New fmea reference manual. Get aiag ppap manual pdf file for free from our online library. Aiag ppap manual 4th edition free download www. Aiag fmea manual. Search for:. CpIcis an indicator of process capability based on process variation within each subgroup of a set of data. CpI,does not include the effect of process variability between the subgroups.
Cplcis an indicator of how good a process could be if all process variation between subgroups was to be eliminated. Therefore, use of Cpkalone may be an incomplete indicator of process performance. For more information, see the Statistical Process Control reference manual.
Ppk- The performance index. The estimate of sigma is based on total variation all of individual sample data using the standard deviation [root mean square equation], "s". Pplcis an indicator of process performance based on process variation throughout the full set of data.
Unlike Cpk,Ppkis not limited to the variation within subgroups. However, Pplccannot isolate within subgroup variation froin between subgroup variation. When calculated from the same data set, Cplcand Ppkcan be compared to analyze the sources of process variation.
Initial Process Studies. The purpose of the initial process study is to understand the process variation, not just to achieve a specific index value. When historical data are available or enough initial data exist to plot a control chart at least individual samples , Cplccan be calculated when the process is stable. NOTE 2: For Initial Process Studies involving more than one process stream, additional appropriate statistical methods or approaches may be required.
NOTE 3: For bulk material, the organization should obtain customer agreement regarding the appropriate techniques for initial process studies, if required, in order to determine an effective estimate of capability.
Contact the authorized customer representative for a review of the study results. NOTE 1: Meeting the initial process study capability acceptance criteria is one of a number of customer requirements that leads to an approved PPAP submission.
NOTE 2: See 2. The organization shall identify, evaluate and, wherever possible, eliminate special causes of variation prior to PPAP submission. The organization shall notify the authorized customer representative of any unstable processes that exist and shall submit a corrective action plan to the customer prior to any submission. NOTE: For bulk materials, for processes with known and predictable special causes and output meeting specifications, corrective action plans may not be required by the customer.
NOTE: The above mentioned acceptance criteria 2. When this is not true, using this analysis may result in unreliable information. These alternate acceptance criteria could require a different type of index or some method of transformation of the data. The focus should be on understanding the reasons for the non-normality e. Refer to the Statistical Process Control reference manual for further guidance.
Variation reduction efforts shall continue until the acceptance criteria are met, or until customer approval is received. When an externallcoinmercial laboratory is used, the organization shall submit the test results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that performed the tests, the date s of the tests, and the standards used to run the tests shall be identified. A separate Appearance Approval Report AAR shall be completed for each part or series of parts if the productipart has appearance requirements on the design record.
Upon satisfactory completion of all required criteria, the organization shall record the required information on the AAR. The completed AAR.
AARs complete with part disposition and authorized customer representative signature shall then accompany the PSW at the time of final submission based upon the submission level requested.
See customer-specific requirements for any additional requirements. The master sample shall be identified as such, and shall show the customer approval date on the sample. The organization shall retain a master sample for each position of a multiple cavity die, mold, tool or pattern, or production process unless otherwise specified by the customer. NOTE When part size, sheer volume of parts, etc. The purpose of the master sample is to assist in defining the production standard, especially where data is ambiguous or in insufficient detail to fully replicate the part to its original approved state.
The organization shall document all released engineering design changes that have been incorporated in the checking aid at the time of submission. The organization shall provide for preventive maintenance of any checking aids for the life of the part see Glossary - "Active Part". Measurement system analysis studies, e.
NOTE 2: Checking aids, etc. If checking aids are used for bulk materials, the organization should contact the authorized customer representative regarding this requirement. For bulk materials, applicable customer-specific requirements shall be documented on the Bulk Material Requirements Checklist. A separate PSW shall be completed for each customer part number unless otherwise agreed to by the authorized customer representative. If production parts will be produced from more than one cavity, mold, tool, die, pattern, or production process, e.
The specific cavities, molds, line, etc. The organization shall verify that all of the measurement and test results show conformance with customer requirements and that all required documentation is available and, for Level 2, 3, and 4, is included in the submission as appropriate.
A responsible official of the organization shall approve the PSW and provide contact information. NOTE 1: One warrant per customer part number can be used to summarize many changes providing that the changes are adequately documented, and the submission is in compliance with customer program timing requirements. The weight shall not include shipping protectors, assembly aides, or packaging materials. To determine part weight, the organization shall individually weigh ten randomly selected parts, calculate and report the average weight.
At least one part shall be measured from each cavity, tool, line or process to be used in product realization. NOTE: This weight is used for vehicle weight analysis only and does not affect the approval process. Where there is no production or service requirement for at least ten parts, the organization should use the required number for calculation of the average part weight. For bulk materials, the part weight field is not applicable.
The organization shall notify the authorized customer representative of any planned changes to the design, process, or site. Examples are indicated in the table below see Table 3. Upon notification and approval of the proposed change by the authorized customer representative, and after change implementation, submission is required unless otlienvise specified. Use of other construction or material For example, other constsuction as documented on than was used in the previously approved a deviation permit or included as a note on the part product design record and not covered by an engineering change as described in Table 3.
