Pre-Production Inspection Report (PPIR) Process Overview

Pre-Production Inspection Report (PPIR) Process Overview
Quality Engineering Last update: 02 October 2017 Author: Antonio Tedesco, D8 Programme Quality Engineering

PPIR Process Overview Introduction - What is PPIR?
PPIR in Relation to Project Timing Measurement Requirements Expectations within Submission Approval Process Role of JLR Engineering Role of Supplier Role of JLR Programme Management Team Role of JLR Quality Engineering JLR Quality Assessment Summary

Introduction - What is PPIR?
Any parts non-PSW for M1, VP and/or HTFB builds Software revision without physical changes will also require a PPIR Why Confirm part are to design intent, suitable for build and engineering sign-off Equivalent of PPAP for any non-PSWed parts in pre-production build phases When PPIR Templates will be distributed at MRD – 4 weeks by Prototype Build Preparation & Planning Team through PPIR Tool Special arrangements to be made for long-lead items Must be returned and approved by JLR engineer before parts are shipped to JLR (and before MRD) Where PPIRs are sent (via ) to supplier’s PPIR champion PPIRs are to be completed and returned via in the same format they were sent So why do we need PPIRs? First, hands up if you know what an ISIR is? [If someone in the delegates do, ask them what its purpose is, if not, explain it is Initial Sample Inspection Report, a Ford-origin report, basically measurement reports for prototypes] PPIR is the same, but includes function and material aspects if needed.

Prototype Build Preparation Team
PPIR Introduction - What is PPIR? (cont.) High Level Process Lead Engineer Agree measurements with suppliers Confirm parts requiring PPIR with Prototype Build Preparation Team On-board to the PPIR tool Prototype Build Preparation Team Responsible for inputs Send PPIR request Maintenance of data Consumer of metrics Support the process and manage PPIR tool Lead Engineer Review PPIRs and approve through PPIR tool Feedback any issues to supplier Supplier Receive PPIR request Complete PPIR Ship parts only when the PPIR is approved 2 Way Process Quality Engineering Provide training sessions Assess and report the quality of the information in SCSS and PPIR

Introduction - What is PPIR? (cont.)
Approving a PPIR The PPIR RADs approval tool, managed by the Prototype Build Preparation & Planning team, is only accepted method for JLR engineering to confirm the status of a reviewed PPIR Whilst supplier do not have visibility of this tool, they will receive communications when: An approval status is allocated to a PPIR, or The PPIR has been rejected The PPIR approval acts as a OK to ship for supplier, to send the parts to JLR Rejected PPIR A PPIR may be rejected because: Part deemed not fit for purpose due to deviations Submission failing PPIR audit, ie. minimum requirements not achieved If a PPIR is rejected, the supplier is expected to make the necessary corrections and re-submit

Introduction - What is PPIR? (cont.)
Benefit of success in PPIR and implication of failure Evidence that the part is good That evidence forms audit trail Enabler to achieve PSW on time Parts shipped without Approved PPIR No time to react to non-conformances detailed within PPIR Cost of delaying a build is significant Additional pressure on all stakeholder’s workloads Implication to PSW achievement PARTS REJECTED AT PLANT Approval to ship without PPIR. Escalation:- Engineer – ML – PL – CPE Build stops Build re-starts Urgent activity to recover PPIR supplied retrospectively

In Relation to Project Timing - UN
PPIR In Relation to Project Timing - UN PS PSC PTCC PTC PA iDJ M1DJ ATV 1 ATV2 UNV1 UNV2 M1 Dwg MRD M1DC FMA Plan Boundary Diagram DJ DJ Interface Analysis M1 Build M1 Vehicle Quality History S-Rel P-Rel Functional Analysis Parameter Analysis Failure Modes Causes & Countermeasures Identified Actions Closed Final FM Risk Assessment YC/YS on SCSS & Cascaded (Supplier & AME) Supplier & AME Reviews YC/YS Requirements CC/SC Confirmed Controls Identified (Supplier & AME) Notes All activities are responsibility of Engineering Quality Engineering will coach, report and help facilitate SCSS = Special Characteristic Summary Sheet (Supp K) YC/YS = Potentially Critical / Significant characteristics Agree PPIR Content & Reqs with Suppliers (all NTEI) 4 Weeks PPIR Template Issued to Supplier PPIRs required for UNV PPIR Received & Approved by Eng

