Ppap training presentation
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The document provides information about a PPAP (Production Part Approval Process) training programme held on August 17th, 2013. It discusses the introduction of APQP (Advanced Product Quality Planning) which was jointly developed by major automakers to provide a systematic approach. The training covers the objectives of PPAP which is to ensure a product satisfies customer requirements. It also describes the different PPAP levels and highlights that effective teamwork is essential for success. Various elements of the PPAP process are outlined such as design reviews, prototyping, process capability studies and production validation testing.
Ppap training presentation
- 1. PPAP TRAINING PROGRAMME (17th AUGUST-2013) Presented by: B.D.Sharma (PMC) SHIVANI LOCKS PVT. LTD.
- 2. APQP INTRODUCTION This system was jointly developed by M/S. Chrysler Corporation, Ford Motor Company & General Motors Corporation in the year 1994, to provide systematic working environment in the organisation. All the methods related to above system are captured in this program. The two main requirements of a good Product Development are, first to developing a robust product and 2nd developing the product in a shortest time. The first & important principle for the success of this system is the ability to work in a team. For this it is necessary to develop and implement the team working culture in the organization. If we do not adhere to this principle of team working, we may end up without the benefits. PPAP TRAINING PROGRAMME – 13th AUG. 2013
- 3. WHAT IS PPAP ? Production Part Approval Process is a structured & systematic method to assure that a product satisfies the customer’s requirements. The commitment from the Top Management an essential requirement for the success of this process. THE OBJECTIVENESS OF PPAP Effective communication with everyone involved. On-time completion of all required steps Minimal or no quality problems Minimal product launch quality risks Minimal cycle time to launch the product THE BENEFITS OF PPAP Resources are directed toward customer satisfaction Required changes are identified early Changes close to or after product launch are avoided A quality product is provided on time at the lowest cost. An element of Continuous Improvement is built into the company. PPAP TRAINING PROGRAMME – 13th AUG. 2013
- 4. LEVEL – 5. LEVEL – 1. LEVEL – 2 . LEVEL – 3 . LEVEL – 4 . PPAP LEVEL PPAP LEVEL : PPAP TRAINING PROGRAMME – 13th AUG. 2013
- 5. Advanced Product Quality Planning Date: 25.06.2009 Status Report Review No.: 00 Diamond Point: Supplier SHIVANI LOCKS PVT LTD Program AMBASSADOR MODEL Location FARIDABAD-HARYANA Model Year Supplier Code Lead Part No. M-03S-121000/ Cust.Part No :4308300026 Risk Assessment Part Name New: Site Technology Process Eng. Level 00 Other Risks Follow source support Not Avbl User Plant(s) HINDUSTAN MOTORS LIMITED (HML) KOLKATA Team Members Company/Title Phone/Fax 0129-4049479: Fax: 0129-2279479 0129-4049479: Fax: 0129-2279479 0129-4049479: Fax: 0129-2279479 0129-4049479: Fax: 0129-2279479 0129-4049479: Fax: 0129-2279479 0129-4049479: Fax: 0129-2279479 0129-4049479: Fax: 0129-2279479 0129-4049479: Fax: 0129-2279479 Build Level Material Quantity Concurred P.I.S.T. P.I.P.C. Required Date No. SC's No. CC's % % PROTOTYPE - TOOLED UP - - - PRODUCTION TRIAL RUN START OF PRODUCTION APQP Elements GYR Focus Program Supplier Closed Resp. Remarks or Status Element Need Timing Date Engineer Assistance Required Rating Date Date Initials 1) Design FMEA 25.06.09 25.06.09 A Kalra 2) Design Review(s) A.Kalra 3) Design Verification Plan 25.06.09 25.06.09 A.Kalra 4) Subcontractor APQP Status N.A N.A S.K.Sharma 