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					                                               ADAC Supplier PPAP Request and Requirements

Date:           January 0, 1900                              Submit All PPAP's To:       nsoltys@adacautomotive.com                                                                       0




                                                                                                                                      Submission Due Date: 1/0/1900
                                                                                                                                                                      Submission Level:
                                                                                                                                                                                          Attention: 0
                                                                                                                                                                                                                    Supplier: 0
Requested By:      Nancy Soltys                                       Submit All     Nancy Soltys
                   Senior Buyer                                       PPAP's To:     2929 32nd Street, Unit C
                   616-957-0520 Ext. 5686                                            PO Box 888375 (if sent U.S. Mail)
                   616-446-2533 Mobile                                               Grand Rapids, MI 49588-8375
4.5 PPAP Requirements
     PPAP’s are requested by and submitted to ADAC Purchasing. Final PPAP date will be established after delivery of ADAC




                                                                                                                                                                                      0
controlled documents. ADAC uses a default of level (3) AIAG format – for all PPAP submissions (See Page 17 PPAP 4th
 Edition). Use current AIAG reference manuals for appropriate documentation and guidance.
           (ADAC may require suppliers to use “End Customer Specific” documentation when available/requested).
   QE:                     0                          (616) 957-3800                              0
* Any deviation to these requirements will result in a rejection of PPAP unless approved by appropriate ADAC personnel
prior to submission.
4.5.1 ADAC PPAP Requirements/Checklists ( 18 PPAP sections required/organized as follows)




                                                                                                                                      Print Date:
                                                                                                                                                                      Ref. Print:
                                                                                                                                                                                              Previous Part #:
                                                                                                                                                                                                                    *New Part #:
      (Check box X as Completed/Submitted)                      (Submit this completed checklist with PPAP)
 1) Design Records:
             The organization shall have the design record for the saleale product/part, including design records for components
              or details of the saleable product/print.
                                                                                                   CN#:        0




                                                                                                                                      1/0/1900
                                                                                                                                                                      0
 2) Engineering Change Documents (if applicable)




                                                                                                                                                                                          1/0/1900
                                                                                                                                                                                                                    1/0/1900
             Supplier Internal Change Notices, Supplier Eng. Change Notices, Etc.
               o      Supplier related documents that pertain to product/program changes.
 3) Customer Engineering Approval:
             PPAP must include a signed “Request for Functional Approval”. (See Tab – "Functional Approval")……………
               o      "MUST BE SIGNED" by ADAC Engineering prior to and submitted with PPAP Package.
                    * Please submit request to ADAC engineering along with sample product for functional evaluation.
 4) Design FMEA (when applicable):
             All Components/Assemblies/Systems must be included/covered in a Design FMEA.
             DFMEA will be detailed with specifics (In general FMEA’s are usually longer than 1 page).
             YC, ACC, YS, etc will be identified in the “Class” column.




                                                                                                                                                                      CN #:
                                                                                                                                                                                          Previous Rev.: 1/0/1900
                                                                                                                                                                                                                    *New Rev.: 0
             Will Identify Prevention (P) & Detection (D) for Current Design Controls.
             Shall use consistant Severity, Occurrence and Detection Rankings. (See S.O.D.Rankings Tab)……………




                                                                                                                                                                      0
 5) Process Flow Diagram:
             CC, ACC, SC, etc will be identified in the Flow Diagram.
             Header will include current Print Date/Revision Level.
             List all sub-suppliers on the Flow Diagram.
 6) Process FMEA:
             PFMEA will be detailed with specifics (In general FMEA’s are usually longer than 1 page).
             CC, ACC, SC, etc will be identified in the “Class” column.
             Will Identify Prevention (P) & Detection (D) for Current Design Controls.
             Shall use consistant Severity, Occurrence and Detection Rankings. (See S.O.D.Rankings Tab)……………
                                                                                                                                                                                              Program:
                                                                                                                                                                                                                    Description:
                                                                                                                                      Reason for
                                                                                                                                       PPAP: 0


               o        Root cause shall be identified when Severity is 9 or 10.
 7) Control Plan:
             Control Plans will be detailed with specifics and are linked to the PFMEA & Flow Diagram.
             CC, ACC, Etc will be identified in the “Special Char. Class” column.
                                                                                                                                                                                          1/0/1900
                                                                                                                                                                                                                    1/0/1900


             Header will include current Print Date/Revision Level.
             DVP&R requirements must be included on Control Plan.
               o       Including: Submission Time intervals (Must state specific date of last Submittal).
 8) Measurement Systems Analysis Studies:
             Complete MSA Studies including: R&R, Linearity, Bias and Stability are required for all new or modified
             gages, measurement, and test equipment (See MSA reference manual).
             Checking aids/Gages/Documentation will address each CC, ACC, SC, etc. designated on the print.
             Gage R&R’s shall be documented/submitted for all checking aids that are relative to the design record/control plan.
               o       Variable Studies shall utilize 10 parts, 3 operators and 3 trials,
               o       Attribute Studies shall utilize 50 parts (pre measured), 3 operators and 3 trials,
             The Gage's % R&R shall be 10% or below & NDC (Number of Distinct Categories) must be 5 or greater
               o       Ford Specific Variable R&R's must be reported in ANOVA method.
                                                                                                                                                                                          0