In Relation to Project Timing - UP
PPIR In Relation to Project Timing - UP PS PSC PTCC PTC PA iDJ M1DJ FDJ Virtual Series Pre-VS (iDJ) UPV0 UPV1 UPV2 UPV3 VP DRAW MRD Boundary Diagram DJ DJ VP Build Interface Analysis Quality History T-Rel P-Rel Functional Analysis Parameter Analysis Failure Modes Causes Identified Countermeasures Identified Actions Closed Final FM Risk Assessment Internal YC/YS on SCSS & Cascaded to AME AME Reviews YC/YS Requirements AME CC/SC Confirmed Controls Identified External YC/YS on SCSS & Cascaded to Supplier Supplier Reviews YC/YS Requirements Supplier CC/SC Confirmed Controls Identified Notes Discussions with AME and Suppliers to review FMEA, special characteristics and measurement requirements, should be regular and on-going Although not shown here, the requirement and process for PPIR repeats for HTFB, although BIW builds have additional requirements from the Dimensional Maturation and Build Integrity team Agree PPIR Content & Reqs with Suppliers (all NTEI) 4 Weeks PPIRs required for UNV & UPV PPIR Template Issued to Supplier PPIR Received & Approved by Eng

In Relation to Project Timing - Overall
PPIR In Relation to Project Timing - Overall PS PSC PTCC PTC PA iDJ M1DJ FDJ ATV 1 ATV2 Vehicle Phase UNV1 UNV2 M1 Dwg M1DC 10 ANA 5 10 ANA 5 11 ANA 5 11 ANA 6 FMA Plan Boundary Diagram 5 DJ Interface Analysis DJ M1 Parts/Build M1 Vehicle Quality History S Functional Analysis Parameter Analysis Failure Modes Causes & Countermeasures ID Actions Closed Final FM Risk Assess YCYS Cascade SCSS Controls Confirmed PPIRs issued to suppliers Completed PPIRs submitted by supplier for approval VP Build Vehicle Phase UPV0 UPV1 UPV2 UPV3 VP Dwg Virtual Series Pre-VS (iDJ) ANA 5 11 ANA 5 11 ANA 5 14 ANA 5 12 ANA 5 12 Boundary Diagram Interface Analysis DJ DJ Quality History Functional Analysis T P Parameter Analysis Failure Modes Causes Identified Countermeasures Identified Actions Closed Final FM Risk Assess Internal YCYS Cascade External YCYS Cascade Whole Vehicle SCSS Confirmed PPIRs issued to suppliers Completed PPIRs submitted by supplier for approval

PPIRs are driven by preceding activities
In Relation to Project Timing - Overall Virtual Series Pre-VS (iDJ) UPV0 UPV1 iDJ UPV2 M1 Dwg ANA ATV 1 ATV2 5 M1 Parts/Build UNV1 UNV2 DJ P M1 Vehicle Vehicle Phase M1DJ UPV3 VP Dwg 12 14 11 6 M1DC 10 PA PTC PS PSC PTCC FDJ Actions Closed Failure Modes Causes & Countermeasures ID Boundary Diagram Interface Analysis Functional Analysis Parameter Analysis Causes Identified Countermeasures Identified Final FM Risk Assess Quality History FMA Plan VP Build S T PPIRs are driven by preceding activities The Special Characteristic Summary Sheet (SCSS) should direct decision-making behind measurement strategy and activities This should include: Measurement points How to measure the parts Material property tests Functional tests Sample size YCYS Cascade SCSS Controls Confirmed External YCYS Cascade Whole Vehicle SCSS Confirmed Internal YCYS PPIRs issued to suppliers Completed PPIRs submitted by supplier for approval

In Relation to Commodity Planning CCDS
PPIR In Relation to Commodity Planning CCDS CCDS is a new framework based on commodities delivery and not on vehicle programmes delivery. It doesn’t change what needs to be done, but could have an impact on when it has to be done for your commodity.

