Presentation is loading. Please wait.

Presentation is loading. Please wait.

PPAP 215 Per ASQR-09.2 Rev B Supplier Awareness Session Course I.D. # 996971 Four Hours COPYRIGHT © HAMILTON SUNDSTRAND CORPORATION. THIS DOCUMENT IS THE.

Similar presentations


Presentation on theme: "PPAP 215 Per ASQR-09.2 Rev B Supplier Awareness Session Course I.D. # 996971 Four Hours COPYRIGHT © HAMILTON SUNDSTRAND CORPORATION. THIS DOCUMENT IS THE."— Presentation transcript:

1 PPAP 215 Per ASQR-09.2 Rev B Supplier Awareness Session Course I.D. # Four Hours COPYRIGHT © HAMILTON SUNDSTRAND CORPORATION. THIS DOCUMENT IS THE PROPERTY OF HAMILTON SUNDSTRAND CORPORATION (HS). YOU MAY NOT POSSESS, USE, COPY OR DISCLOSE THIS DOCUMENT OR ANY INFORMATION IN IT, FOR ANY PURPOSE, INCLUDING WITHOUT LIMITATION, TO DESIGN, MANUFACTURE OR REPAIR PARTS, OR OBTAIN ANY GOVERNMENT APPROVAL TO DO SO, WITHOUT HSS EXPRESS WRITTEN PERMISSION. NEITHER RECEIPT NOR POSSESSION OF THIS DOCUMENT ALONE, FROM ANY SOURCE, CONSTITUTES SUCH PERMISSION. POSSESSION, USE, COPYING OR DISCLOSURE BY ANYONE WITHOUT HSS EXPRESS WRITTEN PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND/OR CIVIL LIABILITY. This document contains no technical data. ECCN:EAR99

2 INTRODUCTION TO ASQR-09.2, UTC PPAP PPAP 215, Supplier Awareness Training as prepared from PPAP 101 and PPAP 201 Course I.D. #: Course Length: 4 HOURS Prepared by :George Bashura SDE Date: February 29, 2012 Revision: B Note to Instructors: DOCUMENT ALL TRAINING PER SP0809 PRODUCTION PART APPROVAL PROCESS Control Page HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 2

3 What PPAP is and what is Hamilton Sundstrands vision on PPAP PPAP key deliverables Your role in PPAP Risk mitigation through FMEA OBJECTIVES By The End Of This Session You Should Understand: HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 3

4 Whats PPAP? HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 4

5 PPAP is a specification used to establish confidence in component suppliers and their production processes, by proving that: "....all Hamilton Sundstrands requirements are met by the supplier and that the process under review has demonstrated, during an actual production run, to have the potential to consistently produce parts meeting these requirements." INTRODUCTION TO PPAP A Definition (Reference AIAG PPAP Manual) Production Part Approval Process HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 5

6 HISTORY OF PPAP Roots in Automotive In 1982 the management staff of General Motors, Chrysler and Ford Motors founded AIAG (Automotive Industry Action Group). The group then created to Advanced Product Quality Planning & Control Plan (APQP), within these standards, the AIAG developed PPAP to advance the parts production approval process of quality planning. The first manual spelling out the multiple requirement of PPAP was published in PPAP is part of the auto industry's overall Advance Product Quality Planning initiative, step-by-step procedures designed to ensure production of an end-product that will satisfy consumers. HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 6

7 7 UTC PPAP Deployment methods to suppliers How deployed? Automotive (Benchmark) – ISO/TS 16949/PPAP Manual Commercial – Supplier Quality Manuals Aerospace – Purchase Order (ASQR-09.2) Automotive 1 st Edition BENCHMARK UTC COMMERCIALUTC AEROSPACE HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99

8 UTC PPAP Why is UTC Aerospace adopting PPAP? COMPONENT RELIABILITY BATHTUB CURVE Failure Rate Time Infant Mortality (Unbudgeted Costs) Useful Life (Warranty Costs) Wear Out PPAP would reduce Infant Mortality costs incurred on a new program KEY DRIVER - Escapes due to: * Poor/Changing designs * Poor manufacturing processes * Misunderstanding requirements * Workmanship errors * Supply Chain fluidity * Control of sub-tiers KEY DRIVER - Inherent Design component reliability based on constant failure rate $ * Beyond Warranty * Aftermarket sales of spare parts B787 TPRs initiated due to key drivers above HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 8

9 UTC PPAP Benefits to Customers, Plant Sites and Suppliers Manufacturing process functions that are clearly planned, validated, documented and communicated that result in: Reduced process variation Statistically controlled processes Enhanced customer confidence in suppliers capabilities Consistent approach in assuring quality and providing evidence Reduced COPQ (infant mortality escapes) Better controlled process changes DevelopmentProduction Prevention through PPAP Current state Time $$ Total Cost of Quality Redesign Re-qualifications Escape Investigations HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 9

10 UTC PPAP PROCEDURE – ASQR-09.2 ASQR-09.2 – AS9102 Comparison Matrix HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 COMPARISON HIGHLIGHTS 14 of 19 elements are covered in AS9102 UPPAP per ASQR requires both design and process risk identification & mitigation UPPAP requires more than one part to be 100% dimensionally verified (requires 5) to show process stability 10

11 Company Private ACCESSING ASQR-09.2 ON HS SUPPLIER PORTAL Click on Quality Click on Aerospace Quality Requirements Scroll down to ASQR-09.2 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 11

12 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 HS SUPPLIER PORTAL HELP 12 Go to: Click on Help tab Get PPAP related materials concerning: 1)FMEA 2)Process Certification 3)Capacity Analysis Tool 4)Manufacturing Process Review forms 5)Quality Clinic Implementation 6)Ito University 7)Training Schedule 8)Supplier Gold 9)Transition Process 10)PPAP 11)….and much more! s can be sent to the following address

