Project description

The project involves the transfer of 52 progressive dies for the manufacturing of parts for,
subsequently, carry out assemblies and finally be part of bodies.

Basically, for each of the dies, the corresponding PPAP was carried out. To accomplish this
the activity was related to the areas of quality, metrology, logistics, production, process, and even
maintenance.

What is a PPAP?

Purpose

The Production Part Approval Process (PPAP) is to define the general requirements for
the approval of parts for production, including materials for production and in bulk.
The purpose of a PPAP is to determine if all specification requirements and design records of the
clients are understood appropriately by the organization and that the manufacturing process has the potential
de fabricar productos que cumplan en forma consistente con estos requerimientos, durante corridas de
current production and the quoted production ratio.

Characteristics

The PPAP is required by the client when one of the following cases arises:

Development of a new product or assembly by the supplier.

Correction of non-conformities in previous presentations of the PPAP.
Update or replacement of specifications by the client or the supplier.
Use of a material, process, or component different from those previously used in products.
approved.
Significant production or modification of the tools used to manufacture the product.
Inspection of an element, material, or component not inspected in previous presentations of the
PPAP.

Requirements for PPAP

The organization must comply with all the requirements for PPAP specified and listed below, 18
main points:
Design Records
2. Engineering Change Documents
3. Client Engineer Approval, if required
4. AMEF's Designs
5. Flow Diagrams of the Processes
6. AMEF of Processes
7. Control Plans
8. Studies on Measurement Systems Analysis
9. Dimensional Results
10. Material Test Results, Performance
11. Initial Process Studies
12. Documentation of Qualified Laboratories
13. Appearance Approval Report
14. Muestras de Producto
15. Master Samples
16. Assistance for Checking
17. Compliance Records 1
18. Certificate of Issuance of a Part (PSW)
Requirements description

1.-Designregistration.

It is necessary to have all the design records of the products, including the design records themselves.
components or product details. When design records are in electronic format,
(CAD/CAM), the organization must reproduce copies of these (e.g., diagrams, tolerance sheets and
Geometric Dimensioning and Tolerancing (GD&T), drawings to identify the measurements taken.

In 'THE COMPANY', the design registration refers to two documents:

Plan that includes the characteristics of the part as well as its respective tolerances, number and
the name of the part and the second refers to
Format in which the engineering level is described, where two are managed: TM and TZ, which they do.
reference to the degree of review and changes in the design; these 'codes' of engineering level are
managed by AUDI AND VW.

[Link]

Authorized engineering change documents must be available for those changes where
they have not yet been recorded in the design documents but are already incorporated into the product,
part or tool.
In case there is no engineering change, a 'WAIVER' is issued, which is a temporary waiver.
In this way, it is justified that there has not been an engineering change in the product on the part of the client.
This manner serves to justify in front of an audit and/or future reviews.

[Link]'sapproval,ifrequired

When specified by the client, the organization must have evidence of approvals from
client engineering: in this case, we also handle two documents:
Feature matrix: it includes those critical features that need to be reviewed in the
piece for example punches, oblongs, slots, burrs, among others, and the measurement must be added
nominal as well as its tolerances.

TRY-OUT: "Birth certificate" is prepared this document where it shows how they were
conditions for the release of the process in which the main information is the number and name of the
parte, nivel de ingeniería, las medidas de la herramienta, nombre del proyecto, características del material,
the advance, the pressures from the press among others, in the end I will show the document that is made so that
make it more understandable.

[Link]'sDesigns

The organization with responsibilities for designing must develop AMEF'S of Designs in accordance with, and in
compliance with the requirements specified by the clients, in case the organization does not have
this responsibility is likewise carried out with a "WAIVER" referring to this point.

[Link]

Flow process diagrams must be created in the format specified by the organization itself and
that clearly describe the steps and sequences of the production processes, as appropriate and
in addition, they meet the specified needs, requirements, and expectations of the client.

[Link]'sofProcesses 2
The FMEA should be written by part number. If an FMEA is generated by families, the organization must
conduct regular reviews of the documentation. When there is a complaint or a new failure in the
the process must involve an analysis of the possible solution or how to avoid this problem and not continue or
advance to a greater severity.

[Link]

It is necessary to have Control Plans that define all the methods used for process control.
the same and meet the requirements specified by the clients.
The control plan goes hand in hand with the FMEA.

[Link]

All measurement equipment and gauges used in the process must be evaluated as follows
tests:
R&R
Accuracy or Bias
Linearity
Stability
Such tests must be carried out by the metrology department and must be documented.
approved by the client.

[Link]

There is evidence that the dimensional checks required by the design records and the
Control plans have been completed, and the results indicate compliance with requirements.
specified. Those dimensional results are issued by the metrology department and will be
approved by the client. For this, CMM is used to report the dimensions of the part
just as there must be a similarity between the dimensions made by them.

