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PPAP Checklist - Home - Sauer-Danfoss

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					                                                     Supplier PPAP Review Checklist                                                                                    Revision M (Jan 29, 2010)


             Part # :                               Supplier:                                            Reviewer:                   Accept   Cond    Reject     N/A   Date:
                                                                                                                                         (Global Standard GS-0008)
                                                 PSW (PART SUBMISSION WARRANT)                           Sauer-Danfoss PSW Form
                                                                                                                                        (Powerpoint PPAP Training)
                                                                                                                                                                               COMMENTS

Part number and revision level corresponds to the requirements (one part# per submission unless prior agreement).
Reason for submission is indicated (reference PPAP Worksheet - dictates content required).                 PPAP Worksheet
Requested submission level is indicated (typically level 4 as requirements are defined by Sauer-Danfoss).
Acknowledgement that all specifications have been met or a detailed explanation of non-conformances (signed PSW).
Acknowledgement that samples were manufactured in production environment (with production operators, tooling and
gaging) at Stated production rate (rate is filled in).
                                                    PROCESS FLOW CHART                                                                   (Global Standard GS-0063)             COMMENTS
Schematic (graphical) representation of complete process flow ("door to door").
Identifies all process steps (operations) from initial receiving through the final shipping process. Includes all value-added
functions & lists sub-supplier names for outsourced activities (deburr, wash, heat treatment, plating, packaging, labeling).
Each machine (piece of equipment) within the flow identified by a specific asset or unique machine number.
Potential multiple process flows (including machines/fixtures) and multiple external sub-suppliers are clearly identified within
the diagram.
                                                            PFMEA                                                                       (Global Standard GS-0006)              COMMENTS
Contains all process steps from initial receiving through the final shipping process and corresponds to those identified within
the Process Flow Chart.
Format identifies specific processes influencing Sauer-Danfoss # of S, K & P                    # of S, K & P
Safety, Key & Process characteristics.                                identified by             recognized by
                                                                         Sauer                      supplier
PFMEA rankings are aligned with GS-0006 (e.g. single visual Detection cannot be < 8, Occurrence rankings based on actual
PPM and/or projected long-term process capability).
Safety, Key & Process characteristics identified with minimum Sauer-Danfoss Severity rankings (Safety = 10, Key = 8,
Process = 4).
Error-proof methods identified for all Safety characteristics. Potential failure modes and control for those methods captured
within PFMEA (e.g. "Golden unit", PM, TPM).
Potential multiple causes for failure modes have been identified within the PFMEA.
PFMEA used as a continuous improvement tool & addresses the highest RPN values with actions identified to reduce risk.
RPNs ranked ≥ 100 have corrective action plans identified including estimated completion date & person(s) responsible.
Sub-supplier PFMEA information included for all external processes that may influence Safety, Key & Process characteristics
(Additionally - heat treat, plating and coating processes).
                                               ISIR (Initial Sample Inspection Report)                                                  (Global Standard GS-0015)              COMMENTS
Sauer-Danfoss "bubble" print submitted and identifies (with numbers or letters) that ALL features and notes have been
recognized including cleanliness, heat treat, material specification, and/or raw material part number, etc. (excludes reference
Revision level of the bubble drawing corresponds to engineering change level identified within PSW.
Results format includes bubble ID, print specification, measurement value and results (ok/not ok).
Dimensional values recorded for all features and notes where possible.
Minimum of one piece sample from each process flow (machine/cavity/mould/fixture/etc).
