Transcript PQR PPAP GUIDE - Polaris Supplier Information System

Teaching Aid
(SCARs are not addressed in this guide)
Last Revised February 18, 2015
Table of Contents
PQR Description ---------------------------3
PQR Received Status -------------------25
SQAM ------------------------------------------4
FAQ -------------------------------------------27
PQR Sample Label ------------------------9
Drawing Status ---------------------------32
Default Level 4 Requirements -------10
DCR & Deviation Status ---------------33
Polaris PPAP Manual --------------------11
Rejected PQR Procedure -------------34
PQR Creation ------------------------------14
Rejected PQR Table of Contents ---35
PQR Form -----------------------------------15
Reason A – Documents ----------------36
“Same as Except” PQR-----------------19
Reason B – Dimensional --------------37
Data Compression -----------------------20
Reason C – Misc -------------------------39
PQR Performance Rating --------------21
Submission Recap -----------------------22
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The PQR System ensures product complies with
all engineering requirements, specifications and
standards specified on the Polaris Design Record
prior to delivery to the designated Polaris site. All
PQRs must be approved (conditional or full
approval) prior to suppliers shipping product.*
Supplier Quality Assurance Manual
The Polaris Supplier Quality Assurance Manual (SQAM) is an online
guide which defines supplier expectations. Please refer to this manual
for information and helpful links.
Imbedded
SQAM
* www.polarissuppliers.com (Supplier
Portal) provides suppliers with access to
many helpful tools and downloadable forms
including the SQAM
SQAM Ref
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http://www.polarissuppliers.com/
View of the Supplier Portal and access to
the SQAM from the Portal
(Note Supplier Policies and Procedures
making the SQAM part of the purchasing
agreement and therefore part of the Design
Record)
SQAM Ref
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Portal Path to SQAM (Cont)
SQAM Ref
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SQAM Table of Contents
SQAM Ref
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Content within the SQAM
SQAM Ref
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Label for PPAP/FAIR Samples
Be sure to ship
samples with the
proper label per the
instructions in the
SQAM (recommended
label color is orange)
SQAM Ref
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Default Level 4 PPAP Request
Polaris exclusive, we do have a
default Level 4 list of requirements if
not otherwise specified on the PQR
SQAM Ref
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Polaris PPAP Manual
Imbedded
PPAP
Manual
PPAP Manual
Last Revised September 17, 2014
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“Blue Books” (PPAP-4, APQP-2, SPC3, FMEA-4, MSA-4, TS Rules-3) which
are used by Polaris Industries can be
purchased at:
www.aiag.org or Amazon.com
There are 3 ways a PQR is created within the
Polaris system:
1. Print Release (initial or revision)
2. Manually created (often used as SCAR’s or in
response to PCR’s)
3. Automated from Mapics when a vendor
number changes
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PQR Creation (Cont)
The information required to generate a PQR:
• Drawing
• Revision
The information required to define a PQR:
• Supplier
• Buyer
• QE (or authorized QA representative)
•
A purchase order is not required to generate, define or process a
PQR
•
Suppliers do not have visibility of the PQR until the PQR is
defined
•
The designated contact in the Polaris Supplier Net system will be notified when a
PQR is defined for your organization
• Important note: Once the PQR is defined to a Supplier’s
organization the supplier has 100% ownership of the
PQR until the PQR is approved by Polaris.
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The Polaris PQR Form
Overview of the PQR
details including
PQR #, Part #,
Supplier & Buyer
Important PQR
dates, both due and
received
submissions are
noted here
Supplier comments related to the PQR
submission (completed by the supplier)
Running PQR history
Polaris site QE
assigned to define
the requirements
and review the
submissions
Submission requirements as defined by the site QE
based on mitigating risk and ensuring design intent.
One or more items may be selected and are due from
the supplier prior to the due date indicated here.
Polaris comments related to the PQR, additional detail, submission
approved, submission rejected noting reasons for rejection, etc.
FAIR and PPAP Requirements (dual dates)
Typically used for engineering
samples (PV, PI, etc.) and
Production Tooling Approval.
Product run on Production Tooling
but not run at rate and/or by
production procedures.
Evidence that all customer Design Record
requirements are properly understood and
that the manufacturing process
(encompassing the entire production
process – production tooling, gaging,
process, materials, and operators) has the
potential to produce product consistently
meeting these requirements during an
actual significant production run at the
quoted production rate.