                                                                  Page 1 of 13                            Control# 486 - Quality Rev O 6-6-08
 9) Dimensional Results:
              Dimensional results (5 pcs per cav.) shall be submitted to the current print revision level for PPAP.
              Dimensional results shall include all dimensions (except reference dim.), characteristics, and specifications
              as noted on the design record and Control Plan.
10) Records of Material / Performance Test (DVP&R):
              The organization shall include records of material and performance test results for tests specified on the Design Record
              or Control Plan. Submit these results on a collection sheet (ie: DVP&R, CFG-1004, CFG-1005).
              All Material Certification will be for current production lot. (Shall be less than 1 year old at PPAP date)
              Supplier will have a copy of all applicable specification requirements available for review.
              Plastic Molder/Regrind Certification Letter must be submitted with each PPAP. (See Regrind Certification Tab)…………
              * GM Specific - A copy of the Trim Transmittal Form must be included for each "Class A" Resin component.
11) Initial Process Studies:
              Capability studies shall be performed on a minimum of 100 pieces per cav. (Out of the 300 pc min. production run)
                o       Ppk and/or Cpk must exceed 1.67. (see attachment for details)
                o       Ford specific capability studies shall be performed on a minimum of 125 pieces per cav. (Out of the 300 pc min. run)
              Capability studies shall be performed and identified for all special characteristic designated by the customer or organization.
              Where no Special Characteristics have been identified, contact the Program QE for verification on what characteristics require data.
12) Qualified Laboratory Documentation:
              Lab certifications shall be current.
              Labs shall be accredited to ISO/IEC 17025 or national equivalent (A2LA, NVAP and ICBO ES)
              Complete Lab Scope must be included for each lab used.
13) Appearance Approval Report (AAR): (when applicable)
              AAR’s shall be signed prior to and submitted with PPAP Package.
14) Sample Production Product:
              3 samples (per production cavity) shall be submitted with PPAP (use dimensional parts)[Sec 9].
15) Master Samples:
              Supplier shall identify one of the parts (Layout) measured as the master sample.
              Shall be representative of PPAP run. One sample for each cavity, mold, tool or pattern, or production process.
16) Checking Aids:
              ADAC owned gages shall meet the “ADAC Plastics Inc, Gage & Check Fixture Guidelines” (latest revision).
              Gage Designs must be approved by ADAC personnel prior to kick-off of ADAC/Customer owned gages.
              Gages layouts, certification, and instructions shall be in this section.
17) Customer Specification Requirements / Records of Compliance:
              IMDS Data shall be completed for each component/sub-component or assembly associated with a PPAP request.
                o     IMDS must be submitted and approved each time the product is PPAP’d.
                o     IMDS shall be submitted within 1 week of receipt of PPAP request and Print to (ADAC's) Customer Code # 1086
                o     Suppliers shall submit a printed copy of the IMDS submission with PPAP.
              Please submit ISO/TS certifications for all suppliers& Sub-suppliers that pertain to each program. (Current, Non-Expired)
              PPAP must include a “Request for Packaging Approval”. (See Tab – "Packaging Approval")……………
              Supplier shall submit a copy of the Production Label with PPAP.
                o       See http://www.adacautomotive.com website for detailed instructions & latest revision.
           ADAC requires it's Canadian Suppliers to provide documented proof of compliance to the Partners in Protection (PIP) requirements. For
           information on how to join PIP, See http://www.cbsa-asfc.gc.ca/general/enforcement/partners/join-e.html. ADAC strongly encourages all its
           domestic suppliers to be in compliance with the Customs Trade Partnership Against Terrorism (C-TPAT) and to provided documented proof of
           compliance if available. All other Foreign Suppliers are subject to a Security Risk Assessment by either ADAC or it's designated 3rd party. Said
           Assessment shall follow C-TPAT security criteria. See http://www.customs.gov/xp/cgov/home.xml
18) Part Submission Warrant (PSW):        ALL lines shall be filled in (no blank spaces).
            A PPAP/PSW is required for each component, assembly and sub-assembly as listed on the Print BOM.
            Purchase Order must be filled in.        Checking Aid Number must be filled in. (If various, please attach list)
            Weight (kg) = Enter the actual weight in kilograms to four decimal places.
            Suppler & Buyer codes must be filled in.
            Production Rate must be filled in. Mold/Cavity/Production Process must be filled in. (If various, please attach list)
    Bulk Material Requirements / Checklist:
            For bulk material. Review PPAP 4th edition for each sections requirements.
        Comments / Remarks:




                                                                      Page 2 of 13                                Control# 486 - Quality Rev O 6-6-08
1) Design Records:
      AIAG-PPAP 4th Edition - Page 4. Sec. 2.2.1 (Note 1)


2) Engineering Change Documents (if applicable)
      AIAG-PPAP 4th Edition - Page 5. Sec. 2.2.2

3) Customer Engineering Approval:
      AIAG-PPAP 4th Edition - Page 5. Sec. 2.2.3 & FORD Specifics for ISO/TS 16949:2002, 2nd Edition - Page16. Sec. 4.29 (Note)
      AIAG-PPAP 4th Edition - Page 5. Sec. 2.2.3 & FORD Specifics for ISO/TS 16949:2002, 2nd Edition - Page16. Sec. 4.29 (Note)

4) Design FMEA (when applicable):
       AIAG-FMEA 3rd Edition - Page 9.
       AIAG-FMEA 3rd Edition - Page 9.
       AIAG-FMEA 3rd Edition - Page 45. Sec.13.
       AIAG-FMEA 3rd Edition - Page 23-25. Sec.16.
       AIAG-FMEA 3rd Edition - Page 19-27, Sec. 12, Sec. 15, Sec. 17.
5) Process Flow Diagram:
       ISO/TS 16949 Second Edition - Page 16. Sec 7.3.2.3.
       AIAG-APQP - Page 77. A-6 Process Flow Chart Checklist
       AIAG-APQP - Page 10. Sec. 1.10. & Page 84.
 6) Process FMEA:
       AIAG-FMEA 3rd Edition - Page 35.
       AIAG-FMEA 3rd Edition - Page 45. Sec.13.
       AIAG-FMEA 3rd Edition - Page 49. Sec.16.
       AIAG-FMEA 3rd Edition - Page 41-53, Sec. 12, Sec. 15, Sec. 17.

