supplier quality management ppap training...

Supplier Quality ManagementPPAP Training Seminar

Electric, Inc.•ALPS Appreciates your Participation in this PPAP Seminar•We all recognize the importance of continual Quality self-improvements•We at ALPS feel that the PPAP submissions submitted by our Category 1 Suppliers is the first step, or start point in this improvement effort.

Electric, Inc.•PPAP process begins with a PAR Form:

•The Part Approval Request Form (PAR)•is the document that defines for the Supplier what the exact requirements are for that specific PPAP Submission

Electric, Inc.•Part Approval Requirements Form (PAR)• To be used as:

• A Table of contents for PPAP submission.• May be used as a check sheet to verify completeness of submitted materials.

Electric, Inc.

•First Section of PAR Form:•Program information, completed by the ALPS SQE

Electric, Inc.•Second Section of PAR Form• The Submission Level indicates to the Supplier which of the defined PPAP criteria applies to his submission. The requirements for PPAP Submission are defined by these levels.• Unusual requirements will be defined in Level 2G• PPAP Approval is the responsibility of the ALCOM SQE.

Electric, Inc.

•Submission Level 3• A submission level of 3 will include the documents for all 19 sections indicated on the PAR• 3 sets of identical Master Boards• 1 complete shot, or sample in a loose or unattached condition• Comments will include any special conditions or instructions.

Second Section of PAR Form

Electric, Inc.

•Submission Level 1• A submission level of 1 will include only those documents indicated in the open sections on the PAR• 3 sets of identical Master Boards• 1 complete shot, or sample in a loose or unattached condition

• Comments will include any special conditions or instructions.


Electric, Inc.

•Submission Level 2• Submission requirements are defined by the reason for the submission and the sub-level: 2A, 2B, 2C,etc.• An undefined reason for submission will be identified as a level 2G and the reason will be included under the indication of Submission Level in the header.• Darkened requirements indicate those requirements that are not required for that submission category.

• Comments will include any special conditions or instructions.


Electric, Inc.

• Typical PPAP Documents

Electric, Inc.

• Robust Mold Tryout - Molder•(Plastic Molded, Insert Molded and Metal Stampings)

ITEM# 1

Electric, Inc.• Part Submission Warrant

– ALPS Specific Form only

– Vigorous Mold Approval

•

ITEM# 1

Electric, Inc.• PFMEA

– Generic: Failure Analysis defining complete system

– Item Specific: Failure Analysis based on this specific Part

FMEA Number

Page of

Item: Prepared By

Model Year(s)/Vehicle(s) FMEA Date (Orig) (Rev.)

Core Team

Actions Taken

Sev

Occ

Det

RPN

Process Responsibility

Key Date

Process Function Requirements

Potential Failure Mode

Potential Effect(s) of Failure

Sev

Action Results

Proc Num

Detec

RPN

Recommended Action(s)

Responsibility & Target

Completion Date

Class

Potential Cause(s)/

Mechanism(s) of Failure

Occur

Current Process Controls

POTENTIALFAILURE MODE AND EFFECT ANALYSIS

(PROCESS FMEA)

ITEM# 2

Electric, Inc.

P/N: Number:

Description: Page: of

Process / Operation: Date (Orig): (Rev):

Prepared by:

Storage Points

Inspection Points

Contrlled Launch

Process Flow Diagram

Proc Step Process Name & Description Important CharacteristicMovement

Fabrication Point

Use to Letter "G" to identfy Actions Below

ITEM# 3

Electric, Inc.

P/N: Number:

Description: Page: of

Process / Operation: Date (Orig): (Rev):

Prepared by:

Storage Points

Inspection Points

Controlled Launch

1015203040505560708090100110115120

Process Flow Diagram

Proc Step Process Name & Description Important CharacteristicMovement

Fabrication Points

Use to Letter "G" to identfy Actions Below

IncomingControl Point

Warehouse

Manufacturing / 1st Article ApprovalControl Point

Manufacturing / 1st Article Approval

Warehouse

Final InspectionControl PointShip

Specified Process ControlsSpecified Launch Controls

Inventory Control


Specified Process Controls

Inventory Control


Process Flow Diagram with Controlled Launch

ITEM# 3

Electric, Inc.• Control Plan

– Defining Generic PFMEA’s & Control Plans to Specific Process applications

Pre-Launch Production Key Contact/Phone Date (Orig.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd)

Part Name/Description Supplier Plant Approval/ Date Customer Quality Approval/Date (If Req'd)

Supplier/Plant Supplier Code Other Approval/Date (If Req'd) Other Approval/Date (If Req'd)

Size Freq.

Reation PlanSample Control Method

Methods

Evaluation/ Measurement

Techinque

Process

Special Char. Class.

CharacteristicsProduct/Process

Specif ication/ Tolerance

No. Product

Part/ Process Number

Process Name/ Operation Discription

Machine, Device, Jig, Tools for Mfg.

Prototype

Control Plan Number

ITEM# 4

Electric, Inc.• Controlled Launch Plan

– Defining additional control points and methods to validate the process capability.

