pre-production inspection report (ppir) process overview · ppirs are driven by preceding...
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Pre-Production Inspection Report (PPIR)
Process Overview
Forward Model Quality Programmes
Last update: 21 July 2015
PPIR
Process Overview
• Introduction - What is PPIR?
• PPIR in Relation to Project Timing
> Underbody (UN)
> Upperbody (UP)
• Measurement Requirements
• Expectations within Submission
• Role of JLR Engineering
• Role of Supplier
• Role of JLR Programme Management Team
• Role of Forward Model Quality (FMQ)
• Auditing
Purpose
• To confirm parts are to design intent, suitable for build and engineering sign-off
• Equivalent of PPAP for any non-PSW parts in M1, VP and HTFB build phases
> Parts with new tooling or modifications both come under this category
> Software revision without physical changes will also require a PPIR
Timing
• Distributed 4 weeks / 20 working days before MRD by Programme Team through
PPIR Tool
• Must be returned & approved, before parts are shipped to JLR (and before MRD)
High Level Process
PPIR
Introduction - What is PPIR?
Engineering
• Inform Programme Team of parts requiring PPIRs
• Agree measurements with suppliers
Programme Team
• Maintenance
and input of data.
• Send PPIR pro forma through tool
GSI Team / ODEC
• Support the
PPIR process and manage tool support
Supplier
• Receive PPIR via email
• Complete PPIR • Return
completed PPIRs to JLR to [email protected]
Engineering
• Review PPIRs for approval
• Feedback any issues to supplier
Approving a PPIR
• The PPIR approval tool, managed by the GSI team, is only accepted method for JLR
engineering to confirm the status of a reviewed PPIR.
• Whilst supplier do not have visibility of this tool, they will receive email
communications when:
> An approval status is allocated to a PPIR, or
> The PPIR has been rejected
• The PPIR approval acts as a OK to ship for supplier, to send the parts to JLR
Rejected PPIR
• A PPIR may be rejected because:
> Part deemed not fit for purpose due to deviations
> Submission failing PPIR audit, ie. minimum requirements not achieved
• If a PPIR is rejected, the supplier is expected to make the necessary corrections and
re-submit
PPIR
Introduction - What is PPIR? (cont.)
iDJ
M1 Dwg ATV 1 ATV2
M1 Build
UNV1 UNV2
M1 Vehicle
M1DJ
M1DC
PA PTC PS PSC PTCC
Actions Closed Failure Modes
Causes & Countermeasures Identified
Boundary Diagram
Interface Analysis
Functional Analysis
Parameter Analysis
Final FM Risk Assessment
YC/YS on SCSS &
Cascaded (Supplier & AME) CC/SC Confirmed
Controls Identified (Supplier & AME)
Quality History
FMA Plan DJ
S-Rel
DJ
Supplier & AME Reviews YC/YS Requirements
MRD
Notes
• All activities are responsibility of Engineering
• Forward Model Quality will coach, report and help facilitate
• SCSS = Special Characteristic Summary Sheet (Supp K)
• YC/YS = Potentially Critical / Significant characteristics
Agree PPIR Content & Reqs with Suppliers (all NTEI)
PPIR Received & Approved by Eng
PPIR Template Issued to Supplier
4 Weeks
PPIR
In Relation to Project Timing - UN
P-Rel
PPIRs required
for UNV
iDJ M1DJ
PA PTC PS PSC PTCC
Actions Closed Failure Modes Causes Identified
Boundary Diagram
Interface Analysis
Functional Analysis
Parameter Analysis
Final FM Risk Assessment
Internal YC/YS on SCSS
& Cascaded to AME
Quality History
AME Reviews YC/YS Requirements
Notes
• Discussions with AME and Suppliers to review FMEA,
special characteristics and measurement requirements,
should be regular and on-going
• Although not shown here, the requirement and process
for PPIR repeats for HTFB
Agree PPIR Content & Reqs with Suppliers (all NTEI)