7) Control Plan:
      AIAG-APQP 1st Edition - Page 31, 44. -Control Plan Methodology
      AIAG-APQP 1st Edition - Page 41. Sec. 21.
      AIAG-APQP 1st Edition - Page 36 - 39.
      AIAG-APQP 1st Edition - Page 31, 44.

 8) Measurement Systems Analysis Studies:
       AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8 & MSA 3rd Edition - Page 83-123.

       AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8.
       AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8 & MSA 3rd Edition - Page 83-123.
       AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8 & MSA 3rd Edition - Page 83-123.
       AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8 & MSA 3rd Edition - Page 125-140.
       AIAG-MSA 3rd Edition - Page 77.
       Ford Specific Requirements (3/31/06) page 3, sec 9. & AIAG-MSA 3rd Edition - Pages 177 & 125.



                                                            Page 3 of 13                        Control# 486 - Quality Rev O 6-6-08
 9) Dimensional Results:
       AIAG-PPAP 4th Edition - Page 6. Sec. 2.2.9 & Page 9. Sec. I.2.2.13. Ford & Chrysler requirements are 3pcs per cav.
       AIAG-PPAP 4th Edition - Page 6. Sec. 2.2.9

10) Records of Material / Performance Test (DVP&R):
        AIAG-PPAP 4th Edition - Page 6. Sec. 2.2.10.
        AIAG-PPAP 4th Edition - Page 31 & 32.
        ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3
        ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3
        GM Specific Lab Approval Requirement/ ADAC to validate the Material Spec Requirements for Regrind
        GM Specific Lab Approval Requirement
11) Initial Process Studies:
        AIAG-PPAP 4th Edition - Page 7. Sec. 2.2.11.1 (Note 5).
        AIAG-PPAP 4th Edition - Page 7, 8 & 9. Sec. 2.2.11.
        Ford Specific Requirements (3/31/06) page 4, sec 11.
        AIAG-PPAP 4th Edition - Page 7. Sec. 2.2.11.1.
        AIAG-PPAP 4th Edition - Page 7. Sec. 2.2.11.1 (Note 1).
12) Qualified Laboratory Documentation:
        ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3
        ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3.2
        ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3.1 & 7.6.3.2
13) Appearance Approval Report (AAR): (when applicable)
        AIAG-PPAP 4th Edition - Page 10. Sec. 2.2.13
14) Sample Production Product:
        AIAG-PPAP 4th Edition - Page 10. Sec. 2.2.14
15) Master Samples:
        AIAG-PPAP 4th Edition - Page 10. Sec. 2.2.15
        AIAG-PPAP 4th Edition - Page 10. Sec. 2.2.15
16) Checking Aids:
        ADAC Requirement
        ADAC Requirement
        AIAG-PPAP 4th Edition - Page 11. Sec. 2.2.16
17) Customer Specification Requirements / Records of Compliance:
        International Requirement for PPAP Approval
        AIAG-PPAP 4th Edition - Page 22/23.
        ADAC Requirement
        ADAC Requirement
        ISO/TS 16949:2002 Requirement for business with OEM's
        ADAC Requirement
        ADAC Requirement (See: http://www.adacautomotive.com)

       ADAC Requirement - Government Required




18) Part Submission Warrant (PSW):     ALL lines shall be filled in (no blank spaces).
       AIAG-PPAP 4th Edition - Page 11. Sec. 2.2.18
       AIAG-PPAP 4th Edition - Page 22/23. / ADAC
       AIAG-PPAP 4th Edition - Page 12. Sec. 2.2.18.1 & Page 22/23.
       AIAG-PPAP 4th Edition - Page 22/23.
       AIAG-PPAP 4th Edition - Page 11. Sec. 2.2.18 & Page 22/23. / ADAC
    Bulk Material Requirements / Checklist:
       AIAG-PPAP 4th Edition




                                                             Page 4 of 13                           Control# 486 - Quality Rev O 6-6-08
                                                     ADAC Supplier PPAP Request and Requirements

