Yordam › PPAP & SPC

Auto‘lar bilan: PPAP Yiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiy SPC

Avtomobil ishlab chiqaruvchiga qismlar beradigan ustaxonada ikki savol doim so‘raladi: “bu qismni ishlab chiqarishga ruxsatingiz bormi?” (PPAP) va “jarayoningiz bu joizlikni haqiqatan ushlay oladimi?” (SPC). Qo‘llanma ikkalasini boshidan tushuntiradi.

1. Nadiq o‘ PPAP?

PPAP — mijozning "bu detalni seriyali ishlab chiqara olasiz" tasdig‘i. Tasdiqsiz detalni seriyali ishlab chiqarish jo‘natilgan tovarning butunlay rad etilishini bildiradi. HNRda PPAP hujjatlar to‘plami tasdig‘i: nazorat rejasi, FMEA, o‘lchash hisoboti kabi hujjatlar tugatilib, keyin qaror beriladi.

2. PPAP jarayoni: qoralama → taqdim etilgan → tasdiqlangan

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. Nadiq o‘ SPC? Tolerans və kontrol limiti bilan bilan bilan olmaygan.

Bu qotʻi bütün yeni SPC Yiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiy

• 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. Operator: qizimliklar qizimliklar

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 — qot o‘zʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻyʻy

6. «Suping» baytadi?

Xarakteristika ta’rifida To‘xtatuvchi katagi bor. Standartda o‘chirilgan va mijoz o‘lchovni muhim deb belgilamaguncha shunday qolsin.

• 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: Nadi RPN Yatdan yadi AP O‘zadi’ni

FMEA — “nima buziladi, qanchalik yomon, sezamizmi?”ning yozma shakli. Uch son berasiz: S (og‘irlik — mijozga ta’sir), O (sodir bo‘lish — qanchalik tez), D (aniqlash — o‘tib ketsa sezamizmi). Uchovi ham 1-10 oralig‘ida.

• 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. Nazorat rejasi va maxsus xususiyat (CC / SC)

FMEA "qanday xato bo‘lishi mumkin" deydi; nazorat rejasi "uni qayerda, nima bilan, nechta donada, qanchalik tez-tez topamiz va topganda nima qilamiz" deydi. Har satrda javob harakatlari rejasi bor — nazorat rejasida eng ko‘p bo‘sh qoladigan va auditda eng ko‘p so‘raladigan maydon shu.

• 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. U‘ziyari: o‘ziyari CC Yiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiy AP-Uqlar bilan bilan bilan bilan?

Nazorat yoqilganda: ish buyrug‘i detalining faol nazorat rejasi bo‘lsa, undagi CC belgilangan yoki AP-High FMEA satriga bog‘langan satrlar uchun shu buyruqda kamida bitta o‘lchov bo‘lishi kerak. Aks holda tasdiq rad etiladi va xabar yetishmagan xususiyat nomi hamda raqamini ko‘rsatadi. O‘lchov kiritilishi bilanoq nazorat o‘zi ochiladi.

Tekshiruv o‘chirilganda ayni ro‘yxat ko‘rsatkich bo‘ladi: Nazorat rejasi bo‘limining “Buyurtma tekshiruvi” katagi qaysi CC/AP-Yuqori satri o‘lchanmaganini aytadi, ammo hech narsani to‘xtatmaydi.

10. MSA (Gage R&R): o‘lchovga ishonsa bo‘ladimi?

SPC grafigi o‘lchov to‘g‘riligini faraz qiladi. MSA shu farazni tekshiradi: bir operator bir detalni ikki marta o‘lchab ayni sonni oladimi (takrorlanuvchanlik, EV), ikki boshqa operator ayni sonni oladimi (qayta hosil qilinuvchanlik, 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. Yetkazib beruvchi auditi (VDA 6.3) va A/B/C sinfi

Ta’minotchi baholash varag‘i bo‘lgan ishni o‘lchaydi (hujjat, qaytarma, NCR). Audit esa jarayonni baholaydi — yomon jarayon hali yomon yetkazish qilmagan bo‘lishi mumkin. Ikkalasi alohida qayd, varaqda yonma-yon.