                                          MATERIAL / PERFORMANCE TEST RESULTS                                                           (Global Standard GS-0017)              COMMENTS
Test report indicating compliance with Sauer-Danfoss design record and related engineering specification.
Material notes or other characteristics measured (e.g. - porosity).
Test report values for all material Safety, Key & Process characteristics including Gage R&R and Capability Studies.
                                                     GAGE R&R STUDIES                                Gage R&R Template                  (Global Standard GS-0010)              COMMENTS
One study completed for each gage that is used to control Key characteristics (number of Gage R&R studies submitted
matches the number of Key characteristics identified).
Variable (measurement) gaging is used to control all Key characteristics.
Studies completed are for those production gages stated within the Control Plan.
Studies were performed for this specific submission and corresponding features (unless previous agreement exists for family
of parts - dated studies).
Studies were performed on randomized samples using production operators @ production rate (3 operators, 3 trials,
on 10 parts - unless otherwise agreed upon with Product Team Quality Engineer). Production rate is defined as the time
taken by an operator for measurement in normal production setting.
Results of studies presented according to Global Standards (% of tolerance based on 5.15 Sigma Measurement - based on
AIAG MSA 2nd Edition).
Raw data measurements, graphed analysis and results are included.
Results of all Gage R&R studies are within acceptable limits as defined by Sauer-Danfoss Standards: Key characteristics
≤20% and Process characteristics ≤30%. If Gage R&R requirements are not met, work must be done to resolve the issue.
                                                PROCESS CAPABILITY STUDIES                               Capability Study Template       (Global Standard GS-0007)             COMMENTS
All Key & Process characteristics studied.
If multiple process streams exist, studies are presented from each flow.
Raw data measurements, graphed analysis and results are included.
Results are for this specific part (unless previous agreement for family of parts).
Data is from a minimum of 30 consecutive pieces from a single process stream.
If process capability indices for Key & Process characteristics are statistically stable (no out of control conditions),
minimum capability requirements are met (Cp 1.83/Cpk 1.33 for Key, Cp 1.00/Cpk 1.00 for Process).
If process capability indices for Key & Process characteristics are not statistically stable (out of control conditions),
minimum capability requirements are met (Pp 1.83/Ppk 1.33 for Key, Pp 1.00/Ppk 1.00 for Process).
                                                         CONTROL PLAN                                                                    (Global Standard GS-0012)             COMMENTS
Contains all process steps from initial receiving through final shipping and corresponds to those identified within the Process
Flow and PFMEA ("door to door").
Presented format clearly identifies Safety, Key & Process characteristics.
Variable (measurement) gaging is used to control Key characteristics and is clearly identified.
Stated methods for measuring Key characteristics correspond to those submitted within Gage R&R's.
Error-proof control methods implemented for all Safety characteristics.
Control method, sample size and frequencies on control plans for Process characteristics are reasonable (allow for evaluation
of multiple flows when present).
Control methods for Key characteristics employ statistical-based methods (samples to print unacceptable - 100% inspection
alone is considered containment only and is not an acceptable method of long-term control).
Key & Process characteristics that utilize containment control of 100% inspection alone apply an inspection tolerance
reduced by 50% of the total Gage R&R to both sides of the tolerance to negate the measurement system variation.
Reaction plans for out-of-control conditions are defined and acceptable (internal standards included if referenced).
Sub-supplier Control Plan information included for all external processes that may influence Safety, Key & Process
characteristics (Additionally - heat treat, plating and coating processes).
                                                        PPAP ACCEPTANCE                                                                 (Global Standard GS-0008)              COMMENTS
PPAP non-conformances include a Containment and Corrective Action Plan including names and dates.
       Sauer-Danfoss                                                                 Printed 4/12/2010
PPAP approved by Sauer-Danfoss before parts are shipped (PSW signed by SD & supplier, copy returned to
supplier).




