NCR Supplier Webcast Agenda-April 15, 2013
I Welcome and Introduction to the Agenda-Patrick Harger
II Supplier Quality Mission/Responsibilities and Organization
III PPAP Playbook-Revision “E”-Phani Vutukuri
IV PQV(Part Quality Verification) Instructions/ImportancePatrick
V PPM(Part Per Million-Defective)–Change in calculationsPatrick
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NCR Global Supplier Quality Team
Global Director of
Supplier Quality
Patrick S Harger
PPAP and PQV Manager of
Supplier Quality
Phani Vutukuri
European Region Manager of
Supplier Quality
Norbert Teker
India Region Manager of
Supplier Quality
Venkatesan Mohan
APAC Region Manager of
Supplier Quality
YL Chang
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Americas Region Manager of
Supplier Quality
JD Thieke
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European Region Supplier Quality Team
Global Director of
Supplier Quality
Patrick S Harger
European Region Manager of Supplier Quality
Norbert Teker
SQE Engineer
Nairn Mitchell
SQE Engineer
Edina Szujo
SQE Engineer
Open position-UK
SQE Engineer
Open position-BUD
4-5-13
• Total H/C – 5
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Asia Pacific Supplier Quality Team
Global Director of Supplier
Quality
Patrick S Harger
Asia Pacific Region Manager of Supplier Quality
YL Chang
SQE
Tone Li
SQE
Sally Liu
SQE
Yao Peng
SQE
Nemo Ruan
SQE
Amanda Yang
SQE
Leo Xu
4-5-13
• Total H/C – 7
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Global Supplier Quality – Americas
Last update: 2013-04-08
JD Thieke
Supplier Quality
Americas Mgr
North America
South America
Barry Kohut
Luciano Barros
Supplier Quality
Southern Region
Supplier Quality
Manaus Region
Jinwu Fan
Supplier Quality
Midwest Region
Alexandre Iartelli
Supplier Quality
Sao Paulo Region (Metals)
Open
Supplier Quality
Auditor
Dante Maneschi
Open
Supplier Quality
Sao Paulo Region
Repair Supplier Quality
Central America Region
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India-Supplier Quality Team
Patrick Harger
Global Director – Supplier
Quality
Venkatesan Mohan
Manager – India SQE
Srinivasan M
Lakshminarasimhan, T
Ganasaraman J
New
SQE/Sustainment Lead
SQE - Metals
SQE - Plastics
SQE - Electricals
Senthilrajan S
Suresh P
Ganesh CK
New
PQV Engr
PQV Engr
PQV Engr
PQV Engr
4-5-13
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India-PPAP & PQV Team
Phani Kumar V
Manager - PPAP
Rajesh Kanna
Senthilraja
Jagadeesan
Arun Kumar
Pandian
PPAP Planning
PPAP Review
PPAP Effectiveness
NPI Lead
PQV Lead
Vijay
Ramkumar
Chellam
LC Lead
Review Engr.
Senior Engr.
Rakesh
Shanmugaraj
Sathappan
LC Review
Review Engr.
Senior Engr.
TBA
Sadhasivam
NPI Analyst
SSE
Backfill Sriganesh
TBA
Balasubramani J
Project Mgmt.
SSE
Backfill David
Balaji
Gayathiri
Muthu
Sridhar P
Review Engr.
Review Engr.
Senior Engr.
SSA
Guhan
Sasi Kumar
Manmohan
Madhan Kumar
LC Analyst
Review Engr.
Review Engr.
SSA
Venkatesh
Balasubramani N
Ganesh NN
Bharathidasan
Supplier Performance
Review Engr
Review Engr.
SSA
Viswanathan
Gangatharan
Review Engr
Review Engr
TBA
Analyst
Backfill Suresh
TBA
Review Engr.
4-5-13
Backfill Sathish
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NCR New Parts Supplier Quality Responsibilities
• Mission: Create processes and infrastructure within NCR and our Supply Base to
insure all active parts are consistently, statistically capable going into our factories
and field.
• Therefore:
• We perform Supplier Assessments to add/remove from our Approved Supplier List
• We formulate the PPAP policies and procedures and maintain the PPAP (Production Part
Approval Process) Playbook on the NCR website for all suppliers.
• We assess risk factors for each part and establish the PPAP Levels
• We schedule and review all PPAP submissions from suppliers
• We schedule and perform either Physical PQV (Part Qualification Verification) audits at
suppliers or review Eaudits submitted by suppliers.
• We issue SCARs for PPAP or PQV failures and approve all SCAR responses even if
initiated by another part of the organization.
