PPAP-Training-PresentationPPAP專(zhuān)業(yè)培訓(xùn)資料

ProductionPartApprovalProcess(PPAP)WhatisPPAP?ProductionPartApprovalProcessStandardusedtoformallyreduceriskspriortoproductorservicerelease,inateamorientedmannerusingwellestablishedtoolsandtechniquesInitiallydevelopedbyAIAG(AutoIndustryActionGroup)in1993withinputfromtheBig3-Ford,Chrysler,andGMAIAG’s4theditioneffectiveJune1,2006isthemostrecentversionPPAPhasnowspreadtomanydifferentindustriesbeyondautomotivePurposeofPPAPProvideevidencethatallcustomerengineeringdesignrecordandspecificationrequirementsareproperlyunderstoodbytheorganizationTodemonstratethatthemanufacturingprocesshasthepotentialtoproduceproductthatconsistentlymeetsallrequirementsduringanactualproductionrunatthequotedproductionratePPAPmanageschangeandensuresproductconformance!WhenisPPAPRequired?NewpartEngineeringchange(s)Tooling:transfer,replacement,refurbishment,oradditionalCorrectionofdiscrepancyToolinginactive>oneyearChangetooptionalconstructionormaterialSub-supplierormaterialsourcechangeChangeinpartprocessingPartsproducedataneworadditionallocationPPAPisrequiredwithanysignificantchangetoproductorprocess!BenefitsofPPAPSubmissionsHelpstomaintaindesignintegrityIdentifiesissuesearlyforresolutionReduceswarrantychargesandpreventscostofpoorqualityAssistswithmanagingsupplierchangesPreventsuseofunapprovedandnonconformingpartsIdentifiessuppliersthatneedmoredevelopmentImprovestheoverallqualityoftheproduct&customersatisfactionProductionRunPPAPdatamustbesubmittedfromaproduction

run

using:ProductionequipmentandtoolingProductionemployeesProductionrateProductionprocessAlldatareflectstheactual

production

processtobeusedatstart-up!Run@RateThepurposeofaRun@Rateistoverifythesupplier’smanufacturingprocessiscapableofproducingcomponentsthatmeetNCR’squalityrequirements,atquotedtoolingcapacity,foraspecifiedperiodoftimeVerificationoftheRun@RatewillbeattheSupplierQualityEngineer’s(SQE)discretion.ThesupplierwillbenotifiedoftheneedtoperformaRun@Rateasearlyintheprocessaspossible.ThenumberofcomponentstobeproducedduringtheRun@RateshouldbesufficienttodemonstrateprocesscapabilityandwillbepredeterminedbytheSQEandthesupplier.Factorssuchasproductcomplexity,shelflife,storage,costandsingleshiftvs.multipleshiftoperationswillbetakenintoconsiderationOfficialPPAPRequirementsDesignRecordsAuthorizedEngineeringChangeDocumentsCustomerEngineeringApproval,ifrequiredDesignFailureModesandEffectsAnalysis(DFMEA)appliedinspecialsituationsProcessFlowDiagramProcessFailureModesandEffectsAnalysis(PFMEA)ControlPlanMeasurementSystemsAnalysis(MSA)DimensionalResultsRecordsofMaterial/PerformanceTestResultsInitialProcessStudiesQualifiedLaboratoryDocumentationAppearanceApprovalReport(AAR)SampleProductionPartsMasterSampleCheckingAidsCustomer-SpecificRequirementsPartSubmissionWarrant(PSW)Now,let’stakeacloserlookatNCR’srequirementsNCR’sPPAPRequirementsDesignRecordsAuthorizedEngineeringChangeDocumentsCustomerEngineeringApproval,ifrequiredDesignFailureModesandEffectsAnalysis(DFMEA)appliedinspecialsituationsProcessFlowDiagramProcessFailureModesandEffectsAnalysis(PFMEA)ControlPlanMeasurementSystemsAnalysis(MSA)DimensionalResultsRecordsofMaterial/PerformanceTestResultsInitialProcessStudiesQualifiedLaboratoryDocumentationAppearanceApprovalReport(AAR)SampleProductionPartsMasterSampleCheckingAidsCustomer-SpecificRequirementsPartSubmissionWarrant(PSW)–NCRcallsthisthe“ProductionWarrant”Suppliershallsubmitthese12itemsandretainacopyofrecordsatappropriatelocationsDesignRecordsAuthorizedEngineeringChangeDocumentsCustomerEngineeringApproval,ifrequiredDesignFailureModesandEffectsAnalysis(DFMEA)appliedinspecialsituationsProcessFlowDiagramProcessFailureModesandEffectsAnalysis(PFMEA)ControlPlanMeasurementSystemsAnalysis(MSA)DimensionalResultsRecordsofMaterial/PerformanceTestResultsInitialProcessStudiesQualifiedLaboratoryDocumentationAppearanceApprovalReport(AAR)SampleProductionPartsMasterSampleCheckingAidsCustomer-SpecificRequirementsPartSubmissionWarrant(PSW)–NCRcallsthisthe“ProductionWarrant”Suppliershallretainthese6itemsatappropriatelocations,andmakereadilyavailableuponrequestNCR’sPPAPRequirementsLevel1ProductionWarrantandAppearanceApprovalReport(ifapplicable)submittedtoNCRLevel2ProductionWarrant,productsamples,anddimensionalresultssubmittedtoNCRLevel3ProductionWarrant,productsamples,andcompletesupportingdatasubmittedtoNCRLevel4ProductionWarrantandotherrequirementsasdefinedbyNCRLevel5ProductionWarrant,productsamplesandcompletesupportingdata(areviewwillbeconductedatthesupplier'smanufacturinglocation)PPAPSubmissionLevelsPPAPSubmissionLevelTableS=SuppliershallsubmittoNCR&retainacopyofrecordsordocumentationitemsatappropriatelocationsR=SuppliershallretainatappropriatelocationsandmakereadilyavailabletoNCRuponrequest*=Suppliershallretainatappropriatelocations,andsubmittoNCRuponrequest.NCRwillidentifywhatisneededforsubmission.DefinitionofRiskHighRisk

