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MDNQT1017 -SQA PPAP Checklist

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					                                                                                              Supplier Quality Assurance
                                                                            Production Part Approval Process (PPAP) Submission Checklist
      Part Number:                                                       Part Description:

     Vendor Code:                                                        Supplier:

 Drawing Number:                                                         Revision:

      Tool/Cavity #

   Date Reviewed:                                      Reviewed By:
                                                      Check Box as
     PPAP LEVEL
                                                       Appropriate
                                                                            Reason for Submission:
       LEVEL 1            (Sections 1 & 2 only)                          NOTICE: PPAP submission is to be made according to the AIAG Production Part Approval Process (PPAP) manual. Refer to Retention/Submission requirements table 4.2 in AIAG
       LEVEL 2               (Sections 1-8)                              PPAP manual section for detailed submission requirements for each level. This document should be used as a reference guide only and does not supersede the requirements set
       LEVEL 3               (All Sections)                              forth in the AIAG PPAP manual.
       LEVEL 4                (As defined)
                                                                         * Please allow a minimum of one week for processing. Ensure you have adequate inventory to support shipment until the PPAP is processed and approved.
       LEVEL 5               (All Sections)


Documentation Evaluation Criteria: If that specific evaluation criteria is highlighted in yellow and the supplier's results are not acceptable, this constitutes as a PPAP REJECTION. A limited/interim approval will not be authorized. It will be at the
Supplier Quality Engineer's direction as to whether the remaining items constitute a rejection or limited/interim approval.

                                                                                                            SECTION 1 - WARRANT FORM
    Acceptable            Not Acceptable            Not Required
                                                                         DOCUMENTATION EVALUATION CRITERIA                                                                                      COMMENTS
      (YES)                (LPA or REJ)                 (N/R)
                                                                         1.1 There is a supplier Part Submission Warrant Form included in the submission.
                                                                         1.2 Current revision of the AIAG warrant form is used

                                                                         1.3 The heading is accurately & fully completed. Include multiple buyer & application information if available.

                                                                         1.4 The “Results” and “Declaration” are properly completed (e.g. all applicable blocks must be check marked)
                                                                         and the form is signed and dated. Electronic submissions require an authorized signature.

                                                                         1.5 Identifies applicable tool/cavity number
                                                                                   SECTION 2 – INTERNATIONAL MATERIAL DATA SYSTEM (IMDS)
    Acceptable            Not Acceptable            Not Required
                                                                         DOCUMENTATION EVALUATION CRITERIA                                                                                      COMMENTS
      (YES)                (LPA or REJ)                 (N/R)
                                                                         2.1 ID version number from IMDS system and printed report detailing tree specifics is included in the package.

                                                                                          SECTION 3 - APPEARANCE APPROVAL REPORT (AAR)
    Acceptable            Not Acceptable            Not Required
                                                                         DOCUMENTATION EVALUATION CRITERIA                                                                                      COMMENTS
      (YES)                (LPA or REJ)                 (N/R)
                                                                         3.1 If part is an appearance item, there is an AAR included in the package and includes the following:
                                                                         a. Tool Source        b. Type of Tool Steel     c. No. Tools        d. No. of Cavities
                                                                         e. Texture Type      f. Texture Source        g. Gloss             h. Material
                                                                         i. Material Spec     j. Paint Spec           k. Performance Spec l. Painter (if outsourced)




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                                                                                                       SECTION 4 – SAMPLES
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                    COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 4.1 There are two samples of each process stream and/or cavity which represent the production part Quality
                                                                 capabilities (unless otherwise directed by the appropriate Magna Mirrors SQA representative). These samples
                                                                 must be properly identified in the package (e.g. tagged or marked with Magna Mirrors part number, revision level,
                                                                 cavity number, etc.).

                                                                 4.2 Samples provided are not visually different when compared to the previous level or supplied component.

                                                                 4.3 A sufficient number of samples have been run through Newaygo’s assembly operation in a Manufacturing
                                                                 Line Trial with no issues or concerns. (Magna Mirrors use only)
                                                                                    SECTION 5 - CHECKED DRAWINGS OR SKETCHES
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                    COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 5.1 A Magna Mirrors approved drawing (i.e. as stated on P.O.) which matches the Magna Mirrors Engineering
                                                                 release level is included in the package. All Dimensions, characteristics, and notes are numbered for use with the
                                                                 inspection reports. (If the drawing does not match the part revision level of the submission reference Section 6).

