Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Produd~(!In
First
Eoditi~IiI~$Sru.lJeliIIF,cb['uar'.Y
~.9'J
See0nd E~dhion!.ht rm'int~ng, F,eblI'u~ry 1995; 2~d fr~n.twng,Ju~y 1995 Th iird Edliti,oO" September ~.9~19;:2 n~.Pf'i~nting:, A ugm.~ .2100
fQ'lmrth Edi~woOO1J, Mareh 2100'6 C(i)pym'ig;h~ ©l993,. ©l9'!)5" ©HI97,. ©199'9, ©2000~ ©2106 .Dn~m~el~Chrysrner::~lll·llllot:a.thD<m~. ord Mot!~.r Com.,any, GencFa~ Moton COr'plor'9Jti.o.1iJJ f F
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PI1''Ol)iuctiJl)IliIP:8!rt APi,fOll:!lJ1 Pn'cest> (PP AP) First Editilon Issued FeillI'l!tary 1993 SelCond E'~it[olm"b;t P'!I'ii!l!iijng~ February 1995; :2 nd P,riililiting1 July 1995
Tib~m 1IE4:1ition~ ,epitemlller 1999'; 2nd r,li.int~ng, August ]JOOO S Fourth Editiiol!!!, anb 2006 M
Da!im~eFChrys~er
Co"yri:g;bt ©l~'~n~©l~lH~5~ 1997, ©1999'"©200n~ ©100{i, © Corporntil!!iml, Ford Mo:toF 'Com;pa,li1Jy~ GeliJier:ililMoron OllciJoration
EUecti.ve June I ~2:006~PPAr Fourtb E,dliti.Od replacts .PPA.P Third Edi.fi'o,n gn~ess, ofhen;v:ise specifie-d by you!r cgston~er.
Edit]cin replacesPPAr
.PnilliIl!lIdion
focusedprecess
rrocJCss (ll'PAP) is~pdJa1ed to t~e 4~ GdIl'tO:iil to incerporate the eustomer <li(ppmllcl:ia:ssodated. wl,th Isorrs 16949':2002 aad other cFI<lnge-slisted belowto um:u:lame
requirements. PP AP',s purpose contiuues to be to provide the evidence that aU customer e~ineeri[Jg design record and specificatiea requirements are pmpedy understood by the orgamruiZ<llt:ionaad thet the maJl:'JJufadmiIDIJJg process bas the potential to produce pmduet C{)iDS~stentLy eetin.g these requirements dmi.ng an aetna] m
produdio-n run at the queted production rate, FPAP 4th Edition includes the following chaages:
.,AJignmen:t
• • AUgning
ofPrAP
~,Q
ITII!I!Jlufactmil"lg process
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P S W (P~!:iI: SI!]Jblnissic;m W<I:lTIlnt)to: ProviJe a more lo'gical (low fO!r tnepart 1 dcs:igll!de~[i!pt:iQIlI fields 1'I.lakethe $I!l,,p;iieraddress i'ic]ds applicabic to intem8!tiO:mi,aJ1loca:liQl1!s mllclll!lrl.c ]M DS milte:ria~rse~rlirlg to im:li.caitc ['cpomt.ilng StaJl!i'S r
tffiJJf::
Updated specific PPAr requirements, 1ndud]n£;: '. Milt!.\ria]s re:portimi.gflnd pO~ymeri!cid!entifi.Mti.on.O€qu~rem~n:~ tn .. PFl)C!CSS t::!llPahulilj' adex usage (Cpk and Ppk) i .. The ddiFJ!it'iol1! and approva] of cstelog p.arrtsaJtl!~the defilllllN of
black
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C~ 0, alnd E to rH.atl>C~the:PIP'APl1epon1:ingrequirements
dll,ilipl"~cat~QllS
Revised T~re Appendb::. to aUow OEM specification of app]:icab~~itya!ldt@, Ljj~i~ate e with <I11~)':l;·<Inceslllready provided in tJm:e PP AP reqairemeats
N~lte: The Tire Appendix is not aw]icaMe to' orgarrizatiolls, supp:.~yi.ng 1.0Ford Motor Ccmpany, t]re!l Reorgan ized aad I!l!pda'tedAiPpendix. F to stressthe importance of 'I:h.eBulk Matena]s Checklist N~h~'; Fo:!!d Mo~or Oo:mpan)' [~ql!J.iOO;S o:;g3nizalti.oms .sIJPj::i~yrur.l!g 3~1. 'bu~k material to. Ford Motor Com.piIlny to,
oo!1i1]l11y w]th "PAP.
..
PP AP refers t'O tbe .fo.llo"",lmgreference manuals: Advanoed r:r<!Ili1lU;:t Ql!I!aliltyrlanD~gg & Contli~~ PI:!!)", Pob!nlialFlili~ll!IfiC Moilil!es and Efrc.cts Analiysis.Measuf\e:meilllt SyS:~e'mJ AillaEys1s~ and Statisttta[ PN!l:eSS Cont[lot These manuals are authored by ])a~mlilerClirurys],eil: OOrpOfUL@liiII. Ford M@t@r O:um,arnzy. a'[!;dGeneral Moton OorporaJtio]l and :area\fai~able~hrougb the Autereotive Industry Action Gf01ilP I(AIA:G)
at www.aiag.org, The Supp~~er Q~al~ty Reqairements Task Forcegrate1mHyacuo'wledg.e":s, tfue contrihutions of the many indiv]dl1als and t~eir respective eampenies t:ilatpartiliclparred in the revisioupreeess.
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CUSTOMER.
C~~~orn.er
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Custornar"Sj)ad~~ Re(jlJlreme!ill~
1--+-.., OR.GANIIZA.TIOINJ
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Part 'D~S"'i'I
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C~tomer S;p>eeifica~lons
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Requil'el'l,lmbs
Notes:.
T'A]3'.L.E OF ,CONTENTS
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SECTION 3 - CUSTOIvlliRNOHFlCATION AND SUBM]SS.[QN R6QUUtEMENTS 3..1 ,Customer JVofijicatian -.----- ----------.. .. -- -",..•......, ..".,
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SECT~ON 6 - RECORD RETENTiON. -_.- .---.. _ - .. - ------_--.. .-.-.-.. .-., ---.. -.-, - -_ --_.. - - - --.. -_._ APPENDICIES
Al?iP'.EN1DIXA. - eOMPLET"[ON
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APPEJo-LDD: C - PRODUC:110N
Ap'PfNI:iLX PRiQDUCTIO'N
DIMENSIONAL
RESULTs
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H - TRUCK
]:NIDUS'fRY - SP,EClfICREQ'UIREMBNTS
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57
GLOSSARY __. .. .. . ..
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'INTRODIUCTION
'PUl'p,ose
Proodudiofll Part Applr0"f3~P!FOCess (PFAP) defines generic req'lliI~rem.emtsor prooucti.Oifl part approval, f jncludw[l,g prodJuchon end b"ulJl::mate:iials (see G]OSS::Ir;y),. Th,e purpose of PP APi s to determine if aU customer ,engineering destgn record and specification require:m.enl;S,[iFe properly understoed by tine organizatian end thaJt l1e m~!:l~facrnliin_gpreeess has the potential to' p:rod'u.ceprodlllc:~ consistently meeting these requirements durrung anacnaal pnxlucti1i:m fUl!JJ at ~he quowed p:rrod."ijctiO'!'I ate, r
PPAP sl:liaU.apply ,
10 lnternaland
service paets prodaction materia~s. or bldk materials, specified by m.eauthorlzcd CUS!tOMe:r representative.
An OifgaJilWlzaUonllpplyh'JJg ~millD,da:mcOl!!talQg s p:[lJduot~mil ©il" service pam shall com.ply with pr Ar unless fonnally waived by the authorized cu,s,wcm:'le!r representative ..
NOTEl: Seeeustoraer-speeifie ~egjuireme[Jjtsfor addutioll.<ll m:fo.ml@lti.o.mt. questions AI] sh.O!iJ be addressed! ~othe <l'luimrized custerner re~[e5eIl!t:U]V,e. l.d 1I0Cm.1.I'PAP'
NOTE 2: A cussomer can ]'OITnal]ywaive r'p AP requ iremeets for an o.rgllnizatiol1. Such waivers can only be issued by 11[1 llutho.r,uzed customet .re<presentative. NOm.3: Alii organuzatioill or s'U~pLi.e.,req)Ue-stinga lWai.wr of a .PI"Al'requireme.nt s:tlOllJl.d eentaet t~.e aud'lo.r:ized, customer representative. Th.e erganization or sl.I!P'P]iersheald obtain docum.e'ntationl. of waivers fromthe auth{)irJze(:jcustomer representative. NOIJ'E4:: CilJtal.og pans. I(e.g.. bolts) are ]die[JItified .uiLdlfoxo1"«red by eJilcti.onal specifiestiens or by
recognized industry stendards.
App,rolalch
l'~:e word "shal I."ind icaees mandatory requiremenrs, faragrapbs
Tihle ",'oro "shoutd" .<'lpp.iy.
marked "NOrrE" ere for ,g:uid,.;ilnc-e uaderstendieg orcLa]"i~ing the assacieted requirement. in <I[,peaTiQg ina NOTE isfm guidance om~y. AI', the Wem:Jisand.definitiens given in ]Sorr-s ] 6949an:d~he PPAr Glossary
for;
sl1omitl:ed parrt
forrr
representative penstesied,
:F1 or
bulk~~ateri.ds: N00specific E!!Lnnber of '~~a:rts" required, The s.ubm]t"l:ed sample slmU be taken in a is manner as to <ISSl1[1ethat it represents ~'steadJy~:Mate"opemtion of tililepr@oess.
NOTrE:; for bulk ma1lerill[,prodll.!ot:tOIii bJistories of eurrent produets .r.mty oien 00 ussd to estimate rue, il1i~ial. p.rocess,capa,bi.ljt:y or perfenaaace of new and sjmil.ar pFmJJuds. ill eases where ne p.roduotio.lll b~s;l"O:ryof a :s~mUa:r ulk material product or technology exists, a cO[JItammelll p]l}[1 may be put i:nto eWecll!![JItil sufficient b production has diemons,tlra'ted capalj)i]ity Or perfcrmance.ualess otherwise specified by U'lf cusmmer,
BlLl!~k Ma.~eria:~ PPAP requ]rem.e~ts are defrne..dby:a comple~ed.BIJi~kMlI.lIEH:ia] Requirezeents Checklist (see
.-0.',1,·
_..
I. - . ,_. ~
I•
If!!Jtly pan specifications cannot be met. the organization 'shaU docull:tent their prcblenr-solving
and shall eentaet the authoriaed eusterserrepresentstive
eerrecti ve action.
for eoneusrence
]]:1
,,-;
NO'.,·E: Hems Ot racorda from 2_2_1 tihn,lliigh .::t2_I Sma.;!" :IDIot neeessanly IlPP~Y to every C'llstomerpilrt number fr[)m e'olery o:~gal1l.Zii!lioriLFor ¢.1'1.amp]c. $Qm.~ parts do not have appeafaJlC>e req~.i[lemel.1ts. olll.ers diD !!lot have: color ['~qJiI1irumenl<l, andplastic parus may harvcpQl)m1eric part marking requirements If! erder jo d.eteFn:rlii.li1~ with oel!tainty whucb i.1:c:msmustbe lnelnded, ,consult the de;s~.gl"lrewnl. e.g., part print, the relevant Ellg,uneerillg doeumeus or sped.l'i.CfI~io[ls, and your lil!ithQnzed customer ~.ep[esenbtive-
t"';
.)
2..2,1.1 Reporting ofPnt Material Com,osiUon The '@Fga:ni~ti on shall provide customer-specific req_uirem.ents. evideaee t!l1at tl1J.e MaJte[lal!lSubstaElce Compos]ti:@iJl('ieportin.g
fOJ
tMrt ~s
NOTE: n-.is m8!l.~rials rC.poQrti!ll[g may beentered ~.mJtotne ]MDS (Irrl.t:e:ma.tionaiMflterial.s D.a!ta.Sys!.mn) Qr ,other cllstoltle-;r·spec:ifh:;d s-y.s~-mfm.e:th.od" [MDB is a.vailabk: ili[ou,ghr bup:Jlwww.rmJlsys1em.comflndex.jsp.,
NOrrIE; Nom.eo.d<!tu.fe ad .aJb!b;r>e\~iat]Q[lrefe{~r.uoes~o slq)rpOirt the use of ~:sO l l 469 l043-1 fOT basic: polynl.e-ifSilind .in ISO l 043 ~2 fUI fiUer$ ariel ",eill!force.m.enm.
contained
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2.2. Sf'roce:ss
F~ow [):iiagra,mf s)
Theorgani.zat~.cm shall have a proeess flow diagram in an organization-specified format tnat dearly describes the production process step-s and. sequence, as appropriate, and meets the specified customer needs, requirements and expectations [e.g., Advanced Preduct Q~lJa~U'Y rbnning and Cont[iol. Plan reference manual}. f()'f bu]k materi~!s, 3[1 equiv~lent to a Process Flow Diagramis a Precess Flow
Description,
NO'FIi:,~ Precess flow diagrnlIhsfor 'famulies·' of similar partsate ,acceptable if title newpens reviewedfor commona.~~Llyythe organization, b bave been
2 ..2.6Pr~ce:5,S
The; o~ga[luzat;ion shall develop a Process fMEA in accordance With> and comp~]~nt to, customer-speeifled requiremenrs, (e "g.,r0,tenUal F,ailuiileMade ll!liId Effects Analysis reference manual],
.NOTE I: A si:ngle Process f'MEA .rnay beflppl.ied to 11 process manufacturing material'> if reviewed for commonfll~1iYby the orgllni.zJtion. NOTE 2.~ FDr bulk roateria~s.
~GlC
Appendix F.
The organ]za!tion sha]] ]:mve ill Comrol Plan that defines an methods used for process COln.t!1Q] andccmplies with eustomer-specifiedrequirements (e.g., Advau,cedProdllH::t 'Q'I!l!antyPlanl!l!ing and Con.trol. Plan reference manual),
NOTE 1.; Controi .P]am fOIr "families" of parts areacceptable oomm(JI1ls1uty by tl\ieo:rganlzaliol1.
]f
NOTE
:z;
~11 the
Me~suli'cment
Sys'tcrn.s AlJa~ys~s.[,eference
NOTIE 2~ For bulk mate~,al:s, Measll!["tlmmt System A:na]ysis may not apply. Customer agtt:E;:me[IJt~hould
be 'i)btarurnoo onilctl!,ll reql1irements.
1:.•2.'9 DimnensionalResults
1
The orgam::l;flltion shallpravide evidencethat dlmeusienal verifieaticns requked by t!lic de:si.~ record <lind the Control Plan have been oom.p~~tedand resu lts ind]ca.te 'CO~1ip1i:uJJoe with specified requiremeets, The organi:lalionsh<liU. have dimensional r,esu~~ fo!!"~ch uniqae marr-llf:act!lMllimg process. e.g ..,. cells C!f production Iines and all cavities molds, patterns Or dies [see 22:, 18)" l'h,e ,or_ga!lizati,cm. shall record. with the actual resalts: aU. dimeesieas (except reference di meesioas ),. charaeeerisries, ruld spedfl.cati.ons as noted on the designteeord and (;olltro:~Plan. The orga[ilJiza:t]on shall indicate tile dfllte oft!he designrecQrdi. change leve~.ao.dany ~uthorized engineeringebenge doclilmellil not yetinoo]"po.rared III the des~gn recordto :which the part was made" The organization sha Ilrecol.rrl tJw:e, chenge level, d:rnwing date, o.rg<ll.li.zation name <lrnd pari! number on all auxiliary documents (e .. ., s~pp~.e:ment:<liryltlyout resultkssheets. skeroli:les,. tracings cross sectieas, CMM g inspection point [egu~ts, :geol11etric dimens iO[[l.i.ng and to leF.a:ndng shee1s,. or o~he, auxiliary drawings used in conjnnction with. the pert drall~ing). Copies 'of these auxil.iary materials siiI:aU aocompany the dimensional results acoonlhl1l.gto jhe Retenti@:ru'Subm]ssion~equirell1le:nt5 Table, A trodllig s:l]aU be included when an optical .compamtor is necessary for inspectioJi)J.
p~it1Smeasured
NO(fE 1: The Dimensio[}a~Results rmm~11Appendix C, ...piclOiJ.al,geQmetui; JimcmJsio])mg &tole.rn:J];cing [GDlt T] 'Sheets, or a checked p.illlt wbere theresults arelegib liy wrinen On a part drai\?i'i:ng illdudin.,g crossseclions.mu;:]ng~.
