PPAP Process Requirements-Significant Production Run

S

Sarang

#1
We have just started working towards getting QS in the company. We have never done any PPAP before and our knowledge base in that area is very limited. I plan to start off with PPAP in a couple of weeks. I went through the manual and it seemed too ambiguous to me. The very first requirement:

"I.2.1 Significant Production Run:
Product shall be taken from a specific production run. Production run shall be from one hour to eight hours of production, and with specific production quantity to total a minimum of 300 consecutive parts. "

is eating my guts out for the last few days. Could someone explain this requirements to me in plain and simple english? PLEASE!!!

Thanks in advance.
 
Elsmar Forum Sponsor
#2
My understanding;
When all required customer approvals have been received,i.e.,Engr. Samples, Prototypes,Pre-launch and production is scheduled, then production runs 300 consecutive parts. From these 300 parts the required data for the PPAP is generated.
Depending the type of product you are producing you may get some relief from your customer on the quantity of parts to run.
At a previous company we called this run a "Pilot Lot" which we would place on hold until the PSW was approved.
 
S

Sarang

#3
Thanks Sam,
We make custom truck bodies and trailers. Most of our customers have altogether different specifications. Some of our customers do order in bulk, say 50 bodies or so. Where do I get 300 production parts from??? What kind of relief do I ask my customers for?? Is there any specific way to get something relieved?
Help me before I bang my head into a wall!!
 
L

Laura M

#5
We had a product with less than a 300 piece order. The customer waived the 300 piece requirement. The 1 to 8 hour run is because some processes can produce 300 pieces in 5 minutes...you may manufacture several months worth if you run 8 hours. On the other hand, if you run at a rate of 300 pieces a day, the "significant production run" must represent a full days production. Partly to ensure "typical" variation is accounted for in your sample. Not looking for "special cause" variation at this point, but that your process is "capable" of producing parts to specification. Correct establishment of controls in the control plan make sure the process stays there....or, more at, that any shifts are detected, set-up is correct, etc.

As far as the specifics of collecting 300 parts, if your processes are similar, and you can group them into "families" then you probably do not need 300 of each kind, just 300 process samples. Depending on how "custom" the truck bodies and trailers are...it sounds like families is the way to go. You can probably PPAP your process using 300 pieces...mixed models. You may need to do specific Layouts for the different models. Do your customers require PPAP? Hopefully they at least know about it, so you can ask for the waiver and they know what you are talking about!
 
#6
Our present PPAP sample/production run consists of four (4) pieces max. We keep one as the sample and send three (3) to the customer with level II PPAP(modified). We have a letter on file from the customer approving this quanity.
 
S

Sarang

#7
Thanks Laura, Sam and Marc,
I get some idea about what I should be doing. Now to clarify some stuff for you guys so that you can pass on any more ideas you have:

Laura "Do your customers require PPAP? Hopefully they at least know about it, so you can ask for the waiver and they know what you are talking about!"

None of our customers require PPAP at this time. Infact no one has ever asked us about it and I am sure not many of them have the slightest idea about the topic. But we are going for QS9K because we plan to supply the B3 in the near future.

Marc: "I'd really like to hear from someone who has gone through this myself"

What exactly did you mean Marc?? I am sorry I am all messed up today, so I might not really be able to grasp things quickly.
 

Marc

Hunkered Down for the Duration
Staff member
Admin
#8
Originally posted by Sarang:

Marc: "I'd really like to hear from someone who has gone through this myself"

What exactly did you mean Marc?? I am sorry I am all messed up today, so I might not really be able to grasp things quickly.
I have not experienced a situation (or had a client who) only made 4 or 5 pieces - or even 50 - a year and had to do PPAP. I am saying I would like those who have to tell us their experience(s).
 
S

Sarang

#9
Marc,
I was confused on whether PPAP required first 300 pieces from a production run of 8 hours and that too on the same day. Thats the reason I initially questioned the ambiguity of the requirement. You misunderstood me when you said "I have not experienced a situation (or had a client who) only made 4 or 5 pieces - or even 50 - a year and had to do PPAP". I meant to say we do not do 300 pieces every day or in a run of 1 to 8 hours.
Anyway, I think I've got a few good answers from you guys and I can base my PPAP on these answers now. Thanks again.
Sarang
 