• 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 materializmi bilan, 8D Yiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiyiy 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. Multi-plants planlar: Plants-scoped MRP E-Kanban qumq

Presslash, payvandlash, kataforez va yig‘ish boshqa-boshqa binolarda bo‘lsa, “korxona bo‘yicha 500 ta bor” deyish foydasiz: material yig‘ishda yetishmasdan, presslashda turgan bo‘lishi mumkin. Shu sabab MRPga qamrov tanlagichi qo‘shilgan (Ishlab chiqarish › Rejalash tasmasi): Umumiy va Ombor (ikkalasi mavjud ishlash tartibi), shuningdek Obyekt.

• 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.

e-Kanban. Kod+manba+maqsad kartasi soni serverda: N = ⌈ kunlik talab × tranzit kuni × (1 + xavfsizlik ulushi) ÷ idish miqdori ⌉. Panel erkin zaxirasi qayta buyurtma nuqtasidan pastlarini. Faollashuv mavjud ko‘chirish yo‘lida: to‘rt ko‘z, zavod chegarasi, mulk nazorati, hech biri o‘tkazilmaydi.

Uchala nazorat ham odatda o‘chirilgan (Sozlamalar › Xavfsizlik nazoratlari): depo.mrp_transit_arz (yo‘ldagi ko‘chirish tovari MRP taklifi hisoblansinmi), depo.kanban_otomatik (panel faqat tavsiya bersinmi yoki ko‘chirish buyrug‘i ham ochsinmi), depo.kanban_tesis_disi (zavodlararo kanban avtomatik rozilik olsinmi). Oxirgisi o‘chirilganda zavodlararo kanban TESIS_TRANSFER_ONAY bilan to‘xtaydi; avtomatik ishga tushirish zavod chegarasini o‘zicha buzmaydi.

14. Subcontractor portal (/fason)

Subpudratchida HNR hisobi yo‘q va bo‘lmasligi kerak: unga ERP foydalanuvchisini ochish litsenziya va xavfsizlik jihatidan noto‘g‘ri. O‘rniga xodim va diler portallaridagi ayni usul qo‘llanadi — alohida identifikatsiya jadvali, PIN va o‘z seansi. Manzil /fason; foydalanuvchi nomi va PINni korxona belgilaydi.

• 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.

Ikki nazorat darajasi bor, ikkalasi ham odatda o‘chiq: kalite.fason_portal portalni ochadi (o‘chiq paytda kirish 403 PORTAL_KAPALI oladi), kalite.fason_portal_asn esa yozishni ochadi (o‘chiq paytda portal faqat o‘qiladi). O‘qishning foydasi xavfsiz; tashqi foydalanuvchiga ERPga satr yozdirish alohida qaror.

15. Tadi fasing və plant kapasity: "Nammi koʻshayni?"

MRP avval bir jami yetishmagan miqdor: olti hafta keyin va bu hafta kerak bir satr/qizilda, nima avval xarid qilinishi noma’lum. depo.mrp_zaman_fazlama ochilsa talab/ta’minot muddat bo‘yicha oraliqlarga (haftalik/oylik, 1–26) taqsimlanib yig‘ma qoldiq, ilk yetishmaslik sanasi ko‘rsatiladi. Sanani bosish har oraliq talab, ta’minot, qoldig‘i tasmasini ochadi.

Zavod quvvati. Zavod MRPsi yonida tugma (uretim.tesis_kapasite, odatiy o‘chiq). Ochiq buyruq qolgan miqdori yo‘nalish daqiqasiga (ko‘p uya ⌈miqdor/uya⌉ × vaqt), muddat oraliqlariga, zavod stanok quvvatiga. Zavodi hosil qilinadi, URT_MAKINE.DEPOdan ombor siyosati orqali. Kartaga alohida zavod yo‘q, bitta haqiqat ikki joyda ajraladi.