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					                                            PRODUCTION PART APPROVAL PROCESS (PPAP) SUBMISSION CHECKLIST

                                    The following guideline / checklist shall be used for PPAP level 1-5 submissions. PPAP packages should be submitted for
                                    approval to the appropriate SDE/ASDE Manager 10 days prior to PPAP required date if not level 1 approved by ACH.



        Supplier   Supplier           Customer
      Check (X)    Approval           Approval      Part Number:
      if Included  Required           Required      Reason for Submission:
        in PPAP Prior to PSW        Prior to PSW
         Binder   Submission         Submission                                          PPAP Level:
                                                                                         PPAP Phase:
                                                        ACH PPAP Checklist (this document) as the table of contents

                                                        1. Design Records of Saleable Product
                                                        a.   Verify PPAP is to the latest released Engineering Specification/Drawings (part design level, date and notice number)
                                                        c.   Special Characteristics Identification Form (SCIF)


                                                        2. Engineering Change Documents if applicable
                              YES       YES
                                                             SCR approved by all customer functions as specified on SCR forms

                              N/A       YES             3. Customer Engineering approval, if required
                                                        a.  Product Engineering Approval (ESER Form)

                              YES       N/A             4. Design FMEA (See I.2.2.4)
                                                             DFMEA must be included if supplier is design responsible

                              YES       N/A             5. Process Flow Diagrams
                                                             Detailed Flow Diagram from start of process to ACH's manufacturing facility.

                              YES      YES              6. Process FMEA - in accordance with AIAG manual, current edition
                                                             (Including: Shipping, Handling, Warehousing, Packaging, and Bar Coding)

                                                        7. Dimensional Results
                                                        a.   Drawings numbered to correlate with submitted dimensional results and drawing notes
                              YES      YES              100% layout for 6 randomly selected parts from the first production tooling run from each cavity (Number of layouts
                                                             may be modified with approval from ACH SDE, with a minimum of one per cavity - attach if applicable)
                              YES       N/A             b. Tabular Summary Format (according to AIAG manual) - with 100 % in tolerance results
                                                             Note: Data cannot be older than one year
                              YES       YES             c    Use of surrogate data must be approved by ACH SDE

                                                        8. Records of Material/ Performance test results
                              N/A       YES             Data should be collected from Production Trial Run parts
                                                             (per AIAG APQP/Control Plan Manual, current edition)
                                                        Any material certification cannot be older than one year
                                                             (per AIAG PPAP manual, current edition)
                                                        Use of surrogate data must be approved by ACH's Product Engineering office
                              YES       N/A                  Test Results need to include:
                                                              - Collect component PV requirements as documented in the design record (print & Engineering
                                                                Specifications) and verify that all PV requirements were fulfilled successfully
                                                             - Material Certification with test results
                                                             (use tabular format from AIAG PPAP manual, current edition)
                                                             - Approved PV test results by Product Engineering

                              YES       N/A             9. Initial Process Study
                                                        a.     At least 125 parts measured and at least 25 subgroups to be considered (sub-group size = 5)
                                                               For each SC/VS and CC/VC. Include raw data in the PPAP package.
                                                        b. Workplan required to improve capability for SC/VS and CC/VC 1.33 ≤ Ppk/Cpk < 1.67
                                                        c.     For all SC/VS and CC/VC, if any Ppk/Cpk < 1.33, work plan and 100% in process
                                                               inspection to be implemented as a control method in the Control Plan
                                                               (per AIAG PPAP manual, current edition)
                                                        d. 30 piece capability study required for all other part characteristics* with target Ppk/Cpk > 1.0, take action
                                                               and/or install controls to contain non-conforming product for characteristics with poor capability (<1.0 Cpk)
                                                               *(Number of characteristics to be studied may be modified with approval from ACH SDE - attach if applicable)
                              YES       YES             e.     ACH Supplier Process Characteristic Analysis
                                                        Note: The matrix of raw data needs to specify the cavity as appropriate if cavities are considered
                                                        * The statistical Capability study must show statistical charts per AIAG PPAP & SPC requirements
                                                        * If the study is being done per cavity, at least 125 parts/cavity and at least 25 subgroups (sub-group size = 5) should
                                                           be considered for each SC/VS and CC/VC. If less than 30 parts/cavity contact SDE/ASDE Manager
                                                            responsible activity to develop a suitable plan.
                                                               (Number of parts may be modified with approval from ACH SDE - attach if applicable)




SQF-013a ACH PPAP Checklist                                                 Hard Copies of this Document are Uncontrolled
Revision Date: October 28, 2009                                                               Page 1 of 3                                                                      Printed on 3/30/2010
                                              PRODUCTION PART APPROVAL PROCESS (PPAP) SUBMISSION CHECKLIST

                                      The following guideline / checklist shall be used for PPAP level 1-5 submissions. PPAP packages should be submitted for
                                      approval to the appropriate SDE/ASDE Manager 10 days prior to PPAP required date if not level 1 approved by ACH.



        Supplier          Supplier     Customer                                                                                                              ACH PPAP Checklist, Page 2
      Check (X)           Approval     Approval       Part Number:
      if Included         Required     Required       Reason for Submission:
        in PPAP           Prior to      Prior to
         Binder            PSW           PSW                                                           PPAP Level:
                         Submission   Submission                                                       PPAP Phase:

                              YES         N/A             10. Measurement System Studies (Gage R&R)
                                                              Gage R&R < 10% is the standard. Take corrective action if GR&R >10%. Production with 10<GR&R<30
                                                              permitted with gage redundancy or truncated operating limits (see AIAG MSA Manual, current edition).