13 VISION What does HS want to achieve with PPAP? All new HS designed product (components and assemblies), significantly revised product, and/or product transitions are produced, at all times, using formally validated process in order to mitigate the risk of Customer escapes. HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 13

14 TECHNICAL PROCESS REVIEWS Findings in the production phase HS Supplier Quality conducted 700+ supply base Technical Process Reviews over the last 2 years for various programs Major process weaknesses identified were: Misinterpretation of drawing requirements Operator work instructions inadequacies Little or no use of PFMEA to identify/mitigate process risks Lack of using process controls and mistake-proof methods Inadequate sub-tier supplier flowdown of critical HS requirements Not enough usage of Gage Capability Studies and SPC PPAP will address all the short-comings discovered during these reviews HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 14

15 FORMAL VALIDATION What does this mean? For a Supplier? Suppliers will perform formal production reviews, QC on processes used to manufacture HS product with PPAP requirements Reviews conducted by SQA with functional experts where appropriate (i.e., X-Ray, Heat Treat, etc.) Suppliers will prepare the Objective Evidence Package QC and the checklist QC that supports each element selected HS Supplier Quality will perform a full or partial review of Objective Evidence Package based upon Suppliers PPAP Level UPPAP Approval Submission Form sign-off by Supplier and HS HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 15

16 Company Private HSC PPAP Tool Kit Hamilton Sundstrand has created a PPAP Kit for use by internal plant sites and suppliers Contains all the forms required for submission Includes instruction on the use of the forms Fully compliant to ASQR-09.2, UTC PPAP specification The HSC PPAP Tool Kit contains everything required for submission and is available on the HS Supplier Portal at HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Process Readiness Study Assessment QC PPAP 215 Training Package HT1000 PPAP Implementation Manual PPAP Checklist QC Objective Evidence Package & Forms QC PPAP 1 Review Checklist QC

17 PPAP – PASSPORT RELATIONSHIP P0P1P2 P3P4 P5 Passport 5 Approval to go to serial production and service Passport 4 Validation & Verification Passport 3 Detailed Design Passport 0 Proposal Element 1 Released Production Element 2 SPD/SMD and SI sheets Element 3 Production PO and demand fulfillment Element 4 DFMEA Element 5 Process Flow Element 6 PFMEA Element 7 Process Control Plan Element 8 Process. Readiness Study (PRS) Element 9 Initial Process Capabilities Study Element 10 Measurement System Analysis Complete PD by determining PPAP P/Ns, applicable elements and oversight levels; Begin DD working to communicate PPAP requirements, conduct training and complete the PPAP 1 Review per HT & 11 1, 2, 5, 6, 7, 8, 14, 15, 16, 17 & 18 3, 9, 10, 12, 13, & 19 Element 11 Eng Frozen Planning and/or Source Approval Element 12 Dimensional Report Element 13 Production Verification Testing Element 14 Special Process Approvals & NDT Element 15 Material Certification Documentation Element 16 Raw Material Approval Element 17 Parts Marking Approval Element 18 Pkg, Pres. & Labeling Approval Element 19 Review & Sign-Off PPAP 2 Review PASSPORT GATES Key Reviews PPAP Element Number Expected Completion Time Key Outcomes DCAR PDR CDR Complete DD and starting VV with Producer preparing package. During VV complete PPAP 2 Review per HT0990. Close any gaps with Producer. Complete VV via sign-off of UPPAP Form 1. Enter into Serial Production Legend 1 st Shipment 12 months Months 1-4Months 5-9Months DCAR Design Concept Architecture Review PDR Preliminary Design Review CDR Critical Design Review PPAP 1 Review: Conducted to teach and prepare a Producer for compliance with ASQR-09.2 PPAP 2 Review: Conducted to validate a Producers compliance to ASQR-09.2 F/N=L:\SQ\SD\PPAP\PPAP-Passport Relationship – August 5, 2011 PPAP 1 Review Passport 1/2 HS Awarded Contract Preliminary Design

18 METHOD What are the key elements? PPAP specifies steps and standards for every phase of the planning and production process. PPAP documentation, which follows the product from inception to completion, contains 19 separate elements by the time production is completed. Key documentation requirements are validated on a form called a UPPAP Approval Submission Elements are shown on next page HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 18

19 PPAP ELEMENTS PER ASQR-09.2 Contents for Objective Evidence Package HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 19

20 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Process Flow & Process FMEA GR&R, SPC & Sampling RPN Calculation (Supplier-selected KPCs and/or M/P controls) Process Control Plan & Initial Process Studies Work instructions Visual Aids RCCA (address poor capability) Process Planning PPAP CORE ACTIVITIES SUMMARY HS CTQ Features Escapes, QN & COPQ Interface 20

21 FAILURE MODE EFFECTS ANALYSIS (FMEA) FMEA is a tool used to identify product or process risks Risk mitigation plans are created to reduce probability of failure modes occurring DFMEA (Design FMEA) is completed on a product design for suppliers with design authority per ASQR-09.2 PFMEA (Process FMEA) is completed on all the process steps of the manufacturing and assembly process per ASQR-09.2 Risk Identification and Mitigation Tool See Appendix 1 for FMEA Guideline HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 21

22 FAILURE MODE EFFECTS ANALYSIS (FMEA) Linkages that must be demonstrated ASQR-09.2 requires Suppliers to demonstrate this chain reaction DFMEA PFMEA Control Plans Work Instructions Controls Focus is on the product design and/or specifications Required for suppliers with design authority Look at similar design, Customer MFA, VOC, major escapes & field issues Focus is on the part process including its flow; begins with a flowchart of operational steps Required for all suppliers to perform Look at internal & external escapes, defect data, labor variances, and turnbacks Look linkage to DFMEA where applicable Focus is on how specific process steps will be controlled Required for all suppliers to perform Define Key Process Inputs, Control Methods, Gage Capability, SPC chart and reaction plan Look linkage to PFMEA Focus is on the Operator instructions created for each specific process step Required for all suppliers to perform Look at clarity, user-friendliness Look linkage to Control Plan and HS requirements Focus is on the ability to prevent high RPN failure modes Required for all suppliers to perform Assure compliance to UTCQR-09.1 and ASQR-20.1 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 22

