ppap requirements
TRANSCRIPT
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Global Supplier Quality ManualPPAP 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
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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
****
****
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SSS****
****
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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
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*
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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
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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#:
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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)
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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
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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
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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
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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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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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Commercial: PPAP Submission / Notification
• Email PPAP Documents to:– [email protected]