PPAP Submission

Date Initiated: Part Name Part Number Purchase Order # Engineering Change Level Engineering Change Level Date Supplier Name Street Address City State ip Ph!ne Number Supplier C!ntact

PPAP Submission Level Guide Quick reference Level 4 Level 4" Level 4b
- Will be defined by ACTIA during t e PPAP re!uest - Predetermined by ACTIA - Predetermined by ACTIA

T e "ddition"l comments belo# "re only "n ACTIA summ"ry of AIAG m"nu"l$ %efer to AIAG &"nu"l current edition for com'lete inform"tion$
PPAP %e!uirements AIAG PPAP .ourt ,dition

Level 4b

Level 4"

,lement -rder

Level (

Level )

Level *

Level 4

Level +

%e!uired /ocuments

Addition"l Comments

"

Part Submissi!n &arrant 1PS&2

# # # $ # # #

AC%IA PS& !nly

3p!n c!mpleti!n !4 all PPAP re5uirements- the !rgani6ati!n shall c!mplete the Part submissi!n 7arrant 1PS&28 I4 pr!ducti!n parts 7ill be pr!duced 4r!m m!re than !ne cavity- m!ld- t!!l diepattern- !r Pr!ducti!n pr!cess e8g8- line !r cell- the !rgani6ati!n shall c!mplete a dimensi!nal evaluati!n !n !ne part 4r!m each 8 %hese speci4ics cavities- m!lds- line- etc888- shall then be identi4ied in the 9,!ld:Cavity:Pr!ducti!n Pr!cess9 line !n a PS&- !r in a PS& attachment8 A resp!nsible !44icial !4 the !rgani6ati!n shall appr!ve the PS& and pr!vide c!ntact in4!rmati!n8

'

Design ;ec!rds < =ubbled part print1s28

# # $ # # #

AC%IA design rec!rd bubbled

%he !rgani6ati!n shall have the design rec!rd 4!r the saleable pr!duct:partincluding design rec!rds 4!r c!mp!nents !r details !4 the saleable pr!duct : part8 &here the design rec!rd is in electr!nic 4!rmat- e8g8- CAD:CA, math data- the !rgani6ati!n shall pr!duce a hard c!py 1e8g8- pict!rial- ge!metric dimensi!ning < t!lerancing 1>D<%2 sheets- dra7ing2 t! identi4y measurements ta?en8

Auth!ri6ed Engineering Change D!cumentati!n Cust!mer Engineering Appr!vals

# # $ # # # # $ # $ # # #

@ari!us engineering d!cumentati!n

%he !rgani6ati!n shall have any auth!ri6ed engineering change d!cuments 4!rm th!se changes n!t yet rec!rded in the design rec!rd but inc!rp!rated in the pr!duct- part !r t!!ling8 &here speci4ied by the cust!mer- the !rgani6ati!n shall have evidence !4 cust!mer engineering appr!val8 %he pr!duct designAresp!nsible !rgani6ati!n shall devel!p a Design +,EA in acc!rdance 7ith and c!mpliant t!- cust!mer speci4ied re5uirements81e8g8p!tential +ailure ,!de and E44ects Analysis re4erence manual2 %he !rgani6ati!n shall have a pr!cess 4l!7 diagram in an !rgani6ati!nA speci4ied 4!rmat that clearly describes the pr!ducti!n pr!cess steps and se5uence- as appr!priate- and meets the speci4ied cust!mer needsre5uirements and eBpectati!ns 1e8g8- Advanced Pr!duct Cuality Planning and C!ntr!l Plan re4erence manual28 +!r bul? materials- an e5uivalent t! a pr!cess +l!7 Diagram is a Pr!cess +l!7 Descripti!n8

Cust!mer engineering appr!val pr!!4 Can be AC%IA D+,EA +!rmat !r an AIA> c!mpliant D+,EA8

Design +,EA-

Pr!cess +l!7 Diagrams

# $

# #

Any standard 4l!7chart 4!rmat8

Pr!cess +,EA

# $

Can be AC%IA P+,EA +!rmat !r an AIA> c!mpliant P+,EA8

%he !rgani6ati!n shall devel!p a pr!cess +,EA in acc!rdance 7ith and c!mpliant t!- cust!merAspeci4ied re5uirements- 1e8g8- P!tential +ailure ,!de and E44ects Analysis re4erence manual2

C!ntr!l Plan

# $

# #

Can be AC%IA 4!rmat !r AIA> c!mpliant 4!rmat8

%he !rgani6ati!n shall have a c!ntr!l plan that de4ines all meth!ds used 4!r pr!cess c!ntr!l and c!mplies 7ith cust!merAspeci4ied re5uirements 1e8g8Advanced Pr!duct Cuality Planning and C!ntr!l Plan re4erence manual28

