沃尔沃汽车流程05-Phased PPAP process VCC CH_EN

VCC Phased PPAP process 沃尔沃汽车Phased PPAP流程

COURSE OVERVIEW 课程概述This course describes the purpose and applicability of
VCC Phased PPAP(Production Part Approval Process)PPAP PPAP order order R@R R@R Ph0+ Ph0+ Ph1/2 Ph1/2 Ph3 Ph3
Section1: General introduction to PPAP/PPPAP简介 Section2: VCC Phased PPAP Introduction VCC阶段PPAP介绍? ? ? VCC phased PPAP 沃尔沃阶段PPAP Supplier Roles & Responsibilities 供应商角色和职责 Submission to Customer + Exception management 递交客户和让步管理流程
Section3: Phased PPAP Benefits 阶段PPAP的优势? ? Difference between PPAP & VCC Phased PPAP PPAP和阶段PPAP的差别 Phased PPAP handbook 阶段PPAP手册
VCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 2

Section 1: General introduction to PPAP PPAP简介
Purpose for this Section: ? PPAP Introduction
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What is PPAP? 什么是PPAP

PPAP stands for

?Production Part Approval Process (PPAP 是生产件批准程序）

PPAP defines

?Generic requirements for production part approval.（PPAP 定义了生产件批准的基本要求）Purpose of PPAP

?is to determine if all customer engineering design records and specification requirements are properly understood by the organization

评估组织是否完全理解客户所有的设计和技术要求

?is to ensure that the manufacturing process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate 保证在确定的产线上有能力生产出稳定的满足客户产品

PPAP shall apply to sites supplying:

?Production and Service parts. (PPAP 适用于生产件和售后件)

The 18 PPAP Elements/PPAP的18项要素1. Design Records 2. Engineering Change Documents 3. Engineering Approval 4. Design FMEA 5. Process Flow Diagrams 6. Process FMEA 7. Control Plan 8. Measurement System Analysis Studies 9. Dimensional Results 10. Records of Material / Performance Test Results 11. Initial Process Studies 12. Qualified Laboratory Documentation 13. Appearance Approval Report 14. Sample Production Parts 15. Master Sample 16. Checking Aids 17. Customer-Specific Requirements 18. Production Part Approval Process Submission Warrant (PSW)
The above section numbers are in alignment with the AIAG published PPAP 4th Edition ManualVCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 5

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When is submission of PPAP required?什么时候需要递交PPAP is to be submitted for:

? A new or modified part 任何新的或更改的零件

?Process or material changes 任何工艺和材料的变更

?Correction of a deviation to spec on a previously approved part.对之前的临时认可的产品的更正

?Volume increase or change in supplier capacity.供应商产能的增加或改变?Site Relocation 生产场所的变更

Note that:

?The Supplier must notify VCC using the Supplier Request for Engineering Approval (SREA) or Supplier request for Industrial Change Approval (SRICA)

供应商变更需按照沃尔沃“SREA”或“SRICA”流程进行

?

The Supplier is required to notify the STA Engineer of any changes after initial PPAP approval 有任何初始PPAP 批准后发生的变更，供应商必须通知STA

Section 2: VCC Phased PPAP Introduction 沃尔沃Phased PPAP介绍
Purpose for this Section: ? VCC phased PPAP ? Supplier Roles & Responsibilities 供应商角色和职责 ? Submission to Customer + Exception managementVCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 8

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?VCC Phased PPAP is a VCC approach to PPAP process management VCC Phased PPAP 是VOLVO 管理PPAP 流程的方式

?Introduced to improve launch performance 目的是提高项目启动开发效率?Requires a supplier site to demonstrate 要求供应商的现场满足

?Manufacturing/geometry capability 生产和尺寸稳定的能力

?Product quality 产品质量

?And production capacity 产能要求

?…prior to job #1在job #1之前

?Is derived from the Ford process but is not equal to it. It is important to ensure that the Volvo Car Corporation version is always used for Volvo Car Corporation business as both are NOT interchangeable.

?是从Ford 起源但并不相同，所有VCC 的供应商必须使用VCC 的版本。What is VCC phased PPAP?

