Foundry Quality Systems: PPAP, APQP, FAI, NDT & IATF 16949
THE 18 ELEMENTS OF PPAP LEVEL 3 FOR FOUNDRIES
When qualifying a foundry for high-volume serial production (automotive engine blocks, heavy equipment transmissions, or hydraulic manifolds), STALFE requires a complete PPAP Level 3 Dossier (QAI-001). Below is the exact operational requirement for each of the 18 mandatory PPAP elements.
| PPAP Element Number & Name | Mandatory Technical Content & Documentation Required | STALFE Acceptance Criteria (Zero Deviation) |
|---|---|---|
| 1. Design Records & CAD Models | Approved 2D engineering drawings (PDF) and 3D CAD models (STEP) annotated with ISO 8062 CT8 tolerances and GD&T datums (A-B-C). |
Exact drawing revision letter stamped and verified against customer purchase order. |
| 2. Engineering Change Documents | Any documented engineering change notes (ECN), deviation authorizations, or concessions agreed between STALFE and OEM buyer. |
Visiškai pasirašė kliento vyriausiasis inžinierius prieš pilant FAI formą. |
| 3. Kliento inžinerinis patvirtinimas | Written sign-off from STALFE engineering approving the pattern layout, gating/risering simulation (MAGMASOFT), and parting line location. |
MAGMASOFT modeliavimas turi parodyti nulinės centrinės linijos susitraukimo karštąsias vietas kritinių viršūnių viduje. |
4. Design FMEA (DFMEA) |
Systematic analysis of potential part design failures under mechanical fatigue, hydrostatic pressure (500 bar), or thermal shock. |
Risk Priority Number (RPN) must be < 100 for all critical operating modes. |
5. Process Flow Diagrams (PFD) |
Visapusiškas liejimo proceso vizualinis žemėlapis: laužo įkrovimas -> elektrinis indukcinis lydymas -> OES -> pilimas -> kratymas -> smūgis -> CNC tekinimas -> CMM -> NDT -> pakavimas. | Turi apimti visus gaunamus, vykstančius ir galutinio patikrinimo tikrinimo vartus. |
6. Process FMEA (PFMEA) |
Rigorous analysis of manufacturing failure risks (e.g., core shift during pouring, damp sand causing gas porosity, or OES drift). |
Must incorporate automated Poka-Yoke checks (e.g., core setting alignment pins and automated radiation monitors). |
7. Control Plan (CP) |
The master operational inspection schedule specifying check frequency, gauge type, and corrective action (CAPA) for every process step. |
Must mandate 100% CMM sampling on first 5 parts and hourly green sand moisture checks (3.0 - 3.5%). |
8. Measurement System Analysis (MSA) |
Statistiniai Gage R&R tyrimai, atlikti su visais CMM, kiaurymių mikrometrais ir suportais, naudojamais kritiniams brėžinio matmenims patikrinti. | Gage Repeatability & Reproducibility (Gage R&R) percentage must be ≤ 10.0%. |
9. Dimensional Results (CMM Layout) |
Complete 100% dimensional inspection reports on 5 to 6 consecutive First Article Inspection (FAI) castings measured across all CAD features. |
All dimensions must fall within ISO 8062 CT8-CT10 raw casting or H7 machined tolerance bands. |
| 10. Medžiagų ir metalurgijos ataskaitos | Certified laboratory test reports: OES chemical composition (% C, Si, Mg, Cr, Mo), tensile/yield tests from cast bars, and nodularity image analysis (ISO 945-1). |
Must prove Nodularity ≥ 85% (ductile iron) and tensile yield properties conforming to EN 1561 / EN 1563 (EN 10204 Type 3.1 signed by independent QA). |