Key Contact/Phone Date (Orig.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd)

Part Name/Description Supplier Plant Approval/ Date Customer Quality Approval/Date (If Req'd)

Supplier/Plant Supplier Code Other Approval/Date (If Req'd) Other Approval/Date (If Req'd)

Size Freq.

Process Name/ Operation Discription

Machine, Device, Jig, Tools for Mfg.

Controlled Launch

Control Plan Number

No. Product

Part/ Process Number

Evaluation/ Measurement

Techinque

Process

Special Char. Class.

CharacteristicsProduct/Process

Specif ication/ Tolerance

Reation Plan & Corrective Actions

Sample

Methods

Control Method

Error Proofing

ITEM# 5

Electric, Inc.• Balloon Drawings

– Original: Identifying all Dimensions and Notes on Drawing

– Transfer: Identifies Specific limited Dimensions and Notes

ITEM# 6

Electric, Inc.

• Dimensional Data– Original: 100% of all dimensions, notes & Tolerances on Drawing

– Transfer: Identified Dimensions, notes & Tolerances

– Dimensional Layout Format: Supplier’s option

• Note: ALPS specific method of Drawing Deviation

ITEM# 6

Electric, Inc.

• Dimensional Data– Revision Levels of Drawing:

• Note: ALPS specific method of identifying Revision Levels

ITEM# 6

Electric, Inc.• Header Information

– Reason for readings– Company Name– Metrology Source– Part Name– Part Number– Revision Level– Color– Customer

• Dimensional Data– Balloon Number– Print Dimension– Print Tolerance– Actual readings

ITEM# 7

Electric, Inc.

• Capability Data – based on;– 350 Pcs Lot size– 125 Pcs Sample (25 Groups of n=5)– SPC Calculation by Cavitation

• 5 Group of n=5 Minimum• X of n=5 to 125 Pcs total

– Gage R&R Data

ITEM# 8

Electric, Inc.•1st Step - Complete • Gage R&R

– Gage Description– Gage ID#– Part Number of article– Description of article– Characteristic being measured–Date of Measurements– Dimension being measured– Tolerance– Number of Appraisers– Number of Trials– Actual Dimensional data

–Confirm acceptability

ITEM# 8

Electric, Inc.

•2nd Step - Complete • Data Matrix

– Part Name– Part Number– Rev. Lev.– Color– Customer– Dimension– Tolerance– Cavitation– Cavity IDs– Actual Dimensional data

ITEM# 8

Electric, Inc.•3rd Step - Complete • Capability Report

– Submission Reason– Company Name & Address

– Metrology Source– Sub-Group size– Matrix ID Number

• Calls dimensional data from Matrix

ITEM# 8

Electric, Inc.•Material Certifications

• Identifying Material & Customer specific requirements• Identifying ALPS Specific Requirements

ITEM# 9

Electric, Inc.•Material Cert of Compliance•ALPS Form FM06022

• IMDS InformationVerification that the component has been registered on the international IMDS Web Page

ITEM# 9

Electric, Inc.• Test Requirements

– The Component Drawing defines specific Supplier responsibilities– Certifications or test data detailing acceptance of these specific test requirements

ITEM# 10

Electric, Inc.• Appearance Form (AAR)

– Customer vs. ALPS Appearance acceptance

ITEM# 11

Electric, Inc.• Part Submission Warrant

– ALPS Specific Form only

– Vigorous Mold Approval

• PPAP Approval

ITEM# 12

Electric, Inc.

• Approval Types– Vigorous Mold Approvals: Accepts Tool and allows– shipment of material for Pre-Production requirements– Limited Approvals: Short term / Interim Approval – meeting intent of Production requirements.– Full Approvals: PPAP compliant, production ready.

– Approvals for ECR changes: Change specific– Tool Repair Approvals: Repair specific– Deviations: To use non-compliant material

ITEM# 12

Electric, Inc.

•Disaster Recovery Form• (ALPS Form FM06023A)

ITEM# 13

Electric, Inc.•Packaging Form (ALPS Form FM06027)

ITEM# 14

Electric, Inc.

•Bar Code Label Format–ALPS Packaging Specification AS-002

ITEM# 14

Electric, Inc.•Misc. Information

– Work Instructions– Laboratory Scope– Inspection format– Inspection Criteria (AAR)

ITEM# 15

Electric, Inc.•Run@Rate Information• – Process Validation

ITEM# 16

Electric, Inc.

• Sample Parts– FFF Samples for Engineering review

• Complete sets (shots)

• Master Boards– Golden Samples for ALCOM (2 samples), Supplier (1 sample)

• 3 Boards with 1 complete set (shot) of parts

• Limit Masters– Max condition samples

• Unique Defect explanation

Electric, Inc.• ALPS Electric, Inc. Appreciates your efforts in achieving a better understanding of the ALPS Automotive Supplier requirements.

•As parts of ALPS partnership philosophy we feel that Zero Defect Philosophy can only be achieved through our common efforts for Product and Process controls.