Bantuan › PPAP & SPC

Pembekalan Kereta : PPAP dan SPC

Sebuah bengkel yang menyediakan pembuat kereta ditanya dua soalan berulang-ulang: "Adakah anda bersetuju untuk membuat bahagian ini?" (PPAP) dan "Adakah proses anda benar-benar boleh menahan toleransi ini?" (SPC). Panduan ini menjelaskan kedua-duanya daripada scratch.

1. Apa yang PPAP?

PPAP Adakah kelulusan pelanggan berkata "Anda boleh menghasilkan bahagian ini secara besar-besaran". Menghasilkan tanpa itu bermakna keseluruhan penghantaran boleh ditolak. dalam HNR, PPAP Adalah A fail kelulusan: dokumen seperti pelan kawalan, FMEA Laporan pengukuran telah selesai dan keputusan hanya akan dibuat.

2. yang PPAP Rancangan : diserahkan dan diluluskan

1. Open a record — part code and revision are mandatory; PPAP is granted to one specific revision of a part.
2. List the required documents — control plan, PFMEA, measurement report… Which ones are mandatory varies by customer, so the list is yours to set.
3. As documents are completed, mark them "done".
4. A manager makes the decision. If even one mandatory document is missing, approval is refused — approval granted with missing paperwork is the single most audited item.

3. Apa yang SPC? Perbezaan antara toleransi dan kawalan bukanlah perkara yang sama.

Inilah yang baru bagi semua orang untuk SPC Perbezaan :

• Tolerance is what the customer demands: "the diameter must be between 9.9 and 10.1 mm."
• Control limits are the process's own voice: "your machine naturally produces between 9.98 and 10.02."
• On the chart the tolerance is drawn red and the control limit dashed amber. A point past the amber means the process changed; past the red means the part is scrap.

4. Untuk pengendali: memasukkan pengukuran

1. Production window → SPC tab. Pick the characteristic you measured from the list (part + e.g. "Diameter").
2. Type the values into one box, separated by spaces or commas: 9.98 9.99 10.01 10.00 10.02. All five are stored as one subgroup.
3. If the measurement belongs to a work order, fill in the Work order no box — only then does the stopping gate apply to that order.
4. Save. If any value is out of tolerance, the warning turns red and tells you what to do next.

5. Cp, Cpk, Pp, Ppk - apa yang dikatakan oleh setiap orang?

6. Apa yang ‘berhenti’ bendera?

Terdapat kotak semak dalam definisi ciri: berhenti. Ia ialah keluar secara lalai dan sepatutnya berhenti - sehingga pelanggan mengisytiharkan dimensi itu kritikal.

• Off: an out-of-tolerance measurement is only recorded and shows up in reports. Production does not stop.
• On: if that order has an unresolved out-of-tolerance measurement, the work order moves to stopped and no confirmation can be written. Once the decision is recorded the order returns to its previous state by itself — nobody has to remember to "reopen the order".
• Not measuring at all is not a block. An unmeasured characteristic is only listed as a warning; making measurement mandatory would lock the line in a one-person shop.

7. FMEA: Mengapa RPN telah pergi dan AP mengambil tempatnya

FMEA Adakah bentuk yang ditulis "apa yang boleh salah, betapa buruknya, kita akan menangkapnya?" S (Keselamatan - kesan kepada pelanggan) O yang (Bagaimana kerap dan berapa kerap) D (Penyelidikan - kita akan menangkapnya) Ketiga-tiga daripada mereka adalah 1-10.

• AP High (red): either write an improvement action or write down why no action is taken. HNR will not save a high-priority row with an empty action field.
• AP Medium (amber): an action is expected but not mandatory.
• AP Low (grey): action is optional.
• DFMEA / PFMEA are two different questions about the same part (design and process) and live in separate records; they cannot be mixed.

8. Rancangan dan ciri-ciri khas (CC / SC)

FMEA kata "apa yang boleh gagal"; rancangan kawalan kata "di mana, dengan apa, berapa banyak keping, berapa kerap kita menangkapnya - dan apa yang kita lakukan apabila kita melakukan." Rancangan Reaksi — bidang yang paling kerap meninggalkan kosong dan paling kerap ditanya mengenai dalam audit.

• CC (critical characteristic) — a dimension with safety or regulatory impact. HNR will not save a CC row without a link to an SPC characteristic: an unlinked CC is only a label, and the system cannot ask "was it measured?".
• SC (significant characteristic) — affects customer satisfaction or fit; linking is recommended but not required.
• Level: prototype · pre-launch · production. Three plans can sit side by side for one part; the gate only looks at the active one.
• The row list has a CSV button for the shop floor. The PDF design of the traveller card is not part of this round.

9. Pintu pengesahan: Adakah CC dan AP-Tahap yang tinggi diukur?

Apabila pintu masuk: jika bahagian perintah kerja mempunyai Aktiviti yang Rancangan kawalan, baris yang ditandakan CC atau berkaitan dengan satu AP-Tinggi FMEA Roda mesti mempunyai Sekurang-kurangnya satu Pengukuran kepada perintah itu. Jika tidak, pengesahan ditolak dan mesej menamakan ciri yang hilang dan nombornya.Sebaik sahaja pengukuran dimasukkan, pintu terbuka sendiri.

