Presentation on theme: "NCR Confidential1 I Welcome and Introduction to the Agenda-Patrick Harger II Supplier Quality Mission/Responsibilities and Organization III PPAP Playbook-Revision."— Presentation transcript:
NCR Confidential1 I Welcome and Introduction to the Agenda-Patrick Harger II Supplier Quality Mission/Responsibilities and Organization III PPAP Playbook-Revision “E”-Phani Vutukuri IV PQV(Part Quality Verification) Instructions/Importance- Patrick V PPM(Part Per Million-Defective)–Change in calculations- Patrick NCR Supplier Webcast Agenda-April 15, 2013
NCR Confidential2 NCR Global Supplier Quality Team Global Director of Supplier Quality Patrick S Harger European Region Manager of Supplier Quality Norbert Teker APAC Region Manager of Supplier Quality YL Chang Americas Region Manager of Supplier Quality JD Thieke PPAP and PQV Manager of Supplier Quality Phani Vutukuri India Region Manager of Supplier Quality Venkatesan Mohan 6/51
NCR Confidential3 Total H/C – 5 Global Director of Supplier Quality Patrick S Harger European Region Manager of Supplier Quality Norbert Teker SQE Engineer Nairn Mitchell SQE Engineer Edina Szujo SQE Engineer Open position-UK SQE Engineer Open position-BUD European Region Supplier Quality Team 2
NCR Confidential4 Asia Pacific Supplier Quality Team Total H/C – 7 Global Director of Supplier Quality Patrick S Harger Asia Pacific Region Manager of Supplier Quality YL Chang SQE Sally Liu SQE Yao Peng SQE Nemo Ruan SQE Amanda Yang SQE Tone Li SQE Leo Xu 6
NCR Confidential5 Barry Kohut Supplier Quality Southern Region Global Supplier Quality – Americas JD Thieke Supplier Quality Americas Mgr South AmericaNorth America Open Supplier Quality Auditor Open Repair Supplier Quality Central America Region Last update: Luciano Barros Supplier Quality Manaus Region Alexandre Iartelli Supplier Quality Sao Paulo Region (Metals) Dante Maneschi Supplier Quality Sao Paulo Region Jinwu Fan Supplier Quality Midwest Region
NCR Confidential6 Patrick Harger Global Director – Supplier Quality Venkatesan Mohan Manager – India SQE Srinivasan M SQE/Sustainment Lead Senthilrajan S PQV Engr Suresh P PQV Engr Ganesh CK PQV Engr New PQV Engr Lakshminarasimhan, T SQE - Metals Ganasaraman J SQE - Plastics New SQE - Electricals India-Supplier Quality Team 6
NCR Confidential8 NCR New Parts Supplier Quality Responsibilities Mission: Create processes and infrastructure within NCR and our Supply Base to insure all active parts are consistently, statistically capable going into our factories and field. Therefore: We perform Supplier Assessments to add/remove from our Approved Supplier List We formulate the PPAP policies and procedures and maintain the PPAP (Production Part Approval Process) Playbook on the NCR website for all suppliers. We assess risk factors for each part and establish the PPAP Levels We schedule and review all PPAP submissions from suppliers We schedule and perform either Physical PQV (Part Qualification Verification) audits at suppliers or review Eaudits submitted by suppliers. We issue SCARs for PPAP or PQV failures and approve all SCAR responses even if initiated by another part of the organization. We manage data to provide PPM and supplier performance data to the suppliers and to the NCR Organization We work with suppliers to resolve quality issues and drive Root Cause Corrective Action
NCR Confidential Parts Quality Plan Services Parts “Usage” Focus Top 10 – Asia, Europe, CLA, Top 20 – NAMER 40 Unique Parts 2013 Volume Part Focus 3200 parts (includes 190 above) Impact Parts List parts Logistics Parts “Spend” Focus - 15 Unique Parts Mfg Parts Focus 85 Parts (PQV only) Repair Supplier Focus 50 Unique Parts Time to 1st Failure Improvement PQV Capability 2013 Start Target Yield= 97% Time to 2nd Failure Improvement OBF% Improvement Target= 3.0% PQV Capability Target = 3200 parts, Yield = 97% NFF% Improvement Target= 23% PQV Count Achievement (3200 part/qtr.) = 100% PQV SCAR Accountability Resolve Issues Preventatively