Consignment quantity / batch size as shipped Sample size requirement
PPIR Measurement Requirements The following requirements relate to the minimum sample size for all sections of the PPIR, including the Declaration of Mass JLR engineering may supersede these 2 requirements, on the proviso that: This is agreed between JLR and the supplier, which may be stated within the RFQ, and The agreement is documented in the PPIR, as part of the submission Sampling Requirements A new PPIR must be submitted for any new batch of parts Sampling size requirement: Sampling This is a guideline only, PD may supersede this, bottom line is sample size is considered and agreed The sample size is automatically calculated by the template, based on the value in the consignment quantity field in Section 1 – Summary For batches of 6 parts or fewer, 100% of parts to be measured For batches of more than 6 parts (up to 150 parts), minimum of 6 parts and at least 20% are to be measured For batches of 150 parts or over, it is recommended that 30 parts are measured for PPIR report purposes Consignment quantity / batch size as shipped Sample size requirement ≤ 6 parts 100% 6 to 150 parts Minimum of 6 parts or 20% (whichever is the greater quantity) ≥ 150 parts 30 parts

Measurement Requirements (cont.)
PPIR Measurement Requirements (cont.) Declaration of Mass It is required to declare the actual mass of the components manufactured, to supply any given build Suppliers are expected to weigh the parts, in accordance to the sampling requirements, and record them in the PPIR submission Mass (weight) is to be measured on equipment calibrated with Weights traceable to National Standards, and quoted within the following range of tolerances: This forms part of Section 3 of the PPIR submission (see slide 18) Suppliers are expected to measure the actual mass of parts manufactured to supply any given build, in the same manner as any other features, and to the same sampling size requirement. The tolerance stated is for general guidance only, it does not supersede the tolerance stated in the drawing. This is to be recorded in Section 3 of the PPIR template, to be covered later. Components / assemblies mass (weight) according to the released drawing General Tolerance (to be applied only when not stated in Drawing / CAD) <0.100 kg +/- 5 g 0.100 to kg +/- 10 g 1.000 to kg +/- 20 g 5.000 to kg +/- 25 g >20.000 kg +/- 50 g

What a Good PPIR Looks Like
Inclusion of a SCSS cascading the special characteristics (YC / YS) produced from the DFMEA, or an agreed measurement strategy For modified parts concentrate on what has ‘changed’ on the part Measurement quantity: up to 6 is 100%, 6 to 150 is minimum of 6 or 20%, greater than 150 is 30 parts The PPIR contains data, drawing / CAD (measurement report also acceptable), test results or reports “OK” / “NOK” is not an acceptable measurement result, ie. we need numeric values Take into account what is appropriate testing criteria, perhaps a gauge for pipework, doing functional testing of the part Reports are embedded in the PPIR, everything must be eligible Weight for the batch of parts are measured and recorded in the PPIR Non-conformances / figures not to spec are identified, with a correction plan Anyone should be able to make an assessment of parts’ ‘Goodness’, just from data in the PPIR…. if not, the PPIR has failed Bottom line is, the data tells a story – What have we, JLR & supplier, agree to measure / control? What is the sample size, does it give representative view of what the entire batch is like? Are the data usable, to show if the parts are any good, for fit, form and function? What do the parts actually weigh? Did anything go wrong with making the parts? If so, what is the supplier doing to fix it? The data is used in 2 scenarios – The engineer who owns the part can let the part in for build Problem-solve if anything goes wrong, so the build team, engineer, whoever it might be, can work out which part caused the problem. Imagine this – if you have no data, how do you know which is the guilty party?

