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PQR / PPAP GUIDE Teaching Aid Last Revised March 17, 2014 (SCARs are not addressed in this guide)

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Presentation on theme: "PQR / PPAP GUIDE Teaching Aid Last Revised March 17, 2014 (SCARs are not addressed in this guide)"— Presentation transcript:

1 PQR / PPAP GUIDE Teaching Aid Last Revised March 17, 2014 (SCARs are not addressed in this guide)

2 PPAP Requirements are Based on the AIAG Blue Books “Blue Books” (PPAP-4, APQP-2, SPC- 3, FMEA-4, MSA-4, TS Rules-3) which are used by Polaris Industries can be purchased at: if you are an AIAG member or

3 Supplier Quality Assurance Manual  The Polaris Supplier Quality Assurance Manual (SQAM) is an online guide which defines supplier expectations. Please refer to this manual for information and helpful links.  0.pdf Web Address to Supplier Quality Assurance Manual via the Supplier Portal* Proprietary 3 * (Supplier Portal) provides suppliers with access to many helpful tools and downloadable

4 4 Proprietary

5 pdf Proprietary 5

6 SQAM Table of Contents 6 Proprietary

7 Content within the SQAM 7 Proprietary

8 Label for PPAP/FAIR Samples 8 Proprietary Be sure to ship samples with the proper label per the instructions in the SQAM (recommended label color is orange)

9 Default Level 4 PPAP Request 9 Proprietary

10 Polaris PPAP Manual  Image below is a link to the Polaris PPAP Manual Proprietary 10

11 FAIR and PPAP Requirements (dual dates) Typically used for Production Tooling Approval. Product run on Production Tooling but not run at rate and/or by production procedures. Evidence that all customer Design Record requirements are properly understood and that the manufacturing process (encompassing the entire production process – production tooling, gaging, process, materials, and operators) has the potential to produce product consistently meeting these requirements during an actual significant production run at the quoted production rate. Note: Click on any link (in blue) for a list of requirements Proprietary 11

12 Sample Part and Required Documentation Submission as Noted on the PQR Per the SQAM please place the shipment method of your sample part and tracking number here (this will help if your sample submission is lost) Most email systems will support this link to the QE’s email address for the electronic portion of your submission. Please note in the Supplier Issues section the date electronic documents were submitted, method, and to whom. If documented here and submitted correctly the accountability is now with Polaris. Hard copies may accompany submitted samples but electronic copies must be sent for PQR submissions to the link above Proprietary 12

13 Polaris Comments Section of the PQR rec’d = Received lvl 4 = Level 4 (referring to PPAP level) s/b = Should Be referring to the design record requirement (print) is = The actual measurement bal = Supplier balloon print number associated with the feature sub = Submit or submitted req = Requirements The Comments section of the PQR has a limit to the number of characters we can use when addressing the submission. We want to communicate as much as we can in our responses and because of this we often abbreviate our responses. We thought it might be helpful to explain some of these abbreviations… Proprietary 13

14 Data Compression for Submission Electronic PQR submissions can be quite large. In order to submit the documents via email to the appropriate QE please compress by using PDF, ZIP or PowerShrink (preferred is PowerShrink) Note: Regarding zip files in order for zipped files to pass through the Polaris firewall the name Polaris must be in the file name Proprietary 14

15 PQR Performance Rating Proprietary 15 Supplier Performance – Quality Policy Statement: Quality will have a 30% weight toward the overall GPA in 2012. PPM Performance will make up 20% of the Quality Performance. PQR (Part Qualification Request) Performance will make up 10% of the Quality Performance