Thread starter Similar threads Forum Replies Date
P Managing How PPAP Requirements are Communicated in the Manufacturing Process and to Suppliers APQP and PPAP 5
Sidney Vianna AS9100 News PPAP in the Aerospace Sector - What is it? AS9145 - Requirements for Advanced Product Quality Planning and Production Part Approval Process AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 10
J PPAP (Production Part Approval Process) Requirements for Annual Revalidations APQP and PPAP 1
V Plating Supplier PPAP Revalidation Requirements - A-Coat GM 9984132 Plating Process APQP and PPAP 1
Y PPAP requirements: Submission date and PSW (Statistical Process Package) APQP and PPAP 6
R Process Specification - What is the name of this PPAP form? APQP and PPAP 15
H Informational What is PPAP (Production Part Approval Process)? APQP and PPAP 26
N Who shall manage PPAP process? APQP and PPAP 4
kedarg6500 APQP & PPAP for Process Industry - Concept for Waste to Energy Program APQP and PPAP 0
K FAI (First Article Inspection) vs PPAP (Production Part Approval Process) APQP and PPAP 15
Q Need guidance new APQP and PPAP Process Improvement Software Idea Quality Assurance and Compliance Software Tools and Solutions 1
B PPAP Level 3 Process Submission Capability, Accuracy and Stability - Processes, Machines, etc. 5
V Supplier?s PPAP - Production Process Control Plan Review, Evaluation and Approval? FMEA and Control Plans 5
R PPAP requests for old parts that pre-date your PPAP Process APQP and PPAP 2
T Quality Control System Ideas to stream line the PPAP Process ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 4
A In-Process Inspection Results ALWAYS With PPAP? APQP and PPAP 8
B Supplier changed their Manufacturing Process - Is a PPAP resubmission required? APQP and PPAP 17
K Which Department or Process is Responsible for Leading the PPAP Process? APQP and PPAP 3
L Contents of PPAP Control Plan - Product & Process Characteristics? FMEA and Control Plans 10
M PPAP (Production Part Approval Process) files for Ford APQP and PPAP 11
R PPAP & Value Stream Mapping - How to eliminate waste in PPAP process APQP and PPAP 10
D PPAP Audit Checklist to Audit our PPAP?s against the Current Process APQP and PPAP 7
A What is PPAP (Production Part Approval Process) Why submit it and/with PSW APQP and PPAP 2
Q Can a waivers for external calibration labs be implemented via the PPAP process? IATF 16949 - Automotive Quality Systems Standard 3
B Help for beginner - PPAP (Production Part Approval Process) APQP and PPAP 9
R Is Kappa Study Required during PPAP (Production Part Approval Process)? IATF 16949 - Automotive Quality Systems Standard 9
T Production Part Approval Process (PPAP) Presentation in ppt. format APQP and PPAP 3
F Who should Sign Supplier PPAP (Production Part Approval Process) documents? APQP and PPAP 13
H Who can require PPAP (Production Part Approval Process)? APQP and PPAP 7
J Plastic Injection Molding Mold Change - PPAP Process Question APQP and PPAP 8
S Tell Me All About PPAP (Production Part Approval Process) APQP and PPAP 7
kedarg6500 PPAP for Continuous Process like Copper Wire Enameling but SWG differs per customer APQP and PPAP 3
H Statistical process programs for PPAP: Expecting some to become obligatory? APQP and PPAP 9
O PPAP Process Map - Does anyone map out the PPAP process for the Big Three? Process Maps, Process Mapping and Turtle Diagrams 2
I APQP Process Review and the Purpose of PPAP APQP and PPAP 13
S PPAP for my tier 3 suppliers - Sub-Supplier Process Changes APQP and PPAP 16
A Need help with the process flow chart on my 4th edition PPAP! APQP and PPAP 5
N Process capability for blended fluids? PPAP book section 1.2.2.9.1, page 6 Capability, Accuracy and Stability - Processes, Machines, etc. 6
M APQP & PPAP - Does Toyota follow the APQP and PPAP process? Customer and Company Specific Requirements 5
Ron Rompen Need help with Flowcharting the PPAP Process APQP and PPAP 6
L Does the APQP process end with the approval of the PPAP? APQP and PPAP 5
M QS-9000 level 3 PPAP - Can anyone inform me on the process? APQP and PPAP 7
E What is the purpose of the AIAG's PPAP process? Elimination of customer inspection? Inspection, Prints (Drawings), Testing, Sampling and Related Topics 4
B No Supplier PPAP or PSO (process approval) Requirement APQP and PPAP 3
J AIAG PPAP (Production Part Approval Process) Manual Fourth Edition Released APQP and PPAP 69
A PPAP (Production Part Approval Process) - Where can I buy the AIAG Manual? Preventive Action and Continuous Improvement 2
J PPAP (Production Part Approval Process) Submission Level Differences - Forms attached APQP and PPAP 17
B Is PPAP the same process as a ISIR (Initial Sample inspection report)? APQP and PPAP 15
A Can FMEA's and CP's be process specific according to the PPAP handbook? APQP and PPAP 5
S Students trying find information on Producation Part Approval Process - ABC of PPAP APQP and PPAP 2

Similar threads

Top Bottom