    Supplier Code:                 0                 Feasibility Commitment                                        Return Date:               1/0/1900
Date:                                    1/0/1900                              Part Number:                                      1/0/1900
Supplier:                                    0                                 Current Eng. Rev. Level:                              0
Part Name:                                   0                                 Print Number:                                     1/0/1900
                                                                               Print Date:                                       1/0/1900
Program:                                    0                                  CAD file#:                                            0
                                                                               Previous Part#:                                       0
Part Submission Due Date:                        1/0/1900                      Previous Eng Rev. Level:                              0
    Feasibility Considerations:
Our quality team has considered the following questions, which are not intended to be all-inclusive in performing a feasibility evaluation. The drawings and/or
specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All "No" answers shall be supported with attached
comments identifying concerns and/or proposed changes to enable us to meet the specified requirements. Please work with ADAC Engineering to resolve any issues of
concerns that prevents the product from being feasible. Production parts may not be shipped without PPAP approval or written deviation. Failure to return this form to
ADAC on or before the "Return Date" (listed below) is an automatic acceptance of the part being "Feasible".
   YES           NO   CONSIDERATION:
                      Can Engineering Performance Specifications be met as written?
                      Is the product adequately defined (cosmetic, dimensional, performance, application, requirements, etc) to enable a feasibility
                      evaluation?
                      Has material compatibility with matting components been reviewed and confirmed that there are no issues?
                      Can Product be manufactured to tolerances specified on drawing?
                      Can Product be manufactured to CAD data provided?
                      Can Product be manufactured with Cpk's that meet requirements?
                      Is there adequate capacity to produce the product?
                      Does the design allow the use of efficient material handling techniques?
                      Can Product be manufactured without any unusual costs for capital equipment?
                      Can Product be manufactured without any unusual costs for tooling?
                      Can Product be manufactured without any unusual Alternative manufacturing methods?
                      Is statistical process control required on the product?
                      Is statistical process control presently used on similar products?
                      Where statistical process control is used on similar products, are the processes in control and stable? And are the Cpk's greater than
                      1.67?
    All "No" answers shall be supported with attached comments/documents identifying concerns and/or proposed changes.
    Conclusion
                   Feasible            - Product can be produced as specified with no revisions.
                   Not Feasible        - Design review/changes required to produce product within the specified requirements - (explanation attached).
Comments/Concerns:




(Sign-off by Supplier Personnel)
Team Member/Title/Date:
Please complete, sign and return to:    Nancy Soltys
    Note:      4.0 Advanced Product Quality Planning (APQP)                                 Return Date:        1/0/1900
               See ADAC Automotive Supplier Manual                                          Email:    nsoltys@adacautomotive.com
                 www.adacautomotive.com                                                     Phone:    616-957-0520 Ext. 5686


                                                                             Page 5 of 13                               Control# 486 - Quality Rev O 6-6-08
                                        ADAC Supplier PPAP Request and Requirements

                     REQUEST FOR FUNCTIONAL APPROVAL
                                       (PER SECTION 3 OF PPAP CHECKSHEET)

SUPPLIER TO COMPLETE:
SUPPLER NAME:                                                                               SUPPLIER MFG. CODE:
                                             0
ADDRESS:
                                                 PHONE:                                                        0
                                                 FAX:


DESCRIPTION OF CHANGE:                                    DESIGN                                      PROCESS




PART NUMBER(S) AFFECTED:            REV. LEVEL:         REV. DATE:        PLANT(S) AFFECTED:
            0                             0               1/0/1900           ADAC
            0                             0               1/0/1900
            0                             0               1/0/1900
            0                             0               1/0/1900
            0                             0               1/0/1900
            0                             0               1/0/1900
            0                             0               1/0/1900


ADAC ENGINEERING TO COMPLETE:                                                                 0
A PLANT TRYOUT IS:                                        REQUIRED                                    NOT REQUIRED

  NAME:                                                                                   DATE:

TRYOUT MATERIAL SHIPPING INSTRUCTIONS:                                                      TRYOUT QUANTITY:




TRYOUT RESULTS:

CHANGE IS APPROVED FOR PRODUCTION:                                        Approved by:

CHANGE IS NOT APPROVED FOR PRODUCTION:                                     Rejected by:

COMMENTS/RATIONALE:




* A completed/approved Functional Approval Form is a requirement for each PPAP prior to submission.




                                                           Page 6 of 13                           Control# 486 - Quality Rev O 6-6-08
                  MOLDER/REGRIND CERTIFICATION LETTER
                                           (PER SECTION 10 OF PPAP CHECKSHEET)


DATE:

SUPPLER NAME:                                       -                              SUPPLIER MFG. CODE:               0

PHONE:

FAX:

E MAIL:




CUSTOMER NAME:                                     ADAC Automotive

PART NAME:                                              -

PART NUMBER:                                                 -

MATERIAL SUPPLIER:

PRODUCT CODE:

COLOR:




We certify that the above parts provided to your company for PPAP and Product Validation
Testing were produced with                 % regrind.


Our production parts will be provided at the above stated regrind % or less.
We will submit a supplier request for change to ADAC if we require a need to produce product
made with higher levels of regrind.




Print Name:                                                                 Signature:


Title:


Note: This form is to be filled out by the plastic molder.




                                                                 Page 7 of 13                     Control# 486 - Quality Rev O 6-6-08
                                                     REQUEST FOR PACKAGING APPROVAL
ADAC P/N:                 0                                                                                                                                                      DATE:
PACKAGING BOM (Components for one carton consist of:)                                                                                                                                                        1/0/1900
   PACKAGING P/N                             DESCRIPTION                                 #/CTN                  #/PC         Rev. Level:                      0                        Issue Date

                                                                                                                             Part Name:                                                    0

                                                                                                                             Customer:                                           ADAC Automotive

                                                                                                                             Carton Dimensions:

                                                                                                                             Pallet Dimensions:

                                                                                                                             Part Weight:                                        Pkg. Tare WT:

                                                                                                                             Pcs. per Carton:                                    Carton Gross WT:                0

                                                     INSTRUCTIONS:                                                           Pcs. per Cell:                                      Pcs. Per Pallet:                0

                                                                                                                             Layers per Carton:                                  Cartons per Layer:

                                                                                                                             Layers per Pallet:                                  Cartons per Pallet:             0

                                                                                                                             Pallet Tare WT:                                     Pallet Gross WT:                0

                     PICTURE # 1 - PART                                                   PICTURE # 2 - PACKAGE                                                      PICTURE # 3 - PALLET/STACK




                                    *ADAC "APPROVAL" of this request for packaging prior to PPAP, is only required for Class "A" products shipping to/for ADAC.
                                             All other products are required to fill out the request and is considered final when PPAP/PSW is approved.
                                      Suppliers wishing to change packaging after PPAP will be required to submit a PCR (Process Change Request) to ADAC.
                                         SUBMITTED BY:         (Name/Title/Date)                                                                         APPROVED BY:         (Name/Title/Date)



                                0                                                             0
* Note: The responsibility for ensuring component quality from supplier to ADAC Automotive remains with the Supplier, regardless of whether or not this form is approved by ADAC automotive.