Of
NOTEl: D ~me[l1sklll!fl1esults r
Th.e 'Organization shall have reeasds of m.a:tetiai and/or perfoFmanoe d'es~gn n,lOOifd or CQ[!.t[iQl Plen ..
2.2.1 m!.l Mate!f'illJ~ 'fest [{esu[1s
The organization shallperform tests fm: an parts and productmatueFi.;ds\';belilichem:ic~l, metaU~rgical[1equ;ln,~.m.e[l1l:s<lin:sped'fied by the des]gn n;::card (If Conool Plan. Material test results shall [nd]calleal1dim::~ude; • • .' .. ..
phys iCaJl, or
Ute design reaoro c~Mge levelef the palm. tested; .any all1tbon2ioo ,e:ngmee:ni[lg change doc~mei!illts t~tbave not yet: been irloorpora:red ~~ t~e design Feooro~ tD.enumlbeI., dawe~a[ld change level ()if~be s!pedfic~tions to which the part. was tested; the date on which the testing took place; the qU(lolti:lytested;
"
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suppUertvendOi code.
NOTE:
Appendix D,.
for products W~U'l eustomer-developed material speeificetionsand iii custcmer-epproved s:olPpHerUsc, tlle o,g~u],i;z;a6on shall promre materials andilor services [e.g., p<ai]]tillg,. plaiting, fuea:t-treating,wdding) IToOm suppUewson that list
2:.2:.10.2,
Pierfof.aan!ce
1',estt:1!te:Sll~ts
8]]
Oir
functional
'. •
• •
•
the aumber, diate,and dta.l.lge ]evd of~he specifications to which the part was tested; the date on which the testi ngtaok place;
the CJ!uantity ~iested;
aillYCOI'IIVetllen~ fl!)m:Lt!l!t.
jo
be acceptsble prioa to
suhmission for all Special Characteristics designated by the customeree org.anjzaltiQ:!1_ The organiza!ltion shall obtain customer ceacurrenee on thejndex for estimaiing initial process capability prior tn submission,
The organ iz;atiOI[l shall perform mea.su:reme']1fl system a]llial.ys]s to u.!){k:rsttlJ_tld how measurement affects the study measurements, (see 2.2.8)
error
NOTE J1.; Where]1.o s~ecja]ch<l!(acte.r~stir;!i bave been ideJiuified>UiIe customer reserves the rightto require demoasnatiorr of initialprecess capabi lit}' Q!JI ottier e:~t.eristics_ NOTIE 2; The parpase of this ~eqjuil'emen.t isto d.ere.rm_ine II lie production processis .like1yto p:!'Imliuce
product that will meet the cusiomer's (@i;[l,lir~rn..:m:ts- TheiDjtial process studiy is tocused on variables not <liUr~bute data. As~rnbTy errors, testrail[1~, $urface defec!:S are exmples of O1Jtil:ribule ata, whichis d i.mpo:rt.m:u w und.e.rstand, bl,lt~8ID:1t ClOve['ecli In tht~ injt~al sfudy _ To uJ1den!alil;clthe Fffu.rmanceof cbaeaeteeisties moaitered by <liuriblIoo dab wiU~l)!Ii~ more data cellectsd Q¥'er time. U nless applo<wd! by tlite authorized customer :repre:sentati.'II'e.,Ilmll)ll1~edam Me aot a.c.Ci!'ip'lJa1ille WAf' submissioaa For ,
"
NO"lE 3: Cpk and Ppfr .are deserlbed below, Other methodsmere appropri8!~e fo., cenala proeesses or products may be substitared with ~riO'.iappmval.£rom H1Jiurlioxroedi custosner .repre-seotativ,e. NO"F.E 41:Initialprecess studies are sFI.mHernn .ulldwin [lot predict ile, effects of time :oo;d! variation ~1Ji peoiIi!e:, mseerials, me1llilods. eqlll,ipmenl, measuremeat systems e 'and enVIDll1ment, Even forr these short-teem saidies, it ts irn.p!Ylitant to cnllectand analyze the dlllta [rnthe o:rne,r produced! using control charts, NOTE 5~ for those ch!l![8:cteds~ics tl1ff~ carl be .srud!~.ed Ilsing X~bar8!ll:dIR charts •. a shert-tsrm stuJy should be based On.a ffil:nimtlm of 25 subgroups oonta,ining at least l OOrnad:ingslrom eonsecutivcpans of rhe
,_~.---
6i.gr.li.fiC1lil[~prcductian run (see 2.1)1. The mltifli! process sru~y ~ait.l requir-em.en.ts nlay be replaced by 1(I!l]g,eif~ liGI][1nistQrica1 data fr:!i:mttli1e: same: or simibr processe-s; with eustnmez oonc11I:rre:noe" For eertain processes, aherm.8!tive ,'!!lillytic,d toob ~!l¢tJ as ~llidJi'l,fidua[ movmg ruge charts .may be approl?ri.8!~eal:'ldpe:mlil!:e~ and with pni:Q:[ ppF(l¥:!'I~,oom a~ tlll!I1il.orlZW cI]Mom~rreprl'l~llIl:ati¥e. a f
2.1.l1.2
Qu;aUty liIlIdtces NOTE 1: Th.eunitiill procees smdlyresl1I]ts are d.f5Pf;fld!em o[l~epurpose of theswdJy, method of ,d1ata 8icquisi~ioml.sa.fi'lp!.l1i11g., m;Qi1!l]1~. dara, d!emQJilsbillitiOJiiJ Qf sblitisti.cal ocmwol, ete, See the Statiisti'c8.~ P:r.oeess a of Contm~refcfC1!lce manual for a.ddi.tioJ1al ~f1ftlrmat:iQI1 h:J!ulld~rs~!1clilllg the basic prilJJc~ph:I\ of'statistical stabiliry amid process measuees (indices), For glll.daJrlce On ~re~ listed below., contact the a~~horized
eusiomer fe]l'rest11tatcive.
C~ ~ The eapi8bUi.ty iUldic% .for a stab.le pr~ceS$. The e$tiWl!itfl o( si,IDtrlais b~~ (I[I~iliithin subgroup var,ialioi.i (R;[w"Jdl O:f S-:bru'/04). Cp.l:is all'lindh:;atQ:rof pFOceS!!i,eapabi lity based 011PI~S vari ..tion wi!hill!l each Sl1bgooup of a set ofda:I:EI.Cpii; oes motinc]l1rn:e the effect. of proeess vaii.:!'Ibility ~MWIli tbe suibgrolap5. d c~ 1.6an indtcfltor of how geoda process cOIJ~dbe if all process variation between subgroups was 1'(11' be e.~umiu[l<lted, Therefore, use of Cp&: :~o[le may !be <In.inoompl,e,te'u[I[iic8IllOD: of prooess per:[or:ma:n.ro. Po:! more a
,uuformatioll. see the Sta:tis,tical.Pr,o eess COmItro~ reference marlllal. Ppi. .~ Tile ~H!Ii"![oftman0e ~m!l!cx.The estimate of sigma us based Omi.,vtalmri'atiol'l f {all of imtdividua] &arnple: data uslog me stam:lap[i ,d!evia~io:n.[root. mesn square eqUfI.tiOIlJ]. "s"), : F~i& .8!I'I~midicak:lir ofpmccs$ performance based on process variatio.l'lllhrou.gJlout mefuU W~ of d.a:~, U~]~ki~CpW. PIM ]S, not ~im:ited to the varlaHoll wi[h:in :subgroll~s,. Howeve:!",. PpJ, ,Mnnot isolate wit:h:ill subgroup va:ria~iQIli f{o:m behvee'&!. sulbgm~p 'l!'a:,.~aHoil:l.When ()8ikll~8Itedi fr.oM tll.e same data set" Cp ,and! PjN;. can ~ compared! t08!nal)'2iel the s![)l[[fCes of process variatioIl. For 1:l1C1re:nfoEma.th:m. see tile St:at.lstic81~ Pmesss 'C'O.lltlrll!l~eferellCemlHl!1l£lL i r Initi8i~ Pmcess Studies. The pu~ose of tie ilThi~:iil~ process, study is ti:lllmd.erstand(h.e process V8Iriall01l. not just to achievea specific indexvalue, Will/en.h.isrorica~ data are ava:i]ab~e .or ellough i.<J.i;tua~ exist to plot data a ~mltro~.chart (alt least 100 i:n[ii.vidmd S<lrllp.les.),. Cp.tcan be calculered when lilleproce5s, is staOle. O~iJ:Je"'\l'·is-e.far p:mcesses, with !rn:OI\;\1D p[iedicu~b.le' special causes and @utput~lleeti[lg specifieasiens, and Ppl should be, 1!lse[j. When [lot enough dliita axe aVll]l",Me (.;:;:100 samples) Of ~hen are unknown sources of variatioJll, coataet t:h.eautho.iized eustnmer rf-:p'Jj'esm.tatillveto dieveLop a sllIilubre plan, NOTE 2; for ]nitial Process Stm:lles lnvelving .:statis{ucal methods or a,pl\Mches ~lii1I!Yerequired, b
IUQf'e
......
•
NOTE J.: .For bulk nn:at~na~j the org.arl1Ji:zaJtiortl. shoiLlld ebtain C'U5l'O:m~raJgfttment reg.8!itI:ung the appropriate ltx:hnlCjues .rovill~ti;8i!.prOOf:SSsmdies.,if required, in erderte de~~m1ilte;:um.. ~ffective ,eg6m~~e of c8!pab~ IhJi.
2.2.11.3
The organ~zaltOitiL s~aH usethe folLowmg.as eeeeptanee eriteria for rev,aluattinginiti;al. process smdJy results
fm processes
,mfJrt?tetu#tm
Iadex>
~.67
The process currently meers the aoceptance criteria. The process mary be: aco~p[al~l.e. Contact Ulieauthorized customer r1l(pl1e'.sentatruv e. areview of the study results, for
r
does Hot curreatly meet Ulie acceiPt1il!];cecrliwn<'l. Contact the al!Jthorized.customer representetive far a review of 'fheprocess the ,studiy results. cnteria ws o,~e of a number of easterner
NOTE 1. Meclillg~ih.e' imirNa~pmcess study ,capability acceptance requaements tllat leads to (l]1,appoovedrPAF' s,]!~misslolli.
NOlJ'iE 2,: See 2.2. ~L] and 2,2.11.2.
2.2.11 ..1 r
1]J ~stable
Precesses
Oe;pending 'on the nature of the i,msrn:bl]i.ry. <'Inuru;mMe process maynot meet eustomerrequirements, Tbe OFgallJ.iza~ioIl. shall ].deIlH~. eva1uaitl;': nd. whereverpossible, eliminate special eauses of variation priertn a f'rA p ,sllllmi.ssion_ n.e orgi!lniZ<lJtiQl1shaU notify the UJtrn.~YI".izedc~tome:r representative of aJoy !mSmb~e processes th<ll~,existand shall submit <1. eorrective actionplan to the customer p.riJlilI" a.lilIy flO :sui:rmJiuiolil.
NO"{'E:: Fer bulk Dale rials, for processeswith knewn ad predieteble spec ial causes and ollllpu~meeting speci ficatioas, correctiveaetion p~<tn_smaYIm$.lt be r¢quir,e;d by the customer.
2.:2:.11.5
w~th 'lheautl1mlzedcustom.errepresen'tui.veal.temative criteria for precesses with one-sided speciflcat~ons GiI liD,o~!1orwaldistributions,
,
,[J,ccep:l:anoe
nle above memi.o.n.ed acceptance criteria r(2..2.11.3) assume ]lo'l'tlli'.ll.ity and a two-sided speejfleetion (target ia the cell[erl,Whel1th~:sus not true, using th.is am..~ysis may result in unreliable im) formatioa, These aUerl1la:wacceptance eraeria 'OOll,ld require a differe:nt~'pe OF index 0:, some method of lnu'I&forttt'l!8!lio]l of the data. 'I11C f'OclJssholilld be on nd.en:irUmd:ing thereasons forthen.on-Itor:ll!l,dity (e.,g.,is i~s:~aMeOVel" time?) and l'llJ.a:ooging vMia!tJ:ollJ. Refer to tn.e :Sbtffisti~) ProccS:!l Contll"o~ reference m<lllilliil] fOF furtherguidaaee,
NOn?:
1.2:.U.6
The orgenizatien shall contact the authorieed custom.er represeotative if the .acceptam,c.ecriteria: r(2.2.1].3.) cannot be attained by the requized PP AP submission date. T1The rganiza!Jt:ioril 8h~n sulbmlt to time o suihorized customer representative for app.r'(lv.ala oorwectruve;actiol1l pla:n aada moomed Contro~ Plan . normally providing feu lOO%i:nspootioJ!ili. VarlattoJiDJeduc,no.lmJ ,eft:o:ru shall 'oo~tIDue until d'le aecepeanee r cnw.ria are met, or u.ntil eustomer ap;prOrvai is .receivedI
1: I •....... ,
I
by the (;1LI.s~o:m.e:I" ..
NOTE 2, For bulk materials, lOO%im.pe-c'l:io[lmea]!8 <111 revaluation of a saJmple(s)of p&Od!.l~t from!'! coatinuous pr-ocess orn.omogellJel[lus batch whiclt is [epreselJltati ve ~f tlile entire r[{) jjJl,.u~luQI'I nm,
2.2,.11 QU3UfledLaboraro:ry
DlenlW:enbtiln
,
Inspection <lind~estingtoFrpAP shall beperformed by a qualified laboratory as defined by customer reqrulremL~ts (e.g .• an secrediied ~aJoorntory)" The quaUfied laboratory (i.ntem<li] OF external. to the organi~lti()in) shall have a ~.abo'J<I1to.ry scope and d~OIlrne:l1ltat:ion shJ)w]~g mat the laboratory is qualified for the type of measurements or tests eondueted,
laboratory is used, the OrgaWz,atiOro silThaU submit the test results On the laboratory letterhead Qir the ~ormal. 1a bomJt:ory reporn format The name of the lal!)O~atory thasperfermed the tests, the date (s) of l$u.e tests" and the standards used to run the-tests shan beidentified,
1
When an exremel/commereial
(AA.R)'
Appearance AppirovarnRepo:rt (AJ\R) shall be completed for eaeh part Or series ofpans if the Feql1l!~rell1eQ~S Oi[! the design. recolrd.
Upon satlsfaclo.ryoompleti!QF1 of all reqjuiIl":d ,c:riteTia,~he orga~zation sham record tilwe reqjuiired ][1UfolJInationo]JJ the MR.. The completed Al\R aadrepresentative produetion pl10diucts/parts shan be subm]~e>d roU"elocalio!1 specifi ed by t~e Cl1stOfJJl!e',~o receive dispcsition, A1\.Rs (compl~te w ith part disposition and 1l.1I.lItfiorizedcustomer representstive ,s,i.gna:turej shaH~\hen accomp<l!ny the PSW atthe time offiilillialsebmissiee based open the submission levelrequested, See eustomer-specifie requ1remerUs for any additional requirements,
NOTE 1; AAR typi.cally <l:PIP]ies lJily fur pads with color, gacaillL. 0:1' s~daoe appearance requirements" o NOTE 2: Ce:mrio customers may not require entries
]0 <I]~ MR
fields.
2.2.J4
t)
aoo
HI
••••
I-
,.,_ -
_......-
cllliecikimgai.d.
The organizadaa s~aH certrnfy ~ataU ,aspects of ~e checking aid agree:w~th pact. d:imensi(jna~. requirements" Tbe Qrganlza:ti!Q]Il shan dOClllnrJie:nt all released eilgiueering design changesthat have been incorporated in the: c:hed:ing a]d a:t the time ef s~bmi:ssio:n. The organization :shaU provide for prev,~m.ti ve
tnaintenacce
of any cbeckrn,ga~ds t@r the] ife of the PaJrt'(Sie:e G~QssaQ' _,"Active Part").