      Sauer-Danfoss                                                    Printed 4/12/2010
                Revision M (Jan 29, 2010)



                                                       Documentation source
                      COMMENTS
                                                       PPAP Powerpoint presentation
                                                         PSW form - definition tab
                                                         PSW form - definition tab
                                                         PSW form - definition tab

                                                         PSW form - definition tab

                      COMMENTS
                                                           GS-0063 - definition

                                                GS-0063 and PPAP Powerpoint presentation

                                                GS-0063 and PPAP Powerpoint presentation

                                                GS-0063 and PPAP Powerpoint presentation

                      COMMENTS

                                                       PPAP Powerpoint presentation


                                                GS-0006 and PPAP Powerpoint presentation


                                                                 GS-0006

                                                                 GS-0004

                                                                 GS-0004

                                                GS-0006 and PPAP Powerpoint presentation

                                                GS-0006 and PPAP Powerpoint presentation

                                                       PPAP Powerpoint presentation

                      COMMENTS

                                                                 GS-0015

                                                       PPAP Powerpoint presentation
                                                       PPAP Powerpoint presentation
                                                                 GS-0015
                                                                 GS-0015
                      COMMENTS
                                                                 GS-0017
                                                                 GS-0017
                                                                 GS-0017
                      COMMENTS

                                                                 GS-0008

                                                                 GS-0008
                                                       PPAP Powerpoint presentation

                                                       PPAP Powerpoint presentation


                                                                 GS-0010


                                                                 GS-0010

                                                       PPAP Powerpoint presentation

                                                          GS-0004 and GS-0010

                      COMMENTS
                                                       PPAP Powerpoint presentation
                                                       PPAP Powerpoint presentation
                                                       PPAP Powerpoint presentation
                                                       PPAP Powerpoint presentation
                                                GS-0007 and PPAP Powerpoint presentation

                                            GS-0004, GS-0007, and PPAP Powerpoint presentation

                                            GS-0004, GS-0007, and PPAP Powerpoint presentation

                      COMMENTS

                                                   GS-0012 and Powerpoint presentation

                                                          Powerpoint presentation
                                            GS-0008 (Gage R&R), PPAP Powerpoint presentation
                                                             Supplier checklist
                                                                 GS-0004

                                                          Powerpoint presentation

                                                            Supplier checklist

                                                         Current supplier checklist

                                                  GS-0012, PPAP Powerpoint presentation

                                                       PPAP Powerpoint presentation

                      COMMENTS

Sauer-Danfoss                                         Printed 4/12/2010
Sauer-Danfoss   Printed 4/12/2010
                                                                                                                                                           Insert reviewer         Insert current
                                                          Supplier PPAP Review Checklist                                                                       name.                   date Revision K (July 20, 2009)


                                        Insert part                                       Insert supplier
              Part # :                   number.         Supplier:                            name.           Reviewer:                      Accept    Cond     Reject       N/A           Date:
                                                                                                                                                   (Global Standard GS-0008)
                                                      PSW (PART SUBMISSION WARRANT)                            Sauer-Danfoss PSW Form                                                              COMMENTS
                                                                                                                                                  (Powerpoint PPAP Training)
Part number and revision level corresponds to the requirements (one part# per submission unless prior agreement).
                                                                                                                                                                                             Text in blue are links to
Reason for submission is indicated (reference PPAP Worksheet - dictates content required).                                PPAP Worksheet                                                       templates/training.
Requested submission level is indicated (typically level 4 as requirements are defined by Sauer-Danfoss).
                                                                                                                                                                                       Place an "x" in box that corresponds
Acknowledgement that all specifications have been met or a detailed explanation of non-conformances (signed PSW).                                                                       to appropriate level of acceptance.
Acknowledgement that samples were manufactured in production environment (with production operators, tooling and gaging)
at Stated production rate (rate is filled in).
                                                         PROCESS FLOW CHART                                                                        (Global Standard GS-0063)                       COMMENTS

Schematic (graphical) representation of complete process flow ("door to door").
Identifies all process steps (operations) from initial receiving through the final shipping process. Includes all value-added
functions & lists sub-supplier names for outsourced activities (deburr, wash, heat treatment, plating, packaging, labeling).
                                                     Insert # of Sauer-Danfoss asset or unique machine number.
Each machine (piece of equipment) within the flow identified by a specific S, K, and P's       Insert # of Sauer-Danfoss S, K, and P's This Accept box will automatically       This Reject box will populate if the # on the
                                                     identified by print and/or product teams.
Potential multiple process flows (including machines/fixtures) and multiple external sub-suppliers are clearly identified within the populate if the # on the drawing
                                                                                                       that supplier recognized.                                                  drawing and the recognized # are not
                                                                                                                                        and the recognized # are equal.                           equal.
diagram.
                                                                     PFMEA                                                                        (Global Standard GS-0006)                        COMMENTS