,easurement System Analysis Studies

# $

N!t re5uired by AC%IA

%he !rgani6ati!n shall have applicable ,easurement System analysis studies- e8g8- gage ;<;- bias- linearity- stability- 4!r all ne7 !r m!di4ied gages- measurement- and test e5uipment81 see the ,easurement Systems Analysis re4erence manual2

"E

Dimensi!nal ;esults

# # $ # # #

%he !rgani6ati!n shall pr!vide evidence that dimensi!nal veri4icati!ns re5uired by the design rec!rd and the C!ntr!l Plan have been c!mpleted and result indicate c!mpliance 7ith speci4ied re5uirements8 %he !rgani6ati!n shall Can use AC%IA +!rmat !r have dimensi!nal results 4!r each uni5ue manu4acturing pr!cess- e8g8- cells an AIA> c!mpliant4!rmat !r pr!ducti!n lines and all cavities- m!lds- patterns !r dies8 %he !rgani6ati!n 4!r dimenti!n rep!rt shall rec!rd - 7ith the actual results : all dimensi!ns 1eBcept re4erence dimensi!ns2- characteristics- and speci4icati!ns as n!ted !n the design rec!rd and C!ntr!l Plan8 %he !rgani6ati!n shall identi4y the parts measured8

""A"

,aterial %est ;esults and Per4!rmance test result and related design n!tes

# # $ # # #

Industry Standard rep!rts !r test result 4!rmats designated by AC%IA8

,aterial test results shall indicate and include : "2 %he design rec!rd change level !4 the parts testedF '2 Any auth!ri6ed engineering change d!cuments that n!t yet been inc!rp!rated in the design rec!rdF (2 %he number- date- and change level !4 the speci4icati!n t! 7hich the part 7as testedF )2 the date !n 7hich the testing t!!? placeF *2 the 5uantity testedF .2 the actual resultsF /2 %he material supplierGs name and- 7hen re5uired by the cust!mer- the cust!merAassigned supplier:vend!r c!de8

""A'

Per4!rmance %est ;esults

# # $ # # #

Industry Standard rep!rts !r test result 4!rmats designated by AC%IA 8

%he !rgani6ati!n shall per4!rm tests 4!r all part1s2 !r pr!duct material1s2 7hen per4!rmance !r 4uncti!nal re5uirements are speci4ied by the design rec!rd !r C!ntr!l Plan8 Per4!rmance test results shall indicate and include : "2 %he design rec!rd change level !4 the parts testedF '2 Any auth!ri6ed engineering change d!cuments that n!t yet been inc!rp!rated in the design rec!rdF (2 %he number- date- and change level !4 the speci4icati!n t! 7hich the part 7as testedF )2 the date !n 7hich the testing t!!? placeF *2 the 5uantity testedF .2 the actual resultsF

"'

Initial Pr!cess Study 1Cp?2 Capability Studies

# $

Pr!cess Capability Study using any statistical pac?age !r AC%IA Capability +!rm8

%he level !4 initial pr!cess capability !r per4!rmance shall be determined t! be acceptable pri!r t! submissi!n 4!r all Special Characteristics designated by the cust!mer !r !rgani6ati!n8 %he !rgani6ati!n shall !btain cust!mer c!ncurrence !n the indeB 4!r estimating initial pr!cess capability pri!r t! submissi!n8 A &here n! special characteristics have been identi4ied- the cust!mer reserve the right t! re5uire dem!nstrati!n !4 initial pr!cess capability !n !ther characteristics8 IndeB H "8./ : the pr!cess currently meets the acceptance criteria8 "8((IJ IndeB IJ "8./ : the pr!cess may be acceptable8 C!ntact the auth!ri6ed cust!mer representative 4!r revie7 !4 the study results8 IndeB J"8(( : Pr!cess d!es n!t currently meet the acceptance criteria8 C!ntact the auth!ri6ed cust!mer representative 4!r a revie7 !4 study results8

"(

Cuali4ied Lab!rat!ry D!cumentati!n

# # $ # # #

Inspecti!n and testing 4!r PPAP shall be per4!rmed by 5uali4ied lab!rat!ry as de4ined by cust!mer re5uirements 1e8g8 an accredited lab!rat!ry28 the 5uali4ied lab!rat!ry 1internal !r eBternal t! the !rgani6ati!n2 shall have a lab!rat!ry sc!pe and d!cumentati!n sh!7ing that the lab!rat!ry is 5uali4ied Lab Sc!pe and !utside lab 4!r the type !4 measurements !r tests c!nducted8 pr!!4 !4 accreditati!n8 &hen an eBternal:C!mmercial lab!rat!ry is used- the !rgani6ati!n shall submit the test results !n the lab!rat!ry letterhead !r the n!rmal lab!rat!ry rep!rt 4!rmat8 %he name !4 the lab!rat!ry that per4!rmed the tests- the date1s2 !4 the tests- and the standards used t! run the tests shall be identi4ied8

