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PPAP Submission

Date Initiated: Part Name Part Number Purchase Order # Engineering Change Level Engineering Change Level Date Supplier Name Street Address City State Zip Phone Number Supplier Contact

PPAP Submission Level Guide Quick reference Level 4 Level 4a Level 4b


- Will be defined by ACTIA during the PPAP request - Predetermined by ACTIA - Predetermined by ACTIA

The additional comments below are only an ACTIA summary of AIAG manual. Refer to AIAG Manual current edition for complete information.
PPAP Requirements AIAG PPAP Fourth Edition

Level 4b

Level 4a

Element Order

Level 1

Level 2

Level 3

Level 4

Level 5

Required Documents

Additional Comments

Part Submission Warrant (PSW)

X X X * X X X

ACTIA PSW only

Upon completion of all PPAP requirements, the organization shall complete the Part submission warrant (PSW). If production parts will be produced from more than one cavity, mold, tool die, pattern, or Production process e.g., line or cell, the organization shall complete a dimensional evaluation on one part from each . These specifics cavities, molds, line, etc..., shall then be identified in the "Mold/Cavity/Production Process" line on a PSW, or in a PSW attachment. A responsible official of the organization shall approve the PSW and provide contact information.

Design Records & Bubbled part print(s).

X X * X X X

ACTIA design record bubbled

The organization shall have the design record for the saleable product/part, including design records for components or details of the saleable product / part. Where the design record is in electronic format, e.g., CAD/CAM math data, the organization shall produce a hard copy (e.g., pictorial, geometric dimensioning & tolerancing (GD&T) sheets, drawing) to identify measurements taken.

Authorized Engineering Change Documentation Customer Engineering Approvals Design FMEA,

X X * X X X X * X * X X X

Various engineering documentation

The organization shall have any authorized engineering change documents form those changes not yet recorded in the design record but incorporated in the product, part or tooling. Where specified by the customer, the organization shall have evidence of customer engineering approval. The product design-responsible organization shall develop a Design FMEA in accordance with and compliant to, customer specified requirements.(e.g., potential Failure Mode and Effects Analysis reference manual) The organization shall have a process flow diagram in an organizationspecified format that clearly describes the production process steps and sequence, as appropriate, and meets the specified customer needs, requirements and expectations (e.g., Advanced Product Quality Planning and Control Plan reference manual). For bulk materials, an equivalent to a process Flow Diagram is a Process Flow Description.

Customer engineering approval proof Can be ACTIA DFMEA Format or an AIAG compliant DFMEA.

Process Flow Diagrams

X *

X X

Any standard flowchart format.

Process FMEA

X *

Can be ACTIA PFMEA Format or an AIAG compliant PFMEA.

The organization shall develop a process FMEA in accordance with and compliant to, customer-specified requirements, (e.g., Potential Failure Mode and Effects Analysis reference manual)

Control Plan

X *

X X

Can be ACTIA format or AIAG compliant format.

The organization shall have a control plan that defines all methods used for process control and complies with customer-specified requirements (e.g., Advanced Product Quality Planning and Control Plan reference manual).

Measurement System Analysis Studies

X *

Not required by ACTIA

The organization shall have applicable Measurement System analysis studies, e.g., gage R&R, bias, linearity, stability, for all new or modified gages, measurement, and test equipment.( see the Measurement Systems Analysis reference manual)

10

Dimensional Results

X X * X X X

The organization shall provide evidence that dimensional verifications required by the design record and the Control Plan have been completed and result indicate compliance with specified requirements. The organization Can use ACTIA Format or shall have dimensional results for each unique manufacturing process, e.g., an AIAG compliantformat cells or production lines and all cavities, molds, patterns or dies. The for dimention report organization shall record , with the actual results : all dimensions (except reference dimensions), characteristics, and specifications as noted on the design record and Control Plan. The organization shall identify the parts measured.

11-1

Material Test Results and Performance test result and related design notes

X X * X X X

Industry Standard reports or test result formats designated by ACTIA.

Material test results shall indicate and include : 1) The design record change level of the parts tested; 2) Any authorized engineering change documents that not yet been incorporated in the design record; 3) The number, date, and change level of the specification to which the part was tested; 4) the date on which the testing took place; 5) the quantity tested; 6) the actual results; 7) The material supplier's name and, when required by the customer, the customer-assigned supplier/vendor code.

11-2

Performance Test Results

X X * X X X

Industry Standard reports or test result formats designated by ACTIA .

