ppap_生产件批准程序ppap概述

,生产件批准程序ProductionPartApprovalProcess(PPAP),Presentedby:MaxZhangFordCSOSTA9thAugust2007,PPAPistodemonstratesuppliersunderstandingof:PPAP是为表明供应商怎样理解以下内容的一个过程：,-零件的用法PartsUsage-相关的项目Associatedprograms-车辆Vehicle-型号年份ModelYear(MY),零件的功能Partsfunctionality,零件的特性PartsCharacteristics,特性的关键性Criticalityoffeatures,怎样测量零件Howtogaugethepart,生产要求Productionrequirements,工程图纸要求Engineeringdrawingrequirements工程规范(ES)材料特性MaterialCharacteristics材料处理(热处理,外观)MaterialTreatment(HeatTreat,Appearance),安全特性OperatorSafetyfeatures,ifany关键特性CriticalCharacteristics重要特性SignificantCharacteristics高影响的特性HighImpactCharacteristics传递特性PassThroughCharacteristics,使用哪些最为合适的量具Whatmostsuitablegaugestouse?-计量型量具Variablegauges-计数型量具Attributegauges基准Datum测量方法和装配工厂存在相关性MeasurementCorrelationwithusingplants,何时需要？Whenneeded?哪里需要?Whereneeded?多少数量?Howmuch?-按节拍生产RunatRate-生产能力确认CapacityVerification,Application什么时候用到PPAP?,PPAPisrequiredfor,butnotlimitedto:PPAP对以下情况适用（但不局限于）：Allnewtooledparts（使用新模具生产零件）Allnewvehicleprogramsandrunningchangesforvehiclescurrentlyinproduction(新车型，或者是对现有车型的变更)Anychangeinsupplieroperatingpattern(i.e.newshift)(生产模式的变更)Anyadditional,modifiedorreconfiguredproductiontooling,equipmentorworkstreams（模具，设备或生产线的增加，改造或重新装配）RevisedcustomerDPV(DailyProductionVolume)exceedingverifiedsuppliercapacitylevel（客户需求量的增加）,Content内容,PhasedPPAPintroduction阶段性生产件批准程序的介绍FordspecialrequirementstoPPAP18elements.福特汽车对于生产件批准18个项目的要求。VPPusageVPP的使用方法,阶段性生产件批准程序PHASEDPPAPPROCESS,WhatisthePhasedPPAP?什么是PhasedPPAP？,PhasedPPAPisFordsapproachtoPPAPprocessmanagementPhasedPPAP是福特特有的生产件批准管理程序。Introducedtoimproveuponlaunchperformance用来提高项目开发和实施的表现。RequiresasuppliersitetodemonstrateManufacturingcapability（制造能力）Productquality（产品质量）Andproductioncapacity（产能）priortojob#1（在J#1之前）,PhasedPPAPvstheoldPPAPPhasedPPAP与PPAP的比较,PhasedPPAPorganizestheprocessintofourphasesPhase0:Run-at-RatePhase1:QualityVerificationPhase2:ProductionVerificationPhase3:CapacityVerification,PPAP,X,1PP,FEU,Job1,PhasedPPAPPhase0Phase1Phase2Phase3,SupplierPhasedPPAPProcessMap阶段性生产件批准程序示意图,STATUS:,Phase2,Completed,Phase2,Warrant,#18,Yes,StatusTracking,Database,2,3,4,Proceedtonextpage,Submitto,Customer,Importantnote:,Phase2andPhase3canhappen,concurrentlyifallInputsand,Outputsaresatisfied,No,Phase0Run-at-Rate,Phase1QualityVerification,Phase2ProductionVerification,Phase3CapacityVerification,1-DesignRecords2-EngineeringChangeDocuments3CustomerEngineeringApproval4-DesignFMEA5-ProcessFlowDiagrams6-ProcessFMEA7-ControlPlans8-MeasurementSystemAnalysisStudies16-CheckingAids17-Customer-SpecificRequirements,9-DimensionalResults10-RecordsofMaterial/PerformanceTestResults11-InitialProcessStudies12-QualifiedLaboratoryDocumentation13-AppearanceApprovalReport14-SampleProductionParts15-MasterSample18-PPAPWarrant,PPAPWarrant(element18),Run-at-Rateforallproductionstreams(element18,16,17),QualityVerificationforallproductionstreams(element915),CapacityAnalysisReport,CapacityAnalysisReport,PPAPWarrant(element18),HaveRun-at-Rates(Phase0)beenconductedandQualityVerifications(Phase1)beensatisfiedforALLproductionstreams?,Phase0:Run-At-Rate（按节拍生产）,Phase1Prerequisites(Phase1的先决条件）,InordertobeginPhase1,thefollowingarerequired:要进入Phase1，必须达到以下条件：SuccessfulcompletionofRun-at-Rate(Phase0)foratleastoneworkstream对至少一条生产线成功完成节拍生产CapacityAnalysisReportcompletedforatleastoneJob1-intendedproductionworkstream对至少一条生产线成功完成产能分析Tier“X”successfulcompletionofPhase1分供方完成了Phase1PPAP.,Phase1:QualityVerification(质量验证）,1,ContinueProductionPartApprovalProcess(PPAP)usingpartsfromPhase0Dimensionalmeasurements#9Materialtests#10Statisticalprocesspackage#11Performancetests#12Appearancecriteria#13Sampleparts#14Mastersamples#15Customer-specificrequirements#17AsdefinedbyPPAP,ReturntoPhase0forcorrectiveaction,STATUS:Phase1Complete,Phase1Warrant#18,StatusTrackingDatabase,4,2,NO,Submittocustomer,YES,HavethePPAPelementsbeensatisfied?,Importantnote:forsupplierswithonlyoneproductionstream,completionofPhase1&2occuratthesametime.,4,WhatisrequiredtogetPhase1PSWapproval?获得Phase1PSW的条件,InputRequirements（Phase2的先决条件）,Phase2requiresthefollowing（Phase2需要以下条件）:AllJob1intendedproductionworkstreamshavesuccessfullycompletedRun-at-Rate（所有生产线都成功完成了节拍生产）CapacityAnalysisReportscompletedforallJob1intendedproductionworkstreams（所有生产线都成功完成了产能验证）TierXsuccessfulcompletionofPhase2(分供方完成Phase2PPAP).,Page51DefineTierXandincludenoterequestingaddlinfoforscriptduetosound,Phase2:ProductionVerification（生产验证）,2,STATUS:Phase2Complete,Phase2Warrant#18,StatusTrackingDatabase,3,NO,Submittocustomer,YES,HaveRun-at-Rates(Phase0_beenconductedandQualityVerifications(Phase1)beensatisfiedforALLstreams?,Importantnote:Phase2andPhase3canhappenconcurrentlyifallinputsandoutputsaresatisfied.,4,Phase3:CapacityVerification,3,FordSpecialRequirementstoPPAP18Elements福特对生产件批准18个要素的要求,DesignRecord设计记录,ThedesignmustbereleasedandauthorizedbyFordD&R.总成图必须获得福特设计工程师的批准，并在福特系统中(WERS)发布。Wherethedesignrecordisinelectronicformat,theorganizationshallproduceahardcopy(e.g.,GD&Tdrawing)toidentifymeasurementstaken.当设计记录(如CAD/CAM数模、零件图纸、技术规范)是以电子格式（如数模）存在时，供应商必须复制一份硬拷贝（如示意图、几何尺寸和公差表、图纸）以标识测量的内容。Engineeringchangelevelproperlyindicatesthelatestdesignchange.工程变更等级必须符合最新的设计变更状态ForFSS,ifthepartsareidentifiedasblackbox,thedesignrecordshouldatleastspecifiestheinterfaceandperformancerequirements.