Production from new or modified tools This requirement only applies to tools, which due except perishable tools , dies, molds to their unique form or fimction, can be expected patterns, etc.
It is replacement tooling not meant to describe standard tools new or repaired , such as standard measuring devices, drivers manual or power , etc.
Rearrangement is defined as activity that changes the sequence of productlprocess flow from that documented in the process flow diagram including the addition of a new process. Production from tooling and equipment Production process tooling and lor equipment transferred to a different plant site or from transferred between buildings or facilities at one or an additional plant site.
Change of supplier for pasts, non- The organization is responsible for approval of equivalent materials, or services e. Product produced after the tooling has For product that has been produced after tooling been inactive for volume production for has been inactive for twelve months or more: twelve months or more. Notification is required when the part has had no change in active purchase order and the existing tooling has been inactive for volume production for twelve months or more.
The only exception is when the part has low volume, e. However a customer may specify certain PPAP requirements for service parts.
Change in testlinspection method - new For change in test method, the organization should technique no effect on acceptance criteria have evidence that the new method has measurement capability equivalent to the old method.
Additionally, for bulk materials: These changes would normally be expected to have an effect on the performance of the product. New source of raw material from new or existing supplier. The organization shall review and update, as necessary, all applicable items in the PAP file to reflect the production process, regardless of whether or not the customer requests a formal submission.
The PPAP file shall contain the name of the authorized customer representative granting the waiver and the date. A new part or product i. Correction of a discrepancy on a previously Submission is required to correct any submitted part. A "discrepancy" can be related to: e The product performance against the customer requirements 0 Dimensional or capability issues 0 Supplier issues o Approval of a part replacing an interim approval Testing, including material, performance, or engineering validation issues 3.
Engineering change to design records, Submission is required on any engineering specifications, or materials for production change to the production productlpart design record. Additionally, for Bulk Materials: 4. Process technology new to the organization, not previously used for this product. Level 2 Wai-sant with product samples and limited supporting data submitted to the customer.
Level 3 Warrant with product samples and complete suppoi-ting data submitted to the customer. Level 4 Warrant and other requirements as defined by the customer. Level 5 Warrant with product samples and complete supporting data reviewed at the organization's manufacturing location. See RetentiodSubmission Requirements Table 4. The organization shall use level 3 as the default level for all subinissions unless othenvise specified by the authorized customer representative.
I: The authorized customer representative may identify a submission level, different from the default level, that is to be used with each organization, or organization and customer part number combiliation.
Different customer locations may assign different submission levels to the same organization manufacturing location. NOTE 2: All of the f o r m referenced in this document may be replaced by computer-generated facsimiles. Acceptability of these facsimiles is to be confirmed with the authorized customer representative prior to the first submission. Upon approval of the submission, the organization shall assure that future production continues to meet all customer requirements.
NOTE: For those organizations that have been classified as "self certifying" PPAP submission level 1 by a specific customer, submission of the required organization-approved documentation will be considered as customer approval unless the organization is advised otherwise.
The organization is therefore authorized to ship production quantities of the product, subject to releases from the customer scheduling activity. Interim Approval will only be granted when the organization has: 0 clearly defined the non-compliances preventing approval; and, c prepared an action plan agreed upon by the customer. PPAP re-submission is required to obtain a status of "approved. Note 2: Parts with a status of "Interim Approval" are not to be considered "Approved.
No additional shipments are authorized unless an extension of the interim approval is granted. For bulk materials, the organization shall use the "Bulk Material Interim Approval" form, or its equivalent see Appendix F. The submission shall be approved before production quantities may be shipped. Part Name and 2a. Customer Part Number: Engineering released finished end item part name and number. Org, Part Number: Part number defined by the organization, if any. Shown on Drawing Number: The design record that specifies the customer part number being submitted.
Safety andlor Government Regulation: "Yes" if so indicated by the design record, otherwise "No. Weight: Enter the actual weight in kilograms to four decimal places unless otherwise specified by the customer.
Checking Aid Number, Change Level and Date: If requested by the customer, enter the checking aid number, its change level and date. Street Address, Region, Postal Code, Country: Show the complete address of the location where the product was manufactured. For "Region," enter state, county, province, etc.
Customer NameIDivision: Show the corporate name and division or operations group. Application: Enter the model year, vehicle name, engine, transmission, etc. If submitted via other customer format, enter the date customer confirmation was received. Check the appropriate box es. For bulk materials, in addition to checking the appropriate box, check "Other" and write "Bulk Material" in the space provided. Check the appropriate boxes for dimensional, material tests, performance tests, appearance evaluation, and statistical data.
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This is referred as based on a Ppk estimate of for the underlying process. However this is not necessarily the sample size that is recommended under all circumstances. Its primary focus is systems where readings can be replicated on each part. These are example scales and will need to be tailored to individual company appli- cations. Reference Chapter 5 , Section 5. PDF; Thank you for visiting our website and your interest in our free products and services. All basic functions are implemented and ready to use.
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