ncr-supplier-PPAP-Training-Presentation.pptx

Click to edit Master title style,Click to edit Master text styleavdcvzxcv xcv zxcv zxcv zxv zxcv xcv xcv xccv zxcv cv zxcv zxcv zxcv zxcv zxcv zxcv zxcv zxcv zxcv s,Second level,Third level,Fourth level,Fifth level,*,NCR Confidential,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,NCR Confidential,*,Click to edit Master title style,Click to edit Master text styleavdcvzxcv xcv zxcv zxcv zxv zxcv xcv xcv xccv zxcv cv zxcv zxcv zxcv zxcv zxcv zxcv zxcv zxcv zxcv s,Second level,Third level,Fourth level,Fifth level,Production Part Approval Process(PPAP),What is PPAP?,P,roduction,P,art,A,pproval,P,rocess,Standard used to formally reduce risks prior to product or service release,in a team oriented manner using well established tools and techniques,Initially developed by AIAG(Auto Industry Action Group)in 1993 with input from the Big 3-Ford,Chrysler,and GM,AIAGs 4,th,edition effective June 1,2006 is the most recent version,PPAP has now spread to many different industries beyond automotive,Purpose of PPAP,Provide evidence that all customer engineering design record and specification requirements are properly understood by the organization,To demonstrate that the manufacturing process has the potential to produce product that consistently meets all requirements during an,actual production run,at the quoted production rate,PPAP manages change and ensures product conformance!,When is PPAP Required?,New part,Engineering change(s),Tooling:transfer,replacement,refurbishment,or additional,Correction of discrepancy,Tooling inactive one year,Change to optional construction or material,Sub-supplier or material source change,Change in part processing,Parts produced at a new or additional location,PPAP is required with any significant change to product or process!,Benefits of PPAP Submissions,Helps to maintain design integrity,Identifies issues early for resolution,Reduces warranty charges and prevents cost of poor quality,Assists with managing supplier changes,Prevents use of unapproved and nonconforming parts,Identifies suppliers that need more development,Improves the overall quality of the product&customer satisfaction,Production Run,PPAP data must be submitted from a,production,run,using,:,Production,equipment and tooling,Production,employees,Production,rate,Production,process,All data reflects the,actual,production,process,to be used at start-up!,Run Rate,The purpose of a,Run Rate,is to verify the suppliers manufacturing process is capable of producing components that meet NCRs quality requirements,at quoted tooling capacity,for a specified period of time,Verification of the Run Rate will be at the Supplier Quality Engineers(SQE)discretion.The supplier will be notified of the need to perform a Run Rate as early in the process as possible.,The number of components to be produced during the Run Rate should be sufficient to demonstrate process capability and will be predetermined by the SQE and the supplier.,Factors such as product complexity,shelf life,storage,cost and single shift vs.multiple shift operations will be taken into consideration,Official PPAP Requirements,Design Records,Authorized Engineering Change Documents,Customer Engineering Approval,if required,Design Failure Modes and Effects Analysis(DFMEA),applied in special situations,Process Flow Diagram,Process Failure Modes and Effects Analysis(PFMEA),Control Plan,Measurement Systems Analysis(MSA),Dimensional Results,Records of Material/Performance Test Results,Initial Process Studies,Qualified Laboratory Documentation,Appearance Approval Report(AAR),Sample Production Parts,Master Sample,Checking Aids,Customer-Specific Requirements,Part Submission Warrant(PSW),Now,lets take a closer look,at NCRs requirements,NCRs PPAP Requirements,Design Records,Authorized Engineering Change Documents,Customer Engineering Approval,if required,Design Failure Modes and Effects Analysis(DFMEA),applied in special situations,Process Flow Diagram,Process Failure Modes and Effects Analysis(PFMEA),Control Plan,Measurement Systems Analysis(MSA),Dimensional Results,Records of Material/Performance Test Results,Initial Process Studies,Qualified Laboratory Documentation,Appearance Approval Report(AAR),Sample Production Parts,Master Sample,Checking Aids,Customer-Specific Requirements,Part Submission Warrant(PSW)NCR calls this the“Production Warrant”,Supplier shall submit these 12 items and retain a copy of records at appropriate locations,Design Records,Authorized Engineering Change Documents,Customer Engineering Approval,if required,Design Failure Modes and Effects Analysis(DFMEA),applied in special situations,Process Flow Diagram,Process Failure Modes and Effects Analysis(PFMEA),Control Plan,Measurement Systems Analysis(MSA),Dimensional Results,Records of Material/Performance Test Results,Initial Process Studies,Qualified Laboratory Documentation,Appearance Approval Report(AAR),Sample Production Parts,Master Sample,Checking Aids,Customer-Specific