Expectations within Submission
PPIR Expectations within Submission Each section of the PPIR submission is set out in such a way that it informs the end user about the pedigree of the part: Section 1 – Summary Documents the part details, and summarises the key findings of the PPIR Section 2 – Geometry Confirms the form of the part is as per design (e.g. data, drawing / CAD, gauge) Section 3 – Laboratory Verifies the parts’ physical properties are in accordance to specification (e.g. material test) This includes the measured part mass of the components Section 4 – Functional Demonstrates the part is able to function as intended (functional check) Section 5 – In-Vehicle Software (IVS) Shows the software compatibility between the part and the vehicle system Only required for parts containing software The key changes makes the requirements explicit, over the next few slides, examples of what is accepted in each section is shown

Expectations within Submission (cont.)
PPIR Expectations within Submission (cont.) Supporting Documentation All documents intended to support a PPIR must be: Embedded into the PPIR document, ie. the entire submission must be contained in one document In a legible, in a readily usable format (eg. PDF, .xls / .xlsx, .ppt/.pptx) This includes agreements with JLR to: Neglect a specific section, or to deviate from the PPIR template This may be due to finite modifications from a already PSWed part, with very specific minor changes (such as software upgrade only) Supersede measurement requirements with part / commodity-specific requirements In sections 2, 3 & 4: Features measured shall include, but are not limited to, characteristics marked CC or SC in the SCSS, and identified in the section where the measurement is recorded Enter numeric values into the OK, NOK and NI columns, to confirm the quantity of parts within tolerance, outside of tolerance and not inspected respectively This is irrespective of any agreements to deviate from the template Record all non-conformances in Details of Non-Conformances, within Section 1 - Summary It is vital to keep all relevant information to a particular PPIR submission in a single file, for traceability and ease of access

PPIR Section 1 - Summary This section is in 2 parts, which outlines the part, the build it is intended for, the key features and the batch’s conformance to specification Summary Provide overview of the part in the submission Summarise all non-conformances identified in the process Non-conformances, in this instance, are features identified as outside of specification, or were not inspected State actions and timings to bring non-conformances back to specification SCSS Outlines the key requirements agreed between supplier & JLR, which are fulfilled within the PPIR submission Fulfilled by attaching existing Special Characteristics Summary Sheet (SCSS) If a SCSS is not used, the expectation is to provide the document which states the agreement between JLR & supplier in this section, for instance a measurement plan / measurement strategy / a Control Plan equivalent Summary Supplier to use checklist to indicate what is present to support their submission Use the ‘Additional Comments’ box to document any additional communications SCSS Attach the SCSS which was agreed with JLR, which documents the special characteristics identified in the DFMEA, and the method(s) agreed to measure/control said characteristics If no SCSS is available, possibly due to supplier is prototype only, attach any relevant documentation which states what has been agreed to be measured, as part of the submission

PPIR Section 2 - Geometry
This section is in 3 parts, which in its entirety is intended to demonstrate the parts manufactured are geometrically conforming to design specifications Geometry Record the outcome of the measurement activities in this page. It is acceptable to use gauges / checking fixtures / reference samples as part of the geometry confirmation Any objective output / measurements should be recorded as a value to provide a verification to conformance to specification Only if the measurement output is an absolute, ie. pass / fail, is it acceptable to record this as a measurement outcome Measurement Plan Using suitable visuals, illustrate where datums and measurement points are Include co-ordinated cut planes when required It is acceptable to use a 2D drawing to satisfy this requirement At the most basic level, the information in the 3 tabs should clearly state what geometric features are being measured, and what is the outcome

