Donaldson EMEA Supplier Quality Assurance PPAP TRAINING January 2013 CORP MAN 006 PPAP WORKBOOK TRAINING – Rev 5– dd 03/04/2013

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Donaldson EMEA Supplier Quality Assurance PPAP TRAINING January 2013 CORP MAN 006 PPAP WORKBOOK TRAINING Rev 5 dd 03/04/2013 Slide 2 What is PPAP? Production Part Approval Process Standard used to formally reduce risks prior to product or service release, in a team oriented manner using well established tools and techniques Initially developed by AIAG (Auto Industry Action Group) in 1993 with input from the Big 3 - Ford, Chrysler, and GM AIAGs 4 th edition effective June 1, 2006 is the most recent version PPAP is part of the Donaldson Supplier Business Operating Standard (S.B.O.S.S.) Slide 3 Purpose of PPAP Provide evidence that all customer engineering design record and specification requirements are properly understood by the organization To demonstrate that the manufacturing process has the potential to produce product that consistently meets all requirements during an actual production run at the quoted production rate PPAP manages change and ensures product conformance! Slide 4 When is PPAP Required? New part Engineering change(s) Tooling: transfer, replacement, refurbishment, or additional Correction of discrepancy Tooling inactive > one year (needs Cpk study) Change to optional construction or material Sub-supplier or material source change Change in part processing Parts produced at a new or additional location PPAP is required with any significant change to product or process! Slide 5 Benefits of PPAP Submissions Helps to maintain design integrity Identifies issues early for resolution Reduces warranty charges and prevents cost of poor quality Assists with managing supplier changes Prevents use of unapproved and nonconforming parts Identifies suppliers that need more development Improves the overall quality of the product & customer satisfaction Slide 6 DBV = online supplier monitoring After a successful submitted and approved PPAP, part can be supplied to the Donaldson organization Each supply gets monitored and deliveries are measured in ppm and in % on-time When defect parts are found, an NCR and 8D is executed Monthly the DBV committee communicates supplier ranking Yearly SQA management at headquarter organizes an supplier PPM improvement event, based on a 6 months supplier base performance. Our purchase department has an active role encouraging our suppliers to be the best in class Slide 7 Production Run PPAP data must be submitted from a production run using: Production equipment and tooling Production employees Production rate Production process All data reflects the actual production process to be used at start-up! Slide 8 Readiness Review (R-R) The purpose of a R-R is to verify the suppliers manufacturing process is capable of producing components that meet Donaldsons quality requirements, at quoted tooling capacity, for a specified period of time Verification of the R-R will be at the Supplier Quality Engineers (SQE) discretion. The supplier will be notified of the need to perform a R-R as early in the process as possible. The number of components to be produced during the R-R should be sufficient to demonstrate process capability and will be predetermined by the SQE and the supplier. Factors such as product complexity, shelf life, storage, cost and single shift vs. multiple shift operations will be taken into consideration Slide 9 The start of using the PPAP workbook Safe the Workbook template as an Excel Workbook. File name = Donaldson Part number followed by Donaldson Part rev number. E.g. P566611-rev8-(+ free suffix) Fill out the sheet: PPAP Submission Info To do so, headers of other sheets are filled out automatically. Most of the fields are filled out by the Donaldson PPAP team Slide 10 Official PPAP Requirements 1.Design Records 2.Authorized Engineering Change Documents 3.Customer Engineering Approval, if required 4.Design Failure Modes and Effects Analysis (DFMEA) applied in special situations 5.Process Flow Diagram 6.Process Failure Modes and Effects Analysis (PFMEA) 7.Control Plan 8.Measurement Systems Analysis (MSA) 9.Dimensional Results 10.Records of Material / Performance Test Results 11.Initial Process Studies 12.Qualified Laboratory Documentation 13.Appearance Approval Report (AAR) 14.Sample Production Parts 15.Master Sample 16.Checking Aids 17.Customer-Specific Requirements 18.Part Submission Warrant (PSW) Have a closer look Slide 11 Donaldsons PPAP Requirements Supplier shall submit 12 items and retain a copy of 12 + 2 (R) records at appropriate locations For PPAP Level 5, SQA will witness at supplier location and will fill out PPAP level 5 work sheet. Slide 12 PPAP Submission Levels Level 1 Production Warrant and Appearance Approval Report (if applicable) submitted to Donaldson Level 2 Production Warrant, product samples, and dimensional results submitted to Donaldson Level 3 Production Warrant, product samples, and complete