")

Appearance Appr!val ;ep!rt

# # # $ # # #

AC%IA 4!rmat !r AIA> 4!rmat

A separate Appearance Appr!val ;ep!rt 1AA;2 shall be c!mpleted 4!r each part !r series !4 part i4 the pr!duct:part has appearance re5uirements !n the design rec!rd8 3p!n satis4act!ry c!mpleti!n !4 all re5uired criteria- the !rgani6ati!n shall rec!rd the re5uired in4!rmati!n !n the AA;8 %he c!mpleted AA; and representative pr!ducti!n pr!duct:part shall be submitted t! the l!cati!n speci4ied by the cust!mer t! receive disp!siti!n8 AA;s 1c!mplete 7ith part disp!siti!n and auth!ri6ed cust!mer representative signature2 shall then acc!mpany the PS& at the time !4 4inal submissi!n based up!n the submissi!n level re5uested8

"*

Sample Pr!duct Parts

# # $ # # #

3p!n AC%IA re5uirements

%he !rgani6ati!n shall pr!vide sample pr!duct as speci4ied by the cust!mer8

".

,aster Samples

$ # # #

%he !rgani6ati!n shall retain a master sample 4!r the same peri!d as the pr!ducti!n part appr!val rec!rds- !r a2 until a ne7 master sample is pr!duced 4!r the same cust!mer part number 4!r cust!mer appr!val- !r b2 7here a master sample is re5uired by the design rec!rd- C!ntr!l Plan !r inspecti!n criteria- as a re4erence !r standard8 %he master sample shall be identi4ied as such- and shall sh!7 the cust!mer appr!val date !n the sample8 3pp!n Actia re5uirements %he !rgani6ati!n shall retain a master sample 4!r each p!siti!n !4 a multiple cavity die- m!ld t!!l !r pattern- !r pr!ducti!n pr!cess unless !ther7ise speci4ied by the cust!mer8 &hen part si6e - sheet v!lume !4 parts- etc8 ma?es st!rage !4 a master sample di44icult- the sample retenti!n re5uirements may be m!di4ied !r 7aived in 7riting by auth!ri6ed cust!mer representative8

"/

Chec?ing aids

$ # # # $ # #

Part speci4ic assembly !r chec?ing aids

I4 re5uested by cust!mer- the !rgani6ati!n shall submit 7ith the PPAP submissi!n any pert speci4ic assembly !r c!mp!nent chec?ing aid8 %he !rgani6ati!n shall have rec!rds !4 c!mpliance t! all applicable cust!merA speci4ic re5uirements8 +!r bul? materials- applicable cust!merAspeci4ic re5uirements shall be d!cumented !n the =ul? ,aterial ;e5uirement Chec?list8

"0

Cust!mer speci4ic re5uirements

%! submit 4!r PCA suppliers !nly

PPAP SA&PL, PA%TS - LA0,L

Send identified sample(s). ach sample used for PP!P must be clearl" identified #ith their identification number correspondin$ #ith data. Please complete% print in color and attach this pa$e on the outside of each pac&a$e in plain vie# of a for& lift'material handler'operator. Put the Pac&in$ slip poc&et near the label. (n the event parts are )Loose* shipped% a label should be placed on each part. +his #ould appl" to parts la"in$ on pallets also. Label on a Painted Part must be #ire tied or attached in a #a" painted surface is protected from label adhesion.

INSPECTION VERIFICATION REQUIRED

Purchase Order#: Part Number: Revision Level: Supplier Name:

PPAP SAMPLE PARTS

0 0 0 0

P"rt Submission W"rr"nt

Part Name E Sa4ety and:!r >!vernment ;egulati!n Additi!nal Engineering Changes Sh!7n !n Dra7ing n!8 Chec?ing Aid N!8 -%GA1I2ATI-1 &A13.ACT3%I1G I1.-%&ATI-1 E Supplier Name E Street Address E E E State ip City N!te:
/oes t is '"rt cont"in "ny restricted or re'ort"ble subst"nces Are 'l"stic '"rts identified #it "''ro'ri"te IS- m"rking codes

Part Number E Kes N! Engineering Dra7ing Change Level

Dated Dated

Purchase !rder N!8 Engineering Change Level

&eight 1?g2 Dated

C3ST-&,% S30&ITTAL I1.-%&ATI-1 Cust!mer Name : Divisi!n =uyer Name:C!de Applicati!n

Kes Kes

N! N!