Apabila pintu keluar, senarai yang sama muncul sebagai Indikator: kotak "Pesan semak" pada tab Rancangan Kawalan memberitahu anda yang CC/AP-Garis tinggi tidak diukur, tetapi tiada apa yang berhenti.

10. MSA (Kejadian R&Q: Bolehkah kita mempercayai pengukuran?

dan SPC Jadual Menganggap Pengukuran itu betul. MSA (satu pengendali mempunyai nombor yang sama dua kali pada bahagian yang sama)boleh diulang, EV), orang yang mempunyai jumlah yang sama (boleh diulang, AV)?

• Open a study: device, characteristic, parts × operators × trials (AIAG suggests 10 × 3 × 3). If tolerance is left blank it is taken from the SPC characteristic.
• Fill the grid and press Calculate. The result box shows %EV, %AV, %GRR, %PV, ndc and which base (tolerance or total variation) the percentages used.
• Acceptance: %GRR < 10 accept · 10-30 conditional · > 30 reject, plus ndc ≥ 5. The thresholds are settings (kalite.msa_grr_esik / _iyi / _ndc_alt).
• A number from thin data is not hidden but not presented as reliable: a "LOW DATA" badge sits next to it.
• In an attribute study cells take 1/0; within- and between-appraiser agreement and kappa are computed (≥0.75 accept).

11. Pengurusan Perkhidmatan (VDA 6.3) Kelas A/B/C yang

Pembekal Tarikh Scorecard mengukur apa yang berlaku (dokumen, pengembalian, NCRs). Audit menilai proses pembekal - proses yang buruk mungkin tidak menghasilkan penghantaran yang buruk sehingga kini. mereka adalah rekod berasingan dan duduk di samping pada skor.

• Scores follow the VDA scale: 0 · 4 · 6 · 8 · 10. There are no values in between; there is no such thing as "6.5 conformity".
• A 0 or 4 is a finding: it cannot be saved with an empty action field. A low score with no action is the easiest way to make an audit look "done".
• An unanswered question does NOT count as 0 — it stays out of the denominator. The percentage is the percentage of what was audited, and the number of blanks is reported separately.
• Class thresholds are parameters: A ≥ 90, B ≥ 80, below that C (kalite.denetim_sinif_a / _b). VDA's own downgrade rules depend on the customer specification and are not invented here — element percentages are shown separately and the decision is human.
• Question texts are not seeded: the VDA 6.3 catalogue is a copyrighted publication. The P1..P7 element structure is ready; the company enters its own questions.
• A closed audit cannot be edited. To correct it, open a new audit; the old report stays with its date.

12. IMDS Pernyataan bahan, 8D dan EDI

• IMDS — what the part is made of (material, CAS number, share, grams) is recorded. The CAS check digit is verified: a wrong CAS silently defeats the restricted-substance scan. For a part with a bill of materials the declaration is rolled up from the components; a component without a declaration is not hidden but listed as "missing declaration" — the number one reason IMDS submissions are rejected. When the ELV (2000/53/EC Annex II) lead/mercury/cadmium/hexavalent-chromium thresholds are exceeded a warning appears; production is not stopped, the exemption call belongs to the engineer. The official IMDS XML is out of scope for this round.
• 8D — no new table was created: the existing NCR/CAPA record already holds half of 8D (root cause = D4, corrective action = D5, closure = D8). The six missing steps were added as columns. An empty step is not hidden; in a report sent to the customer a missing step is the reason for rejection. An OEM-format PDF is for a later round.
• EDI — the customer's order/release message is received as JSON or CSV and its fields are bound to ours through a mapping table the company defines. The message is written to the existing integration ledger and an idempotency key prevents the same message being processed twice. Processing produces an order draft plus a production request; it does not open a work order and does not debit the customer — turning the draft into a real order is a human decision. A line whose part code cannot be resolved is not skipped; it stays as "unmatched". ⚠ The OEM's real EDIFACT/VDA segment schema is not invented before the customer specification arrives; the OFTP2/VAN transport layer is out of scope.

13. Perancangan pelbagai tumbuhan: tumbuhan-sepeda MRP dan e-Kanban

Apabila menekan, menggiling, e-cover dan perhimpunan duduk di bangunan yang berbeza, "kami mempunyai 500 syarikat-syarikat luas” tidak berguna: bahan boleh pendek dalam Perhimpunan semasa duduk di dalam Tekan. MRP Oleh itu, beliau mendapat a Lapangan Selektor (Pengeluaran › Bar Rancangan): Syarikat dan Penyimpanan (Kedua-dua perilaku hari ini) dan tumbuhan.