16 Recap  Send all data electronically (in.xls,.pdf,.tif or.doc format) to the e-mail link of the appropriate Quality Engineer listed in the PQR system. –Please be sure to include a numbered (bubbled or ballooned) Polaris print with any Dimensional Results (including FAIR) submissions. A submission will not be approved based on electronic data alone. A sample part is required. –If the files are “zipped”, please make sure that “Polaris” is included in the name of file or the e-mail will be quarantined by the Polaris Firewall (‘sometimes’ the POLARIS needs to be bold). –Please only send one e-mail for each PQR with the PQR number AND part number in the “subject” line of the e-mail.  Dimensional Results (including FAIR’s) shall include 100% measurement of a print (including notes) unless otherwise requested in the PQR.  If any dimensions do not meet the print/specifications, a Polaris Approved DCR or Deviation shall be included with the submission.  Make sure that the revision of the part measured matches the revision of the print AND the revision listed on the PQR.  Please ensure that the print revision states “Released”…NOT “Prerelease” or “WIP” in the left hand lower corner of the Polaris Title Block (on the print). Only Polaris Released Prints will be accepted for submission of a PQR. –If you don’t have the Polaris released print, please contact the Polaris Purchasing agent. Proprietary 16

17 Recap (cont)  Ship the sample part(s) to the attention of the responsible Quality Engineer listed on the PQR. Also, include the tracking number on the PQR in the appropriate area. –Sample parts are required for any PPAP or FAIR submission. The sample part(s) must be shipped shortly after the electronic data is submitted.  PPAP PQR sample parts shall be produced (from production tooling, using production personnel, and run at rate) off of production tooling.  FAIR PQR sample parts should be produced from production tooling unless otherwise specified by the QE  Do not ignore a PQR due date or submit late. If you can not meet the PQR due date, please notify the responsible Quality Engineer through the PQR under Supplier Issues. –Make your request noting to whom (QE), when (date) and why.  The Sample Part Tag shall be fixed to the shipping containers. The samples shall be free of charge. DO NOT SEND SAMPLE PARTS WITH INVENTORY / PRODUCTION SHIPMENTS. DO NOT SHIP THE SAMPLE PARTS AGAINST ANY PURCHASE ORDERS. The bill of lading AND/OR the Invoice must clearly state that the parts are “samples” at NO COST TO POLARIS. If samples are shipped against a purchase order, they will be received into inventory and will not be considered as PQR samples. Proprietary 17

18 Example of a Data Submission Example of a PPAP submission (in Excel format) with embedded.pdf files in each of the required element cells. This method of PQR assembly ensures the supplier and assures Polaris that all requirements were met (at a glance) Proprietary 18

19 PQR Received Status Suppliers are responsible until their PQR is received. PQRs aren’t received until both electronic submissions AND sample parts are received by QA. Once received, the received date will display here. Proprietary 19

20 FAQ  If a supplier submits the PQR on the due date and Polaris does not select received on that day, will the supplier get penalized? –It must be flagged as at least received within the calendar month that it is due PQRs are expected to be submitted prior to the due date on the PQR.  When there are two due dates in the system (for example 1 for a FAIR and 1 for a PPAP) and we receive the FAIR data on time, does the due date automatically move out to the later due date once the first on has passed? –Each requirement date is viewed independently however a PQR is only counted once in a given month. For example if the FAIR is due in December and the PPAP in January. The FAIR is approved in December. It counts positively for the supplier in December. The metric does not look at the PPAP date until January.  Confirming the time stamp for calculating “on time” PQRs based off checking “received”, correct? –Suppliers should try to make sure their submission reaches the plant at least 48 hrs prior to the due date to allow for it to be processed by plant QA. Plant QA should at least flag it as received within 48 hrs of its arrival at the plant.  If a supplier submits a late PQR (and they get dinged) and we conditionally approve the PQR submission when received a new date is set for the conditional approval – will the supplier get dinged again for being late to the conditional approval date? –If a PPAP is due in December and the supplier has not submitted it by December 31 st, they would get dinged. If we came back in January and conditionally approved the PPAP to be due in January and by January 31 st we had not received the resubmission the supplier would have received two hits. One for December and one for January. Proprietary 20