• We manage data to provide PPM and supplier performance data to the suppliers and to
the NCR Organization
• We work with suppliers to resolve quality issues and drive Root Cause Corrective Action
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2013 Parts Quality Plan
Services Parts “Usage” Focus
Top 10 – Asia, Europe, CLA, Top 20
– NAMER
40 Unique Parts
Logistics Parts
“Spend” Focus - 15
Unique Parts
NFF%
Improvement
Target= 23%
Repair Supplier Focus
50 Unique Parts
Mfg Parts Focus
85 Parts (PQV only)
Impact Parts List - 190
parts
OBF%
Improvement
Target= 3.0%
Time to 1st
Failure
Improvement
Time to 2nd
Failure
Improvement
PQV Capability
2013 Start
Target Yield=
97%
2013 Volume Part Focus
3200 parts (includes 190 above)
PQV Count
Achievement
(3200 part/qtr.) =
100%
PQV SCAR
Accountability
Resolve Issues
Preventatively
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PQV Capability
Target = 3200 parts,
Yield = 97%
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PPAP PLAYBOOK
Production Part Approval Process (PPAP)
PPAP Playbook
Changes
Document Number: 497-0469479
Revision: E
Date: April 1, 2013
Prepared by:
Venkatesan Mohan
Ganesha Pandian S
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Major Changes
• Characteristics on the prints & Capability Requirements –
Modified
• Mandatory Fields Interlocked with Production Warrant Sign off
• Packaging & Labeling Requirements added
• Improved Clarity & Reporting of Performance Test Requirements
• Guidance provided for Equivalent / Alternate Material
documentation
• Added features to guide users to avoid Administrative issues
• User Manual Created to help Users on how to fill the PPAP
Playbook and the requirements
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Dimensioning & CpK Standards – Sep 2011
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Dimensioning & CpK Standards – Nov 2012
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Dimensioning & CpK Standards – Feb 2013
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Packaging
 Documentation Requirement
• Production Warrant
• Packaging Test Report
 Test result format provided in PPAP Playbook
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Labels
 Documentation Requirement
• Production Warrant
• Dimension Report
• Material Test Report
• Appearance Report
• RoHS
 PPAP will be Granted “ Interim Approval” with PPAP
PSW sign off
 Full approval granted after Successful LTO
Completion
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• Pop Up Error Message – for any errors in mandatory fields
Pop Up Error Message
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• Pop Up Error Message for If alternate material is used without
RFC approval
•
Do not allow Production Warrant Sign off
Pop Up Error Message
• Once RFC details provided – Production Warrant Sign off is enabled
RFC Number
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Separate Tab sheets added for
New
1.
RoHS Compliance Report
2.
Salt Spray Test Report
3.
Performance Test Report
4.
Balloon drawing
5.
Sub supplier source
6.
Packaging Test Report
New
New
New
New
New
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CCD to RCD
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Request
for PPAP
PPAP
Commit
Date
Actual
Submitted
Date
Review
Date
Accepted
Update to
Merlin & tracker
CCD
Reject
Path
• Performance Measured to Suppliers Committed Dates
RCD – Require d Closure Date
NPI /
ESECC /
ECC DR
Release
Request for
PPAP with
RCD
Submit
PPAP
Review
Date
Approved
Date
Parts Availability
/ AT Builds
B Builds
etc.
RCD
Reject
Path
•
•
Last
Submitted
Date
Performance Measured to NCR Requested Dates
Target to achieve >95% for Q4
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Additional Changes
• PPAP Request shall have
• Engineering Drawing [ OR Print ]
• Drawing from PPAP team – with Critical Dimensions identified
where required – in pdf version
• Required Closure Date [ RCD ]
• Contact Information in case of queries / issues
• Blank Playbook Rev E
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PVQ (Part Quality Verification) Process
Objective:
To routinely verify that suppliers are providing consistent, statistically compliant parts and assemblies to NCR plants ,
repair suppliers and customers.
Preparation for NCR SQ Engineer (SQE) and the Supplier
1. Review PPAP history and revision level on file. Take copy for comparison.
2. Note and take any active Engineering Change Notices to discuss impact
and timing of next PPAP.
3. Determine status of parts to be measured:
A. Preference is to use parts that are being manufactured at time of
PQV or
B. Take parts from supplier stock-note date of manufacture and
revision level or
C. Take parts from NCR stock as last resort.
4. Pull SCARs and PPM/Quality history for reference for continuous
improvement.
5. Pull past PQV history for follow up and notation of consistency of control.
6. The preparation, by the supplier, is critical to be efficient and effective when
the SQE arrives.
7. Parts should be gathered, numbered and data should be taken prior to
SQE arrival.
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PVQ (Part Quality Verification) Process
Objective:
To routinely verify that suppliers are providing consistent, statistically compliant parts and assemblies to NCR plants,
repair suppliers and customers.
On-Site PQV Instructions-II Manufacturing Process/Control Plan Review
A. Review the process flow chart. If it has changed,
supplier should resubmit PPAP.
B. Review Control Plan & data collection. Note any
actions taken when not in control.
C. Verify that the operators know how to STOP the
process and what they need to do contain product and
re-start the process according to their control plan.
