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  • Supplier Quality Management Production Part Approval Process (PPAP) Manual

    February, 2009 Rev 6 Release

    Cooper Industries 600 Travis Suite 5600

    Houston, TX 77002

    Macro Setup

    Important: To use this spreadsheet without issue you must set your computer's Macro security to one of the following:

    Otherwise the calculations will not work correctly!!

    1. LOWWhich will force no cautions with respect to Macros and allow all Macros with this spreadhseet to run.

    2. MEDIUMWhich will allow you to "ENABLE" the Macros to run.

    IMPORTANT NOTE: This setting will be the default setting for ALL Spreadsheets that you open with EXCEL until changed.

    Not resetting to a higher level can leave you vulnerable to Macro virus's with other spreadhseets!

    Directions on how to set up Macro Security.

    1. Open Excel..

    2. Go to TOOLS, OPTIONS

    3. Click on "MACRO SECURITY"

    4. Set Macro security to either Low or Medium.

    5. Click OK and close Excel.

    6. Re-open the file and use spreadsheet.

    PPAP Supplier Checklist Externa

    PPAP Production Part Approval ProcessSubmission RequirementsSupplier ChecklistSubmission Level(Please Type 1-5)3

    Cooper Part NumberPart DescriptionSupplier Name

    Revision LevelCooper Purchasing Rep.Submission Date

    Primary Manufacturing SitePurchasing Rep Phone #PPAP Due Date

    Element OrderPPAP RequirementsAIAG PPAP Fourth Edition

    Important: Submit your documents in this order.Level 1Level 2Level 3Level 4Level 5Required DocumentsAssigned toInternal Due DateComments/Concerns/QuestionsIncluded

    1Part Submission Warrant (PSW)ARCooper PSW Required

    2Design Records & Bubbled part print(s).ARTWO Cooper Divisional Parts Prints

    3Approved Engineering Change DocumentationARARVarious engineering documentation

    4Customer Engineering ApprovalsNot Required for Cooper Submissions

    5Design FMEA,ARARARCan be Cooper FMEA Format or an AIAG compliant DFMEA.

    6Process Flow DiagramsARAny standard flowchart format.

    7Process FMEAARCan be Cooper PFMEA Format or an AIAH compliant PFMEA.

    8Control PlanARCan be Cooper supplied format or AIAG compliant format.

    9Measurement System Analysis StudiesARARCooper GRR format or any statistical package format for gage R&R.

    10Dimensional ResultsARMust be on Cooper Dimensional report format

    11Material, Performance Test ResultsARARIndustry Standard reports or test result formats designated by Cooper Industries.

    12Initial Process Study (Cpk)Capability StudiesARARProcess Capability Study using any statistical package or Cooper Capability Data Forms.

    13Qualified Laboratory DocumentationARLab Scope and outside lab proof of accreditation.

    14Appearance Approval ReportARARARARARAIAG format AAR

    15Sample Product PartsARParts tagged in accordance with Cooper PPAP reference manual

    16Master SamplesRequired only for level 5

    17Checking aidsARChecking aid design prints and GRR for checking fixtures.

    18Customer Specific RequirementsDocuments as specified by Cooper Industries

    aTooling Information FormARSpecific document required by Cooper Industries.

    bPackaging FormARSpecific document required by Cooper Industries.

    cInspection Plan(ASC Suppliers only)IAIAIAIASpecific ASC Formate

    dSpecification Deviation FormIAIAIAIASpecific document required by Cooper Industries.

    eSupplier PPAP ChecklistARSpecific document required by Cooper Industries.

    Required for PPAP submissionNot requiredDocuments on a case by case basis are marked AR for "As Requested"IF Applicable

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    YES

    AR

    IA

    YES

    Cooper PSW Format

    Part Submission Warrant

    Part NameCooper Part Number

    Safety and/or Government Regulation

    Engineering Drawing Revision LevelDated

    Additional Engineering ChangesDated

    Shown on Drawing NumberPurchase Order No.Weight (kg)

    SUPPLIER MANUFACTURING INFORMATIONSUBMISSION INFORMATION

    Supplier Company NameSupplier Vendor NumberCustomer Name:

    Additional Manufacturing SitesCooper Manufacturing Locations using the part (list all)

    Street AddressPurchasing RepresentativePurchasing Office

    CityStateZipPPAP Due Date:SOP Date

    Does this part utilize Cooper owned tooling? Is it properly identified?If yes, P.O. #

    Does this part contain any restricted substances or require IMDS submission?Substance(s)?