Partsassociatedwithmultiplecriticalfeatures,complexdesign,orhighendtechnologythatisnotyetestablishedinthegeneralmanufacturingenvironmentSupplier’squalitysystemand/orqualityperformanceisnottoNCRsatisfactionMediumRiskPartsthathaveatleastonecriticalfeatureLowRiskPartsthathavenocriticalfeaturesandcanbemanufacturedbyanymanufacturerinthecommoditycategorySupplier’squalitysystemandqualityperformanceareacceptableSubmissionLevelRequirementsNewPartsLevel2isrequiredforLowRiskPartsLevel3isrequiredforMediumandHighRiskPartsPartChangesLevel3isrequiredforPartsproducedataneworadditionallocationSupplierQualityExcellencewilldefinethelevelrequiredforallotherchangesNCRreservestherighttoredefinethesubmissionlevelrequiredPPAPStatusApprovedThepartmeetsallNCRrequirementsSupplierisauthorizedtoshipproductionquantitiesofthepartInterimApprovalPermitsshipmentofpartonalimitedtimeorpiecequantitybasisRejectedThepartdoesnotmeetNCRrequirements,basedontheproductionlotfromwhichitwastakenand/oraccompanyingdocumentationProductionquantitiesmaynotbeshippedbeforeNCRApprovalElectronicSubmissionRequirementsNCRrequiresthatallPPAPsbesubmittedelectronicallyUseofpapersubmissionmusthaveprior

approvalbytheSQESubmissionmustbereceivedonorpriortothePPAPduedateReviewandApprovalProcess:NCRwillattempttoreviewandprovidefeedbackwithin2businessdays