23 New PPAP Workbook Allow suppliers to understand exactly what needs to be completed and submitted for each of the 19 PPAP elements per ASQR-09.2 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 23

24 New PPAP Checklist QC Incorporates all 19 PPAP elements required by ASQR-09.2 Spikes out specifically what to look for each PPAP element HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 24

25 New Process Readiness Study – Element 8 Allow suppliers to self-assess the processes building UTC product to ensure production readiness Originally developed by PWC; added Capacity Planning and FOD Focus areas include: Manufacturing Operation Sheets Tooling Gaging Equipment & TPM Control of Key Product Characteristics (KPCs) Control of Sub-tier Suppliers Capacity Planning Control of Foreign Object Debris (FOD) HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 25

26 Company Private HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 PROCESS CERTIFICATION Applied to HS drawings & specifications per HSC16199 HSM17 now provides specific instructions to DQR relative to Process Certification compliance Suppliers must control KPCs using Statistical Process Control (SPC) Suppliers must enter compliance data into HS Process Certification Database available on HS Supplier Portal General Characteristic Information Key Process Inputs Gage Capability Information Initial Process Capability Results Milestone Tracking Supplier KPC Requirements Documented Process Control Plan Completed Gage Capability Study SPC Data Collection at Operator Workstation Control Charts filled out by Operator Calculated Process Capability Indexes Action Plan to improve KPCs with Low Cpk GOAL: Achieve Milestone IV – Certified Process 26

27 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 27 CAPACITY ANALYSIS REVIEW Recently developed to support Rate Readiness Reviews A tool to assess current & future capacity Conducted to assure ability to meet a ramp-up in schedule Used to identify potential and existing over-capacity situations Develop risk mitigation plans to address over-capacity situations CAT Tool training package and spreadsheet available at: Click on Help tab Click on Quality MPR

28 PPAP Deliverables HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 28

29 Gathered in a specific location, physical (binder) or electronic (e.g., Visual IPI software) to create a "PPAP Objective Evidence Package (OEP) PPAP Approval Submission (Form 1) summarizes its 19 elements and which elements apply to the producer and what level of PPAP surveillance is required PPAP OEP is formally approved by the Producer & HS MFP (Member Focal Point) A PPAP OEP approval means that: The supplier has reviewed and approved the evidence collected and HS has not identified any issues that prevent its approval If issues are identified, interim approval can be granted (there are 5 levels of interim approval) WHAT DOES PPAP LOOK LIKE? HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Retention of Evidence 29

30 SUBMISSION LEVELS Determined based on risk using Decision Tree Tool LevelSubmitted documentation Reviewed at 1PPAP Approval form onlyHS 2 PPAP Approval form with limited supporting data HS 3 PPAP Approval form with complete supporting data HS 4 PPAP Approval form with complete supporting data Suppliers location HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 30

31 PPAP Level Decision Tree – New Parts

32 PPAP Element Exemption Decision Tree PPAP Required Member Defined Raw Material? Special Process Approvals (ref HSM17) No Supplier Design? Frozen Requirements? No Element 11 Exemption Element 13 Exemption Element 14 Exemption Element 15b Exemption Element 16 Exemption Material Purchase Requirements? Element 15a Exemption No Element 4 Exemption Product Verification Testing Raw Material Source DFMEA HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 32

33 PPAP SUBMISSION STATUS & DISPOSITION ASQR-09.2 Interim Classes Pending Full Approval Interim class Characteristics & deviation type Examples (situations or missing evidence) A 100% production tooling. Meet all drawing & specifications Not all production approval requirements are met Incomplete capability studies Drawing changes desired B 100% production tooling Require reprocess / rework to meet all drawing & specifications Temporary operations duly documented C Meet all drawing & specifications Produced using non-production tooling and/or process Temporary manufacturing operation/detail source D Do not meet all drawing & specifications Parts can be considered salable Deviations still exist Plan to address deviations in place E Do not meet all drawing & specifications Parts cannot be considered salable Any unacceptable situation Process is kept in the radar until all requirements are met HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 (CAD) 33

34 PPAP CHANGE NOTIFICATION ASQR-09.2 Form 2 - Criteria for submission The supplier shall notify the member using the UPPAP Notification, ASQR-09.2 Form 2 when any situation described below occurs. Ownership changes (of the Supplier). A change in design. A change in manufacturing source(s), process(s), inspection method(s), locations of manufacture, tooling or materials. A change in numerical control program or translation to another media. A natural or man-made event, which may adversely affect a manufacturing process. A lapse in production for two years or as specified by the customer. HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 34

35 PPAP SUMMARY Key take away PPAP being implemented to reduce infant mortality escapes Upfront validation and verification of critical part processes will enable production readiness HS Customers in full support of this effort and strongly encouraging its deployment Our experience with recent new programs suggest implementation of PPAP is warranted and very appropriate PPAP is flowed out to suppliers by ASQR-09.2 via purchase order HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 35

36 IMPLEMENTATION HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 36

37 HS PPAP 1 Review Purpose: –To prepare Producer for the PPAP 2 Review prior to approval to begin serial production –Teaches the Producer what to do to prepare a PPAP Objective Evidence Package per ASQR-09.2 Conducted by: –HS SQE for external suppliers –Operations Quality Engineer for internal plant sites Whos required to attend the PPAP 1 Review? –Supplier Designated Quality Representatives –Key QA and Production personnel –Engineering representation for Producers with Design Authority Key elements include: –UPPAP Checklist QC –Process Readiness Study QC –UPPAP Workbook QC –UPPAP Submission Form 1 –UPPAP Submission Form 2 for subsequent changes HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 37