(e.g.VehicleAssemblyPosition).对全服务供应商，对于定义为黑盒子的零件，设计记录要规定和其他件配合的关系和性能要求。,2.EngineeringChangeDocuments工程变更文件,SREAsignedbyCFT.供应商工程变更申请WERSConcern.-如果有权限进入WERS，供应商可以通过WERSConcern来提交设计变更-福特提出的设计变更通过WERSConcern来通知供应商和内部相关人员WERS=WorldEngineeringReleaseSystem,3.CustomerEngineeringApproval客户工程批准,TheorganizationshallobtaindocumentedFordProductDevelopmentengineeringapprovalofDV(DesignVerification)andPV(ProductionValidation)testsoftheinitialsampleparts.供应商必须获得福特PD部门对D/PVP&R的书面批准。TheorganizationshallconductthePVtestingonparts/productswhichwereproducedat“runatrate”.（使用节拍生产出来的零件进行PV试验）Whereappropriate,FordEngineeringrecordsinitialsamplepartapprovalontheESER/ESO.工程批准的方式可能有很多：ESER,ESO,DVP&RWERSAlertforInterim-Approval.临时批准需要有WERSAlert支持。,4.DFMEA设计不良模式效应分析,WhendevelopingFMEA,therequirementsofFordFMEAhandbook(specialcharacteristicdefinition)shallbemet.有产品设计职责的组织，必须按照福特的FMEA手册开发设计FMEA。ForpartswithYC/CC,DFMEAsmustbeapprovedinwrittingbyFordD&Rengineer.如果零件有关键特性（YC/CC,车辆安全规范或政府法规控制），DFMEA要获得福特设计工程师的书面确认。Fordreservestherighttoreviewandapproveallorganization-developedDFMEAs.福特保留审核和批准供应商开发的DFMEA的权利。Overpatentconcerns,sometimes,supplierdoesnotwannashareDFMEA,wecouldreviewitatthesuppliersiteorhavethesupplierbringthemtoouroffice.（现场审核DFMEA硬拷贝）,5.ProcessFlowDiagram过程流程图,制造过程绘制MappingtheManufacturingProcess.组队Organizetheteam制作过程流程图DevelopAProcessFlowDiagram确定每一过程的偏差来源Identifysourcesofvariationineachprocess结合经验教训Incorporatelessonslearned记述各个步骤的目的Describepurposeofeachstep,5.ProcessFlowDiagram过程流程图,6.PFMEA过程FMEA,GeneralProceduretodevelopPFMEA:编制过程FMEA的一般流程Askthequestions:哪些方面可能会出现错误？Whatcangowrong?如果发生了会怎样！产生什么影响？Sowhat!Effect?不产生功能Nofunction产生部分功能Partial出现不需要的功能Unintendedfunction原因？Cause(s)?,6.PFMEA过程FMEA,GeneralProceduretodevelopPFMEA:编制过程FMEA的一般流程(续)当此情况发生需要采取何种措施？Whatdowedowhenthishappens?来预防故障Topreventthefailure来发现故障Todetectthefailure假如还不够，那么：Ifthatisnotenough,then:还需要做什么？Whatelseneedtobedone?,6.PFMEA过程FMEA,ProcessFEMAOutput过程FEMA输出：哪些需要被控制Whatneedstobecontrolled对于产品和过程来说哪些是关键的？Whatiscriticalintheproduct&theprocess怎样来控制这些Howtocontrolthesethings,6.PFMEA过程FMEA,IfDFMEAdoesnotexist,theteammusthaveameetingwiththeDesignEngineer-usingtheCRTapproach.如果没有DFMEA，供应商需要和福特设计工程师确定关键特性和显著特性的清单。ForpartswithCC,PFMEAsneedtogetFordEngineering&STAApproval.对有关键特性的零件，PFMEA要获得福特PD和STA的批准。CharacteristictraceabilityisrequiredfromtheDFMEAthroughthePFMEAtotheControlPlan(Supp.K).要保证特殊特性在各个文件中的一致性。ErrorProvinglistisoneoutputofPFMEA.防错清单是PFMEA的一个重要输出。PFMEAislivingdocument.(8D,SREA)PFMEA要不断更新。