VCC PHASED PPAP TIMING 时间节点PPAP PPAP order order R@R R@RRun-at-Rate
Ph0+ Ph0+Phase 0 + Geometry verification
Ph1/2 Ph1/2Phase 1 Quality Verification Phase 2 Production Verification
Ph3 Ph3Phase 3 Capacity Verification
Geo Geo++capability capability PV PVtesting/ testing/AAR AAR
R@R
mrd
mrd
mrd
TT = Tooling Tryout 工装验证 PP = Pilot Production 试生产 mrd = Material Required Date 产品需求日期VCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 11
MP1 = Mass Production 1 量产1

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Timing 时间节点

?

Specific timing dates for PPAP are set by each program team.VCC 项目小组会定义PPAP 的详细时间节点?Suppliers are required to communicate planned PPAP timings that supports the program build mrd dates to the responsible Purchaser.

供应商与对应的采购沟通，获取能满足项目MRD 日期的PPAP 时间节点

–PPAP Phase 0 + geo should be submitted by TT mrd (Tooling Trial)

–PPAP Phase 1/2 should be submitted by PP mrd (Pilot Production)

–PPAP Phase 3 should be submitted one week prior to MP1 (Job #1)

?If the supplier cannot support the sample promise date, the supplier must communicate new timing to the Program STA Engineer

如果供应商不能满足确认的样件递交日期，必须和项目STA 沟通并确定新的节点

?If the parts are not approved at PP mrd (Ph1) the supplier must request a customer approval (TPD) prior shipment. (required by ISO/TS 16949)

如果供应商产品没有在试产日期前批准，必须在交货前申请临时认可（TPD ）

?The supplier will then support the program with parts shipped with TPD and

Interim PSW Approval until PPAP is fully approved.

供应商在PPAP 完全认可之前，按照临时的TPD 和临时PSW 交货

VCC PHASED PPAP PROCESS MAPPPAP PPAP order order R@R R@RRun@RatePlanned timing for all PPAP phases PPAP Confirmation
Ph0+ Ph0+Phase 0+ Geometry Verification 尺寸验证145678Design Records Design FMEA Process Flow Diagrams Process FMEA Control Plans Measurement System Analysis Studies 9 - Dimensional Results 11 - Initial Process Studies PPAP Warrant (Ph0+)
Ph1/2 Ph1/2Phase 1 Quality Verification 质量验证Continue PPAP using parts from R@R Parts made during Phase 1 must meet all 18 PPAP Requirements for one production stream. PPAP Warrant (Ph1)
Ph3 Ph3Phase 3 Capacity Verification 产能验证Normal Weekly Capacity requirements fulfilled PPAP Warrant (Ph3) Capacity Analysis Report
4567-
Design FMEA Process Flow Diagrams Process FMEA Control Plans
Capacity Analysis Report
Phase 2 Production Verification 生产验证Run@Rate for all production streams Quality Verification for all production streams PPAP Warrant (Ph2)VCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 13

PPAP Order/ Confirmation PPAP order确认
Objective 目标: Confirm planned timings for all PPAP phases are in line with VCC build/program requirements 确定满足项目时间节点的 Phased PPAP的时间节点 Required Inputs 要求的输入: ? Part Folder For Supplier (PFFS) sent 供应商产品数据包已发放 ? PPAP Confirmation order sent PPAP需求已发放 Timing 时间节点: ? Orders should be placed in time to meet: Order必须及时发放并预留以下时间： – Purchasing of tooling, equipment, installation, fixtures, etc 工装，设备，夹具的购买和安装 – Purchase of raw material/ingoing Components 原材料和采购件的购买 – Process preparation (PFMEA > Control plan, operator instruction, workforce training, etc) 工艺的准备（PFMEA,控制计划，培训等.) System 系统: ? Timings updated in SI+ 时间节点更新至SI+系统
PPAP PPAP order order
VCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 14

Run-at-Rate (R@R) 节拍生产Objectives 目标: To confirm that all production input requirements are available and understood, and can support a limited production run.
R@R R@R
确认所有生产所必需条件可用并理解，并且能支持条件生产Required Inputs要求的输入: ? Trained Supplier production Operators.培训合格的操作工 ? Sub-supplier material status from Tier-x , Phase 1.下级供应商必须是Phase 1 ? Quantity of parts required as defined by Customer (default 300 consecutive parts). 产品数量由客户定义（默认300件） ? Job 1 location (final site & line).必须是Job 1的生产场所（即最终的场所和产线） ? Planned production cycle times required to support NWC.计划的满足NWC的生产节拍 Timing 时间节点: ? R@R timings supports geo/capability verification before MRD R@R的时间必须能确保后续在前完成geo/capability的认可 Documents 文件: ? Capacity Analysis Report requirements fulfilled 完整的产能分析报告 System 系统: ? CAR reported to site STA 产能分析报告提交给STAVCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 15