5) Facilities, Tools and Gages N.A. N.A. S.K.JHA / S.C.Sharma 6) Prototype Build Control Plan 26.06.09 26.06.09 A.K.Singh 7) Prototype Builds 26.06.09 26.06.09 05.07.09 A.K.Tyagi 8) Drawings and Specifications 25.06.09 25.06.09 10.07.09 A.Kalra 9) Team Feasibility Commitment 25.06.09 25.06.09 25.06.09 CFT 10) Manufacturing Process Flow Chart 26.06.09 26.06.09 S.K.J / S.C.S./ A.K.S. 11) Process FMEA 26.06.09 26.06.09 S.K.Jha /A.K.Singh 12) Measurement Systems Evaluation A.K.Singh 13) Pre-Launch Control Plan 20.07.09 20.07.09 A.K.Singh 14) Operator Process Instructions 20.07.09 20.07.09 S.K.Jha /A.K.Singh 15) Packaging Specifications 20.07.09 20.07.09 A.Kalra 16) Production Trial Run 30.07.09 30.07.09 S.K.Jha / A.K.Tyagi 17) Production Control Plan 25.07.09 25.07.09 S.K.Jha /A.K.Singh 18) Preliminary Process Capability Study 30.07.09 30.07.09 S.K.Jha / A.K.Tyagi 19) Production Validation Testing 01.08.09 01.08.09 A.K.Singh / A.K.Tyagi 20) Production Part Approval (PSW ) 5.08.09 5.08.09 A.K.Tyagi /S.K.J./A.Kalra 21) PSW Part Delivery at MRD 15.08.09 15.08.09 A.K.Tyagi / S.K.Jha Head (PDC) A K Singh Head (PDMC) S.K.Jha Head (Manufacturing Operations) S.C.Sharma Head (Tool Engg. Center) Head (Marketing) A.KALRA Head (PRODUCT DESIGN CENTRE) 10.08.2009 A.K. GUPTA Atul Kumar Head (Central Quality Assurance) S.K.Sharma Head (PURCHASE & STA) A K Tyagi 2009 - - SEE NOTE-1 G R LEVER T/LID RELEASE 26.06.2009 25.07.2009 50 NOS. 300 NOS. ON GOING R G G G G G G G G G G G R R R project goahead no:-162 EXISTING R G 5 NOS. R G 30.07.2009 COMMENTS : 1. ALL PARTS ARE COMMON WITH M 01S-8800 EXCEPT DELETION OF LEVER FUEL LID AND ADDITION OF WASHER . 2. 03 NOS. SAMPLES SUBMITTED TO CUSTOMER,FEED BACK AWAITED FROM CUSTOMER END. 3.ANNUAL VOLLUME :6000 NOS, & SUPPLY FROM S3 (PRITHLA PLANT). 4.ELEMENT NO. 6 ,10 & 11 ARE DELAY/RED DUE TO PROJECT GO AHEAD RECEIVED ON JULY 2009. APQP TRAINING PROGRAMME - 29th July -2009 APQP FORMAT
- 6. PLAN AND DEFINE PROGRAM OBJECTIVES Determine customer needs Plan a quality program (which includes Scope, Time, Budget, etc.) INPUT -Voice of the customer -market research -historical warranty and quality information -team experience -Business plan/marketing strategy -Product/process benchmark data -Product/process assumptions -Product reliability -Customer inputs OUTPUTS -Design goals -Reliability and quality goals -Preliminary bill of material -Preliminary process flow chart -Preliminary listing of special product and process characteristics -Product assurance plan -Management support APQP TRAINING PROGRAMME - 29th July -2009
- 7. PRODUCT DESIGN AND DEVELOPMENT OBJECTIVES -Develop design features and characteristic -Critically review engineering requirements -Assess potential manufacturing problems INPUTS -Design goals -Reliability and quality goals -Preliminary process flow chart -Preliminary listing of special product and process characteristics OUTPUTS BY DESIGN RESPONSIBLE ACTIVITY -Design failure mode and effects analysis(DFMEA) -Design for manufacturing and assembly -Design verification -Design reviews -Prototype build – control plan -Material specification -Drawing and specification changes OUTPUTS BY PRODUCT QUALITY PLANNING TEAM -New equipment tooling and facilities requirements -Special product and process characteristics -Gages/testing equipment requirement APQP TRAINING PROGRAMME - 29th July -2009
