global supppp ylier quality manual ppap...

Global Supplier Quality Manualpp yPPAP RequirementsRevision 1.3

What is PPAP?

• Production Part Approval Process (PPAP)• The purpose of PPAP is to determine if all customer

i i d i d d ifi ti i t engineering design record and specification requirements are properly understood by the Suppliers and that the manufacturing process has the capability to produce product g p p y p pconsistently meeting these requirements during an actual production run at the quoted production rates.

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Oshkosh PPAP Level Definitions• Level 1 PPAP:

– One page document that “warrants” the part meets the design intent, know as a Part Submission Warrant.

• Level 2 PPAP:– Part Submission Warrant Part Submission Warrant – Dimensional reports– Drawing / Design Criteria– Material certifications– Performance test reports– Welding StandardsWelding Standards– Surface Finish test reports – Incoming Inspection approves Level 2 PPAP’s

• Level 3 PPAP– Includes Level 2 PPAP with additional process control documentation.

• Process Flow Diagrams

AIAG PPAP

Process Flow Diagrams• PFMEA• Control Plans• Capability Studies

– Supplier Quality Engineer Approves– Incoming Inspector still verifies all initial sample parts.

Oshkosh Corporation

PPAP

Long TermBenefit

• Level 4 PPAP– PSW – Dimensional reports (ISIR)– Drawing– Incoming Inspection approves Level 4 PPAP’s

P500

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g p pp

Example of PPAP Workbookhtt // hk h / hthttp://osn.oshkoshcorp.com/gsq-en.htm

Click on: Production Part

Approval Process (PPAP)

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PPAP Workbook – “Excel workbook”

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PPAP Workbook – Level 2 Requirements

• Intro:– Type in Part / Supplier Information, this will be transferred throughout the workbook.

• PSW Requirements:PSW Requirements:– This outlines the PPAP submission requirements. (Informational only)

• Labeling:– This is the label to be used to Identify the PPAP sample part when shipped to OSK

• PSW:– This documents the warrant that the Part Meets the design Intent– This will be used to communicate back to the supplier the acceptance or rejection of the PPAP

• Dimensional:– This is used in conjunction with a “bubble print” to document the actual dimensions of the PPAP part.

• Print Notes:– This is used to document all the remaining notes on print (Material Certs, Surface Finish, Performance Testing, Labeling, etc…)

• Print Notes – Paint:– This is optional depending if there are Print Notes specifying paint / coating requirements.

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• Print Notes – Welding:– This is optional depending if there are Print Notes / Welding requirements specified.

Intro “TAB” – PPAP WorkbookPPAP INTRODUCTION

PPAP packages are expected to be received by Oshkosh Corporation by the date assigned by Purchasing. If for any reason you cannot meet this date, contact Purchasing for resolution.

The Default PPAP is Level 2 unless otherwise required by the Oshkosh Segment Quality Representative

It is the policy of Oshkosh Corporation to approve initial samples of supplier provided parts before receiving production orders of those parts Oshkosh has developed the PPAP PROCESS to facilitate this requirement.

1) New parts. 2) Existing parts from a new supplier. 3) Existing parts from existing supplier where there has been a substantive change in the supplier's manufacturing process, tooling, materials, and/or location.

The Default PPAP is Level 2, unless otherwise required by the Oshkosh Segment Quality Representative

PPAP requirements apply to the following parts:

There may be occasions where parts may be excluded from the PPAP PROCESS requirements. These may include parts that are manufactured to a higher standard or recognized external standard specification. Some examples of acceptable standards include ISO (International Standard Organization) SAE (Society of Automotive Engineers) and NIST (National Institute of Standards and Technology)

4) Any changes that affect the fit, function or appearance of the part. 5) Any request by OSK based on part rejection history.

1. Part Information2. Supplier Information

N t Thi i f ti ill

Important Note: These sheets have not been protected, so you can add additional information if needed. However, the information in blue is interlinked to the other spreadsheets. FILL IN THE BLUE SECTIONS FOR AUTOMATIC INPUT INTO FORMS

Please reference the Oshkosh Corporation Global Supplier Quality Manual for more detail on PPAP requirements. The Manual can be retrieved on the https://www.oskgpsc.net/ website.

