a component of APQP, includes fail- ure mode element analysis (FMEA) and a control plan. T rough record- keeping, PPAPs are used to prove how the supplier will produce the casting and that the process used will result in a quality part. “T e PPAP is a group of reports that is documenting the process and providing measurements to show the part is being produced and made to the required specifi cations,” said Ron Helgeson, Caterpillar, Mapleton, Ill. “It is a verifi cation you are getting the part you asked for.” PPAP recordkeeping requirements
are outlined in six sections: 1. General 2. PPAP Process Requirements 3. Customer Notifi cation and Sub- mission Requirements
4. Submission to Customer—Lev- els of Evidence
5. Part Submission Status 6. Record Retention. T e essence of the PPAP lies in
Section 2, where the control plan, FMEA and process fl ow are ad- dressed. Collaboration with the casting supplier on this section can ensure potential problem areas are identifi ed early and avoided before the parts are ever produced.
Control and Statistics
Caterpillar is well known for its supplier development program, so it is no surprise it emphasizes collaboration in its PPAP planning. “We like to include the process
control engineer and the potential supplier very early in the design
process to make the part as manufac- turable as we can and still address the functionality required by the design engineer,” Helgeson said. T e process control engineer as- signed to a supplier at Caterpillar has most likely been to the supplier and knows the casting process. T is is not always possible, but it helps provide initial expectations for outlining the control plan. “Our preference is always to work with our customer,” Hartigan said. “T e more give and take there is, the more successful the part will be. We are in the middle of a huge program, and it is fantastic to have them on the phone with us every day, or in our building often enough that we practi- cally need to set up cubicles for them.” According to Hartigan, PPAPs
Table 1. Sample of PPAP Requirements and Responsibilities of Core Reviewers at Caterpillar AIAG PPAP Fourth Edition Requirements
2.2.1 Design record
2.2.1.1 Reporting of part material composition 2.2.1.2 Marking of polymeric parts
2.2.2 Authorized engineering change documents 2.2.3 Customer engineering approval 2.2.4 DFMEA
2.2.5 Process fl ow diagrams 2.2.6 PFMEA
2.2.7 Control plan
2.2.8 Measurement system analysis studies 2.2.9 Dimensional results
2.2.10 Records of material/performance test results 2.2.10.1 Material test results
2.2.10.2 Performance test results 2.2.11 Initial process studies 2.2.11.1 General
2.2.11.2 Quality indices
2.2.11.3 Acceptance criteria for initial study 2.2.11.4 Unstable process
2.2.11.5 Process with one-sided specifi cations or non-normal distributions 2.2.11.6 Actions to be taken when acceptance criteria non satisfi ed 2.2.12 Qualifi ed laboratory documentation 2.2.13 Appearance approval report (AAR) 2.2.14 Sample production parts 2.2.15 Master sample 2.2.16 Checking aids
2.2.17 Customer-specifi c requirements 2.2.18 Part submission warrant 2.2.18.1 Part weight (mass)
Yes Yes Yes Yes Yes Yes
Engineering Evaluates Yes
Yes Yes Yes Yes Yes
Yes Yes
Yes Yes Yes Yes Yes
Quality Evaluates PCE Evaluates Yes
Yes Yes Yes
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Jul/Aug 2013 | METAL CASTING DESIGN & PURCHASING | 33
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