阶段性PPAP生产零件批准流程课件.ppt

1、阶段性阶段性PPAP生产零件批准流程生产零件批准流程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 developm

2、ent of a product that will satisfy the customer5 Phases-APQP ElementsAPQP（先期产品质量策划）（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。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时间计划供应商开发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满足顾客需求的产品5 个阶段个阶段-APQP 要素要素What is PPA

3、P. 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 t

4、ime)Engineering SpecificationManufacturing Process meets the specActual production runProduction rate 什么是什么是PPAPn它是一个流程，用于评估它是一个流程，用于评估n-供应商是否理解了规范的要求（图纸，材料，测试）供应商是否理解了规范的要求（图纸，材料，测试）n-生产过程是否能制造出符合这些要求的产品生产过程是否能制造出符合这些要求的产品n-过程是否稳定过程是否稳定n它发生在按照生产速率（周期时间）进行的实际生产过程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

5、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 PPAPrefer to AIAG PPAP Manual 4th Edition for more 最重要的是n它是用来批准一个零件的方法n每个新零件都有一个PPAPn有设计变更就有一个新的

6、PPAPn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 PPAPFordGMDaimler ChryslerAIAGJohnson ControlsDelphiLearMoreMazdaToyotaHondaVWFiatMoreNon-AIAG谁使用PPAP？ FordGMDaimlerJohnson Controls Delphi Lear 更多更多MazdaToyotaHondaVWFiat更多更多AIAG非非AIAGPPAP Requirements. Design Record. Authorized Engine

7、ering 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

8、Results. Qualified Laboratory Documentation. Appearance Approval Report (AAR). Sample Production Parts. Master Sample . Checking Aids. Customer-Specific Requirements. Part Submission Warrant(PSW)StandardindustryrequirementsCustomerSpecificrequirementsPhased PPAPRun-at-rateCapacity VerificationSREAPP

9、AP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 ev

10、ents -Align the activities at suppliers to the program needsPPAP PhaseBuild EventPPAP Phase 0PPAP Phase 1PPAP Phase 2PPAP Phase 3FEUMPPP什么是阶段性PPAP？n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阶段阶段试制活动试制活动PPAP阶段0PPAP阶段1PPPPAP阶段2FEUPPAP阶段3MPPhased PPAP AlignmentPPFEUMPJ1Phase 0Phase 1Phase 2Phase 3阶段

11、性PPAP的调试PPFEUMPJ1阶段0阶段1阶段2阶段3 PPAP Phase 0:Run-at-Rate Objectives:nTo confirm that all production input requirements are available and understood, and can support a limited production run.nTo provide an early indicator that the design of the process/tool/facility has the potential to produce at rate

12、 the required number of acceptable parts as determined by the prelaunch control plan.PPAP阶段0：节拍生产 目的：n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。n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?nThe supplier shall have all engineering information to be able to design its manuf

13、acturing process.nThe supplier conducts a run-at-run -Hard tooling -Mass Production environment -300 parts -Job 1 Manufacturing location nProduction capacity studies Engineering Specifications Manufacturing Process Run-at-rate Capacity Analysis阶段0阶段会发生什么？n供应商需要掌握所有工程信息以便能设计制造过程。n供应商实施节拍生产（Run at Rat

14、e）验证 -硬模 -量产环境 -300个零件 -Job 1制造场所n生产能力研究工程规范工程规范制造流程制造流程节拍生产节拍生产产能分析产能分析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 (Proce

15、ss FMEA) Control Plan Checking Aids Customer-Specific Requirements EngineeringSpecificationsManufacturingProcessRR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 QuestionsnIs there a PSW at the end of Phase 0?nDose the RR have to be witnessed b

16、y the STA?nHow many parts does the supplier have to produce for the Run-at-Rate?nCan we do Phase 0 before all the DV tests finish?nDo all the component drawings have to be available?问题n阶段0结束前有没有PSW？n需要由STA见证RR吗？n供应商需要按照节拍生产制造多少零件？n我们是否必须在阶段0前完成所有DV试验吗？n是否所有零件图纸都已经具备？PPAP Phase 1:Quality Verification

17、nUtilizes parts produced during Phase 0. Objectives:nTo confirm all customer design record and specification requirements are properly understood by the supplier.nTo provide an early indicator that the design of the process/tool/facility has the potential to produce product consistently meeting thes

