How to Implement PPAP

O

Oskar_S

#1
Well, now I have been working with PPAP for a week. The goal is that I will help the project department getting a full PPAP for all their new project. This is what I have done, so far.

1)Made a guideline with easy to read and understand demands for each "PPAP requirement" also added a column that shows which requeirements affects each others. Made a clarification on what deparment is responsible for completing each "PPAP requirement". I also stole the PPAP templates from the "sticky" and changed all logos. NOW IT's MY TEMPLATES :D
2) Made a timeframe connected to the differents stadiums of project development.

What is the next step???? A major problem is that it doesn't exist good control plans, no one used FMEA before, none of Design Records are marked out with specific charistiristics and so on.....:bonk:
 
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Howard Atkins

Forum Administrator
Staff member
Admin
#2
Please Please

Despite the fact that PPAP is called a process the real process is in the APQP system and the PPAP is only the documentation of the actions taken in the development of part and process.

However pretty the pieces of paper you are putting the cart before the horse.
You need to study APQP and its stages and tools before you can report the actions in the PPAP documents.
Start ith APQP and FMEA get the TEAM on board and start to work.
Please come back search for answers and ask questions we will help but with no Control Plans or FMEA then you are not ready for the PPAP stage
 
J

JaxQC

#3
Nicely put Howard. Another way of looking at it Oskar is that your group needs to look at what you’re going to build & how it works (GD&T on print, DFMEA, materials), how you are going to make it (Process Flow), what can go wrong (PFMEA), how you are going to control the process so it doesn’t happen (Control Plan, approved suppliers, CoC’s), how reliable / sure are you that your measurement & audits are going to catch a problem (Gage R&R) and if something does start occurring…how do you find it prior to your Customer (scrap review, follow-up). The forms will help make sure that everyone is doing the same and don’t skip a step but don’t let them dictate you quality. Define it and then the forms will naturally follow as to what you need to control.
 
O

Oskar_S

#4
Ahh, Well I have studied the AQPQ, MSA, SPC -manuals so I know the background. The thing is that we have 2 Black Belt guys trying to fix everything needed (Now it's a complete jungle with half finished documentation) so my part is just to sell in how good PPAP would be for the project department and serve them with easy understanding documentation.
 

qusys

Trusted Information Resource
#5
Well, now I have been working with PPAP for a week. The goal is that I will help the project department getting a full PPAP for all their new project. This is what I have done, so far.

1)Made a guideline with easy to read and understand demands for each "PPAP requirement" also added a column that shows which requeirements affects each others. Made a clarification on what deparment is responsible for completing each "PPAP requirement". I also stole the PPAP templates from the "sticky" and changed all logos. NOW IT's MY TEMPLATES :D
2) Made a timeframe connected to the differents stadiums of project development.

What is the next step???? A major problem is that it doesn't exist good control plans, no one used FMEA before, none of Design Records are marked out with specific charistiristics and so on.....:bonk:

You should evaluate the orders of the Customers and then go with APQP and PPAP.
PPAP is composed of several documents ( including Control Plan, FMEA , Process flow, MSA and so on), that have to be signed off by your Customer.
:bigwave:
 

Caster

An Early Cover
Trusted Information Resource
#6
What is the next step???? A major problem is that it doesn't exist good control plans, no one used FMEA before, none of Design Records are marked out with specific charistiristics and so on.....
As others have said, if a strong APQP process is in place, PPAP becomes a clerical exercise in collecting the documents.

However, I feel your pain. I think for a lot of companies, the PPAP becomes the only focus because the customer demands it before you get paid. Any possible value from a good APQP is of course lost.

So if that is the case, here is my idea to start "backwards" and assemble the required documents.

Start with the inspections and tests you are already doing on the part. Somewhere, someone must have looked at customer requirements to come up with these I & Ts.

From this list create a simple control plan that includes just these inspections and tests. A few pages is enough to start.

From this control plan you can easily create a process flow. Just put things in the order of operations.

Then create an FMEA for each item on the control plan. Keep it simple to start. The idea is that everything on the CP should have come from a high RPN on the FMEA, so you are creating this in reverse.

Do family MSAs for each TYPE of gage on the control plan.

There you have it - the least you can do. It may be enough for now, it is amazing how bad a PPAP some customers will accept and sign off on. You get paid, and you can improve with each subsequent PPAP (or not).

If you want to take the next step, look at the blueprint for customer required measurements, and look up all test specifications for required tests, make sure they are all covered. This will add some heft.

Then for even more, add in your process control steps to the the Flow/FMEA/CP triad (heat treat, machining speeds and feeds, paint, etc). This is where the real focus should have been in the first place, how you control the process to ensure a good part is made, but most of us limit things to measuring only features that the customer asks for. They are called process control documents, not part control documents after all.

This can even be a one man band effort. It should have come from a team effort, but sometimes you just have to get it done.

Hopefully your APQP process will develop and the rightful owners will step up and take over.

Good luck!
 
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