38 STANDARD WORK PPAP 215 Training HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 PEG OR OQE –Provide the Producer with PPAP 215 Awareness Training What is PPAP History of PPAP Overview of ASQR-09.2 When PPAP is invoked Producer Deliverables FMEA Overview PPAP Tools (ProCert, Capacity Analysis Tool, etc.) on the HS Supplier Portal Help Tab (www.hssupplierportal.com)www.hssupplierportal.com Process Readiness Study Assessment QC PPAP 215 Training Package HT1000 PPAP Implementation Manual PPAP Checklist QC Objective Evidence Package & Forms QC PPAP 1 Review Checklist QC

39 Conduct PPAP 1 Review HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Purpose: –To prepare Producer for the PPAP 2 Review prior to approval to begin serial production –Teaches the Producer what to do to prepare a PPAP Objective Evidence Package per ASQR-09.2 Conducted by: –HS SQE for external suppliers –Operations Quality Engineer for internal plant sites Whos required to attend the PPAP 1 Review? –Supplier Designated Quality Representative –Key Quality Assurance and Production personnel –Engineering representation for Producers with Design Authority Key elements include: –QC , PPAP 1 Review Checklist –QC , PPAP 2 -FAI Review Checklist –QC , Process Readiness Study –QC , PPAP Objective Evidence Package All forms available in Documentum and the HS Supplier Portal Help tab Both PPAP 1 and PPAP 2 -FAI Checklists are loaded in the STAT Tool PRS Assessment QC PPAP 1 Checklist QC PPAP 2 – FAI Checklist QC Obj. Evidence Package QC

40 HS PPAP 2 Review Purpose: –To formally validate the quality and delivery requirements, based on the applicable elements described in ASQR-09.2, are met for a specific part or part family Conducted by: –Initially by the Producer Supplier if externally sourced part Operations QE if internally sourced part –Reviewed HS SQE for external suppliers –Reviewed by Operations Quality Engineer for internal plant sites Approved by: –Operations QE for make parts –PEG for buy parts –Approval level based on completed element requirements and documented actions to close any gaps What gets submitted? –Completed UPPAP Checklist QC –Completed Process Readiness Study QC –Completed UPPAP Objective Evidence Workbook for all applicable elements QC –Producer signed UPPAP Submission Form 1 –Producer signed UPPAP Submission Form 2 for subsequent changes (when applicable) HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 40

41 Producer Prepares PPAP Package HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Use Form QC PPAP Objective Evidence Package, QC is used by the Producer to substantiate justification for allowance to enter serial production HS PEG reviews drawings and establishes the PPAP scope of work by filling out the matrix contained in Tab A-Input Sheet –Place X if PPAP Element should be reviewed and if MFP wants Producer to provide objective evidence PEG forwards to SDE/OQE to use with Supplier or plant site cell Producer receives package from HS PEG For supplier PPAP part, Producer DQR, per HSM17, required to ensure package is reviewed using PPAP 2 Review Checklist, Form QC For internally made PPAP part, OQE required to ensure package is reviewed using PPAP 2 Review Checklist, Form QC Review includes Element 8, Process Readiness Study –Form QC is to be used All forms available in Documentum and the HS Supplier Portal Help tab Both PPAP 1 and PPAP 2 -FAI Checklists are loaded in the STAT Tool TAB A, INPUT SHEET FROM QC

42 PPAP Objective Evidence Package HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Use Form QC available in Documentum or the HS Supplier Portal COVER & INDEX SHEET Click on button for tab you wish to open When on another tab, click on Index button to return to Cover & Index control panel PRODUCT DEFINITION –Released Engineering drawing that defines design requirements –Specifications called out from the drawing that provide additional definition –PO Notes that specify quality & demand requirements UPPAP CORE ELEMENTS –Risk identification & mitigation with D/P FMEA –Process control using SPC on Key Product Characteristics and gage Capability Studies on measurement systems –FAI dimensional reports that validate feature conformance –PRS that assesses the production process to 8 specific requirements UPPAP SPECIAL ELEMENTS –Frozen Process/Flight Safety approval –Acceptance of test procedure for the product being procured REQUIRED APPROVALS –HS approval for special processes and adherence to suppliers listed on the Report –Part Marking approval utilizing the Part Marking Wizard –Raw Material approval for castings, forgings, etc. that require HS approval of the suppliers FAI APPENDICES –Useful spreadsheet templates the supplier or internal plant site cell may use to support a specific PPAP process control element MAJOR PACKAGE SECTIONS 42

43 43 The 19 PPAP Elements Per ASQR-09.2 Elements 43 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99

44 Element Description Element 1 – Released Production Drawings HS HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Requirement per ASQR

45 Element Description Element 1 – Released Production Drawings HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 NOTE: Any identified action items get transferred to Form 1, UTC Approval Form. This applies to all PPAP Elements under review. 45 PPAP 2 -Checklist – Form QC

46 Element Description Element 2 – SPD/SMD and SI Sheets HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 2AcceptableNot Acceptable SPD/SMD & SI Sheets (for HS, these are the PO Notes) PO Quality Notes are reviewed and found include proper references to ASQR-01, HSC16199 in case part is a CTQ Part, FAI requirements per ASQR-01 are specified, etc. No references made to a required HS and/or UTC specification when required by the HS drawing. Definition per ASQR

47 Element Description Element 2 – SPD/SMD and SI Sheets HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 NOTE: Any identified action items get transferred to Form 1, UTC Approval Form. This applies to all PPAP Elements under review. 47 PPAP 2 -Checklist – Form QC

