SECTION II.2.4 PRODUCTION PART APPROVAL PROCESS (PPAP)

Transcription

1 SUPPLIER SECTION II.2.4 PRODUCTION PART APPROVAL PROCESS (PPAP) PURPOSE: To define the methods by which the supplier is to submit Production Part Approval Process (PPAP) level parts. SCOPE: This applies to all suppliers of purchased production intent parts to HTNA. EXPLANATION: The purpose of the PPAP is to determine if the supplier completely understands all aspects of design and the specification requirements. The results of the PPAP should also help the supplier determine if the process has the potential to produce consistent product while meeting the demands of the specifications during an actual production run at the quoted production rate. Suppliers of HTNA specific parts, bulk, or off-the-shelf items are required to submit a PPAP to the level indicated by HTNA (see below). The supplier must follow the standard requirements for PPAP submission and not implement these changes until HTNA has issued formal written approval. A PPAP is to be submitted for anyone of the following situations: 1. New part or components (i.e. a specific part, material, or a color/appearance change) 2. Tooling change/update 3. Correction of a discrepancy on a previously submitted part 4. Product modified by an engineering change to design records, specifications, or materials 5. Any situations that are called out in Section I.3 of the AIAG Production Part Approval Process (PPAP) reference manual. SUPPLIER RESPONSIBILITIES: 1. Production Part Approval Process (PPAP): HTNA Supplier Quality System Requirements match TS Section Product Approval Process. HTNA Clarification The supplier shall have systems in place that meet or exceed the requirements that have been stated in the AIAG Production Part Approval Process (PPAP) reference manual. Unless HTNA waives the requirements for PPAP submission all suppliers shall follow the following submission requirements. A. All suppliers that manufacture custom materials specific to HTNA are to submit the PPAP to a Level 3 submission unless otherwise requested. In some cases HTNA may wish to perform a Level 5 (validation at supplier location) to expedite the process. B. Suppliers that produce items that are considered bulk items that are specific to HTNA will be required to submit to a level 3 PPAP unless otherwise negotiated with HTNA quality personnel (plant and supplier quality) C. Suppliers that produce off-the-shelf or non-htna specific materials are only required to submit to a Level 1 PPAP. Level 1 or Level 2 PPAP s may also be applicable to supplier-only changes (no change to material or purchased part). Page 1 of 5

2 SUPPLIER D. Products that HTNA feels are extremely critical to the overall performance of the final product may require the supplier to submit to Level 4 PPAP. HTNA identifies Level 4 as where the supplier submits all Level 3 documentation in addition to other documents that may be required. These other documents may contain but are not limited to: Operator Work Instruction Sheets Standardized Work Analysis/Sequence Sheets List of Poka-Yoke (error proofing) Devices and their Audit Schedule Preventative Maintenance Instructions and Schedule Employee Training Matrix E. Suppliers are to use the appropriate Automotive Industry Action Group (AIAG) forms or forms that are agreed upon between the supplier and HTNA QE/QC for all PPAP related documentation. F. The following documents are to be contained within the PPAP submission package and are as follows per the AIAG Production Part Approval Process (PPAP) reference manual: (HTNA will review, status, and provide feedback to these submitted documents using the PPAP Submission Results Sheet (page 5) against the appropriate PPAP submission level) Design Records Engineering Change Records Engineering Approval Design FMEA Process Flow Diagrams Process FMEA Dimensional Results Records of Material/Performance Test Results In Process Studies (minimum 25 per cavity) Measurement System Analysis Studies Qualified Laboratory Documentation Process Control Plan RMIS (raw material inspection standards approved) Part Submission Warrant IMDS reference SoC (Substances of Concern) Compliance Evidence Summary Sheet (Toyota applications, possibly others). Ref. Toyota form , with instructions, on page 5. Appearance Approval Report (if applicable) Bulk Material Requirements Checklist (if applicable) Rate Results (if not performed by HTNA) Sample Production Parts (minimum 3 per cavity) Master Samples Checking Aids Identified and their Gauge R&R Results Attached HTNA Specific Requirements (if applicable) G. Electronic submissions are preferred unless otherwise requested by HTNA purchasing or supplier quality. The award letter issued by HTNA Purchasing specifies proper contact information for PPAP submission. H. While the timing of trial events will vary between applications, initial PPAP submissions are typically due in their entirety at least 4 months before SOP. Page 2 of 5

