2025. 2. 7. 04:42ㆍAutomotive
PPAP은 자동차 부품의 공급처에서 공급처의 신뢰성 관련 data와 제품생산공정등에 관련한 승인을 위한 절차입니다.
실제 뜻은 PPAP(Production Part Approval Process)의 약자로,
일반적으로는 각각의 기업이 자체 생산품에 대하여 특별한 spec을 가지고 있고 그 spec에 의해 제품이 제작되지만
그래도 자동차 부품의 경우 좀 더 강화된 품질관리를 위한 PPAP의 표준이 필요하여 AIAG(Automotive Industry Action Group)라는 단체에서 표준 PPAP을 개발하였습니다.
AIAG에서 개발한 PPAP표준은 AIAG에서 개발한 APQP(Advanced Product Qualfity Planning)를 위한 방법론입니다.
--- APQP는 별도로 다뤄야할 정도로 방대한 Manual이지만, 간단히만 소개하면, 자동차부품의 개발, 산업화, 제품 생산에 관련된 23가지의 main topic을 담고 이 23가지 topic이 자동차 부품의 생산전에 만족되어야 합니다. 이를 통하여 design상의 건실함(robustness), 스펙과 test조건을 얼마나 잘 따르고 있는지, 생산공정에 설계는, 품질검사의 표준은, 공정능력, 생산능력 등등등을 사전에 두루 검토합니다.---
하여 반도체를 포함한 자동차업계에서 이야기하는 PPAP은 AIAG의 표준을 이야기 하는 경우가 많습니다.
PPAP은 기본적으로 부품생산업체가 고객사에 제공하는 것으로 반도체에서의 PPAP은 서류뭉치로 영어로는 PPAP package라고도 합니다. PPAP은 위에서 말씀드렸듯이 서류뭉치이기 때문에 제공되는 서류가 뭔지를 정리한 마지막 서류 PSW(Part Submission Warrant)가 있습니다.
PPAP은 보통 supplier의 Quality engineer가 검토하고, PSW에 양사의 담당자가 서명하여 나눠가지는 것으로 마무리 합니다.
AIAG 표준의 PPAP의 구성은 아래와 같습니다.
1.Design Records
A printed copy of the drawing needs to be provided. If the customer is responsible for designing, this is a copy of customer drawing that is sent together with the Purchase Order (PO). If supplier is responsible for designing this is a released drawing in supplier's release system. "Each and every feature must be “ballooned” or “road mapped” to correspond with the inspection results (including print notes, standard tolerance notes and specifications, and anything else relevant to the design of the part)."[3]
2.Authorized Engineering Change (note) Documents
A document that shows the detailed description of the change. Usually this document is called "Engineering Change Notice", but it may be covered by the customer PO or any other engineering authorization.
3.Engineering Approval
This approval is usually the Engineering trial with production parts performed at the customer plant. A "temporary deviation" usually is required to send parts to customer before PPAP. Customer may require other "Engineering Approvals".
4.DFMEA
A copy of the Design Failure Mode and Effect Analysis (DFMEA), reviewed and signed-off by supplier and customer. If customer is design responsible, usually customer may not share this document with the supplier. However, the list of all critical or high impact product characteristics should be shared with the supplier, so they can be addressed on the PFMEA and Control Plan.
5.Process Flow Diagram
A copy of the Process Flow, indicating all steps and sequence in the fabrication process, including incoming components.
6.PFMEA
A copy of the Process Failure Mode and Effect Analysis (PFMEA), reviewed and signed-off by supplier and customer. The PFMEA follows the Process Flow steps, and indicate "what could go wrong" during the fabrication and assembly of each component.
7.Control Plan
A copy of the Control Plan, reviewed and signed-off by supplier and customer. The Control Plan follows the PFMEA steps, and provides more details on how the "potential issues" are checked in the incoming quality, assembly process or during inspections of finished products.
8.Measurement System Analysis Studies (MSA)
MSA usually contains the Gage R&R for the critical or high impact characteristics, and a confirmation that gauges used to measure these characteristics are calibrated.
9.Dimensional Results
A list of every dimension noted on the ballooned drawing. This list shows the product characteristic, specification, the measurement results and the assessment showing if this dimension is "ok" or "not ok". Usually a minimum of 6 pieces is reported per product/process combination.
10.Records of Material / Performance Tests
A summary of every test performed on the part. This summary is usually on a form of DVP&R (Design Verification Plan and Report), which lists each individual test, when it was performed, the specification, results and the assessment pass/fail. If there is an Engineering Specification, usually it is noted on the print. The DVP&R shall be reviewed and signed off by both customer and supplier engineering groups. The quality engineer will look for a customer signature on this document.
In addition, this section lists all material certifications (steel, plastics, plating, etc.), as specified on the print. The material certification shall show compliance to the specific call on the print.
11.Initial sample inspection report The report for material samples which is initially inspected before prototype made
12.Initial Process Studies
Usually this section shows all Statistical Process Control charts affecting the most critical characteristics. The intent is to demonstrate that critical processes have stable variability and that is running near the intended nominal value.
13.Qualified Laboratory Documentation
Copy of all laboratory certifications (e.g. A2LA, TS) of the laboratories that performed the tests reported on section 10.
14.Appearance Approval Report
A copy of the AAI (Appearance Approval Inspection) form signed by the customer. Applicable for components affecting appearance only.
15.Sample Production Parts
A sample from the same lot of initial production run. The PPAP package usually shows a picture of the sample and where it is kept (customer or supplier).
16.Master Sample
A sample signed off by customer and supplier, that usually is used to train operators on subjective inspections such as visual or for noise.
17.Checking Aids
When there are special tools for checking parts, this section shows a picture of the tool and calibration records, including dimensional report of the tool.
18.Customer-Specific Requirements
Each customer may have specific requirements to be included on the PPAP package. It is a good practice to ask the customer for PPAP expectations before even quoting for a job. North America auto makers OEM (Original Equipment Manufacturer) requirements are listed on the IATF website.
19.Part Submission Warrant (PSW)
This is the form that summarizes the whole PPAP package. This form shows the reason for submission (design change, annual revalidation, etc.) and the level of documents submitted to the customer. There is a section that asks for "results meeting all drawing and specification requirements: yes/no" refers to the whole package. If there is any deviations the supplier should note on the warrant or inform that PPAP cannot be submitted
모든 PPAP package가 위의 19개 항목을 모두 담고 있을 필요는 없고 요구되는 PPAP의 Level에 따라 제출하는 자료나 샘플이 다릅니다.
보통의 경우 반도체의 PPAP은 Level 2나 Level 3를 제출합니다.(PPAP Level은 따로 정리하였습니다.)
PPAP Level 3의 경우 1, 5, 7, 8, 9, 10, 12, 13, 19(PSW)를 제공합니다.
PPAP의 내용은 아래 주소를 참고하시면 영문으로 좀더 자세히 설명되어 있습니다.
http://en.wikipedia.org/wiki/Production_part_approval_process
AIAG의 자세한 정보는 아래를 주소를 참고하세요.
http://en.wikipedia.org/wiki/Automotive_Industry_Action_Group
더 궁금한 내용이 있으시거나 문의가 있으시면 아래 주소의 게시판에 글을 남기시거나, 담당자에게 메일을 주시면 됩니다.
[출처] 자동차용 반도체의 PPAP|작성자 카이사르