Requirements,Part Submission Warrant(PSW)NCR calls this the“Production Warrant”,Supplier shall retain these 6 items at appropriate locations,and make readily available upon request,NCRs PPAP Requirements,Level 1,Production Warrant and Appearance Approval Report(if applicable)submitted to NCR,Level 2,Production Warrant,product samples,and dimensional results submitted to NCR,Level 3,Production Warrant,product samples,and complete supporting data submitted to NCR,Level 4,Production Warrant and other requirements as defined by NCR,Level 5,Production Warrant,product samples and complete supporting data(a review will be conducted at the suppliers manufacturing location),PPAP Submission Levels,PPAP Submission Level Table,S=Supplier shall submit to NCR&retain a copy of records or documentation items at appropriate locations,R=Supplier shall retain at appropriate locations and make,readily,available to NCR upon request,*=Supplier shall retain at appropriate locations,and submit to NCR upon request.NCR will identify what is needed for submission.,Definition of Risk,High Risk,Parts associated with multiple critical features,complex design,or high end technology that is not yet established in the general manufacturing environment,Suppliers quality system and/or quality performance is not to NCR satisfaction,Medium Risk,Parts that have at least one critical feature,Low Risk,Parts that have no critical features and can be manufactured by any manufacturer in the commodity category,Suppliers quality system and quality performance are acceptable,Submission Level Requirements,New Parts,Level 2 is required for Low Risk Parts,Level 3 is required for Medium and High Risk Parts,Part Changes,Level 3 is required for Parts produced at a new or additional location,Supplier Quality Excellence will define the level required for all other changes,NCR reserves the right to redefine the submission level required,PPAP Status,Approved,The part meets all NCR requirements,Supplier is authorized to ship production quantities of the part,Interim Approval,Permits shipment of part on a limited time or piece quantity basis,Rejected,The part does not meet NCR requirements,based on the production lot from which it was taken and/or accompanying documentation,Production quantities may not be,shipped before NCR Approval,Electronic Submission Requirements,NCR requires that all PPAPs be submitted electronically,Use of paper submission must have,prior,approval,by the SQE,Submission must be received,on or prior to,the,PPAP due date,Review and Approval Process:,NCR will attempt to review and provide feedback within 2 business days,NCR requires all submissions to be electronic,NCR PPAP Playbook,What is the NCR PPAP Playbook?,An Excel spreadsheet containing templates of the documents suppliers are required to submit to NCR,Why use the PPAP Playbook?,Simplifies the process for suppliers by serving as a“checklist”of what needs to be submitted to NCR,Reduces the number of files to manage,Enables the SQE to quickly see if anything is missing,Show PPAP Playbook,PRODUCTION WARRANT,Production Warrant,Now,lets take a closer look,What is It?,Document required for all newly tooled or revised products in which the supplier confirms that inspections and tests on production parts show conformance to NCR requirements,Used to:,document part approval,provide key information,declare that the parts meet specification,Objective or Purpose,When to Use It,Prior to shipping production parts,Production Warrant,Part Name/NCR Part Number,Engineering released finished,end item part name and number,Safety and/or Government Regulation,“Yes”if so indicated by the Design Record,otherwise“No”,Engineering Change Level&Date,Show the change level and date of,the Design Record,Additional Engineering Changes,List all authorized Engineering,changes not yet incorporated in,the design record but which are,incorporated in the part,Shown on Drawing Number,The design record that specifies,the customer part number being,submitted,Checking Aid Number,Change Level,&Date,Enter if requested by the customer,Purchase Order Number,Enter this number as found on,the contract/purchase order,Supplier Part Number,Part number defined by,the supplier,if any,Production Warrant,NCR Location,Show the location where,parts will be shipped to,Buyer/Buyer Code,Enter the buyers name,and code,Restricted Substances,Enter“Yes”or“No”,Model Name/Number,Enter the model name,and number,Parts Identified with Appropriate Marking Codes,UL,=Underwriters Laboratories safety standards,CE,=Conformite Europeenne(European Conformity),Certifies that a product has met European consumer,Safety,health,or environmental requirements,ISO=International Organization for Standardization,Enter“Yes”or“No”,Supplier Manufacturing Information,Show the name and code assigned to,the manufacturing site,on the,purchase order/contract,Production Warrant,Reason For Submission,Check the appropriate box(es),Requested Submission Level,Identify