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Global Supplier Quality Manual PPAP Requirements.

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Presentation on theme: "Global Supplier Quality Manual PPAP Requirements."— Presentation transcript:

1 Global Supplier Quality Manual PPAP Requirements

2 2 What is PPAP? Production Part Approval Process (PPAP) The purpose of PPAP is to determine if all customer engineering design record and specification requirements are properly understood by the Suppliers and that the manufacturing process has the capability to produce product consistently meeting these requirements during an actual production run at the quoted production rates.

3 3 Global Supplier Quality Manual: PPAP Requirements

4 4 Oshkosh PPAP Level Definitions Level 1 PPAP: –One page document that “warrants” the part meets the design intent, know as a Part Submission Warrant. Level 2 PPAP: –Level 1 Warrant –Dimensional reports –Material certifications –Performance test reports –Welding Standards –Surface Finish test reports –Incoming Inspection usually approves Level 2 PPAP’s Level 3 PPAP –Includes Level 2 PPAP with additional process control documentation. Process Flow Diagrams PFMEA Control Plans Capability Studies –Supplier Quality Engineer Approves –Incoming Inspector still verifies all initial sample parts. AIAG PPAP P500 Oshkosh Corporation – PPAP Long Term Benefit FMTV - REQUIREMENT

5 5 Defense Website - Example of PPAP Workbook Click on: Production Part Approval Process (PPAP)

6 6 PPAP Workbook – “Excel workbook”

7 7 PPAP Workbook – Level 2 Requirements Intro: –Type in Part / Supplier Information, this will be transferred throughout the workbook. PSW Requirements: –This outlines the PPAP submission requirements. (Informational only) Labeling: –This is the label to be used to Identify the PPAP sample part when shipped to OSK PSW: –This documents the warrant that the Part Meets the design Intent –This will be used to communicate back to the supplier the acceptance or rejection of the PPAP Dimensional: –This is used in conjunction with a “bubble print” to document the actual dimensions of the PPAP part. Print Notes: –This is used to document all the remaining notes on print (Material Certs, Surface Finish, Performance Testing, Labeling, etc…) Print Notes – Paint: –This is optional depending if there are Print Notes specifying paint / coating requirements. Print Notes – Welding: –This is optional depending if there are Print Notes / Welding requirements specified.

8 8 Intro “TAB” – PPAP Workbook 1. Part Information 2. Supplier Information Note: This information will Be transferred to all “like” fields In this PPAP Workbook. 2 1

9 9 PPAP Submission Requirements 1.Level 2 Submission is the Default PPAP level. 2. This is the list of what is Required per submission level (Level 1, 2, or 3) 1 2

10 10 PPAP Parts Labeling Requirements 1.All PPAP sample parts must Be tagged with this label on the Part and / or on the box. 2. Document all the appropriate Part / Supplier / PO information On the label. 1 2

11 11 PSW – Part Submission Warrant

12 12 ISIR – Initial Sample Inspection Report 1.Numbering Matches Drawing “bubble print”. 2. Specification and Tolerances 3. Gage Used to measure item 4. How many measured 5. Actual Results 6. Good or Bad 7. Supplier sign off All dimensions on the print must be verified by the Supplier!

13 13 EXAMPLE: ISIR – Initial Sample Inspection Report Example of ISIR Filled out.

14 14 EXAMPLE: Bubble Print Bubble Print to Match Dimensional Layout (ISIR) Includes Notes! Material type surface finish performance part I.D.

15 15 Print Notes (Material Certs, Performance Tests & Part Identification) 1. Numbering Matches Drawing “bubble print”. 2. Specification and Tolerances 3. Gage Used to measure item 4. How many measured 5. Actual Results 6. Good or Bad 7. Supplier sign off Note: This sheet to be used to document all Print Note requirements via the “bubble print” and reference any applicable Test report numbers in the PPAP Package

16 16 EXAMPLE: Print Notes (Material Certification) 1.Print Requirement 2.ASTM Chemical Requirement 3.ASTM Mechanical Requirement 4.PPAP document to outline Requirement and actuals per the Print and Industry standard (ASTM)

17 17 EXAMPLE: Print Notes (Material Certification) 1.Use Chemical Weighted % from material cert. and transfer to print notes PPAP Page. 2.Mechanical Results to be transferred to print notes PPAP Page. 3.Signature on Cert. approving material 1 2 3