Measurenl1e'Jlt system enalysis stu.di,e:s,'e"g., ~~ge R & R, accuracy, bias lin.earity. s:tiMlily studies, shan be conducted in co.mp:.li<lIDi.ce witii customer requirements. {see 2.2.. am]theMc9£urnm~nJt 8 SysteMs AUaJlysis reference ~a:Duan,
NOTE 1: Cfu.eeik:ingaids
'C8!r1
NOTE 2! C!!J.~king al~,. etc" typicaJUy diG!~ot aJpply~o SIIDI! M:a:~8!ls. ~f eheeking ai.ds are ~sed [QI,i bulk should cantaet tilefll]Worized customer {Cpn::';$ElllJtative regard ~Ilg this requieemene,
2:.2.17 Custom~er-Spedfiiceequ.h:'eme1illts
The, oirg:an~zation shall have records of compl iaace to ~~~a.ppUca;b]e castcmer-specific requirements. For bu~k materials, epplicable custoIne:i~specdi,c requirements shall be docurnemed en the Bulk Material
Requirements Checklist,
'.
2.2.18 (P'SW).
Part SuD,missiio11llWar.rant
,(PSW), the '[r,~anizal~o:n shall cotnp le1te the P:art Suhrn~ss~on Warrant
A seperate P SW shaU be oomp.leood fOI each customer pan nsmber unless otbe["\\'lse agreed to by the
autherieed
cnstomerrepreseutati ve,
partes win be produced. from more than one cavity, mold, mol, die, pattem, orprodnction
I.f prcduction
Tin: specific cavities. melds, line. etc., sbaH ~hen be, identified in the ~'Mo]difC<llv.i.tyfProdnct;i(m
Process" lime ana PS W. or in a P:SW ~Ua.chme.lJ.t mgabza[~On shall verify thatall of the meesuremeetand lest resu]is show cenformanee wiill. customer requirements and tbat all Ieqruired docUmID1lentatillo:n ava~J<lJbl.e <'I!nd,fur Level 2" 1, and 4, us is included in the submission as approprri.uie. A respensible ·oiffidal of tJh.e organiza:tion shal I approve the PSW and provide eontaet ~rrformati(m,"
NO'I'm I ~ One watrant per custa.rner pMl [JJumlbercan be used to summarize marry ch<l!nge5 providing that ili.e changes are a.d.equ8ite:~y docume'ntet1, and rue !ruomi:ss,i.o[lis in eemptiance w:~th eustomer program tim1ng, requh~,em.e:lilils. NOTE 2: PS \,Vs may be sub:m.itted ele(1;mlll.caUy in co.flllP]ial1ce with custnmer requirements .
•
• I_ •• • __ ~I ." _.. • ., •• .~ I .,_ ~~. I •• ,_ --
11
..------~----------------------------~~----------------~----
.2.2.UU Part W!e~mu (Mass) The organization shall reccrd.en theP;SW.e part w~l~t of fhepart as shipped, ffiea:5l!]red<rnrnelq,uessed ]]].krulogmms ~o fom dec:i IJI;1I1 p!la.ces.(O.!OOOO) ualess othernr~se specified by ~.e c~soomer. Th.e weigilwtsl:i.<'!U ~ot iru;:lil!1de,bipp~!}g pro~ocrorn> ~sSlemb!y aides, 01' packagjngm.arerialss Too:ere'[mine part we~ght, the organizadan shan. ]nd~vJdu<linyw,eigiJ[ te]iJJ. mnd!o.~y selected parts. ca101ai~ate and report tile average weig~t:. At least eae part shall be measured from eamcavHy, tool,~ine or process tobe used inprodnet realization ..
NOTE-; Thisweigffil~ Is used to.r ve~ide weigbtma]ysis only :andl does. not affiectthe appllQval proce~. \VbeiL'e.I~e ]$ ll10 ~rodlJctiJomt0:; service requj~em.mt fO\i at ~eilSt tea patts,.the QI~tiOH l :sllOuh~U!se.~.e I!e>rJlllli:redIlurn'her for ci1.I[culation onib.e average part 'W'eightfo:r bL!U..~teria]s. the pi3!(I: we:igbtfie;ld ~s I:'!@t app]ica.b1e. ~
12
The orgam~zation shall fiotlf)r the authO.l;'l2iOO. customer rep.resenlltalive of any p.lall1!ned ehangea
design, pmoe":ss, or site. Examples <Ireindicated in the ta'Me below (see T.a];)]e 3d )_
the
Upon notification and approvalof the proposed change bythe 1I.llJ!thQr]zedcustomer representative, after change iln:plemenmti!orn" PI"AP' :submission J;S required unless otherwise specified
Ta'blle 3.1 ,Exa.• ples of changes req uii!iiiD:g notifieatjon l . Use of other construction or material rhau was used in the previously approved
~L'md or
and
product
P o'.r example, olih.e'i oom1tmct'ion <IS documented on a dev~aUolilJ(permit) or included as a note on the designreeord aadnet eovesed by an enginee .• ing ,chiao e as descrioed in Table 3.2. #3. This, requirement onlyapplies to tools, which due
to theiliruniqae form
teinflaence
0.1"
tffillie~~egrity oflJfue tina] p.mdJuct Itis i not mea.fJ!tto describe smnd~rd tools (new or repaired), such as staodard meesuring devices,
dri vers manual or ower, etc, U pgwad.e means the reconseuctiocand/cr modification ofa toQI. or maehine 'ijr tn increase the
equipsneut.
cap~tity. performance, Or c~a:nge its existing fll!nctioll. This is nor meantto be confused with noemal maintenance, re:pa~ror replacement of parts. etc., for wllM:cb DO ch~ge lR performance is
and post repair verification methods have been estabBshed. Rearr~~_,gementi$ defined as adivity that. changes the sequenceofprod,~C'rJprroCle;ss flow from that documented in the process now diagram. (iillildw:ru~iIi!lS tile :ad!diti.onof a, uewprneess),
Minaradjlllsil:rn;e:OItsofproductio.n installation 'ij,fPI(ltl;lctive M:eillWUa~ ES]) risks. etc.
'C>Q'II,eTS,
~ij'be' expected
equiprnentmay
4. frodll![ctionfiQm tooling equipme~t transferred to til different p laatsite Or from , an additional ·la:nJJt S]te,
I I
a~d.
P'l1@du.cti,@1[I process b:d~I].g: and /<riJli equipnlent transferred between buiMings or fadHt(aes an Orne OJ
more s]tes. 'fbe@Fgani.zatimil is, responsib]efm: approval of ;suprp]ier provided materialand services"
____
,. _., _
• ~ .• I
I ••
._
,. - -
_ ••
~ I~.
I I ••••
_.
,_
•••
, .. I..
I I••
_ •• , -
_ ••••••
I FOfpIOd!U.ot ~lIathas been produoedafte:r tooling has been inactive for-twelve mOI]t115 or more: N olificalioFi is reqll!J]red w!lU;enfhe part has had no dumge in active purchase Older and the ex iS1]~g ~ooU[i[g~as oeeftlmacU 'lie for volume pmduclliolill
II
suppliers.
Any cnafi!es, jncludl~q, changes a,i the suppliers to the orgamru~zatinIlad~eir supplieT~.tfuJal,dlbc:t customer req ulrements.e.g, ,flt,fiomll. function, perfonnance, dJu:rnib!i~~i;y.
measuremeot capab]1ity equivalertt to the old method. These changes w@~~dnOffilaJWly be expected to 9.. 'New source of raw material from new ~r e%]sting s.upp~ier_
have
an
pirodulc-t
The organlZli1tionshaU review and update,. asuecessary, all applicable items ~n the PlP'AP'fi~e to reftecttae productionproeess, regardless of whether OI not the customer requests a formal s1!lbmiss]on. The I:tpAP me shan contain the name of illIe .allliwm:tzed customer representative grl!l:llItingthe waiverand the date.
1. A new part or product (i.e. a specifle p~rt:, material, or (;ol,oF mlmtpreviously suppliedto the
SUbtIDSS,tOn isrequ]red
(in]~ial.release
'{OF
lor
13!.
previously appn)lved
or revised
euseamer)
previously approved P<I:rI: within the S<lnle prod~c1 fam.iJy. Submission. is required to correct any
discrepencies on a previously 8~bhu:ed part, A "discrepancy" can be IeI.... to: ted .. The product perfm:mance .aga~figl tile
customer requ irements
..
•
Dimensional
Supplierissues
A,ppr.ova:~ of
Or c;)lpaMli~y
issues
.1
•
a.pprova~
TeSling,ind.uding
Submission
for tl1sproduct
]5
I..
LE,VEtS
below in 1'aMe 4. ]:
'fable 4.1
Level l Level :2
Level 3 Warrant on]y (and for desi,gl1iatedappearance i~eJJls.a:n Apperu:anC-e Approy,al
tn
the
customer, Level 4 WaJf['a.utand other [lequi.l'eme'l1ltsas defi ned by the customer. Warmllt with prednet samples and. cQlu,1ete Sl)]Ip'portjng dati reviewed organizatio[lJ's manufacturing ]OC-atlOXil •
;;Iii:
the
See ReoontiowSubml!5Si.o.n R,equiremen~s Table 4.2 for exact retenti@ws~bmissioIThrequ]reme,nts for each submiss ion leve 1The organization shall use level :3 as the defuu~t~evel.foll all submissions unless othen-vise specified by the
authorized customer representative, The minlmom subrnission requirerneat for bulkmaterisls is the PSW and the Bulk Materials Checklist,
For Bu]kMaJtec]:3!] rp'ld' submi.sslons, check "OtheT"'in the-Reason fOirSubmission Section on the PSW form and ~pecify "Bulk MaJtedaL" This indieates thatthe "Bulk Material R:equkemellts Checklist" was used to specify the PF.AI' reqllUJire:menls fOil the bulk material and shall. beincksded ][11 the submission packet NOTE 1; Th.eautil,orued customer rerreselltaJti ve may id)entil)<~ subrnissien ~Je¥et,dlfferenl fr.om the
deKau.b level, that is to ibe ~sed with each orgaIDI:izalion"or Q:rgoo]Zl'I!f.h~r1 and CI1M.OMcr parl:r1Lllm.oor eembiaaticn, Differe.flt cU!5hn]1~ locations may8!ss~.gu!I. dlff(l[eil~ submission levels to d\Il.'~; ame organization. s manl1fu.crurmg ]ocatio;mL.
NOTE 2; All of the fOIDh<l refeU(lneedin th iso;oclI:meI!.t may MrC:p.la.ct\ldi by eemputer-generared facsimiles, Acceptability ofilies.e fi'lc~imile'sis to be confirmed with the flillilhod.zedmls'tome'.r representative priorto the firs~5ubl]ilissiolfl.
17
Retenfh):n/Submission
Reqluirelm,enrtsTaltlile
4.2
(Normative)
(NOTE.- :rQ~J:e lists swmwiem and rettmUrm .r:equ.il"emeflt~_ 4."2 Mandamry mui applicable r~lj'uiroments .fo,~a PPA'P' rocord <Iredejimld in the PPA'P man~!21 (Jnd by tM CilSlo.mer 1 Suibmissmn .Levell
&g_uireme:nl
L
Level I
R ~ornpol1.eilWdetails R R R It
["ewell
Le'IIeJ 3 S
R
u"!!'e14
OJ:
.Lewd 5
It It R It R R R
R
Design Record
.fM~roprle~_ry'
s
R
2.
3_
4.
.:S_
- forliH ohr c6IDponen(&i\details El'lginee~ln,g Clm[lge DOOumeilt5., ihny ClIsLmliler E<J]gi"ee~ <"lpp.~(l".a:~, ir~e;ql,lired Design fMEA
PFoceS'~ FIIIl.w Di~ll!l'l1s
PI'OC"Css
S S
R
S S S S S S S S S S S S
8 51 R
'"
oj,
R
R
R
R
'" '" *
*
rtl
6. 1_ 8.
FMEA
Sysrrem Aru'dys.:is StlJuili,es
R
R R R R R Fe
R
It R
,e
R R R R
9-
*
$,
n, n,
13, 1'1,
w.
Reslllts,
S S
R
'" ~, '"
,~
R.
R: R
s
R
R
s
S
R R R
.~
rs.
Hi,
l7, ]8..
R
R
R R
S
R S S 'S
'"
Il'
R
R R
'*
S S
S S
R.
slmll[~ submit
18
Upon. approval ofthe submission, the organization shall assure that future production continues to' meet
an. customer requiremerus,
NOTE; For those Q'rgaoi~liorrs that bave beenclassified as "self oelilify.iI}g"(F'lPAP submissio]1 h'lve] ])1 by ,!lj specific cus,to:mer, subm.iss.iQ.IiI oflherequirrecl orgaJitizartiou"O<lppr"Oved, doeumentation will be coms.lderecl! as C~~~Qmer !lIpproll'llIl u!ll~s the orgi3!l"liza:liQnis ..dvisedetherwise.
5,.1:.1
Approv1ed
Approved indicates t~;11,t the part Of m~,terial,.indlading all su.b-GQ<mpQl:lents, meets all custoreer requiremeats. The o,rgaJl] izationis therdore al!l!tlliD,Oll"ized ~o s~ip prod:llJcctionquantiti,e's of the pr..od!uc:l. :subj ectto releases from t~heCUS~O~1Jjile]" :scheduling Olic6vruty.
5.2.2,
lnter~m A.pproval
~ntefim Approval permits shipment of material for production requirements on a limited time or piece quantity basis. Interi In Applioval will. o]"l~ybe granted when the Q:r-gan iZl3!£ion has;
.' dearilly defined the, nen-compl iencespreventi ngappreeal;
•'
<Ind• PPM
No~e t ; The orga!:liz~lioJ1iisres-roJ:l$ibh;l fQr imple:me:mt~Ilg contaimnent acceptable material is being shippe-ci to the customer. M,lJeri,al covered
r the
Male:rij.a~.mnterim
Approv<lf'
fO'rm., or jts
5..2.3 R,cjected.
Rejected means that ~:fuJe prAP' :SU[II:[1Ilssion does ]JJot meet cllstn.e,I requirements, based On the: producti·on. lou fHn/.m which it was mken and/o[ a.ooomp{l!llY~ID1g docu~.entatitn:l:l"m such cases, tll.e submissieaand/os process, as approp.riale, shall be con:ected to 11111eei castnmer requ itements _ The submission sham be a.ppl1@,ved before production quantities mary be shipped.
1.9
I:
__ •••• ,11 • I •• • _, __ • ••.• __ ~ ~~ .,. ----. _ ••••• ---••• -.~ •• , ••• 1.'" .,--". _ •• _-
PPAP' records (see 2,2), re:gardh:ss ofsuib.m]ss~onleve~,> shall be ma]ntained for the length of rime tba~ the part: is active {see Glossary )p]IiS orne,calendar year,
The ()Ig<lrJJ~zil:tio[i[shall. ensure mat the ,appropriate PI' Arreooros ~mLdurded. referenced in the new pa:rtPf' AI' file, or
from a superseded part
PP AP'liile are
NOTE: An ,example of all!app:ropria~fldeeumenereeord tfuat sheuld be carried f~[1;O,Iard from the ,oldn~e to the new pan. .~le w'OHM be a material certi fiosrion from a. raw f1m.a:n:eiial sllrpplh:;r f'O'F ,SJ.IiiI,eWpalIil: that [l:lpr'~$erib.[)n!lya dimel1istOl1!8i~, ,change from jhe eldpart number, T~is5hould be i4ellil~fled by com:lfLlcting a
PPAP "gap analysis" lDe;~eenl~e old andnew pari: numbers.
21
W,arrant (,PS,W)
PARJL[tIl1iFJ1H,MA 'Ilj'lON
~_M~
L
2b. 3. 4. 5. liS, i_ 8~ '9<J] 0..
hll't Name
Org, rart
SIUlWllij;g,
Ellgrn~fing fiel~~dtill'llii&llw
end [tempart
p;lift fijJjnber
iiI~meillltt'l.num'bcr.
