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1 Global Supplier Quality Manual PPAP Requirements

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Page 1: PPAP Requirements

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Global Supplier Quality ManualPPAP Requirements

Page 2: PPAP Requirements

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What is PPAP?

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

engineering design record and specification requirements are properly understood by the Suppliers and that the manufacturing process has the capability to produce product consistently meeting these requirements during an actual production run at the quoted production rates.

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Global Supplier Quality Manual: PPAP Requirements

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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:

– Level 1 Warrant– Dimensional reports– Material certifications– Performance test reports– Welding Standards– Surface Finish test reports – Incoming Inspection usually approves Level 2 PPAP’s

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

• Process Flow Diagrams• PFMEA• Control Plans• Capability Studies

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

AIAG PPAP

P500

Oshkosh Corporation –

PPAPLong Term Benefit

FMTV

- R

EQ

UIR

EM

EN

T

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Defense Website - Example of PPAP Workbook

http://osn.oshkoshcorp.com/

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:– 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.

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

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Intro “TAB” – 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 CITYState STATECountry COUNTRYZip ZIPPhone Number 555-555-5555Fax Number 555-555-5554Application OSK MODEL

Email Address [email protected]

EDITION PRINTING

Second edition Jul-08

Third edition May-03

Fourth edition Jun-08

Fourth edition Nov-09

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.

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

PPAP 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.

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.

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

PPAP requirements apply to the following parts:

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.

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) 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.

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

PRODUCTION PART APPROVAL PROCESS

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

ADVANCED PRODUCT QUALITY PLANNING AND CONTROL PLAN REFERENCE MANUAL

MEASUREMENT SYSTEM ANALYSIS

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS

1. Part Information2. Supplier Information

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

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PPAP Submission Requirements

1. Level 2 Submission is the Default PPAP level.

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

Part Number: P-NUMBER Purchase Order No.Revision Level: ECN Part Description: NAMESupplier Name: SUPPLIER COMPANY Reason for Request:

Supplier Number: NUMBER OSK Program: OSK MODELDate Issued: Submission Due Date:

SS

SSSS

SSSS

SSSS

****

****

***

SSS****

****

*

*

**

Additional Submission Instructions below:17.) Sample Products For Layout * * S

14.) Master Sample - One Sample to be Identified as a Master Sample and Retained by Supplier (<$100)15.) Checking Aids (Fixture, gage, template, etc) - Specific to the part being submitted

10.) Measurement System Analysis (MSA) 11.) Qualified Laboratory Documentation 12.) Process Control Plan13.) Appearance Approval Report (AAR) - if applicable

9.) Initial Process Capability

5.) Engineering Change Documents (ECN) - if applicable6.) Design Failure Modes effects Analysis (DFMEA) - if design responsible7.) Process Flow Diagram (PFD)

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8.) Process Failure Modes Effects Analysis (PFMEA)

2.) Intitial Sample Inspection Report (ISIR) 3.) Print Notes: (a. Material / b. Performance / c. Surface Finish / d. Labeling / e. Paint Test Results / f. Welding)

4.) Design Records - For all other components / details

**

*

S

Oshkosh CorporationPPAP Part Submission Requirements.

ALL PPAP CRITERIAMUST CONFORM TO

Oshkosh Corporation Customer Specifics defined in the Global

Supplier Quality Manual

1.) Part Submission Warant (PSW) S

UNLESS OTHERWISED SPECIFIED IN WRITING BY OSHKOSH CORPORATION:

Default PPAP Submission Level 2 - Unless Otherwise Specified by Oshkosh Corportion (Segment Specific Requirements may vary)S = Supplier Must Send Items to Oshkosh Corporation for Approval* = Supplier to Send items to Oshkosh Corporation Upon Request

Submission LevelPPAP Submission Requirements and Detail Description

S**16.) Records of Compliance with Customer Specific Requirements as specified

12

Page 10: PPAP Requirements

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PPAP Parts Labeling Requirements

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

2. Document all the appropriate Part / Supplier / PO information On the label.

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

PPAP SAMPLE PARTS - LABEL

Supplier Number:

Supplier Inspected By:

Revision Level:

Supplier Name:

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.

Part Number:

PPAP SAMPLE PARTSINSPECTION VERIFICATION REQUIRED

Purchased Order#:

1

2

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PSW – Part Submission Warrant

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ISIR – Initial Sample Inspection Report

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

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

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EXAMPLE: ISIR – Initial Sample Inspection Report

Example of ISIR Filled out.

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EXAMPLE: Bubble Print

Bubble Print toMatch DimensionalLayout (ISIR)

Includes Notes!Material typesurface finish performancepart I.D.

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

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

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

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EXAMPLE: Print Notes (Material Certification)

1. Print Requirement2. ASTM Chemical Requirement3. ASTM Mechanical Requirement4. PPAP document to outline Requirement and actuals per the Print and Industry standard (ASTM)

1

2

3

4

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EXAMPLE: Print Notes (Material Certification)

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

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

3. Signature on Cert. approving material

1

2

3

Page 18: PPAP Requirements

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1. Verification Prime Coat:permeability, Adhesion, thickness Salt Spray, Ambient Cure Time& Oven Cure Time2. Verification Prime Coat:permeability, Adhesion, thickness Salt Spray, Ambient Cure Time& Oven Cure Time3. Document what print standardIndustry Standard the part has been Painted to.4. Supplier Sign Off

Print Notes – Paint Testing

1

2

3

4

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1. Print Note Paint Note Requirement2. Prime Coat Verification3. Top Coat Verification4. Document what print standard orIndustry Standard the part has been Painted to.