N:A N:A

%,AS-1 .-% S30&ISSI-1 Initial Submissi!n Engineering Change1s2 %!!ling: %rans4er- ;eplacement- ;e4urbishment- !r additi!nal C!rrecti!n !4 Discrepancy %!!ling Inactive H than " year %,Q3,ST,/ S30&ISSI-1 L,4,L 5C eck one6 Level " Level ' Level ( Level ) A A A A &arrant- !nly 1and 4!r designated items- an Appearance Appr!val ;ep!rt2 submitted t! cust!mer8 &arrant 7ith pr!duct samples and limited supp!rting data submitted t! cust!mer8 &arrant 7ith pr!duct samples and c!mplete supp!rting data submitted t! cust!mer8 &arrant and !ther re5uirements as de4ined by cust!mer8 Include Level 1)a2 and 1)b2 prede4ined in 1c!mpany2 pr!cedure8 Change t! Opti!nal C!nstructi!n !r ,aterial SubASupplier !r ,aterial S!urce Change Change in Part pr!cessing Parts Pr!duced at Additi!nal L!cati!n Other A please speci4y

1Chec?2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Level * A &arrant 7ith pr!duct samples and c!mplete supp!rting data revie7ed at supplierGs manu4acturing l!cati!n8 S30&ISSI-1 %,S3LTS %he results 4!r dimensi!nal measurements material and 4uncti!nal tests appearance criteria statistical pr!cess pac?age %hese results meet all dra7ing and speci4icati!n re5uirements: Kes N! 1I4 9N!9 A EBplanati!n ;e5uired2 ,!ld : Cavity : Pr!ducti!n Pr!cess: /,CLA%ATI-1 I hereby a44irm that the samples represented by this 7arrant are representative !4 !ur parts and have been made t! the applicable Pr!ducti!n Part Appr!val Pr!cess ,anual )th Editi!n ;e5uirements8 I 4urther 7arrant these samples 7ere pr!duced at the pr!ducti!n rate !4 : 0 h!urs8 I have n!ted any deviati!ns 4r!m this declarati!n bel!78 E#PLANA%ION:CO,,EN%S: Print Name Supplier Auth!ri6ed Signature .-% ACTIA 3S, -1L7 5I. APPLICA0L,6 Part &arrant Disp!siti!n: ;eLecti!n:Other C!mments: %itle Ph!ne N!8 Date +A# N!8

APPROVED

REJECTED

OTHER

Cust!mer Name

Cust!mer Signature

Date

P"ge 8 of *9

Potenti"l ."ilure &odes "nd ,ffects An"lysis /esign .&,A

P"rt : P"rt 1"me %ev : Process %es'onsibility E E E .&,A 1umber Pre'"red 0y .&,A /"te 5-rig$6 .&,A /"te

1otes ; Ple"se refer to t e #orks eet </.&,A = P.&,A list 4t edition< to fill u' S,4> -CC "nd /,T<
Item 1umber C l " s s Current Product Controls Potenti"l C"use5s6? ."ilure &ec "nisms C C / % , P T 1 %es'onsibility %ecommended "nd Action5s6 Com'letion /"te Action %esults S , 4 - / C , C T % P 1

Item? .unction

%e!uirements

S Potenti"l Potenti"l ,ffects , ."ilure &ode of ."ilure 4

Prevention

/etection

Actions T"ken

E E E E E E E E E E E E E E E E E E E E E E E E E E E E

E E E E E E E E E E E E E E E E E E E E E E E E E E E E

P"ge @ of *9

Potenti"l ."ilure &odes "nd ,ffects An"lysis /esign .&,A

P"rt : P"rt 1"me %ev : Process %es'onsibility E E E .&,A 1umber Pre'"red 0y .&,A /"te 5-rig$6 .&,A /"te

1otes ; Ple"se refer to t e #orks eet </.&,A = P.&,A list 4t edition< to fill u' S,4> -CC "nd /,T<
Item 1umber C l " s s Current Product Controls Potenti"l C"use5s6? ."ilure &ec "nisms C C / % , P T 1 %es'onsibility %ecommended "nd Action5s6 Com'letion /"te Action %esults S , 4 - / C , C T % P 1 E

Item? .unction

%e!uirements

S Potenti"l Potenti"l ,ffects , ."ilure &ode of ."ilure 4

Prevention

/etection

Actions T"ken

Process flo#
P"rt : P"rt 1"me %ev : Process %es'onsibility
Pr!cess N!8

E E E

Control 'l"n 1umber Pre'"red 0y Control 'l"n /"te 5-rig$6 Control 'l"n /"te
Operati!n %ransp!rt Inspect St!re Idle

"E

'E

(E

)E

*E

.E

P"rt : P"rt 1"me %ev : Process %es'onsibility

Pr!cess N!8

E E E

Control 'l"n 1umber Pre'"red 0y Control 'l"n /"te 5-rig$6 Control 'l"n /"te
Operati!n %ransp!rt Inspect St!re Idle