N1JIIDber:
lJeim;g;5ubmittm :
hgJll.eeriJlg:'C!!~!li~'
l'ec.om
odwm.'~:;.e"i">i(!!. ~ ..
Add'lti(lIl:i!J Engin~Illr']Dl! C1il;'ln~ '& U!!i!~f~: Ll.!;tall aud!l;J!Jizgd ~nsill~exlng dUl_1)g.e£nM yet i.ilCOl'pOfllteflin [he dMtgn nloernH.DIll Vi·h11[;dbBre ~1l'IX!fpt!i<lite.d. in th~.1fI3rtSillJ~t'!1r' 1I0d/'tIt 'Gu\l\tlfmmtiit J'u~~hfiSt lVei::=ht: Q,ruKr ~lllm'bef: R.egjilill!i'1)ii~ ~yes,~U[.so ini'lltaiCd by lire dc5igll.rooord, Ell •. r ti1it;ii1iJ.i:'tl.~ a.sfMi!ld Oil !he OQni:ta.cllpwrcbill;~ oocLer.. e deocii1'lill places Ilm.liess OO'Ieii'wiise sP'\ciified. Dy the customer
me cilimurner.
MA~!l!!M~UcBII]lGJ.t.u~-"GJ1i11.!ll!!ulONI
Dam~,~l1d toc!~
a5!i1igm~dlQItq~ nl~i:l!!flII;!lUrjog~iliootl'!.el!)~i\CI'L~e
Stn:ti ..oli.c:{llm;ls,. R~gAilfi.r,~Sl~~m Code·, 'Country:: fur ·~R.'egi:or.L,"eillU Sla~e, cOlIl'It),.llw"'ince. ete, 8'l!l1 B MIIlilrAl M>liFOiRMA,TIOI\II
CIl15llj);ljjtjf
So""" lite
.cUS:'li\OM:~R
D_ ]4_ 15.,
'l6,
Mln!:.and
,division
0.1:
~ii'a!iMS,
!¥fIup,
BU~'f'rfBu~'>er ode: .lEr.t>!tr tbeMlY~'s, ruune.aM ro(fc. C A.,rpplic~~i(l!l: Enter the lllotrcl y~r, ~'cl1i~k name, C'ng;ill(1:, i{l!ns!llii:ssk!.D. ew,
S!lb~~lIi!l~e:l' 'C~miCull1;~m1.cr ,~f
MIAiOERl.!!.L.8If;1EJ'ORiI'I~M:G
"Y~~;~"Ne,"
~r ~.oh.~ ..
IMB&!t)thci: '('IJJ~tDI1ii:Il:, [<lonn~:!: Cir,d'l:: eilh~ ~[MDS" Or ''Otbcr Cu~tm1!lC=" Frn:mIl!"'SS apPfQllri:lt~. If51l!brn~!led~i~ 1]..1DS tQ"du~; MotMe Ij. Version ill. ;ttu:l C=ti.ooDale.lfsl.lb:f!!:lltled via! oit!et CIlSOOll\et fOrm;U:, clil1NtlJ.e&re eliiS!nmer eii:!D.flmlati.on was
received.
~,', 18,
.l"{llymeric
II:it~ASON fOftS'~:EtiM ILSSli:ON Cltec.k. (~,e ~PJl~OiPri.a:t~ ~,,(es}. For bl!lrk !I1al~ri~h;.ill ad~ itLf;i!l ~"ch~cki:nig !Il~ app.ropri3!t~ Mj[Lerial" in t1~~~pilre provided. ILIE.VEIL ~,rlIcD,tify the SUD:rlli!;:;iIIm Ic~cl .re!llue~tJOO. by the customer, tests:.. a~ S'IJBl\US:SfO'i'I LEVEL:
i)(IX,
,SUBMLi$!S~iON 19c
n.
22_
Ji)!I!lCLAIRATfO'N
2324_ 25_
J)6,
Em:~~r!he
i1li:lt.dti-erCif
Enk<r In~ me (in. IJtQLIl:'S) '~~n foc~ltc fi[gni Ili~-@t prnd~tl(m ~li EXPL.\.l"!iA T,IONlCOMl'rl.l!N'WS: f'll)\fiod~ !Ill}' ~x.plllJ!21t~ ~~mr.nc:m:t:!i Ih~ :Su.bml:!15l00 Qn! Re,5UHs Dr iIrI)' (lellr.o:t!oo~ from lihe Dee~~ratiO:IlI. i\ruJ;ch ~d'di~iorul~ infmmatocln as appFOprillf~ .. CUS'IO',M!~Hl T'OOl. 'I·ACG~I:'\lGiNID!fB~R!lND: An: ruSlomet-~,~oo~s i~elLtlliil)din. ~~~m w.ith mOlTS: 16949 ~m:1J any ~-U!;mmN-_~Fihe ~lIiremetit-r;. ~''Yes~ O~ ~~ May IK"I be f!Pp!i~bl~ 00 'OEM im.t=n:1. ~FJ1IHft'li~
OR(M.NmZA:nON AUl'IiiOiRlZEID S[GNAW!JRIE: A respoonsib!c .arS3!nml:i.t!l!1Jomcl~l, after ~·crir)'inliS.th~4Eh~ w..uUs she .... ' wnfb:lT.J]aru:e ~o all cus~omerl'e!!l.l!iN;mellts, ~.d!lhat an~oiFc:d daeumcntatiJOii~,avajJa,b.lie. IsMIl approve ili~ dl!'iC!a;~[Q1I alld [lr{I"'id~ rme, Plume N!!lIIbem:, .FJiM NlJ"mb~f., !I.ml E-m:a:n1 alldl'CS!5.
27
FOR nrSTO!ll'n:RJjLS~t:!JS
le~"eblmk.
22
III
Pari.Submliss~ol1ll Warr.a:nt
0IJIst. Part Nwrober __ ~"'-"----;,..,..,:--
t?. ,
@ ---'_""""
~ __ _
IVa
o o o
D
on~l' @1 ~6
. . '. or a;dCliliMa!'
nanr;r.er, "'~~iMnl,
In:ro1i:ve.>!ban
RlIrurbishmffit.
o lIoolri1ig
o o o
l.e~el:2 Level::l
C@rFe!(;lio.nof Disc~anc'l'
CGnstrueliM
Dt'
IMaterial
Cbal'\ge
P_asing
@
b'j' eustQmer_
D 0Uile.r
items. an tilppe-arancB Awrc.~al
Parts. PrQd~C!
at Ad!d!llooall.Oc:atiDri
- pla;as,e ~
p(OX!ucl SilLffipteS aQ!lI .In!te!;I SY:;<J)OIi1I~ aaJIi! .~bmllte!1 'to ~omef. supporting (data submitteo1i to customer. as; dellned
D D
I TlIB
SY~IM.!$$IO,N r.BSull5lCr
~_!:is~l.:r$
@
few.'
FMf!urad.wl'ling [OCa1iM.
mateiiiaJ andl'fuIl~
~B'.s[!!;
appear.anca
mlsutalD
atalislicall
paQ~8
0 v.e~
(ggl
Q. _ ..• '.
NO
FI~ulre;:,n
I ",ffi./m.'tl1.al~e sa ...m~J~presem'edl !:I'I'!hi~ _ rmentare re~1ive. .. {]i 001 parta..""'hi£h~1e ~'by ~p~~. ~.U.~.!I;S a~.· .~. _. Parl #!(p~1 ?roeess ~ 4lt1 EdJ)lon Requlrem~. ~~er ~JfWmth8.l1fuese,~rn;pI~ ""'-ere ~uoed'a~ !he ,PrWliIC1!OQ f~ Q~ ~ ~ours" ~atSo Ce!1liI1It'!alliloet!!ne!'l~ e\I1C!e1'lM a.{~lJch.~planoe !s. Qfi me and ,a!la\lsble f-or ~-e.w. na...-e· otedl.~_~y cIe~~t1oll!S. fl'OO! ~ c!ee!~J81kln below. i n EX~LANATIOMfOO.MME~ ----:;::;:_
aM nuinbere(!?
D '(>S8
----
D iN'~ @
Date -
-------------
FAX No.- __
-_-_
_
0 RB'j8~'ad
DOli!b!lr
O~le _
Ou~tQmer S<!gml.lure ,
Print N8im8
CFG-~IOCl1
.23
,_.
_. __
I••• ·--·-
.-.~.
IPal1·Sut)miission W,arra,ni
Pa~ Mame S!hewn
00
Cust PM Number
Org_ P~rl: N)Amiber _ {)~~dl _
~_
Chang:es
Oalad
_ _
_
Weight ~gl----.Datedl __
0 Yes 0
C~I~9 Aikl
No
PurchaseOmer Cnanga
No. laval
e~nMn..'1g
C~y MAliE'RIAILS
~bn
F(~PORTING
DYes D
Nc'
n!a
10 ~e$ D No 0
fll.a
o Inrl,ai o D o
o
Level
I.Ched!: at lea~t
,one)
Subm;;ssion
Chan~etsl'
Enginsering
·~Oc.lin9; Tf.;3Mlar_ Rlspla'CSflEm, RelurblsJwnent, Corl,eablcn O'f EII~epl(lney lnactiv.e :.. Ihan 1 year lLeva. fcncck Oiil~} foaling
oor Mt111100al
o SUPf;1lier
Otber
D Change
o
de~n~led ~weara~oe
i!t:ms,
REQUES,TEIL! SUBMISSION
o o o o lLevei o
~vel
1 - Waflfant
an App8\3:lanaa
to (;US10Ii'iBf.
ttl custemer, ail O~i'lilatiM"S
lLevel.3 _ Warran' \'.119 Pfot;lO!1Jil:l S~lmpl'es,and cornp!e~~ su.pportingl data auemlned ~ _ WaJ.raF!1 ",.,LI'IP'I'Odlli:i samples and oomplata suppoIli1ng d~·ta ~·ted
rnanuiacturing criteria.
Iccsllol'1l.
0 Yes D ~o
II1i3lsrial
amiiunctlon~II'~
!Illp9a~e
8IatiIicai
~s
pad(age
I .~Ilirlfril fhal ilia samples rapreserned by bhis: warrell' are repIe!OentaM ot our parts wNch'l~rB matia by a prccaas tha; m~ aJ ProdUC[1OfI PM Approval Procaas Manual A,lh Edilil;jI'1Il'I~l,Jifernen~ I ful1rer affirm Ih~t 'lIlIelill samples ""'BfI~ produead 13.1: lhe ~uction n~te 01'__ - ' __ l'Iilurll. I also ceflifytha~ ~mented ~de~ ad$uctI compli~.l'lQ6 is. on r!le andii,~ailalikl fOr review_ I have nOle.;! ~JrlY ...latlon~, 'I'roon, '1I'IiS, cBclara.lioo m-alow. de
SXPlANAliIOWDOMMiENTS: .
DECLA.RA.iiON
DYes 0 NII;l 0
Qf'!Ilanlzlltlon
Prjnl' Name Tille _
nfa
AulhOr:ll:ed
Signa1nme _
_ _
pilone N'o,
PPAP WaITsnt
OiSPQslllon:
D Appr(>,,~
Rej~oted
DOlliar
Cusromer ,Signa;l!J'ra
Print Name
[)i!!B
CF,G-1001
2:5
_.-
-- - - -
_ .. - - - --------------------------------
Rep,ort:
]. 2.
1.
O!~sti0meJr,art number: Engi~eeilin.g re]easoo customer part num ber; Uratl;¥igg Number: Use the nsmber of the, drow1ng on.\vhicllru the part is shown if different fr·om
the p.llt u!;mm,ber.
'~)[I
4,
.. i 6.f7.
8.
rad
mu.yerCollille:
EIC Level,&: Date: Eng][iI:eerlling change level and EtC dat~, f~;lir submissi.on thus Or.g;lIImzaU~!i] Name,: OfgMlW!Jt.i:OliJi resp@i.c$iib~.e sltbm:ission (include supplier ~fappliea.hleJ. f@;I"
.Manl!l!:f:ac1tl!l!ringLl)lclilltion~
9..
Location
'0', assembled.
10.
1]• ] 2,
Supplie:r:fVenlllor (;ode: Customer-assigned! code fOE organization location where the pi3irtwas manufactured or assembled. Rea~'On~or Subnllission: Check b GXI~e:s)exp~.a.ining the :reaJson for th~s submis.s:l[l'fi.
Or'gan:iizatlou SQiIlIFdng Termre l.iilJfl1l'rmaJtiolill~Ust aU first surfacetecls, gra~ni~g &
SOlif\Cle{s),
grain type(s}, and grain and gloss masters used to check pan,
1.3.PIm~l'iCXhjn·~ JEva~u3t~on:. 1'0 beeomplesed byau~ho]'.iz:ed customer represeetative '(not
~sedby
'~Jillumeric:o@ior [
identification.
[0
the
2I.
2~t
23.
24. 25.
customer-authorized master. MlIIsh~.1!" IUlmli)ell": E~ler alpm.lITIumeric masle:ride:OIt:ifk:aJtio:r1l (nQt~used by Ford). N [Vb:!lf'CF Dat~: Elder the date on whichthe master was approved .. Ma.te.ri.aJl'fYlile: Idenltify first surfaee fin ish and sulbstr.ate:(e.g .• painuASS}. Material SO~I!]iCie: ld.e:l]ttiifY first surface and sl!ibsb'a!te seppliers, Exsmple: RedspoUDow. OllIIQl' EVIli~u~rn.t)ln,Ml!le~ V,lJJllUle~'Cnr~m;3i. 'G~.o.s:s 3.nd.M.cUdlili:; Brri~liance: Visealassessment customer. 'Colm1'Shipi,in:g Suffh:: Color part number suffix or coler number" .Pan [)iis,.rJ\sirtton: 1'0 be deternlliined by cussomee (approved.oi[ rejected):. Co,mmen,ts: General comments by iliLeorgaruza.Uon or eustemer (Op'tiOillaJ]). OrgalliliDltiil@D Sigl!l;amre~ PhQine NOI. &Iil:mte: Org<lniz.alt~.o]Thcertification that the decumeut
infarmatien
by
specified.
Representadve a:pJ.'!ron~s]gll~tu;re. THE AREAS INSIDE THE, BOLm' LINES ARiE~FOR ellS-TOMER USE ONLY ..
26
. !PART
ilL
APP'EARANCE. APPROVAL
REPORT
iAlPP!JCA flO:t\I i{\J'EHI~C!LES)
NUMBeR
PART
NAME
o
o o
1("9'\
LJ
SIH IPME:!NT
1-----------------1--------------------:1
20
VALl),!;:
LIGHT
I
(21)
MET.AJU..iC COU)R
I
~
\::::;;
CH ROMA~l.OOS
OOIIV
I
~ Rll,ILlIANCE SHJPP!N!G
bOW HlGHI LOW .
PART
DIIJ1K
CLE!'J>I
IOOMM~MTS
FI
~~~-4~2~.r.----------------------------------------------------------~--~~~~~
~
(~)
March
I'lHQNE NO.
eces
CFG-1002
AP'PEARANCE APPROVAL
DRAWINIG
REPORT
N 00
F-~--------------~--------~---r--------------~~~~------------~~
OORRECiAND RlE:SUElMIT
PBOCEED
F-~--------------------~------~-------------------------------------iETC~TOOUEDM
.APPROV"ED TO
eOlOIR EVAUu.AnON
METAl-LIe COLOR SUFF~X TRISTIMUI..US 01.· DATA MASTIER MA.,s,TER MAiERIAl DATE TYP~ COLOR
MATERIAL
SOURCE
Rim
YR
HUE.
I Mt4 BU!.I
VALUE
~!(lHT DARK
CHROMA
GRAY
GII.OSS
HIGH LOW·
)3RILUANCi I SHIPPING
HigH LOW
MRT
DISPOOiTION
D.:i.·1
I CLIYINI
SUF'FIX
I~
,I
COMMENTS
O:RGANiiZA iliON
PHOrNiE NO.
