阶段性PPAP生产零件批准流程(ppt).ppt

阶段性PPAP生产零件批准流程,APQP,.Product Quality Planning is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer.,Supplier Timing PlanSupplier Development Plan,.Guidelines to produce a product quality plan which will support the development of a product that will satisfy the customer,5 Phases-APQP Elements,APQP（先期产品质量策划）,.产品质量计划是一个结构化的方法，用于定义和 建立一些必要的措施以确保产品满足顾客的需求。,供应商时间计划供应商开发计划,.制订产品质量计划的指导方针，能支持开发出 满足顾客需求的产品,5 个阶段-APQP 要素,What is PPAP,.It is a process to evaluate-If the supplier understands the specification requirements(drawings,material,tests)-If the manufacturing process can produce product meeting these requirements-If the process is stable,.It take place during an actual production run at the production rate(cycle time),Engineering SpecificationManufacturing Process meets the specActual production runProduction rate,什么是PPAP,它是一个流程，用于评估-供应商是否理解了规范的要求（图纸，材料，测试）-生产过程是否能制造出符合这些要求的产品-过程是否稳定它发生在按照生产速率（周期时间）进行的实际生产过程,工程规范制造过程符合规范实际生产运行速率,Most important,.It is the method used to approve a part.There is a PPAP for each new part,.If there is a design change,there is a new PPAP.If there is a production site change,there is a new PPAP,refer to AIAG PPAP Manual 4th Edition for more,最重要的是,它是用来批准一个零件的方法每个新零件都有一个PPAP有设计变更就有一个新的PPAP有生产地点的变化就有一个新的PPAP（更多信息参见AIAG，即汽车行业行动组的PPAP手册第四版）,Who uses PPAP,FordGMDaimler Chrysler,AIAG,Johnson ControlsDelphiLearMore,MazdaToyotaHondaVWFiatMore,Non-AIAG,谁使用PPAP？,FordGMDaimler,Johnson Controls Delphi Lear 更多,MazdaToyotaHondaVWFiat更多,AIAG,非AIAG,PPAP Requirements,.Design Record.Authorized Engineering Change documents.Customer Engineering Approval.Design Failure Mode and Effects Analysis(Design FMEA).Process Flow Diagram.Process Failure Mode and Effects Analysis(Process FMEA).Control Plan.Measurement System Analysis Studies.Dimensional Results.Records of Material/Performance Test Results.Qualified Laboratory Documentation.Appearance Approval Report(AAR).Sample Production Parts.Master Sample.Checking Aids.Customer-Specific Requirements.Part Submission Warrant(PSW),Standardindustryrequirements,CustomerSpecificrequirements,Phased PPAPRun-at-rateCapacity VerificationSREA,PPAP要求,设计记录 经过授权的工程变更文件 顾客工程批准 设计失效模式及其后果分析（DFMEA）过程流程图 过程失效模式及其后果分析（PFMEA）控制计划 测量系统分析研究 尺寸结果 材料/性能测试结果 初始过程能力研究 合格的试验室文件 外观批准报告（AAR）生产件样品 标准样本 检查辅助 顾客特殊要求 零件提交保证书（PSW）,标准工业要求,阶段性PPAP节拍生产（Run-at-rate）产能确认供应商工程批准申请（SREA）,What is Phased PPAP,.A procedure to-Align the PPAP requirements to the program events-Align the activities at suppliers to the program needs,PPAP Phase,Build Event,PPAP Phase 0PPAP Phase 1,PPAP Phase 2,PPAP Phase 3,FEU,MP,PP,什么是阶段性PPAP？,一个流程，用于-按照项目节点调整PPAP要求-按照项目需要调节供应商进行的活动,PPAP阶段,试制活动,PPAP阶段0PPAP阶段1,PP,PPAP阶段2,FEU,PPAP阶段3,MP,Phased PPAP Alignment,PP,FEU,MP,J1,Phase 0Phase 1,Phase 2,Phase 3,阶段性PPAP的调试,PP,FEU,MP,J1,阶段0阶段1,阶段2,阶段3,PPAP Phase 0:Run-at-Rate,Objectives:To confirm that all production input requirements are available and understood,and can support a limited production run.To provide an early indicator that the design of the process/tool/facility has the potential to produce at rate the required number of acceptable parts as determined by the prelaunch control plan.,PPAP阶段0：节拍生产,目的：确保所有产品的输入要求都已具备和被理解，并能支持小批量的生产运行。提供早期指标，表明工艺/模具/设备的设计具有按一定生产速率，生产前期投产控制计划所决定的合格零件需求数量的潜力。,What happens on Phase 0?,The supplier shall have all engineering information to be able to design its manufacturing process.The supplier conducts a run-at-run-Hard tooling-Mass Production environment-300 parts-Job 1 Manufacturing location Production capacity studies Engineering Specifications Manufacturing Process Run-at-rate Capacity Analysis,阶段0阶段会发生什么？,供应商需要掌握所有工程信息以便能设计制造过程。供应商实施节拍生产（Run at Rate）验证-硬模-量产环境-300个零件-Job 1制造场所生产能力研究,工程规范制造流程,节拍生产,产能分析,Applicable Elements,Design Record Authorized Engineering Change documents Customer Engineering Approval Design Failure Mode and Effects Analysis(Design FMEA)Process Flow Diagram Process Failure Mode and Effects Analysis(Process FMEA)Control Plan Checking Aids Customer-Specific Requirements,EngineeringSpecifications,ManufacturingProcess,RR,适用要素,设计记录 经过授权的工程更改文件 顾客工程批准 设计失效模式及其后果分析（设计FMEA）过程流程图 过程失效模式及其后果分析（流程FMEA）控制计划 检查辅助 顾客特殊要求,工程规格,制造过程,RR,Questions,Is there a PSW at the end of Phase 0?Dose the RR have to be witnessed by the STA?How many parts does the supplier have to produce for the Run-at-Rate?Can we do Phase 0 before all the DV tests finish?Do all the component drawings have to be available?,问题,阶段0结束前有没有PSW？