The Production Part Approval Process (PPAP) is a standardized process in the automotive and aerospace industries that helps manufacturers and suppliers. Are all documents controlled? 5. Is the submission to PPAP 4th edition requirements? 6. Is there clear and proper detail provided on “Reason for Submission”?. There are five generally accepted PPAP submission levels. The PPAP manual contains detailed information, guidelines and sample documents useful for.
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PPAP Submission Items. R Y G FMEA reflects applicable engineering change documents g n . content of their PPAP to the expectations of Eaton for the part. List of PPAP Documents. Customer: Number of samples: Part: Drawing number: Submission date: Document. Requirement to submit. Number of comment. 1. This document is not meant as a training primer on PPAP or any of the many .. Submit PPAP to Hypertherm electronically (in one PDF file).
Not all of the elements are required for every submission.
There are five generally accepted PPAP submission levels. The PPAP manual contains detailed information, guidelines and sample documents useful for completing the process requirements. Why Perform Production Part Approval Process PPAP The PPAP process verifies that the supplier understands all customer engineering design specifications and requirements and that the process is capable of consistently producing product meeting those requirements during an actual production run at the quoted production rate.
PPAP and other quality tools continue to be implemented into more industries; therefore it is important to gain an understanding of the PPAP requirements to remain competitive as a parts supplier. The customer may request a PPAP at any time during the product life.
This demands that the supplier must maintain a quality system that develops and documents all of the requirements of a PPAP submission at any time. This detailed process is a collection of key elements that must be completed to verify that the production process will produce a quality product.
Not all of the elements are always required for a PPAP submission. The particular requirements of the PPAP are usually negotiated during the quoting process. The documentation should also include a copy of the download order. In some cases the supplier is required to supply documentation of material composition.
The download order is used to confirm that the correct part is being ordered and that it is at the correct revision level. The design engineer is responsible for verifying that the two drawings match and all critical or key characteristics have been identified.
Engineering Change Documentation If the PPAP is being required due to a request for a change to a part or product, the documentation requesting and approving the change must be included in the PPAP package. This documentation usually consists of a copy of the Engineering Change Notice ECN , which must be approved by the customer engineering department.
Customer Engineering Approval When required as part of the PPAP, the supplier must provide evidence of approval by the customer engineering department.
If required, pre-PPAP samples are ordered by the customer for onsite testing. The samples must be production intent and ship with a waiver so that testing can be done. When testing is complete, the test engineers will provide an approval form for inclusion in the PPAP submission.
Suppliers are required to obtain PPAP approval from the vehicle manufacturers whenever a new or modified component is introduced to production, or the manufacturing process is changed. Obtaining approval requires the supplier to provide sample parts and documentary evidence showing that: PPAP may be required for all components and materials incorporated in the finished product, and may also be required if components are processed by external sub-contractors.
The term is also used by some other companies like Hyundai and Kia. ISIR is a summary of the initial sample being presented at what ever state. This does not mean the product being presented is under serial conditions but just states with evidence the current status. PPAP is the confirmation that the product meets the customer requirements for series production.
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The severity or impact of each failure is rated, the potential that a specific failure may actually occur is factored in and the probability that the failure can be prevented or at least detected is considered. The intent is to identify risks that are unacceptable and initiate corrective plans that mitigate those risks and help make the process more robust.
Element 7: Control Plan The primary intent of a Control Plan is to create a structured approach for control of process and product elements while focusing the organization on characteristics important to the customer. Control Plans are a compilation of process and product characteristics, test methods to monitor those characteristics, specifications and sampling or testing intervals. A Control Plan does include well thought-out reaction plans to be used in case an out-of-control condition occurs.
Element 8: Measurement System Analysis MSA The analysis of a measurement system involves understanding the uncertainties associated with taking a particular measurement and then, where possible, quantifying those uncertainties. The uncertainties that can be quantified by statistical means include issues of accuracy, linearity, stability, repeatability and reproducibility. Element 9: Dimensional Results For the report of Dimensional Results, identify part numbers and change or revision levels.
For approval, all dimensions must be within the specification tolerances designated by the Design Record.
Dimensional Results are to be reported for each manufacturing process the supplier will use. Performance Tests must be performed and results reported for all parts or product materials when performance or functional requirements are specified by the Design Record or Control Plan.
Objectives of Initial Process Studies are to determine if production processes are stable, will yield acceptable outputs for critical or special characteristics and are ready to begin process validation builds.
Element Qualified Laboratory Documentation Inspection and testing is to be performed by a lab qualified or accredited to conduct the types of tests and measurements.