PPAP ( Production part approval process)

PPAP (Production part approval process)

Production part approval process is a valuable tool that develops confidence in the component manufacturers and their suppliers. PPAP is the risk identification process. PPAP ensures better communication between supplier and manufacturer about the product.

 

1. PPAP is the outcome of APQP.

2. PPAP is the fourth stage from APQP (Advanced product quality planning).

3. PPAP ensures to the supplier that the product is manufactured without any defect in the controlled production process.

4. In the automotive industry, PPAP is the document from AIAG (Automotive Industry Action Group).

 

What is PPAP?

1. It is an approval process for the new or revised parts produced from new production methods.

2. PPAP consist of eighteen elements needed for approval.

3.PPAP consist of five submission levels.

4. Also, it is a tool that develops the confidence in the manufacturer and the supplier about the product being produced and supplied by the manufacturer to his supplier.

Why PPAP?

1. PPAP verifies the fact that the manufacturer understands all the design requirements and process developed and he is capable and proven to produce the part as per guidelines by his supplier.

2.PPAP process is only required when there is a change in the process. Also, during machining the new parts the same process is required.

3.During PPAP, a discussion is done with the customer about each parameter being machined. In case, the manufacturer is unable to achieve the specified dimension in the samples, he should inform about it to the customer and if required, he should appeal for more dimensional tolerance to the customer.

 

Documents needed for PPAP: -

1.     Design records.

2.     Engineering change documents.

3.     Customer engineering drawing approval.

4.   DFMEA/PFMEA (Design failure mode effect analysis/ Process failure mode effect analysis)

5.     Part feasibility report.

6.     Process flow diagram.

7.     Control Plan.

8.     Measurement system analysis (Report).

9.     Material Test report.

10.   SPC report.

11.   Dimensional results.

12.   Third-party test report.

13.    List of checking instruments.

14. PSW (Part submission warrant).

15. Product samples.

16. Master sample.

17. Customer-specific requirement.

18. Process drawings.

 

PPAP submission levels

1.     Part submission warrant (PSW) submitted to customer.

2.     PSW with product samples and limited supported data.

3.     PSW with product samples and complete supporting data.

4.     PSW with other requirements from the customer.

5.     PSW with product samples and complete supporting data.

 

Elements of PPAP

1.     Design records: - It shall include the copies of customer and suppliers’ drawings with revision levels. It should also include purchase order and material composition information.

2.     Engineering change: - PPAP is required for a change in product and documentation approving change must be included in PPAP. This copy is an Engineering Change Notice (ECN).

3.     Customer drawing approval: - Here the trial is done at customers premises with production parts from the supplier. Here, all the evidence must be provided with the documentation.

4.     FMEA: - Here the total modes of failure are examined with their possible effects. FMEA is a live document. Risk priority number (RPN) for every possible mode is calculated in FMEA stage.

5.     Part feasibility report: - At this stage, engineering drawing is numbered as per the dimension. And each dimension parameter is cross-checked for its machining feasibility.

6.     Process flow diagram: - It outlines the entire process of the product from start to end.

7.     Control Plan: -It is an output of PFMEA. It includes the list of all the dimensions, inspection methods and special characteristics required while machining to deliver the customer quality requirements.

8. Measurement system analysis: - It includes Gauge repeatability and reproducibility.  Gauge R and R should be below 10%. Study of measuring equipment is done in MSA.

9.     Material Test report: - It should include the documents about the properties of material ex. Mechanical/ Chemical properties, Microstructure etc.

10. SPC: - Initial process study about Statistical process control is done on special characteristics. Here, the process variation is been checked with the 32nos or 50nos of samples reading and Cp and Cpk values are been calculated.

11. Dimensional results: - Dimensional layout of sample parts are prepared at this stage and every dimension is measured after machining of samples.

12. Third-party test report: - Third-party material test report is conducted at this stage. The third-party should be NABL accredited.

13. List of checking instruments: List of gauges required during machining is finalized here.

14. PSW (Part submission warrant): - It is PPAP summery. It includes the reason for submission, level of documents submitted to the customer, supplier authorization signature, declaration of part confirmation. PSW is not required unless the customer specifies it.

15. Product samples: - Samples after machining are sent to the customer and they are either stored at the customer’s end or supplier’s end.

16. Master sample: - It is a final sample product. It is used for the training for operators and long-run production periods.

17. Customer-specific requirement: -At this stage, specific customer requirement is noted in PPAP. If it is not provided by the customer, do not fill it.

18. Process drawings: - After the process is defined, its drawing is been drawn on any 2D/3D software.

 

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Kaushik