The organization shall perform tests for all part(s) or product material(s) when performance or functional requirements are specified by the design record or Control Plan. Performance test results shall indicate and include : 1) The design record change level of the parts tested; 2) Any authorized engineering change documents that not yet been incorporated in the design record; 3) The number, date, and change level of the specification to which the part was tested; 4) the date on which the testing took place; 5) the quantity tested; 6) the actual results;

12

Initial Process Study (Cpk) Capability Studies

X *

Process Capability Study using any statistical package or ACTIA Capability Form.

The level of initial process capability or performance shall be determined to be acceptable prior to submission for all Special Characteristics designated by the customer or organization. The organization shall obtain customer concurrence on the index for estimating initial process capability prior to submission. - Where no special characteristics have been identified, the customer reserve the right to require demonstration of initial process capability on other characteristics. Index > 1.67 : the process currently meets the acceptance criteria. 1.33=< Index =< 1.67 : the process may be acceptable. Contact the authorized customer representative for review of the study results. Index <1.33 : Process does not currently meet the acceptance criteria. Contact the authorized customer representative for a review of study results.

13

Qualified Laboratory Documentation

X X * X X X

Inspection and testing for PPAP shall be performed by qualified laboratory as defined by customer requirements (e.g. an accredited laboratory). the qualified laboratory (internal or external to the organization) shall have a laboratory scope and documentation showing that the laboratory is qualified Lab Scope and outside lab for the type of measurements or tests conducted. proof of accreditation. When an external/Commercial laboratory is used, the organization shall submit the test results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that performed the tests, the date(s) of the tests, and the standards used to run the tests shall be A separate Appearance Approval Report (AAR) shall be completed for each part or series of part if the product/part has appearance requirements on the design record. Upon satisfactory completion of all required criteria, the organization shall record the required information on the AAR. The completed AAR and representative production product/part shall be submitted to the location specified by the customer to receive disposition. AARs (complete with part disposition and authorized customer representative signature) shall then accompany the PSW at the time of final submission based upon the submission level requested.

14

Appearance Approval Report

X X X * X X X

ACTIA format or AIAG format

15

Sample Product Parts

X X * X X X

Upon ACTIA requirements The organization shall provide sample product as specified by the customer.

16

Master Samples

* X X X

The organization shall retain a master sample for the same period as the production part approval records, or a) until a new master sample is produced for the same customer part number for customer approval, or b) where a master sample is required by the design record, Control Plan or inspection criteria, as a reference or standard. The master sample shall be identified as such, and shall show the customer approval date on the Uppon Actia requirements sample. The organization shall retain a master sample for each position of a multiple cavity die, mold tool or pattern, or production process unless otherwise specified by the customer. When part size , sheet volume of parts, etc. makes storage of a master sample difficult, the sample retention requirements may be modified or waived in writing by authorized customer representative.

17

Checking aids

* X X X * X X

Part specific assembly or checking aids

If requested by customer, the organization shall submit with the PPAP submission any pert specific assembly or component checking aid. The organization shall have records of compliance to all applicable customerspecific requirements. For bulk materials, applicable customer-specific requirements shall be documented on the Bulk Material Requirement Checklist.

18

Customer specific requirements

To submit for PCA suppliers only

PPAP SAMPLE PARTS - LABEL


Send identified sample(s). Each sample used for PPAP must be clearly identified with their identification number corresponding with data. Please complete, print in color and attach this page on the outside of each package in plain view of a fork lift/material handler/operator. Put the Packing slip pocket near the label. In the event parts are Loose shipped, a label should be placed on each part. This would apply to parts laying on pallets also. Label on a Painted Part must be wire tied or attached in a way painted surface is protected from label adhesion.

PPAP SAMPLE PARTS


INSPECTION VERIFICATION REQUIRED
Purchase Order#: Part Number: Revision Level: Supplier Name:

0 0 0 0

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Potential Failure Modes and Effects Analysis Design FMEA


Part # Part Name Rev # Process Responsibility FMEA Number Prepared By FMEA Date (Orig.) FMEA Date

Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
C l a s s Item Number Current Product Controls Potential Cause(s)/ Failure Mechanisms O C C D E T R P N Responsibility Recommended and Action(s) Completion Date Action Results S E V O C C

Item/ Function

Requirements

Potential Potential Effects Failure Mode of Failure

S E V

Prevention

Detection

Actions Taken

Page 8 of 26

Potential Failure Modes and Effects Analysis Design FMEA


Part # Part Name Rev # Process Responsibility FMEA Number Prepared By FMEA Date (Orig.) FMEA Date

Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
C l a s s Item Number Current Product Controls Potential Cause(s)/ Failure Mechanisms O C C D E T R P N Responsibility Recommended and Action(s) Completion Date Action Results S E V O C C

Item/ Function

Requirements

Potential Potential Effects Failure Mode of Failure

S E V

Prevention

Detection

Actions Taken

Page 9 of 26

esults D E T R P N

Page 10 of 26

esults D E T R P N

Process flow
Part # Part Name Rev # Process
Process No.