D. Assign action plans to supplier if not satisfied with
controls in place and follow up.
E. Review the PFMEA, discuss any additions performed
and/or needed.
F. Issue SCAR(s) as required to assure documented non24
conformances.
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PVQ (Part Quality Verification) Process
Objective:
To routinely verify that suppliers are providing consistent, statistically compliant parts and assemblies to NCR
plants , repair suppliers and customers.
On-Site PQV Instructions-Data Gathering and Analysis
A. For critical dimensions (CD); review Gage R&R (GRR) and note
who were the ‘operators’ and measurement instruments. Assure
that the same operators and instruments are used for PQV.
B. Witness at least 3 samples (of the 30 samples for Cpk
calculation) for all CD when operator is taking data.
C. Collect data, review and draw conclusions relative to
requirement of Cpk>1.67
D. Assign actions items to correct/contain any non conforming parts
from supplier to NCR.
E. Select 5 samples for ‘minor’ dimensions that have had SCARs.
All measurements must be within print tolerance.
F. When there are no critical dimensions for a PQV, review SCARs
for verification of effectiveness with documented evidence.
G. Assure the Control Plan has been modified and/or the PFMEA
modified.
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PPM-Defective-The Basic Formula
Supplier PPM = Quantity of “supplier liable parts defects”
Quantity of all parts receipts
Eligible supplier PPM parts will be those received by NCR into
our factories and warehouses and on the books of NCR
Parts located inside of supplier locations, their distributors and
VMI warehouses are not eligible for PPM defect reporting as
they are not received by NCR
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Rejects counted as Supplier PPM
Parts are rejected from the following areas where deemed
supplier fault
• Reject from NCR WIP inventory
• Reject from NCR stock purge or screen
• Counted regardless of supplier or NCR performing the screen / rework
• Reject from NCR incoming inspection screen or full lot
rejection
• Counted regardless of supplier or NCR performing the screen / rework
• Supplier spills/escapes - recall of defective parts or NCR
finished goods
• Customer spills/escapes – recall of defective parts that
reached customer
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Rejects NOT counted as Supplier PPM
Parts rejected where supplier fault cannot be established or
is yet to be established
• Parts returned to supplier for defect analysis – typically
electronics
• Typically known as “in process” disposition
• Will not be recorded as supplier PPM at time of disposition
• Will be recorded as PPM once supplier analysis is completed
• In transit parts shipped prior to closure of a reported SCAR
• Parts received at NCR at time of raising a SCAR will be counted
• Parts remaining in transit – not yet received by NCR after the closure
of the SCAR will not be counted – will be flagged for quarantine at
incoming
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Rejects NOT counted as Supplier PPM (cont’d)
Transit damage parts
• Will not be counted if damage is due to carrier mishandling
• Will not be counted if legacy packaging is deemed to be inadequate and
needing improvement – correct action is to raise a SCAR for correction
• Will be counted where supplier did not follow their defined packaging process
• Will be counted where supplier did not follow NCR specified packaging
requirements
• No clear specification for the defect
• Will not be counted if the defect is completely within published design
specifications, Corporate standards, drawings, or quality criteria of which they
have been informed.
• Improved criteria should be negotiated with Engineering / PPAP / QA as
required to eliminate ambiguous criteria
• Co-parts rejected
• i.e. when a defective harness damages a motor – the harness supplier is
liable for one defect, the motor supplier is not liable for a defect
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Wrap Up and Summary
 The revised PPAP Playbook (Rev E) is now in force and will be on the NCR website after 4/18/13
 It has been expanded to include items such as packaging and labels
 Access to the PPAP Playbook including forms and training is at:
 http://www.ncr.com/about-ncr/suppliers/manuals-forms-and-templates
 The PPM calculation has been expanded beyond receiving inspection to include all supplier-caused
rejected parts.
 The focus this year is on the 3200 parts we have identified for PPAP and PQV
 The 190 “Impact Parts List” is included in the 3200 parts list
 There will be a higher level of PPAP and PQV performed on assemblies and electronics this
year with more emphasis on identifying critical characteristics of the functioning assembly or
electronic unit.
 Your India PPAP Team, NCR Engineering and your assigned SQE will be in touch with those
suppliers who have parts on the 190 Impact Parts List to focus on field usage and/or field
failures to improve the MTBF (Mean Time Between Failure).
 It is imperative that our suppliers contain issues and drive for sustained, statistical control of their
products delivered to NCR.
 Expect quarterly PQV Audits (either physical audit or Eaudit) by your NCR Team. Please be
prepared!
Thank you for attending. There will be a hard copy of
the presentation available soon on the website.
Are there any questions or comments?
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Contact Information
 My contact information is:
 Patrickshelby.harger@ncr.com
 Cell phone: 802-310-1691
I look forward to traveling to many of your sites in early 2013 to
meet your staff and view your facilities.
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