PPIR Received & Approved by Eng
PPIR Template Issued to Supplier
4 Weeks
Virtual Series Pre-VS (iDJ)
UPV0 UPV1 UPV2 UPV3 VP
DRAW
DJ
T-Rel
DJ
Countermeasures Identified
External YC/YS on SCSS
& Cascaded to Supplier
Supplier Reviews YC/YS Requirements
AME CC/SC Confirmed
Controls Identified
Supplier CC/SC Confirmed
Controls Identified
VP Build
MRD
FDJ
PPIRs required
for UNV & UPV
PPIR
In Relation to Project Timing - UP
P-Rel
Virtual Series Pre-VS (iDJ) UPV0 UPV1
iDJ
UPV2
M1 Dwg
ANA
5
ATV 1 ATV2 ANA 5
M1 Parts/Build
UNV1 ANA 5
UNV2 ANA 5
DJ
P
M1 Vehicle
Vehicle Phase
Vehicle Phase
M1DJ
UPV3 ANA 5
VP Dwg ANA 5 12 12 14
11 6
ANA 5 11
11
11 ANA 5 ANA 5
M1DC
10 10
PA PTC PS PSC PTCC
FDJ
Actions Closed Failure Modes
Causes & Countermeasures ID
Boundary Diagram
Interface Analysis
Functional Analysis
Parameter Analysis
Actions Closed Failure Modes Causes Identified
Boundary Diagram
Interface Analysis
Functional Analysis
Parameter Analysis
Countermeasures Identified
Final FM Risk Assess
Final FM Risk Assess
YCYS
Cascade SCSS Controls
Confirmed
External
YCYS Cascade
Quality History
Quality History
Whole Vehicle
SCSS Confirmed
FMA Plan
Internal YCYS
Cascade
DJ DJ
PPIR
In Relation to Project Timing - Overall
VP Build
S
PPIRs issued
to suppliers Completed PPIRs submitted
by supplier for approval
Completed PPIRs submitted
by supplier for approval
PPIRs issued
to suppliers
T
DJ
Virtual Series Pre-VS (iDJ) UPV0 UPV1
iDJ
UPV2
M1 Dwg
ANA
ATV 1 ATV2 ANA 5
M1 Parts/Build
UNV1 ANA 5
UNV2 ANA 5
DJ
P
M1 Vehicle
Vehicle Phase
Vehicle Phase
M1DJ
UPV3 ANA 5
VP Dwg ANA 5 12 12 14
11 6
ANA 5 11
11
11 ANA 5 ANA 5
M1DC
10 10
PA PTC PS PSC PTCC
FDJ
Actions Closed Failure Modes
Causes & Countermeasures ID
Boundary Diagram
Interface Analysis
Functional Analysis
Parameter Analysis
Actions Closed Failure Modes Causes Identified
Boundary Diagram
Interface Analysis
Functional Analysis
Parameter Analysis
Countermeasures Identified
Final FM Risk Assess
Final FM Risk Assess
Quality History
Quality History
FMA Plan
DJ DJ
VP Build
S
T
DJ
PPIR
In Relation to Project Timing - Overall
YCYS
Cascade SCSS Controls
Confirmed
External
YCYS Cascade Whole Vehicle
SCSS Confirmed
Internal YCYS
Cascade
PPIRs issued
to suppliers Completed PPIRs submitted
by supplier for approval
Completed PPIRs submitted
by supplier for approval
PPIRs issued
to suppliers
PPIRs are driven by preceding activities
The Special Characteristic Summary Sheet (SCSS)
should direct decision-making behind measurement
strategy and activities
The following requirements relate to the minimum sample size for all sections of the
PPIR, including the Declaration of Mass.
JLR engineering may supersede these 2 requirements, on the proviso that:
1. This is agreed between PD and the supplier, and
2. The agreement is documented in the PPIR, as part of the submission
Sampling Requirements
• A new PPIR must be submitted for any new batch of parts
• Sampling size requirement:
PPIR
Measurement Requirements
Consignment quantity / batch size
as shipped Sample size
≤ 6 parts 100%
6 to 150 parts Minimum of 6 parts and 20%
≥ 150 parts 30 parts
Declaration of Mass
• It is required to declare the actual mass of the components manufactured, to supply
any given build.
• Suppliers are expected to weigh the parts, in accordance to the sampling
requirements, and record them in the PPIR submission
• Mass (weight) is to be measured on equipment calibrated with Weights traceable to
National Standards, and quoted within the following range of tolerances:
• This forms part of Section 3 of the PPIR submission (see slide 18).
PPIR
Measurement Requirements (cont.)