supporting data submitted to Donaldson Level 4 Production Warrant and other requirements as defined by Donaldson Level 5 Production Warrant, product samples and complete supporting data (a review will be conducted at the supplier's manufacturing location) Slide 13 PPAP Submission Level Table S = Supplier shall submit to Donaldson & retain a copy of records or documentation items at appropriate locations R = Supplier shall retain at appropriate locations and make readily available to Donaldson upon request * = Supplier shall retain at appropriate locations, and submit to Donaldson upon request. Donaldson will identify what is needed for submission. Slide 14 Definition of Risk and PPAP level High Risk Parts associated with multiple critical features, complex design, or high end technology that is not yet established in the general manufacturing environment Suppliers quality system and/or quality performance is not to Donaldson satisfaction Medium Risk Parts that have at least one critical feature Low Risk Parts that have no critical features and can be manufactured by any manufacturer in the commodity category Suppliers quality system and quality performance are acceptable Slide 15 Submission Level Requirements New Parts Level 2 is required for Low Risk Parts Level 3 is required for Medium and High Risk Parts Part Changes Level 3 is required for Parts produced at a new or additional location Supplier Quality Excellence will define the level required for all other changes Donaldson reserves the right to redefine the submission level required Slide 16 PPAP Status Approved - The part meets all Donaldson requirements - Supplier is authorized to ship production quantities of the part Interim Approval - Donaldson permits shipment of part on a limited time and quantity clearly in writing defined. On Hold - SQA needs more info Rejected - The part does not meet Donaldson requirements, based on the production lot from which it was taken and/or accompanying documentation Production quantities may not be shipped before Donaldson Approval Slide 17 Electronic Submission Requirements Donaldson requires that all PPAPs be submitted electronically Use of paper submission must have prior approval by the SQA Submission must be received on or prior to the PPAP due date Review and Approval Process: Donaldson will attempt to review and provide feedback within 3 business days Donaldson requires all submissions to be electronic Slide 18 Donaldson PPAP book What is the Donaldson PPAP book? An Excel spreadsheet containing templates of the documents suppliers are required to submit to Donaldson. Organization formats are allowed as long these documents are providing the same. (Preferred language is English) Why use the PPAP book? Simplifies the process for suppliers by serving as a checklist of what needs to be submitted to Donaldson Reduces the number of files to manage Enables the SQA / PPAP team to quickly see if anything is missing Show PPAP book CORP SQADOC 004 Slide 19 Part Submission Warrant Slide 20 What is It? Document required for all newly tooled or revised products in which the supplier confirms that inspections and tests on production parts show conformance to Donaldson requirements Objective or Purpose Used to : document part approval provide key information declare that the parts meet specification When to Use It Prior to shipping production parts Have a closer look Slide 21 Part Submission Warrant Donaldson Part Number Engineering released finished end item part number Safety and/or Government Regulation Yes if so indicated by the Design Record, otherwise No Engineering Change Level & Date Show the change level and date of the Design Record Additional Engineering Changes List all authorized Engineering changes not yet incorporated in the design record but which are incorporated in the part Shown on Drawing Number The design record that specifies the customer part number being submitted Checking Aid Number, Change Level, & Date Enter if requested by the customer Purchase Order Number Enter this number as found on the contract / purchase order Product weight Enter the product weight Slide 22 Part Submission Warrant Donaldson Location Show the location where parts will be shipped to Buyer / Buyer Code Enter the buyers name and code Restricted Substances Enter Yes or No Model Name / Number Enter the model name and number Parts Identified with Appropriate Marking Codes UL UL = Underwriters Laboratories safety standards CE CE = Conformite Europeenne (European Conformity) Certifies that a product has met European consumer Safety, health, or environmental requirements ISO = International Organization for Standardization Enter Yes or No Supplier Manufacturing Information Show the name and code assigned to the manufacturing site on the purchase order / contract Slide 23 Part Submission Warrant Reason For Submission Check the appropriate box(es) Requested Submission Level Identify the submission level requested by Donaldson Submission Results Check the approp