Integrating the PPAP Elements

Most PPAP Workbooks AreMulti-Tabbed Excel Files Which …

… Force Users to Jump Between Many Tabs to Compare Key Elements

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A Better System Would IntegrateAll Key Elements Into a Single Tab

Element #1:Everything starts with the customer specification; it establishes the baseline against which the process is compared

Element #2:Specifications with variable data require gage R&R studies to estimate percent of toler-ance occupied by gaging error.

Element #3:Measurements from T1 samples provide an initial insight into a new part’s evolution from concept to production.

Element #4:All processes have variability. A cap study is designed to measure this variability and compare it to the customer spec.

Element #5:Customers require cap studies for every cavity. This is another aspect of a PPAP that engineers need to evaluate & judge.

Reminder: Our Objective is to Integrate These 5 Unique Elements

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Integration Step 1: Plot the Customer Spec; in this case 0.870” ± 0.004”

Integration Step 2: Plot the Gage R&R Estimate; in this case 7.6% of Tolerance

Integration Step 2: Plot the Gage R&R Estimate; in this case 7.6% of Tolerance

At 7.6%, measurement error is in the acceptable range and will notdistort the signal with noise.

Integration Step 3: Plot Stats from the T1 Samples; Assume All Cavities are Mixed

Integration Step 3: Plot Stats from the T1 Samples; Assume All Cavities are Mixed

With a Cp of 10.45 and Cpk of 8.36, the T1 samples show promising results.

Integration Steps 4 & 5: Plot Capability Study Stats (±3 Sigma) from Every Cavity

Integration Steps 4 & 5: Plot Capability Study Statistics from Every Tool Cavity

Capability studies of all 4 cavities mirror the early T1 results.

Once Symbols Are Understood, Users Learn to See Success in New Patterns

inside the customer spec’s goal postsoutside

outside

Bonus #1: Use an Excel slider bar to scroll through every CTQ trait … chart will auto-matically vlookup each trait’s spec, R&R & cap studies.

Bonus #2: Use Excel lookup tables to pull highlighted prints; assist PPAP users to connect the print to capability data.

One Excel tab.One chart plots every element.One slider bar reveals all CTQs.One lookup table shows highlighted areas of print.

Do.Simple.Better.