                                                                                              SECTION 6 - CHANGE DOCUMENTS
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                    COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 6.1 If drawing is “marked up” to a part revision level different than the submission level it must be signed by a
                                                                 Magna Mirrors Project Engineer and include the Magna Mirrors Engineering Change Order number (EO#). A copy
                                                                 of the approved EO should be included in the submission.
                                                                                             SECTION 7 – DIMENSIONAL RESULTS
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                    COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 7.1 There is a signed and dated Dimensional Inspection Report included in the submission. Use of the AIAG
                                                                 format is recommended.
                                                                 7.2 The heading is accurately & fully completed.
                                                                 7.3 All dimensions on the appropriate blueprint are listed exactly as stated (i.e. in the metric system) under
                                                                 “Dimension/Specification”. All notes must be included. Reference and basic dimensions do not need to be listed
                                                                 on the report.
                                                                 7.4 Results for all dimensions are reported on 3 to 6 parts per cavity as agreed upon with the appropriate Magna
                                                                 Mirrors SQA representative.
                                                                 7.5 All dimensions meet print requirements or change documents per section 5.

                                                                 7.6 The supplier’s results are consistent with Magna Mirrors' findings. (Magna Mirrors' use only)

                                                                                                  SECTION 8 – CHECKING AIDS
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                    COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 8.1 If checking aids (fixtures, etc.) were requested by the appropriate Magna Donnelly SQA representative, they
                                                                 are included with submission package.

                                                                 8.2 Gage certification is provided if requested by the appropriate Magna Mirrors SQA representative.




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                                                                                   SECTION 9 – LABORATORY/FUNCTIONAL RESULTS
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                     COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 9.1 There are actual test results for all chemical, physical, metallurgical, and performance requirements as
                                                                 specified on the print provided on a signed and dated report, unless otherwise agreed upon with the appropriate
                                                                 Magna Mirrors SQA representative. All applicable notes and specifications must be included in the report as well.

                                                                 9.2 Supplier will summarize material and performance test results utilizing the forms as found in appendix D and
                                                                 appendix E of the AIAG PPAP manual. A copy of the specification is to be included in the PPAP package and each
                                                                 section of the specification is to be ballooned to match each line item as indicated on the results form.

                                                                 9.3 The results are from an “Accredited”, TS 16949 or QS 9000 compliant Laboratory” (evidence may be required).

                                                                 9.4 The results from a commercial laboratory shall be submitted on the laboratory’s letterhead, or on the normal
                                                                 laboratory report format.
                                                                 9.5 All laboratory and test results are less than one year old.

                                                                 9.6 For all heat treated components, a CQI 9 audit form is completed and shows compliance to the Heat Treat
                                                                 System Survey Guidelines. A copy of the CQI-9 Ford Specific Requirements must also be completed for all Ford
                                                                 heat treated components, to ensure compliance to Ford's Heat Treat Specification W-HTX. The audits must be
                                                                 uploaded onto Supplier Connection and updated on an annual basis. If supplier does not meet the requirements,
                                                                 all nonconformances are documented and action plans are in place. To reduce the risk of embrittlement, heat-
                                                                 treated steel components are required to conform with Ford material specification WSS-M99A3-A.

                                                                 9.7 For all plated components, a CQI 11 audit form has been completed and shows compliance to the Plating
                                                                 System Survey Guidelines. The supplier survey must be uploaded onto supplier connection and updated on an
                                                                 annual basis. All nonconformances are documented and action plans are in place.

                                                                 9.8 For all coated and painted components, a CQI 12 audit form has been completed and shows compliance to the
                                                                 Coating System Survey Guidelines. The supplier survey must be uploaded onto supplier connection and updated
                                                                 on an annual basis. All nonconformances are documented and action plans are in place.