NCRrequiresallsubmissionstobeelectronicNCRPPAPPlaybookWhatistheNCRPPAPPlaybook?AnExcelspreadsheetcontainingtemplatesofthedocumentssuppliersarerequiredtosubmittoNCRWhyusethePPAPPlaybook?Simplifiestheprocessforsuppliersbyservingasa“checklist”ofwhatneedstobesubmittedtoNCRReducesthenumberoffilestomanageEnablestheSQEtoquicklyseeifanythingismissingShowPPAPPlaybookPRODUCTIONWARRANTProductionWarrantNow,let’stakeacloserlookWhatisIt?DocumentrequiredforallnewlytooledorrevisedproductsinwhichthesupplierconfirmsthatinspectionsandtestsonproductionpartsshowconformancetoNCRrequirementsUsedto:documentpartapprovalprovidekeyinformationdeclarethatthepartsmeetspecificationObjectiveorPurposeWhentoUseItPriortoshippingproductionpartsProductionWarrantPartName/NCRPartNumberEngineeringreleasedfinishedenditempartnameandnumberSafetyand/orGovernmentRegulation“Yes”ifsoindicatedbytheDesignRecord,otherwise“No”EngineeringChangeLevel&DateShowthechangelevelanddateoftheDesignRecordAdditionalEngineeringChangesListallauthorizedEngineeringchangesnotyetincorporatedinthedesignrecordbutwhichareincorporatedinthepartShownonDrawingNumberThedesignrecordthatspecifiesthecustomerpartnumberbeingsubmittedCheckingAidNumber,ChangeLevel,&DateEnterifrequestedbythecustomerPurchaseOrderNumberEnterthisnumberasfoundonthecontract/purchaseorderSupplierPartNumberPartnumberdefinedbythesupplier,ifanyProductionWarrantNCRLocationShowthelocationwherepartswillbeshippedtoBuyer/BuyerCodeEnterthebuyer’snameandcodeRestrictedSubstancesEnter“Yes”or“No”ModelName/NumberEnterthemodelnameandnumberPartsIdentifiedwithAppropriateMarkingCodesUL=UnderwritersLaboratoriessafetystandardsCE=ConformiteEuropeenne(EuropeanConformity)–CertifiesthataproducthasmetEuropeanconsumerSafety,health,orenvironmentalrequirementsISO=InternationalOrganizationforStandardizationEnter“Yes”or“No”SupplierManufacturingInformationShowthenameandcodeassignedtothemanufacturingsiteonthepurchaseorder/contractProductionWarrantReasonForSubmissionChecktheappropriatebox(es)RequestedSubmissionLevelIdentifythesubmissionlevelrequestedbyNCRSubmissionResultsChecktheappropriateboxesMold/Cavity/ProductionProcessIfproductionpartswillbeproducedfrommorethanonemold,cavity,tool,die,pattern,orproductionprocess,thesuppliershallcompleteadimensionalevaluationononepartfromeach.Thespecificmolds,lines,etc.shallthenbeidentifiedhere.ProductionWarrantTheapprovedProductionWarrantofficiallywarrantsthepartsreadyforproductionDeclarationEnterthenumberofpiecesmanufacturedduringthesignificantproductionrunandthetime(inhours)takenforthesignificantproductionrunExplanation/CommentsProvideanyexplanatorycommentsonthesubmissionresultsoranydeviationsfromtheDeclaration.Attachadditionalinformationasappropriate.SupplierAuthorizedSignatureAresponsiblesupplierofficial,afterverifyingthattheresultsshowconformancetoallNCRrequirementsandthatallrequireddocumentationisavailable,shallapprovethedeclarationForNCRUseOnlyTobecompletedbyappropriateNCRSupplierQualityEngineerDeclarationAffirmationthatthesamplesrepresentedbythewarrantarerepresentativeandweremadebyaprocessthatmeetsNCR’sPPAPrequirementsPPAPWarrantDispositionApproved,Rejected,OtherNCRSignatureSignedbyNCRSupplierQualityEngineerReviewersChecklistMustbecompletelyfilledoutMustbesignedbythesupplierP/NmustmatchthePOSubmittedatthecorrectrevisionlevelSubmittedatthecorrectsubmissionlevelSpecifythereasonforsubmissionProductionWarrantAUTHORIZEDENGINEERINGCHANGEDOCUMENTSAuthorizedEngineeringChangeDocumentsThesuppliershallprovideauthorizedchangedocumentsforthosechangesnotyetrecordedinthedesignrecord,butincorporatedintheproduct,partortooling,suchas:ECNs(mustbeapproved,notpending)SpecificationsFeasibilitystudiesSupplierchangerequestsSub-assemblydrawingsLifeorreliabilitytestingrequirementsPROCESSFLOWDIAGRAMProcessFlowDiagramWhatisIt?Avisualdiagramoftheentireprocessfromreceivingthroughshipping,includingoutsideprocessesandservicesTohelppeople“see”therealprocess.Processmapscanbeusedtounderstandthefollowingcharacteristicsofaprocess:Set-by-stepprocesslinkageOfflineactivities(measurement,inspection,handling)Rework,scrapObjectiveorPurposeWhentoUseItTounderstandhowaprocessisdonePriortocompletingthePFMEAProcessFlowDiagramsTheprocessflowdiagramutilizesthesesymbolstoclearlyidentifyeachstepintheprocessProcessFlowDiagram-ExampleStarExerciseDivideintoteamsDistributesuppliesPaperforStarsInstructionsformakingStarsScissorsUsingtheinstructionshandedoutinclass,make10ShurikenStarsThisexercisewillprepareyourteamtocompletefutureexercises45MinutesProcessFlowDiagram–StarExercise05IncomingInspection10PaperFolding15Cutting20StarFolding2535Tucking30FinalInspectionPacking40ShippingInspectionasperOperationlayoutIfreworkpossibleRework100%InspectionScrapNextOperationNotOKOKPatrolInspReportReviewersChecklistProcessFlowmustidentifyeachstepintheprocessShouldincludeabnormalhandlingprocessesScrapReworkProcessFlowmustincludeallphasesoftheprocessReceivingofrawmaterialPartmanufacturingOfflineinspectionsandchecksAssemblyShippingProcessFlowDiagramsPROCESSFMEAProcessFMEA(PFMEA)WhentoUseItAftercompletionoftheprocessflowdiagram.PriortotoolingforproductionWhatisIt?Atoolusedtoidentifyandprioritizeriskareas