P"ge () of *9

Potenti"l ."ilure &odes "nd ,ffects An"lysis Process .&,A

P"rt : P"rt 1"me %ev : Process %es'onsibility E E E .&,A 1umber Pre'"red 0y .&,A /"te 5-rig$6 .&,A /"te

1otes ; Ple"se refer to t e #orks eet </.&,A = P.&,A list 4t edition< to fill u' S,4> -CC "nd /,T<
Process 1umber Current Process Controls Process?Ste' .unction %e!uirements C S l Potenti"l Potenti"l ,ffects , " ."ilure &ode of ."ilure 4 s s Potenti"l C"use5s6? ."ilure &ec "nisms C C / % , P T 1 %ecommended Action5s6 %es'onsibility "nd Com'letion /"te Action %esults

Prevention

/etection

Actions T"ken

S - / % , C , P 4 C T 1

E E E E E E E E E E E E E E E E E E E E E E E E E E E

E E E E E E E E E E E E E E E E E E E E E E E E E E E

P"ge (* of *9

Potenti"l ."ilure &odes "nd ,ffects An"lysis Process .&,A

P"rt : P"rt 1"me %ev : Process %es'onsibility E E E .&,A 1umber Pre'"red 0y .&,A /"te 5-rig$6 .&,A /"te

1otes ; Ple"se refer to t e #orks eet </.&,A = P.&,A list 4t edition< to fill u' S,4> -CC "nd /,T<
Process 1umber Current Process Controls Process?Ste' .unction %e!uirements C S l Potenti"l Potenti"l ,ffects , " ."ilure &ode of ."ilure 4 s s Potenti"l C"use5s6? ."ilure &ec "nisms C C / % , P T 1 %ecommended Action5s6 %es'onsibility "nd Com'letion /"te Action %esults

Prevention

/etection

Actions T"ken

S - / % , C , P 4 C T 1 E

Control Pl"n
Prototype
Control Pl"n 1umber P"rt 1umber E Core Te"m

Pre-La !"#
L"test C "nge 5%ev6 Level E

Pro$ "t%o!
Aey Cont"ct ? P one P"rt /escri'tion E Su''lier 1"me E Qu"lity /e'"rtment A''rov"l /"te 5-rig$6 Current %ele"se Level Pl"nt Loc"tion Current %ele"se /"te

PA;% : P;OCESS N3,=E;

,ACMINE DE@ICES : P;OCESS NI> : %OOLS +O; NA,E : ,AN3+AC%3;IN> OPE;A%ION DESC;IP%ION

CMA;AC%E;IS%ICS

,E%MODS P;OD3C% : SPECIAL P;OCESS : CMA;8 SPECI+ICA%ION : CLASS %OLE;ANCE SA,PLE E@AL3A%ION: ,EAS3;E,EN% %ECMNIC3E +;EC SI E

NO8

P;OD3C%

P;OCESS

CON%;OL ,E%MOD

;EAC%ION PLAN

P"ge (4 of *9

DIMENSIONAL RESULT
P"rt n"me P"rt number; %evision : C"vity number;

E 9 E

Tooling num C"vity : S"m'le siBe ; C eck by;

+otal # of measurements ta&en , 0 +otal # of measurements #ithin in spec , 0 % of measurements meeting s e! " #DIV$%& G"uge Ty'e Lo#$ tol$ 3''$ tol$ %esult Actu"l me"surements S"m'le ( : Ins' out Pts of S"m'le ) S"m'le * tol 0ubble :

S'ecific"tion

G"uge Ty'e

S'ecific"tion

Lo#$ tol$

3''$ tol$

S"m'le (

%esult

Actu"l me"surements

: Ins' out Pts of S"m'le ) S"m'le * tol

0ubble :

G"uge Ty'e

S'ecific"tion

Lo#$ tol$

3''$ tol$

S"m'le (

%esult

Actu"l me"surements

: Ins' out Pts of S"m'le ) S"m'le * tol

0ubble :

comment

comment

comment

Production P"rt A''rov"l

&"teri"l Test %esults "nd %el"ted /esign %ecord 1otes
PA;% N3,=E;: PA;% NA,E: E E SPECI+ICA%ION : LI,I%S %ES% DA%E C%K8 %ES%ED DESI>N ;ECO;D CMAN>E LE@EL: EN>INEE;IN> CMAN>E DOC3,EN%S date: E "':(E:"0DD NO% OO

1A&, of LA0-%AT-%7;
=ubble # ,A%E;IAL SPEC8 NO8 : ;E@ : DA%E S3PPLIE; %ES% ;ES3L%S 1DA%A2 OO

=lan?et statements !4 c!n4!rmance are unacceptable 4!r any test results8 SI>NA%3;E %I%LE DA%E