DATIE:
AUTHORIZED
CUSTOME.R $IGrr..tATURE
DATE
I SIGNA
inURE
RE.PRESENTATIVE
Mardh
2006
CFG~1002
0:1(
NOT OK
I .131aJrnkelstallemeifl:ts
M~Fl)h ~00i6
~I
II
GIFG~1003
29
~1I1
ORGANI!lA no Nt PARII NUMaER; ""S""U""Ii'F'"",L"",IE",,:ru'iJ-::' '-::-::EN=D:-:-O-:-:::,:R=C_O_DiE~-:~_~
t#;.TE~I,I!!ILSUI"PL!~R;
'CUSTOMER SPECI FlED SUPPLlERIVENlDllfl GOlDE:
~,_P,A!Rlif>4.WE:: I)SSlGN RE.OORIJCI'IAMGE lEVEL: ENmNE,!"J~IN!3! CI-IA~e ,DOellM!: MrS: NGlir otr.:
I
OIK
_jL
____j
[II BI.u'!k)3l
sta:temeJJlls of
<combnma:nwa:1le
~,maooeiPtable
f()r
any~,e;s;l
t~e<s~u:s.1
,Marcil! 2000
S!IGNA11LIRE
31
:I~G!;N::cRIING
CtlANG~
··lr900r,ce8:!lIl_.~iB
-;
OOCUMElN-rS:
UMITS
I,
;1
'II
I
!II
:2006
CfG-1005
SIGMA. TUJRE
:33
the requirements
ill.
this Appen.d~x
Or USe
heJ:eiiofo]" da:riJiclIti.on of .P.PA.P. The requ]rero:e-nt:s, [II this A,Ppencl~x.<Ire inimums m suplplieoemed at the discretion of the orgsnizaaon and/or tih,e custorner,
<l!nd maybe
PP AP
to their :s:uppliers
of ingredients
which
have
Where OE~i~. r'Ar a~pmva'~ of a bulk ma1le:ri.al exists, ev~d~oe of t1h.a~ p appreval
is sufficient as the'PPAP
cll<I~[t
Examples (If bWilik ml~lterialinc~ude" but are not l~ID1IlIi.led. ti():ad.fuJesi.ves and sealants (solders, elastomers); chemicals (rii[1[ses,polisJu~s, aClditi'!1es.tre.a:tmt~ts.oo]orsJp]gM!e-nts. solvents); eaatings (tOip coats, undercoats, primers. p~~OspllaJJtes. surface treatments); engine ecolants (a:l1ti.ft~eze); fa.brwc8~mm end film
laminates; ferrous <lind non-ferrous metals (bUi]k steel, alnmieum, coils ingots); fuundry (s<lnd/si~ic:a• .alloyi o:g materials, other rui nerals/eres )~rneb; and fuel component:s; glass and glass components~ lubeicants (oiJs. greases, etc.); usonomers, pre-polymers and polymers (rlL.ltlbers. plastics, resins a[ld their precursers]; aad perfcrmanee fluids i(n.aIDIsmissim1!> :po'wersteeriag.brake, :refr~gi(;rn~t).
Cnedclist
Checklist
,el.em:ents required are defined by the BulJk: Materials AilY customer'-Ispedfiic roqui rements .':i,haU documented on the Bulk Materials be Checklist as follows:
item listed in the checklist either
Requirements Requ~rel:1[);e:n1J:s;
Dl1lt:e:. Foreach
enter a target
date for
I.
..
..
•' ..
Comments I Cond itions: Idenl]fy any q:l;JJa~jfy.i[lgnformation ee reterences to attached i doeumeres that p:r1;lvide specificinfermation rega[diDg~fue element Fo·[ example, tbis may include spedfi.c formats to be used for the Deslgn Matrix or :acceptab~e toleraaces :£'0 1 Measurement System Analysis rMSA) studies . Approved by: .Ente;r ~:he initials of U'D.,e authorized eustomer representarive who has reviewed and accepted the element Plan agreed to by: h~,en;lify theindividuals (aad their functions) who made and. agreed upon
1
35
••
--_.
__
---
••• _
••
•••
,_
• __
LL
I~"
.,---
Reqnieed I
Target Date
Comments! CormtdJitions
Approyed by/date
De;s]gll Matrix
Checking Aids
Change Documemetian
36
.--
I •••
, ••••
I&r--·
f.4 D'e!siigFtlMaJl!rix
, O(gam~~t10ns slIipplyrnfig bulk [iJ:lIa~e-ria]ge~ernUyeillwilh the cbemlsrry <IndW!n.ctiofl('lmy of the produet d being designed. Usc of these suggestions willarri ve <ill! the same end point of a completed Des,i.gl"l MEA, F
but wid] greater applicabi Iity to bulk materials, Fo<rbu Ik materials, a Design Matrix, when req IIired, shall
F.4.1 lotrjJjIdudi.oB
be prepared prier to deve:[op.JIlg tle Design. .fMEA, The .Desi.!;,liiI M.ll;~[illx. determines the cmm_p]ex iateractions offomll[j,hl ingredients, ingred.ie]]Jl cb,ar<l,ot.e:ristics., p'wdJuu characteristies, process corrstrn]]]Jts. and conditions for customer lise, High impact items 'can then be effeeti ve~y analyzed in the Design
FMEA.
r~~s atrix m
earrelaseseustomer
'.
"
'.
3.
Producr Chamd:erist]cs Process COIlBtrai nts ComJill.o'IDIsfQr Use (customer process eoastraints)
tbeeurrent robustrhreshold range levels and units,
4, Ccrrelate the porential causes to [he potential failure modes using a number, leuer, or symbol representi ng theimpact m :strength of the relationship. As.k what would happen if a potential ceuse item isallowed to go under or over itsrobust min IIDu m or maximum ..respectively,
:s:.
After cempletien of the rankings in the Des]gn Matrix, review the eategcry/eharaeterisrics
for
CATEGOfty.f GH!MAlCTIEIR!IIS'I"IICS
'I 1
I 'I
1 ,
""~,
_
I
I
~~"'r,
~noj .. ,~~
I~' "
'I
I,
I~ ~
'I 'I
.1
2
I
::10'"
I I
~
:.!
'!
'
a
I
1
,
1 iii
D~ I
l'
11111 ,
1 1
1 :
I
I
II
II ~
'I
_.
L1
1 1
'I
I· I.
1
~I 1 1
~ ,I,
I1
: 'I ,
I
~~ 5t;ilwili
I
I
...
1)1~2112D
r
1~
~ F~!.J ~~ 1 I I I ~
'I
L I
l'
I
~,~
I
I
1
~
~
::I I
~"
:i! I I
~
~ I
I~ ~ , I
1 1 ~ ~ .~
ul"J...~r u .... r
I'
'I
~"I
'I'
I'
'I'
l'
I 1
~,
J'
,I
'illdU' ['".
~1
1lii:1g.liJh!."¥
i~~ ' I
I I'
Q g
(I ~
;;: ~
0,1 ~
I,
0
U
0
~
[i
!J U
I]
0:
~
(I
(!
;,.
'I
(I
ii! ~
I
I
1"
, 1 ,
I
1
Q,
I.)!
I~
, '11
~; I
11
, , I I
~ 1
~ I
11
I
!l
2
I
0
'I
u",,",
II
2'T~
It~
I,j
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~I
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a .L
I~
Mai Or Owner Dlssarisfaction (Loss of Owner Lovaltv) Moderate Owner Dlssac sfactiou
(1nconvenience)
8 6
4
I
,I
Desig,n Matrix
as the Potential
From the Design Matrix (if used). list the high negative impact characteristics Causes/Mechanisms of Failure which are associated with Potentia] Failure Modes.
Mechanismsare generally described as over or under a certain threshold, These thresholds define the boundaries of the product approval and subsequent requirements for change notification,
'i
, I I
F .S 3 LJik~Liiboad of Oejculr:r'em:eRankjng~
.e
The foUQwing step provides en ~Memate method for Bssigni.l1lg Oeesrtence ~tings. the ranking scale ~[11 the r!J)t,c'u:tiaJ FaUure MoiiiJ.~andEfftlc:ts: Ana.~ys;i.s manual is d~ffic~]l to relate to bufkmateriets and gene:m]lyreSIJIUs ~1:11 very hJ<wnumbers, with. htU.e di fferemJUauion III Rank Occurrencethe ultimate ris,kTne foHow]Rg matrix is recommended, as a Iepb.ce:meffi[t It. evaluates the frequency of
ODCUUOOCJe OMOOupon. observed evidence the fonn~~at:or basin the design, Occunence Matrix Formulation
.LOW
FREQUENCY
. UDKRA.'1E M
HIGH .
7
Actual Experience
2 3
10
Actua I Experience:
S.imiIat lExperience: A ssumpt ion: Frequmcyraflkjn,g • ,. .'
Obtained from appropriate experim:enbti on on the speci flc~ nal produet eud the
poteFIJlia!fllilme Based
UPCJiIl
lmodJe·.
H~ghis dell ned as - Repealed f<lJ]ll!.m~s Mode:rate is defined as. - Occasional failures Low is defiaed as - RJe;lative]y few failures
F .5 ..4
,e !II rrent
Design. Co wtIr'"Q·~s·
Design Control: Supplementing the FdlU"1il M.ode EffecttS and An3~.ysis manual, bulk material design oO:l1lt.mls may alse ~[!IdUl:k • ,. DesignedlEx.perime[IJts (DOE's) ~ Listeaperiment #'s C ustorner validafian tests ruldlidaJ~ runs - e.g, grave]om1e$e:r pandii. fender customer reference #' s). Test p'w~oe.o]s- list Test Met]]oos. Stan.d!ard OperafiagPsoeednres, ere. Variation of supplier specifications. formulating p'fadice robust ranges. sprn.you,ts (Iist
•
,. •
Design controls rude:!lltifi·ed bya number should be aval.La:M.eso ~halUle relevant coneent of that control cali'!
be understeod,
F .5,.5 J..EkieUboid of IDet.ecttiOin. Ra.n.kWgl!i The next step provides an alternate me~fuod for as8~gnj'l.'JigDetection ramri.ngs. Rank Detection - the ran_k~[i1gseale in tjne r(!!'~e:liJda]. Failil.!lll!'eM.ode a.ndEfteds Analysis maanal is difficult to .re:late~o bulk materials andgeaerally results ]]]J very low numhers with r itde d.i.ffer.l;:nti.at]on in. ~he ultimate risk. TWe<folLowing. matriix maybe used. It evaluates the; Detectiorn as the abHity of the current Desi.g[l Cont.TlilIl~oactua:ny detect a cause ·of faUIillJ~e ndlforfuilure mode based upon Ute assessed a
40
Testing Method R&R'spercenl of speeificatian range (see the M'euureUlent manual) and the quality o f ev idence. Deteetion by Design
COll't~0~ •
>100% 7
9 10
Analysis)
Screening Experiments
:5 No Evidence
DOE (Response Surface Analysis): Symmetric design spaceanalyzed with appropriate statistical tools. Screening Experiments: Screening desD.gJ1 (If ladder evaluation srraregically set to develop DOE_ Assumption/Experience: Informadon/data based upon si milar products or processes. Note: The above R&R limits are suggested unless. otherwise agreed. I!1pon by the customer and organization. R&Rcal.cul<ltions can i.ilhia]1y be based using design nmt.rix~lfrres.hj{)kls. .
Severity Rankings
, Severity of Effect
Very High: Potential failure mode may result in a field failure (9). or censtjtute a safety
Ranking
9-10
7&8
hazard or noncompliance with a government regulation nO). disseaisfactios dUlL: tu t~e nature of the failure. May cause serious disruption to .subsequeru processing of the product or result in the prodact failing to meet its. sales specifications. Willresult ill 3! customer complaint and product rerum. Failure is likely 10 be detected during the customer's final product testing.
High.: High degree of custemer
Moderate: F ai lure C£Lll'SeSsome eustomer dissatisfact~o[l OIiI1d may result in a customer complaint or limitation on shelf Hfe. The custemer may need to make modifications or adJm;tmenl:s to their process to accommodate the material Tile problem is likely to be detected as part of an incoming inspectiOlil or prior to use (4). The problem will be detected duringprocessing (5)_ The problem wi,Ube detectedin subsequent processing steps (6). Low: Failure causing only 11 slight customerennoyence. Customer will notice only slight dererioratien or iilleollvcni.·cncewith tiheprod'Il. cl or processing of the product.
l
4·<1)
3!
2-3
Minor: Reasonable 1(.0 expect tharihe miner nature oflhis failure would not cause' filly rea] effect on. the product or its processing by the customer _ Customer will probably not even notice the failure.
4]
Frequency of Failure
VeryHigh~
fan.h.m:s.
9 - 10
Moderw,'c :8imilar
Remote:
VerylLow:
may
l10ti
is
7-3
Modemte: CO:I:I~15hke~y to dC'te"Cl the e;.llste!!lctof !he r<lihue, bllll n(U lJJlhl .hn 1It.'t:CplllIle.t: testing .ha&beelll O®ffip!eted_ TeMS whh !lh~:ghe:rdegree of Yariabul.itywiU h!lJ\I'ethe hug!ler rnnklng. High: ,Controls have a good ehence of dletecH!ilg ~he exls~'ell'Ce(lht\e defect before the fll!:!nu.facturilJg process has been cerapleted, ][l.Pro~ess~esfing is used to monitor t!ie malllufactuInll ..g process.. J ,4 1-2
dsteet the eX·~s.1J.ent:elfl~~ defeet be:foll>e theprorlm:1 { f~cWj'ing pro.oe£~. ]mpona.11l FciW l'rIIl1~e'rials <Irecentre U~d "'1:8
erganizanon
5pecuf1JiGa~j.o[l~.
42
:1
IIhl'StMiO{lS ofltte nOA\I of mil[e:riill;s.fhrou~. fillal prodJllIC~ foHDW (~.g., ~o.~im Res~1l A, % % U V A intended). are lil.Qt. [le(:~sa:lli!yirnteilld'~d te be Spec lal (:haracl:er~stic-s~
nese
The di f:fewn~s between blllLk p.rodlilC:1 ch!l!r:llc~.eri:Sitic~(fearurlllS ohhe sU!P'plied. md~(:n and the p firml !I~.Hilbutcs (fetltmes of the transformed product) ~hDUld be !m(krsw(1o(l. Duril1g the d~iWl phase, the prud,ll~"t ~l:U:U-'-I~~~I~S~lICS be C-iU:!, CQJ]tr-o~s for fina! prodlllct! iluribu~es. (ltt:Ls doesoo[ imply tool ~hcy :1m:cuntw.~ chm:aoterislics}. ThiIril!l;g i't'l anufaemre ofl:he bulk material, proces.sp~fiI!me~ers are the coneol characteristics. i):uri~g -~l1JJiIsformi"nij)[1 from bulk. :IlMducl teflnal pr-oduct, both bulk
Examples. of prod!llct 'c<'hcarncteri~tics are: \fiscosity. NV Solids, % RfZsin "A". Examples of fLna~ product buil.dl. f'MVSS
product ami bllll:!;;sesn 00 c~otmUed hr eustomer pr-oceS'~ control ~tJ.;arncte>r~sh,(s. Symbols for clIIskm:ter-ld!e!1tifLed Special Characteristics OrgaTliZlltion~ may d:es!gnate theur own hUtrmd s}'moo~8l(I desiJ.gn<l~ Sp6Ci.a~ Chl3imc~gri_s,ticsin. their ",,"ooon" dloe-uments: . .;;,; Fer cllr;.DIiR!:N~.csigru~tedJ identi tied Speci~.I Charac:!erhtics, tfilc cusllI)mer-spcc~fic symbols wiUIoo '!lI5eO,fo.r reqlll:ur'ro C-llS~OJ]}!;ir dlx--IJ:menlalioll and. r-.Bqlllired
Exampks. of eustomer 1T:alllsfo.m1ation process pal"1llll,B<te~ (cmltro] ~.h_(lwcte:r~s~iCi>} are; l:1ui.d flow, tm:lilpCrn~lJreflILIrIlUd iI:)', air
P:w,i:S;Uf'e_
The organizalLOIll
may cheese to
Of "sp" {specut!.~)\
Thecll5~omcr d~signatcd sbidd, inverted delta, dlianu:md, etc, will be used wla requiredper 'C'lli!il~omt:r i.dcmifiCiiiltion.
smppuilg l~boeiLs,
cheracieristiesthrough
I~~lI stli'at~o:n,of the Fl,ow of· Mlater~alis ·tlhlliOlUg 111 ina II Produ et: 1 F Item A (Pain~) Hem 18(Paint) Item C {Sea.h1!nt),
Supplier (rEm- [[) I'l.l.Ilk I!·roducl Cha:racte:ds~ic (Raw M<!~erial) Sup;pli.er (fiel' Il) Btllk Pmi!lm::tCh.!lmRel:eristic (Raw M".:!reri::d) Suppli.er (Ti.er II) BIl~k Prodllle~Chlmlcter~s~ic fbw M,Merbl) P-olyme\l' Vis!IlosHy SuppliG.f {Tic:r U} Mfg_ Control Ch=Dteris~ic
Suwlier (TIe; U)
M:fg. Gon~rrd.1 Characteristic
Org<rni:o:atioFl Crier [)
Bun. Produ~~Ciharac..elistic
0fll.1lnizalUOl) {Ti.ei!' [)
D'UIl: ProdU~l Chamcreristic
Orga:nizalicUl (T'ier
OrganizatioIl
Finilll Product
ffttrribule
44
f .8,_Cmttol
F.B.t Introduction
The Bu lk Material ControJ Plan serves as a mechen ism to: ..