(International Standard Organization), SAE (Society of Automotive Engineers), and NIST (National Institute of Standards and Technology) among others. The supplier will have to provide documentation of higher standard or external standard specification. However, this will be at the discretion of the responsible Oshkosh Corporation Quality Representative.

Note: This information willBe transferred to all “like” fieldsIn this PPAP Workbook.

Part Name NAMEPart Number P-NUMBERRev # REV #Engineering Change Level ECNEngineering Change Level Date ECN DATEModels / Vehicle MODEL / VEHICLE

Supplier Name SUPPLIER COMPANYSupplier Number NUMBERStreet Address ADDRESSCity CITY

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City CITYState STATECountry COUNTRYZip ZIPPhone Number 555-555-5555Fax Number 555-555-5554Application OSK MODEL

Email Address [email protected]

EDITION PRINTINGSecond edition Jul 08

THE FOLLOWING LEVELS OF DOCUMENTS WERE USED TO PREPARE THIS WORKBOOK.DOCUMENT

ADVANCED PRODUCT QUALITY PLANNING AND CONTROL PLAN

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Second edition Jul-08

Third edition May-03

Fourth edition Jun-08

Fourth edition Nov-09PRODUCTION PART APPROVAL PROCESS

ADVANCED PRODUCT QUALITY PLANNING AND CONTROL PLAN REFERENCE MANUAL

MEASUREMENT SYSTEM ANALYSIS

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

PPAP Submission Requirements

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1. Level 2 Submission is the Default PPAP level.

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2. This is the list of what is Required per submission level(Level 1, 2, 3, 4)

Note: Level 4 is commonly usedFor New Product Development(Prototype parts)

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PPAP Parts Labeling Requirements

Send identified sample(s), such as, Piece#1, Piece#2, Piece#3, etc to Oshkosh Corporation with appropriate label.

PPAP SAMPLE PARTS - LABEL

Pl l t d tt h thi th t id f h k i l i i f f k lift/ t i l

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1. All PPAP sample parts must Be tagged with this label on thePart and / or on the box.

Please complete and attach this page on the outside of each package in plain view of a fork lift/material handler/operator. Put the Packing slip pocket near the label.

In the event parts are “Loose” shipped, a label should be placed on each part. This would apply to parts laying on pallets also. Label on a Painted Part must be wire tied or attached in a way painted surface is protected from label adhesion.

PPAP SAMPLE PARTS2. Document all the appropriate Part / Supplier / PO information On the label.Part Number:

PPAP SAMPLE PARTSINSPECTION VERIFICATION REQUIRED

Purchased Order#: 2On the label.

Supplier Number:

Revision Level:

Supplier Name:

Supplier Inspected By:

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PSW – Part Submission Warrant

Note: All fields must be completed. if an area is not applicable mark as “N/A”.Below is a definition of what each “numbered” section is.

1 2

3 45 6

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1.) Name of part on drawing2.) Oshkosh part number on PO/drawing3.) Oshkosh part number on drawing4.) Supplier part number if applicable (n/a if not)5.) Engineering change level (ex. Rev B, this will be on the drawing / PO)6.) Engineering date (ex. 4/7/11, this will be on the drawing / PO)7.) Is this is Safety / Government regulation (ex. Drawing will indicate if it is

FMVSS, or other industry standard safety regulation.

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FMVSS, or other industry standard safety regulation.8.) PO number from Oshkosh driving demand for this part / PPAP.9.) This section requires all applicable Supplier location information. 10.) Oshkosh location part to be shipped11.) Buyer Name12.) Materials Reporting, acknowledgment the parts meet the hazardous

material restrictions outline per the drawing, Supplier Standards Guides or other contract Flow down requirements.

13.) Check the reason for the PPAP submission

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13.) Check the reason for the PPAP submission14.) Check the Level of PPAP that was requested by Oshkosh Corp. and check

what documents in the PPAP have been submitted that are applicable for this component.

15.) If Supplier has Oshkosh Corp. owned tooling document here. 16.) Supplier Point of Contact Information17.) Oshkosh will complete this section and send back to the

Supplier Point of Contact.