18、e 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”n利用阶段0期间生产的零件。 目的：n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。n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?nMeasurement

19、and testing of the parts produced on Phase 0nMeasurement studies and statistical studiesnAppearance review阶段1会发生什么？n测量并测试阶段0期间生产的零件n测量研究和统计研究n外观品审 Applicable Elements nMeasurements System Analysis StudiesnDimensional ResultsnRecords of Material / Performance Test ResultsnInitial Process StudiesnQual

20、ified Laboratory DocumentationnAppearance Approval Report (AAP)nSample Production PartsnMaster samplesnCustomer Specific Requirements适用要素n测量系统分析研究n尺寸结果n材料，性能测试结果记录n初始过程能力研究n合格的试验室文件n外观批准报告（AAR）n生产样件n标准样本n顾客特殊要求 Questions nIs there a Phase-1PSW?nCan Ford approve a Phase 1 PSW if the PV tests are not

21、completed?问题n阶段1有PSW吗？n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:nTo 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 me

22、eting these requirements during an actual production run at the quoted production rate.阶段2：“生产确认” 目的：n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 StreamCUT&SEWCUT&SEW1CUT&SEW2CUT&SEW3ASSEMBLY1ASSEMBLY2ASSEMBLY1DELIVERYDELIVERY生产线切割和缝合切割和缝合装配装配1装配装配2切割和切割和缝合缝合1切割和

23、切割和缝合缝合2切割和切割和缝合缝合3装配装配1运输运输运输运输 Applicable ElementsnConduct 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n所有生产线采用PPAP阶段0和1所有所有PPAP要素再次适用要素再次适用（对于附加生产线）（对于附加生产线） QuestionsnWhat happens if the supplier has only one

24、 line / one production stream?nDoes the supplier have to measure the parts again?nDoes the supplier have to conduct the PV tests again?nHow many parts to produce?问题n如果供应商仅有一条生产线怎么办？n供应商需要再次测量零件吗？n供应商需要再次进行PV试验吗？n生产多少零件？ Phase 3:“Capacity Verification” Objective:nVerify the suppliers production syste

25、m can support the CPV (Capacity Planned Volume) while meeting Phase 2 requirements.nAlso known as “1-Day full production ”阶段3：“产能验证” 目的：n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）n即为“1整天全能力生产” What happens on Phase 3?nThe supplier runs production at full capacity (all production streams)nCapacity studies o

26、n: -CPV (Capacity Planned Volumes) -Bottlenecks -TACT (Total Actual Cycle Time) -OEE (Overall Equipment Efficiency)nAt the end of the day of production, the daily target must be met.阶段3会发生什么？n供应商以全部生产能力生产（所有生产线）n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

27、 ）n一天生产结束时，每日目标必须完成。 QuestionsnCan a supplier submit a Phase-1,Phase-2 and Phase-3 PPAP simultaneously?nDoes the supplier have to conduct additional tests or measurements to the parts produced in PPAP Phase-3?nWhat are the documents required for this PPAP Phase?问题问题n供应商可以同时提交阶段1，阶段2和阶段3的PPAP吗？n供应商需要

28、给PPAP阶段3生产的零件进行额外的试验和测量吗？n这个PPAP阶段需要的文件是什么？ Wrap UpnPPAP -Scope, elements, purpose, PPAP submissions and re-submissionsnPhased PPAP -Purpose, Alignment to Vehicle build events, targetsnPhase-0 (Run at Rate) -Elements applicablenPhase-1 (Quality Verification) -Applicable ElementsnPhase-2 (Production

29、Verification) -single / Multiple Production Streams -Applicable ElementsnPhase-3 (Capacity Verification 1Day Production) -Capacity analysis综述综述nPPAP -范围，要素，目的，PPAP提交和再次提交n阶段性PPAP -目的，配合车辆试制活动，目标n阶段-0（节拍生产） -适用要素n阶段1（质量验证） -适用要素n阶段2（生产验证） -单条，多条生产线 -适用要素n阶段3（产能验证-1天生产） -产能分析 Reference MaterialnAIAG PPAP ManualnFord Specifics for PPAPnPhased PPAP requirements handbook参考资料nAIAG PPAP 手册n福特特殊的PPAP要求n阶段性PPAP要求手册