•
Addhi onal]y, this cOli1rtroI plan is not intended to recreate specification and/or tolerance limits that exist in (lither control sources such as batch tickets WOIik instructi ens and testing protocols,
..
Prototype (when
required) - A listing of tests, evaluations and their associated specificationsrtolerances used to assess an experimental or developmental formnlericn, This may be tile only eontrol plan that 'us product spec ifie. Pre-launch - Documentati oncf the product/process control characteristics, process controls affecting Special Characteristics, associated tests" and measurement systems employed during product scale up and prior te normal production.
Pre-launch and production eonrrol plans ma~ be applied to a family of products or specific processes .
•
45
Measurement
variabiliiy
industries (e.g .•
mechanical industries (e,g,., di mension s). Mea.surem.ent may account for 51J'k or more of the total ebserved vanatiolDi. ISO) are often fonowed. The organizstioa need not re-
Smndru:d]zed test methods (e.g., AS n.t, ~S. 'Ve:ri~ bias. 1inearfuty. s~:<Ib.i.~.]I:y. Gage: R&R. and
MSA sludies arenot required where standardiaed tests are used, however ~t is sti.n ~llID]pm1antfor the' organizanon to uaderstand the measurement component of variation lID llfue~e.stmetheds used,
Customer aJgreem;ell~ Oil! the actul3!W requi:!:ern.eijts for MBA fer either aon-standard
supp~ier" test methods should be ,obtained. during tile p]arto.ing phase.
Amry MSA studies :s:hou]d,be app]ied to each test m.e~boo. assoc;iail:eo with Specia~ C~ar:acrejri.sti.c:s, and not to each individual pmduc; measured by the test method, Therefore. the MSA studies sh.ould be conducted as broadly as po:ssib]e across all products wh ich use a particu I,IT lest method. If the resulting variO'lbiHty is
unacceptable.then
be taken
t~, imp[i~I"ethe
The uUnJufacmre of bulk materials consists of indastries wh~ch Spii3!1il !3IV3:]'"iety'0'( product~Qn processes. from high volume P[O~ucts ~o spedaity prooll]:ctsproduced in small quannries nomore than caee or twice per year, Often me production process is completed or already in place before sufficient samples CIIn be re;s.~oo, By the time the product is madeagain, personnel andJoiI equ~pnli.enm Hlay ~ave ehaeged, Also, these processes have mm:l!eroij$ .~npul variables, many C!ontro~W1r.iaJb]es> and a variety (Of prodll:lct variations, There <Irenon-lineaeities - meaningfor example tha:tdouhl ing the change in aparticu lar inp;![:!t The effeetsand rdl!!tiQ:t1l!ships behveen all these vaeiables and conltTds <Ire <I.~SO net U:!;UiIUy '.krn:town without error. MM~ti.p;l.ep:n)cesses are usually interconnected, sOMe:tti:mes w~th feedback ~,[)QPs. There are also timing eonsideratiousend delays in reacnon fime, Furtber, measueements 'of component v<l!ri<lol,e:s <Ire generally ~e5S p'fec ise than measerements of ccmpeaent parts, suc:l1~ha:ltil many cases correlated variables m~st be: used.
MaDu[adurillll:g Sa,!mp~e RecJord: Wheflll:l'~Lk. aterials can not be disfincjly idel!l!llfied OI change over m t]me~ a mal1iufa.ctllu~ng samlP~e[eo~m shouldbe generated, The record should mchMle the informaUon required rolllimuf:ac~~re "ncrmal pmducUoJiID size" rua (let or ba:tch), according tothe final "Preducticn a O;lI~trQ] P]<In" suppO.rtitl,@: the: PSW" Tbis record. provides an "audit trai~]"rothe inf'om!aJt.ionwhich may be steredinvarieus documen:ts and Or electronic sys~eMs. The foll!Owingis the basic irnfo<rmatiO!1 sug.gesred to aeeempl ish thistask: .'
• ..
..
•
.,
47
F.U.lraint
Number
Dade':
1 :1;97'
Produ ct Code:
XXR';1iTI'YBa5~ooat
Formula
tI I.8191 _
I TESTING IINIFORMATION
INarn,e
WVGallr,on % ~on Volatile ViiS:cosity
30 - 40 Sees
Da1te1Time
°iP€ir8ilOir
Inili<li~s
Amt
Amt
Loaded
I Lotrfan'k #
12151979:35 ,AM
iResillii B
501 l.bs.
CD 618
~~~'~n~~~ ~ __
l. r- -~.---~ ~'-'-.
.~ _.
1~:~~ __ l~o:~:-1~~:--1~2~5~9~~::5_~ _
:11
._.
__ ~-
~ -_._
-'_'-,'
~ -._ -~.
.. _ . _
~. __
'~
fltUNG
INSTRUCT~ONS
250 GallTote
25-Mi.cmn Bag
48
Paint: Mig !Master Sample Recanl .: Product Test Results, xxR -yyyy Product Name: White Basecoat MarmJacmring location: Plant # 1
Batch '# Batch S.ize
~
WtJGaUon
TM[lOl
W_50-
%non~
Vo~a)tile
Gallons
1215/97
lMD04
10.70
Vi~c:osity TM003
Ijlni'ial'
30-40 Sees 34
OK
Certificate of Analysis
Material Na:me:Filmfonne:r Material Code; Resin A Resin lot/Ba:~ch #: AB345
. Specification Requirements
Property M:U[l._
Result
% Non Volatile (TM004)
:51% '7
61'% 7.3
58.. % 8 7.2
ph
(IM005)
Certification
Signature:
Date: ------------------
APart Subm.i.s.s.ion Warrant sb;a]] be prepared andsabmlned for apprcval when required by thecnstomer _ ~f a customer agrees dlSltP.PAP ]S ]]JOlt required, no warrant needs to be prepared. The information required by the Snbmission Wam:nt whicl"l does not appLy to bulk msterial (e.g., part w,ei.gM, dimensional measureruent) does [lot Heed ttO be fll1Ovided.
I ,I
For those organizatioes that have been classified as "self oertifying" by a specific customer, submission. of a warrant signed ooly by the organizationsball be evidence of PPAP approval, unless the organization is advised otherwise. F or a]1 other Q<rg~nizati!on-s,evidence of PPAP approval shall be a warrant signed by both the authorized customer .r'errese:nMl.M:ve nd orgamizll.tioi.l1om: ether customer approval documents, a
49
Most ~;II:00Il,lCtS w~U aeh ieve approval prior to initial. use. I.Ii1I 'cases where approval CiUl!110t be ebtained, a "Bulk M,a1ieriaJ Interim Approval" may be granted. A form is shown on the faeing pege; other forms !.1I,1!ay
be used.
t.
•
BULK MATERIAL INTER.[M AI"PROVAL .FORM
N8m~ IIl5sj!WlOO to T[![)N NAME:
COMPLETION OF mE
ORGANI:L4 PRODUCT
Doeuments.
OI;8lU1i7..l!!ti!lllo's, 1I\I1i!L!lr\!lC!W'IDg
2. J.
'It .5. 6. 7. 8.
NAME::
Tb~ Orsami7~~ioo·~~igl1!l.wd
CODE:. Coo.c' (DUNS, number
lEn~[neoJiillg
R,~!~8S~
cquuvaknl'
8S!>igll.~d~o~lte
CuS[WllI~['S
lJut!i.I~ whiebtb~
fe~C:!I!S~(!,
SITE.:
Pbysicaliltl.drt:ss
Plll:!l;llall~ ordee,
Custtl1m:['S
Par! Num'ber.
er nlJjrTi\~r
ldi:<nlif'yin_gtbG fQmlula.
in
i!cmil7.
9.
10.
!l:ECIWVED D.n.E:
CII!llt~IIlCr
Us.: ()Q1y.
Reprcs.m~i~.'~), OrggliZllltioo expJres,
I! •
12.
SUBMISS[ON
noS) I~
is required
.1) ~ll.bmit
to as d~fHMd hy the
Cusloll1!lCr.
13.
14. I j. 16.
,[MCK[NG
RE-SUBMIS:5[ON ST AruS:
for each Jrum. enter .approptiate coo.r: (NR - Nat .ReCjl1ited -.'\lfPruvro, •.A
OF MA TIREAL AUTIlDRnZHD~
1i'.PR!D:Dl'Cl~0}.1 r~eilit)'.
TRIAL .AtlllHORtZA.nON:
Ul. 19.
20.
REASON(S) FORUNT6RilM APPROVAl...: fudicMe rcasen for InLieiim Reques.~ iSSUES TO .B[ RESOl.VED', EXP.EC"I"iD COMPJ.,ET~O~~ DA1iE: rn:g,p:i:dim_g pn;:t!blem iml~~ andfl!JJllL<lh a d2ltoc for pmb<l~m :~s.ol~.ti,on,
F'm eachitem
~J[pI8IWJ!b[}.TY d>=lail~
ACTIONS TO BE ACL"OM fLrSIiIED IJlJRmG O<Il'ER.1M PERIOD, HFECfIVIE DA'il'E: Wb.ilJ(i~ bei:rng; cl!cne kI ensure ,or[~!iv,c pr'OOl!JA:t i~cOOllllin~d, .~ ·\¥:rn~n the 8E~iI;Jf!Wi·1l$ im,pI~nn(>nt~.!lllC E:><h trit~ri:aJ n~o;ssat'}' .~ ~n.(j need .fOf ~Gnl[nliimg theaeticn '00" it's r ndividua] elernems, PROGRESS REVI!EW io.tOOmperiod, [lAn· WHAT .DATI: Updalte 11m proW~!i of problem reselution,
SJ=m.c<rl!Uy ~
mldpooint
[tOO'! ~ss~ce
site, SU6MWS~ONS
8g<1i:rn?
'r A K~~O
and A~lru:mm:dI OrgaEl!iGr<J.titmll!f:liiciaJ~ ensure rompli.axmc l'IJ'toe 8bQ.".,Cm~U\ttcnc-d 8clions~n(i! 1:0 phenenurnber, :mdJ da~. 2l!ndi dat~.
dll!.ws.
25. 2J6..
27.
mmlC, p:h.o:ruilliurribcr:,
En.jl.im.eer'~ ~~1Jure,
28.
Onb·
511
PR.o.[)UCT
NftJME: -----7'-.;-:""'""'------
SUPPLIER COD:E,:
MA~I!J~., SI1~:
----"'"7""",..---',.._ ~
ENG. SPiEC,: __
FORMI!JlILA DA
~?---'--~~~
__
PART #: ----l.".___.L:,~~-----
rs.
~-d~~~
__
(~
A;pprolV:a.t_
~sl!!lts:.__
-,Masferr' Sem;p~~:_~~_
Ap:p:rovaIRepCItt;
SPECIFIC QUANllTY
air
1:----"'(W)._,,_~6"'_··
tt:~~~~_~~_~L~~
ISSU~S TO BIE RESOLVED', EXPECTED COMPLEIUJN D.AT~ (;;\ (CLASSU::Y AS ENGIIINEERING .• DESIGN, PROCESS, OR. OTHIER):_O~19,-··' ..
ACTIONlS TO BE ACCOMPUSHED
PROGRESS R:EVU~WDATE: 21 'DATE MAIERJAJl DUE. TO. PLANT: 22 WHAT ACTIONS ARE lAKUNG P ~-E TO E:NSUR.~.THAI FUTURE SU:8M~.sSI "s, Will CONFORM TO BU~K MATEiRi,Al. PPAP REQU~IREMENlIIS.BY THE SAMPLE ,P,ROMISE DATE.?
S'l!J~I?'PILIER tA.llfTHClR!ZEDSIGNATURE)\....-_..J".
(PRINT rN!AME)
PHON~;, _ _
MTE.._:
_____"V~~"-
... l
PHO:ME
FORMI
~ __
_ _
it.:.
ORMULA DAlE:
RECI:.IIVI~D BY: EXIi'IRATIUJ:N 11[)1A1E.~ RIE~SUE!MISSION
_
_ _ _
TRACKING CODE:
DATE:
STATUS:
Controll
t,est Res~lts:~~~Process
Samp!e:~~~~
SIPECllflC QUANTffY
OF M~TIEIRIIIAlAU1HOIR~Z'EID(IF .APPLICABLIE},:
~~~
#:
---------------_
ACTIONS TOoBEACCOMPUSI~IED
PIROGRJESS iREVIEW DATE: DATE MATERIAL DUE TO PLAJINT= _ WH~:r ACTIONS ARE TAKING PLACE TO IENSURIETHAT FUTURE SUBMIISSIONS WILL COtNi"ORM TO ,BUllK MlAIER~Al PPAP REQUI~IREMENTS BY THE SAMPLE IPIROMISE
DAlE?
---,PFtOHE:---iDA1iE:· PiFiONE
_ _
----
ImEIRIM
:52
• • 0' ~ .-_., -..... -' ...I.' _,. _ _ __~I
r_ •••• --
process controls. 'PAP does no& require a PoooessFMlEA or Co~trol.f]f1[!1 ilDorth:e CIl~sto~eTpr(u;:eSJ;_ Since thep'f{uiu.c"[ is t frequently two products (bu]k and fini shed).tjh_e:.re I:S.lI shared responsibility for~befi[Ja~ pWduct attribute,
FQ]'example, percent solids and viscosity ofa bulk coa~i~,g which impacts the final oOiHltiug's film build a~tribut:e. may be affected by the customer's mix roorn peH:e]]ls~)l\!ent redll.l:~lion. The percent reduction process parameter may therefore, be controlled to aid in ccntrol of film build. The process stepsat CUS;W'I'l'iLer p lants !H<ly be matrixed v,eFSUS the Special Characteristics [determined jioimt]y by the organization and theeustomer), Wl\te:rebi.gh impact is evident, those precess steps m.ay be analyzed by the ProcessfMEA mctbodo[ogyThe Special Cha;racteristics maytJhen be determined, and beiacluded in a Control f]an for the, CllS~Oi[fiet process. These special control charaeterlstic itemsmay be moaitoredand oonUIDIuo1!lsly improved .
CJ~ntro~s bu lk materials. for l , Assernble cress- funct]Om'li~le-am.g, of customer Include apP.fOp:r:ialte@FgaO]zati.onepresesuatives r 2.. Seleet Ciwmpi Ol1lS for each team -these'<lirelhe engineer, area superviser, ete.),
4. Reviewthe attributes 5.
On
area"
~1i'ganjzat~on'sDesigfl Matr.ix. and. Design FMEA items fm applicatirm functions which have been dcs]gn<lted. <IS Special Charaereristics, Alsereview the desired final product
for ]~eiIDs. eed]figc.o[[1trl].I . n
<I
fr1;Dm#4. develop
53
6. 7.
Construct a Customer Precess M.a;lri.ll:., using #3 asthe KiP. aad #5 as the side ef a matrix. Performa Customer Process fNffiA, focl!sing on the b.i.gh impact customer precess areas whicl.lI.impact the Special Charaeterisfics, (Do the .PFMEA per Appendix FJ.
