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 PPIR@jaguarlandrover.com

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

PPIR

Section 2 - Geometry (cont.)

PPIR

Section 2 - Geometry (cont.)

• 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.)

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 PPIR@jaguarlandrover.com

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