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ISIR – Initial Sample Inspection Report

1. Numbering Matches Drawing

21 3 4 5 61. Numbering Matches Drawing“bubble print”.2. Specification and Tolerances3. Gage Used to measure item4. How many measured4. How many measured5. Actual Results6. Good or Bad7. Supplier sign off

All dimensions on the print must be verified by the Supplier!

Key Note: y1 Piece required for Level 2 3 Pieces required for Level 3

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EXAMPLE: ISIR – Initial Sample Inspection Report

E l f ISIR Fill d tExample of ISIR Filled out.

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EXAMPLE: Bubble Print Bubble Print toMatch DimensionalLayout (ISIR)

I l d N t !

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Includes Notes!Material typesurface finish performancepart I.D.

Print Notes (Material Certs, Performance Tests & Part Identification)

1 N b i M t h D i

21 3 4 5 6

1. Numbering Matches Drawing“bubble print”.2. Specification and Tolerances3. Gage Used to measure itemg4. How many measured5. Actual Results6. Good or Bad7 Supplier sign off7. Supplier sign off

Note: This sheet to be used to document all Print Note requirements via the “bubble print” and reference any bubble print and reference any applicable Test report numbers in the PPAP Package.

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EXAMPLE: Print Notes (Material Certification) 1 Print Requirement1. Print Requirement2. ASTM Chemical Requirement3. ASTM Mechanical Requirement4. PPAP document to outline Requirement and actual’s per the

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Print and Industry standard (ASTM)

Note: If material certification is the Same specification on the drawing, the chemistry and mechanical

2the chemistry and mechanical requirements do not need to be on the Print Notes PPAP sheet. Certification will need to be referenced.

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EXAMPLE: Print Notes (Material Certification)

1. Use Chemical Weighted % from material cert. and transfer to print notes PPAP Page.

22. Mechanical Results to be transferred to print notes PPAP Page.

3. Signature on Cert. approving t i l

1

material

2

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Print Notes – Paint, Plating & Coating Testing

1. Document what print standard,Industry Standard, and Process Steps used to paint this the part

2. Verification Prime Coat:permeability, Adhesion, thickness Salt Spray, Ambient Cure Time& Oven Cure Time

1& Oven Cure Time

3. Verification Prime Coat:permeability, Adhesion, thickness Salt Spray, Ambient Cure Time& Oven Cure Time

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4. Document plating / coating processUtilized to manufacture this part

5. Acknowledge process isn’t using

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Any hazardous material that is not Allowed per the Supplier’s Standard Guide or Contract requirements.

6. Supplier Sign Off4

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1 Print Note Paint Note Requirement

Example: Print Notes – Paint Testing1. Print Note Paint Note Requirement

2. Document what print standard orIndustry Standard the part has been Painted to

2Painted to.

3. Prime Coat Verificationa. Reference standard for each process stepb. document blast profile

3c. document actual thickness including profiled. Ensure that the thickness spec includes blast

(1.0mil blast profile + 1.3 mil primer = 2.3 min thickness including blast profile)

4. Top Coat Verification

5. Compliant to hazardous material Restrictions (Sign off)4

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1 Print Note: Plating Requirement

Example: Print Notes – Plating Testing1. Print Note: Plating Requirement

2. Technical drawing requirement

3. Document process required & Document standard process executed to plate 1 standard process executed to plate part.

4. Compliant to hazardous material Restrictions (Sign off)

5. Provide Material certification

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5

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Welding specification

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1. Document the Welding Symbol / Weld Description from From “bubble print”.2. Document WPS / PQR (if not prequalified)3. Document visual verification of weld size, Weld length, Weld Quantity.Weld length, Weld Quantity.4. Supplier Sign Off

Note: WPS’s and PQR’s may be requested d t b id d tand must be provided upon request.

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Example: Welding specification

1. Document the Welding Symbol / Weld Description from From “bubble print”.2. Document the Welding Specification /WeldSymbol from “bubble print”

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Symbol from bubble print .3. Document WPS / PQR (if not prequalified)4. Document visual verification of weld size, Weld length, Weld Quantity.5. Supplier Sign Off

Note: WPS’s and PQR’s must be provided upon request.