18 18 1. Verification Prime Coat: permeability, Adhesion, thickness Salt Spray, Ambient Cure Time & Oven Cure Time 2. Verification Prime Coat: permeability, Adhesion, thickness Salt Spray, Ambient Cure Time & Oven Cure Time 3. Document what print standard Industry Standard the part has been Painted to. 4. Supplier Sign Off Print Notes – Paint Testing

19 19 1. Print Note Paint Note Requirement 2. Prime Coat Verification 3. Top Coat Verification 4. Document what print standard or Industry Standard the part has been Painted to. Example: Print Notes – Paint Testing

20 20 Welding specification 1. Document the Welding Specification / Weld Symbol From “bubble print”. 2. Document WPS / PQR (if not prequalified) 3. Document visual verification of weld size, Weld length, Weld Quantity. 4. Supplier Sign Off Note: WPS’s and PQR’s may be requested and must be provided upon request

21 21 Example: Welding specification 1. Document the Welding Specification / Weld Symbol From “bubble print”. 2. Document the Welding Specification /Weld Symbol from “bubble print”. 3. Document WPS / PQR (if not prequalified) 4. Document visual verification of weld size, Weld length, Weld Quantity. 5. Supplier Sign Off Note: WPS’s and PQR’s must be provided upon request

22 22 PPAP Workbook – Level 3 Requirements Same Requirements as Level 2 with the following additional requirements: DFMEA – Design Failure Mode Effects Analysis is required if the Supplier is design responsibly FLOW DIAGRAM – Process Flow diagram is required to outline and standardize the production process that is being approved. This should outline the entire process that is being used to manufacture the component & assembly. PFMEA – Process failure Mode Effects Analysis is required to be conducted to understand all the potential failure modes and mitigate know failure modes. CONTROL PLAN – The control plan is to be used to document and be used on the shop floor to monitor and control the standardized manufacturing process being approved. TOOLING – This sheet is used to visually document any Oshkosh owned tooling. CAPABILITY STUDY – This sheet is to be used to show evidence the production process is capable to meet the design intent. This is required when Critical Characteristics are identified on the print or other wise specified by Oshkosh Corporation. Gage R&R – This sheet is to be used to show evidence that the measuring method used for the capability studies is repeatable and reproducible.. LEVEL 2 - PPAP LEVEL 3 - PPAP

23 23 DFMEA 1. Design Failure Mode Effects Analysis is required if the Supplier is design responsible Note: Utilize AIAG manuals as required.

24 24 Process Flow Diagram 1. Process Flow diagram is required to outline and standardize the production process that is being approved. This should outline the entire process that is being used to manufacture the component / assembly. Note: Utilize AIAG manuals as required.

25 25 PFMEA 1. Process failure Mode Effects Analysis is required to be conducted to understand all the potential failure modes and mitigate any know failure modes. Note: Utilize AIAG manuals as required.

26 26 Control Plan 1. The control plan is to be used to document and be used on the shop floor to monitor and control the standardized manufacturing process being approved. Note: Utilize AIAG manuals as required.

27 27 Tooling – Oshkosh Owned 1.This sheet is used to visually document any Oshkosh owned tooling. It is required to attach a picture of tooling as well as the tooling identification method.

28 28 Capability Studies 1. This sheet is to be used to show evidence the production process is capable to meet the design intent. This is required when Critical Characteristics are identified on the print or other wise specified by Oshkosh Corporation. Note: Utilize AIAG Manuals as required.

29 29 Gage R&R 1. This sheet is to be used to show evidence that the measuring method used for the capability studies is repeatable and reproducible. Note: Utilize AIAG manuals as required.

30 30 PPAP Process Flow

31 31 5/1/ Defense: PPAP Submission / Notification Process Oshkosh Purchasing FTP Site Homepage –Upload all PPAP’s to the FTP Site –https://ftp.oshkoshcorp.com/thinclient/https://ftp.oshkoshcorp.com/thinclient/ Notification of Documents on FTP site – Level 2 PPAP’s Notification to: – Level 3 PPAP’s Notification to SQE’s – Note : Do not the PPAP’s load them to FTP Site due to ITAR regulations.

32 32 5/1/ Defense: FTP Site Oshkosh Purchasing FTP Site Homepage: https://ftp.oshkoshcorp.com/thinclient/

33 33 5/1/ Defense: FTP Site – APQP Folder Supplier should load PPAP’s into APQP folder. Open APQP folder.

34 34 5/1/ F&E: PPAP Submission / Notification PPAP Documents to:

35 35 5/1/ Commercial: PPAP Submission / Notification PPAP Documents to:

36 36 5/1/ JLG: PPAP Submission / Notification PPAP Documents to:


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