                                                                                                             Page 8 of 13                                                              Control# 486 - Quality Rev O 6-6-08
                                                                                                                                          DESIGN FMEA RANKING CRITERIA
                                                                                                                                                              Suggested DFMEA Occurrence
                                    Suggested DFMEA Severity Evaluation Criteria                                                                                                                                                 Suggested DFMEA Detection Evaluation Criteria
                                                                                                                                                                   Evaluation Criteria


                                                                                                                                                          Probability of Likely Failure
Effect        Criteria: Severity of Effect                                                                                                      Ranking                                    Ranking   Detection      Criteria: Likelihood of Detection by Design Control                           Ranking
                                                                                                                                                          Failure        Rates

Hazardous     Very high severity ranking when a potential failure mode affects safe vehicle                                                               Very High:     > 100 per                   Absolute       Design Control will not and/or can not detect a potential
without       operation and/or involves noncompliance with government regulation without                                                                  Persistent     thousand                    Uncertainty    cause/mechanism and subsequent failure mode; or there is no Design
Warning       warning.                                                                                                                           10       failures       vehicles/items     10                      Control.                                                                       10
Hazardous     Very high severity ranking when a potential failure mode affects safe vehicle                                                                              50 per thousand             Very           Very remote chance the Design Control will detect a potential
with          operation and/or involves noncompliance with government regulation with                                                                                    vehicles/items              Remote         cause/mechanism and subsequent failure mode.
Warning       warning.                                                                                                                            9                                          9                                                                                                      9
Very High     Vehicle/item inoperable (loss of primary function).                                                                                         High:          20 per thousand             Remote         Remote chance the Design Control will detect a potential
                                                                                                                                                          Frequent       vehicles/items                             cause/mechanism and subsequent failure mode.
                                                                                                                                                  8       failures                           8                                                                                                      8
High          Vehicle/item operable but at a reduced level of performance. Customer very                                                                                 10 per thousand             Very Low       Very low chance the Design Control will detect a potential
              dissatisfied.                                                                                                                                              vehicles/items                             cause/mechanism and subsequent failure mode.
                                                                                                                                                  7                                          7                                                                                                      7
Moderate      Vehicle/item operable but com-fort/convenience item(s) inoperable. Customer                                                                 Moderate:      5 per thousand              Low            Low chance the Design Control will detect a potential
              dissatisfied.                                                                                                                               Occasional     vehicles/items                             cause/mechanism and subsequent failure mode.
                                                                                                                                                  6       failures                           6                                                                                                      6
Low           Vehicle/item operable but com-fort/convenience item(s) operable at a                                                                                       2 per thousand              Moderate       Moderate chance the Design Control will detect a potential
              reduced level of performance. Customer somewhat dissatisfied.                                                                                              vehicles/items                             cause/mechanism and subsequent failure mode.
                                                                                                                                                  5                                          5                                                                                                      5
Very Low      Fit & finish/squeak & rattle item does not conform. Defect noticed by most                                                                                 1 per thousand              Moderately     Moderately high chance the Design Control will detect a potential
              customers (greater than 75%).                                                                                                                              vehicles/items              High           cause/mechanism and subsequent failure mode.
                                                                                                                                                  4                                          4                                                                                                      4
Minor         Fit & finish/squeak & rattle item does not conform. Defect noticed by 50% of                                                                Low:           0.5 per                     High           High chance the Design Control will detect a potential
              customers.                                                                                                                                  Relatively     thousand                                   cause/mechanism and subsequent failure mode.
                                                                                                                                                  3       few failures   vehicles/items      3                                                                                                      3
Very Minor    Fit & finish/squeak & rattle item does not conform. Defect noticed by                                                                                      0.1 per                     Very High      Very high chance the Design Control will detect a potential
              discriminating customers (less than 25%).                                                                                                                  thousand                                   cause/mechanism and subsequent failure mode.
                                                                                                                                                  2                      vehicles/items      2                                                                                                      2
None          No discernible effect.                                                                                                                      Remote:        < 0.01 per                  Almost         Design Control will almost certainly detect a potential
                                                                                                                                                          Failure is     thousand                    Certain        cause/mechanism and subsequent failure mode.
                                                                                                                                                  1       unlikely       vehicles/items      1                                                                                                      1
              Critical Characteristic =                                      , CC, YC or equivalent must be designated as 9 or 10. These are required to have a controls in place regardless of RPN.
              Significant Characteristic & High Impact = ACC, YS, SC, HI or equivalent will be (Sev. = 5 to 8) & (Occ. = 4 to 10). These are required to have a controls in place regardless of RPN.
              NOT a Critical or Significant Characteristics = No specific criteria.