                                                                 9.9 All sub-suppliers of base materials and finishings (heat treat, plating, coating, etc.) must be on the approved
                                                                 supplier list for the appropriate OEM.
                                                                                           SECTION 10 - PROCESS FLOW DIAGRAM
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                     COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 10.1 There is a Process Flow Diagram included in the submission.
                                                                 10.2 The heading is accurately & fully completed. Should conform to the AIAG format.
                                                                 10.3 Based on the blueprint and parts, the operation descriptions are clear & the process steps are all there &
                                                                 follow a logical sequence.
                                                                 10.4 Operation/Process steps correlate with PFMEA & Control Plan.
                                                                 10.5 If PPAP is for transfer of part to new supplier or same supplier producing at a different location, SQE has
                                                                 reviewed old and new process flow to ensure critical processes and characteristics have been considered.
                                                                 (Magna Mirrors use only)




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                                                                           SECTION 11 - FAILURE MODE AND EFFECTS ANALYSIS (FMEA)
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                     COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 11.1 There is a PFMEA (and Design FMEA if supplier has design responsibility) included in the submission which
                                                                 conforms to the AIAG requirements, rating scales, etc.
                                                                 11.2 All areas listed in the supplier’s Process Flow Diagram are included for failure analysis.
                                                                 11.3 The heading is accurately & fully completed.
                                                                 11.4 When the severity of a failure mode is 9 or 10, special attention must be given to ensure that the risk is
                                                                 addressed through existing design actions/controls or process preventive/correction action(s), regardless of the
                                                                 RPN. Once all severity rankings are lowered, then the supplier team should address other failure mode rankings
                                                                 in occurrence, then detection.
                                                                 11.5 All of the Magna Mirrors Safety and Critical Characteristics (MDS/MDC) identified on the drawing have been
                                                                 listed on the FMEA.
                                                                 11.6 If PPAP is for transfer of part to new supplier or same supplier producing at a different location, SQE has
                                                                 reviewed old and new FMEA to ensure critical processes and characteristics have been considered. (Magna
                                                                 Mirrors use only)
                                                                 11.7 PFMEA Ratings for severities match the DFMEA. If the DFMEA is not available, ensure that all MDS and MDC
                                                                 characteristics are scored appropriately (reference section 11.4). Ratings for occurences and detection may be
                                                                 reduced through actions taken. Ratings for severities can not be reduced unless a failure mode is eliminated
                                                                 through a design change.
                                                                                          SECTION 12 – PROCESS CONTROL PLAN
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                     COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 12.1 A process control plan is included in the submission.
                                                                 12.2 The heading is accurately & fully completed. Should conform to the AIAG Advanced Product Quality
                                                                 Planning and Control Plan Reference Manual
                                                                 12.3 All of the Magna Mirrors Safety and Critical Characteristics (MDS/MDC) identified on the drawing have been
                                                                 listed on the Control Plan.
                                                                 12.4 All columns are completed for each item.
                                                                 12.5 The type and frequency of controls are adequate to ensure product quality.
                                                                 12.6 The Control Plan covers all parts of the process from receiving inspection through processing/assembly
                                                                 including final packaging and any required annual validation.
                                                                 12.7 If PPAP is for transfer of part to new supplier or same supplier producing at a different location, SQE has
                                                                 reviewed old and new process flow to ensure critical processes and characteristics have been considered. (Magna
                                                                 Mirrors use only)
                                                                 12.8 All specification requirements are included on the control plan, and are checked at a minimum, on an annual
                                                                 basis.
                                                                          SECTION 13 – PROCESS PERFORMANCE CAPABILITY RESULTS
Acceptable         Not Acceptable           Not Required
                                                                 DOCUMENTATION EVALUATION CRITERIA                                                                                     COMMENTS
  (YES)             (LPA or REJ)                (N/R)
                                                                 13.1 Process Potential Studies have been performed for all agreed-upon Magna Donnelly Safety and Critical
                                                                 Characteristics (MDS/MDC). The parts studied must be from production tooling, gauging, process, materials and
                                                                 operators at the production intended site.
                                                                 13.2 Unless otherwise approved by the appropriate Magna Mirrors SQA representative, a 100 part minimum study
                                                                 has been conducted with at least 25 subgroups containing consecutively produced parts from a 300-piece or
                                                                 larger run. Each subgroup should be consecutive or at short intervals & the time-order relationship maintained.
                                                                 This applies per process stream (i.e. cavity).
                                                                 13.3 (Variable Studies) The studies have all been properly displayed on a Control Chart and demonstrate process
                                                                 control.
                                                                 13.4 (Variable Studies) Process Potential has been calculated correctly for each study. Process Control is
                                                                 demonstrated and Ppk > 1.67.
                                                                 13.5 (Variable Studies) For each study not in control or with a Ppk < 1.67 a Corrective Action Plan with timing has
                                                                 been submitted and approved by Magna Mirrors SQA.
                                                                 13.6 (Attribute Studies) Attribute studies showing a defect percent >0 must be approved with the appropriate
                                                                 Magna Mirrors SQA representative.