[Link]

The organization must conduct tests for all parts and materials of the products, when
specify chemical, physical, or metallurgical requirements in the design records or in the Plans of
Control. The most common thing is that this result of materials is issued by our client since they...
and the type of material that should be used in that process as well as the characteristics.

[Link]

The initial skill or performance level of the processes must be established at the acceptable level prior to
the issuance for all Special Characteristics designated by the customer or the organization. The
The organization must obtain agreement with the client on the index to estimate the initial skill of the
prior process to issuance.
It is necessary to conduct an analysis of measurement systems to understand how errors in measurements affect
the measurements of the studies.
At this point, we handle the skill diagrams or better known as CP and CPK, which we
allows to qualify the variability of the product and process. This is done by measuring 30 pieces and the
parts to be measured with those critical characteristics described in the characteristics matrix, in this way
It can be demonstrated that one can carry out and perform a stable process that meets the characteristics of
our client. 3
 [Link]

The tests for PPAPs must be carried out by qualified laboratories. Qualified laboratories (internal
or external to the organization) must have a scope and documentation of them, showing that
they are qualified for the types of measurements or tests conducted. In this case, we turn to:
CIDESI - Chemical analysis
UPAEP - Mechanical properties

[Link]

A separate Appearance Approval Report must be completed if the product/part has

appearance requirements in design records.
In our case... a WAIVER is again executed

ProductSamples

Sample products must be offered as specified by the customer. Parts produced in the release of
processes that are within specification. These parts will be evaluated by the client. They are taken
physical sample pieces and also through digital means for visual aid.

[Link]

Each release must retain a master sample for the same period as the approval records.
the part for production, or
until a new master sample is produced for the same customer part number and for
approval by the client himself, or
b) when a sample is required by the design records, by the Control Plans or by the
inspection criteria, as a reference or standard. The master sample must be identified as
such, and must show the client's approval date on the sample itself. Generally, this piece is
signed and approved by the client.

[Link]

For operational assistance, it is necessary to certify that all aspects of the assistance for verification match.
with the dimensional requirements of the part in question. We prepared the following documents
just as they are also visual aids.

Inspection receipt record

Release process register
Production inspection record
Packaging sheets
Inspection sheets

[Link]

The organization must have records of compliance with all specific requirements of the
clients that apply to you.
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 [Link](PSW)

At the completion of all the requirements of a PPAP, the organization must complete the Certificate of
Issuance of a Part (PSW). A PSW must be completed separately for each number.
The PSW is the final guarantee and document with which a project is concluded.

Well, a small description of each point that makes up a PPAP has finally been completed.
To conclude, I leave a practical case for better understanding.

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PPAP Practical Case
1DesignRegistration
Technical drawing of the piece:

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Design registration: The engineering levels that are available are registered; as I mentioned before, the engineering levels.
they refer to the degree of review and changes that have been made to the tool.

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[Link]

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 [Link],ifrequired

Preparation of TRY-OUT: Pressures (clutch brake, balancing cylinder, feeder pressure and machine pressure)
Dimensions of the tool, characteristics of the material, and of the press are the main data that should be noted in this.
format.

Feature matrix: format where

document the critical dimensions that need to be
control in the part, since some variation
considerable can affect the assembly that is
I was able to do.

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 DesignAMEF's

A design FMEA is only carried out when the organization

is part of the design of the tool; in this case it is not.
a WAIVER is issued.

[Link]

It describe the process from the receipt of raw materials until

vessel.
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 [Link]'sofProcesses
The FMEA is carried out according to the specifications cited by the customer.

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 [Link]

The methods used to control the process must be defined in such a way that they meet the specifications of the customers.

[Link]

In this section, dimensional reports must be made for all those devices
that are used in the process.
In this case, I should include the reports of Vernier, micrometer, and dial indicator.
The activity is the responsibility of metrology. (I just put a brief format, it would be too much)
extended the display of each dimensional report

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[Link]

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As I mentioned, they are sent to laboratories where the material composition of this is explained.
way ensures that there is control of
MP also has an environmental purpose.

[Link]

This study called CP and CPK must be performed where stability and control are tested.
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our process; is carried out with 30 pieces, and we must take measurements of those characteristics
Critiques such as being punched, oblong, grooves. This format is available and I will include the table at the end.
where it specifies what the minimum is for it to be accepted.

[Link]

Specification of the material provided by the client.

[Link]
Approvalof
Appearance

Samplesof
Product
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 [Link]

Parts approved and signed by the client.

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 16.

CheckupAssistance

Sheets for help and check on the

process the which is used by the
operator and auditor, where he records that
the process meets the
client specifications.

17. Recordsof
Compliance
This record is issued and provided
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by the client once it has been
Authorized and released the process, this way the serial run can begin.
product.

[Link](PSW)

As can be seen, in the preparation of a PPAP, there are documents that can be created from
individual form; but others like the case of AMEF'S and Control Plan need to be carried out.
together with a multidisciplinary team, since each member knows the process therefore it will be
easier to detect any anomaly throughout the entire production process.