andtheirmitigationplans.ThePFMEAshouldbecompletedusingacross-functionalteam!IMPORTANT!ObjectiveorPurposeIdentifiespotentialfailuremodes,causes,andeffects.Inputscomefromtheprocessflowdiagram.Identifieskeyinputswhichpositivelyornegativelyaffectquality,reliabilityandsafetyofaproductorprocess.FMEAOriginCreatedbyNASAfollowingApollo1missionfailureAllowsustotakeaproactiveapproachtowhatcangowronginaprocessandmanageourrisksbetterProcessFMEA(PFMEA)ThisisincludedinthePPAPPlaybook!TIPSThereshouldbeatleastonefailuremodeforeachinput.UsingthecompletedProcessFlowDiagram,entertheprocessstep.FailureModesForeachProcessInput,determinethewaysinwhichtheinputcangowrong.PFMEA-Step1TIPSThereshouldbeatleastonefailureeffectforeachfailuremode.Effectsshouldbespecific,clear,andleavenodoubttotheuninformedreviewer.PotentialFailureEffectsForeachFailureMode,determinewhateffectthespecificfailurecouldhaveontheprocessoutput.PFMEA-Step2TIPSThereshouldbeatleastonepotentialcauseforeachfailuremode.PotentialCausesForeachFailureMode,determinethepossible

causeofthefailure.PFMEA-Step3TIPSThisstepintheFMEAbeginstoidentifyinitialshortcomingsorgapsinthecurrentcontrolplan.Ifaprocedureexists,enterthedocumentnumber.Ifnocurrentcontrolexists,listas“none.”CurrentControlsForeachpotentialcause,listthecurrentmethodusedforpreventingordetectingfailure.PFMEA-Step4AssignSeverity,Occurrence,andDetectionratingsAssignSeverity(Howseriousisthe

effectifitfails?)AssignOccurrence

(Howlikelyisthe

causetooccur?)AssignDetection(Howeasilycanthe

causeorfailuremodebedetected?)Severity,OccurrenceandDetectionratingdetailsonnextslidePFMEA-Step5PFMEA-DefinitionofTermsSeverity(ofEffect)

