PPAP Introduction Training - TPK Supplier Management …sqp.tpk.com/sqp/sqpfile/45047447PPAP-...

PPAP Introduction Training

TPK Confidential and Proprietary Information 1

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Scott Wan, Anita Lin

What is PPAP ?

PPAP(Production Part Approval Process)

Customer approves supplier’s

manufacturing condition/process

/product with required document

evidence and warrant.


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evidence and warrant.

PPAP Interactive Flow

Project Team

Data Collection

Fulfill PPAP Request

Items

PSW Approval

PPAP Process

Customer Customer

Customer Design Request

Customer Order/Special

Request

Supplier


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Items

Supplier’s PSW

Approval

Summit PSW

PPAP Process Audit

Customer Process Request

Customer Spec

PPAP Purpose

Then supplier would To prove

Purpose


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Then supplier would

have the potential

to provide a

continual stable

quality material to

TPK for the end

customer demand.

To prove

manufacturer knows

customer’s design

and spec as well as

the process control

for the potential to

meet customer’s

demand.

PPAP Advantage

1• Maintain design integrity and early

defective finding before MP

2• Identify supplier quality control

shortage for improvement


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2 shortage for improvement

3• Avoid non-confirmed material usage.

Trim down unnecessary quality waste

When to Use PPAP?

New Parts Approval for PVT

ECN after MP


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Idle Tooling

Tooling Change or Material Change

Process Change( Including new factory implementation)

PPAP Records Retention

铸铸A铸铸铸A铸铸铸A铸铸铸A铸


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+1

PPAP Process Data Request

铸铸A铸

1

-

2

1 8

3


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.300

.

.

PPAP Levels for Submission & RetentionSubmission Level

Requirement Level 1 Level 2 Level 3OCA//LCM/PETOCA//LCM/PETOCA//LCM/PETOCA//LCM/PET PF/FPC/CGPF/FPC/CGPF/FPC/CGPF/FPC/CG

1. Design Records of Saleable Product R R Ra. For proprietary components/details R R Rb. For all other components/details R R R

2. Engineering Change Documents, if any R S S3. Customer Engineering approval, if required R S S4. Design FMEA R R R5. Process Flow Diagrams R R S6. Process FMEA R R S7. Control Plan R R S8. Measurement System Analysis Studies R R S


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8. Measurement System Analysis Studies R R S9. Dimensional Results S S S10. Material, Performance, Test Results R S S11. Initial Process Study R R S12. Qualified Laboratory Documentation R R R13. Part Submission Warrant (PSW) S S S14. Appearance Approval Report, (AAR) if applicable S S S15. Sample Product R S S16. Master Sample R R R17. Checking Aids R R R18. Records of compliance with Customer-Specific Requirements R R R

S = The supplier shall submit to TPK and retain a copy of records or documentation items at appropriate locations.R = The supplier shall retain at appropriate locations and make readily available to TPK upon request.

After PPAP- 1. Design Record

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CA来/CA虑 .

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3~术 CT预 32铸cs C铸签 .

�


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.

>PCB Layout

>Mechanical Drawing

>Package Drawing

> Soft Ware Rev.

Customer Approval ECR List

After PPAP- 2. Design ECR


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After PPAP- 3. Customer Engineer Approval

�

�

....�

....


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After PPAP- 4. DFMEA

� .

� 则虑严A .

� , .


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Design FMEA Example


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Remark: S( >8 RPN( ≥60 , , S(O( D RPN .

Design FMEA Criteria


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After PPAP- 5. Process Flow Diagrams

断

� .

� ,

.

�


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� 铸则虑严A .

� CT预CT预铸arameter .

Process Flow Diagrams Example


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After PPAP- 6. PFMEA

则A检编U验严虑连来严 A调来严则则严CTS A调A编YS检S则A检编U验严虑连来严 A调来严则则严CTS A调A编YS检S则A检编U验严虑连来严 A调来严则则严CTS A调A编YS检S则A检编U验严虑连来严 A调来严则则严CTS A调A编YS检S 则虑严A则虑严A则虑严A则虑严A

a .

b .

c , .

� 则虑严A .� .


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.� .� .� .� 则虑严A .� 则虑严A .� .� 则虑严A S>类验铸调时0 验ecommended Action Action ,

S 连来验铸调 .� 则虑严A .� S .

PFMEA Example


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Remark: S( >8 RPN( ≥60S( O( D RPN .

After PPAP- 7. Control Plan

� .

� 铸则虑严A , 铸则虑严A .

� .

�

铸则虑严A ,.


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� .

� .

� .

Control Plan Management

Control Plan in each PhaseControl Plan in each PhaseControl Plan in each PhaseControl Plan in each Phase

For each phase need to release control plan before production, the process set up must base on control plan to manage. And Audit by IPQC in the meanwhile.

Input Material for Control planInput Material for Control planInput Material for Control planInput Material for Control plan

1. Special Characteristics definition.

2. Process Flow Chart.

3. PFMEA.

4. Design Record/Drawing and Spec.


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Special Characteristics ManagementSpecial Characteristics Management

1. For test/measure environment needs to do MSA.

2. For CTQ items according to the drawing, Cpk evaluation and SPC control should be taken.

Process FAIProcess FAIProcess FAIProcess FAI

Based on control plan definition, come out Process FAI check list. It needs to be verified before each production.

Control Plan Example


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After PPAP- 8. MSA(Measurement System Analysis)

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.

� 备验&验 % 备验&验 % 备验&验 % 备验&验 % 编ong 虑ethod 编ong 虑ethod 编ong 虑ethod 编ong 虑ethod A调连VAA调连VAA调连VAA调连VA .

