PPAP & Value Stream Mapping - How to eliminate waste in PPAP process

[razahaider]

We are back logged in customer PPAPs. Company is asking to do a VSM (Value Stream Map) on PPAP process and I am confused. How do we eliminate any waste in PPAP process when its AIAG requirement and needs to be fulfilled. Or do we have to eliminate waste in processes related to PPAP, like support processes? Can anyone help?

 

[brahmaiah]

We are back logged in customer PPAPs. Company is asking to do a VSM on PPAP process and I am confused. How do we eliminate any waste in PPAP process when its AIAG requirement and needs to be fulfilled. Or do we have to eliminate waste in processes related to PPAP, like support processes? Can anyone help?

Firstly pl.tell us what VSM stands for.
To answer your question 1)There is no requirement for eliminating waste in PPAP process.What is required is elimination of waste in the supply chain which includes all processes involved in production of the part. Ref.extracts below:

"0.5 Goal of this Technical Specification

The goal of this Technical Specification is the development of a quality management system that provides for

continual improvement, emphasizing defect prevention and the reduction of variation and waste in the supply

chain."
V.J.Brahmaiah

 

[Umang Vidyarthi]

We are back logged in customer PPAPs. Company is asking to do a VSM on PPAP process and I am confused. How do we eliminate any waste in PPAP process when its AIAG requirement and needs to be fulfilled. Or do we have to eliminate waste in processes related to PPAP, like support processes? Can anyone help?

AIAG has standardised the PPAP, but it is the customer's specific requirement. Every customer does not need all the 19 documents. Some need only 5-6 documents, some need a few more and some (who have originally designed the part) asks for full PPAP. There fore you have to comply with individual customer's specific requirement. That is why your management is asking you to eliminate 'waste' in the PPAP.

Hope this helps

Umang

 

[razahaider]

Umang,

Thank you for your input. I think I am on right track now.

 

[Umang Vidyarthi]

Umang,

Thank you for your input. I think I am on right track now.

U R Welcome razahaider.

Umang

 

[prototyper]

AIAG has standardised the PPAP, but it is the customer's specific requirement. Every customer does not need all the 19 documents. Some need only 5-6 documents, some need a few more and some (who have originally designed the part) asks for full PPAP. There fore you have to comply with individual customer's specific requirement. That is why your management is asking you to eliminate 'waste' in the PPAP.

Hope this helps

Umang

Most customers will expect you to have completed every part of the PPAP process so that they can view it if required. The only difference with the level 1 to 5 submissions is the amount of documentation presented to the customer.

 

[prototyper]

We are back logged in customer PPAPs. Company is asking to do a VSM on PPAP process and I am confused. How do we eliminate any waste in PPAP process when its AIAG requirement and needs to be fulfilled. Or do we have to eliminate waste in processes related to PPAP, like support processes? Can anyone help?

I would look at grouping together similar products. Can you use the same control plan or FMEA (maybe with minor modifications) for parts which have similar characteristics or processes.

 

[Howard Atkins]

The PPAP process requires that all the actions are done but the level refers to the documents submitted.
The issue of control plans can be very time intensive, some customers demand all dimensions in the CP, others are happy to allow a reference to the specific inspection document.

Some companies also spend large amounts of time on non value added actions such as "beautifying" the documents

The main problem though is likely to be that the assembly of the documentation is difficult.
Essentially apart from the dimensional, functional and statistical report all the rest of the documents should be prepared before the PPAP run by the team.
PPAP is a report of the actions performed from the initial acceptance of the order.
Don't let it fall on you show the responsibilities for the documents and do not allow the PPAP run before the availability of the documents.

 

[Miner]

Value Stream Mapping will help identify such waste as time spent waiting (e.g., on parts, on information, etc.), and opportunities to move things currently done serially into parallel processes.

 

[razahaider]

Prototyper, Howard and Miner .. Thank you all for your replies, I am having my VSM event tomorrow and your replies did help me a lot.

Thanks again & Cheers

“We are what we repeatedly do. Excellence, then, is not an act, but a habit".