-severityoftheeffectontheCustomerandotherstakeholders(HigherValue=HigherSeverity)Occurrence(ofCause)

-frequencywithwhichagivenCauseoccursandcreatesFailureMode.(HigherValue=HigherProbabilityofOccurrence)Detection(CapabilityofCurrentControls)

-abilityofcurrentcontrolschemetodetectthecausebeforecreatingthefailuremodeand/orthefailuremodebeforesufferingtheeffect(HigherValue=LowerAbilitytoDetect)Caution:NoticethescaledifferenceforDetection!High 10Low 1RatingSeverityOccurrenceDetection*HazardouswithoutwarningVeryhighandalmostinevitableCannotdetectordetectionwithverylowprobabilityLossofprimaryfunctionHighrepeatedfailuresRemoteorlowchanceofdetectionLossofsecondaryfunctionModeratefailuresLowdetectionprobabilityMinordefectOccasionalfailuresModeratedetectionprobabilityNoeffectFailureunlikelyAlmostcertaindetection*IfNoControlsExist,Detection=10Createaratingsystemthatmakessenseforthedefectsyouaretryingtoprevent.AnExampleofRatingDefinitionsTIPSTheRPNisusedtoprioritizethemostcriticalrisksidentifiedinthefirsthalfoftheFMEA.HighRPNs(125orabove)areflagstotakeefforttoreducethecalculatedrisk.RegardlessofRPN,highSeverityscores(9or10)shouldbegivenspecialattention.CalculatetheRiskPriorityNumber

RPN=SeverityxOccurrencexDetectionPFMEA-Step6OncetheRPNNumbersaredetermined,theycanbeusedtoprioritizethemostsignificantfailuremodes.SorttheFMEAbytheRPNnumbers.Graphicalandstatisticaltoolscanhelptheteamselecta“cut-off”RPNforthenextsteps.RPNThresholdsWhenusinganRPNthreshold,DONOTforgettoaddresshighSeverityscoresParetoChart?Howmanyitemsshouldbethefocusofthenextsteps?SortbyRPNtodeterminethemostsignificantfailuremodesAnalyzingthePFMEAPFMEA–RemediationGuidelinesSeverity

–canonlybeimprovedbyadesignchangetotheproductorprocessOccurrence

–canonlybereducedbyachangewhichremovesorcontrolsacause.Examplesareredundancy,substitutingamorereliablecomponentorfunctionormistake-proofing.Detection

–

can

bereducedbyimprovingdetection.Examplesaremistake-proofing,simplificationandstatisticallysoundmonitoring.Ingeneral,reducingtheOccurrenceispreferabletoimprovingtheDetectionDetermineActionsRecommendedtoreduceHighRPNsForthehighRPNnumbers,determinetherecommendedactions.FMEA–Step7NowrecalculateyourRPNs

basedonmitigationplans.TIPS:Continueupdatingtheactionstakenand

resultingRPNsuntilallrisksareatanacceptablelevel(below125).Resp(responsibility)Assignaspecificpersonwhowillberesponsible

forrecommendedactions.ActionsTakenAsactionsareidentifiedandcompleted,documentinthe“ActionsTaken”column.FMEA–Steps8and9SEV,OCC,DET,RPNAsactionsarecompletereassessSeverity,Occurrence,andDetectionandrecalculateRPN.ForeachProcessInput,determinethewaysinwhichtheProcessStepcangowrong(theseareFailureModes).ForeachFailureModeassociatedwiththeinputs,determineEffectsontheoutputs.IdentifypotentialCausesofeachFailureMode.ListtheCurrent

ControlsforeachCause.AssignSeverity,OccurrenceandDetectionratingsaftercreatingaratingskeyappropriateforyourproject.CalculateRPN.DetermineRecommendedActionstoreduceHighRPNs.TakeappropriateActionsandDocument.RecalculateRPNs.Revisitsteps7and8untilallthesignificantRPNshavebeenaddressed.SummaryStepsToCompleteaFMEA

PFMEAExercise30MinutesInstructionsOpenthePPAPTrainingTemplates.xlsfile,thenselectthePFMEAworksheet.