                                                                                                                                       PROCESS FMEA RANKING CRITERIA
                                                                                                                                                              Suggested PFMEA Occurrence
                                    Suggested PFMEA Severity Evaluation Criteria                                                                                                                                                 Suggested PFMEA Detection Evaluation Criteria
                                                                                                                                                                   Evaluation Criteria
              Criteria: Severity of Effect: This ranking results when a potential failure mode results in a final customer and/or
              manufacturing/assembly plant defect. The final customer should always be considered first. If both occur, use the higher of the             Probability of Likely Failure
Effect        two severity rankings.                                                                                                            Ranking                                    Ranking   Detection      Criteria          A B C Suggested Range of Detection Methods                  Ranking
                                                                                                                                                          Failure        Rates
              (Customer Effect)                                              (Manufacturing/Assembly Effect)
Hazardous     Very high severity ranking when a                              Or may endanger operator (machine or                                         Very High:     > 100 per                   Almost         Absolute                    Cannot detect of is not checked.
without       potential failure mode affects safe                            assembly) without warning.                                                   Persistent     thousand pieces             Impossible     certainty of
Warning       vehicle operation and/or involves                                                                                                           failures                                                  non-
              noncompliance with government
                                                                                                                                                 10                                         10                      detection.
                                                                                                                                                                                                                                            X                                                      10
              regulation without warning.

Hazardous     Very high severity ranking when a                              Or may endanger operator (machine or                                                        50 per thousand             Very           Controls will               Control is achieved with indirect or random
with          potential failure mode affects safe                            assembly) with warning.                                                                     pieces                      Remote         probably not                checks only.
Warning       vehicle operation and/or involves                                                                                                                                                                     detect.
              noncompliance with government
                                                                                                                                                  9                                          9                                              X                                                       9
              regulation with warning.

Very High     Vehicle/item inoperable (loss of                               Or 100% of product may have to be                                            High:          20 per thousand             Remote         Controls have               Control is achieved with visual inspection
              primary function).                                             scrapped, or vehicle/item repaired in                                        Frequent       pieces                                     poor chance                 only.
                                                                             repair department with a repair time                                 8       failures                           8                      of detection.           X                                                       8
                                                                             greater than one hour.
High          Vehicle/item operable but at a       Or product may have to be sorted and a                                                                                10 per thousand             Very Low       Controls have               Control is achieved with double visual
              reduced level of performance.        portion (less than 100%) scrapped, or                                                                                 pieces                                     poor chance                 inspection only.
              Customer very dissatisfied.          vehicle/item repaired in repair department
                                                   with a repair time between half an hour
                                                                                                                                                  7                                          7                      of detection.           X                                                       7
                                                   and an hour.
Moderate      Vehicle/item operable but com-       Or a portion (less than 100%) of the                                                                   Moderate:      5 per thousand              Low            Controls may                Control is achieved with charting methods,
              fort/convenience item(s) inoperable. product may have to be scrapped with no                                                                Occasional     pieces                                     detect.                     such as SPC (Statistical Process Control).
              Customer dissatisfied.               sorting, or vehicle/item repaired in repair
                                                   department with a repair time less than
                                                                                                                                                  6       failures                           6                                            X X                                                       6
                                                   half an hour.
Low           Vehicle/item operable but com-                                 Or 100% of product may have to be                                                           2 per thousand              Moderate       Controls                    Control is base on variable gauging after parts
              fort/convenience item(s) operable at                           reworked, or vehicle/item repaired off                                                      pieces                                     many detect.                have left the station, OR Go/No Go gauging
              a reduced level of performance.                                line but does not got to repair                                      5                                          5                                        X X       performed on 100% of the parts after parts          5
              Customer somewhat dissatisfied.                                department.                                                                                                                                                        have left the station.
Very Low      Fit & finish/squeak & rattle item does Or the product may have to be sorted,                                                                               1 per thousand              Moderately     Controls have               Error detection in subsequent operations, OR
              not conform. Defect noticed by most with no scrap, and a portion (less than                                                                                pieces                      High           a good                      gauging performed on setup and first piece
              customers (greater than 75%).          100%) reworked.                                                                              4                                          4                      chance to     X X           check (for setup causes only).                      4
                                                                                                                                                                                                                    detect.
Minor         Fit & finish/squeak & rattle item does Or a portion (less than 100%) of the                                                                 Low:           0.5 per                     High           Controls have               Error detection in-station, OR error detection
              not conform. Defect noticed by 50% product may have to be reworked, with                                                                    Relatively     thousand pieces                            a good                      in subsequent operations by multiple layers of
              of customers.                          no scrap, on-line but out-of-station.
                                                                                                                                                  3       few failures
                                                                                                                                                                                             3                      chance to
                                                                                                                                                                                                                    detect.
                                                                                                                                                                                                                                  X X           acceptance: supply, select, install, verify Can
                                                                                                                                                                                                                                                not accept discrepant part.
                                                                                                                                                                                                                                                                                                    3
Very Minor    Fit & finish/squeak & rattle item does Or a portion (less than 100%) of the                                                                                0.1 per                     Very High      Controls                    Error detection in-station (automatic gauging
              not conform. Defect noticed by         product may have to be reworked, with                                                                               thousand pieces                            almost certain              with automatic stop feature). Can not pass
              discriminating customers (less than no scrap, on-line but in-station.                                                               2                                          2                      to detect.     X X          discrepant part.                                    2
              25%).
None          No discernible effect.                                         Or slight inconvenience to operation or                                      Remote:        < 0.01 per                  Very High      Controls                    Discrepant parts can not be made because
                                                                             operator, or no effect.                                              1       Failure is
                                                                                                                                                          unlikely
                                                                                                                                                                         thousand pieces     1                      certain to
                                                                                                                                                                                                                    detect.
                                                                                                                                                                                                                                      X         item has been error proofed by
                                                                                                                                                                                                                                                process/product design.
                                                                                                                                                                                                                                                                                                    1
                                                                                                                                                                                                                   Inspection Types: A = Error Proofed - B = Gauging - C = Manual Inspection