• In plant scope, netting sums ALL warehouses mapped to that plant, and demand (open work orders and production requests) is filtered to the same plant. Every factory sees its own shortage.
• Plant membership is not copied anywhere new. It is derived from the warehouse mapping (Corporate › Plant / Warehouse). The only new field is the production request's target warehouse.
• Never a silent “nothing missing” over an empty set. If no warehouse is mapped the plan refuses to run and MRP_TESIS_DEPOSUZ tells you to map one. Sending warehouse and plant together returns MRP_KAPSAM_CAKISMASI — there is no silent precedence rule.
• Requests with no target warehouse belong to no plant; the plan header states how many were left out. You can map them in bulk from the multi-select list on the Corporate › Plant / Warehouse screen.
• Source-plant suggestion: when an item is short and another plant holds a surplus, that plant is shown on the row — an internal transfer is considered before purchasing.

dan kanban. Untuk kad (item + sumber gudang + sasaran gudang) bilangan kad dikira pada pelayan: N = permintaan harian × hari transit × (1 + margin keselamatan) ÷ bin kuantiti. Jadual senarai kad yang stok yang tersedia telah jatuh di bawah titik perintah. Pergerakan bergerak melalui laluan pemindahan yang sedia ada: empat mata kelulusan, dinding tumbuhan dan pintu pemilikan semua masih digunakan - kanban kapal tidak ada daripada mereka.

Tiga pintu gerbang ini ialah Menghapus secara default (Situs untuk pintu keselamatan : depo.mrp_transit_arz (Bahan-bahan yang dibayar dalam pemberian hendaklah dikira sebagai bekalan MRP), depo.kanban_otomatik (Jika jadual hanya perlu mencadangkan, atau juga membuat pemindahan Perintah dan depo.kanban_tesis_disi (Mungkin kanban antara tumbuhan membawa kelulusan secara automatik). Apabila yang terakhir keluar, kanban antara tumbuhan berhenti dengan TESIS_TRANSFER_ONAY: Sebuah pemicu automatik tidak boleh melompat melalui dinding tumbuhan sendiri.

14. Portal Sub kontraktor ( / fason)

Sub kontraktor tidak mempunyai HNR dan tidak boleh mempunyai satu: memberi mereka ERP pengguna salah untuk kedua-dua lesen dan keselamatan. corak yang sama seperti kakitangan dan portal peniaga digunakan sebaliknya — Jadual identiti yang berasingan, a PIN dan sesi sendiri. Alamat ialah /fason; Syarikat ini mendefinisikan nama pengguna dan PIN.

• Only their own records. The supplier sees the subcontract packages, accreditation certificates and audit score tied to their own customer code. Asking for someone else's package returns 404 — a 403 would leak that the record exists.
• Identity is never read from the request. The customer code is stamped from the session on every call; writing a different one into the request body changes nothing.
• The portal creates no stock movement, issues no delivery note and does not change the shipment status. The supplier only reports (ASN number, lot, serial list, measurement report file). The dispatch decision belongs to the HNR user, because the accreditation gate runs there.
• The PIN lock is per user: five wrong attempts lock that account for 15 minutes and another supplier in the same office is unaffected. “No such user” and “wrong PIN” return the same message so account names cannot be probed, while the server log distinguishes them.
• Audit questions are never shared. The supplier sees the score, the A/B/C class and the number of open actions; the VDA 6.3 question catalogue stays with the company.

Terdapat dua buah pintu dan kedua-duanya Menghapus secara default: kalite.fason_portal membuka portal itu sendiri (login mendapat 403 PORTAL_KAPALI (Selepas penutupan dan kalite.fason_portal_asn membuka penulisan (portal hanya dibaca semasa ditutup). Membaca tidak membawa risiko; membiarkan pengguna luar menulis baris ke dalam ERP Ini merupakan keputusan yang berasingan.

15. Masa fasing dan kapasiti tanaman: "apakah ia pendek?"

Sebelum ini MRP melaporkan kekurangan jumlah keseluruhan. Item yang diperlukan enam minggu lagi dan item minggu ini muncul pada baris sama dengan warna merah sama; perancang tidak dapat menentukan pembelian yang perlu didahulukan. Apabila kawalan depo.mrp_zaman_fazlama dibuka, permintaan dan bekalan dibahagikan kepada tempoh mengikut tarikh perlu, mingguan atau bulanan, 1–26 tempoh. Baki terkumpul setiap tempoh dikira dan tarikh kekurangan pertama muncul pada baris. Klik tarikh itu untuk membuka jalur tempoh yang menunjukkan permintaan, bekalan dan baki setiap tempoh.

Kapasiti tumbuhan Berhampiran dengan Pabrik-Pabrik MRP Terdapat butang “Plan kapasiti” (uretim.tesis_kapasite Pintu, keluar secara lalai yang kekal jumlah pesanan kerja terbuka ditukar kepada minit laluan (untuk alat multi-cavity Kantiti/kekuatan × masa), disebarkan ke dalam bucket mengikut tarikh pesanan dan dibandingkan dengan kapasiti minit mesin yang dilampirkan kepada kilang. yang mana sebuah mesin yang digunakan adalah Pengeluaran daripada URT_MAKINE.DEPO melalui kilang kebijakan gudang; tiada medan kilang yang berasingan ditambah kepada kad mesin, kerana menulis fakta yang sama di dua tempat bermakna kedua-duanya akan bertiup secara berasingan.