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LEVEL 2 - PPAP

LEVEL 3 - PPAP

• Same Requirements as Level 2 with the following additional requirements:• DFMEA

– Design Failure Mode Effects Analysis is required if the Supplier is design responsibly• FLOW DIAGRAM

Process Flow diagram is required to outline and standardize the production process that is being approved This should outline the entire process that is being used to manufacture the component & assembly– Process Flow diagram is required to outline and standardize the production process that is being approved. This should outline the entire process that is being used to manufacture the component & assembly.• PFMEA

– Process failure Mode Effects Analysis is required to be conducted to understand all the potential failure modes and mitigate know failure modes.• CONTROL PLAN

– The control plan is to be used to document and be used on the shop floor to monitor and control the standardized manufacturing process being approved.• MASTER SAMPLE:

– This is used to document visually how the parts are being marked and pictures of the PPAP parts.• TOOLING

– This sheet is used to visually document any Oshkosh owned tooling. • CAPABILITY STUDY

– This sheet is to be used to show evidence the production process is capable to meet the design intent. This is required when Critical Characteristics are identified on the print or other wise specified by Oshkosh Corporation.• Gage R&R

– This sheet is to be used to show evidence that the measuring method used for the capability studies is repeatable and reproducible..

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DFMEA

1DFMEA - DESIGN FAILURE MODES EFFECTS ANALYSIS

1. Design Failure Mode Effects Analysis is required if the

System

Subsystem Design Responsibility: FMEA Number:

Component Key Date: Prepared by:

Date (Orig.):

Core Team: Date (Rev.):

C O Current DS l c Design e R.e a c Controls t P. S O D R.v s u -Prevention e N. e c e P.

s r -Detection c v c t N.

Recommended Action(s)

Responsibility & Target

Completion Date

MODEL / VEHICLE

RequirementsPotential Effect(s) of Failure

Potential Failure Mode

Model Year(s)/Vehicle(s):

Item / Function

Potential Causes(s)/

Mechanism(s) of Failure

Action Results

Actions Taken

required if the Supplier is design responsible

Note: Utilize AIAG manuals as required.

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www.aiag.org

Process Flow Diagram

1 Process Flow diagram is

Product Program Issue Date ECL ECNSupplier Name Part Name

Supplier Location Part NumberADDRESS

PROCESS/INSPECTION FLOWCHART

MODEL / VEHICLESUPPLIER COMPANY NAME

P-NUMBER

1. Process Flow diagram is required to outline and standardize the production process that is being

Legend:

Operation Transportation Inspection Delay Storage

Operation or Event Description of EvaluationOperation or Event and Analysis Methods

Operation p gapproved. This should outline the entire process that is being used to manufacture the component / assembly

Inspection

Transportation

Storage

Transportation

Operation

component / assembly. Operation

Inspection

Operation

Operation

Operation

Inspection

Inspection

Operation

Inspection

Inspection

Note: Utilize AIAG manuals as required. www.aiag.org

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Operation

Change HistoryDate Revision

PFMEA

1 fPFMEA - PROCESS FAILURE MODES & EFFECTS ANALYSIS

1. Process failure Mode Effects Analysis is required to be

Print # P-NUMBER Rev. REV # FMEA Number:

Item: n/a Process Responsibility: Prepared by:

MODEL / VEHICLE Key Date: Date (Orig.)

Core Team: Date (Rev.)

C O Current DS l c Process e R.e a c Controls t P. S O D R.v s u -Prevention e N. e c e P.

s r -Detection c v c t N.

RequirementsProcess Step /

FunctionPotential Failure Mode

Potential Effect(s) of Failure

Model Year(s)/Vehicle(s):

Recommended Action(s)

Potential Causes(s)/

Mechanism(s) of Failure

Responsibility & Target

Completion Date

Action Results

Actions Taken

required to be conducted to understand all the potential failure

d d modes and mitigate any know failure modes.

Note: Utilize AIAG manuals as required.

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Control Plan

1CONTROL PLAN

1. The control plan is to be used to document and be used on the shop

Control Plan Number Key Contact/Phone Date (Orig.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)P-NUMBERPart Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date (If Req'd.)NAMESupplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

1/1/1996

MACHINE

CONTROL PLAN

PART/ CHARACTERISTICS METHODS

NUMBER

1/1/1996

Prototype Pre-Launch Production

used on the shop floor to monitor and control the standardized

f t i

PRODUCT/PROCESS EVALUATION/ SAMPLESPECIFICATION/ MEASUREMENT

TOLERANCE TECHNIQUE

MACHINE,DEVICE

JIG, TOOLSFOR MFG.