             Reference AIAG FMEA Manual                            8-15-05                                                                                               Page 9 of 13                                                                                 Reference Document 6-6-08
                                           CLASSIFICATION DESCRIPTIONS & CRITERIA GUIDELINES

                   FMEA Type                      Classification                       To Indicate:                           Criteria             Actions Required

                                                                             A potential Critical Characteristic
                      Design                               YC                                                            Severity = 9, 10     Highlight for PFMEA team focus
                                                                                    (Initiate PFMEA)
PRODUCT




                                                                           A potential Significant Characteristic      Severity = 5 - 8 and
                      Design                               YS                                                                                 Highlight for PFMEA team focus
                                                                                     (Initiate PFMEA)                  Occurrence = 4 - 10

                                                                          Not a potential Critical Characteristic or
                      Design                          BLANK                                                                  Severity < 5              Not required
                                                                                 Significant Characteristic


                      Process                              or CC                  A Critical Characteristic              Severity = 9, 10       Special controls necessary


                                                                                                                       Severity = 5 - 8 and
                      Process                          ACC                  An ADAC Controlled Characteristic                                   Special controls necessary
                                                                                                                       Occurrence = 4 - 10

                                                                                                                       Severity = 5 - 8 and
PROCESS




                      Process                              SC                   A Significant Characteristic                                    Special controls necessary
                                                                                                                       Occurrence = 4 - 10

                                                                                                                       Severity = 5 - 8 and    Emphasis (controls) may be
                      Process                              HI                           High Impact
                                                                                                                       Occurrence = 4 - 10            necessary


                      Process                              OS                         Operator Safety                    Severity = 9, 10             Safety Sign-off



                      Process                         BLANK                     Not a Special Characteristic                    Other                  Not required




                                                                     Acceptable Criteria for Initial Study
                                            Results                       Interpretation
                                            Index > 1.67                  The process currently meets the acceptance criteria.

                                            1.33 < Index < 1.67           The process may be acceptable. Contact the authorized
                                                                          customer representative for a review of the study results.

                                            Index < 1.33                  The process does not currently meet the acceptance criteria.
                                                                          Contact the authorized customer representative for a review
                                                                          of the study results.

                                                                    AIAG-PPAP 4th Edition - Page 7, 8 & 9. Sec. 2.2.11.
                                                                   Also Statistical Process Control manual Second Edition.




          Reference AIAG FMEA Manual   8-15-05                                               Page 10 of 13                                                     Reference Document 6-6-08
                                                      Submit PPAP To: Attn: Nancy Soltys
                                                                    2929 32nd Street, Unit C
                                                                    PO Box 888375 (if sent U.S. Mail)
                                                                    Grand Rapids, MI 49588-8375



                       Retention/Submission Requirements
Requirement:                                                                               Submission Level:
                                                                                1          2      3        4                  5

  1        Design Record                                                        R          S          S           *           R
           - For proprietary components /details                                R          R          R           *           R
           - For all other components /details                                  R          S          S           *           R
  2        Engineering Change Documents, if any                                 R          S          S           *           R
  3        Customer Engineering Approval, if required                           R          R          S           *           R
  4        Design FMEA                                                          R          R          S           *           R
  5        Process Flow Diagrams                                                R          R          S           *           R
  6        Process FMEA                                                         R          R          S           *           R
  7        Control Plan                                                         R          R          S           *           R
  8        Measurement Systems Analysis Studies                                 R          R          S           *           R
  9        Dimensional Results                                                  R          S          S           *           R
 10        Material / Performance Test Results                                  R          S          S           *           R
 11        Initial Process Studies                                              R          R          S           *           R
 12        Qualified Laboratory Documentation                                   R          S          S           *           R
 13        Appearance Approval Report (AAR), if applicable                      S          S          S           *           R
 14        Sample Product                                                       R          S          S           *           R
 15        Master Samples                                                       R          R          R           *           R
 16        Checking Aids                                                        R          R          R           *           R
 17         Records of Compliance                                               R          R          S           *           R
            With Customer Specification Requirements
 18        Part Submission Warrant (PSW)                                        S          S          S           S           R
           Bulk Material Requirements / Checklist (as                           S          S          S           S           R

  S     = The supplier shall submit to designated customer product approval activity and retain a copy of records or
          documentation items as appropriate locations, including manufacturing.

  R     = The supplier shall retain at appropriate locations, including manufacturing, and make readily available to the customer
          representative upon request.

  *     = The supplier shall retain at appropriate locations, and submit upon customer request.

        ADAC requires a Level 5 PPAP for "Annual Revalidation" requirements and expectations. The supplier shall retain up-
Level
      = to-date documentation at appropriate locations, including manufacturing, and make readily available to the customer
  5
        representative upon request.

Note:      All 18 requirements are applicable for all level submissions, the level only states what documentation are required for
           submission. All retained documentation must be up to date and available for immediate request.




