B
Hello.
We are a TS16949 company. I am working with a supplier of lead (Pb) alloys. For new product development the supplier made a single kettle of the custom alloy. So the process for making this alloy has only been done once, with process controls in place and a single content test at the end. This kettle supplied enough lead to make a large number of finished products that all passed testing. We are now working on a production PPAP, but we can't complete it until we have all our supplier PPAPs.
1. How do I complete a PPAP when the bulk material was only tested once? Can I count all the testing of the finished products that the alloy went into?
2. What is the point of the Bulk Material Checklist (section F.3) anyway? As far a I can tell it lists all the same things as the normal PPAP checklist in Table 4.2.
3. Since this is a custom alloy, there is an element of design work in it. Basically, Engineering has told the supplier they want x% of Element A and y% of Element B, etc. Since the supplier is just "building to spec" should I ask them for design documentation? I would guess no, but I welcome any thoughts.
4. So far the supplier's PPAP consists of test results, flow diagram, control plan and PFMEA. Am I missing anything?
5. Alloy testing is done with an Optical Emission Spectrometer. I believe this counts as a "standardized test" as discussed in section F.9. So gage R&R is not required. Your thoughts?
Thanks for the feedback.
We are a TS16949 company. I am working with a supplier of lead (Pb) alloys. For new product development the supplier made a single kettle of the custom alloy. So the process for making this alloy has only been done once, with process controls in place and a single content test at the end. This kettle supplied enough lead to make a large number of finished products that all passed testing. We are now working on a production PPAP, but we can't complete it until we have all our supplier PPAPs.
1. How do I complete a PPAP when the bulk material was only tested once? Can I count all the testing of the finished products that the alloy went into?
2. What is the point of the Bulk Material Checklist (section F.3) anyway? As far a I can tell it lists all the same things as the normal PPAP checklist in Table 4.2.
3. Since this is a custom alloy, there is an element of design work in it. Basically, Engineering has told the supplier they want x% of Element A and y% of Element B, etc. Since the supplier is just "building to spec" should I ask them for design documentation? I would guess no, but I welcome any thoughts.
4. So far the supplier's PPAP consists of test results, flow diagram, control plan and PFMEA. Am I missing anything?
5. Alloy testing is done with an Optical Emission Spectrometer. I believe this counts as a "standardized test" as discussed in section F.9. So gage R&R is not required. Your thoughts?
Thanks for the feedback.