    IMDS Number

    Are plastic or polymeric parts identified with appropriate ISO marking codes?

    REASON FOR SUBMISSION

    Initial submission (New Parts and Part Number Changes)New Supplier, New material or new source for existing material

    Engineering Change: New/Revised drawing or other specificationChange of supplier, material or non-equivalent materials/services

    Tooling: transfer, replacement (new), refurbishment, modified or additionalNew process or a change in production process or method

    Correction of Non-conformance or discrepancyChange of manufacturing location, sub-supplier or additional location

    Change to optional construction, material or componentOther - please specify

    REQUESTED SUBMISSION LEVEL (Check one)

    Level 1 - Warrant only submitted to the customer (Applied to non-critical parts and raw bulk material)

    Level 2 - Warrant with product samples amd limiting supporting data. (Applied to critical bulk product and simple changes)

    Level 3 - Warrant with product samples and complete supporting data. (Applied to new parts on Cooper programs)DEFAULT COOPER SUBMISSION LEVEL

    Level 4 - Warrant and other requirements as defined by Cooper.(Applied only with prior approval from Cooperspecial situations only!)

    Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. (Applied to parts requiring onsite review )

    SUBMISSION RESULTS

    The results fordimensional measurementsmaterial and functional testsappearance criteriastatistical process package

    These results meet all drawing and specification requirements:(If "NO" - Explanation Required in Explanation/comments section below )

    Is this a multicavity tool?How many Cavities/Spindle (for molds or dies) ?Number of parts submitted by cavity/spindle

    DECLARATION

    I affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable Production Part Approval Process Manual 4th Edition

    requirements. I further warrant these samples were produced with the specified materials on regular production tooling with no operations other then the regular production

    process. The data and samples were produced at the production rate of in on Any deviations to this warrant submission

    are noted below in the explanation/comments section.#parts # hours date

    EXPLANATION/COMMENTS:

    Print Name:Job TitlePhone No.Fax No.

    Supplier Authorized SignatureDateEmail

    FOR COOPER INDUSTRIES USE ONLY

    Quality/Supplier QualityDate

    Initial Part Warrant Disposition:Quality/Supplier Quality ManagementDate

    Expires:

    Final Part Warrant Disposition:

    Quality or Supplier QualityDate

    Print Approver Name:Cooper PPAP Tracking Number:

    YES

    NO

    Yes

    No

    Yes

    No

    Yes

    No

    Approved

    Rejected

    Interim

    Yes

    No

    Part Name on Cooper component level print

    "Yes" is so indicated on part drawing, otherwise "No"

    Engineering Revision level on Cooper component level print.

    Located either in engineering tittle block or revision matrix on component level print. This is the date the part was revised to the most recent rev level.

    List all authorized engineering changes not yet incorporated on the drawing but which are incorporated in the part.

    Date you were authorized to incorporate these changes.

    Used when the part submitted is on a different drawing then the Cooper component being submitted. The design record that specifies the customer part number being submitted.

    Enter this number as found on the first production release purchase order.

    Enter the actual weight in kilograms to four decimal places. Must be weight of a completely finished part.

    Full Name of Company or Division.

    List all locations producing the part for Cooper use.

    List all division manufacturing sites that use this part:

    Street address of either the primary site of manufacture or origin of submission.

    Buyer who has been your primary contact for business with Cooper.

    City that Buyer's office is located in.

    Please state the ORIGINAL date requested by your buyer representative.

    Estimated start of Cooper production or first Cooper production release due date.

    Please add the PO # that matches both the part and the revision level being submitted.

    List the controlled or restricted substance contained in this part.Please attach additional list or information if required.

    Check the appropriate box. Add explanatory details in the "other" section

    Identify the submission level requested by your customer and that you are submitting to.

    Check the appropriate boxes for dimensional, material tests, performance tests, appearance evaluation, and statistical data if included in the submission. Level 3, 4 and 5 submissions typically require all sections.

    Please provide details on the number of molds. cavities or production pr

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