8. Determine Sp~dal Cfuara.cteristi.c-s from the CustomerPlrooes;s. fluid now, gum. distance, etc.). 9.
Prepare a Control Plan foreach affected customer process area- The plan (~tiIi:z!ecurrent Oa.im.lerCh.rys~e:r,FQrd" GM A.PQP gu]d!eHnes)mig:ht eontain at a minimum aU process steps containing Speda~ Charaeteristies, and recm:daU Special Ch~racteristics, bya:ppr@priate means (control
10. Monitor
cham,
Painl%
reduetion
I
Gun
atQm8!]t
G.!:R
f,aJ1l
Gun
Gun
distance 1
ca:p
;3 2
tnr 2
22,
Booth lem.]) 1 1
900th hUmJ.idhy
Bake
temp
3
:1
3 :2
J.
3 .3
2
2 3 3
1 I
2 2-
l
~ 2-
2
2.
]
:3
!.
.3 3 :2 2: 3
l
II
I
I I 1 l
l 3
.~
I 2:
]
54
•
of30 tires ..
-'
An organizati 0]] s.upplying tires shan omn!p~y with the reqllir-em.e]]!ts ·offP'AP.
Trois Appendix ]SI!O be used as glllid;am:,Oe for- darificatlon of requireme,nt5 the authorized OEM custemer representative.
unless etherwise
specified by
Performance testing. based uffi.loTII. design req;ui~remenrl:s used by eaeh OEM b) select Ike construction (technical approval), reducestheneedje repea,t all tests dUf.ing PPAr. Specific I'P,,"P confirmation tests ~re speeified by each OEM.
Ie; ,,2 G'1lII iideUE1Ies for P'AIP' Reg Uli fiem,ents, (Refe!~erlce Secti £1 [lL2 jJ
J
me producriontun
fOf
NOTE I: The' ebove definitioa applies to all uses of''s~gllificamp.ooduotuolJJ rua" wfutillinlPFAP.
NOl'iE :!: The typical deve·.~op.lillf!in.lof a new tire des~~:ninvolvesmul.tipre builds of iii. s~:lf.IU qMal1!liliy of tires, Most designs axe basic to the o:rganiZ<lt]O!lJ'S precess. for the tire ][Id!ustry. ~PAP is tylP~ca.Hy complewd wdh om !1Ilih!!~mold fir molds. and well in ;wv;l!l]ce of castotaer feq1l!'ir-emellts for large vO~lIme
prOOl)ic'l.iol1NOTE 3; "The rpAP fOlr tte tireindustry typically 18 derived from. 1 to 8110ms of tire curing f'romtbe appr;(}ved, pr.oo.uct:i:O!lJprocess as 5.~jf~ediI! the mg,m~zat~:o:~.'·s ,oon:lro~plan. prA:IJis not required fo.r1.td.ditio[Ja~ molds tb<Iftare bmugl1!t on line in the approved production process, An additional molds shall be certified by erganisation's ~~te:rnal cernficadon criteria. 3!1'1d docu me O!UIt i0 r1,
m.e
NOT.E 4: F or tires, tOQ:~i.ng is d!efl.n.ed. s jhe tire meld; Tbi.s deli'in:iltlo[l of~ooH[lg spplies to .a.~~ a uses of "wo~ing" within P.PAP ..
rsw
to
Re'Cords ofirems submitted (8) and retained {R} are maJ~~taJwneda:t eppropriate Iocanons des~gllaJtedby the
A[l oIgaffi1liza:t]on sll(llplymg~o s:l[:IiJ:sc:ribh:l:g tneek OEMs shan o@mply wit/h. tili\!e requiremeats J]] this Appe:[!)dix or use guidance herein for clarification of p'r AI. Toe requiremeets ~rnthis Appendix are
minimums and may be :s~pp].emei.ltedat&e discretion ,of tbe '@F-gll[l]zalt~@lnand!for eustomer, the Ap'pUe:ability
•
(seePege I)
[We
<lidded:
ill
Feature BasePrecess or Part N1:l!mber Generated compOW6:nlt;s1.tJit'i r,'AP' qualified using the highest eontent configuration to' qual i.:fy the master P'8!rt: umber, AU other configumtion:s.may n be approved with the submissiQIl ofaPSW link:img,(be Jflewpart number with the ma;swer part
Humber. f 0:1 bulk mll.teTial and standard cataJog pans'j the Qrg~n izatiO<[!J sl1aU formaUy q~aJi.fy the]F product totaeir desigareeord and submit aPSW when requested by the customer;
ltlll 0
Sig,n~fi(;ant Prod~etiolil!
(see 2.1)
It isimportant that adequaee quantities of pans be manulaemred dll1nng this mn to confirm tibequai.ity <lind clIp13Jbi]iry of production pmcess at: rate prier to full preduction. U is recog.z~dthal in low volume app]icaJtkD~S,.sample sizes as small as 3,0pieces may be ll~inzed forpreliminary prooess capalb~]if1y studies. When perform ing the S~glliflc:;i!m Production Run. sholLl]d be considered and tested wherepracticsble, related issuesidentified within the PFMEA.
am .a:s.pec:ts of '\{,aTI<'lIbmuywldliin me
Sample sizes m~~$tbe discussed and agreed (0 early in APQPprocess. UpIOjected volumes <lire low SIO that 30 samples <Ire no,t attainable p.ri.o:rto pT(lductiol],i~terinl rpAP' approv.al may be granted. A dimensional report witih I00% inspection On special eharacteristiesis required dillri.ng theinterim period"
Oaeetbe 30 consecutive prodnenon samples Me produced, measured accepted, then the interim appl1Qvalis changed to approved_ llimel!l.siional. ResuUs, (see 2..2.9)
The Oi[-,ganizat~.ollshan snbmit, as part oHhe r.p'A._[) palicl:age,. a copy of the d:mw.ing w~flh each dimension,
test. and er s'pedfl.caJUon Identlfied w~tIDi aunique number. These WiD.iql1.le numbers shall be e,noored on~~J'llle dimensional or test results sheet asap:p~kable> and actual resultseatered onto the appropriate sheets. The o'[_g1l!nizati.o!1 shal] abo identi.fy tifue print zone [OF each. D.lIJImbered chM<I!creT.ist]c1l;5, <I!ppi icable,
57
.,-
-_
.... -- - - - . - -- -
or ,. conduct an ]liLiUalprocess cap~bi~]ty swdy wiuha. m[[IJ.[m.1ll:m 30 producti.on pieces end maintain of SPC connol charts of the characte'Fjstics during production,
F Olf s:pecruOlJ] characteristics thateaa be studied using variables dat~>the o[ggiza,t~():IIlishall unlize oneef the following techniquesto study the slabiUtyof the process:
..
SUbgr01rupS.
simUar process run on the same equipment wifh prior customer concurrence. Muster Sample (see 2.2,.15)'
The mask', sl:Iil'Wlpl sfulal~be retai ned afiler PPAP approval whecmls'f,leci ~,ed by the customer. e
Part S'UlJ)l1riliss~,w \Varr:a.~U (see 2.2.18)' When specified by jhe custemer, orgasuzations shall use the Truck liil~;b.l!stryPSW (see the Truck Industry
PSWf
Orin
thatfollows),
cilla:!l~es-
58
•.• , .... ~_.I.I •• ··•-_. ~--.. ••• _, ...... -----•••• ••• -.-.... , ,--
3_
4"
if applicable,
[)'<ite,:
:5.
6. 7. 8_ 9.
Enghileedfig
Additional Englneerlng Changes:bldydeaH authorized engineering cb<l[ru!W decumests approval dates not yetincorporated on the draw:ing but wh ich are iaeorporated inthe part. Shown on Drawing submitted.
Part weight
Number:
]]u.m1oer being
actual weiglJit
lO. Checking Aid Number: Earuterhe eheeking aid number, if one is used t and
] I. ]2. lts ~ngineering Change Level and Approva] .Date. Orpniz:'uion purchase order ..
WEIS
ORGANIZATION
ihe manutacturing
b::ati.(m on the
] 3. Orga[llzam:lOJiili Manu fa.cru.ring Address: Show tJae: complete address of the .loc;1.I,t[on where theproduct
manufactured.
Or
SlTIIJNnSS~ON~.NFIORI\1iA 1'ION
eperationsgtoup,
etc.
1.6" Appl ication: Enrer l:fuemodel year, vehicle name. Or engine, transmission, l1,
REOlJEST.~O SlfB.M""ESSION LE''El. 19.. Id!entify the sUOro.iSSlOIDIevel requested by your cusiomer. l
requested, DECLARATION
20.. Exp]anatlm:a!Conm:lent:s: Prov ide any explan:.uory details om the; submission ]'esu]ts ;additk:rtm! Inforrm:aUon D1;3!Ye attad.lod as apprQpri<lte_ b 21. Enter t(he u1llImber or eede tJ1llia,t ~deIDtifie"sthe specific mo.~d, cavity, aiirnd/or production precess used ~D manufacmre the semple parts. 22. The respong~ble supplier officia.1. afl:e:1iverifying ~hat the res"WID[show confonnance [0 an eustorne» s reqjuirenlJJenrnlIm:d that a]l required documentafica ]8 available. shall. appreve the declarsden and
provide l'ide,Phone Nlllmber. Email Address, <lnd fax. NlLI![i]!1.be[·. FOR, CUSTiO!\.'lEIt. USti: ONt Y: Leave blank.
59
__,Q)._;_.'._. .
Engi~
O-.ii'ig ()~;j,I.t!<d
__;~~~
(5"'\..• .
Ih'IBd
.::.A~11..1l· •.;". •
031£!d _~
__
IIH:FOru.tATT.ONI
Customer
~I!IoOO
OlllStomer COOtact
~Ion
®
~QH
Dyes
o D o o
(~~k.
~ I~a$tolilt!')
D DO
~,to,
O~
Goo;;iJ1jJJ;;~OO
or Mat!3ilial
o o
p,!§!'w~
al A.ddiOOmII
!l.OC<!t!oo
Otht?l,~~~~if:!'-I;Ie!Dw
~ ~~
2 • J,'If~nt
Wiln
to GU'5\J;!r:Mf.
:2
4.
:5
Il
910
~~
DOD
~~
11
12 ·13 14
;.'!!
0 01.00 0 0
~i~ no flPer~ljJn~ ravi8Tll'_
al:~
15 HI 17
18
19
$yppW$,m~n~~duri!'!!:lIOC<'iliO!'l,
~eCbAA;i!!,TI!QNI
Ir; (!lis; ~
~fe ,"~~.fI:'Om ,~~ 1m documented at
;jr·e~i,..-e¢l_·~.atJlI male_
1M}
~~er 1I103J!l1he, ~l
(ii')
Ol'fl~nlzalJooAuthofiz.ed,~ru[B,;_,
_
FaJ(
O'Jle
~""--iI1
-iI
~ ~
I'ot!;):!;!"
CI!IIS.TOMSR.
O5lE: ONLY
DAppf'rl"\!Ed
DR~
Data_
I
Dlmlmm~1
THE·l001
I I
60
TIUct; lndus1Iy
_____________
___________
Rav.
Ei.ee~1ng i)r;;rhll1ng ChallQlll.i!!l\'~'I _ _______ ~ ~ !P'un:rn:s:e Order No. ___________________ SI!iBMISSf.ON INFORMATlOiN
_ _
W.~(kllI
~t~ __
Customer iNamelDi'li8iDJl
dm;10meli Contact
o o
I!!ilial :Sllbmill~ =~gi~~9IC~~s, fcdl!lfl: TraJSfer, Replecernen!, Cooac1ian of rusc;rep81lC)' T~I Imaelhtl ~ llian 1 ~r RaMbishmcnt. ~diLiOlIII!l
I
,
D D
o o
o
o o
Gnanll9
to Op.1iofla! 'C;onsirLittioo
proce9Blng
01 M'a~aiial
Souree CI1~nge
at A;:kiliollEi'l LDCattoo
o o o
~'!<')!
i'l~~
~bmii~>iJ
'Ib ¢uSlom(l1\'.
~~
t.Uibml~ed ID ~U!j=er,
~DDDDDDDDDDDDDDDDDDD
Level 5 . Warrarn ."ojh produ<:l ~p!es
~i'i~
'1
of
is
S9
III 1-1
~plel'!!
8~rting
CECI..ARAlilON ! ,~!lin[il ~ plOlb:tiom Ihe semplas re;pi!eS£fliEll!l by 'lt1i811!'8rrili1~ arc ~pr,~(;'!'iI~io;e, ,and ,ilr", ~ 'froM,
$~i~
h~e been made to !M spp\ol:aMs 009'tomer toolilljj \..tth no ape-Ja1.ions,oihBr ~'J,;a., 't!tM rB1Jul~f'
Organization
AIllh~e>(!
$lfl~lUre::.
~~
l)ate
-1
Phone No.
5-i'n~il
Fa~__ -------~
o D
0 fIi~eDte!iI
f'OR CWiSitiM
Comment:
6]
I.
2,
To: Customer
Customer:
O()illll~ct name,
Customer n<"liim!e.
3 4. 5:.
,6.
Org:amb':a:Uon Pert Number: The salable part mlumber to undergoa product or process c~ange. E:n_gi]J!eerin.g Roevisio~ Level: The Org<lnizatio<n,dial'!N~q revision le-.... and. date, e]
Customer Engineering Part NUimJher:
CI!i:!llome'F
Rev]s]onLeve]:
r.
8. 9.
ORGANlfZA.'fJON MANUFACTURING
10" Name; ]npn~ t:heMme andaddress of the oompany thatis/wi U manufacture the component
l 1. Code: Customerassigned
12. [4. U5. .~6"
13" Change Type: Check all the properties that marybe affected by the cbange. Check iftbe oF~a[li.zation Or Customer has d!esig[l respon:si.biUry .. wi U haJve O:rgarni:z;ation Chang.e TI~at May AWed End Item: Check eppl lcable boxes for .aprodm::t change . CompletioIlllS1!1bm]ssionDlI;1!:e: s,timate the date that the Organizeriea E
O!E,CI..ARATION
] 9" Expla]lJ1lJtionJCQmlI!e[lts:~ndude
20.
2~ " Title: Business tiUe ofthe personsigJ!lin,g the declaration. 22. Business Phone number; TeJephoil)e DUITlbe:i whereperson sigrung the decleranen csn bereacbed,
23. 24. 25. Business Fax m!illm~be!i: Faxnlilllmoe:r of the per;SQD s~gni]]g the deelarafion, Email address:.E~.ma]l address of'jhe person s~gllj]lJcg(Jfiedeelaratica, Dale; Date thePPCN ~sSiigned, clarification is
Ot'her required ttlt=numbeJ'ed document in.f().nl'~(lt.i'o.l2 should be self--.fu"ltpla~atory_ Iffurther necessary, please contact your ,c!~tomef" r-epr-(tSrmta#ve.
62
~ - - _. ~ - _ ... - . .. ..
,
__
• .,...
_.
••
_-
_.
--
-_.
--_
•••
'''---,.
Complete this form .m!! email fp j,l'(Wf CiIS!ofrnlr ,organizatilm whenever Ci1s.~ome,rtIDtmoa,~f()rr is r-equjred by the PPAP Manum in' Tallie' 3" 1. V:our cuS1Mie( wm~'sporr.r1 Meli: m~1l an ,acknowledgement ami may '9q~!ist .uJdilionaS change
ckiriffc-atkm' orlPPAIP' s!!l'bmis;sfQn ,Il8qailfl&m8Jlls_
io:
0I9af'lizatioiil Pari N'u:mber:
---==,..,0 ...
5
(3)
o
"""-" _ _ -
0)
Appli'catiQn:
_,:0~1I .. ..·~·
-->®-l O""-.>-,
I
~allN:~;
Str1e:et Address,:
Code:
~~~1~1_.
Cily,
®
o
1~)Clpecwdl p'PAJP CO\l!Ilipl{llJjo,1Il1,Sl.lbmislSiol'l Da~e:
®
Organization
D D
Appearaf1loe
®;:,,·~.'6;;;...· .
..