0 0 0

Control plan Number Prepared By Control plan Date (Orig.) Control plan Date
Operation Transport Inspect Store Idle

10

20

30

40

50

60

Page 12 of 26

Potential Failure Modes and Effects Analysis Process FMEA


Part # Part Name Rev # Process Responsibility FMEA Number Prepared By FMEA Date (Orig.) FMEA Date

Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Process Number C S l E a V s s Current Process Controls Potential Cause(s)/ Failure Mechanisms O C C D R E P T N Responsibility Recommended and Action(s) Completion Date Action Results

Process/Step Function

Requirements

Potential Potential Effects Failure Mode of Failure

Prevention

Detection

Actions Taken

S O D E C E V C T

R P N

Page 13 of 26

Potential Failure Modes and Effects Analysis Process FMEA


Part # Part Name Rev # Process Responsibility FMEA Number Prepared By FMEA Date (Orig.) FMEA Date

Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Process Number C S l E a V s s Current Process Controls Potential Cause(s)/ Failure Mechanisms O C C D R E P T N Responsibility Recommended and Action(s) Completion Date Action Results

Process/Step Function

Requirements

Potential Potential Effects Failure Mode of Failure

Prevention

Detection

Actions Taken

S O D E C E V C T

R P N

Control Plan
Prototype
Pre-Launch

Production

Control Plan Number Part Number 0 Core Team

Key Contact / Phone Latest Change (Rev) Level 0 Part Description 0 Supplier Name 0

Date (Orig.)

Current Release Level Plant Location Quality Department Approval

Current Release Date

PART / PROCESS NUMBER

MACHINE DEVICES / PROCESS JIG / TOOLS FOR NAME / MANUFACTURING OPERATION DESCRIPTION

CHARACTERISTICS

METHODS PRODUCT / SPECIAL PROCESS / CHAR. SPECIFICATION / CLASS TOLERANCE SAMPLE EVALUATION/ MEASUREMENT TECHNIQUE FREQ SIZE

NO.

PRODUCT

PROCESS

CONTROL METHOD

REACTION PLAN

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DIMENSIONAL RESULT
Part name Part number: Revision # Cavity number:

0 0 0

Tooling num Cavity # Sample size : Check by:

Total # of measurements taken = 0 Total # of measurements within in spec = 0 % of measurements meeting spec = #DIV/0! Gauge Type Low. tol. Upp. tol. Actual measurements Sample 1 # Insp out Pts of Sample 2 Sample 3 tol Bubble # Result

Specification

comment

Gauge Type

Specification

Low. tol.

Upp. tol.

Actual measurements Sample 1

# Insp out Pts of Sample 2 Sample 3 tol

Bubble #

Result

comment

Part Submission Warrant


0 Part Name Safety and/or Government Regulation Additional Engineering Changes Shown on Drawing no. Checking Aid No. ORGANIZATION MANUFACTURING INFORMATION 0 Supplier Name 0 Street Address 0 0 0 State Zip City Note:
Does this part contain any restricted or reportable substances Are plastic parts identified with appropriate ISO marking codes

Part Number 0 Yes No Engineering Drawing Change Level

Dated Dated

Purchase order No. Engineering Change Level

Weight (kg) Dated

CUSTOMER SUBMITTAL INFORMATION Customer Name / Division Buyer Name/Code Application

Yes Yes

No No

N/A N/A

REASON FOR SUBMISSION Initial Submission Engineering Change(s) Tooling: Transfer, Replacement, Refurbishment, or additional Correction of Discrepancy Tooling Inactive > than 1 year REQUESTED SUBMISSION LEVEL (Check one) Level 1 Level 2 Level 3 Level 4 Warrant, only (and for designated items, an Appearance Approval Report) submitted to customer. Warrant with product samples and limited supporting data submitted to customer. Warrant with product samples and complete supporting data submitted to customer. Warrant and other requirements as defined by customer. Include Level (4a) and (4b) predefined in ACTIA procedure. Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part processing Parts Produced at Additional Location Other - please specify

(Check) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. SUBMISSION RESULTS The results for dimensional measurements material and functional tests appearance criteria statistical process package These results meet all drawing and specification requirements: Yes No (If "No" - Explanation Required) Mold / Cavity / Production Process: DECLARATION I hereby affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable Production Part Approval Process Manual 4th Edition Requirements. I further warrant these samples were produced at the production rate of / 8 hours. I have noted any deviations from this declaration below. EXPLANATION/COMMENTS: Print Name Supplier Authorized Signature FOR ACTIA USE ONLY (IF APPLICABLE) Part Warrant Disposition: Rejection/Other Comments:
APPROVED REJECTED OTHER

Title

Phone No. Date

FAX No.

