PPAP knowledge

Prepared by PE

PPAP Training

PPAP Training

First, what is PPAP

Production Part Approval Process

Production Product Accreditation Procedure

PPAP

II. Purpose of PPAP

Purpose:

PPAP is used to determine whether the supplier fully understands all customer engineering design information and production requirements, and whether there is potential for high supply under specified productivity in actual production operations to ensure that the production products continue to meet these requirements.

Third, the scope of application of PPAP

Suppliers engaged in standard product manufacturing or service industries shall perform PPAP approval procedures unless the customer formally abandons them; tools shall be guaranteed to support their operations throughout the operation period.

3.1 Scope of Application (I)

In the following cases, the supplier must submit PPAP for approval before the first batch of products are shipped unless the customer concedes. If necessary, the supplier must review and update the project reflecting the production process in the PPAP file, regardless of whether the customer requests it or not. The PPAP file should contain the name and date of the authorized person.

1. New products. A new product (initial version) or a previously approved product is assigned a new or revised product number, which must be submitted to PPAP.

2. Correct the deviation of the products delivered before. Including: product performance does not meet customer requirements, size or size does not match; problem of the outsourcer; full acceptance of the replacement part of the product; testing (including materials, performance)

3. Product changes engineering design records, technical specifications, or production materials.

3.2 Scope of Application (II)

When any of the design and process changes described below occur, the supplier shall notify the customer of the need to submit PPAP.

1. Products that have been approved by customers use another raw material;

2. Products use new or modified tools (excluding vulnerable tools), moulds, drawings, etc., including additional or alternative tools. This requirement applies only to tools with unique shapes or functions, whose changes will affect the intrinsic integrity of the product.

3. Renovation of existing tools and equipment (increasing capacity, improving performance or changing existing functions) and readjustment (product/process changes), in addition to replacement or renovation of vulnerable tools.

4. When tools and equipment are moved (to or from another plant)

5. When the outsourcing supplier who provides outsourcing products, raw materials and other services (such as electroplating, etc.) changes, the installation, appearance, function, life and performance of the customer's products are affected.

6. When the tool has stopped using for 12 months or more, it is used again.

7. When the process and manufacturing methods change (including internal manufacturing or outsourcing manufacturing), the installation, appearance, function, life and performance of customer products are affected;

8. When testing/inspection methods are changed, such as new processes (but not acceptance criteria)

3.3 Scope of Application (3)

In the following cases, the supplier does not need to notify the customer or submit PPAP, but it is the supplier's responsibility to track these changes and/or improvements and update any affected PPAP documents (once the customer's requirements in installation, shaping, function, life and performance are affected, the supplier should notify the customer).

1. When changes in component drawings (internal or external) do not affect customer product design records;

2. Tool movement within the plant (for similar equipment, but without changing the production process or disassembly tools), or equipment movement within the plant (same equipment, but without changing the production process)

3. Equipment change (same production process, same basic technology or method)

4. Replacement of the same instrument;

5. Re-coordination of operator's work content under the premise of unchanged production process.

6. Change of RPN reduction in PFMEA (without affecting process), such as increasing control factors, increasing sampling size and frequency, and establishing preventive measures.

IV. PPAP Procedure Requirements

Typical production operation

PPAP requirements

4.1 Typical Production Operation

Products for PPAP shall be obtained from a typical production operation, which shall produce at least 300 continuous components from 1 hour to 8 hours, unless otherwise specified by the authorized customer quality representative.

Tools, equipment, processes, materials and personnel in the production environment should be used for this operation in the production site, and products with each unique production process should be measured and tested for representative components.

4.2 PPAP Requirements

The supplier shall satisfy all specified requirements (e.g. design records, specs). If any result exceeds spec, the supplier shall not submit parts, documents and/or records.

The inspections and tests required in PPAP shall be performed by a qualified laboratory (see QS9000 3rd Edition 4.10.6). Commercial/independent tests conducted in the laboratory shall be carried out using approved equipment (see QS9000 3rd Edition 4.10.7 and 4.11.2.b.1). When using a commercial laboratory, the supplier shall submit a letter for writing in the laboratory. Or the test results on the formal report form of the laboratory. The name of the laboratory for which the test was performed, the date of the test, and the criteria used for the test should be specified. For any test results, the absence of substantive data is unacceptable.

4.2 PPAP Requirements

For the projects mentioned below, regardless of the level of submission, the supplier should have appropriate records. For items 1-15,19 (if any), they should be readily available in PPAP FILE; for items 16,17,18, they should be readily available to customers when using PPAP. For all the projects mentioned below, not all of them are applicable to each supplier. For each customer product, for example, some products do not have appearance requirements.

PPAP Requirement

4.2.1 Design Records

Design Records Design Records

The supplier has all the design records of the products it sells, including the design records of the parts or details it sells. When the design records (such as CAD/CAM mathematical data, part drawings, specs) exist electronically, such as mathematical data, the supplier should have a hard copy (such as drawings).