Usingprocesssteps20and25fromthecompletedStarProcessFlowDiagramhandout,complete2rowsofthePFMEA.UsethefilePPAPTrainingTemplates.xlsCollaborativeEffort:Donottryalone,useagroupVerylaborious:Timeconsumingprocess.Takenecessarybreaks.ActionitemsarerequiredforcompletionTrainteamaheadoftimebyexplainingscoringcriteriaProperpreparationisneededformeetingsSummarizeoften:FMEAisalivingdocumentTipsandLessonsLearnedProcessFMEA(PFMEA)ReviewersChecklistVerifythereisasystemforprioritizingriskoffailuresuchasRPNnumbersof125oraboveMakesurethathighRPNprocessconcernsarecarriedoverintothecontrolplanMakesurethatallcriticalfailuremodesareaddressedSafetyForm,fit,functionMaterialconcernsProcessFMEA(PFMEA)CONTROLPLANControlPlanAdocumentthatdescribeshowtocontrolthecriticalinputstocontinuetomeetcustomerexpectationsoftheoutput.WhatisIt?ObjectiveorPurposePrimaryreferencesourceforminimizingprocessandproductvariation.Descriptionofhowteamsshouldreacttoout-of-controlsituations.Sinceprocessesareexpectedtobecontinuouslyupdatedandimproved,thecontrolplanisalivingdocument!NOTEWhentoUseItImplementationofnewprocessFollowingaprocesschangeProcessStepsNew/RevisedProcessStepsProcessFlowchartNew/RevisedProcessStepsProcessStepsProcessFMEARiskPrioritizedProcessStepsImprovedControlsControlPlanToolInteractionControlPlanNCR’sControlPlanThisisincludedinthePPAPPlaybook!ControlPlan3DistinctPhasesPrototype–adescriptionofthedimensionalmeasurementsandmaterialandperformanceteststhatwilloccurduringPrototypebuild.3DistinctPhases3DistinctPhases2. Pre-Launch–adescriptionofthedimensionalmeasurementsandmaterialandperformanceteststhatwilloccurafterPrototypeandbeforefullProduction.3DistinctPhases3. Production–acomprehensivedocumentationofproduct/processcharacteristics,processcontrols,tests,andmeasurementsystemsthatwilloccurduringmassproductionControlPlanAdministrativeSectionIdentifiespartnumberanddescription,supplier,requiredapprovalsignatures,anddates.AdministrativeSectionControlPlanPart/ProcessUsethisareatodefinepart/processnumberanddescription.Machine/ToolsListthemachine,device,jig,ortoolsthatwillbeusedinthemanufacturingprocessCharacteristicsDefinethecharacteristicsoftheproductorprocessProcess,Machine/Tools,CharacteristicsControlPlanSpecifications/ToleranceUsethisareatodefineupper/lowerspeclimitsforeachcontrolelement.MeasurementTechniqueForeachlineinthecontrolplan,listthemeasurementprocedurethatwillbeused(maylistR&RGagePlanorPoka-Yoke).SampleSizeWhatisthesizeofthesampleyoushouldgatherdatafrom?FrequencyDefinethefrequencyforwhichthemeasurementwillbetaken.Specifications,Measurement,SampleSize&FrequencyControlPlanControlMethodMethodthatwillbeusedtocontroltheprocessReactionPlanActionstobetakenifcontrolsfailControlMethod,ReactionPlanControlPlanAuditPlansAuditplansshouldbeincludedinthecontrolplanasaseparateline.Auditingisanimportanttoolforcontrol.Processauditingshouldbeakeyelementofthequalitysystemofabusiness.Auditsgenerallycover:EffectivenessofcontrolsControlplan(say)vs.whatisactuallydone(do)Auditsshouldbeobjective(donebyinternalorexternalthirdpartiesifpossible).Auditfrequenciesshouldbebasedonbalancinglevelofrisk(FMEA)andcost.ControlPlan–ExampleAsuppliermanufacturesacircuitboardwithelectroniccomponentssolderedontheboard.Properlysolderedconnectionsarethemajorproductcharacteristics.Twomajorprocesscharacteristicsforthewavesoldermachinearesolderlevelandfluxconcentration.Anautomatedfeedercontrolsthesolderlevelbysensingthelevelofsolderandfeedinginadditionalsolderasthelevelisreduced.Thischaracteristicismeasured100%bycheckingelectricallyforcontinuity.Thefluxmustbesampledandtestedfortheconcentrationlevel.3DistinctPhasesProductionPart/ProcessSolderingConnectionsMachine/ToolsWavesoldermachineCharacteristicsProduct=WavesolderheightProcess=FluxconcentrationSpecifications/ToleranceProduct=2.0+/-0.25mcProcess=Standard#302BMeasurementTechniqueProduct=SensorcontinuitycheckProcess=TestsamplinglabenvironmentSampleSizeProduct=100%Process=1pcFrequencyProduct=ContinuousProcess=4hoursControlMethodProduct=AutomatedinspectionProcess=x-MRchartReactionPlanProduct=AdjustandretestProcess=SegregateandretestInstructionsOpenthePPAPTrainingTemplates.xlsfile,thenselecttheControlPlanworksheet.