,7.ControlPlan控制计划,对过程按从开始到结束的逻辑顺序Documentingthelogicalorderofprocesses,starttofinish说明产品特性及过程参数Specifyproductcharacteristicsandprocessparameters对什么进行控制及怎样控制Whattocontrol&how何时进行控制及控制程度Whentocontrol&howmuch如遇故障，下步需做什么Whattodo,ifallfailed,7.ControlPlan控制计划,CC/SClistisproperlycascadedintoCP.控制计划要体现对特殊特性的有效控制。IncomingInspectionisthe1stpartofCP.来料检验是控制计划的第一部分。TheReactionPlanshouldbeevaluatedforeffectivenessanduse.评估应变计划以验证其有效性Listsallprocessparametersandpartcharacteristicsthatrequirespecificqualityplanningactions.对产品特性和过程特性都要规定有效的控制措施STAapproval.STA批准（对CC件，要获得福特PD和STA批准）Livingdocumentation.（根据变更和8D更新控制计划）,7.ControlPlan控制计划,8.MeasurementSystemAnalysis测量系统分析研究,Allgauges(bothgeneralordedicated)inControlPlan.无论测量系统的类型是什么，用于检查福特产品的所有量具,都需进行量具再生/再现性分析。MSA3.0based.基于MSA3.0版本Associated%toleranceand%studyvariation.在总偏差中的量具误差占公差的比例和过程变差的比例。Tovariablegages,thepartsusedfortheGaugeR&RstudymustbewithinDesignRecordspecifications.对计数型量具，用于MSA的零件必须符合设计规范。TheacceptancecriteriaforGaugeR&RasapercentofTOLERANCEislessthan10%.If%toleranceisover10%customerapprovalisneeded.TheGaugeisunacceptableif%toleranceisover30%.NDCmorethan5.ANOVAMethodpreferredwithMinitab.（优先使用方差方法）,9.DimensionalResults全尺寸报告,DimensionalMeasurementstocomparetheactualpartwiththedrawing(bubbleprints).Defaultare3partsmeasured(5pcspreferred).比较实际零件是否符合设计记录的要求，默认三件。Ifproductionpartswillbeproducedfrommorethanonecavity,mold,tool,die,patternorproductionprocess,adimensionalevaluationononepartfromeachshouldbecompleted.对于每个独立加工的过程，如：生产单元或生产线，和所有的多模腔、成型模、模型或冲模，都必须有全尺寸测量结果。MakeoneofthepartsmeasuredasMasterSample“.将其中一个零件作为标准样品,10.Material/PerformanceTestResults材料/性能试验结果的记录,WhereFordspecifiesthatmaterialsaretobepurchasedfromanapprovedsupplier,theorganizationshouldcontactthebuyertodetermineappropriatematerialssuppliers.对特殊材料必须选择福特指定的供应商。FordPDissupposedtoapprovethePVtestplan,andtosignthePVP&R.PV试验计划要获得福特PD的确认。PV试验成功完成后，PD要在PVP&P上签字。AllPVtestrequirementsareclearlyidentifiedintheDVP&R.(PVP&R)D/PVP&R中必须规定试验设备。PVtestingissupposedtouserunatrateparts.PV试验的零件来自节拍生产AlltestequipmentusedforPVTestingisavailableandintheappropriatelocation(fullycalibratedandcertified).试验设备要经过校准和确认。,11.InitialProcessStudy初始过程研究,MSAshouldbeconductedbeforePpkstudy.在进行初始过程研究之前，必须确保量具已经做过MSA。PpkisrequiredforInitialProcessStudy,SCsandCCsmustmeetatminimum1,67Ppk.特殊特性要满足Ppk=1.67的要求。Focusonvariablesdata.针对计数性数据IfPpk=1.67的条件，必须采用防错或者100%检测来控制该特性。,CpkorPpk?,Cpkistodetermineiftheprocessiscapabletomeetspecifications,andisapredictionofwhatyourprocesscando.Theprocesshastobeinstatisticalcontrol.Atleat100individualsamplesavailable.,whenyoucantdeterminestatisticalcontrolorifyouarelookingataveryshortproductionrun,Ppkshouldbeused.,12.QualifiedLabDocumentation合格的实验室文件,Thequalifiedlaboratory(internalorexternal)shallhavealaboratoryscopeanddocumentationtoshowitisqualifiedtoconductedtheinspectionandtestingforPPAP.