EXAMPLE 1 EXAMPLE 2 PPIR Section 2 - Geometry (cont.)
Example 1 – following PPIR template, with annotated 2D drawing highlighting measurement points Example 2 – deviation from original template using CMM report, accompanied by annotated CAD EXAMPLE 2

EXAMPLE 3 PPIR Section 2 - Geometry (cont.)
Example 3 – providing detailed annotation of datums, measurement points Example 4- demonstration of cut-planes

EXAMPLE 1 EXAMPLE 2 PPIR Section 2 - Geometry (cont.) Gauging
Where gauges / checking fixtures are used to verify conformance to design, attach the relevant instructions to this section For CMM, provide visual which illustrates how the part is held for measurement EXAMPLE 1 EXAMPLE 2 Example 1 – illustrates how part is mounted on gauge, and correlates to measurement Example 2 – gauge instruction sheet detailing how part is located and checking points

EXAMPLE 3 PPIR Section 2 - Geometry (cont.)
Example 3 – Graphical representation of gauge inspection points and illustrate how conformance to specifications is confirmed

EXAMPLE 1 EXAMPLE 2 PPIR Section 3 - Laboratory
This section verifies that the parts manufactured fulfils the requirements relating to: Physical properties Appearance / finish requirements Measured parts mass EXAMPLE 1 Also, record the mean measured value in Section 1 – Summary, in the Measured Part Mass (kg) field EXAMPLE 2

EXAMPLE 1 EXAMPLE 2 PPIR Section 4 - Functional
This section relates to any testing and/or functional analysis on the parts manufactured to verify the function to design intent before shipment Should contain outcomes of end of line tests / assessments, for example load tests and continuity checks This differs from design verification (DV) Embed test reports for confirmation as necessary EXAMPLE 1 EXAMPLE 2

EXAMPLE PPIR Section 5 - In-Vehicle Software
This section should contain information which shows the software and hardware supplied are to the level intent at each build phase, and as such compatible with the relevant production systems If parts are supplied for software changes only (ie. no physical changes from a PSWed part) - Indicate this in Section 1 – Summary Include comments stating the programme & model year PSW is obtained neglect Sections 2 -4 EXAMPLE

PPIR Approval process High-level events sequence
The supplier will receive the PPIR template by from JLR Prototype Build Preparation Team approximately 4 weeks before MRD, with the definitive part number. The document has to be submitted by the supplier sending it to and contacting the lead engineer for the approval. The lead engineer has to review the PPIR on the RADs tool ( and approve it or reject it because he deems the part does not fit for purpose due to deviations or the PPIR minimum requirements (explained in next slides) are not achieved. If a PPIR is rejected, the supplier is expected to make the necessary corrections and resubmit. The PPIR approval acts as a OK to ship for supplier to send the parts to JLR

PPIR RADs Tool http://rads.portsmouth.jlrint.com/ppir/
Portal where all the JLR PPIR are collected and approved.

PPIR Classification Rating Guidelines

Role of JLR Engineering
PPIR Role of JLR Engineering Before distribution of PPIR Identify parts requiring a PPIR All parts which are not delivered under PSW Generally new parts, or existing parts with major changes, including new tool Communicate parts requiring PPIR to JLR Prototype Build Preparation Team UNV2 for underbody & powertrain parts UPV3 for upperbody parts Understand what needs to be measured In particular Special Characteristics Consider measuring new features / sections only for reused modified parts Review & agree measurement plan / strategy with suppliers Consider whether the generic measurement requirements will suffice Once PPIRs are submitted Review parts for suitability to build Indicate approval / non-approval of part at Approve in accordance to classification rating guidelines GSI PPIR support site Training package now in Catalyst, search for PPIR tool

PPIR Role of Supplier Before distribution of PPIR
Understand what needs to be measured In particular YC/YS characteristics Consider measuring new features / sections only for reused modified parts Review & agree measurement plan / strategy with JLR engineering Once PPIRs are distributed Populate the PPIR pro forma with agreed information Embed all supporting documents to the relevant sections Compress the PPIR into a .zip file to reduce file size if required Return completed pro formas by ing it to If PPIRs are rejected Correct all errors identified and resubmit If there are non-conformances which cannot be corrected, submit recovery plan and timing Note: an automated message will be sent to supplier when a PPIR is reviewed for approval to indicate outcome If the PPIR is approved, the automated message now becomes the OK to ship statement, from JLR to supplier. If it is rejected, supplier must not send in the parts to JLR, but instead carry out actions to resolve the reason(s) for rejection.