~_
sa!'l1!ple<S \'Ioill be manUiract\! red ~$il'llgl~he revised prodUct andiio:r prooess and v~;ijtiedl. dimell1lsiomlll chaliilge. appearance (m~lIiiIge. physl'cal propelity chan:g€<,~unotiQn811!f rm
peliformance
or :such
oom~lianoo
is oniire
INJO:
__
~_~_
THE-1002
63
Con:tpfete Bl'is fQIiman.d emOlilliO }'Our cU$/omer o.rgarozatiO'll iI'L!.a~.ualin Tab'e 3., 1. YOfurrc~stOiine! respotl'diback w.llh c.larific-olWn or PPAP $Ubmis.sio~ mquire,i'l'J'€Jits.
wit,
&. Zip:
o o
D Customer D
OrgaimizaiHon
'Chiillilg;e
iype
Desigli1ll R.espollsiblU.'ty:
D D
DimenStofial1 MareriarcS
iFUII1Qjjio:nal
APlpearranoo
InEf;lA~ON;
I mer,eby certify ~hat ,reprresent.alive5ampl~s, Will be manu(aotured u5'lng !I'I~ ~evii5ed product andJ'or process and vermed, where apPMpriale, ror dlmens.10na~ cmngra. appwranc~ dhange, physi:cal propoe~ change,. IUllcliooally lOF pe:rron:rumDe 81ii1[11 urab~ity_ ;13150 certify !hat. d\)oomei'ill~ d evidence ,oj' SiUolfil oompliai'liOO is oi'lfile and avat'abl~ for olls!ome~ rell/tew.
iITLE: .
DATE: ~
~~
Mar'on
2006·
THE-1002
I ......
------~
....
__ •• ,
••.• ,.,,
•• _
•• _.-
,GLOSSARY
A.CCREIDITlE.o
is, one that has been reviewed and approved by a ru,uionall.yalternative, a customer recognized accredisation body, cornf()f!ning to ISOllEe Guide 58 for c~libra~lon OF~eS;l.Ia!borntory aocredrta:lim to ]SOllEe 17025, or national eqnivalerr;
LABORJ\liORY
~S:8:]]j
A:CTIVE PART is one currently being sW!pphed (0 the customer for or.igl[]l.<l] equiprneruet
applications,
service
The part .rema]rnn,sOJ:c,tive ntil tooUngSlcrap aUltholjization is given lily th.. aiPPIOpnare u e custom~.r aotivlty.for p~ with no cestomes-owned ®Oo]illg Of sifuati(m:swil.ere multiple pads are maJde fm'm the same tool, written oollfinna!t]on frtDm toe customer PlIrcihasln.g a.ctiv]tyis requiredlo (k~a(;tiva~e a p~rt. NOTE: For bulk Inate:ria], "aetive pil'Iril." refers to the bl!1!]k material contr.ac:~tHl, not the parts that are $ubse{Jjuemltly produced from tbat maooriiat
APPEARANCE ITEl\-~. is a product that is vis~ble, once the vehich~:is, comple,ted. Certain euseomers will ~dej}~ify ~p.pearnfice items onthe engineering d!rawi]~gg, In these cases, spec ial approval for appearance (co,1o]", grain. texture, etc.) is required prior tio produG~ki<rlpari: suhmission.
APPROVED ]8 used in PPAr ro mea]il~hat the parts, lIIa~eF.ials. <lndiGr related documentation (or records submitted to, ()iI" reviewed by, Ule customer) mee~ an custom.er rl?Q!uinm:Jeot<;,After approval or interim
approval, the o.r,gallizatien is apt:hOT.ized to ship product as d irected by Ute customer. DR1\. WINGi:s,an AP'PROVED
'etnginee:ring cl:ra.w]]JJg :sigmed by the engineer and released through the either byindl.llSl[')' standard specifications (e.g .• SAB,
custemer's system.
APf'ROVI1:U MATERIALS <Ire materials gevemed ASTh1. DIN". mSO) or by customer specificetions.
APPROVED
of .respo]'JJs~bHiryfor the qUaJhty of [hal product, A.1'TRIBUT.E DATA are qualitasive data thal call be counted for recording and analysis, Examples
inelade tile pre,selm:c:e absence of a required label. the wFlsla~.rualiQIliof <1]1equ ired fasteners, or r AUl'HOIUZED
ClfS'TOMIER
R1EPRESEN1'A
T1VE(8}
having
appr,(D'vaJ~ aulhor:l.ty en behalf of the customer. NOTE: The customer's process s~ouid ~de:~tifythe app[l)Va~auUtor:ity.
l,lI.LACKBOX refers ~o a part (e.g., ami<ISSie~b1y, electric-a] device, mechaaical device, orccetrol modnle) where design responsihility m;.longs ttl the otgaliitUa:ti.m1J orjhe s1Jl!pp~]er ..Black Box requirements are g;elI!le:r:aUy limited to those eha!DcwristiCsJj[ern_g [equired for customer interface eonneetions :arid
verifieation effunctional mea![l~ll'Ig. reqlLllrurements. ~'O.D.D." (OlJlts]de .oes~gn and Development] has the
equivalent
BULK MATERIAL
is a substance (e.g, non-dGcl1isioo.al solid, ~lquid.gas} such as adbesives, sealanrs, chemk<l~s. eoetingsfabrics, hibricants. etc. A bulk material may becomeprcduction material. if issu eel a customer pmdllction pm F:llu!ilJibersee P~ODUCT10N IviATERlAI.). ( BULK MATEIUAI.S
CAD/CAlvIMATH
responsible
R_E:.QumEl\ImNl'S
F).
Oil
CH!E'CKLIST
defines the
for
to
DATA is
dimensioaal inspection.
dedronicalWy
a drawingto
65
---
CAUBRA TION is a set of operatieres which compares values taken froma pieCleof ~ nspection, measuring ilInd.test eqUlipme[U;t 0]" a ~.ge to a known standard under specifi.ed conditions. ,CAPABILITY is fhe total. ram1JigE; ofim:erent varietionina ()Qintr'ot reference manu',) st~b~fl rocess. (see tile Sta.tisticilil. Pmeess p
resu]t;s. recorded
by the
CHECKED PRlN'Ti:s a released mg~neerin.g dnlwi:o:g with <licllhiaJ easurement m organiza:Uon adjac-ent to each dmwlllg dimeasiou and otber rcqui:rem.ents.
CONF'ORl'dANCE
CONTROL
requiremeets,
- see g-TATISTICAIL CONTROl._ CHARTS - see the Stli!ti:st~ea~Preeess OJlHtt"oi reference m;;l~u;3!l
CONTROL CONTROL
materials
and p:[iocesse:s,. Theyare writl:el1L by ovga:nizationsto address tbe important characteristics and eWtlgi:neel'iirog ooqJulrlemenLs of theprcdacr, Each p'8!ril must have a Control Plan, but in rrII!l!ly cases, "':fum~ly"ContrQ] Plans can <1\pplylD a number of paets p.WdliDOO using <lIoommcm. prooe:s,s." Refer fLO AJdivanCledl Pf'odillJl,ctQUaJUty Plagging and '€)i1ifth'i(!l1 rlag reference maJiJllHII, ISOffS 16949. and
PLANS are written descr~phons of the system. for OO[]jtrol~~ng pf\oducUon parts or bulk
c1!J!st:om,eT~s.pedfiic requieernests,
'CUSI"OM.ER is the recipient oHhe otrg::l]"1]z<'ltion's supplier's m produc-t
Or
service,
DES:~GN~.IN'F.EN[)ED .ROBUS1r RANG,E are limitswithin lj,\'lliicD.perameters may be aHo\.ved to vary while .stUl ensuring iliat a product complies with fitness for use l1equirements • .DESIGN RE OORD is. the part. drawi~g. spec:ificalions.,mdJQ'i eleettonic {CA Dc} data used to
~nfQfI]lati:~ln necessary ~opro[htl:oe a pwdlJlct.
ICQ]1!vey
.MODE AN.D EFlF.ECM'S ANALYSIS (FMIl:A) is a systemJahc group of activities intended 10: end evaloalle the polel]l~alf<l~h.lirie <I pmduct/process of <lind effects of that failure, (bJI the identify actiens that could elimiaate Of reduce dIe chance of me poie:nUa]faU~r·eoccurring. and (c) doc1ll!mle-nm entire process, It is cOlTlplemen~ry to the process of defin ing what 11. desi gn or process ~he must do to satisfy the customer, Refer to Potentwal F;i1JHun::Modes a nd Effec:ts A 0 ;)j~ysiis,eferenee r
FAlLURE
(a) recognize
ma[iLua~. OOTM.LPROCESS
LAIORA
TORY ls a lest f~e~]ity that H1:3Jjf inelndechemical, electrical, Fe liab.i1ity testing Of rest valida:t]on..
.,
.,
l"tIA.RKED PRINT· is an en:ghweenBg dJrawing ~di fied.signed, and! dated by the custemes e:nguFlee:r (the engLIl.eenng change m,llind;u~:r beinelnded], must ORGANIZATIONS a:rep!'QvideiiS 'of: <li) roductio.n materials, b) prodaetien or servi.©eparlS, c) p assembl ies, OF d) heat treating, '!.'\fe]d:ing, aJmtill:g, pLating O[ other finishing services, d irecUy 00 till!;'! p OEM or other customers requiring this docW!m~llt PART SUB-MISSIONW A!FI:RA_NT I(f'S\1V) is <Inind:lill!stry~s.tand,ndoenment required fOJ aU newlyd tooled or revised prndaetsi» ltvhid the organization confirms tbatinspeceices and tests on production p~ sho'l;\" conformance to customer requireraeets.
66
_. ,_. ,•••••••
_.••• -
- _.
I-
••• -
I~
--
••
PEJiUSJIIAml.E
TOOLS ar,e drill bits, cutters, ~nserns,e:tc.used to produce a prodnct and which are inputs into outputs,
consumed ill the process, P'ROCESS is a 8e,'I; f ]~le.rr>elalt:ed iO:llernc'li:ng actwvi:t]es wihlkh traasfomrs o Or PROCESS
NOTE 1: For PPAP,. the process flow d~~gram should focus npon the maaufacturiag proc~ss, including rework and. repair . NOTEl:Processfl!Ow
is the manil1fac~ri.ng lecation w~~fuJwn U~ep.roduJCtionshe WhlCb includes the pmducUoll tooLing" gagh1Jg,process.neaterials, '()per;a:~ors. environment, and p'rooe:ss settings" e.g., feeds~speed:s. cycle times, pressures, h;Jmp(:rcaJmes"quoted line rate. E:l]VirOflLm.eflf is defined as all of theprocess cOlldlltlOJi'liS s'-luToilinndl~. Or affediflg UIDemal1~faclJ.uJre.1iill].d quality of a pm or product Bnvireement wiH va:ry f'OI eachsile, but ge:l];e:roJUy includes: bousekeep]ng~ Ugh.ling, E1Ci'lSe, HV AC •. IESB controls, and s:a,fe~ hazards relating to lho1l1ook!eep.ing. rRODUCl'lON MlAT.ERI.AL 1:8 material Whl~ hM beenissaed a productieu part number by m~ shipped directlytn theeustomer,
PR01lVCnON E~VIRONM.ENT
customer aud
]5
PROnUC .. ONPAR.T is marusfacteeed at the productioa site I:ilsi.ng the producnan tooLing.gagjng. n process, marerials, operators, env]oonmet'llt,flmdproces8 settings, e.g., feedslspeedslcyde ti!11eslpressuresJtel'ij,pera;tul1e~L
P.R.oDUCTIONPART APPROVAL SUBMISSION is based on specified quantities of production parts 0;[ prodnctioa mat.e:nabtakl!io from tie s~gflmcal'l&pmduc:UoliDJ run made '!-'1 ]lDprodiuctriml tooling, processes, and cyde times. These parts or materials ~5IJ)IDbm[lil::ed production part approvat are to be for verified by the organizadon as meetingall specified requirements from 'the design record,
i
PR:OnUCTION RATE is the agreed t!P~llI number.ofpfI!liil.s.produced]]1 aplaaned time period bJ meet eustomer assembly Of!11a!I1J;li'otctu:r.i[!g plant prodaetion volume requiremeets - with consideration of other product m~x and machineavailability,
NO'l'E: The agreed predueuon rnte is. typlicaHy sped fled in the purchase agreement,
Q UAUl'fYINDIC['S are measures of caJpabiifuty or perfom1ancei"o1i eitherproduct Cpk~r Ppk> S~ U'leSb~tist:i:calrro~es:s(:![Iinh'l(!ll refe:rence m!'lntl~],
Of
.'
process, such as
QUALlfyrLANNING isa s~cttlrod precess for defiflJ~o.,gtae methods (e.g., measnrements, test~.)tha~ WIUbe used in the production of a specific prodiuct or film iLy of'products (e.g., parts. materials). Q1il~~ty i p]aJlm ing embodies the, ~(m:ce1pls of defect prevention <lind eentinual im.pfov,e:ment as eontrastedwith defect detection 1~:fIee dwute!ill Produd 'Quality PJaJ!!ning and CllIlntrl!ll Plain refereuce manual), A 'QUAL1TY RECORD ~sa document stl.ting resu]t:s achieved or providi:!1ig evideIl©e of activities performed.,. e"g., test results, internal audit results, caUbraJl:io~ data,
RiEGULAR.P'ROOOCnON produ.c~ionprl)dl!Jct customer andOi.!:g,<llllli.~ti.Oi.rL SIGNIFil.C.ANT paODUCTION IUJN - seerrAP, 2.·~. TOOLING
([ID1.I~ufad{Jf,eIintends
~iO produce
00
67
..
... _ I ._, -, .., • ---"" ... _.-
SPECIAL CHAJtACT~R.Is;,'f~CS <Ire pFOO1Uc:t chaeacteristics or manefacturing pmcessparameters wbich can affect safely at ,oompUaJi1cew~tfu regll]atiOTIs, fit, fi.ll[l[ctimll, peeformance (l'rsubsequent precessing of product Rde:r toO cust:onl,er~srecific requi[em.ents.
S:PECIFlfCA"nON
isa decument
st:<lting re[I,11:J]rements.
NOTE: F(DF:rr A' ~every feamre of the PWdilllot s identified by engineerilng specitications must a meet requkemeuts. ActuaJ[ measuremeat "mild tes:~resultsare reqJ1!lj~red. Specifications should not
be confused w.~lh.eontrol ~]miitswhich rep.resent "the voice of the precess,"
See tilileStatistical.
P'!!0CJesS,
Oll:ntrol
ST Al"ISl'l:CAL CONTROL is thecQltdit:ioll of 81 processftomwhich a]1 special. causes of nri.adoJiJl have been eliminated and only CCUlIIl1O'I1 eansesremaia, See, the Stillfigti1ca.~ .Pf'O[;E::SS CODtr1i)~ reference manaal,
SUBMJ1:SSI0N LEVEL Iefers to the level of e\!id:ellJceequired forPfi'AP subm~ssion (see:P'PA:P, r SUlPL.mRS, OEM orether
treating.w,eld;iug~
4_1),_
are providers of prodaetien materials, (lifprodtllct~OJJiL orservice parts.llssemblies. he~t pa]nring~ 1P~<litingr ather finishing services d~redl.y to ilIO (l!ir~rCl!],iZ'i3ltiQn. s1!l!pplyingthe o
cusiemers .req~~r1:11iglliJJis ocument t d
1'0001. is defiD.ed es the portion ofpr(lcess machinery wlli.c~ is speeiflc 110 a component OF sub-assembly. Tools (or tool ing] are used in precess machinery to transforrn raw material i.nto a finished. part or assembly.
V.ALIDATION is ,ooJIaJfinnatiofi, tkough[be provision ef objective evidence, that the requirements for a. specific intended use ,gra:pp,li.ca.tion have been fulflUeilL DATA are qJu<mt]~:at;ive data,wh.ere measurements <lire used for analysis, Exareples include the dim:neter of 8ibeaJ~ j~1!l1.malinmimmeters> the dosing efIort of~. door hi Newtons. the conceorradon of electrolyte in peroent. or the torque of a fiil:sre]1J:e'l~im1 Newtnn-mete:[~. VARIAJILES
VERIFICAll0N is
cOliIl:llrma'~i@iI!It
through
me provision
63