3 SUPPLIER 2. Interim Approval / Final Approval: The approval process may be split into two separate and distinct methods, Interim and final approval. HTNA understands that many suppliers have a great deal of capital expenditure invested but the suppliers must also understand that HTNA must meet the final tuning requirements of its customers. HTNA will work with each supplier on a case by case basis to determine the payment schedule. A. Interim Approval is awarded to the supplier after all the PPAP and quality requirements of the SQM have been reviewed and approved by HTNA QE/QC. If HTNA rejects the request for Interim approval, HTNA will provide the reason and the information required to obtain the approval. In many cases, Interim approval is given for a specified time period, usually SOP plus 90 days, to ensure the process can consistently meet requirements. B. Final Approval may be held until after the supplier has been given Interim approval and the supplier can prove that the process can consistently provide acceptable quality parts at production volumes. In order for HTNA to confirm that the supplier s process is under control the supplier must submit the results of long term capability studies for confirmation. The requirements are as follows below: The supplier is to submit the request for approval using the standard Part Submission Warrant (PSW) and to check the Initial Submission (see page 4 for an example of the (PSW)). The supplier must submit this request along with the long term capability results no sooner than 30 manufacturing days after Start of Production (SOP). HTNA will provide either Interim or Final Approval no later than 45 manufacturing days after the supplier PPAP submittal. If after 45 days HTNA has not provided Final Approval the supplier can automatically assume final approval. HTNA will sign, copy, and return the original Part Submission Warrant for confirmation of final approval. Supplier may be charged a late fee of a pre determined amount for each day after due date unless an extension is accorded by an authorized HTNA associate. Supplier must request the extension in writing if they can not meet due date for legitimate reasons. HTNA retains the right to waive late fee partially or fully. If HTNA rejects the request for final approval, HTNA will provide the reason and the information required to obtain the approval. Any supplier changes requested after SOP and initial full approval by HTNA, must be initiated by out Process Change Request, detailed in Section II-9.9. Page 3 of 5

4 SUPPLIER Part Submission Warrant Part Name Part Number Safety and/or Government Regulation Engineering Drawing Change Level Dated Additional Engineering Changes Dated Shown on Drawing Number Purchase Order. Weight (kg) Checking Aid Number Engineering Change Level Dated SUPPLIER MANUFACTURING INFORMATION Supplier Name Street Address SUBMISSION INFORMATION Dimensional Materials/Function Appearance Customer Name/Division Buyer/Buyer Code City State Zip Application te: Has Substances of Concern information been reported? IMDS or other customer format? REASON FOR SUBMISSION 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 Processing Parts produced at Additional Location Other - please specify REQUESTED SUBMISSION LEVEL (Check one) 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. Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. SUBMISSION RESULTS The results for dimensional measurements material and functional tests appearance criteria statistical process package These results meet all drawing and specification requirements: YES NO (If "NO" - Explanation Required) Mold / Cavity / Production Process DECLARATION I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were produced at the production rate of / 8 hours. I have noted any deviations from this declaration below. EXPLANATION/COMMENTS: Print Name Title Phone. Fax. Supplier Authorized Signature Date Part Warrant Disposition: FOR CUSTOMER USE ONLY (IF APPLICABLE) Approved Rejected Part Functional Approval: Other Approved Waived Customer Name Customer Signature Date Page 4 of 5

5 SUPPLIER SoC COMPLIANCE EVIDENCE SUMMARY SHEET (ESS) Delivery Part Information 1 Vehicle Delivery Part Delivery Part. Delivery Part Name Supplier Code Code Supplier Name Sign / Date SUPPLIER APPROVAL SIGNATURES APPROVER APPROVER ORIGNATOR Sub-Component Part Name Sub-Component Part. Supplier Name Name / A. Tyler Title Manager 5 A. Smitth J. Mills *Please reference TSZ0001G to obtain allowable limits. Asst Manager Engineer Basis for SoC Judgment Pb Cd Hg Cr+6 Asbestos PBB PBDE Deca-BDE HBCD Method Result Method Result Method Result Method Result Method Result Method Result Method Result Method Result Method Result Method Result PFOS Judgment Judgment Meets requirements X Does not meet requirements Form : Issue 5, Rev. G Page 5 of 5