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汽车供应: PPAP 和 SPC

一个提供汽车制造商的研讨会,随时提出两项问题: "你是否同意做这部分?” (PPAP) 和 "你的过程真的能忍受这种宽容吗?” (SPC). 此指南解释了两者从斯克拉奇。

1. 什么是 PPAP?

PPAP 客户的批准是说 "你可以大规模生产这个部分”. 生产没有它意味着整个发货可以被拒绝。 HNR, PPAP 是A 文件批准: 文件,如控制计划, FMEA 测量报告完成,只有这样才会做出决定。

2. 那一 PPAP 流:草案 → 提交 → 批准

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. 什么是 SPC? 宽容和控制的限制并不相同。

这是每个人都新的一点 SPC 混淆:

• 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. 对运营商:输入测量

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 - 每个人都说什么?

6. 什么是“停止”旗帜?

特征定义中有一个检查框: 停止. 它是 离开 默认情况下,应该停留 - 直到客户宣布这一尺寸是关键的。

• 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: 為什麼 RPN 已离开和 AP 取了自己的位置

FMEA 是“什么可以错了,它有多糟糕,我们会抓住它吗?”的书面形式。 S (安全性 - 对客户的影响), 奥 (常见的,有多少次) 二、D (探测 - 我们将抓住它) 所有三 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. 控制计划和特殊特征(CC / SC)

FMEA 控制计划说“什么可以失败”;控制计划说“在哪里,用什么,多少件,我们捕捉它多频繁 - 我们做什么当我们做。 反应计划 — 该领域最常留下空白,最常被审计中询问。

• 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. 证据:是 CC 和 AP-测量高线?

门关闭时:如果工作命令的部分有 活跃 控制计划,标记的行列 CC 或与一个 AP-高 FMEA 路由必须有 至少一个 测量 这个命令。 否则,确认被拒绝,消息称失去的特征和其号码。

当门关闭时,相同的列表显示为 指标: 控制计划选项卡上的“订单检查”框告诉你 CC/AP-高度线是不可衡量的,但什么都不会停止。

10. MSA (重定向R)&问:我们能信任测量吗?

一个 SPC 图表 假设 测量是正确的。 MSA 测试这个假设:一个运营商在同一部分获得相同的数字两次(重复性, EV), 二人,同一数字(可再生性, 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. 供应商(VDA 6.3) 和 A / B / C 等级

供应商 斯科克 测量发生了什么(文件,返回,NCR)。 审计 判断供应商的过程 - 一件坏事可能还没有产生一个坏交付。

• 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 物质申报, 8D 和 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. 多种植物规划:植物规划 MRP 和e-Kanban

当按压、焊接、电子衣和组装在不同的建筑物中坐着时,“我们有 500 公司全域“是无用的:材料可以短暂 會議 當你坐在 压力. MRP 因此,他获得了A 范围 选择器(生产 › 规划栏): 公司 和 仓库 (今天的两种行为)和 植物.

• 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.

电子坎班 对于卡(项目 + 源仓库 + 目标仓库)的卡数计算在服务器上: 日期需求 × 过渡日 × (1 + 安全边缘) ÷ 千量. 板列出可用的库存落在订单点以下的卡片。 转移通过现有转移路径: 四眼批准,植物墙和所有权门都仍然适用 - 坎班船只没有其中。

三个门都是 按默认 (安全门设置): depo.mrp_transit_arz (商品在开放转账上应计算为供应 MRP), depo.kanban_otomatik (董事会应该仅建议,或者还创建转会 命令(和 depo.kanban_tesis_disi (可能一个植物间的坎班会自动承认)。 最后一刻,一个植物间的坎班停止了 TESIS_TRANSFER_ONAY: 自动发射器不能自行通过植物墙冲动。

14. 主持人(/fason)

一个子公司没有 HNR 算,不應該有一個:給他們一個 ERP 用户错误的许可和安全。 相同的模式,员工和经销商门户被用来代替 - 单独的身份表,A PIN 其自己的会议. 地址是 /fason; 公司定义用户名和 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.

有两层控制，都默认关闭：kalite.fason_portal 打开门户本身，关闭时登录返回 403 PORTAL_KAPALI；kalite.fason_portal_asn 打开写入，关闭时门户只读。读取不带来写入风险；允许外部用户向 ERP 写入记录是另一个需要单独决定的事项。

15. 时间阶段和植物能力:“什么时候是短暂的?”

到目前为止 MRP 可能单人 总体 一个项目需要六周,而一个项目需要本周坐在同一行中,在同一红色;规划者无法从屏幕上说出哪个要先买。 当你 depo.mrp_zaman_fazlama 门打开,需求和供应分散到 按日期预订 每周或每月, 1–26 每個布克的累積平衡,並且 第一日期 缺点 出现在序列上。 点击此日期打开了布克特条:需求、供应和平衡布克特。

植物能力。 接近工厂的 MRP 点击“Plant Capacity”按钮(uretim.tesis_kapasite 门,按默认方式开。 那一 留下 开放工作订单的数量转换为路由分钟(多卡维特工具) 量/cavity × 时间), 按订单日期分布到包装箱,并与附加到工厂的机器的分钟容量进行比较。 哪个机器是属于的 衍生 从 URT_MAKINE.DEPO 通过仓库政策的工厂;没有单独的工厂领域被添加到机卡,因为写同一个事实在两个地方意味着两者将分开。