Role of JLR Prototype Build Preparation Team
PPIR Role of JLR Prototype Build Preparation Team The PPIR Tool must be used for all M1, VP and HTFB build events (and the associated Quality Loops), irrespective of programme scalability, or number of parts due in Before distribution of PPIR BOM creation and validation Identify parts which are not delivered under PSW (with support from JLR Engineering) Includes identifying key contacts within suppliers These are contacts who will receive communications and PPIR templates Create the programme in PPIR Tool Including administration throughout preparation to the build event Agree timing of PPIR submission with JLR Engineering and supplier Consider timing for long lead parts and parts which are not due for first car MRD Send out supplier communications to prepare suppliers for PPIRs Organise supplier and engineering training with the support of JLR Quality Engineering, if required To ensure common understanding across the build event

Role of JLR Prototype Build Preparation Team
PPIR Role of JLR Prototype Build Preparation Team At MRD -4 weeks Issue out PPIR template using PPIR tool It may be necessary to issue out template earlier than this for certain suppliers / systems, JLR Engineering to advise / request Before and After MRD / During Build Event Report out and follow-up on parts due in for MRD Utilising existing metrics within PPIR tool Parts Arriving in Plant without PPIRs Parts should not be shipped without JLR Engineering approval of the PPIR submission(s) The automated notification from the PPIR tool, once the PPIR is approved, serves as an ‘OK to ship’ notice to supplier

Role of JLR Quality Engineering
PPIR Role of JLR Quality Engineering Identify priority parts Using High Hurts brochure, PAWS, TGW, etc. Before distribution of PPIR Facilitate discussions to agree measurement contents Ensure special characteristics (YS/YC) have been agreed with supplier, communicated and signed-off via SCSS Deliver supplier and engineering training sessions if they are required by the JLR Prototype Build Preparation Team Once PPIRs are submitted Assess and report the quality of the information in SCSS and PPIR and respond as necessary

JLR Quality Assessment
PPIR JLR Quality Assessment The purpose is to ensure information contained within approved PPIRs are: Reflective of parts manufactured Usable for problem solving and concern resolution Confirming part pedigree with respect to form, fit and function Key aspects under scrutiny: Measurement sample size is suitable for batch delivered Special characteristics are identified Drawing (or suitable visuals) identify what was measured Geometric features conform to engineering specifications Physical and appearance requirements are met as appropriate Parts have been proven to function to design as appropriate Non-conformances found have corrective plans to rectify Quality Assessments are carried out by JLR Quality Engineering Assessment failures are raised to engineer responsible for the part To re-evaluate PPIR approval Work with supplier to correct points of audit failure

PPIR Summary Purpose is to ensure parts are suitable for build
Confirms parts are made to spec for form, fit and function Required for all non-PSW parts at prototype build phases (M1, VP, HTFB) Including carryover and reused parts with new tools Also includes software updates, with and without physical changes Measurement requirements are driven by Engineering Determined by FMA activities, summarised by SCSS Measurement plan / strategy also accepted for prototype suppliers FMQ will provide support where required / necessary JLR Engineering notify Prototype Build Preparation Team of parts requiring PPIR by UNV2 / UPV3 Pre-populated templates are distributed 4 weeks before MRD Engineering approval of submitted PPIRs required before MRD This approval serves as ‘OK to ship’ for supplier to deliver parts to plant

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