Detta examensarbete är en del i högskoleingenjörsutbildningen vid linneuniversitetet i Växjö. Arbetet är utfört på Ackurat Industriplast AB i Lammhult. Syftet med arbetet är att ta fram samt utveckla fyra av kravelementen i Production Part Approval Process (PPAP) dokumentationen. Kravelementen vilka ingår inom ramen för detta arbete är flödesschema, process FMEA, styrplan samt kontrollinstruktioner. Ackurat har kunder inom fordonsindustrin, dessa kunder ställer höga krav på kvalitén hos produkterna från sina leverantörer. Denna kvalitetssäkring sker dels genom att leverantören skall följa krav ur ISO/ TS 16949 standarden där PPAP är en del av kvalitetssäkringen. Detta innebär att för varje nytt uppdrag så skall PPAP dokumentation bifogas tillsammans med ett utfallsprov. Ackurat upplever att den dokumentation som finns i dagsläget är bristfällig och i behov av uppdatering. Resultatet är utarbetat genom kartläggningsmetoden ” walk through” där en fallstudie av processer har använts . Informationen om processerna har insamlats genom observationer och intervjuer med personal i processerna.  Denna empiristiska information om Ackurats processer har sedan analyserats samt sammanställts med litteraturstudien i teoridelen. Examensarbetet resulterade i fem olika flödesscheman för att illustrera det verkliga flödet i Ackurats processer. Process FMEA utarbetades och åskådliggör felmöjligheter i processflödet. Genom kartläggningsarbetet sammanställdes en styrplan där alla kontroller i processerna ingår. Slutligen utarbetades kontrollinstruktioner för de kontroller som sammanställts i styrplanen.    Arbetet med kartläggningsarbetet av flödesschemat var en viktig del av genomförandet. Detta berodde på att följande dokument är uppbyggda från det aktuella flödesschemat. Stort fokus har således lagts i utvecklandet samt valideringen av de olika flödesschemana. Vid analys av dessa dokument kom författarna fram till att utformade dokument uppfyller syftet samt målen för arbetet. Denna slutsats framgick genom validering med berörd personal på Ackurat samt handledare. Likaväl som att framtagna dokument kan användas i PPAP dokumentation till Ackurats kunder så kan dokumenten användas till det interna förbättringsarbetet i företagets processer.

ABSTRACTION This thesis is focus on discussion of how automobile fastener manufacturer in Taiwan practice QS9000-PPAP and what is different between domestic and foreign automobile fastener suppliers. Chapter 1 makes a brief introduction in this thesis, including research purpose¡Bresearch motive¡Bresearch method and research structure. Chapter 2 describes QS9000 history and discusses some relational writings. Automobile fastener is getting popular in Taiwan fastener industry, because the unit profit is much better than regular parts. Almost automobile parts suppliers in Taiwan only make OEM parts, and because of this reason, it is no need to process fully QS9000 system, however, it is absolute to practice PPAP before mass production. Customers require PPAP based on protection reason, and PPAP can protect customers and OEM factory from any error. At present, there are only few factories in Taiwan can meet standard PPAP requirements, so Chapter 3 will make questionnaires to 50 automobile factories and distributors in the world. The main purpose of questionnaires is to compare main differences of PPAP processes between domestic factories and foreign suppliers and this will greatly help on domestic suppliers production in the future. Chapter 4 and 5 describes standard PPAP procedure and discusses correct FMEA and Measurement system actions, and there are also some examples in this chapter. Chapter 6 accords to the questionnaires results in chapter 3 and analysis the main problem existed in domestic suppliers. Due to many differences between domestic suppliers and foreign suppliers, this chapter will also discuss how to improve the existent differences and try to build a correct concept in PPAP form them. Chapter 7 will summarize this thesis and make some suggestions to domestic automobile suppliers. I hope this thesis will contribute domestic fastener industry a little, and there will be no any claims from customers in the future. Future researchers can continue focus on how to practice QS9000 system in domestic factories without heavy investment.