48 Element Description Element 3 – Production PO and Demand Fulfillment HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 3AcceptableNot Acceptable Production PO and Demand Fulfillment PO is a production order. 1 st - tier PO to Sub-tier illustrates flowdown of HS/UTC requirements per ASQR-01. Experimental or Advanced PO. Sub-tier flowdown of HS/UTC requirements per ASQR-01 not met. Definition per ASQR-09.2 Requirement per ASQR-09.2 ABC Company, Inc. 240 Charles Street Torrington, CT United States of America 48 PPAP 2 -Checklist – Form QC

49 Element Description Element 3 – Production PO and Demand Fulfillment HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 NOTE: Any identified action items get transferred to Form 1, UTC Approval Form. This applies to all PPAP Elements under review. 49 PPAP 2 -Checklist – Form QC

50 Element Description Element 4 – Design Failure Modes Effects Analysis HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 4AcceptableNot Acceptable DFMEADFMEA is illustrated by the Producer that meets the SAE J1739 standard. Producer can demonstrate VOC data used. DFMEA shows risk analysis that addresses design and prior failures from similar designs. No DFMEA produced by a producer with design authority. Areas of high risk not addressed with adequate process controls. Lack of linkage to PFMEA. No evidence customer data, prior failures & escapes from a similar design used in analysis. Requirement per ASQR-09.2 Learn the details of conducting a DFMEA in PPAP 301 – MFP Certification 50

51 ASQR-09.2 requires Suppliers to demonstrate this chain reaction DFMEA PFMEA Control Plans Work Instructions Controls Focus is on the product design and/or specifications Required for suppliers with design authority Look at similar design, Customer MFA, VOC, major escapes & field issues Focus is on the part process including its flow; begins with a flowchart of operational steps Required for all suppliers to perform Look at internal & external escapes, defect data, labor variances, and turnbacks Look linkage to DFMEA where applicable Focus is on how specific process steps will be controlled Required for all suppliers to perform Define Key Process Inputs, Control Methods, Gage Capability, SPC chart and reaction plan Look linkage to PFMEA Focus is on the Operator instructions created for each specific process step Required for all suppliers to perform Look at clarity, user-friendliness Look linkage to Control Plan and HS requirements Focus is on the ability to prevent high RPN failure modes Required for all suppliers to perform Assure compliance to UTCQR-09.1 and ASQR-20.1 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element Description Element 4–DFMEA linkage to PFMEA must be demonstrated!! 51

52 Element Description Element 4 – Design Failure Modes Effects Analysis HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 52 PPAP 2 -Checklist – Form QC

53 Element Description Element 4 – Design Failure Modes Effects Analysis HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR9900 PPAP Objective Evidence Workbook – Form QC , Tab 4 - DFMEA QC contains a DFMEA template on Tab 4 with full instructions for use Click on upper right hand corner for any column for complete instructions for that given field This template meets the SAE J1739 standard 53

54 Element Description Element 5 – Process Flow HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 5AcceptableNot Acceptable Process Flow Process flow map with operation information: Sequence, flow map symbols used, identification of CTQ Features, alternate paths and formal rework loops identified. Identify if flow map represents a part family. Process Flow steps clearly correlate with PFMEA and Control Plan. Route Sheets/Travelers are acceptable if they contain adequate information. No process flow map exists. A process flow exists that contains insufficient information in describing the process flow. Process Flow steps do not correlate with PFMEA and Control Plan. Process Flow Examples Requirement per ASQR

55 Element Description Element 5 – Process Flow HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 NOTE: Any identified action items get transferred to Form 1, UTC Approval Form. This applies to all PPAP Elements under review. 55 PPAP 2 -Checklist – Form QC

56 Element Description Element 6 – Process Failure Modes Effects Analysis HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 6AcceptableNot Acceptable PFMEADocumented evidence of a PFMEA that meets the SAE J1739 standard. PFMEA illustrates linkage to Process Flow Map. PFMEA shows risk analysis that addresses process risks and prior internal defects and/or Customer escapes taken into account from similar designs. Customer CTQ Features (e.g., KPC1, KPC2, etc.) identified on PFMEA. Producer self-selected KPCs identified on PFMEA where appropriate. No PFMEA produced by a producer. Areas of high risk not addressed with adequate process controls. Lack of linkage to PFMEA. No evidence customer data, prior failures & escapes from a similar design used in analysis. No identification of Customer and/or self-selected KPCs where appropriate. Requirement per ASQR-09.2 Learn the details of conducting a PFMEA in PPAP 301 – MFP Certification 56

57 Element Description Element 6 – Process Failure Modes Effects Analysis HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 57 PPAP 2 -Checklist – Form QC

58 Element Description Element 6 – Process Failure Modes Effects Analysis HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR9900 PPAP Objective Evidence Workbook – Form QC , Tab 6 - PFMEA QC contains a PFMEA template on Tab 6 with full instructions for use Click on upper right hand corner for any column for complete instructions for that given field This template meets the SAE J1739 standard 58

59 Element Description Element 7 – Process Control Plan HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 7AcceptableNot Acceptable Process Control PlanDocumented evidence Process Control Plan meets UTCQR Process Control Plan clearly illustrates linkage to PFMEA. Electronic Control Plans are properly developed for all HS defined KPCs. No documented evidence of a Process Control Plan or the one presented does not meet UTCQR Cannot link controls listed on PCP to high risk areas identified on PFMEA. No and/or impartial evidence Electronic Control Plans are developed for HS defined KPCs in the HS ProCert Database. Requirement per ASQR

60 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 A control plan describes how we mange and control process risks identified on the PFMEA. A control plan is a set of written strategies which define the steps to take to maintain statistical control and capability of the process. The format seen below is used by the Producer for describing how the critical steps of the manufacturing and/or assembly process is controlled. Note that some divisions within UTC may have specific control plan requirements just for KPCs. The next slide illustrates an example of the control plan format utilized by HS for engineering defined Key Product Characteristics. Element Description Element 7 – Process Control Plan CONTROL PLAN QUESTIONS –What do I check? –How do I check it? –How often do I check? –What gage do I use? –What is the capability of the gage? –What inputs do I set? –What setting? –How are the inputs controlled? –What preventative maintenance do I do before I run a part? 60