UsingthecompletedStarProcessFlowDiagram(processsteps20and25)andthecompletedPFMEA,complete2rowsoftheControlPlan.Documentpotentialproblemsthatmightbeencounteredandpotentialsolutionswithyourteams.ControlPlanExercise20MinutesUsethefilePPAPTrainingTemplates.xlsControlPlanUseprocessflowdiagramandPFMEAtobuildthecontrolplan;keepthemalignedControlsmustbeusedtobeeffective.Keepitsimple.EnsurethatthecontrolplanisinthedocumentcontrolsystemofthebusinessGoodcontrolplansaddress:Alltestingrequirements-dimensional,material,andperformanceAllproductandprocesscharacteristicsateverystepthroughouttheprocessThecontrolmethodshouldbebasedonaneffectiveanalysisoftheprocessSuchasSPC,ErrorProofing,Inspection,SamplingPlanControlplansshouldreferenceotherdocumentationSpecifications,tooling,etc.Reviewer’sChecklistMEASUREMENTSYSTEMANALYSIS(MSA)MeasurementSystemAnalysis(MSA)AnMSAisastatisticaltoolusedtodetermineifameasurementsystemiscapableofprecisemeasurement.WhatisIt?ObjectiveorPurposeTodeterminehowmucherrorisinthemeasurementduetothemeasurementprocessitself.Quantifiesthevariabilityaddedbythemeasurementsystem.Applicabletoattributedataandvariabledata.WhentoUseItOnthecriticalinputsandoutputspriortocollectingdataforanalysis.Foranynewormodifiedprocessinordertoensurethequalityofthedata.MeasurementSystemAnalysisis

ananalysisofthemeasurement

process,notananalysisofthepeople!!IMPORTANT!WhoShouldbeInvolvedEveryonethatmeasuresandmakesdecisionsaboutthesemeasurements

shouldbeinvolvedintheMSA.AttributeDataExamples:

Count,Pass/fail,yes/no,red/green/yellow,timekeepingbucketsVariableDataExamples:

Physicalmeasurement(length,width,area,…)Physicalconditions(temperature,pressure…)Physicalproperties(strength,load,strain…)Continuousornon-endingAttributeandVariableMSAUnlessapprovedbyanNCRSQE,attributedataisnotacceptableforPPAPsubmissionMeasurementSystemAnalysis(MSA)ProcessVariationMeasurementSystemVariationObservedVariationTheobservedvariationinprocessoutputmeasurementsisnotsimplythevariationintheprocessitself;itisthevariationintheprocessplusthevariationinmeasurementthatresultsfromaninadequatemeasurementsystem.

ConductinganMSAreducesthelikelihoodofpassingabadpartorrejectingagoodpartMeasurementSystemAnalysis(MSA)ProcessVariationMeasurementSystemVariationObservedVariationTheoutputoftheprocessmeasuredby:CycletimeDimensionaldataNumberofdefects

andothersObservedVariationObservedVariationProcessVariationMeasurementSystemVar