21 FAQ (cont)  Why will Polaris not accept hard copies of submission data in lieu of electronic data? –Hard copies cannot be entered into our system and thus viewed by the many people who need access to the data –Electronic submissions can also be traced verifying date of submission  Why does data need to be submitted in.xls,.pdf,.tif or.doc format? –Data must be submitted in acceptable formats which Polaris can open conveniently  Why are bubbled/ballooned prints required with each Dimensional Results or FAIR submission? –The numbered print is used to correlate dimensional data from the supplier  When submitted data to the appropriate QE per the PQR request should anyone else within Polaris be copied? –It is a good idea to copy the Purchasing Agent and the SQE on submissions  Who approves PQRs and what limits do they have? –Polaris QEs are responsible for final approval of PQRs (in MTY SQEs approval PQRs) –Polaris QEs are not authorized (alone) to make decisions outside of the Design Record for non- compliant submissions unless supported by an approved DCR or Deviation Proprietary 21

22 FAQ (cont)  Why must the submitted data be against a RELEASED Polaris drawing? –Polaris Purchasing Agents and Engineers provide suppliers with pre-released drawings for quoting purposes or early discussion –Preliminary, Pre-release or WIP drawings can change at any time with no notice and are exempt from the Polaris Release Cycle –The Released drawing is a contractual agreement as noted on the PO –PQRs are automatically generated after a print is released –Only production POs and production drawings can be PPAPd  What if multiple revisions exist in the PQR system for the same P/N? –Previous revision requirements can be moved forward to the latest PQR upon supplier request –This is not done automatically and subject to certain conditions –Examples: If the earlier revision has never been purchased the earlier PQR can be retracted If the elements of the next revision has earlier been met the later PQR can be retracted or approved –Earlier PQR included an approved DCR The PQR may be a SCAR It may be a supplier change PQR –Other examples/conditions may exist. Please contact the QE listed on the PQR  What if the due date on the PQR cannot be met? –DO NOT ignore the PQR – your metrics will be negatively affected –Notify the QE through the PQR as noted earlier PRIOR to the PQR due date and provide a reason Proprietary 22

23 FAQ (cont)  How important is the PPAP/FAIR sample label and sample submission information in the Supplier Information section of the PQR? –Polaris has many locations and departments. Unless the samples are routed correctly with the correct information the submitted samples can be delayed or even lost –Providing the Shipper Name, Tracking Number and when shipped in the Supplier Information section of the PQR allows for: –Tracking if deliveries are lost or delayed –Provides evidence that the supplier complied with the request – on time  How will I know if the sample part ship location been changed? –Always check the Quality Engineer section of the PQR under Ship To: (4 th panel right side)  Why must I ship a sample part for a FAIR submission and why must it be made from production tooling? –FAIRs are used for tooling approval. Unless submitted parts are made from production intent tooling the production tooling cannot be verified. –Notify the QE through the PQR as noted earlier PRIOR to the PQR due date  What happens to submitted samples after auditing at Polaris? –Samples are scrapped after approval Sometimes samples may be used for destructive testing and could be destroyed in the process Proprietary 23

24 FAQ (cont)  What if I receive a Conditional Approval and the Req Date on the PQR does not match the Conditional Approval date? –The QE should move the Req Date out to match the Conditional Approval date. It is a manual process so if the QE failed to adjust the date please contact the QE and request the date be changed. Do this to avoid a negative metric for being late.  What common problems to we see regarding PQR submissions? –KPCs are not addressed on Control Plans and PFMEAs –Tier II supplier documentation not submitted –Submission is not in English –Results must be submitted in the same format as the Polaris drawing – mm not inches –PSW is filled out incorrectly –Requested elements and/or samples not submitted –Submissions are past due Proprietary 24

25 Drawing Status for Submission DO NOT SUBMIT PQRSUBMIT PQR Proprietary 25

26 DCR & Deviation Submissions Do Not Submit Submit Proprietary 26

27 PSW Minimum Requirements 27 Proprietary  The two most common reasons for rejections upon receipt are: –Improperly completed PSW –Failure to submit the requested documentation and/or sample parts  PSW (minimum requirements) Include the P/N and Rev Level found on the Released production drawing (not a WIP or Prerelease drawing) Note: Non-Production orders may require a FAIR

28 PSW Minimum Requirements 28 Proprietary Be sure to select at least one box for each section – Reason for Submission, Requested Submission Level and Submission Results

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