the submission level,requested by NCR,Submission Results,Check the appropriate boxes,Mold/Cavity/Production Process,If production parts will be produced from,more than one mold,cavity,tool,die,pattern,or production process,the supplier,shall complete a dimensional evaluation on,one part from each.The specific molds,lines,etc.shall then be identified here.,Production Warrant,The approved Production Warrant officially warrants the parts ready for production,Declaration,Enter the number of pieces,manufactured during the,significant production run,and the time(in hours)taken,for the significant production run,Explanation/Comments,Provide any explanatory comments on the,submission results or any deviations,from the Declaration.Attach additional,information as appropriate.,Supplier Authorized Signature,A responsible supplier official,after verifying,that the results show conformance to all NCR,requirements and that all required documentation,is available,shall approve the declaration,For NCR Use Only,To be completed by appropriate,NCR Supplier Quality Engineer,Declaration,Affirmation that the samples represented,by the warrant are representative and,were made by a process that meets NCRs,PPAP requirements,PPAP Warrant Disposition,Approved,Rejected,Other,NCR Signature,Signed by NCR Supplier,Quality Engineer,Reviewers Checklist,Must be completely filled out,Must be signed by the supplier,P/N must match the PO,Submitted at the correct revision level,Submitted at the correct submission level,Specify the reason for submission,Production Warrant,AUTHORIZED ENGINEERING CHANGE DOCUMENTS,Authorized Engineering Change Documents,The supplier shall provide authorized change documents for those changes not yet recorded in the design record,but incorporated in the product,part or tooling,such as:,ECNs,(must be approved,not pending),Specifications,Feasibility studies,Supplier change requests,Sub-assembly drawings,Life or reliability testing requirements,PROCESS FLOW DIAGRAM,Process Flow Diagram,What is It?,A visual diagram of the entire process from,receiving through shipping,including outside processes and services,To help people“see”the real process.Process maps can be used to understand the following characteristics of a process:,Set-by-step process linkage,Offline activities(measurement,inspection,handling),Rework,scrap,Objective or Purpose,When to Use It,To understand how a process is done,Prior to completing the PFMEA,Process Flow Diagrams,The process flow diagram utilizes these symbols to clearly identify each step in the process,Process Flow Diagram-Example,Star Exercise,Divide into teams,Distribute supplies,Paper for Stars,Instructions for making Stars,Scissors,Using the instructions handed out in class,make 10 Shuriken Stars,This exercise will prepare your team to complete future exercises,45 Minutes,Process Flow Diagram Star Exercise,05,Incoming Inspection,10,Paper Folding,15,Cutting,20,Star Folding,25,35,Tucking,30,Final Inspection,Packing,40,Shipping,Inspection as per Operation layout,If rework,possible,Rework,100%Inspection,Scrap,Next Operation,Not OK,OK,Patrol Insp,Report,Reviewers Checklist,Process Flow must identify each step in the process,Should include abnormal handling processes,Scrap,Rework,Process Flow must include all phases of the process,Receiving of raw material,Part manufacturing,Offline inspections and checks,Assembly,Shipping,Process Flow Diagrams,PROCESS FMEA,Process FMEA(PFMEA),When to Use It,After completion of the process flow diagram.,Prior to tooling for production,What is It?,A tool used to identify and prioritize risk areas and their mitigation plans.,The PFMEA should be completed,using a,cross-functional,team!,IMPORTANT!,Objective or Purpose,Identifies potential failure modes,causes,and effects.Inputs come from the process flow diagram.,Identifies key inputs which positively or negatively affect quality,reliability and safety of a product or process.,FMEA Origin,Created by NASA following Apollo 1 mission failure,Allows us to take a proactive approach to what can go wrong in a process and manage our risks better,Process FMEA(PFMEA),This is included in the PPAP Playbook!,TIPS,There should be at least one failure mode for each input.,Using the completed,Process Flow Diagram,enter the process step.,Failure Modes,For each Process Input,determine the ways in,which the input can go,wrong.,PFMEA-Step 1,TIPS,There should be at least one failure effect for each failure mode.,Effects should be specific,clear,and leave no doubt to the uninformed reviewer.,Potential Failure Effects,For each Failure Mode,determine what effect,the specific failure,could have on the,process output.,PFMEA-Step 2,TIPS,There should be at least one potential cause for each failure mode.,Potential Causes,For each Failure Mode,determine the possible cause of the failure.,PFMEA-Step 3,TIPS,This step in the FMEA begins to identify initial shortcomings or gaps in the current control plan.,If a procedure exists,enter the docu