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.

 

©

Kaushik

 

 

 

Electric Vehicles:- Series2

#EV selection#Charging time#Features#Range#Batterylife#

1.     Choosing the right electric car for use is a tough job.

2.    It depends on lots of factors.

3.    You need to understand completely the vehicle characteristics like speed, torque, and power.

4.    Also, you need to check the battery life and its warranty provided by the manufacturer. General warranty is about 5-8 years. Higher the battery capacity, the lesser you need to charge.

5.    Driving cycle needs to be checked. Here, you need to determine the frequency of vehicle to be used i.e. how many times it will be used? Where it will be used? Rural or urban area etc.

6.    Type of plug required for the car.

7.    Also, the condition and distance between two public charging stations should be checked.

8.    Other the key factor is that you need to check the distance covered by car after full charging. Distance might vary according to the weather conditions.

9.    You need to check out the total charging time required for an electric car. It can take from 30 minutes to 12 hours to charge. It is dependent on the size of the battery and speed of charging point.

10.  3.7 kW slow charging provides 15 miles drive; 7kW fast-charging provide 30 miles driving.

11.   Battery capacity also plays a key factor in selection.

12.  Your driving life needs to be considered during the selection. Ex. In case you travel 250 km per day, EV is not for you. Since average EV range is around 100-150 Km in single charging.

13.  Check out the hardware and software’s upgraded in the EV.

14.  Also, you need to check the alternative charging sources for EV. Ex. Electric vehicles can be charged through renewable energy also.

15.  No of seating seats needed and condition of brakes.

Summery

1.     During the selection of EV, factors like speed, torque and power must be considered.

2.    Along with it, battery life and warranty provided by the manufacturer for it should be noted.

3.    Choose the EV based on your daily routine life.

4.    Make the note of alternative charging source for the battery of EV.

5.    Also, check the battery capacity and software provided.

 

 

 ©

Kaushik

 

 

 

 

 

 

Book Review: - The Monk Who Sold His Ferrari

It is the story of richest lawyer from the USA who sells his everything to find the ultimate serenity and he proceeds in the Himalayan ranges. The book focuses on the healing aspects of life.

1.     It takes only 21 days to change your habit.

2.  It is a time, as little as fifteen minutes to witness the healing power of silence and witness who you are.

3.    Remember, your mind is your biggest muscle.

4.    Development of positive habit is an art. Positive habits develop good results.

5.    Trust yourself. Create the life you want. Kindle your inner fire.

6.  There are no mistakes, only lessons. See the setbacks as the opportunity to grow.

7.   Reading a long book is always boring. But we live one life. We cannot live a hundred lives in one life. Hence reading is greatly beneficial to experience the life of others. Reading helps you to find real you.

8.    Serve others selflessly. You will be happy.

9.    Well-arranged time is the mark of well-arranged mind.

10.  Make sure your food is proper and healthy. Healthy food is a sign of a healthy mind.

11. Your life is all about Kaizen (Continuous improvement). Hence, keep on punching in your daily life and keep improving.

12. Self-disciplined man can enjoy everything then the man who is not at all disciplined about food and time.

13.  Think good, be good and do good. Good things will follow you.

14. Enlightened people are priority-driven.

 

Purchase link:- https://amzn.to/3gRU8Wk

 

Note:- The book review is written to boost the reading habit only.

 

Kaushik

Electric Vehicles Series:-1

1.    Electric vehicle is a vehicle which runs on the electric motor.

2.    Development in the electric vehicle segment has been rapidly increasing.

3.    Due to increasing pollution, CO2 emission use of the electric vehicle will be promoted in the coming days.

4.    In 2018-2019, Electric vehicles sold in India were 1.3 lakh units.

5.    3400 units were sold in FY 2020. Most of them were electric scooters and electric cycles

6.    China is worlds largest electric car market with the sale of 2.2 (45% of the world) million electric cars.

7.    China is followed by Europe (24%) and the United States. (22%)

8.    In India, the government has set the target to convert to EV by 2030.

9.    No of charging points all over the world are about 5.1 million by the start of 2019.

10. Use of fast charging is tremendously increasing. Three lakh fast chargers are installed in China which is about 80% of the world.

11. In the relative terms, China has only 4% of Electric cars while Norway has reached to 50%.

12. 2.2% of the global vehicle, the market is been grabbed by EV by 2019.

13. Charging station facility is been developing vigorously in China, Europe, and the U.S.

14. Global EV sales will reach up to 23 million by 2030.

15. 30% of vehicles other than two-wheelers will be electric by 2030.