NCR Confidential10 PPAP Playbook Changes 10
NCR Confidential11 Major Changes Characteristics on the prints & Capability Requirements – Modified Mandatory Fields Interlocked with Production Warrant Sign off Packaging & Labeling Requirements added Improved Clarity & Reporting of Performance Test Requirements Guidance provided for Equivalent / Alternate Material documentation Added features to guide users to avoid Administrative issues User Manual Created to help Users on how to fill the PPAP Playbook and the requirements 11
NCR Confidential13 Dimensioning & CpK Standards – Nov 2012
NCR Confidential14 Dimensioning & CpK Standards – Feb 2013
NCR Confidential15 Packaging Documentation Requirement Production Warrant Packaging Test Report Test result format provided in PPAP Playbook Note – PPAP Request will cover where Packaging Information required for approval 15
NCR Confidential16 Labels 16 Documentation Requirement Production Warrant Dimension Report Material Test Report Appearance Report RoHS PPAP will be Granted “ Interim Approval” with PPAP PSW sign off Full approval granted after Successful LTO Completion obtain Signature on label from Plant QA and maintain as Master Samples
NCR Confidential17 Pop Up Error Message Pop Up Error Message – for any errors in mandatory fields
NCR Confidential18 Pop Up Error Message RFC Number Pop Up Error Message for If alternate material is used without RFC approval Do not allow Production Warrant Sign off Once RFC details provided – Production Warrant Sign off is enabled
NCR Confidential19 New Separate Tab sheets added for 1.RoHS Compliance Report 2.Salt Spray Test Report 3.Performance Test Report 4.Balloon drawing 5.Sub supplier source 6.Packaging Test Report New
NCR Confidential20 CCD to RCD 20
NCR Confidential21 RCD – Require d Closure Date Request for PPAP PPAP Commit Date Actual Submitted Date Review Date Accepted Update to Merlin & tracker Reject Path Request for PPAP with RCD Reject Path ECC DR Release Submit PPAP Review Date Approved Date Last Submitted Date NPI / ESECC / B Builds etc. Parts Availability / AT Builds Performance Measured to Suppliers Committed Dates CCD Performance Measured to NCR Requested Dates Target to achieve >95% for Q4 RCD
NCR Confidential22 Additional Changes PPAP Request shall have Engineering Drawing [ OR Print ] Drawing from PPAP team – with Critical Dimensions identified where required – in pdf version Required Closure Date [ RCD ] Contact Information in case of queries / issues Blank Playbook Rev E 22
NCR Confidential23 PVQ (Part Quality Verification) Process Objective:To routinely verify that suppliers are providing consistent, statistically compliant parts and assemblies to NCR plants, repair suppliers and customers. Preparation for NCR SQ Engineer (SQE) and the Supplier 1. Review PPAP history and revision level on file. Take copy for comparison. 2. Note and take any active Engineering Change Notices to discuss impact and timing of next PPAP. 3. Determine status of parts to be measured: A. Preference is to use parts that are being manufactured at time of PQV or B. Take parts from supplier stock-note date of manufacture and revision level or C. Take parts from NCR stock as last resort. 4. Pull SCARs and PPM/Quality history for reference for continuous improvement. 5. Pull past PQV history for follow up and notation of consistency of control. 6. The preparation, by the supplier, is critical to be efficient and effective when the SQE arrives. 7. Parts should be gathered, numbered and data should be taken prior to SQE arrival.
