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ISTC-IETEM-2015 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 134 (2016) 012036 doi:10.1088/1757-899X/134/1/012036

Algorithms development of making special techniques in

APQP manufacturing process of automotive components
D T Safarov, K A Fedorov and A I Ilyasova

Kazan Federal University, Naberezhnye Chelny Institute

Pr. Mira 68/19, Naberezhnye Chelny, Republic of Tatarstan, Russia, 423812

Abstract. Special techniques algorithms are worked out, such as MSA, preparation of
management plans, SPC in the preparation of manufacturing automotive components that
improve its effectiveness.

Features of automotive industry are large volumes of products. The vehicle is a structurally complex
object. Head factory itself is not able to produce many automotive components and is forced to work
with no less than 500 suppliers. And if one of them fails to supply (not provide the quality or hamper
deadlines), problems can arise in the entire corporate system. The complexity of working with
suppliers is determined not only by their number, but also by a variety of automotive components.
These are both large aggregates and all electronic components and a variety of materials, standard
products. Therefore, the headquarter plant is extremely important to work with any supplier by one
and the same technique. Now this is a production part approval process (PPAP) [1].
American motor corporations developed it in the early 1990-s, and today it is standardized on the
global scale. The supplier must submit a package of 19 documents and samples (Fig. 1) to the
consumer after completing pre-production of automotive components previously not supplied, as well
as in the event of provider significant changes in the production. The data set should confirm to the
consumer the quality of the components, the stability of its production processes, as well as the
effectiveness of the quality assurance system supplier. A standardized version of the procedure is
fairly common. All the world's leading corporations develop on its own corporate system based on the
approval of the production, that is, require suppliers to provide more detailed information.
Unfortunately, Russian motor corporations continue to operate facing mainly to the domestic
market. From the time of administrative economy it inherited tradition to accelerate the start of series
production without paying attention to the quality of its preparation.
The basis for production management in our enterprises is still the Taylor system, which was
enough to assign standardized requirements and monitor their implementation. And long-running
managers and specialists, and current students, who are still trained with the same Soviet educational
standards that are designed to train future plans for batch production performers.

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ISTC-IETEM-2015 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 134 (2016) 012036 doi:10.1088/1757-899X/134/1/012036

Package of PPAP 1 A bid for

documents and production
approval of
samples
automotive
component

2 Quality of 3 Quality of
automotive 4 System for
technological
component providing quality
process

2.1 Component samples

2.2 Control sample for
PPAP 3.1 Map process
2.3 Full project data flow 4.1 Quality
2.4 Documentation for 3.2 FMEA process Management Plan
technical changes of the 3.3 Preliminary 4.2 FMEA design
component studies of process of automotive
2.5 Proposals on capability components 4.3
modifying a component 3.4 List of Documentation for
2.6 Results of a measuring qualification lab
component size instruments 4.4 Data on the
measurement 3.5 Analyses of specific
2.7 Materials testing measurement compliance
results / performance processes requirements of the
2.8 Report on consumer
harmonization of
appearance

Fig. 1 Set of documents for approval of the production of automotive components.

For our corporation this procedure has not yet been worked out. The owners of the main plant are
not sure of the prospects for development. They are important only for today's high profitability. Main
factories do not pay enough attention to the objectivity of the data set. Russian specifics of preparation
kit are that all suppliers do not concern about the objectivity of the data set. Instead of cooperation to
strengthen the position of consumers in a competitive market environment they solve a simpler
problem: to stay at any cost among the existing suppliers. And for this is considered valid to cover
existing problems in the production by the formal report, not bothering tracking information from the
technical documentation in the form of PPAP.