Example: Print Notes – Paint Testing

2

3

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Page 20: PPAP Requirements

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Welding specification

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

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

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4

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Example: Welding specification

1. Document the Welding Specification / Weld Symbol From “bubble print”.2. Document the Welding Specification /WeldSymbol 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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PPAP Workbook – Level 3 Requirements

• 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.

• 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.

• 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..

LEVEL 2 - PPAP

LEVEL 3 - PPAP

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DFMEA

1. Design Failure Mode Effects Analysis is required if the Supplier is design responsible

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

DFMEA - DESIGN FAILURE MODES EFFECTS ANALYSIS

Potential Causes(s)/

Mechanism(s) of Failure

Action Results

Actions Taken

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

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Process Flow Diagram

1. 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.

Product Program Issue Date ECL ECN

Supplier Name Part Name

Supplier Location Part Number

Legend:

Operation Transportation Inspection Delay Storage

Operation or Event Description of Evaluation

Operation or Event and Analysis Methods

Operation

Inspection

Transportation

Storage

Transportation

Operation

Operation

Inspection

Operation

Operation

Operation

Inspection

Inspection

Operation

Inspection

Inspection

Operation

Change History

ADDRESS

PROCESS/INSPECTION FLOWCHART

MODEL / VEHICLE

SUPPLIER COMPANY NAME

P-NUMBER

Date Revision

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

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PFMEA

1. Process failure Mode Effects Analysis is required to be conducted to understand all the potential failure modes and mitigate any know failure modes.

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 D

S 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.

Requirements

PFMEA - PROCESS FAILURE MODES & EFFECTS ANALYSIS

Process Step / Function

Potential 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

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

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Control Plan

1. 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.

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.)

PRODUCT/PROCESS EVALUATION/ SAMPLESPECIFICATION/ MEASUREMENT

TOLERANCE TECHNIQUE

1/1/1996

MACHINE,DEVICE

JIG, TOOLSFOR MFG.

NO. PRODUCT PROCESS

SPECIALCHAR.CLASS SIZE

CONTROL PLAN

PART/ PROCES

SNUMBER

PROCESS NAME/OPERATION

DESCRIPTION FREQ.CONTROLMETHOD

CHARACTERISTICS METHODS

NUMBER

REACTIONPLAN

1/1/1996

Prototype Pre-Launch Production

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

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Tooling – Oshkosh Owned

1. This sheet is used to visually document any Oshkosh owned tooling. It is required to attach a picture of tooling as well as the tooling identification method.

ORGANIZATION: PART NUMBER:

SUPPLIER NUMBER: PART NAME:

DATE:

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

TOOLING & FIXTURES - PROPERTY OF OSHKOSH CORP.

SUPPLIER COMPANYNUMBER

DESIGN RECORD CHANGE LEVEL:

NAMEP-NUMBER

ENGINEERING CHANGE DOCUMENTS:ECNTOOL / FIXTURE NUMBER:

PHOTO OF OSHKOSH OWNED TOOLING AND FIXTURES

PRINT NAME SIGNATURE TITLE DATE

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Capability Studies

1. 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.

Do not delete any numbers from the "Reading" cells after they are typed in. Rather Highlight the cells, right click your mouse and click on "Clear Contents".

Date/TimeReading

Range 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

INFO

30 Pc. Capability

StudyOngoing Statistics

Avg XbarUCLxLCLxStd. Dev.CrAvg RangeUCLrZ UpperZ LowerSkewnessKurtosisCpk UpperCpk LowerAverageMAXMINCp

30 Pc. Capability Study/Ongoing Process Control (Individual Moving Range Chart)

Plant: Operation: Station: Characteristic:

Dept:

Lower Specification Limit:

DATA POINT #

R

an

ge

Ch

art

IM

R B

ar

Ch

art

Upper Specification Limit:

Part Name: Frequency taken:

Part Number: Sample Size:

Tol: 6 Sigma Lower:

0.0000

0.1000

0.2000

0.3000

0.4000

0.5000

0.6000

0.7000

0.8000

0.9000

1.0000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

0.0000

0.2000

0.4000

0.6000

0.8000

1.0000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

01

5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00 55.00

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.0000 0.1000 0.2000 0.3000 0.4000 0.5000 0.6000 0.7000 0.8000 0.9000 1.0000

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

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Gage R&R

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

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

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PPAP Process Flow

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Defense: PPAP Submission / Notification Process

• Oshkosh Purchasing FTP Site Homepage– Upload all PPAP’s to the FTP Site– https://ftp.oshkoshcorp.com/thinclient/

• Email Notification of Documents on FTP site– Email Level 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: FTP Site

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

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Defense: FTP Site – APQP Folder

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

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F&E: PPAP Submission / Notification

• Email PPAP Documents to:– [email protected]

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Commercial: PPAP Submission / Notification

• Email PPAP Documents to:– [email protected]

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JLG: PPAP Submission / Notification

• Email PPAP Documents to:– [email protected]