Customer Name

Customer Signature

Date

Production Part Approval


Material Test Results and Related Design Record Notes
PART NUMBER: PART NAME: 0 0 SPECIFICATION / LIMITS TEST DATE QTY. TESTED DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE DOCUMENTS date: 0 1/0/1900 NOT OK

NAME of LABORATORY:
Bubble # MATERIAL SPEC. NO. / REV / DATE SUPPLIER TEST RESULTS (DATA) OK

Blanket statements of conformance are unacceptable for any test results. SIGNATURE TITLE DATE

Production Part Approval


Performance Test Results and Related Design Record Notes
PART NUMBER: PART NAME: Bubble # TEST SPECIFICATION / REV / DATE 0 0 SPECIFICATION / LIMITS TEST DATE DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE DOCUMENTS DATE: 0 1/0/1900 OK NOT OK

QTY. TESTED SUPPLIER TEST RESULTS (DATA) / TEST CONDITIONS

SIGNATURE

TITLE

DATE

INITIAL SAMPLES CAPABILITY REPORT


Part Name : Part number : Drawing number : Tool number : Cavity number : Check by : Inspection date : Gauge type Nominal. Low. Upp. dim. tol. tol. Low. dim. 0 Ok Out Upp. dim. 0 Sample size 30 Cat. nbr. 10 0 0 0 Revision #

N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Data

Cp

Cpk

Average

Std. deviation

Maxi. 0.00

Mini 0.00

Range 0.000

Out of spec. 0

QTY

Histogram
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0

0 0.000

0
0.000

0 0.000

0 0.000

0 0.000

0 0.000

0
0.000

0 0.000

0 0.000

0 0.000

Inch

Comments :

ACTIA Corporation APPEARANCE APPROVAL REPORT


Part Name Revision level Supplier name 0 0 0
APPLICABLE ACCEPTED

Part number 0 ECN change 0 level date

PPAP ELEMENTS
1 2 3 4 5 6 7 8 9 10 11 12 14 COLOR BRILLANCE GLOSS GRAIN TRANSPARENCY SINK MARK WELDING LINES INJECTION GATE KNIT LINE MARK EJECTOR MARKS PAINT MARKING AND DECORATION (Silk-screen printing, Pad printing) Approved Sample Matched

COMMENTS

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

ACTIA Special requirement Bill Of Material review (Applicable for PCA only)
Supplier Part # Bubble Number on BOM Is component present? 0 0 Is component orientation correct? Part name Revision level Bubble Number on BOM Is component present? 0 0 Is component orientation correct?

Document Number:

SUPPLIER DEVIATION REQUEST


ACTIA SUPPLIER TO COMPLETE
Supplier Name: 0 Date: Type of deviation:
Limited Qty Limited Time

Part Number: 0 P.O.# P.O Qty


Qty Produced Scheduled Delivery Date

Part Name: 0 Contact Name: EMAIL: PO's affected: PO's affected:

Quantity: From:

To:

Permanent

Reason: (Please include a physical sample or picture depicting the deviation to be approved.)

How does this deviation affect the scheduled delivery date of the product?

Date approval needed to meet scheduled delivery date?


Submit this deviation request to ACTIA Purchasing ACTIA PURCHASING TO COMPLETE
Date product needed to meet order dates? Quantity needed to meet order dates?

Add the document number and forward to ACTIA Engineering and Quality.

ACTIA ENGINEERING AND QUALITY TO COMPLETE


No ACTIA customer approval required - No customer specification or drawing requirements.

Approved by: Engineering: Quality:

Name:

Date:

By:
ACTIA customer approval/PPAP submission required.

Date:

Submitted:

Yes No

**
Add reason below:

** Please provide the customer approval for this deviation.

Approved by: Engineering: Quality:

Name:

Date:

ACTIA ENGINEERING TO COMPLETE


REJECTED
APPROVED* Limited Qty

Reason: By: Quantity: From: ECN #: Date: PO's affected: PO's affected:

Limited Time Permanent

To:

Comments:

Return this completed document to ACTIA Purchasing.


* This approval is granted upon the understanding that it is advisory in nature and in no manner changes the Sellers original responsibility for insuring that all characteristics, designated in the applicable engineering specifications and/or inherent in the samples as originally tested and approved, are maintained.

Form 4.7.19

ACTIA PURCHASING FORWARD THIS COMPLETED DOCUMENT TO THE SUPPLIER Revision C

6-23-10