<<<< <<<< <<<<


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� 备验&验 % 验&验 % 验&验 % 验&验 % <<<<10% 10% 10% 10% 10101010%%%%<<<<备备备备验&验 % 验&验 % 验&验 % 验&验 % <<<<33330% 0% 0% 0% 备验&验 % 备验&验 % 备验&验 % 备验&验 % >>>>33330%0%0%0%

.

� 2 20 2>样0%>样0%>样0%>样0% .

MSA Management

MSA Control list Special Characteristics MSA Control list Special Characteristics MSA Control list Special Characteristics MSA Control list Special Characteristics

� Before each build need to MSA for each Special Characteristics test/measure environment.

�For Go/No-go gauge, need to use Kappa for evaluation. Value >= 90%

�For numerical gauge, need to use Gauge R&R for evaluation. Value <=15%


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Control ListControl ListControl ListControl List

MSA Kappa Template


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MSA Gauge R&R Template


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After PPAP- 9. FAI Measurement Result

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3 .


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After PPAP- 10. Material/Performance Test Report

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.

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� .

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� , 属铸铸A铸 ,

.

After PPAP- 11. Cpk Capability Monitor

� CT预 32Cpk 铸铸A铸 .

�

. 断


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. 断/

.

�

� C铸签≥1.33 Target ≥1.时环

Cpk Acceptance Criteria

1.时环1.时环1.时环1.时环


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1.331.331.331.33≤ ≤1.时环1.时环1.时环1.时环

1.331.331.331.33

SPC Cpk ExampleX barX bar--R chart management for Special Characteristi cs R chart management for Special Characteristics X barX bar--R chart management for Special Characteristi cs R chart management for Special Characteristics

Link to shop floor system,

to auto generate each

30 mins

Cpk Control


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CpkCpk evaluation for Special Characteristicsevaluation for Special CharacteristicsCpkCpk evaluation for Special Characteristicsevaluation for Special Characteristics Based on each phase shop floor data to

do calculation.

* In trial run Cpk should >= 1.67; MP should >=1.33

After PPAP- 12. Qualified Lab Document

� .

� .

� .

� .


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� .

�Certify 验o态S 验eport.

Excellent Lab

�Currently, TPK labs already

passed CNAS L4039 Certification

and ISO/IEC17025 Certification.


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After PPAP- 13. PSW Content

�PSW (Parts

Submission Warrant)

needs to be signed

back by Supplier

Quality Manager/


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Director and Plant

Director/VP.

PPAP Documents---PSW

�Need to submit to TPK CE Dept to reduce the mistake .

�CE will audit the supplier factory for the consiste nce

verification btw PPAP documentation and process whe n

necessary.


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necessary.

After PPAP- 14. AARAppearance Approval Report

断

� ,.

� , /ABS.

� 来编*, 来a*, 来b*,


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� 来编*, 来a*, 来b*, 来严*, C虑C).

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� .

Cosmetic AAR


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After PPAP- 15. NPI Sample Product

� 调铸检, ,

, minimum 3pcs).

� , ,


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� , ,, ,

.

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After PPAP- 16. Master Sample

� .

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� .

After PPAP- 17. Inspection Aids

Drawing Rev Verification Report

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.

�

.


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.

� .

� ,备验验 .

Checking Aids List

Combined check aids list in MSA control list with instrument and fixture function and s/n no..


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After PPAP- 18. Records of Compliance with Customer-Specific Requirements

�List down all documents and specification from cust omer, as specification input for Quality Control.

�Such as cosmetic spec, PCB incoming spec, Hard ware spec and Package …

�New drawing requires customer’s approval.


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Summary - PPAP Requirement List1.Design Record - Drawing record with rev, including CTQ.2.Authorized ECN record(or by customer): Drawing spe c, rev, evaluation record,

apply evidence, reliability test result.3.Process Flow Chart.4.PFMEA - Potential failure vs Degree

RPN=嚴重度嚴重度嚴重度嚴重度x可能性可能性可能性可能性x不易探測性不易探測性不易探測性不易探測性 ; 嚴重級別的降低嚴重級別的降低嚴重級別的降低嚴重級別的降低 , 發生的可能性的降低發生的可能性的降低發生的可能性的降低發生的可能性的降低 , 不易探測不易探測不易探測不易探測性的降低性的降低性的降低性的降低.

5.Control Plan w/ Rev: From receiving through shippi ng with CTQ key parameter.6.Tooling and instrument – MSA for 長度長度長度長度,力度力度力度力度,溫度溫度溫度溫度,化學量測值化學量測值化學量測值化學量測值,光學精準度等光學精準度等光學精準度等光學精準度等, 量测系量测系量测系量测系


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6.Tooling and instrument – MSA for 長度長度長度長度,力度力度力度力度,溫度溫度溫度溫度,化學量測值化學量測值化學量測值化學量測值,光學精準度等光學精準度等光學精準度等光學精準度等, 量测系量测系量测系量测系统变异统变异统变异统变异GRR% ( * 100% 或或或或 (USL-TSL)/TV ).

7.Dimensional result with Drawing and Rev: SPC data , Cpk>1.33 (minitab).8.AAR result with 3 pcs production s/p to IQC (befo re each ECN) and 3 pcs spec

golden sample.9.Material/Performance test result come from certif ied calibrated instrument for

the traceability.10.FAI data confirmation.11.Customer special requirement.12.PSW for supplier PVT-after production parts appr oval.

TPK Schedule

• Supplier PPAP training : 2/28~29/2012• Supplier internal training and data collection on new project : 03/2012• Supplier PPAP document submitting and modification: 04/2012• Start supplier PPAP on-site audit : 05/2012


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• Contact window: Sanki Yeh• email: [email protected]• Tel: 5738999 ext 6285


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PPAP Introduction Training - TPK Supplier Management …sqp.tpk.com/sqp/sqpfile/45047447PPAP-...

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