This thesis is a dissertation to support the development of new domino pericyclic oxy-Cope/ene/Claisen/Diels-Alder reaction, diversity oriented synthesis of PPAPs scaffold via sequential one pot cascade reaction and ethyl aluminum sesquichloride catalyzed highly hindered Diels-Alder reaction. The first part concentrates on the domino pericyclic oxy-Cope/ene/Claisen/Diels-Alder reaction. As a result of this study, we have developed a general methodology for rapidly constructing complex diterpenes and discovered a thermal oxy-Cope/ene/Claisen/Claisen rearrangement, applied to the synthesis of trans decalin benzofurans. The second part involved the development of an efficient synthetic approach towards bicyclo[3.3.1]nonenone core found in many natural products, via a sequential Diels-Alder/gold(I)-catalyzed 6-endo-dig cyclization and its application to the synthesis of a diversified library of PPAPs. Finally, we have developed an efficient synthetic methodology for the formation of cyclohexene rings bearing quaternary carbon centers via an ethyl aluminum sesquichloride mediated highly hindered Diels-Alder reaction. This method solved an important problem encountered in the synthesis of many natural products including PPAPs. This methodology opened new opportunities in the total synthesis of PPAPs.

This thesis is a dissertation to support the development of new domino pericyclic oxy-Cope/ene/Claisen/Diels-Alder reaction, diversity oriented synthesis of PPAPs scaffold via sequential one pot cascade reaction and ethyl aluminum sesquichloride catalyzed highly hindered Diels-Alder reaction. The first part concentrates on the domino pericyclic oxy-Cope/ene/Claisen/Diels-Alder reaction. As a result of this study, we have developed a general methodology for rapidly constructing complex diterpenes and discovered a thermal oxy-Cope/ene/Claisen/Claisen rearrangement, applied to the synthesis of trans decalin benzofurans. The second part involved the development of an efficient synthetic approach towards bicyclo[3.3.1]nonenone core found in many natural products, via a sequential Diels-Alder/gold(I)-catalyzed 6-endo-dig cyclization and its application to the synthesis of a diversified library of PPAPs. Finally, we have developed an efficient synthetic methodology for the formation of cyclohexene rings bearing quaternary carbon centers via an ethyl aluminum sesquichloride mediated highly hindered Diels-Alder reaction. This method solved an important problem encountered in the synthesis of many natural products including PPAPs. This methodology opened new opportunities in the total synthesis of PPAPs.

In terms of Quality, more specifically, the Quality Automotive, we emphasize that the Approval Process Production Parts (PPAP) is characterized by evaluating a series of analyzes of various aspects of manufacturing process of production. Also, refers to the way of reporting the results the process, proving that the vendor has the ability to meet production with the level of quality required by the customer. Quality in need of resources that show where the ERP TECNICON BUSINESS SUITE integrates all departments and business processes with versatility provided by a modular and customizable structure, providing opportunities for solutions aimed at improving communication between all areas of an organization, so specific and complete. Thus, the research aims to define and implement the necessary PPAP procedures for TECNICON company in order to meet the needs of its customers. The implementation is aimed at monitoring and guidance of TECNICON Business Suite users directed to customers. The purpose of use of the system by the company is to provide the use of PPAP for their customers. Thus, the PPAP is characterized by the fact that the need for bureaucratic procedure when clients (where customers TECNICON, are to be PPAP suppliers to their customers) request the documentation on the flow of information between them to review and approval of the PPAP. The methodology was defined as action research, since the researcher provides the search directives during the study period in order to find solutions to the problem in TECNICON in Horizontina (RS). As main results, the implementation stands out PPAP procedures for the use of customers TECNICON Company, was completed from the following tools: Study Capability, DPAR, FMEA, Flow Chart, R & R, Dimensional Report, RAA, RIAI and Linearity. / No âmbito da Qualidade, mais especificamente da Qualidade Automotiva, destaca-se que o Processo de Aprovação de Peças de Produção (PPAP) caracteriza-se por avaliar uma série de análises de vários aspectos de um processo de manufatura. Além disso, refere-se à maneira de relatar os resultados do processo, provando que o fornecedor tem a capacidade de cumprir a produção com o nível de qualidade exigido pelo cliente. Qualidade que necessita de recursos que a comprovam, onde o ERP TECNICON BUSINESS SUITE integra todos os departamentos. Os processos empresariais, com versatilidade proporcionada por uma estrutura modular e personalizável, oportunizam soluções direcionadas à melhoria na comunicação entre todas as áreas de uma organização de maneira específica e completa. Assim, a pesquisa tem como objetivo definir e implantar os procedimentos necessários do PPAP para a empresa TECNICON com o propósito de atender as necessidades de seus clientes. A implantação está voltada ao monitoramento e à orientação dos usuários do TECNICON BUSINESS SUITE direcionada aos clientes. A finalidade da utilização do sistema pela empresa é de proporcionar o uso do PPAP para seus clientes. Dessa forma, o PPAP se caracteriza pelo fato da necessidade do procedimento burocrático, quando os clientes (onde os clientes da TECNICON, passam a serem fornecedores do PPAP para seus clientes) solicitam a documentação referente ao fluxo de informações entre as mesmas para avaliação e aprovação do PPAP. A metodologia foi definida como pesquisa-ação, uma vez que o pesquisador oferece as diretivas de pesquisa durante todo o período de estudo, no sentido de encontrar as soluções do problema na TECNICON, em Horizontina (RS). Como principais resultados, destaca-se a implantação dos procedimentos PPAP para utilização dos clientes da empresa TECNICON, que foi finalizada a partir das seguintes ferramentas: CEP/Estudo de Capabilidade, DPAR, FMEA, Fluxograma, R&R, Relatório Dimensional, RAA, RIAI e Linearidade.