 Reference AIAG PPAP Manual 4th Edition 3-10-06            Pages 11 of 13                          Control# 486 - Quality Rev O 6-6-08
                                                  Submit PPAP To: Attn: Nancy Soltys
                                                                2929 32nd Street, Unit C
                                                                PO Box 888375 (if sent U.S. Mail)
                                                                Grand Rapids, MI 49588-8375


                                            Information Sheet
Submit All PPAP's to Attn of:                    Nancy Soltys
                                         nsoltys@adacautomotive.com

                          Date:
                     Supplier:                                                            Supplier Code:
                    Attention:
           Submission Level:
       Submission Due Date:
                 *New Part #:
             Previous Part #:
           Reference Print #:                                                                  Print Date:
                   *New Rev.:                                                              Previous Rev.:
                         CN #:
            Part Description:
                     Program:
           Reason for PPAP:
           Quality Engineer:                                                                                 (616) 957-3800
                   QE E-mail:
Program Manager/Engineer:                                                                                    (616) 957-3800
                        Buyer:                                                               Buyer Code:
                                                           (to be used on PSW - Buyer infomration section)


         Feasibility Commintment Due Date:

        Subcomponents Revision:
     Print Date:   Current Rev. Level:       Current Part Number:           Old Rev. Level:                  Old Part Number:
      1/0/1900              0                          0                          0                                  0




                                                                                                             Reference Document 6-6-08
                                                                                    REVISION HISTORY

               Rev.                                                                              Requested Change by:
  Date:                 Applicable Sheet:              Description of Change:                                                           Comments:
             Release:                                                                             Reason for Change:
                                                                                           Nancy Soltys wanted it added.
                                              Header information: Added Nancy's Email      So suppliers understand that all     Continuous Improvement
                                              and cell phone numbers to the header         submissions go through Nancy.
                                              Section #17: Added -IMDS shall be                                                 This is so ADAC has time
                                              submitted within 1 week of receipt of PPAP                                        to build IMDS for
                                                                                         Mary Brewer & Mark TeGrootenhuis
                                              request and Print to (ADAC's) Customer                                            customer pre-production
                                              Code # 1086                                                                       builds.
                                              Section #17: Suppliers need to submit a
                                              printed copy of the IMDS submission with   Quality Engineering                    Continuous Improvement
                          PPAP Request        PPAP.
 6/6/2008     486-O                                                                                                             AIAG Requirement per
                                              Section #8: Added NDC requirement of 5 or AIAG Requirement per MSA 3rd
                                                                                                                                MSA 3rd edition
                                              greater to variable R&R                   edition Page: 77
                                                                                                                                Page: 77

                                                                                                                                Ford Specific
                                              Section #8: Added ANOVA method               Ford Specific Requirements
                                                                                                                                Requirements (3/31/06)
                                              required for Ford specied programs.          (3/31/06) page 3, sec 9.
                                                                                                                                page 3, sec 9.

                                              Section #11: Added "(125/Ford)" to verbage   Ford Specific Requirements
                                                                                                                                Continuous Improvement
                                              for Capability Studies.                      (3/31/06) page 4, sec 11.
                            Feasibility       Added lined item in "Considerations"
                                                                                           Nancy Soltys / Mark Good             Continuous Improvement
                           Commitment         section
10/23/2007                                    Release Revision Level
                                              For Label Requirements see ADAC
10/23/2007              Label Requirements                                                 Mark TeGrootenhuis                   Continuous Improvement
                                              Automotive.com

                           PPAP Level         Section #17: Added line item for packaging To tie in with the requested by Kevin
10/15/2007                                                                                                                     Continuous Improvement
                          Requirements        requirements/approval.                     Darby (Packaging Engineer)

                                              Added clarification to the Packaging
                                              approval form for requirement of signature   Requested by Kevin Darby
10/15/2007              Packaging Approval                                                                                      Continuous Improvement
                                              for Class A, and Submission requirement      (Packaging Engineer)
                                              for all product.

                                              Added Part numbers, Rev levels and Rev Requested by Nancy Soltys
10/9/2007               Functional Approval                                                                                     Continuous Improvement
                                              Dates to the part numbers affected section. (Purchased Dept.)

                                              Changed Annual Validation requirements
                                              for suppliers from Level 5 PPAP to Level 4                                        Suppliers will still be
                                              PPAP.                                                                             responsible for the Annual
              486-N        PPAP Level                                                         Agreed upon by QE, Purchasing
10/9/2007                                     * All annual validation requirements will still                                   validation requirements
                          Requirements                                                        and Supplier Development
                                              have to be fulfilled. Suppliers will have to                                      (layouts, certifications,
                                              retain documents and be readily available                                         etc)
                                              upon request.
                                              Added ADAC's IMDS code (# 1086) and
                                                                                           Requested by suppliers thru Nancy
10/3/2007                 PPAP Request        switched the order of the line items in                                        Continuous Improvement
                                                                                           Soltys (Purchased Dept.)
                                              section 17
                            Feasibility                                                    Requested by Nancy Soltys
9/27/2007                                     Added a comment section to the doc.                                               Continuous Improvement
                           Commitment                                                      (Purchased Dept.)

                                              Remove requirement for " Can product be
                            Feasibility       manufactured " " " " " less than 10 PPM?"    Requested by Nancy Soltys
9/27/2007                                                                                                                       Continuous Improvement
                           Commitment         * Also moved around some of the product      (Purchased Dept.)
                                              information (for easier reading)

                                              Added this for traceability of changes going Requested by suppliers thru Nancy
9/25/2007                Revision History                                                                                    Continuous Improvement
                                              forward                                      Soltys (Purchased Dept.)




                                                                        Page 13 of 13                                   Control# 486 - Quality Rev O 6-6-08

				
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