组织必须有一份实验室范围和说明所使用的实验室遵循的证明文件。TheexternallaboratoryshallbeincompliancewiththelatestISO/IEC17025(ornationalequivalent).外部实验室要符合最新ISO/IEC17025的要求（或所在国等同要求）,13.AppearanceApprovalReport外观批准报告,Allparts/productshavingappearancecriteriashallbereviewedandapprovedbytheappropriateFordactivity(DesignQuality).当产品和零件在设计记录上有外观要求且要求提交时，则每一个零件或零件系列都必须填写一份单独的外观批准报告（AAR）。Appearanceapprovalincludes,butisnotlimitedto:overallappearance,surfacequality,color,texture,andgloss.外观批准包括整体外观，表面质量，颜色，皮纹和光泽度等等。Visualmatch-to-masteristhespecifiedrequirementforAARsign-off.Numericevaluationsshouldonlybeusedforon-goingqualitycontrolaftervisuallyacceptableparts/productsareattained.AAR是福特精致工艺部门参照外观标准对零件的视觉比较（主观的）。计量型评价方法只可以作为生产过程控制的方法来使用，但必须在获得AAR之后。AARplanandPre-AAR.,14.SampleProductionparts生产件样品,Customerdefinesthequantity.客户规定生产件样品的数量。SamplePartsareneededforthepartsfunctioningintheVehicleorPowertrainAssembly。生产件样品用来在整车厂或发动机厂作功能性装车试验。Photosasevidenceisacceptable.可以使用照片作为证据。,15.MasterSample标准样件,Mastersamplewhichisretainedinthesupplierssiteforreference.MastersamplehasthesamelifeasPPAPpackage.标准样件由供应商负责保管，保存期与生产零件批准文件的保存期相同。Suppliershallretainamastersamplefromeachpositionofamultiplecavitydie,mold,toolorpartern,orproductionprocessunlessotherwisesepcifiedbythecustomer.组织必须保存一份由多腔模具、铸模、工装、仿形模或生产过程的每一腔模具生产的样件。Customer(STA&PD)signaturewithapprovaldate.标样必须标识顾客批准标样的日期。DimensionalResultisrequiredformMasterSample标准样件要有全尺寸报告,16.CheckingAids检查辅具,Gaugestrategyanddrawingapprovedbycustomer.专用检具和特殊工装的图纸。检验辅具可以是零件专用检具，包括卡具、量规、模形、模版及聚酯薄膜。Thegaugesaretothelatestdesignlevel.检具必须符合零件的最新设计状态。MSAstudytocheckingfixturesisrequired.对专用检具要做MSA分析。,17.CustomerSpecificRequirements客户特殊要求-PackagingApproval包装批准,ExpendablePackageVS.ReturnableDunnage.一次性包装VS.可回收包装Forms:表格-FoE&FAP:FORM1121(viaFSBC)福特欧洲和亚太：1121表（福特澳洲通过FSBC提交）-NA:FORM150E福特北美：150E表Trialshipmentthatsimulatestheproductionlogisticsprocess.(WaterShipmentTrialforexportingsuppliers)如果使用福特指定的物流商，供应商需要完成海运试验来支持包装批准。,17.CustomerSpecificRequirements-CapacityVerification（产能验证）,MeasuretheabilityofasuppliertomeetFordMotorCompanysCapacityPlanningVolume(CPV)withqualityparts,ontime.目的是验证供应商能否满足福特产能的要求。Capacityverificationtoeachworkstationtoidentifythebottleneckprocess产能验证要细化到每个工位来识别瓶颈工序。CPVinformationshouldbeprovidedbybuyer.福特采购部门提供计划产能信息。,17.CustomerSpecificRequirements-Supplement-K&IMDS-K表和国际材料数据系统,Supp.KisusedtodemonstratethelinkagebetweentheDrawing-FMEAs-ControlPlans-OperatorInstructionSheets.K表用来验证不同文件（图纸，DFMEA，PFMEA，控制计划和操作指导书）之间的联接性All