NO. PRODUCT PROCESS

SPECIALCHAR.CLASS SIZE

PART/ PROCES

SNUMBER

PROCESS NAME/OPERATION

DESCRIPTION FREQ.CONTROLMETHOD

CHARACTERISTICS METHODSREACTION

PLAN

manufacturing process being approved.

Note: Utilize AIAG manuals as required

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Master Sample

1. This sheet is used to visually document how the parts are being labeled

2. This seat used to 2. This seat used to document visually the PPAP parts

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Tooling – Oshkosh Owned

ORGANIZATION: PART NUMBER:SUPPLIER NUMBER: PART NAME:

DATE:

TOOLING & FIXTURES - PROPERTY OF OSHKOSH CORP.

SUPPLIER COMPANYNUMBER

DESIGN RECORD CHANGE LEVEL:

NAMEP-NUMBER

ENGINEERING CHANGE DOCUMENTS:ECNTOOL / FIXTURE NUMBER:

1. This sheet is used to visually document any Oshkosh owned tooling. It is required to attach a

Supplier is required to identify all Oshkosh Owned Tools & Fixtures and document with Photo in PPAP workbook

PHOTO OF OSHKOSH OWNED TOOLING AND FIXTURES

is required to attach a picture of tooling as well as the tooling identification method.

PRINT NAME SIGNATURE TITLE DATE

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Capability Studies

11. This sheet is to be used to show evidence the production process is capable to meet the capable to meet the design intent. This is required when Critical Characteristics are id tifi d th i t identified on the print or other wise specified by Oshkosh Corporation.

Note: Utilize AIAG Manuals as required

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Note: Utilize AIAG Manuals as required. www.aiag.org

Gage R&R

1. This sheet is to be used to show evidence that the measuring method used for the method used for the capability studies is repeatable and reproducible.

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• Intro:– Type in Part / Supplier Information, this will be transferred throughout the workbook.

• PSW Requirements:PSW Requirements:– This outlines the PPAP submission requirements. (Informational only)

• Labeling:– This is the label to be used to Identify the PPAP sample part when shipped to OSK

• PSW:– This documents the warrant that the Part Meets the design Intent– This will be used to communicate back to the supplier the acceptance or rejection of the PPAP

• Dimensional:– This is used in conjunction with a “bubble print” to document the actual dimensions of the PPAP part.

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PPAP Process Flow

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Defense Production: PPAP Submission / Notification Process

• Oshkosh Purchasing FTP Site Homepage– Upload all PPAP’s to the FTP Site

https://ftp oshkoshcorp com/thinclient/– https://ftp.oshkoshcorp.com/thinclient/• Email Notification of Documents on FTP site

– Email Level 1&2 PPAP’s Notification to: [email protected]– Email Level 3 PPAP’s Notification to SQE’s email:– Note: Do not email the PPAP’s load them to FTP Site due to ITAR regulations.

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Defense NPD: PPAP Submission / Notification Process

• Send PPAP documentation with the first order.– Not required to send to FTP Site– Not required to notify via emailNot required to notify via email.

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Defense Aftermarket: PPAP Submission / Notification Process

• Send PPAP documentation with the first order.– Not required to send to FTP Site– Not required to notify via emailNot required to notify via email.

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Defense: FTP Site

• Oshkosh Purchasing FTP Site Homepage:https://ftp oshkoshcorp com/thinclient/

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https://ftp.oshkoshcorp.com/thinclient/

Defense: FTP Site – APQP Folder

• Supplier should load PPAP’s into APQP folder. • Open APQP folder

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Open APQP folder.

FTP Site File Naming Convention

• Suppliers are required to load their PPAP packages to the Purchasing FTP site using the following naming convention:

PN_SUPPLIER NAME_MMDDYY_REV

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F&E: PPAP Submission / Notification

• Email PPAP Documents to:– PPAP@piercemfg [email protected]

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Commercial: PPAP Submission / Notification

• Email PPAP Documents to:– PPAP@McNeilusco [email protected]

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JLG: PPAP Submission / Notification

• Email PPAP Documents to:– firstarticle@jlg [email protected]

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