61 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Control Plan Requirements – Part 2 Documented Process Control Plan Completed Gage Capability Study SPC Data Collection at Operator Workstation Control Charts filled out by Operator Calculated Process Capability Indexes Action Plan to improve KPCs with Low Cpk A control plan describes how we mange the KPC The format seen below is used by the Producer for HS defined KPCs using the Process Certification Database available on the HS home page or the HS Supplier Portal. Element Description Element 7 – Process Control Plan for KPCs Each HS defined KPC must be accounted for in the HS Process Certification Database. An Electronic Control Plan for each KPC must be developed and maintained by the supplier (externally made parts) and/or internal plant site (internally made parts) The requirements of UTCQR-09.1 (both internally and supplier made parts), HSM17 (supplier made parts) and HT0985 (internally made parts) must be followed and complied with. Control Plan Requirements – Part 1 61

62 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element Description Element 7 – Process Control Plan Below is a Process Control Plan format that meets the requirements of UTCQR-09.1, UTC Process Certification Requirements. Control Plan Example 62

63 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element Description Element 7 – Process Control Plan 63 PPAP 2 -Checklist – Form QC

64 Element Description Element 8 – Process Readiness Study HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 8AcceptableNot Acceptable Process Readiness StudyDocumented evidence Process Readiness Study completed by the Producer. Overall results of the PRS are >/= 80%. If the overall PRS results are less than 80%, action items are in place with responsible persons and expected completion dates for areas scored 3 and below. No documented evidence of a PRS being conducted by the Producer. Overall PRS score results in less than 80% and no plan exists to address low scores. Requirement per ASQR

65 Allow suppliers to self-assess the processes building UTC product to ensure production readiness Originally developed by PWC; added Capacity Planning and FOD Focus areas include: Manufacturing Operation Sheets Tooling Gaging Equipment & TPM Control of Key Product Characteristics (KPCs) Control of Sub-tier Suppliers Capacity Planning Control of Foreign Object Debris (FOD) Element Description Element 8 – Process Readiness Study HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 65

66 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Capacity analysis one of the eight areas assessed as part of PRS Capacity Analysis Tool (CAT) developed to assess current & future capacity Conducted to assure ability to meet a ramp-up in schedule Used to identify potential and existing over-capacity situations Develop risk mitigation plans to address over-capacity situations CAT Tool training package and spreadsheet available at: Click on Help tab Click on Quality MPR Element Description Element 8 – PRS Capacity Analysis Review 66

67 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element Description Element 8 – Process Readiness Study 67 PPAP 2 -Checklist – Form QC

68 Element Description Element 9 – Initial Process Studies HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 9AcceptableNot Acceptable Initial Process StudiesAll HS defined KPCs are identified on the PFMEA, Process Flow Map, Control Plan and work instructions. In case of SDE suppliers, any HS defined CTSC/CTQC features have lower-level KPCs that were self-selected by the supplier and approved by HS Quality and/or Engineering. Producer can show evidence that SPC is being implemented for HS defined or self-selected KPCs using control charts. Evidence that Producer is addressing KPCs with low Cpks (e.g., Cpks< 1.0). No documented evidence of a Process Control Plan or the one presented does not meet UTCQR Cannot link controls listed on PCP to high risk areas identified on PFMEA. No and/or impartial evidence Electronic Control Plans are developed for HS defined KPCs in the HS ProCert Database. Requirement per ASQR

69 QC , PPAP Objective Evidence Package includes Appendix 5, Capability Calculator that can be used to perform the following tasks: Enter SPC data collected from the process Calculate Cp & Cpk Produce Individuals Control Chart based utilizing 3-Sigma Limits Create Moving Range Control Chart based utilizing 3-Sigma Limits Element Description Element 9 – Initial Process Studies Process Capability Control Charts Raw data entry HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 69

70 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element Description Element 9 – Initial Process Studies In PPAP Objective Evidence Package, Form QC , Producer will provide in Tab 9, Initial Process Studies, an example SPC output along with a summary table for the status of all other HS defined or self-selected KPCs. 70 PPAP 2 -Checklist – Form QC

71 Element Description Element 10 – Measurement Systems Analysis Studies HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 10AcceptableNot Acceptable Measurement Systems Analysis Studies Gage Studies (Short Form as a minimum) are conducted on measurement systems involving HS defined and producer self- selected KPCs Results are entered into the HS ProCert Database. Action plan exists for gage Study results greater than 20% per HSM17 (supplier made parts) or HT0985 (internally made parts). 10% rule-of-thumb employed for measurement resolution. No documented evidence of a Gage Capability Studies performed per HSM17/HT0985. Gage Study results not entered into the HS ProCert Database. Lack of action plans for Gage Study results greater than 20% of tolerance. Gages used have inadequate measurement resolution. Requirement per ASQR

72 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element Description Element 10 – Measurement Systems Analysis Studies In PPAP Objective Evidence Package, Form QC , Producer will provide in Tab 10, MSA, an example Gage Capability Study output along with a summary table for the status of all other HS defined or self-selected KPCs. Sample Gage Study 72 PPAP 2 -Checklist – Form QC

73 QC , PPAP Objective Evidence Package includes the following appendices: Appendix 2, Gage Capability Short Form Study Appendix 3, Gage Capability Long Form Study Appendix 4, Gage Capability Attribute Form Study Templates compute Gage Capability as a % to tolerance and 6-Sigma Long Form separates effects of gage from inspector Element Description Element 10 – Measurement Systems Analysis Studies Example Gage Capability Short Study Form HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 73