Polycyclic polyprenylated acylphloroglucinols (PPAPs) are structurally complex natural products with promising biological activities. These compounds have interesting anticancer and anti-HIV properties as well as other biological activities making them highly attractive synthetic targets. We report a stereodivergent, asymmetric total synthesis of (−)-clusianone in six steps from commercial materials. We have implemented a challenging cationic cyclization forging a bond between two sterically encumbered quaternary carbon atoms. Mechanistic studies point to the unique ability of formic acid to mediate the cyclization forming the clusianone framework. We also present a biosynthesis-inspired, diversity-oriented synthesis approach for rapid construction of PPAP analogs via palladium-catalyzed dearomative conjunctive allylic alkylation (DCAA). These efficient palladium-catalyzed protocols construct the [3.3.1]-bicyclic PPAP core in a single step from their stable aromatic precursors. The first syntheses of 13,14-didehydroxyisogarcinol and garcimultiflorone A stereoisomers are reported in six steps from a commercially available phloroglucinol. Lewis acid-controlled, diastereoselective cationic oxycyclizations enabled asymmetric syntheses of (−)-6-epi-13,14-didehydroxyisogarcinol and (+)-30-epi-13,14-didehydroxyisogarcinol. A similar strategy enabled production of the meso-derived isomers (±)-6,30-epi-13,14-didehydroxyisogarcinol and (±)-6,30-epi-garcmultiflorone A. A convenient strategy for gram scale synthesis of these stereoisomers was developed utilizing diastereomer separation at a later stage in the synthesis that minimized the number of necessary synthetic operations to access all possible stereoisomers. Finally, we report cationic rearrangements of dearomatized acylphloroglucinols leading to the formation of unprecedented PPAP scaffolds. A novel type A [3.3.1]-bicyclic PPAP was produced as a major product and the structure confirmed by X-ray crystallographic analysis. A novel [3.3.1]-bicyclolactone was also produced utilizing an alternative substrate. Efforts will be described to determine the scope of these rearrangements and type A-selective cyclizations. / 2018-08-09T00:00:00Z

<p>This report is a part of the education at the School of Engineering, Jönköping. The content of the report is based on work conducted at Huskvarna Prototyper AB (HPAB). The task of the report is to find out what reasonable quality demands would be for a short run manufacturer and what short run manufactures should do to satisfy the demands.</p><p>The car manufacturing industry is currently setting high quality demands through QS 9000, Production Part Approval Process (PPAP), on their suppliers. They have to show that they have reliable processes and no quality failures on supplied parts. Statistical process control (SPC) methods are used to comply with the demands set. SPC helps the suppliers to secure that their products are shifting within a small interval. Suppliers can with the help of control charts with a upper control limit and a lower control limit see if their process needs adjustment.</p><p>The car manufacturing industry demands that their suppliers have stable processes. In order to show that the processes are stable a Cpk value is used. It has to be greater than 1.33 to assure a stable process.</p><p>HPAB has got problems with a component called Scuff Plate (a part of Volvo XC 90) which has got its standards set by the car manufacturing industry. The authors of this paper have measured the Cpk value at four different occasions with the help of the measurement program, Rektron. The value on observation 1, was 0.15 but has increased to 1.34, on observation 4, thanks to adjustments made.</p><p>The autors have produced an instruction manual for dealing with future short and long run production.</p> / <p>Denna rapport är en del i en högskoleingenjörsutbildning vid Tekniska Högskolan i Jönköping. Arbetet är utfört på Huskvarna Prototyper AB (HPAB). Uppgiften var att ta reda på vilka kvalitetskrav som är rimliga att ställa på småserietillverkare och vad småserietillverkarna kan göra för att uppfylla kraven.</p><p>Bilindustrin ställer i dag höga krav på sina underleverantörer. De ska kunna visa att de har dugliga processer och på de detaljer de levererar ska det inte finnas några kvalitetsbrister. För att säkerställa hög kvalité jobbar många företag med statistiska metoder där man med hög säkerhet kan visa att ens måttvariation skiftar inom ett litet intervall.</p><p>Statistisk processstyrning (SPS) är ett hjälpmedel för att säkerhetsställa god kvalité. Genom regelbundna mätningar får man fram värden som man för in i ett styrdiagram. Med hjälp av detta styrdiagram, som består av en övre och en undre styrgräns, kan man avläsa när processen måste justeras.</p><p>Bilindustrin kräver att deras underleverantörer har stabila processer. Detta kan man visa genom att ta fram ett korrigeradat maskinduglighetsvärde, Cpk. QS 9000 med dess Production Part Approval Process (PPAP), är den standard som har tagits fram av bilindustrin kräver att processerna ska ha ett Cpk som är större än 1,33 för att processen ska vara godkänd.</p><p>HPAB har problem med detaljen Scuff Plate som är en detalj till Volvo XC90. Vid fyra olika tillfällen har maskinduglighetstest utförst på HPAB:s quintusspress. I rapporten kan man följa hur Cpk-värdet vid första observationen på 0,15 har ökat till 1,34 vid det fjärde testet. Att Cpk-värdet har ökat beror på att man ändrat inställningar mellan de olika observationstillfällena.</p><p>Författarna har tagit fram en mall för hur HPAB, som mestadels tillverkar små volymer, ska hantera de krav som bilindustrin ställer vid både långa och korta serier.</p>