Production P"rt A''rov"l

Perform"nce Test %esults "nd %el"ted /esign %ecord 1otes
PA;% N3,=E;: PA;% NA,E: =ubble # %ES% SPECI+ICA%ION : ;E@ : DA%E E E SPECI+ICA%ION : LI,I%S %ES% DA%E C%K8 %ES%ED DESI>N ;ECO;D CMAN>E LE@EL: EN>INEE;IN> CMAN>E DOC3,EN%S DA%E: E "':(E:"0DD OO NO% OO

S3PPLIE; %ES% ;ES3L%S 1DA%A2 : %ES% CONDI%IONS

SI>NA%3;E

%I%LE

DA%E

INITIAL SAMPLES CAPABILITY REPORT

P"rt 1"me ; P"rt number ; /r"#ing number ; Tool number ; C"vity number ; C eck by ; Ins'ection d"te ; G"uge ty'e 1omin"l$ dim$ Lo#$ 3''$ tol$ tol$ Lo#$ dim$ 9 -k -ut 3''$ dim$ 9 S"m'le siBe (E C"t$ nbr$ "E E E E %evision :

1C ( ) * 4 + E F 8 @ (9 (( () (* (4 (+ (E (F (8 (@ )9 )( )) )* )4 )+ )E )F )8 )@ *9

/"t"

C'

C'k

Aver"ge

Std$ devi"tion

&"Di$ E8EE

&ini E8EE

%"nge E8EEE

-ut of s'ec$ E

" E8D E80 E8/ E8. E8* E8) E8( E8' E8" E E

Histogram "'EE8EQ
"EEE8EQ 0EE8EQ .EE8EQ )EE8EQ ;!7 D LSL 'EE8EQ 3SL N!minal E8EQ ;!7 '(

'T(

#DI@:EP #DI@:EP #DI@:EP #DI@:EP #DI@:EP

&!"#
Comments :

(company) Corporation APP,A%A1C, APP%-4AL %,P-%T

P"rt 1"me %evision level Su''lier n"me 9 9 9
APPLICA0L, ACC,PT,/

P"rt number 9 ,C1 c "nge 9 level d"te

PPAP ,L,&,1TS
" ' ( ) * . / 0 D "E "" "' ") C-L-% 0%ILLA1C, GL-SS G%AI1 T%A1SPA%,1C7 SI1A &A%A W,L/I1G LI1,S I1G,CTI-1 GAT, A1IT LI1, &A%A ,G,CT-% &A%AS PAI1T &A%AI1G A1/ /,C-%ATI-1 5Silk-screen 'rinting> P"d 'rinting6 A''roved S"m'le &"tc ed

C-&&,1TS

1?A 1?A 1?A 1?A 1?A 1?A 1?A 1?A 1?A 1?A 1?A 1?A 1?A

5com'"ny6 S'eci"l re!uirement 0ill -f &"teri"l revie# 5A''lic"ble for PCA only6
Su''lier P"rt : 0ubble 1umber on 0-& Is com'onent 'resentH 9 9 Is com'onent orient"tion correctH P"rt n"me %evision level 0ubble 1umber on 0-& Is com'onent 'resentH 9 9 Is com'onent orient"tion correctH

D!cument Number:

SUPPLIER DEVIATION REQUEST

(company) SUPPLIER TO CO
Supplier Name: 9 Date: %ype !4 deviati!n: Part Number: 9 P8O8# P8O Cty
Cty Pr!duced Scheduled Delivery Date

PLETE
Part Name: 9 C!ntact Name: E,AIL: POGs a44ected: POGs a44ected:

L%)%te$ 'ty L%)%te$ T%)e Per)a!e!t

Cuantity: +r!m:

%!:

;eas!n: 1Please include a physical sample !r picture depicting the deviati!n t! be appr!ved82

M!7 d!es this deviati!n a44ect the scheduled delivery date !4 the pr!ductR

Date appr!val needed t! meet scheduled delivery dateR

S!"mit t#is $%&iation r%'!%st to (company) P!rc#asing (company) PURCHASIN( TO CO
Date pr!duct needed t! meet !rder datesR Cuantity needed t! meet !rder datesR

PLETE

A$$ t#% $oc!m%nt n!m"%r an$ ,or0ar$ to (company) Engin%%ring an$ Q!a+ityPLETE Name: Date:

(company) EN(INEERIN( AND QUALIT) TO CO

N! 1c!mpany2 cust!mer appr!val re5uired A N! cust!mer speci4icati!n !r dra7ing re5uirements8

Appr!ved by: Engineering: Cuality:

=y:
1c!mpany2 cust!mer appr!val:PPAP submissi!n re5uired8

Date:

Submitted:

(e+ II ,o

Add reas!n bel!7:

** P+%as% pro&i$% t#% c!stom%r appro&a+ ,or t#is $%&iation-

Appr!ved by: Engineering: Cuality:

Name:

Date:

(company) EN(INEERIN( TO CO PLETE

REJECTED APPROVED* L%)%te$ 'ty L%)%te$ T%)e Per)a!e!t
C!mments: ;eas!n: =y: Cuantity: +r!m: ECN #: Date: POGs a44ected: POGs a44ected:

%!:

R%t!rn t#is comp+%t%$ $oc!m%nt to (company) P!rc#asing* T#is appro&a+ is grant%$ !pon t#% !n$%rstan$ing t#at it is a$&isory in nat!r% an$ in no mann%r c#ang%s t#% S%++%rs origina+ r%sponsi"i+ity ,or ins!ring t#at a++ c#aract%ristics1 $%signat%$ in t#% app+ica"+% %ngin%%ring sp%ci,ications an$2or in#%r%nt in t#% samp+%s as origina++y t%st%$ an$ appro&%$1 ar% maintain%$-

(company) PURCHASIN( .OR/ARD THIS CO +!rm )8/8"D

PLETED DOCU ENT TO THE SUPPLIER .A'(A"E

;evisi!n C

P.&,A LISTS 4t ,dition

S,4,%IT7 SCAL, "E N!nc!mpliance t! a g!vernment regulati!n D A sa4ety ha6ard 0 &ill result in cust!mer c!mplaint and return !4 pr!duct / ,ay cause pr!ducti!n disrupti!n !r 4ailure !4 sales speci4icati!n8 . &ill be caught at subse5uent pr!cessing8 * &ill be caught during pr!cessing ) Li?ely t! be caught by cust!mer at inc!ming inspecti!n ( Only a slight inc!nvenience 7ith pr!duct !r pr!cessing n!ticed ' Li?ely t! cause !nly a slight cust!mer ann!yance " N!t li?ely t! cause any e44ect !r t! be n!ticed by cust!mer -CC3%%,1C, SCAL, "E Migh 4re5uencyN! =ac?gr!und D Migh 4re5uencyAssumpti!n 0 Migh 4re5uencySimilar EBperience / Migh 4re5uencyActual EBperience . ,!derate +re5uency- Assumpti!n * ,!derate +re5uency- Similar EBperience ) ,!derate +re5uency- Actual EBperience ( L!7 +re5uencyAssumpti!n ' L!7 +re5uencySimilar EBperience " L!7 +re5uencyActual EBperience /,T,CTI-1 SCAL, "E Abs!lute certainty !4 N!nAdetecti!n8 D @ery l!7 li?elih!!d !4 detecti!n8 0 C!ntr!ls may detect at end !4 cust!mer pr!ducti!n8 / C!ntr!ls may detect eBistence during cust!mer pr!ducti!n8 . C!ntr!ls li?ely t! detect de4ect in l!t inspecti!n but higher variability8 * C!ntr!ls li?ely t! detect de4ect in l!t inspecti!n8 ) C!ntr!ls have a g!!d chance !4 detecting de4ect at end !4 current pr!cess step8 ( C!ntr!ls have a g!!d chance !4 detecting de4ect be4!re end !4 current pr!cess step8 ' C!ntr!ls alm!st certainly de4ect be4!re neBt pr!cess8 " C!ntr!ls detect de4ect be4!re neBt pr!cess8

/.&,A LISTS 4

S,4,%IT7 SCAL, "E A44ects sa4e vehicle D A44ects sa4e vehicle ! 0 L!ss !4 primary 4uncti / Degradati!n !4 Prima . L!ss !4 sec!ndary 4un * Degradati!n !4 sec!n ) Appearance !4 audibl ( Appearance !4 audibl ' Appearance !4 audibl " N! discernible a44ect8 -CC3%%,1C, SCAL, "E Ne7 techn!l!gy:ne7 D +ailure is inevitable 7 0 +ailure is li?ely 7ith n / +ailure is uncertain 7 . +re5uent 4ailures ass! * Occasi!nal 4ailures as ) Is!lated 4ailures ass! ( Only is!lated 4ailures ' N! !bserved 4ailures " +ailure is eliminated t /,T,CTI-1 SCAL, "E N! current design c! D Design analysis:detec 0 Pr!duct veri4icati!n a4 / Pr!duct veri4icati!n a4 . Pr!duct veri4icati!n a4 * Pr!duct validati!n 1re ) Pr!duct validati!n 1re ( Pr!duct validati!n 1re ' @irtual analysis c!rrel " N!t Applicable8 +ailu