                                                          11. Qualified Laboratory Documentation
                                                          Current version ISO/IEC 17025 Certification or National Equivalent and Laboratory Scope for supplier providing results

                                                          12.   Control Plan
                              YES        YES              a.     Pre-Launch Control Plan
                              YES        YES              b.     Production (Production Process Control & IP Test Plans)
                              YES        YES              c.     ACH Safe Launch Plan Detail Form or equivalent

                                                          13. Part Submission Warrant (PSW)
                              YES                         a.   Copy of the ACH Warrant
                              YES        YES              b. Proof of IMDS acceptance
                                                                     - Screen dump from ACH IMDS showing data is accepted
                                                                     - E-mail from ACH IMDS analyst when alternate submission method is used.
                                                          c.   Appropriate PPAP Phase (I, II or III) marked on the warrant.
                                                          d. Photographic proof of tooling identification (customer owned tools)
                                                          e.   Copy of subcomponents approved PPAP Warrants

                              NA         YES              14. Appearance & Lighting Approval Report, (AAR) if applicable (per AIAG requirement)

                                                          15. Bulk Material Requirements Checklist (per AIAG requirement)

                                                          16. Sample Product (Qty:_____) (specify how many samples to be sent to customer's plant
                                                               according to customer's plant direction)

                                                          17. Master Samples (Qty:_____) (specify how many master samples are retained at the
                                                                    manufacturing site)

                                                          18. Checking Aids ( e.g. pictures of gages and checking aids)

                                                          19. Records of Compliance with Customer-Specific Requirements

                                                          20. Does this part have any rework processes or procedures?
                                                               Yes          No
                                                               If yes, include the Control Plan and PFMEA outlining these procedures (req'd for PPAP).

                             YES          N/A             21. Run at Rate data from production trial run (as required by SDE/ASDE Manager)
                                                          CV (Capacity Verification) preliminary calculation - CV calculation sheet can be found in ASAMS.

                             YES          N/A             22. Evidence of packaging approval form 1121 approved by ACH Plant Packaging Engineer




     Initials:                                        Approvers (Print Name):                          Date:
     ACH:                                             ACH PPAP Checklist Approver




     Supplier:                                        Supplier PPAP Checklist Approver




SQF-013a ACH PPAP Checklist                                                   Hard Copies of this Document are Uncontrolled
Revision Date: October 28, 2009                                                                 Page 2 of 3                                                                 Printed on 3/30/2010
Revision History
 3/16/2006 Release
 7/31/2006 Updated Characteristics Analysis Form calculations.
 2/14/2007 Separated PPAP checklist from ACH SPCA
 3/29/2007 Maintenance change - corrected spelling & numbering.
10/15/2007 Added "PPAP Phase" to heading under "PAPP Level".
            Added "PPAP Phase" at item 13c
 10/1/2008 Item 5 Process Flow Diagrams - added "from start of
            process" to ACH's manufacturing facility.
  3/4/2009 Removed references to ASDE, replaced with ASDE Manager.
            Item 13, Part Submission Warrant (PSW) added
            d.Photographic proof of tooling identification (Ford owned tools) and checkbox.
            Item 22, added reference to packaging form " form 1121 approved".
10/28/2009 Removed statement "SCs and CCs also mean VSs and VCs for all programs launching for MY 07 and later" from header area.
            Removed "(if SCs/VSs or CCs/VCs)" from check boxes, modified check boxes throughout for clarification.
            Item 1a, clarified that the Engineering Specification/Drawings should be verified
            to be at the correct engineering and part design level and correct date and and notice number, removed model year reference.
            Item 1b, moved to item 7, relettered section 7 accordingly. Changed "Drawing number/date correlates with ..." to "Drawings numbered to correlate with ..."
               Item 3a, specified ESER Form. Removed item 3b Engineering test results, now included in item 8.
               Item 7 Dimensional results, changed requirement to 100% layout for 6 randomly selectetd parts from the first production tooling run from each cavity.
               Changed 7b from Supplier Performance to Supplier Quality.
               Item 8 clarified Test Results to include verification of specifications from the print and engineering specification and
               verification that all tests passed or any deviations have written approval from ACH Product Engineering Office.
               Item 9 changed "100 parts/cavity and 20 subgroups" to "125 parts/cavity and 25 subgroups (sub-group size = 5)", clarified item b,
               added item d, relettered former item d to e.
               Item 10, clarified requirements. Item 11 specified Current version of ISO/IEC 17025 Certification or equivalent.
               Item 12 specified ACH Safe Launch Plan Detail Form or equivalent.
               Item 13a specified ACH PPAP warrant & added item 13e proof of subcomponents approved PPAP.
               Item 18 replaced "checking fixtures, mounting box, etc" with "pictures of gages and checking aids".
               Item 22 added "approved by ACH Plant Packaging Engineer".




SQF-013a ACH PPAP Checklist                                                      Hard Copies of this Document are Uncontrolled
Revision Date: August 31, 2009                                                                     Page 3 of 3                                                           Printed on 3/30/2010

				
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