需要由STA见证RR吗？供应商需要按照节拍生产制造多少零件？我们是否必须在阶段0前完成所有DV试验吗？是否所有零件图纸都已经具备？,PPAP Phase 1:Quality Verification,Utilizes parts produced during Phase 0.Objectives:To confirm all customer design record and specification requirements are properly understood by the supplier.To provide an early indicator that the design of the process/tool/facility has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate by operating a minimum of one production stream.,PPAP阶段1：“质量验证”,利用阶段0期间生产的零件。目的：确保供应商已充分理解顾客所有的工程设计记录及工程规范要求。提供早期指标，通过对已选最小单元生产线的运行，显示流程/工装/设备的设计在实际生产时，是否有潜力按照保价时确定的产品生产率，持续地生产符合要求的产品。,What happens on Phase 1?,Measurement and testing of the parts produced on Phase 0Measurement studies and statistical studiesAppearance review,阶段1会发生什么？,测量并测试阶段0期间生产的零件测量研究和统计研究外观品审,Applicable Elements,Measurements System Analysis StudiesDimensional ResultsRecords of Material/Performance Test ResultsInitial Process StudiesQualified Laboratory DocumentationAppearance Approval Report(AAP)Sample Production PartsMaster samplesCustomer Specific Requirements,适用要素,测量系统分析研究尺寸结果材料，性能测试结果记录初始过程能力研究合格的试验室文件外观批准报告（AAR）生产样件标准样本顾客特殊要求,Questions,Is there a Phase-1PSW?Can Ford approve a Phase 1 PSW if the PV tests are not completed?,问题,阶段1有PSW吗？如果PV试验没有完成，福特能批准阶段1的PSW吗？,Phase 2:Production Verification,Objectives:To confirm all customer engineering design record and specification requirements are properly understood by the supplier,and that ALL production streams have the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.,阶段2：“生产确认”,目的：确认供应商是否正确理解顾客工程设计记录和工程规范要求，以及所有生产线是否都有能力按照保价时确定的产品生产率，有潜力持续地生产符合要求的产品。,Production Stream,CUT&SEW,CUT&SEW1,CUT&SEW2,CUT&SEW3,ASSEMBLY1,ASSEMBLY2,ASSEMBLY1,DELIVERY,DELIVERY,生产线,切割和缝合,装配1,装配2,切割和缝合1,切割和缝合2,切割和缝合3,装配1,运输,运输,Applicable Elements,Conduct PPAP Phase 0 and 1 for ALL the production streams ALL PPAP Element are applicable again(for the additional production streams),适用要素,所有生产线采用PPAP阶段0和1,所有PPAP要素再次适用（对于附加生产线）,Questions,What happens if the supplier has only one line/one production stream?Does the supplier have to measure the parts again?Does the supplier have to conduct the PV tests again?How many parts to produce?,问题,如果供应商仅有一条生产线怎么办？供应商需要再次测量零件吗？供应商需要再次进行PV试验吗？生产多少零件？,Phase 3:“Capacity Verification”,Objective:Verify the suppliers production system can support the CPV(Capacity Planned Volume)while meeting Phase 2 requirements.Also known as“1-Day full production”,阶段3：“产能验证”,目的：验证供应商的生产系统在满足阶段2要求时，是否能支持CPV（产能计划量）即为“1整天全能力生产”,What happens on Phase 3?,The supplier runs production at full capacity(all production streams)Capacity studies on:-CPV(Capacity Planned Volumes)-Bottlenecks-TACT(Total Actual Cycle Time)-OEE(Overall Equipment Efficiency)At the end of the day of production,the daily target must be met.,阶段3会发生什么？,供应商以全部生产能力生产（所有生产线）对以下进行生产力研究：-产能计划量（CPV）-瓶颈-总实际生产循环周期（TACT）-整体设备效率（OEE/Overall Equipment Effectiveness）一天生产结束时，每日目标必须完成。,Questions,Can a supplier submit a Phase-1,Phase-2 and Phase-3 PPAP simultaneously?Does the supplier have to conduct additional tests or measurements to the parts produced in PPAP Phase-3?What are the documents required for this PPAP Phase?,问题,供应商可以同时提交阶段1，阶段2和阶段3的PPAP吗？供应商需要给PPAP阶段3生产的零件进行额外的试验和测量吗？这个PPAP阶段需要的文件是什么？,Wrap Up,PPAP-Scope,elements,purpose,PPAP submissions and re-submissionsPhased PPAP-Purpose,Alignment to Vehicle build events,targetsPhase-0(Run at Rate)-Elements applicablePhase-1(Quality Verification)-Applicable ElementsPhase-2(Production Verification)-single/Multiple Production Streams-Applicable ElementsPhase-3(Capacity Verification 1Day Production)-Capacity analysis,综述,PPAP-范围，要素，目的，PPAP提交和再次提交阶段性PPAP-目的，配合车辆试制活动，目标阶段-0（节拍生产）-适用要素阶段1（质量验证）-适用要素阶段2（生产验证）-单条，多条生产线-适用要素阶段3（产能验证-1天生产）-产能分析,Reference Material,AIAG PPAP ManualFord Specifics for PPAPPhased PPAP requirements handbook,参考资料,AIAG PPAP 手册福特特殊的PPAP要求阶段性PPAP要求手册,