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ISTC-IETEM-2015 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 134 (2016) 012036 doi:10.1088/1757-899X/134/1/012036

If the pre-production made with omissions, (it is studied in most universities only as a branch of the
discipline “Production and Management”), then the process documentation and maintenance of PPAP
documents in fact cannot reflect the real state of production.
For a small enterprise specialized in manufacturing parts when PPAP situation occurs, it is
suggested for the representative consumer (he provides interaction) to prepare a work plan agreed with
the customer.
On the plan basis order form is prepared for each performer. In the context of a small business it is
likely to be a representative of the consumer itself, technologist, quality management representative.
Technical work on the design of the kit can be performed by the assistant director.

Fig. 2 Algorithm analysis of measurement processes.

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ISTC-IETEM-2015 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 134 (2016) 012036 doi:10.1088/1757-899X/134/1/012036

Fig. 3 Algorithm of technological process capabilities analysis.

To increase understanding of information value by professionals to manage quality it is proposed to
consider a set of PPAP in relation to the reconciliation of mandatory detention of all documents on
management of production processes. The fact that it is quite often to do this, it is important to do this
as quickly as possible, avoiding mistakes that could lead to a denial of production approval. During
pre-production a number of special procedures is done in accordance with [1, 2, 3, 4]. В том числе
особенное на это этапе особое внимание следует уделить проектированию специального
инструмента, повышающего производительность [5].
Let’s consider algorithms which perform the most complex practical commissioning (Fig. 2.3). So
procedures confirm the suitability of the measurement of quality key indicators which are
accomplished in the following sequence: stability is investigated and then displacement of the
measurement process is estimated and only in case of success of both procedures of convergence and
repeatability is analyzed and then a protocol analysis and registration is issued.
Another procedure is a confirmation of statistical quality (stability) of technological process (SPC).
It requires initial alignment of the content of routings, management planning, briefing operator
registration process conditions - the failure of which may result in the impossibility of the
determination of corrective actions in case of discrepancies.
Наибольшую результативность в улучшении качества продукции можно достичь применяя
одновременно с SPC - методику диагностирования по показателям технологической точности,
когда степень идентификации обрабатываемой детали значительно повышается [6, 7]. C
применением методик непосредственного диагностирования состояния узлов оборудования [8].

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ISTC-IETEM-2015 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 134 (2016) 012036 doi:10.1088/1757-899X/134/1/012036

Algorithms and other mandatory procedures are developed, such as the development of process
flow charts, plans of quality management, action on a result of the production approval by the
consumer.
The entire set of algorithms are the basis of existing management processes in enterprises, which
reduce errors and improve the effectiveness of the procedures for the preparation of production.

References:
[1]State standard R 51814.5-2005. Quality management system in automotive industry. Analysis of
measuring and control processes. (Moscow, Publishng of standards) 63p.
[2] State standard R 51814.3-2001 Quality systems in the automotive industry. Methods for statistical
process control. (Moscow, Izdatelstvo standartov) p.35.
[3] State standard R 51814.4-2004 Quality management systems in the automotive industry.
Production approval of automotive components. (Moscow, Izdatelstvo standartov) p.43.
[4] State standard R 51814.6-2005 Quality management systems in the automotive industry. Quality
management in planning, development and manufacture of automotive components. (Moscow,
Izdatelstvo standartov) p.42.
[5] Kondrashov A G, Safarov DT, Davletshina G K 2015, Bit for the core drilling of nonmetals
(Article) Russian Engineering Research, Volume 35, Issue 8, 26 August Pages 617-618
[6] Kas'yanov S V, Safarov D T. 2004 Diagnosis of technical state of equipment and tools according
to indices of technological accuracy (Article) Avtomobil'naya Promyshlennost Issue 5, Pages 24-
28.
[7] Balabanov I P, Balabanova O N, Groshev A V, Formation of initial data of the workpiece batch
in simulation modeling precision forming, IOP Conference Series: Materials Science and
Engineering, Volume 86, Issue 1, 26 June 2015,
[8] Khusainov R M, Belov S A, Chukhontseva O V 2014, Diagnosis of cnc machine tools in terms
of circular interpolation´s accuracy figure/R M Khusainov, S A Belov, IOP Conference Series:
Materials Science and Engineering, Volume 69, Issue 1