Components / assemblies mass (weight)
according to the released drawing
General Tolerance (to be applied only
when not stated in Drawing / CAD)
<0.100 kg +/- 5 g
0.100 to 0.999 kg +/- 10 g
1.000 to 4.999 kg +/- 20 g
5.000 to 20.999 kg +/- 25 g
>20.000 kg +/- 50 g
Each section of the PPIR submission is set out in such a way that it informs the end user
about the pedigree of the part in question:
Section 1 – Summary
• Documents the part details and summarises the key findings of the PPIR
Section 2 – Geometry
• Confirms the form of the part is as per design
Section 3 – Laboratory
• Verifies the part’s physical properties are in accordance to specification
> This includes the measured part mass of the components
Section 4 – Functional
• Demonstrates the part is able to function as intended
Section 5 – In-Vehicle Software (IVS)
• Shows the software compatibility between the part and the vehicle system
> Only required for parts containing software
PPIR
Expectations within Submission
Embed all additional documents supporting the PPIR submission in the appropriate
section(s). This includes agreements with JLR to:
• Neglect a specific section, or to deviate from the PPIR template
• Supersede measurement requirements with part / commodity-specific requirements
In sections 2, 3 & 4:
• Features shall include, but are not limited to, characteristics marked CC or SC in the
SCSS, and identify them in the section where the measurement is recorded
• Enter numeric values into the OK, NOK and NI columns, to confirm the quantity of
parts within tolerance, outside of tolerance and not inspected respectively
> This is irrespective of any agreements to deviate from the template
• Record all non-conformances in Details of Non-Conformances, within Section 1 -
Summary
PPIR
Expectations within Submission (cont.)
This section is in 2 parts, which outlines the part, the build it is intended for, the key
features and its conformance to specification
• Summary
> Provide overview of the part in the submission
> Summarise all non-conformances identified in the process
• Non-conformances, in this instance, are features identified as outside of
specification, or were not inspected
• State actions and timings to bring non-conformances back to specification
• SCSS
> Outlines the key requirements agreed between supplier & JLR, which are
fulfilled within the PPIR submission
> Fulfilled by attaching existing Special Characteristics Summary Sheet (SCSS)
PPIR
Section 1 - Summary
This section is in 3 parts, which in its entirety is intended to demonstrate the parts
manufactured are geometrically conforming to design specifications.
• Geometry
> Record the outcome of the measurement activities in this page.
> It is acceptable to use gauges / checking fixtures / reference samples as part of
the geometry confirmation
• Any objective output / measurements should be recorded as a value to
provide a verification to conformance to specification
• Only if the measurement output is an absolute, ie. pass / fail, is it
acceptable to record this as a measurement outcome
• Measurement Plan
> Using suitable visuals, illustrate where datums and measurement points are
• Include co-ordinated cut planes when required
• It is acceptable to use a 2D drawing to satisfy this requirement
PPIR
Section 2 - Geometry
• Gauging
> Where gauges / checking fixtures are used to verify conformance to design,
attach the relevant instructions to this section
> For CMM, provide visual which illustrates how the part is held for measurement
PPIR
Section 2 - Geometry (cont.)
This section verifies that the parts manufactured fulfils the requirements relating to:
• Physical properties
• Appearance / finish requirements
• Measured parts mass
PPIR
Section 3 - Laboratory
This section relates to any testing and/or functional analysis on the parts manufactured
to verify conformance.
• Should contain outcomes of end of line tests / assessments, for example load tests
and continuity checks
• This differs from design verification (DV)
• Embed test reports for confirmation as necessary
PPIR
Section 4 - Functional
This section should contain information which shows the software and hardware
supplied are to the level intent at each build phase, and as such compatible with the
relevant production systems.