NCR Confidential24 Objective: To routinely verify that suppliers are providing consistent, statistically compliant parts and assemblies to NCR plants, repair suppliers and customers. On-Site PQV Instructions-II Manufacturing Process/Control Plan Review A. Review the process flow chart. If it has changed, supplier should resubmit PPAP. B. Review Control Plan & data collection. Note any actions taken when not in control. C. Verify that the operators know how to STOP the process and what they need to do contain product and re-start the process according to their control plan. D. Assign action plans to supplier if not satisfied with controls in place and follow up. E. Review the PFMEA, discuss any additions performed and/or needed. F. Issue SCAR(s) as required to assure documented non- conformances. PVQ (Part Quality Verification) Process
NCR Confidential25 PVQ (Part Quality Verification) Process On-Site PQV Instructions-Data Gathering and Analysis A. For critical dimensions (CD); review Gage R&R (GRR) and note who were the ‘operators’ and measurement instruments. Assure that the same operators and instruments are used for PQV. B. Witness at least 3 samples (of the 30 samples for Cpk calculation) for all CD when operator is taking data. C. Collect data, review and draw conclusions relative to requirement of Cpk>1.67 D. Assign actions items to correct/contain any non conforming parts from supplier to NCR. E. Select 5 samples for ‘minor’ dimensions that have had SCARs. All measurements must be within print tolerance. F. When there are no critical dimensions for a PQV, review SCARs for verification of effectiveness with documented evidence. G. Assure the Control Plan has been modified and/or the PFMEA modified. Objective: To routinely verify that suppliers are providing consistent, statistically compliant parts and assemblies to NCR plants, repair suppliers and customers.
NCR Confidential26 PPM-Defective-The Basic Formula Supplier PPM = Quantity of “supplier liable parts defects” Quantity of all parts receipts Eligible supplier PPM parts will be those received by NCR into our factories and warehouses and on the books of NCR Parts located inside of supplier locations, their distributors and VMI warehouses are not eligible for PPM defect reporting as they are not received by NCR
NCR Confidential27 Rejects counted as Supplier PPM Parts are rejected from the following areas where deemed supplier fault Reject from NCR WIP inventory Reject from NCR stock purge or screen Counted regardless of supplier or NCR performing the screen / rework Reject from NCR incoming inspection screen or full lot rejection Counted regardless of supplier or NCR performing the screen / rework Supplier spills/escapes - recall of defective parts or NCR finished goods Customer spills/escapes – recall of defective parts that reached customer
NCR Confidential28 Rejects NOT counted as Supplier PPM Parts rejected where supplier fault cannot be established or is yet to be established Parts returned to supplier for defect analysis – typically electronics Typically known as “in process” disposition Will not be recorded as supplier PPM at time of disposition Will be recorded as PPM once supplier analysis is completed In transit parts shipped prior to closure of a reported SCAR Parts received at NCR at time of raising a SCAR will be counted Parts remaining in transit – not yet received by NCR after the closure of the SCAR will not be counted – will be flagged for quarantine at incoming
NCR Confidential29 Rejects NOT counted as Supplier PPM (cont’d) Transit damage parts Will not be counted if damage is due to carrier mishandling Will not be counted if legacy packaging is deemed to be inadequate and needing improvement – correct action is to raise a SCAR for correction Will be counted where supplier did not follow their defined packaging process Will be counted where supplier did not follow NCR specified packaging requirements No clear specification for the defect Will not be counted if the defect is completely within published design specifications, Corporate standards, drawings, or quality criteria of which they have been informed. Improved criteria should be negotiated with Engineering / PPAP / QA as required to eliminate ambiguous criteria Co-parts rejected i.e. when a defective harness damages a motor – the harness supplier is liable for one defect, the motor supplier is not liable for a defect
NCR Confidential30 Wrap Up and Summary The revised PPAP Playbook (Rev E) is now in force and will be on the NCR website after 4/18/13 It has been expanded to include items such as packaging and labels Access to the PPAP Playbook including forms and training is at: The PPM calculation has been expanded beyond receiving inspection to include all supplier-caused rejected parts. The focus this year is on the 3200 parts we have identified for PPAP and PQV The 190 “Impact Parts List” is included in the 3200 parts list There will be a higher level of PPAP and PQV performed on assemblies and electronics this year with more emphasis on identifying critical characteristics of the functioning assembly or electronic unit. Your India PPAP Team, NCR Engineering and your assigned SQE will be in touch with those suppliers who have parts on the 190 Impact Parts List to focus on field usage and/or field failures to improve the MTBF (Mean Time Between Failure). It is imperative that our suppliers contain issues and drive for sustained, statistical control of their products delivered to NCR. Expect quarterly PQV Audits (either physical audit or Eaudit) by your NCR Team. Please be prepared! Thank you for attending. There will be a hard copy of the presentation available soon on the website. Are there any questions or comments?
NCR Confidential31 Contact Information 31 My contact information is: Cell phone: I look forward to traveling to many of your sites in early 2013 to meet your staff and view your facilities.