Livarski sistemi kakovosti: PPAP, APQP, FAI, NDT & IATF 16949
18 ELEMENTOV PPAP STOPNJE 3 ZA LIVARNE
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.
| Številka in ime elementa PPAP | Zahtevana je obvezna tehnična vsebina in dokumentacija | STALFE Merila sprejemljivosti (ničelno odstopanje) |
|---|---|---|
| 1. Oblikovalski zapisi in modeli CAD | Approved 2D engineering drawings (PDF) and 3D CAD models (STEP) annotated with ISO 8062 CT8 tolerances and GD&T datums (A-B-C). |
Pismo o natančni reviziji risbe je žigosano in overjeno glede na naročilnico stranke. |
| 2. Dokumenti o tehničnih spremembah | Any documented engineering change notes (ECN), deviation authorizations, or concessions agreed between STALFE and OEM buyer. |
V celoti podpisan s strani glavnega inženirja stranke pred vlivanjem kalupov FAI. |
| 3. Inženirska odobritev stranke | Written sign-off from STALFE engineering approving the pattern layout, gating/risering simulation (MAGMASOFT), and parting line location. |
Simulacija MAGMASOFT mora pokazati žariščne točke brez središčne črte znotraj kritičnih izboklin. |
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) |
Vizualno preslikavo livarskega procesa od konca do konca: polnjenje odpadkov -> električno indukcijsko taljenje -> OES -> vlivanje -> stresanje -> peskanje -> CNC struženje -> CMM -> NDT -> pakiranje. | Vključevati mora vsa vhodna, medprocesna in končna vrata za preverjanje inšpekcije. |
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) |
Statistične študije R&R Gage, izvedene na vseh CMM, mikrometrih izvrtine in čeljusti, ki se uporabljajo za preverjanje kritičnih dimenzij risb. | 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. Materialna in metalurška poročila | 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). |