PPAP Requirements in High Mix/Low Volume Manufacturing

[bluesmech]

Hi all. Fairly new to APQP, PPAP, MSA, etc... Trying to implement company direction/goals locally in a non-automotive environment. Having a hard time finding answers to what most in automotive find intuitive. One point to note, I work in a high mix/low volume plant. Here are my questions.

1 - Is a new PPAP required when a new person is performing in a process?
2 - Is a new MSA required when a new person is performing final inspection on MSA dimensions as part of process?
2A - If a new MSA is required, can we just document the MSA, or is a whole new PPAP required?
3 - Is there somewhere I can get guidance on how to document PPAP on assemblies? For instance, when a new sub-part is changed, is a new PPAP required on the assembly? What types of documentation is used for assemblies when no dimensions are listed on the final assembly parts?
4 - Is there a website or document that provides step-by-step guidance? For instance, how many samples should we pull? (Remember high mix/low volume (typically <2,000 pieces). I've read a few articles that suggest 30%. If we pull 30%, do we have to measure all 30% as part of the process study?

I have more questions, but these will give me some good basis for where I am currently. Thanks in advance for your responses.

All the best!
Dan

 

[qusys]

Hi all. Fairly new to APQP, PPAP, MSA, etc... Trying to implement company direction/goals locally in a non-automotive environment. Having a hard time finding answers to what most in automotive find intuitive. One point to note, I work in a high mix/low volume plant. Here are my questions.

1 - Is a new PPAP required when a new person is performing in a process?
2 - Is a new MSA required when a new person is performing final inspection on MSA dimensions as part of process?
2A - If a new MSA is required, can we just document the MSA, or is a whole new PPAP required?
3 - Is there somewhere I can get guidance on how to document PPAP on assemblies? For instance, when a new sub-part is changed, is a new PPAP required on the assembly? What types of documentation is used for assemblies when no dimensions are listed on the final assembly parts?
4 - Is there a website or document that provides step-by-step guidance? For instance, how many samples should we pull? (Remember high mix/low volume (typically <2,000 pieces). I've read a few articles that suggest 30%. If we pull 30%, do we have to measure all 30% as part of the process study?

I have more questions, but these will give me some good basis for where I am currently. Thanks in advance for your responses.

All the best!
Dan

Hi, there is a new release of APQP , PPAP , Control plan blue book of AIAG. Suggestion is to attend a course and read the new relaease.
However for question 1 and 2, the PPAP is independent by personnel. You need to assure that personnel is trained and competent. Check with your direct customer if it is required re PPAP.

 

[Golfman25]

Why would you do any of this if not required? That you don’t, just pick and choose what works best for you organization.

 

[optomist1]

ok, (based upon automotive and some aero experience) let me take a stab at 3/4 questions generally speaking as details always matter:

1 - Is a new PPAP required when a new person is performing in a process?
Negative; assuming the PPAP/MSA were correctly conducted, the manufacturing process should be robust to variation if a new or replacement operator is introduced
2 - Is a new MSA required when a new person is performing final inspection on MSA dimensions as part of process?
Negative; assuming the PPAP/MSA were correctly conducted, the manufacturing (inspection) process should be robust to variation if a new or replacement operator is introduced. Also, what are MSA dimensions?
2A - If a new MSA is required, can we just document the MSA, or is a whole new PPAP required?
Why would a "new" MSA be required? What changed??
3 - Is there somewhere I can get guidance on how to document PPAP on assemblies? For instance, when a new sub-part is changed, is a new PPAP required on the assembly? What types of documentation is used for assemblies when no dimensions are listed on the final assembly parts?
Echoing prior comments- seek out the AIAG training courses, or similar, although not bulletproof this will provide a foundation for additional learning and growth...this is a complex and extremely important area of study

Hope this helps...
Optomist1

 

[Miner]

2 - Is a new MSA required when a new person is performing final inspection on MSA dimensions as part of process?
Negative; assuming the PPAP/MSA were correctly conducted, the manufacturing (inspection) process should be robust to variation if a new or replacement operator is introduced. Also, what are MSA dimensions?

One caveat to this: R&R results presume that the operators in the study were randomly selected from the personnel that actually use the measurement device in production. If this was the case in the original study, there is no need to repeat the study with new people.

I mention this because some R&R studies are performed by engineers that do not use the measurement devices during manufacturing. This has been done for a variety of reasons, such as not interrupting production, convenience, trying to obtain better results, etc. If this was done in the previous study, the results would not be correct, and you would be better off repeating the study with the correct personnel.