This report is a part of the education at the School of Engineering, Jönköping. The content of the report is based on work conducted at Huskvarna Prototyper AB (HPAB). The task of the report is to find out what reasonable quality demands would be for a short run manufacturer and what short run manufactures should do to satisfy the demands. The car manufacturing industry is currently setting high quality demands through QS 9000, Production Part Approval Process (PPAP), on their suppliers. They have to show that they have reliable processes and no quality failures on supplied parts. Statistical process control (SPC) methods are used to comply with the demands set. SPC helps the suppliers to secure that their products are shifting within a small interval. Suppliers can with the help of control charts with a upper control limit and a lower control limit see if their process needs adjustment. The car manufacturing industry demands that their suppliers have stable processes. In order to show that the processes are stable a Cpk value is used. It has to be greater than 1.33 to assure a stable process. HPAB has got problems with a component called Scuff Plate (a part of Volvo XC 90) which has got its standards set by the car manufacturing industry. The authors of this paper have measured the Cpk value at four different occasions with the help of the measurement program, Rektron. The value on observation 1, was 0.15 but has increased to 1.34, on observation 4, thanks to adjustments made. The autors have produced an instruction manual for dealing with future short and long run production. / Denna rapport är en del i en högskoleingenjörsutbildning vid Tekniska Högskolan i Jönköping. Arbetet är utfört på Huskvarna Prototyper AB (HPAB). Uppgiften var att ta reda på vilka kvalitetskrav som är rimliga att ställa på småserietillverkare och vad småserietillverkarna kan göra för att uppfylla kraven. Bilindustrin ställer i dag höga krav på sina underleverantörer. De ska kunna visa att de har dugliga processer och på de detaljer de levererar ska det inte finnas några kvalitetsbrister. För att säkerställa hög kvalité jobbar många företag med statistiska metoder där man med hög säkerhet kan visa att ens måttvariation skiftar inom ett litet intervall. Statistisk processstyrning (SPS) är ett hjälpmedel för att säkerhetsställa god kvalité. Genom regelbundna mätningar får man fram värden som man för in i ett styrdiagram. Med hjälp av detta styrdiagram, som består av en övre och en undre styrgräns, kan man avläsa när processen måste justeras. Bilindustrin kräver att deras underleverantörer har stabila processer. Detta kan man visa genom att ta fram ett korrigeradat maskinduglighetsvärde, Cpk. QS 9000 med dess Production Part Approval Process (PPAP), är den standard som har tagits fram av bilindustrin kräver att processerna ska ha ett Cpk som är större än 1,33 för att processen ska vara godkänd. HPAB har problem med detaljen Scuff Plate som är en detalj till Volvo XC90. Vid fyra olika tillfällen har maskinduglighetstest utförst på HPAB:s quintusspress. I rapporten kan man följa hur Cpk-värdet vid första observationen på 0,15 har ökat till 1,34 vid det fjärde testet. Att Cpk-värdet har ökat beror på att man ändrat inställningar mellan de olika observationstillfällena. Författarna har tagit fram en mall för hur HPAB, som mestadels tillverkar små volymer, ska hantera de krav som bilindustrin ställer vid både långa och korta serier.