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                                                                                     SECTION 14 – MEASUREMENT SYSTEM STUDIES (R&R)
    Acceptable           Not Acceptable           Not Required
                                                                      DOCUMENTATION EVALUATION CRITERIA                                                                                     COMMENTS
      (YES)               (LPA or REJ)                (N/R)
                                                                      14.1 A repeatability and reproducibility (R & R) study has been performed for all control items identified on the
                                                                      Control Plan.

                                                                      14.2 Methods conform to those described in the AIAG Measurement Systems Analysis Reference Manual.
                                                                      For variable gage studies, the ANOVA method must be used. (10 parts, 3 operators, and 3 trials).
                                                                      Attribute gage studies should utilize 50 parts, 3 operators, and 3 trials.

                                                                      14.3 Gauge error is less than or equal to 10%. Gauge error over 10% must be approved by the appropriate Magna
                                                                      Donnelly SQA representative.
                                                                                 SECTION 15 – MISCELLANEOUS MAGNA MIRRORS SPECIFICS
    Acceptable           Not Acceptable           Not Required
                                                                      DOCUMENTATION EVALUATION CRITERIA                                                                                     COMMENTS
      (YES)               (LPA or REJ)                (N/R)
                                                                      15.1 A completed Team Feasibility Form is included to the proper revision level. All areas are completed, and are
                                                                      feasible.

                                                                      15.2 A completed and approved Magna Mirrors Newaygo packaging declaration is included. Weight, size, and
                                                                      quantity information is completed. Sign off from the appropriate parties is included.

                                                                      15.3 Box barcode labels are included in the package and include scannable bar codes for the part number,
                                                                      quantity, and lot information. The part revision level is included on the label. Reference the Magna Mirrors
                                                                      Packaging & Shipping Requirements Manual for further details.
                                                                      15.4 A completed run @ rate form is submitted. If the OEM utilizes a specified format (Chrysler Process Sign-Off,
                                                                      General Motors Run-at-Rate, Honda Are-You-Ready, etc.), supplier will submit the run @ rate utilizing this format.
                                                                      If the OEM does not specify a format, the Magna Mirrors of America Run-at-Rate form will be utilized. A link to the
                                                                      Magna Mirrors of America Run-at-Rate format is provided in Appendix A of the SQR manual or electronically via
                                                                      Supplier Connection.



                       PPAP Status:                                                                                                                 Resubmission Due Date:
    Acceptable           Not Acceptable          Not Acceptable
      (YES)                   (LPA)                   (REJ)
                                                                                                                                                                   PPCA Number:

                                                                                                                                                        PPCA Expiration Date:

A Production Parts Change Authorization (PPCA) allows shipment of parts, at or above the quality level of the parts reviewed for this PPAP submission, until the expiration date as listed above. Any
parts shipped after this date will require an approved PSW or an additional deviation from Magna Mirrors. IF A PPCA IS ISSUED, IT MUST BE REFERENCED ON EACH CONTAINER UNTIL THE PPAP IS
APPROVED OR A NEW DEVIATION IS ISSUED.
LPA = With Magna Mirrors approved corrective action plan, a "Limited Production Approval" may be issued allowing temporary production shipment.
REJ = The Submission is rejected & production shipments are not authorized until corrective action is implemented.




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