74 Element Description Element 11 – Eng. Frozen Planning/Source Approval HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 11AcceptableNot Acceptable Engineering Frozen Planning/Source Approval (EFP/ESA) Where Flight Safety Parts & Characteristics apply, processes generating FSC features have been approved by the HS Flight Safety Parts Review Board per HSC16199/HS Producer has annotated their documentation with a unique identifier per HS16199/HS Flight Safety Audit performed by HS with no findings outstanding. No documented evidence of a HS Flight Safety Parts Review Board approval for Producers processes that generate Flight safety Parts/Characteristics per HSC16199/HS Flight Safety Parts/Characteristics not identified properly per HSC16199/HS Findings documented in prior HS Flight Safety Audit are overdue. Requirement per ASQR PPAP 2 -Checklist – Form QC

75 Element Description Element 12 – Dimensional Report HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 12AcceptableNot Acceptable Dimensional ReportA FAIR (per AS9102A) for 1 part, and four supplementary dimensional reports for 4 additional randomly selected parts. 5 total parts must be represented of all unique process streams per ASQR-09.2, Section C. All features must meet the drawing requirements. Note: Reductions in sample size of amount of inspected drawing characteristics shall be documented and formally agreed to with HS MFP. First Article Inspection Report (FAIR) only for one part Features found to be unaccounted for. Some features checked in an over- inspection found to be out-of-tolerance. QN accepted non-conformances Requirement per ASQR PPAP 2 -Checklist – Form QC

76 Element Description Element 13 – Production Verification Testing HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 13AcceptableNot Acceptable Production Verification TestingATP tests results based on the test specification called out on the engineering documentation are evident for the prescribed quantity or a minimum of 5 units. Tests results are all acceptable to the test specification. Less than five units of data exists. Nonconformances present in the test results. Requirement per ASQR PPAP 2 -Checklist – Form QC

77 Element Description Element 14 – Special Process Approval and NDT HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 HS Report REPORT 80 - Lists all HS suppliers approved to perform a specific special process per an HS specification. These are suppliers that are only special process houses. They do not manufacture product. REPORT 85 - Lists all suppliers approved by HS to perform internally a specific special process per an HS specification. These suppliers manufacture product and have as part of their operations the ability to perform special processes. Example of Report 80 as seen from HS Supplier Portal 77

78 Element Description Element 14 – Special Process Approval and NDT HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Requirement per ASQR

79 Element Description Element 14 – Special Process Approval and NDT HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 14AcceptableNot Acceptable Special Process Approval and Non- Destructive Test (NDT) Supplier aware of all special process/NDT requirements called out on HS documents. Special Process and/or NDT suppliers all have proper approvals for the HS specification called out and appear on the HS Report. Evidence is readily available from 1 st -tier supplier for any special testing required by the HS specification. Supplier did not account for all special process/NDT requirements called out on HS document. Supplier utilized a special process/NDT supplier not on the HS Report. Supplier cannot produce evidence that special testing called out in the HS specification was completed. 79 PPAP 2 -Checklist – Form QC

80 Element Description Element 15 – Material Certification Documentation HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 15AcceptableNot Acceptable Material Certification DocumentationWhen required by HS document, C of C readily available showing material procured from an HS approved source. For SDE suppliers, C of C available that shows material procured from SDE approved source. Materials procured from non-approved HS source have supporting test reports from an HS approved test facility. No evidence of approvals. Requirement per ASQR PPAP 2 -Checklist – Form QC

81 Element Description Element 16 – Raw Material Approval HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 16AcceptableNot Acceptable Raw Material ApprovalA HS approved layout report with no non-conformances No layout report or an approved layout report with QN accepted nonconformances. Requirement per ASQR PPAP 2 -Checklist – Form QC

82 Element Description Element 17 – Part Marking Approval HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Element 17AcceptableNot Acceptable Part Marking ApprovalPhoto of Part Marking including 2D marking if applicable. Copy of 2D marking approval by HS. No photo of marking or no evidence of 2D marking approval from HS. Requirement per ASQR

83 Element Description Element 17 – Part Marking Approval HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Part Marking Wizard available on HS Supplier Portal Aids a supplier in how to mark an HS part using a four step process Encompasses part marking specifications from three HS design centers (Windsor Locks, Rockford and San Diego) Will enable successful completion of PPAP Element PPAP 2 -Checklist – Form QC

84 Element Description Element 17 – Part Marking Approval HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Part Marking Wizard – HS Supplier Portal 84

85 Element Description Element 18 – Packaging, Preservation and Labelling Approval 85 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Requirement per ASQR-09.2 (18) Packaging, Preservation and Labeling Approval The UPPAP file shall contain documented evidence of member approval of packaging per the invoked packaging specification. Element 18AcceptableNot Acceptable Packaging, Preservation and Labeling (PP&L) Approval Documented evidence of HS approved packaging requirements. For Raw Material suppliers, is acceptable. For all other, evidence is copy of HS packing instructions from HS supplier portal. No documented evidence of HS PP&L approval. PPAP 2 -Checklist – Form QC

86 Element Description Element 19 – Review and Sign-Off 86 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Requirement per ASQR-09.2 The Producer shall use the PPAP2-Checklist, Form QC , to assure package integrity Element 19AcceptableNot Acceptable Review and Sign-OffForm 1 completed and signed by the Producer. Evidence review conducted using PPAP 2 - FAI Checklist to assure comprehensive review. Action items with assigned individuals and expected completion dates for any incomplete elements. No documented evidence of HS PP&L approval. No evidence Producer utilized the PPAP 2 -FAI Checklist in their review. No plan exists and/or incomplete plan for unfinished PPAP elements. (19)Review and Sign-Off The supplier shall: a. Verify all measurement and test results show conformance with member requirements. b. Ensure all required documentation is available within the UPPAP file. c. Review all applicable data for content, accuracy, and process repeatability before submitting for approval. d. Upon a satisfactory internal review, complete a UPPAP Approval, ASQR-09.2 Form 1, (refer to Appendix 1), and submit to the MFP for approval. e. Complete a separate ASQR-09.2 Form 1, for each part number unless otherwise agreed to by the MFP.