- 8. PROCESS DESIGN AND DEVELOPMENT OBJECTIVES Develop a comprehensive and effective manufacturing system Ensure that the manufacturing systems meets customer requirements INPUTS -Process failure mode and effect analysis (PFMEA) -Process for manufacturability and assembly -Process verification -Process reviews -Prototype build-control plan -Engineering drawings (including math data) -Engineering specifications -Material specifications -Drawing and specification changes -New equipment tooling and facilities requirements -Special product and process characteristics -Gages/testing equipment requirement -Team feasibility commitment and management support OUTPUTS -Packaging standards -Product process quality system review -Process flow chart -Floor plan chart -Characteristics matrixProcess failure mode and effects analysis (PFMEA) -Pre-launch control plan -Process instruction -Measurement systems analysis plan -Preliminary process capability study plan -Packaging specification -Management support
- 9. PRODUCT AND PROCESS VALIDATION OBJECTIVES Validate the manufacturing process & the product Ensure that customer’s expectations will be met Identify additional concerns INPUTS -Packaging standards -Product process quality system review -Process flow chart -Floor plan layout -Characteristics matrix -Process Failure Mode and Effects Analysis (PFMEA) -Pre-launch control plan -Process instruction -Measurement Systems Analysis Plan -Preliminary process capability study plan -Packaging specification -Management support OUTPUTS -Production trial run -Measurement systems evaluation -Preliminary process capability study - Production part approval -Production validation testing -Packaging evaluation -Production control plan -Quality planning sign-off and management support APQP TRAINING PROGRAMME - 29th July -2009
- 10. FEEDBACK.ASSESSMENT AND CORRECTIVE ACTION OBJECTIVES -To plan the next phase of product development or modification -To improve the system of planning (from lessons learnt) -To identify opportunities for Improvement INPUTS -Production trial run -Measurement systems evaluation -Preliminary process capability study -Production part approval -Production validation testing -Packaging evaluation -Production control plan -Quality planning sign-off and management support OUTPUTS -Reduced variation -Customer satisfaction -Delivery and service APQP TRAINING PROGRAMME - 29th July -2009
- 11. PROGRAM MANAGEMENT TEAM LEADER Each program has a team leader, but a team leader may manage one or more programs. The team Leader :- -should be a senior Production or Quality Manager - interfaces with the customer - ensures that the Program Need Dates (PND) are met - is responsible for resources - is responsible until product launch - forms and manages one or more PPAP Teams PPAP TEAMS -Team should be cross-functional; it is not composed of only people from the Quality Department. Typical members might come from:- - Engineering - Manufacturing operations - Material Control - Marketing - Manufacturing Engg. Centre - Tool Engg. Centre -Customers (as appropriate) PPAP TRAINING PROGRAMME – 13th AUG. 2013
- 12. TGW & BENCHMARK EXERCISE TGW & Benchmarking helps to make the product trouble free & robust / eligent Following to be captured during TGW & Bench Marking :- Identify the gap between current status and the benchmark, Collect data and summaries :- ROLE OF TGW BENCHMARKING IN PROCESS :- 1. Helps to Remove/ minimize the JIG –JAG process, 2. Max.operation in Min. stages, 3. Mistake proof / fool proofing in the process 4. Process will be safe, fast, cheaper, easy & short time. 5. Process will meet the specifications 100% PPAP TRAINING PROGRAMME – 13th AUG. 2013
- 13. ROLE OF TGW & BENCHMARKING IN PRODUCT RELIABILITY Its provide a better methodology related to testing of the Product, To reduce the frequency of repair / replacement of the product and the results of long-term reliability / durability. ROLE OF TGW & BENCH MARKING IN DESIGN :- - Easily Manufacturable - Fitment wise - Functional performance - Dimensions - Weight - Materials - Aesthetic PPAP TRAINING PROGRAMME – 13th AUG. 2013
- 14. THANKS