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Supplier Quality ManagementPPAP Training Seminar
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Electric, Inc.•ALPS Appreciates your Participation in this PPAP Seminar•We all recognize the importance of continual Quality self-improvements•We at ALPS feel that the PPAP submissions submitted by our Category 1 Suppliers is the first step, or start point in this improvement effort.
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Electric, Inc.•PPAP process begins with a PAR Form:
•The Part Approval Request Form (PAR)•is the document that defines for the Supplier what the exact requirements are for that specific PPAP Submission
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Electric, Inc.•Part Approval Requirements Form (PAR)• To be used as:
• A Table of contents for PPAP submission.• May be used as a check sheet to verify completeness of submitted materials.
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Electric, Inc.
•First Section of PAR Form:•Program information, completed by the ALPS SQE
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Electric, Inc.•Second Section of PAR Form• The Submission Level indicates to the Supplier which of the defined PPAP criteria applies to his submission. The requirements for PPAP Submission are defined by these levels.• Unusual requirements will be defined in Level 2G• PPAP Approval is the responsibility of the ALCOM SQE.
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Electric, Inc.
•Submission Level 3• A submission level of 3 will include the documents for all 19 sections indicated on the PAR• 3 sets of identical Master Boards• 1 complete shot, or sample in a loose or unattached condition• Comments will include any special conditions or instructions.
Second Section of PAR Form
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Electric, Inc.
•Submission Level 1• A submission level of 1 will include only those documents indicated in the open sections on the PAR• 3 sets of identical Master Boards• 1 complete shot, or sample in a loose or unattached condition
• Comments will include any special conditions or instructions.
Second Section of PAR Form
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Electric, Inc.
•Submission Level 2• Submission requirements are defined by the reason for the submission and the sub-level: 2A, 2B, 2C,etc.• An undefined reason for submission will be identified as a level 2G and the reason will be included under the indication of Submission Level in the header.• Darkened requirements indicate those requirements that are not required for that submission category.
• Comments will include any special conditions or instructions.
Second Section of PAR Form
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Electric, Inc.
• Typical PPAP Documents
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Electric, Inc.
• Robust Mold Tryout - Molder•(Plastic Molded, Insert Molded and Metal Stampings)
ITEM# 1
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Electric, Inc.• Part Submission Warrant
– ALPS Specific Form only
– Vigorous Mold Approval
•
ITEM# 1
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Electric, Inc.• PFMEA
– Generic: Failure Analysis defining complete system
– Item Specific: Failure Analysis based on this specific Part
FMEA Number
Page of
Item: Prepared By
Model Year(s)/Vehicle(s) FMEA Date (Orig) (Rev.)
Core Team
Actions Taken
Sev
Occ
Det
RPN
Process Responsibility
Key Date
Process Function Requirements
Potential Failure Mode
Potential Effect(s) of Failure
Sev
Action Results
Proc Num
Detec
RPN
Recommended Action(s)
Responsibility & Target
Completion Date
Class
Potential Cause(s)/
Mechanism(s) of Failure
Occur
Current Process Controls
POTENTIALFAILURE MODE AND EFFECT ANALYSIS
(PROCESS FMEA)
ITEM# 2
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Electric, Inc.
P/N: Number:
Description: Page: of
Process / Operation: Date (Orig): (Rev):
Prepared by:
Storage Points
Inspection Points
Contrlled Launch
Process Flow Diagram
Proc Step Process Name & Description Important CharacteristicMovement
Fabrication Point
Use to Letter "G" to identfy Actions Below
ITEM# 3
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Electric, Inc.
P/N: Number:
Description: Page: of
Process / Operation: Date (Orig): (Rev):
Prepared by:
Storage Points
Inspection Points
Controlled Launch
1015203040505560708090100110115120
Process Flow Diagram
Proc Step Process Name & Description Important CharacteristicMovement
Fabrication Points
Use to Letter "G" to identfy Actions Below
IncomingControl Point
Warehouse
Manufacturing / 1st Article ApprovalControl Point
Manufacturing / 1st Article Approval
Warehouse
Final InspectionControl PointShip
Specified Process ControlsSpecified Launch Controls
Inventory Control
Specified Process ControlsSpecified Launch Controls
Specified Process Controls
Inventory Control
Specified Process ControlsSpecified Launch Controls
Process Flow Diagram with Controlled Launch
ITEM# 3
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Electric, Inc.• Control Plan
– Defining Generic PFMEA’s & Control Plans to Specific Process applications
Pre-Launch Production Key Contact/Phone Date (Orig.) Date (Rev.)
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd)
Part Name/Description Supplier Plant Approval/ Date Customer Quality Approval/Date (If Req'd)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd) Other Approval/Date (If Req'd)
Size Freq.
Reation PlanSample Control Method
Methods
Evaluation/ Measurement
Techinque
Process
Special Char. Class.
CharacteristicsProduct/Process
Specif ication/ Tolerance
No. Product
Part/ Process Number
Process Name/ Operation Discription
Machine, Device, Jig, Tools for Mfg.
Prototype
Control Plan Number
ITEM# 4
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Electric, Inc.• Controlled Launch Plan
– Defining additional control points and methods to validate the process capability.
