TRAINING ON
AUTOMOTIVE CORE
TOOL
ADVANCED
STATISTICAL PRODUCT
PROCESS QUALITY
CONTROL(SPC) PLANNING
(APQP)
AUTOMOT
IVE CORE MEASUREMENT
SYSTEM ANALYSIS PPAP
TOOLS (MSA)
FAILURE
MODE
CONTROL
EFFECTIVE
PLAN
ANALYSIS
(FMEA)
PPAP
• PPAP is a common acronym which stands for
Production Part Approval Process.
• Production Part Approval Process is used in the
WHAT IS supply chain for establishing confidence in suppliers
PPAP? and their production processes.
• PPAP is used worldwide in range of industries
including automotive, heavy truck, agriculture etc.
• The purpose of PPAP is to:
1. Determine that supplier understand engineering
requirement for a particular part.
2. Verify that the supplier process is capable to meet
those requirements in full production.
• New
Part
Develop
ment.
• The correction of • Change in tier-
discrepancy in
WHEN IS previous PPAP
submission
2 suppliers.
PPAP • Customer Initiated
• 12 months
inactive.
USED? Engineering
Changes. • Change in
inspection
method.
Alternate Material
Tool modification.
• Supplier initiated
changes w.r.t to
following.
c. Upgrade or rearrangement in process.
d. Transferring the equipment or tool in different facility.
• New Source of
Raw Material
WHAT IS PRODUCTION ?
• PRODUCTION PART APPROVAL PROCESS.
• Parts are made
a. At production site. e. With regular production process
b. At production rate. f. With production material.
c. Using production tool. g. With production operators.
d. Production Gauging
• Samples shall be drawn from significant process run which
is
1 to 8 hours duration.
minimum after production run of 300 parts.
As per customer requirement.
WHAT ARE THE CONTENTS OF PPAP?
• There are 18 standard element available in PPAP package & not all 18 apply to every
situation.
• Customer may have additional specific requirements or eliminate some requirements
which are not applicable
a. Design Records. j. Material & Performance Test Results.
• Following are the 18 elements :
b. Authorized Engineering Change k. Initial Process Studies.
Documents.
l. Qualified Laboratory Documents.
c. Customer Engineering Approval.
m. Appearance Approval Report.
d. PFD.
n. Sample Production Parts.
e. DFMEA.
o. Master Samples.
f. PFMEA
p. Checking Aids
g. Control Plan
q. Customer Specific Requirements
h. MSA
r. Part Submission Warrant.
i. Dimensional Result
WHAT ARE THE LEVELS OF PPAP?
• There are 5 levels of PPAP & following are the level
requirements :
Level 1: Part Submission Warrant (PSW) only
submitted to the customer. (Catalogue products)
Level 2: PSW with product samples and limited
supporting data.
Level 3: PSW with product samples and complete
supporting data.
Level 4: PSW and other requirements as defined by
the customer.
Level 5: PSW with product samples and complete
supporting data available for review at the supplier’s
manufacturing location.
fmea
FMEA
• FMEA is basically “Failure Mode Effect Analysis”
• It is step by step process for identifying all possible failures
• It is common risk assessment & mitigation tool.
• A FMEA list all potential failures, along with their Severity, Occurrence &
Detection level ranking on scale from 1-10.
• Multiplication of ranking of Severity, Occurrence & Detection level is
known as Risk Priority Number (RPN) : S x O x D (which is minimum Min
=1 & Max = 1000). When RPN > 100 corrective action is required to
reduce the RPN value within acceptable range.
• FMEA is carried out for Design & Process
FMEA carried out for design in known as DFMEA(Design Failure Mode
Effective Analysis).
FMEA carried out for process in known as PFMEA(Process Failure Mode
SEVERITY EVALUATION CRITERIA
OCCURRENCE EVALUATION CRITERIA
DETECTION EVALUATION CRITERIA
Dfmea
DFMEA
• DFMEA is basically “Design Failure Mode Effect Analysis”
• It is a type of FMEA that focuses on the design of the product to reduce
the risk of product failure.
• The “Design Failure Mode Effective Analysis” is only submitted by
supplier who are responsible for design.
• For a new product, Design FMEA should start with product design and
before prototype manufacturing.
• A good DFMEA needs to be conducted by the cross-functional team and
led by the responsible product design engineer.
• The other departments should include Testing Analysis Engineer,
Production, Supplier Quality, Product Quality, Service and Logistics.
DFMEA EXAMPLE
pfd
PFD – PROCESS FLOW DIAGRAM
• PFD is basically “Process Flow Diagram”
• It is schematic representation of production
process steps in order they occur from receiving of
raw material to shipping of finished products.
• PFD helps people to see the real process.
• Each process are defined with process number.
• The process numbers are taken reference in
PFMEA & Control Plan.
PFD EXAMPLE
pfmea
PFMEA
• PFMEA is basically “Process Failure Mode
Effect Analysis”
• The Process Failure Mode and Effect Analysis
(PFMEA) is a risk assessment method used
to analyze and evaluate potential failure modes of
processes and drive corrective action to prevent or
decrease the possibility of defects being delivered
to the customer.
• PFMEA takes the process sequence reference from
PFD.
PFMEA EXAMPLE
REVISED FMEA ACTION PRIORITY(AP) GUIDELINES AS IATF 16949 - 2019
control plan
CONTROL PLAN
• Control Plan is basically a written description of system for
controlling the process quality.
• It includes product & process characteristics with proper
specifications, controls, controlling methods & actions to be taken
if any non-conformance observed in the said characteristics.
• There are 2 types of control plan
Pre-launch Control Plan.
Post-launch Control Plan.
CONTROL PLAN EXAMPLE
msa
MSA
• MSA is basically “MEASUREMENT SYSTEM ANALYSIS”.
• MSA is defined as an experimental and mathematical method of
determining the amount of variation that exists within a
measurement process.
• MSA is used to certify the measurement system for use by
evaluating the system’s accuracy, precision and stability.
• In MSA, the major factors calculated are Equipment Variation,
Appraiser Variation, Part Variation, Gauge R&R% & NDC(Number of
Distinct Categories)
MSA FORMAT FOR VARIABLE DATA
MSA
FORMA
T FOR
ATTRIB
UTE
DATA
SPC
SPC
• SPC is basically “STATISTICAL PROCESS CONTROL”
• Statistical Process Control is monitoring & detecting changes in
processes.
• SPC provides a very easy method in understanding whether the
process is stable & in control.
• SPC is carried out majorly for critical characteristics.
WHY SPC IS NEEDED
• Reduce scrap or rework.
• Improve overall quality of part.
• Increase productivity.
WHAT IS Cp & Cpk
SPC
FORMA
T