Gold catalysis has become an important tool to achieve highly chemoselective p-acid activation. Exceptional reactivity and selectivity are often encountered under mild reaction conditions. These properties have made gold(I) complexes suitable catalysts for tremendous applications in the total synthesis of natural products. The first chapter will highlight a number of total syntheses using gold catalysis as a key step. The second chapter will cover our application of the gold(I)-catalyzed 6-endo-dig carbocyclization for the synthesis of bridgehead-substituted scaffolds and its use toward the synthesis of PPAP natural products. This research has opened our eyes to the utility of biphenylphosphine ligands, particularly JohnPhos, in gold(I)-catalysis. The reactivity and selectivity exhibited by gold(I) complexes is modulated by the nature of the ancillary ligand. Recent research rationalizes the impact of these ligands on the divergent reactivity observed between cationic and carbenoid intermediates. Our desire to favor the 6-endo-dig pathway has led us toward the discovery of another example of the diagonal reactivity that NHC carbene and biphenylphosphine ligands can bring to gold(I)-catalysis. Chapter three will explain the development of a selective gold-catalyzed synthesis of fused carbocycles . Our selective divergent synthesis of fused carbocycles, combined with the Diels–Alder reaction, has brought new synthetic opportunities. Chapter four will describe our approach toward the synthesis of various polycyclic diterpene-related frameworks. Starting with a unique linear precursor, we have developed a new “one-pot” process for the synthesis of three different polycyclic compounds related to the terpenoid family. The facile modulation of the linear precursor and the use of different dienophiles during the Diels–Alder reaction could enable the synthesis of diverse polycyclic analogues based on three principal frameworks. The gold(I)-catalyzed synthesis of fused carbocycles reached some limitations during our study. Regioselective control was found to be substantially more challenging, with terminal alkynes or alkynes bearing a sterically and electronically neutral methyl substituent. In chapter five, we will discuss how the complementarity of silver(I) catalysis to gold(I) catalysis enabled the selective divergent synthesis of three different fused carbocycles from a unique precursor. Moreover, copper(I) catalysis has given access to the 6-endo-dig pathway on terminal alkynes without the formation of a vinylidene intermediate.

Gold catalysis has become an important tool to achieve highly chemoselective p-acid activation. Exceptional reactivity and selectivity are often encountered under mild reaction conditions. These properties have made gold(I) complexes suitable catalysts for tremendous applications in the total synthesis of natural products. The first chapter will highlight a number of total syntheses using gold catalysis as a key step. The second chapter will cover our application of the gold(I)-catalyzed 6-endo-dig carbocyclization for the synthesis of bridgehead-substituted scaffolds and its use toward the synthesis of PPAP natural products. This research has opened our eyes to the utility of biphenylphosphine ligands, particularly JohnPhos, in gold(I)-catalysis. The reactivity and selectivity exhibited by gold(I) complexes is modulated by the nature of the ancillary ligand. Recent research rationalizes the impact of these ligands on the divergent reactivity observed between cationic and carbenoid intermediates. Our desire to favor the 6-endo-dig pathway has led us toward the discovery of another example of the diagonal reactivity that NHC carbene and biphenylphosphine ligands can bring to gold(I)-catalysis. Chapter three will explain the development of a selective gold-catalyzed synthesis of fused carbocycles . Our selective divergent synthesis of fused carbocycles, combined with the Diels–Alder reaction, has brought new synthetic opportunities. Chapter four will describe our approach toward the synthesis of various polycyclic diterpene-related frameworks. Starting with a unique linear precursor, we have developed a new “one-pot” process for the synthesis of three different polycyclic compounds related to the terpenoid family. The facile modulation of the linear precursor and the use of different dienophiles during the Diels–Alder reaction could enable the synthesis of diverse polycyclic analogues based on three principal frameworks. The gold(I)-catalyzed synthesis of fused carbocycles reached some limitations during our study. Regioselective control was found to be substantially more challenging, with terminal alkynes or alkynes bearing a sterically and electronically neutral methyl substituent. In chapter five, we will discuss how the complementarity of silver(I) catalysis to gold(I) catalysis enabled the selective divergent synthesis of three different fused carbocycles from a unique precursor. Moreover, copper(I) catalysis has given access to the 6-endo-dig pathway on terminal alkynes without the formation of a vinylidene intermediate.