Key Contact/Phone Date (Orig.) Date (Rev.)
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd)
Part Name/Description Supplier Plant Approval/ Date Customer Quality Approval/Date (If Req'd)
Supplier/Plant Supplier Code Other Approval/Date (If Req'd) Other Approval/Date (If Req'd)
Size Freq.
Process Name/ Operation Discription
Machine, Device, Jig, Tools for Mfg.
Controlled Launch
Control Plan Number
No. Product
Part/ Process Number
Evaluation/ Measurement
Techinque
Process
Special Char. Class.
CharacteristicsProduct/Process
Specif ication/ Tolerance
Reation Plan & Corrective Actions
Sample
Methods
Control Method
Error Proofing
ITEM# 5
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Electric, Inc.• Balloon Drawings
– Original: Identifying all Dimensions and Notes on Drawing
– Transfer: Identifies Specific limited Dimensions and Notes
ITEM# 6
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Electric, Inc.
• Dimensional Data– Original: 100% of all dimensions, notes & Tolerances on Drawing
– Transfer: Identified Dimensions, notes & Tolerances
– Dimensional Layout Format: Supplier’s option
• Note: ALPS specific method of Drawing Deviation
ITEM# 6
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Electric, Inc.
• Dimensional Data– Revision Levels of Drawing:
• Note: ALPS specific method of identifying Revision Levels
ITEM# 6
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Electric, Inc.• Header Information
– Reason for readings– Company Name– Metrology Source– Part Name– Part Number– Revision Level– Color– Customer
• Dimensional Data– Balloon Number– Print Dimension– Print Tolerance– Actual readings
ITEM# 7
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Electric, Inc.
• Capability Data – based on;– 350 Pcs Lot size– 125 Pcs Sample (25 Groups of n=5)– SPC Calculation by Cavitation
• 5 Group of n=5 Minimum• X of n=5 to 125 Pcs total
– Gage R&R Data
ITEM# 8
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Electric, Inc.•1st Step - Complete • Gage R&R
– Gage Description– Gage ID#– Part Number of article– Description of article– Characteristic being measured–Date of Measurements– Dimension being measured– Tolerance– Number of Appraisers– Number of Trials– Actual Dimensional data
–Confirm acceptability
ITEM# 8
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Electric, Inc.
•2nd Step - Complete • Data Matrix
– Part Name– Part Number– Rev. Lev.– Color– Customer– Dimension– Tolerance– Cavitation– Cavity IDs– Actual Dimensional data
ITEM# 8
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Electric, Inc.•3rd Step - Complete • Capability Report
– Submission Reason– Company Name & Address
– Metrology Source– Sub-Group size– Matrix ID Number
• Calls dimensional data from Matrix
ITEM# 8
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Electric, Inc.•Material Certifications
• Identifying Material & Customer specific requirements• Identifying ALPS Specific Requirements
ITEM# 9
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Electric, Inc.•Material Cert of Compliance•ALPS Form FM06022
• IMDS InformationVerification that the component has been registered on the international IMDS Web Page
ITEM# 9
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Electric, Inc.• Test Requirements
– The Component Drawing defines specific Supplier responsibilities– Certifications or test data detailing acceptance of these specific test requirements
ITEM# 10
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Electric, Inc.• Appearance Form (AAR)
– Customer vs. ALPS Appearance acceptance
ITEM# 11
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Electric, Inc.• Part Submission Warrant
– ALPS Specific Form only
– Vigorous Mold Approval
• PPAP Approval
ITEM# 12
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Electric, Inc.
• Approval Types– Vigorous Mold Approvals: Accepts Tool and allows– shipment of material for Pre-Production requirements– Limited Approvals: Short term / Interim Approval – meeting intent of Production requirements.– Full Approvals: PPAP compliant, production ready.
– Approvals for ECR changes: Change specific– Tool Repair Approvals: Repair specific– Deviations: To use non-compliant material
ITEM# 12
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Electric, Inc.
•Disaster Recovery Form• (ALPS Form FM06023A)
ITEM# 13
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Electric, Inc.•Packaging Form (ALPS Form FM06027)
ITEM# 14
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Electric, Inc.
•Bar Code Label Format–ALPS Packaging Specification AS-002
ITEM# 14
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Electric, Inc.•Misc. Information
– Work Instructions– Laboratory Scope– Inspection format– Inspection Criteria (AAR)
ITEM# 15
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Electric, Inc.•Run@Rate Information• – Process Validation
ITEM# 16
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Electric, Inc.
• Sample Parts– FFF Samples for Engineering review
• Complete sets (shots)
• Master Boards– Golden Samples for ALCOM (2 samples), Supplier (1 sample)
• 3 Boards with 1 complete set (shot) of parts
• Limit Masters– Max condition samples
• Unique Defect explanation
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Electric, Inc.• ALPS Electric, Inc. Appreciates your efforts in achieving a better understanding of the ALPS Automotive Supplier requirements.
•As parts of ALPS partnership philosophy we feel that Zero Defect Philosophy can only be achieved through our common efforts for Product and Process controls.