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Sample Part and Required Documentation Submission as Noted on the PQR
Per the SQAM please place the
shipment method of your sample
part and tracking number here
(this will help if your sample
submission is lost)
Hard copies may
accompany submitted
samples but electronic
copies must be sent for
PQR submissions to the link
above
•
•
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Send all data electronically (in
.xls, .pdf, .tif or .doc format)
via the e-mail link of the
appropriate Quality Engineer
listed in the PQR system.
Please note in the Supplier Issues section the date
electronic documents were submitted, method, and to
whom. If documented here and submitted correctly the
accountability is now with Polaris.
Also used to communicate through the PQR system –
‘Request a Conditional Approval*’, ‘Request a Due Date
Adjustment**’, and all formal requests
* When requesting Conditional Approval provide a brief explanation and a Conditional Approval end date
** Same as above when requesting an adjusted Due Date
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Polaris Comments Section of the PQR
The Comments section of the PQR has a limit to the number of characters we can
use when addressing the submission. We want to communicate as much as we
can in our responses and because of this we often abbreviate our responses. We
thought it might be helpful to explain some of these abbreviations…
rec’d = Received
lvl 4 = Level 4 (referring to PPAP level)
s/b = Should Be referring to the design record requirement (print)
is = The actual measurement
bal = Supplier balloon print number associated with the feature
sub = Submit or submitted
req = Requirements
NCR = Non-Conformance Report
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Same as Except PQR
“Same as Except”
In some cases, in order to better control inventory, Polaris
may release a new part number that is very similar to a
previous part number (slight tooling modification, new tool,
refurb, etc.). The Responsible Quality Representative may
choose to allow a “same as except” type of submission. In
this case, the supplier should reference the previously
approved PQR and Part number on the PSW and include
any changes in parts and PQR documentation from the
previous submission to the new submission”.
Same as Except PQR XXXXX
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Data Compression for Submission
Electronic PQR submissions
can be quite large. In order to
submit the documents via
email to the appropriate QA
please compress by using
PDF, ZIP or PowerShrink
(preferred is PowerShrink)
Note:
Regarding zip files in order for zipped files
to pass through the Polaris firewall the
name Polaris must be in the file name
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www.powershrink.com/
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PQR Performance Rating
Supplier Performance –
Quality
Policy Statement: Quality will have a
30% weight toward the overall GPA in
2012. PPM Performance will make up
20% of the Quality Performance. PQR
(Part Qualification Request)
Performance will make up 10% of the
Quality Performance
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Recap
Send all data electronically (in .xls, .pdf, .tif or .doc format) to the e-mail link of the
appropriate Quality Engineer listed in the PQR system.
Please be sure to include a numbered (bubbled or ballooned) Polaris print with any Dimensional Results
(including FAIR) submissions.
A submission will not be approved based on electronic data alone. A sample part is required.
If the files are “zipped”, please make sure that “Polaris” is included in the name of the .zip file or the e-mail will be
quarantined by the Polaris Firewall (‘sometimes’ the POLARIS needs to be bold).
Please only send one e-mail for each PQR with the PQR number AND part number in the “subject” line of the email.
Dimensional Results (including FAIR’s) shall include 100% measurement of a print
(including notes) unless otherwise requested in the PQR.
If any dimensions do not meet the print/specifications, a Polaris Approved DCR or
Deviation shall be included with the submission.
Make sure that the revision of the part measured matches the revision of the print
AND the revision listed on the PQR.
Please ensure that the print revision states “Released”…NOT “Prerelease” or
“WIP” in the left hand lower corner of the Polaris Title Block (on the print). Only
Polaris Released Prints will be accepted for submission of a PQR.
If you don’t have the Polaris released print, please contact the Polaris Purchasing agent.
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Recap (cont.)
Ship the sample part(s) to the attention of the responsible Quality Engineer listed on the
PQR. Also, include the tracking number on the PQR in the appropriate area.
Sample parts are required for any PPAP or FAIR submission. The sample part(s) must be shipped shortly after the electronic
data is submitted.
PPAP PQR sample parts shall be produced (from production tooling, using production
personnel, and run at rate) off of production tooling.
FAIR PQR sample parts should be produced from production tooling unless otherwise
specified by the QE
Do not ignore a PQR due date or submit late. If you can not meet the PQR due date,
please notify the responsible Quality Engineer through the PQR under Supplier Issues.