RUN-AT-RATE
Tools
Op. 10
Op. 10
Op. 10
Op. 10
160 200 sec. Assembly Lines EOL Testing
200 sec.
200 sec.
200 sec.
Run-at-Rate successfully completion includes:Capacity Analysis Report Submission to STA R&R的完成包括 CAR递交给STA
Op. 20
Op. 20
100 80 sec. sec.Op. 30
100 sec. 50 sec. 40 TACT
Supplier SiteCustomer Plant Normal Weekly Capacity: 2700 vehicles planned
Overall Equipment Effectiveness (0.85) pull Samples
Basis for all external suppliersVCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 16
TAKT 60 sec.Basis for all JIT suppliers (Just-in-Time)

PPAP Phase 0 +
Ph0 Ph0+ +
Objectives 目标: To confirm geometry design record and specification requirements are properly understood by the Supplier.
确认供应商正确的理解尺寸和技术要求To provide an early indicator that the design of the process/tool/facility has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate by operating a minimum of one selected production stream. 通过最少一个条生产线的生产（按设计的生产节拍），初次评估供应商工艺/ 工装/设备的设计的稳定性。 Required Inputs 要求的输入: ? Parts produced during R@R / R@R时生产的产品 ? Parts geometrically in spec (5 parts measured) 产品尺寸合格（测5件） ? Process capable (short term capability > 1.67) 过程能力合格（PPK>1.67) Timing 时间节点: ? To be completed before MRD 在 MRD 前完成VCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 17

PPAP Phase 1Utilizes parts produced during R@R.使用节拍生产时的产品 Objectives目标: To confirm all customer design record and specification requirements are properly understood by the Supplier.
Ph1 Ph1
确认供应商是否正确的理解所有的设计和技术规范To provide an early indicator that the design of the process/tool/facility has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate by operating a minimum of one selected production stream. 通过最少一个条生产线的生产（按设计的生产节拍），初次评估供应商工艺/工装/ 设备的设计的稳定性 Required Inputs要求的输入: ? Successful completion of Phase 0 + for at least one work stream 批准的Phase 0 + 以及至少一条产线的生产 ? Tier “X” successful completion of Phase 1 下级供应商已经完成Phase1 ? IMDS reporting complete (part of customer specific requirements) IMDS完成 Timing时间节点: ? To be completed before MRD 在 MRD 前完成 Documents文件: ? PSW Phase 1 or Interim PSW Phase1 PSW 或者临时PSW
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PARTS PRODUCED FOR PHASE 0 ARE USED FOR PHASE 1
Tools
Op. 10
Op. 10
Op. 10
Op. 10
160 200 sec. Assembly Lines EOL Testing
200 sec.
200 sec.
200 sec.Quality Verification:(Phase 1)
Op. 20
Op. 20
100 80 sec. sec.Op. 30
100 sec. 50 sec. 40 TACT
Verify that all 18 Requirements of PPAP are met for at least one production stream. 确认至少一条产线符合 PPAP的18项要素
Supplier SiteCustomer Plant Normal Weekly Capacity: 2700 vehicles planned
Overall Equipment Effectiveness (0.85) pull Samples
Basis for all external suppliersVCC Phased PPAP Process_v2, 53200, Andreas Tomic, atomic Issue date: 12/Jul/2011, Security Class: Public Page 20
TAKT 60 sec.Basis for all JIT suppliers (Just-in-Time)

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PPAP Elements for PPAP Ph1阶段1的PPAP 要素Phase 1: Quality Verification 质量验证

The following marked PPAP requirements must be achieved 下续PPAP 要素需完成1 Design Record 设计记录

2 Engineering Change Documents 工程变更文件

3 Customer Engineering Approval 客户批准文件

4 Design FMEA 设计FMEA

5 Process Flow Diagrams 过程流程图

6 Process FMEA 过程FMEA

7 Control Plan 控制计划

8 Measure System Analysis Studies 测量系统分析

9 Dimensional Results 尺寸报告

10 Material test report 材料测试报告11 Initial Process Studies 过程能力研究

12 Qualified Laboratory Documentation 实验室认可文件

13 Appearance Approval Report 外观批准报告14 Sample production Parts 生产件15 Master Sample 标准样件16 Checking Aids 检具17 Customer specific Requirements 客户特殊要求

18 PPAP Submission Warrant PSW