/.&,A LISTS 4t ,dition

S,4,%IT7 SCAL, "E A44ects sa4e vehicle !perati!n and:!r n!nc!mpliance t! a g!vernment regulati!n 7ith!ut 7arning8 D A44ects sa4e vehicle !perati!n and:!r n!nc!mpliance t! a g!vernment regulati!n 7ith 7arning8 0 L!ss !4 primary 4uncti!n 1vehicle in!perable but d!es n!t a44ect sa4e vehicle !perati!n8 / Degradati!n !4 Primary 4uncti!n 1vehicle !perable but at a reduced level !4 per4!rmance2 . L!ss !4 sec!ndary 4uncti!n 1vehicle !peratable but c!mp!rt: c!nvenience 4uncti!ns in!perable8 * Degradati!n !4 sec!ndary 4uncti!n 1vehicle !peratable but c!m4!rt: c!nvenience 4uncti!ns in!perable8 ) Appearance !4 audible n!ise- vehicle !perable- item d!es n!t c!n4!rm- and n!ticed by m!st cust!mers 1/*Q28 ( Appearance !4 audible n!ise- vehicle !perable- item d!es n!t c!n4!rm- and n!ticed by many cust!mers 1*EQ28 ' Appearance !4 audible n!ise- vehicle !perable- item d!es n!t c!n4!rm- and n!ticed by discriminating cust!mers 1'*Q28 " N! discernible a44ect8 -CC3%%,1C, SCAL, "E Ne7 techn!l!gy:ne7 design 7ith n! hist!ry8 D +ailure is inevitable 7ith ne7 design- ne7 applicati!n- !r change in duty cycle:!perating c!nditi!ns8 0 +ailure is li?ely 7ith ne7 design- ne7 applicati!n- !r change in duty cycle:!perating c!nditi!ns8 / +ailure is uncertain 7ith ne7 design- ne7 applicati!n- !r change in duty cycle:!perating c!nditi!ns8 . +re5uent 4ailures ass!ciated 7ith similar designs !r in design simulati!n and testing8 * Occasi!nal 4ailures ass!ciated 7ith similar designs !r in design simulati!n and testing8 ) Is!lated 4ailures ass!ciated 7ith similar designs !r in design simulati!n and testing8 ( Only is!lated 4ailures ass!ciated 7ith alm!st identical design !r in design simulati!n !r testing8 ' N! !bserved 4ailures ass!ciated 7ith alm!st identical design !r in design simulati!n !r testing8 " +ailure is eliminated thr!ugh preventative c!ntr!l8 /,T,CTI-1 SCAL, "E N! current design c!ntr!lF Cann!t detect !r is n!t analy6ed8 D Design analysis:detecti!n c!ntr!ls have a 7ea? detecti!n capabilityF @irtual Analysis 1e8g8 CAE- +EA etc82 is not correl"ted 0 Pr!duct veri4icati!n a4ter design 4ree6e and pri!r t! launch 7ith '"ss?f"il testing 1Subsystem !r system testing 7ith acceptance criteria / Pr!duct veri4icati!n a4ter design 4ree6e and pri!r t! launch 7ith test to f"ilure testing 1Subsystem !r system testing until 4ailure !ccurs. Pr!duct veri4icati!n a4ter design 4ree6e and pri!r t! launch 7ith degr"d"tion testing 1Subsystem !r system testing a4ter durability test e * Pr!duct validati!n 1reliability testing- devel!pment !r validati!n tests2 pri!r t! design 4ree6e using '"ss?f"il testing 1e8g88 acceptance cri ) Pr!duct validati!n 1reliability testing- devel!pment !r validati!n tests2 pri!r t! design 4ree6e using test to f"ilure ( Pr!duct validati!n 1reliability testing- devel!pment !r validati!n tests2 pri!r t! design 4ree6e using degr"d"tion 1e8g8 data trends- be4!r ' @irtual analysis c!rrelated8 Design analysis: detecti!n c!ntr!ls have a str!ng detecti!n capability and is ig ly correl"ted " N!t Applicable8 +ailure is 4ully prevented thr!ugh design s!luti!ns 1e8g8 pr!ven design standard- best practices- !r c!mm!n material- e

g cust!mers 1'*Q28

A etc82 is not correl"ted t! eBpected !r actual !perating c!nditi!ns8 N!t li?ely t! detect at any stage tem testing 7ith acceptance criteria such as ride and handling - shipping evaluati!n etc82 r system testing until 4ailure !ccurs- testing !4 interacti!ns etc82 system testing a4ter durability test e8g8 4uncti!nal test8 "ss?f"il testing 1e8g88 acceptance criteria 4!r per4!rmance 4uncti!nal chec?s etc82 est to f"ilure 1e8g8 until lea?s- yields !r crac?s etc82 egr"d"tion 1e8g8 data trends- be4!re:a4ter values etc82 nd is ig ly correl"ted 7ith actual !r eBpected !perating c!nditi!ns8 est practices- !r c!mm!n material- etc82