The submission package consisting of requested data and a sample part must be
received by Polaris no later than the due date on the PQR – the sooner the better.
Make your request noting to whom (QE), when (date) and why.
Poor practice: submitting the PQR the date it is due
The Sample Part Tag shall be fixed to the shipping containers. The samples shall be free
of charge. DO NOT SEND SAMPLE PARTS WITH INVENTORY / PRODUCTION
SHIPMENTS. DO NOT SHIP THE SAMPLE PARTS AGAINST ANY PURCHASE ORDERS.
The bill of lading AND/OR the Invoice must clearly state that the parts are “samples” at
NO COST TO POLARIS. If samples are shipped against a purchase order, they will be
received into inventory and will not be considered as PQR samples.
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Example of a Data Submission
Example of a PPAP submission
(in Excel format) with embedded
.pdf files in each of the required
element cells.
This method of PQR assembly
ensures the supplier and assures
Polaris that all requirements were
met (at a glance)
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PQR Received Status
PQRs aren’t received until both electronic
submissions AND sample parts are received by QA.
Once received, the received date will display here.
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PQR Received Status (Cont)
Received Status (both
electronic and sample) can
also be found here
Upper location is received in system,
lower location are received notes
Important note: If Polaris indicates
the data & sample are received and the
supplier or Polaris makes changes (any
change involving submit) the PQR
received status will be removed.
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FAQ
If a supplier submits the PQR on the due date and Polaris does not select received
on that day, will the supplier get penalized?
It must be flagged as at least received within the calendar month that it is due PQRs are expected to be submitted
prior to the due date on the PQR.
When there are two due dates in the system (for example 1 for a FAIR and 1 for a
PPAP) and we receive the FAIR data on time, does the due date automatically move
out to the later due date once the first on has passed?
Each requirement date is viewed independently however a PQR is only counted once in a given month. For
example if the FAIR is due in December and the PPAP in January. The FAIR is approved in December. It
counts positively for the supplier in December. The metric does not look at the PPAP date until January.
Confirming the time stamp for calculating “on time” PQRs based off checking
“received”, correct?
Suppliers should try to make sure their submission reaches the plant at least 48 hrs prior to the due date to allow
for it to be processed by plant QA. Plant QA should at least flag it as received within 48 hrs of its arrival at the
plant.
If a supplier submits a late PQR (and they get dinged) and we conditionally approve
the PQR submission when received a new date is set for the conditional approval –
will the supplier get dinged again for being late to the conditional approval date?
If a PPAP is due in December and the supplier has not submitted it by December 31st, they would get dinged. If
we came back in January and conditionally approved the PPAP to be due in January and by January 31st we
had not received the resubmission the supplier would have received two hits. One for December and one for
January.
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FAQ (cont.)
Why will Polaris not accept hard copies of submission data in lieu of
electronic data?
Hard copies cannot be entered into our system and thus viewed by the many people who need access to
the data
Electronic submissions can also be traced verifying date of submission
Why does data need to be submitted in .xls, .pdf, .tif or .doc format?
Data must be submitted in acceptable formats which Polaris can open conveniently
Why are bubbled/ballooned prints required with each Dimensional Results or
FAIR submission?
The numbered print is used to correlate dimensional data from the supplier
When submitted data to the appropriate QE per the PQR request should
anyone else within Polaris be copied?
It is a good idea to copy the Purchasing Agent and the SQE on submissions
Who approves PQRs and what limits do they have?
Polaris QEs are responsible for final approval of PQRs (in MTY SQEs approval PQRs)
Polaris QEs are not authorized (alone) to make decisions outside of the Design Record for non-compliant
submissions unless supported by an approved DCR or Deviation
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FAQ (cont.)
Why must the submitted data be against a RELEASED Polaris drawing?
Polaris Purchasing Agents and Engineers provide suppliers with pre-released drawings for quoting
purposes or early discussion
Preliminary, Pre-release or WIP drawings can change at any time with no notice and are exempt from the
Polaris Release Cycle
The Released drawing is a contractual agreement as noted on the PO
PQRs are automatically generated after a print is released
Only production POs and production drawings can be PPAPd
What if multiple revisions exist in the PQR system for the same P/N?
