Professional Documents
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PPAP en APQP;
Een route naar succesvol toeleveren
Jan van de Venne
HighTech meets Automotive,
21 juni 2012
Waarom vraagt de automobiel Industrie
ppm kwaliteit
PPAP
Reject level -->
ppb
ISO/TS 16949
Process control
6s
ppm Cp > 2.00
Product control
Ford Q1, QS9000
Cpk > 1.67
%
Ppk > 1.67
AQL
Time -->
Kwaliteit systemen:
70-er jaren: Ford Q101,
90-er jaren: Q-101 wordt
uitgebreid naar QS-9000
Een kwaliteits systeem
voor toeleveranciers aan
de automobiel industrie.
2002:
QS9000 is opgevolgd door
ISO/TS 16949.
Henry Ford with Model T in Buffalo, NY, 1921
www.aiag.org
Non-profit organisatie
Publiceert standaarden: o.a. :
APQP: Advanved Product Quality Planning
PPAP: Production Part Approval Process
Organiseert training programmas,
conferenties etc.
PPAP
Business Technologie Massa
Product & Toelevering
Ontwikkeling Ontwikkeling Pilot productie;
Process aan de
& Program- Voor- productie; Supply
ontwikkeling klant
mering ontwikkeling Chain uitv.
Step and
PFMEA
relevant parameters Eerste Pilot
in the Process POTENTIAL
(PROCESS FMEA)
1
FAILURE MODE AND EFFECTS ANALYSIS
FMEA Number
Page of
Capability studies
Resultaten Item 2 3
Process Responsibility 4 Prepared By
Control Plans
8
Core Team
22
SC O D R. Action Results
Process Function Potential Failure Potential Effect(s) E L Potential Cause(s)/ C E P. Recommended Responsibility Actions S O D R.
9 Requirements
10 11 Mode12 of Failure 16 V A 18 Mechanism(s)
19 of C Current
21 Process Control T N. Action(s) & Target Taken E C O P.
14 S Failure 20 U E Completion Date V C T N.
13 15 S R C
17
SPC
List
Potential Failure
Collect
Modes, Effects, Causes,
Controls and Actions Data
Werkinstructies
Develop Process Controls & #
Checking Devices
Instructions
Reaction Plans
Wetering, pr
Doc Owner:
Key Date :
Marc Valentijn
Vanuit Process Flow Diagram
Vanuit functioneel denken!!
Severity
Occurrence
Classification
Process Step/ Requirement Potential Failure Potential Effect(s) of Potential (Root) Current Process
Detection
GR&R
temperature drop ingot at exit.
1.2 Heat up ingots temperature block at Temperature too low No pres cycle, block = reject
homogeniously during outside, at exit of furnace in process but can be reused.,
automatic transport to be .. oC; ( specified); productivity loss
inside oven by gas at exit of furnace
heating so fer, no temperature
profile defined.
Pressedbut temp low, causing
high press pressures, causing
temperature too high
Temperature homogenuity , Inhomogenious uncontrolled press process,
centre temp. -max X?? oC temperature, centre too dimensions out of control
from outersurface low temp.
temperature
1.3 transport ingot from Max time from exit over to time too long from Ingot cools down causing
overeit to pickup pickup .. Sec overexit too pickup uncontrolled press process or
position by dropping, even ingot reject.
and guidance to ..
time too short unable too process ingots more than specified loaded
sequencial, too many available on chain, due to no empty
in certain time frame; causing rows, due to lack of
reject ingots due to waiting synchronisation of pusher
time causing cooling down. and chainspeed
15
15 HighTech Meets Automotive; PPAP & APQP; 21-06-2012
PFD: Process Flow Diagram,
noodzakelijke voorbereiding voor een P-FMEA
Process/Item :
Model Year (s)/ Process
belong in the PCP not the FMEA Version :
Page: of
Program(s) :
Core Team :
Responsibility :
Key Date :
PFD or PFMEA Prepared by:
FMEA Date (Orig.) :
Process step and Requirement Potential Failure Potential Effect(s) of Potential (Root) Current Process Recommended Responsibility & Action Results
intended function Mode Failure Cause(s) of Failure Action Target Completion
i.e. not meeting process Effect on next process, final 5 times w hy, dow nw ards along Controls Controls Date Actions Taken
specifications process result or consumer requirements;
Classification
Prevention Detection Completion Date
to much , to little w .r.t. requirement of product/service effect due to . Due to due to
Occurrence
Do this. With this. To
finally files only on control spec, ... a method w hich a method w hich
this.
Occurrence
plan prevents the failure detects the failure
Severity
intermittent?
Detection
Detection
mode from mode w hen it happens
Severity
Different behaviour.
RPN
happening
RPN
Identify the Process with its Functions and Requirements
Process: description of the process operation
Function: what the process must do
Requirements: product / process specifications
Process step and Requirement Potential Failure Potential Effect(s) of Potential (Root) Current Process Recommended Responsibility & Action Results
intended function Mode Failure Cause(s) of Failure Action Target Completion
i.e. not meeting process Effect on next process, final 5 times w hy, dow nw ards along Controls Controls Date Actions Taken
specifications process result or consumer requirements;
Classification
Prevention Detection Completion Date
to much , to little w .r.t. requirement of product/service effect due to . Due to due to
Occurrence
Do this. With this. To
finally files only on control spec, ... a method w hich a method w hich
this.
Occurrence
plan prevents the failure detects the failure
Severity
intermittent?
Detection
Detection
mode from mode w hen it happens
Severity
Different behaviour.
RPN
happening
RPN
Determine the functional failures that could occur for each
process and function.
The inability of an item to perform a specific function within the specified limits.
Failure to perform a function.
Over achieve or under achieve the function
Poor performance (degraded or intermittent) of the function.
Performing an unintended function.
APQP PPAP
Business Technologie Massa
Product & Toelevering
Ontwikkeling Ontwikkeling Pilot productie;
Process aan de
& Program- Voor- productie; Supply
ontwikkeling klant
mering ontwikkeling Chain uitv.
Define: De uitdaging,
de CTQ, de gevraagde functionele specificatie.
Design Ys = System
factoren X Specificatie
Y = f (X)
X
Noise, Ruis ;
Niet controleerbare Parameters
Power vragen:
Welke factoren X beinvloeden Y, in welke mate?
Kan ik Y voorspellen, op basis van kennis van de X-en
Holland-Innovative:
Angelique van de Leur angelique.van.de.leur@holland-innovative.nl
Sales Representative info@holland-innovative.nl
040 851 4611