Contains all process steps from initial receiving through the final shipping process and corresponds to those identified within the
Process Flow Chart.
Format identifies specific processes influencing Sauer-Danfoss       # of S, K & P                  # of S, K & P
Safety, Key & Process characteristics.                               identified by                  recognized by
                                                                         Sauer                         supplier
PFMEA rankings are aligned with GS-0006 (e.g. single visual Detection cannot be < 8, Occurrence rankings based on actual PPM
and/or projected long-term process capability).
Safety, Key & Process characteristics identified with minimum Sauer-Danfoss Severity rankings (Safety = 10, Key = 8, Process
                                                                                                                                                  Comments for conditional or
= 4).
                                                                                                                                                     unacceptable levels.
Error-proof methods identified for all Safety characteristics. Potential failure modes and control for those methods captured
within PFMEA (e.g. "Golden unit", PM, TPM).
Potential multiple causes for failure modes have been identified within the PFMEA.
PFMEA used as a continuous improvement tool & addresses the highest RPN values with actions identified to reduce risk. RPNs
ranked ≥ 100 have corrective action plans identified including estimated completion date & person(s) responsible.
Sub-supplier PFMEA information included for all external processes that may influence Safety, Key & Process characteristics
(Additionally - heat treat, plating and coating processes).
                                                 ISIR (Initial Sample Inspection Report)                                                          (Global Standard GS-0015)                        COMMENTS
Sauer-Danfoss "bubble" print submitted and identifies (with numbers or letters) that ALL features and notes have been
recognized including cleanliness, heat treat, etc. (excludes reference and basic dimensions).
Revision level of the bubble drawing corresponds to engineering change level identified within PSW.
Results format includes bubble ID, print specification, measurement value and results (ok/not ok).
Dimensional values recorded for all features and notes where possible.
Minimum of one piece sample from each process flow (machine/cavity/mould/fixture/etc).
                                        MATERIAL / PERFORMANCE TEST RESULTS                                                                       (Global Standard GS-0017)                        COMMENTS
Test report indicating compliance with Sauer-Danfoss design record and related engineering specification.
Material notes or other characteristics measured (e.g. - porosity).
Test report values for all material Safety, Key & Process characteristics including Gage R&R and Capability Studies.
                                                         GAGE R&R STUDIES                                        Gage R&R Template                (Global Standard GS-0010)                        COMMENTS
One study completed for each gage that is used to control Key characteristics (number of Gage R&R studies submitted matches
the number of Key characteristics identified).
Variable (measurement) gaging is used to control all Key characteristics.

Studies completed are for those production gages stated within the Control Plan.
Studies were performed for this specific submission and corresponding features (unless previous agreement exists for family of
parts - dated studies).
Studies were performed on randomized samples using production operators @ production rate (3 operators, 3 trials, on
10 parts - unless otherwise agreed upon with Product Team Quality Engineer). Production rate is defined as the time taken by
an operator for measurement in normal production setting.
Results of studies presented according to Global Standards (% of tolerance based on 5.15 Sigma Measurement - based on
AIAG MSA 2nd Edition).
Raw data measurements, graphed analysis and results are included.

Results of all Gage R&R studies are within acceptable limits as defined by Sauer-Danfoss Standards: Key characteristics ≤20%
and Process characteristics ≤30%. If Gage R&R requirements are not met, work must be done to resolve the issue.

                                                      PROCESS CAPABILITY STUDIES                               Capability Study Template           (Global Standard GS-0007)                       COMMENTS

All Key & Process characteristics studied.
If multiple process streams exist, studies are presented from each flow.
Raw data measurements, graphed analysis and results are included.
Results are for this specific part (unless previous agreement for family of parts).
Data is from a minimum of 30 consecutive pieces from a single process stream.
If process capability indices for Key & Process characteristics are statistically stable (no out of control conditions), minimum
capability requirements are met (Cp 1.83/Cpk 1.33 for Key, Cp 1.00/Cpk 1.00 for Process).
If process capability indices for Key & Process characteristics are not statistically stable (out of control conditions), minimum
capability requirements are met (Pp 1.83/Ppk 1.33 for Key, Pp 1.00/Ppk 1.00 for Process).
                                                             CONTROL PLAN                                                                         (Global Standard GS-0012)                        COMMENTS

