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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 Production Part Approval Process (PPAP)
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. Key Take Away: PPAP ensures the suppliers have the manufacturing process capability to produce product to meet requirements PPAP must be approved prior to any production parts shipped to Oshkosh facilities.

3 Global Supplier Quality Manual: PPAP Requirements
Key Take Away: When required, Level 2 PPAP is the default Each segment can increase or decrease PPAP requirements due to customer or critical or non critical nature of the parts Outlines required documents for Level 2 and 3

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 Key Take Away: Shows the differences in the current P500 vs Level 2 PPAP. Level 2 requires same documents as a P500/legacy processes, plus Material Certifications, Performance test reports, Paint test reports Level 3 is Level 2 documents plus process control information Long Term Benefit FMTV - REQUIREMENT

5 Defense Website - Example of PPAP Workbook
Click on: Production Part Approval Process (PPAP) Key Take Away: This is a Defense example of where the PPAP workbook can be located.

6 PPAP Workbook – “Excel workbook”
Key Take Away: Cover Sheet for the Oshkosh PPAP workbook.

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. Key Take Away: Summary of Level 2 PPAP requirements and how to navigate the Oshkosh PPAP workbook.

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. 1 Key Take Away: Overview of a Intro Tab in the PPAP workbook. When filled out the information will show up on the following workbook to reduce redundancies in documenting simliar information. 2

9 PPAP Submission Requirements
1 2 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) Key Take Away: Overview of a PPAP Submission Requirements This is an outline of what documents are required for each Submission requirements.

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. 2 Key Take Away: Overview of a PPAP Labeling Requirements

11 PSW – Part Submission Warrant
Key Take Away: Overview of a PSW This is the warrant for the PPAP which outlines what is being submitted in the PPAP.

12 ISIR – Initial Sample Inspection Report
1 2 3 4 5 6 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! Key Take Away: All dimensions are listed from the bubble print. All dimensions are measured and documented on form. Focus if there are any items listed out of print. Verify the specification limits are correct. All notes and specifications called out on the print must be verified and compliance shown 7

13 EXAMPLE: ISIR – Initial Sample Inspection Report
Example of ISIR Filled out. Key Take Away: All dimensions are listed from the bubble print. All dimensions are measured and documented on form. Focus if there are any items listed out of print. Verify the specification limits are correct. All notes and specifications called out on the print must be verified and compliance shown

14 EXAMPLE: Bubble Print Bubble Print to Match Dimensional Layout (ISIR)
Key Take Away: All dimensions are listed from the bubble print. All dimensions are measured and documented on form. Focus if there are any items listed out of print. Verify the specification limits are correct. All notes and specifications called out on the print must be verified and compliance shown Includes Notes! Material type surface finish performance part I.D.

15 Print Notes (Material Certs, Performance Tests & Part Identification)
1 2 3 4 5 6 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. Key Take Away: Performance testing on the print must be verified as part of PPAP 7

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

17 EXAMPLE: Print Notes (Material Certification)
Use Chemical Weighted % from material cert. and transfer to print notes PPAP Page. Mechanical Results to be transferred to print notes PPAP Page. Signature on Cert. approving material 1 2 Key Take Away: Insure the correct material is utilized Supplier should sign off on the raw material certification that they have reviewed the information and it meets the requirements 3

18 Print Notes – Paint Testing
1. Verification Prime Coat: permeability, Adhesion, thickness Salt Spray, Ambient Cure Time & Oven Cure Time 2. Verification Prime Coat: 3. Document what print standard Industry Standard the part has been Painted to. 4. Supplier Sign Off 1 2 3 Key Take Away: Supplier document each paint test result for prime / top coat and what print / industry standard it is being tested and processed to. 4

19 Example: Print Notes – Paint Testing
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. 2 3 Key Take Away: Supplier document each paint test result for prime / top coat and what print / industry standard it is being tested and processed to. 1 4

20 Welding specification
1 3 2 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. Key Take Away: Supplier will identify each welding symbol Supplier will provide the WPS for each symbol Supplier will provide the PQR if not a prequalified joint. Supplier will verify PPAP part to meet the print requirements. 4

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. 2 4 3 Key Take Away: Supplier will identify each welding symbol Supplier will provide the WPS for each symbol Supplier will provide the PQR if not a prequalified joint. Supplier will verify PPAP part to meet the print requirements. 1

22 PPAP Workbook – Level 3 Requirements
LEVEL 2 - PPAP LEVEL 3 - PPAP 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. . Key Take Away: Summary of Level 3 PPAP requirements and how to navigate the Oshkosh PPAP workbook.

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

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. Key Take Away: xxx Note: Utilize AIAG manuals as required.

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. Key Take Away: xxx Note: Utilize AIAG manuals as required.

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. Key Take Away: xxx Note: Utilize AIAG manuals as required.

27 Tooling – Oshkosh Owned
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. Key Take Away: xxx

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. Key Take Away: xxx Note: Utilize AIAG Manuals as required.

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. Key Take Away: xxx Note: Utilize AIAG manuals as required.

30 PPAP Process Flow

31 Defense: PPAP Submission / Notification Process
Oshkosh Purchasing FTP Site Homepage Upload all PPAP’s to the FTP Site 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. 31 4/13/2017

32 Oshkosh Purchasing FTP Site Homepage:
Defense: FTP Site Oshkosh Purchasing FTP Site Homepage: https://ftp.oshkoshcorp.com/thinclient/ 32 4/13/2017

33 Defense: FTP Site – APQP Folder
Supplier should load PPAP’s into APQP folder. Open APQP folder. 33 4/13/2017

34 F&E: PPAP Submission / Notification
PPAP Documents to: 34 4/13/2017

35 Commercial: PPAP Submission / Notification
PPAP Documents to: 35 4/13/2017

36 JLG: PPAP Submission / Notification
PPAP Documents to: 36 4/13/2017


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