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PPAP 4 th Edition Rollout / ISO / TS 16949 Status Conference
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I just got back from the PPAP 4 th Edition Roll Out & ISO / TS 16949 Status Conference and would like to report back to you some of the highlights. The PPAP Fourth Edition replaces the Third Edition effective June 1, 2006 . |
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The conference was conducted by the Big 3 automotive OEM's: Hank Gryn, DaimlerChrysler, Russ Hopkins, Ford Motor Company, and Joe Bransky from General Motors gave their presentations on the changes to the PPAP manual and also highlighted changes or emphasized important points from each customer.
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Generally, they are trying to change the culture of suppliers who are using PPAP as a paper chase not as a tool for the supplier to help determine whether the organization understands the customer's requirements and also whether the organization has the ability to produce a product which meets the customer's requirements. The 4 th edition PPAP Manual has been reconfigured to be in line with the TS 16949 standard and AIAG Core tools. It has been streamlined with many redundancies removed. If something was covered in the MSA manual - it will not be reiterated in the PPAP manual. They were also looking to make it more generic to make it more user friendly for use for other OEMs ( Toyota , Honda, etc.) One item that needs to be absolutely clear is that the PPAP manual is a requirements document not to be used as reference only. It does not apply to truck customers.
For customer specific information refer to their web site or the IAOB website. AIAG Excel -spreadsheet with all the PPAP forms will be available from AIAG in April.
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Highlights:
- PPAP manual has been re-arranged to fit with the TS 16949:2002 process approach.
- OEM Customer Specific requirements were removed from the PPAP manual and now will be found on their websites. (OEM & IAOB) (www.iaob.org)
- They have removed the section listing examples of when it is not necessary to notify the customer regarding the possibility of a re-ppap. It is emphasizing to notify the customer to determine whether re-PPAP is necessary.
- Most changes are in section 2.2 which lists the 18 deliverables
- Truck OEM Requirements moved to Appendix H.
- The PPAP should be part of the tools/metrics that we use to evaluate our NMI process.
- Performance, Dimensional & Material Results -
- Blank statements of conformity are not acceptable-must have DATA ;
- Ppk & Cpk do not refer to 'long'/'short' term capability-they are different measures of capability
- Layout inspection is REQUIRED by GM, defaulting to the TS standard. Ford & DCX have written annual requirement for this
- Warrant has been updated. See customer web site for new version.
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So what's next? The current edition of the FEMA is 3 rd edition, July 2001. It is currently under review but not date has been set for release of the new version. There is no review set for the APQP manual.
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See below for customer specific changes / impacts.
- DCX:
- Effective date is 1 June 2006 except for DCX which is 28 Feb 2006
- All DCX submissions are now through Powerway (New version out March 27, 2006)
- PSO is being revised for end-of-year publication
- Must contact customer rep about ANY changes
- Powerway will be expanded to 2nd tier
- GM:
- Effective date is 1 June 2006 except for DCX which is 28 Feb 2006
- 'Interim A - E' has been replaced with 'Saleable' & 'Non-Saleable' status
- Electronic submissions are done through the GQTS
- GM 1411 PPAP Worksheet form is used for all 'less than full' PPAP
- Captures all reasons that prevent part from meeting Approved status
- GM 3660 form is required record for sign-off & final Approval
- IMDS is required for North America & prior to Lab approvals
- Web based training on GM APQP available
- Ford:
- If Ford customer representatives ask for stuff different form written PPAP & CSR then push back-they are still learning their system.
- Required to use Ford's DFMEA & PFMEA handbook (web).
- MSA/GRR MUST have minimum of 5 distinct categories! Spreadsheet with calibration data will be available in June.
- Preferred use of ANOVA to calculate R&R, nor Xbar and R. This is difficult to do manually, but Minitab does this function.
- Initial Process studies MUST use 25 subgroups of data & be in control etc.
- Must use Ppk as capability index.
- SREA will be revised soon .
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