Previous revision requirements can be moved forward to the latest PQR upon supplier request
This is not done automatically and subject to certain conditions
Examples:
If the earlier revision has never been purchased the earlier PQR can be retracted
If the elements of the next revision has earlier been met the later PQR can be retracted or approved
Earlier PQR included an approved DCR
The PQR may be a SCAR
It may be a supplier change PQR
Other examples/conditions may exist. Please contact the QE listed on the PQR
What if the due date on the PQR cannot be met?
DO NOT ignore the PQR – your metrics will be negatively affected
Notify the QE through the PQR as noted earlier PRIOR to the PQR due date and provide a reason
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FAQ (cont.)
How important is the PPAP/FAIR sample label and sample submission
information in the Supplier Information section of the PQR?
Polaris has many locations and departments. Unless the samples are routed correctly with the correct
information the submitted samples can be delayed or even lost
Providing the Shipper Name, Tracking Number and when shipped in the Supplier Information section of
the PQR allows for:
Tracking if deliveries are lost or delayed
Provides evidence that the supplier complied with the request – on time
How will I know if the sample part ship location been changed?
Always check the Quality Engineer section of the PQR under Ship To: (4th panel right side)
Why must I ship a sample part for a FAIR submission and why must it be
made from production tooling?
FAIRs are used for tooling approval. Unless submitted parts are made from production intent tooling the
production tooling cannot be verified.
Notify the QE through the PQR as noted earlier PRIOR to the PQR due date
What happens to submitted samples after auditing at Polaris?
Samples are scrapped after approval
Sometimes samples may be used for destructive testing and could be destroyed in the process
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FAQ (cont.)
What if I receive a Conditional Approval and the Req Date on the PQR does
not match the Conditional Approval date?
The QE should move the Req Date out to match the Conditional Approval date. It is a manual process so
if the QE failed to adjust the date please contact the QE and request the date be changed. Do this to
avoid a negative metric for being late.
What common problems to we see regarding PQR submissions?
KPCs are not addressed on Control Plans and PFMEAs
Please refer to pg 91 of the AIAG 4th Edition PFMEA Manual under Classification (e)
Cpk values are not submitted for KPCs in the MSA or when requested on the PQR
Tier II supplier documentation not submitted
Submission is not in English
Results must be submitted in the same format as the Polaris drawing – mm not inches
PSW is filled out incorrectly
Requested elements and/or samples not submitted
Submissions are past due
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Drawing Status for Submission
DO NOT SUBMIT PQR
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DCR & Deviation Submissions
Do Not Submit
Do Not Submit
Submit
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This can also be used to avoid a rejection with the initial
submission
Last Updated April 14, 2014
Rejected PQR Contents
Rejection Reason ‘A’ – Documents……….5
Most reasons why a PQR was rejected for documentation and how to address
Rejection Reason ‘B’ – Dimensional….…..6
Most reasons why a PQR was rejected for dimensional issues and how to address
Rejection Reason ‘C’ – Miscellaneous……8
Most reasons why a PQR was rejected for miscellaneous issues and how to
address
*Polaris/Supplier Disputed Quality Measurement Results
The Polaris quality labs are equipped with state of the art measurement tools specific for the type of
products we use. The staff is well trained and experienced at measuring the submitted material we
receive from suppliers. We are not immune from error but 96% of the time when measurements are
challenged by suppliers the Polaris staff is proven to be correct – as verified by the supply base which
disputes the results.
Based on common problems when investigating correlation please take the time to check the following:





How are the parts being measured constrained? Parts that meet the print in a clamped state
most often do not meet the print when in a free state. Unless otherwise noted on the print
Polaris does not clamp the parts being checked.
When switching probes are they recalibrated prior to use?
Is the GD&T being interpreted correctly?
Are we checking to the print without assumptions and shortcuts (#1 hitter)?
Verify your data by “dumbing down” the technique. CMM measurements can be complex;
verify with a height gage, bore gage, or caliper.
If, after careful review, you have determined the product was measured correctly against the released Polaris
drawing/model please contact your SQE or QE named on the PQR
THANK YOU!
The purpose of this guide is to assist suppliers in the
resubmission of PQRs which have been rejected by Polaris
for various reasons.
Please use this guide to resubmit before you contact your
Polaris representative about rejected PQR.
Rejected PQRs need to be addressed and resubmitted ASAP
so not to impact delivery schedules. 10 days or less to
resend data and/or ship a new sample is preferred
Only contact the Polaris representative if this guide does not
address the issue and you need further assistance.
Thank you for helping us build a partnership with our supply
base, you are vital to our overall success