87 PPAP Validation HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Producer submits PPAP Package for approval Conduct PPAP 2 Review. – Level 4 PPAP requires that an on-site validation to be conducted. Review must witness the actual process at the Producer. Determine gaps Provide feedback to Producer Producer re-submits updated package 87

88 PPAP Approval HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 Sign UPPAP Form 1 Update PPAP database Forward Form 1 to Producer 88

89 1) PPAP is an acronym for; A.Purchased Part Activity Planning B.Part Planning Approval Process C.Production Part Approval Process D.Part Production Activity Plan E.Process Planning And Production F.Part Planning And Procurement 2) PPAP has 13 elements; A True B False 3) There are 5 levels of PPAP: A. True B.False 4) A DFMEA for a level 3 PPAP is required by all producers: A. True B.False TRIVIA QUESTIONS HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 89

90 F/N=L:\Supplier Quality\Supplier Development\Training Materials\Practical Process Control Applications – P. Teti, October 25, 2007.ppt Page 90 QUESTIONS? HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99

91 F/N=L:\Supplier Quality\Supplier Development\Training Materials\Practical Process Control Applications – P. Teti, October 25, 2007.ppt Page 91 APPENDIX 1 FMEA Guideline HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99

92 FAILURE MODE EFFECTS ANALYSIS (FMEA) A systematic technique to: Identify potential failure modes Identify possible causes and effects of potential failure modes Evaluate and manage risk by prioritizing failure modes according to: – Occurrence probability – Severity – Detection probability – Identify control methods to eliminate or minimize the effect of potential failures – Provide a means of evolving organizational knowledge Definition HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 92

93 A prevention tool used to determine possible failures before they happen. –Results of an FMEA lead to the establishment of process controls. Can be used on a product. –Tree diagram showing how details flow into assemblies. –Understand what the Critical-To-Quality (CTQ) parts are to the Customer that affect performance, reliability, and safety. –Determine Key Product Characteristics for the CTQ parts Can be used on a process (PFMEA) –Flowchart the key process steps (see next two pages). –Identify what could go wrong at each process step. –Identify controls needed on Key Process Inputs (KPIs, i.e., poka- yoke (timers, sensors, guide pins), control charts, etc.). –Determine Key Product Characteristics to measure output. FAILURE MODE EFFECTS ANALYSIS (FMEA) HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 93

94 FAILURE MODE EFFECTS ANALYSIS (FMEA) Failure Mode and Effects Analysis (FMEA) is a preventive analytical technique utilized by designers (product or process) to methodically study the cause and effects of failures before a design is finalized. In essence, a product or process is examined for all the ways in which a failure can occur. For each potential failure, an assessment is made of its effect on the system and its seriousness. In addition, a review is made of the action being taken (or planned) to minimize the probability of failure or to minimize the effects of failure. What is FMEA? HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 94

95 FAILURE MODE EFFECTS ANALYSIS (FMEA) The FMEA supports the design process in reducing the risk of failure by: Aiding in the objective evaluation of design requirements and design alternatives. Increasing the probability that potential failure modes and their effects on system operation have been considered in the design/development process. Providing additional information to aid in the planning of thorough and efficient design test and development programs. Developing a list of potential failure modes ranked according to their effect on the Customer. Providing an open issue format for recommending and tracking risk reducing actions. Providing future reference to aid in analyzing service concerns, evaluating design changes, and developing advanced designs. What does FMEA do? HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 95

96 FAILURE MODE EFFECTS ANALYSIS (FMEA) A cost reduction process, although it may result in cost avoidance. A way to reduce testing requirements – it may result in additional testing requirements. A replacement for formal design reviews. A process we perform at the last minute to satisfy a customer requirement. More useless paperwork we fill out before we get a new development program signed off. An opportunity to document all of the ways we think the plant will mess up when manufacturing the product. What an FMEA is not HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 96

97 FAILURE MODE EFFECTS ANALYSIS (FMEA) Benefits HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 97

98 Use Product or Process Guide Sheets when facilitating an actual FMEA meeting. Key questions relevant to each FMEA column are listed and should be asked. Have a recorder (someone with decent handwriting!) assigned and record Team inputs on a 11" by 17" blank FMEA worksheet. Permanent recording can be done on a computer spreadsheet. Develop action plan for RPN's calculated, such as: – KPC implementation using SPC – Create process control plan – Added test procedure – Mistake-Proof solution based on design or process FMEA GUIDE SHEET HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 98

99 DESIGN FMEA GUIDE SHEET HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 99

100 PROCESS FMEA GUIDE SHEET HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 100

101 101 Holding Spot for NEW D/P FMEA

102 102 Severity – SAEJ1739 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 102

103 103 Occurrence – SAEJ1739 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 103

104 Detection – SAEJ1739 HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 104

105 PFMEA EXAMPLE – MAKING RICE Process Flowchart HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 105

106 PFMEA EXAMPLE – MAKING RICE HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99 106

107 F/N=L:\Supplier Quality\Supplier Development\Training Materials\Practical Process Control Applications – P. Teti, October 25, 2007.ppt Page 107 QUESTIONS? HAMILTON SUNDSTRAND PROPRIETARY INFORMATION. USE OR DISCLOSURE OF INFORMATION ON THIS PAGE IS SUBJECT TO THE NOTICE OF RESTRICTIONS ON THE FIRST PAGE OF THIS DOCUMENT. THIS DOCUMENT OR FILE CONTAINS NO TECHNICAL DATA. ECCN: EAR99


Download ppt "PPAP 215 Per ASQR-09.2 Rev B Supplier Awareness Session Course I.D. # 996971 Four Hours COPYRIGHT © HAMILTON SUNDSTRAND CORPORATION. THIS DOCUMENT IS THE."

Similar presentations


Ads by Google