving expected Approach Improvements Step 1 To analyze the organization s system find the processes Components 1) Entire organization, 2) Analytic Turtle Tool (or equivalent) Actions Identify all of the main processes without classifying them Deliverables Listing of all main processes Acquire Define Plan Buy Build Support Core Mapping Input Core Output Expectations / S pecifications Approved Product Assurance Plan Approved Engineering Design Requirements / Changes Approved Production Part Plan Returns, Complaints and Surveys Current Organizational Functions Engineering Purchasing Manufacturing Sales and Accounting Management Quality And Shipping Marketing Planning Product Design Design Validation Production / Delivery Feedback / Correction Product Assurance Plan Engineering Drawings and Specifications Capability Studies Production Part Approval Product or Service Corrections to Product, and System Step 2 To define the system s model based on work from Step 1 Components A single concept model (in this case the Octopus, which is based on the COP) Note: 2 other models are shown 1) Value Stream model, 2) APQP model Actions Determine model Deliverables A model which identifies / classifies key processes, sequence and interaction O COP I Management es Support Support I Support Support O I Support Support O Organization I COP Support Support Support Step 3 To define the support and management processes Components 1) The actual processes 2) Analytic Turtle Tool (or equivalent), 3) Levels Actions Identify the support and management processes Deliverables Listing of all support and management processes to the detail appropriate to the organization O Linkages Input Measurement and Data Analysis Organization s COP / Core Name / Description: Requirements Output Management Step 4 To adequately define and communicate the QMS Components 1) System documentation, 2) Communication Turtle Tool (or equivalent) Actions Develop the documentation that can adequately communicate the system Deliverables Documents, tools, procedures and forms?linkages???input??measurement and Data Analysis? Input Who How O rganization s COP / Core Name / Description: Definition?Requirements??Output?? Management? What Output Analysis Step 5 To align 1 st and 3 rd party audits by standardizing the analytic and communication tools Components 1) Communication Turtle Tool, 2) Internal Audit, 3) Thirdparty Audit, 4) Analytic Turtle Tool Actions Communicate system to internal and external auditors Deliverables 1) Picture of the system, 2) Internal audit, 3) External audit, 4) Accurate assessment of organization

35 Key Questions to Ask of Your Approach Who is the customer? Are customer requirements understood and fulfilled? Is the process value added? What are the results of Performance and Effectiveness? What is the evidence of Continual Improvement?

36 Questions and Discussion