Production Part Approval Process

Justin Pitts

Design Records Authorized Engineering Change Documents Customer Engineering Approval, if required Design Failure Modes and Effects Analysis (DFMEA)

applied in special situations Process Flow Diagram Process Failure Modes and Effects Analysis (PFMEA) Control Plan Measurement Systems Analysis (MSA) Dimensional Results Records of Material / Performance Test Results Initial Sample Inspection Report Initial Process Studies Qualified Laboratory Documentation Appearance Approval Report (AAR) Sample Production Parts Master Sample Checking Aids Customer-Specific Requirements Part Submission Warrant (PSW)

Elements of a PPAP

零件 /

过程编号Part/

Process No

过程名称 / 操

作描述Process Name/Operati

on Descript

ion

机器、装置

夹具、工装

Machine、 Device

jigtools 、foreMfg

 

特殊特性 Special Characterist

ic

方法 Methods 反应计划 Reaction

Plan

产品 & 过程Product & Process

产品 / 过程规范 / 公差

Product/Process

Specification/Tolerance

检具Gauge

样本 Sample

控制方法Control Method

反应计划

Reaction Plan

纠正措施Corrective

Actions容量Size

频率Frequency

20 锻打Forging

热锻机床Forging Machine

毛坯长度Length

厚度Thickness

 

84.84 ± 0.5 mm

50.8 ± 0.75 mm (10)

REF 23.88 (16)

卡尺Caliper/

0.02

1 次 time

每 4 个小时

Each Four Hours

检验员检验

Checked by

Inspector

隔离不合格品

Quarantine

调整定位块返工

Adjust Positioning Block and Rework

圆角Radius

 

R 3.3 ± 0.75 (4)

R 6.35 ± 0.75 (5)

R25.4 (13)

R12.7-R19.05 mm

(6)

由模具保证Control by Pattern

隔离不合格品

Quarantine

调整定位块返工

Modify Tooling and

Rework

毛刺burrs

 无毛刺

No burrs (19)

目测Visual Inspection

100﹪

操作员检验

Checked by

Operator

隔离不合格品

Quarantine

返工 Rework

Quality Action PlanDeveloped as a means of identifying specific historical quality problems and implementing a plan of action for each if necessary.

as of 1/4/13

PART #Quality Issues found within past 6

monthsQuantity in Inventory

Open Order

QtyQty

AvailableIn-Transit

to Warehouse

WIPDate of last production

run

Estimated Month WIP parts will

arrive

Estimated Month parts will arrive with CMM

reportsVendor's Plan of Action

107-03-0030 GOOD 68 10 58 0 0 Oct 2013 n/a n/a n/a

107-03-0042 GOOD 1,373 0 1,373 0 0 Nov 20123 n/a n/a n/a

501-03-1214

Counterbore not machined, 6.00" Bolt Hole, Runout, Surface Finish,ID/Bolt hole Porosity

causing leaks 0 150 0 230 450 current April April

951pcs returned to the factory for reworking (will stamp "R" for

traceability), every 10th part requires CMM report

501-03-1301 GOOD 466 0 466 0 0 Nov 2013 n/a n/a n/a

501-03-1316

Runout on lands, porosity on ID lands and side causing leaks 91 0 91 0 131 current July July

Vendor to request leak testing and every 10th part requires CMM report

501-03-1344

various issues on diameter and runout (refer to CMM reports) 60 0 60 0 0 Mar 2012 n/a TBD, slow moving

60pcs to be sent stateside for CMM inspection, request every 10th part requires

CMM report on future production

501-06-0838 internal porosity, improvement to concentricity 11 0 11 0 120 current Feb n/a

Vendor to supply 0839 to avoid internal porosity issues

501-06-0773 surface defects on top casting surface, bolt hole porosity 508 100 408 0 0 May 2012 n/a n/a

Qty on hand has been 100% sorted for surface defects, 561pcs returned to the factory for reworking (will stamp "R" for

traceability)

501-07-0140 ID groove undersized (2.900"-2.920" measured 2.898") 540 200 340 0 1,000 current Feb n/a

perform capability study on ID groove, 100% inspect prior to shipment

501-07-0142 GOOD 737 150 587 0 750 current August n/a n/a

501-08-1267 bore to base dimension and bore diameter slightly over tolerance 810 0 810 0 0 May 2012 n/a n/a perform capability study on bore diameter and bore to base dimensions

501-08-1371 90mm±0.5 measured 82.85mm 8 0 8 0 0 Sept 2011 n/a n/a investigate and complete a CAR

501-08-1375 GOOD 10 0 10 90 0 current n/a n/a n/a

501-08-1376 GOOD 3,145 200 2,945 0 0 Mar 2012 n/a n/a n/a

501-08-1147 1.969±0.010" measured 1.954" 2,746 0 2,746 0 0 Jan 2012 n/a n/a 100% inspect CAB inventory and complete a CAR

Thank You