Contains all process steps from initial receiving through final shipping and corresponds to those identified within the Process
Flow and PFMEA ("door to door").
Presented format clearly identifies Safety, Key & Process characteristics.
Variable (measurement) gaging is used to control Key characteristics and is clearly identified.
Stated methods for measuring Key characteristics correspond to those submitted within Gage R&R's.
Error-proof control methods implemented for all Safety characteristics.
Control method, sample size and frequencies on control plans for Process characteristics are reasonable (allow for evaluation of
multiple flows when present).
Control methods for Key characteristics employ statistical-based methods (samples to print unacceptable - 100% inspection
alone is considered containment only and is not an acceptable method of long-term control).
Key & Process characteristics that utilize containment control of 100% inspection alone apply an inspection tolerance reduced by
50% of the total Gage R&R to both sides of the tolerance to negate the measurement system variation.
Reaction plans for out-of-control conditions are defined and acceptable (internal standards included if referenced).
Sub-supplier Control Plan information included for all external processes that may influence Safety, Key & Process
characteristics (Additionally - heat treat, plating and coating processes).
                                                          PPAP ACCEPTANCE                                                                         (Global Standard GS-0008)                        COMMENTS

PPAP non-conformances include a Containment and Corrective Action Plan including names and dates.

PPAP approved by Sauer-Danfoss before parts are shipped (PSW signed by SD & supplier, copy returned to
supplier).
Rev.    Date            Who                             Change
A      22-Sep-05 J. Baldus     Release
                               Added statements for clarification in                     G
                               R&R: 1) Production rate is the time used by operator for
                               measurement in normal production setting.
                               Control Plan: 1) Critical or Key characteristics utilizing a
                               control of 100% inspection, will apply an inspection
                               tolerance reduced by 50% of the total Gage R&R to both
                               sides of the tolerance in negating the measurement
                               system variation.
                               Capability Study: 1) Studies available from each unique
                               process stream if multiple flows are present. If questions
                               exist on what is needed contact Product Team Quality
B       9-Feb-06 G. Hunziker   Engineer for guidance.
                               Control Plan 'Comments' were truncated when printing.
                               Template format corrected. No changes to text or
C      22-Mar-06 G. Hunziker   content.
                               1) Lines 9 and 17 Changed from "PPAP Submission
                               Warrant", to PART SUBMISSION WARRANT
                               2) Added to 'DOCUMENTS TO BE SUBMITTED'
                               comments: Quick check tip…does the number of Gage
                               R&R studies submitted match the number of Critical &
D      25-Oct-06 G. Hunziker   Key features?
                               1) Changed line 6 to: 'Sample parts produced at the
                               quoted production rate?' 'Enter actual production
                               rate'____Pcs. Per____                                   2)
                               Process Flow Chart section - added reference to
                               GS0063, and added comment "Each machine (piece of
                               equipment) should be identified by asset number", in
E       3-Jan-07 G. Hunziker   support thereof.
                               1) PSW: Added line to confirm 'run at rate' per GS0008
                               revsion C section 2.1                                    2)
                               Timing and Other Requirements: Removed reference
F      26-Jan-07 G. Hunziker   to confirming 'run at rate'.
                               Revised overall format, added links for
                               templates/standards, inserted accept/cond/reject
G       9-Apr-08 D. Heintz     columns.
H      15-Apr-08 D. Heintz     Added instruction tab.
                               Revised PFMEA element to include continuous
                               improvement text and added line for to acknowledge
J      1/12/2009 D. Heintz     multiple failure modes have been identified.
                               Revised checklist to compensate for changes to
                               "important characteristic" designations (Keys/Criticals
K      7/20/2009 D. Heintz     changed to Keys/Process characteristics).
                               1) Corrected hyperlink to Capability Template in
                               reflecting current content ID number
                               2) Added "material specification, and/or raw material part
M      1/29/2010 G. Hunziker   number" to ISIR section, line 25.

				
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