16. India has set the target of deploying 2 million electric cars by 2020.

17. India has the largest market for the Electric Vehicles. Yet something needs to be improved in India.

18. India requires the rapid basic infrastructure development for electric vehicles.

19. Present EV penetration market for EV Vehicles in India is just 1%.

20. Mahindra and Mahindra is investing 18 billion in the next three years for EV production.

21. Indian Govt has reduced GST to 5% on an electric vehicle to boost its sale.

22. As of Feb 2020, registrations of 3 lakh plug-in electric cars were done in France.

23. As of Jan 2020, registrations of 305787nos of electric plug-in cars were done in Germany.

24. Germany has a stock of 16690 no’s of light-duty commercial electric vehicles as of 2018.

 

    Summary: -

1.    In 2018-2019, Electric Vehicles sold in India were 1.3 lakh units.

2.    China is the world’s largest electric car market with 45% capacity.

3.    Indian government has set a target for 100% Electric Car implementation till 2030.

4.    Three lakh fast chargers are installed in China (80% worlds capacity).

5.    Total market percentage grabbed by EV in the world is 2.2%.

 

©

Kaushik

Bhagvadgita:- Part24

अधियज्ञः कथं कोऽत्र देहेऽस्मिन्मधुसूदन।
प्रयाणकाले च कथं ज्ञेयोऽसि नियतात्मभिः

Translation: - Arjuna to Krishna: - Krishna, plz tell me who is Adhiyagya? And How every individual remembers you at the time of death?

 

श्री भगवानुवाच
अक्षरं ब्रह्म परमं स्वभावोऽध्यात्ममुच्यते।
भूतभावोद्भवकरो विसर्गः कर्मसंज्ञितः

Translation: - Krishna to Arjuna: - Krishna says- Brahman is a supreme and transcendental living being. His material nature is Adhiyagya. Karma is the action that results in the human body.

 

अधिभूतं क्षरो भावः पुरुषश्चाधिदैवतम्।
अधियज्ञोऽहमेवात्र देहे देहभृतां वर

Translation:- Krishna to Arjuna:- Adhibhuta is also a material nature and universal form of devatas. I am situated in it, and sacrifices are called Adhiyagya.

अन्तकाले च मामेव स्मरन्मुक्त्वा कलेवरम्।
यः प्रयाति स मद्भावं याति नास्त्यत्र संशयः

Translation: - Krishna to Arjuna;- People who remember me during death always attain me.

यं यं वापि स्मरन्भावं त्यजत्यन्ते कलेवरम्।
तं तमेवैति कौन्तेय सदा तद्भावभावितः

Translation: - Krishna to Arjuna:- Remember, the state of mind one has absorbed during death, he gets it in his next life.

तस्मात्सर्वेषु कालेषु मामनुस्मर युध्य च।
मय्यर्पितमनोबुद्धिर्मामेवैष्यस्यसंशयम्

Translation: - Krishna to Arjuna:- Always keep me in your thoughts. You will carry me during karmic actions. Absorb your mind completely in me, you will surely reach me.

अभ्यासयोगयुक्तेन चेतसा नान्यगामिना।
परमं पुरुषं दिव्यं याति पार्थानुचिन्तयन्

Translation: - Krishna to Arjuna:- Practice your thoughts in me and remain devoted to me. You will be happy.

कविं पुराणमनुशासितार
मणोरणीयांसमनुस्मरेद्यः।
सर्वस्य धातारमचिन्त्यरूप
मादित्यवर्णं तमसः परस्तात्

Translation:- Krishna to Arjuna:- God is always omniscient, immortal, eternal, controller, smaller in ever imagined, sustainer, destroyer, transcendental, a person who shows light in the tunnel and drives you away from the darkness.

प्रयाणकाले मनसाऽचलेन
भक्त्या युक्तो योगबलेन चैव।
भ्रुवोर्मध्ये प्राणमावेश्य सम्यक्
स तं परं पुरुषमुपैति दिव्यम्

Translation: - Krishna to Arjuna: - Practice yoga and meditation. You will meet me.

 

यदक्षरं वेदविदो वदन्ति
विशन्ति यद्यतयो वीतरागाः।
यदिच्छन्तो ब्रह्मचर्यं चरन्ति
तत्ते पदं संग्रहेण प्रवक्ष्ये

Translation: - Krishna to Arjuna: - I will never talk about liberation. It is described by the Vedic scholars.

सर्वद्वाराणि संयम्य मनो हृदि निरुध्य च।
मूर्ध्न्याधायात्मनः प्राणमास्थितो योगधारणाम्

Translation: - Krishna to Arjuna: - Person who can shut all the senses, control his mind and the heart can achieve the ultimate serenity.

ओमित्येकाक्षरं ब्रह्म व्याहरन्मामनुस्मरन्।
यः प्रयाति त्यजन्देहं स याति परमां गतिम्

Translation: - Krishna to Arjuna: - In case one leaves his body while remembering me, attains the supreme serenity.

To be continued...