PPIR
Section 5 - In-Vehicle Software
Before distribution of PPIR
• Identify parts requiring a PPIR
> All parts which are not delivered under PSW
> Generally new parts, or existing parts with major changes, including new tool
• Communicate to Programme Team parts requiring PPIR
> UNV2 for underbody & powertrain parts
> UPV3 for upperbody parts
• Understand what needs to be measured
> In particular YC/YS characteristics
• Consider measuring new features / sections only for reused modified parts
> Review & agree measurement strategy with suppliers
• Consider whether the generic measurement requirements will suffice
Once PPIRs are submitted
• Review parts for suitability to build
• Indicate approval / non-approval of part at http://rads.portsmouth.jlrint.com/ppir/
> Approve in accordance to classification rating guidelines
> GSI PPIR support site
> Training package now in Catalyst, search for PPIR tool
PPIR
Role of JLR Engineering
Before distribution of PPIR
• Understand what needs to be measured
> In particular YC/YS characteristics
• Consider measuring new features / sections only for reused modified parts
> Review & agree measurement strategy with JLR engineering
Once PPIRs are distributed
• Populate the PPIR pro forma with agreed information
• Embed all supporting documents to the relevant section
• Compress the PPIR into a .zip file to reduce file size if required
• Return completed pro formas by emailing to [email protected]
If PPIRs are rejected
• Correct all errors identified and resubmit
• If there are non-conformances which cannot be corrected, submit recovery plan and
timing
Note: an automated message will be sent to supplier when a PPIR is reviewed for
approval to indicate outcome
PPIR
Role of Supplier
The PPIR Tool must be used for all M1, VP and HTFB build events (and the associated
Quality Loops where used), irrespective of size and number of parts due in.
Before distribution of PPIR
• BOM creation and validation
> Identify parts which are not delivered under PSW (with support from PD)
> Includes identifying key contacts within suppliers
• These are contacts who will receive communications and PPIR templates
• Create the programme in PPIR Tool http://rads.portsmouth.jlrint.com/ppir/
> Including administration throughout preparation to the build event
• GSI team can provide support and guidance to this activity
> Training package now in Catalyst, search for PPIR tool
• Agree timing of PPIR submission with PD and supplier
• Consider timing for parts which are not due for first car MRD
• Send out supplier communications to prepare suppliers for PPIRs at MRD -8 weeks
• Organise supplier and engineering training, if required
> To ensure common understanding across the build event
PPIR
Role of JLR Programme Management
At MRD -4 weeks
• Issue out PPIR template using PPIR tool
> It may be necessary to issue out template earlier than this for certain suppliers /
systems, PD to advise / request
Before and After MRD / During Build Event
• Report out and follow-up on parts due in for MRD
• Utilising existing metrics within PPIR tool
Parts Arriving in Plant without PPIRs
• Parts should not be shipped without PD approval of the PPIR submission(s)
> The automated notification from the PPIR tool, once the PPIR is approved,
serves as an ‘OK to ship’ notice to supplier
• They should be placed in Impound / Quarantine until approval is given
PPIR
Role of JLR Programme Management (cont.)
Identify priority parts
• Using High Hurts brochure, PAWS, TGW, etc.
Before distribution of PPIR
• Facilitate discussions to agree measurement contents
• Ensure special characteristics (YS/YC) have been agreed with supplier,
communicated and signed-off via SCSS
Once PPIRs are submitted
• Audit PPIRs and respond as necessary
PPIR
Role of Forward Model Quality (FMQ)
• The purpose is to ensure information contained within approved PPIRs are:
> Reflective of parts manufactured
> Usable for problem solving and concern resolution
> Confirming part pedigree with respect to form, fit and function
• Key aspects under scrutiny:
1. Measurement sample size is suitable for batch delivered
2. Special characteristics are identified
3. Drawing (or suitable visuals) identify what was measured
4. Geometric features conform to engineering specifications
5. Physical and appearance requirements are met as appropriate
6. Parts have been proven to function to design as appropriate
7. Non-conformances found have corrective plans to rectify
• Audits are carried out by Forward Model Quality Programmes
> Audit failures are raised to engineer responsible for the part
• To re-evaluate PPIR approval
• Work with supplier to correct points of audit failure
PPIR
Auditing
PPIR
Summary
• Purpose is to ensure parts are suitable for build
> Confirms parts are made to spec for form, fit and function
• Required for all non-PSW parts at prototype build phases, up to HTFB
> Including carryover and reused parts with new tools
> Also includes software updates, with and without physical changes
• Measurement requirements are driven by Engineering
> Determined by FMA activities, summarised by SCSS
> FMQ will provide support where required / necessary
• JLR Engineering notify Programme Team of parts requiring PPIR by UNV2 / UPV3
• Pre-populated templates are distributed 20 working days before MRD
• Engineering approval of submitted PPIRs required before MRD
> This approval serves as ‘OK to ship’ for supplier to deliver parts to plant