PPAP Workbook

This workbook is to be used for Production Part Approval Process (PPAP) submissions to Jacobs Vehicle Systems
(JVS).
Separate tabs are included for each section of the PPAP (as shown in the AIAG PPAP Manual, Fourth Edition).
For Ease of Use with the forms, you should enter all relevant information in the "Data" tab to avoid having to retype it.
The "Submission Plan" defines what sections are applicable for each level of PPAP.
Supplier shall complete each tab. Included are check boxes to be used if the tab is "not applicable". If for some reason,
a document cannot be attached into the designated tab, please submit as a separate .pdf document and indicate in the
tab that the document is being submitted separately.
Supplier shall fill in areas shaded "yellow". JVS uses sections shaded "blue".
Upon completion, please submit your PPAP to JVS_PPAP@jakebrake.com or as requested in the PPAP purchase order
or instruction from JVS Purchasing or Quality.

Part Information
Part Name
Part Number
Revision
Supplier Part Number (if applicable)
Supplier Part Rev or Date (if applicable)
Additional engineering changes
Additional engineering change rev/date
Shown on drawing number
Deviation
Deviation Approval Date
Weight
Application
Purchase Order No
Tooling Purchase Order
JVS Buyer Name

Submission Information
Submission Date
Submission Level (see submission plan)

Reason for PPAP submission

Supplier Information
Supplier Name
Street Address
City
State
Postal Code
Person responsible for PPAP submission
Title
Phone
Fax
e-mail

PPAP Submission Plan

Supplier
Part Number
Reason for submission 0

Part Name

0
0

Date of Submission
PPAP Level

0
0

Revision

0
0

JVS normally requires PPAP level 3, unless otherwise specified. The PPAP P.O. takes precedence.
JVS requires PPAP level 4* (see below) for commercially available product such as fasteners. Item 10 should include material certs, grade certs, mechanical properties, unless otherwise specified. The PPAP
P.O. takes precedence.
This form represents a plan for the submission of requirements. Not all requirements may be applicable in every case.
Key: R - Retain at Supplier S - Submit to JVS W - Waived
Refer to AIAG PPAP Manual, Fourth Edition, for further clarification.

Customer Engineering Approval

JVS Supplier Deviation Request

Design FMEA
Required, if design responsible.

Process Flow Diagram

Process FMEA

Control Plan

Measurement System Analysis Studies

Required for measurement devices used for
special characteristics.

Dimensional Results
Clearly identify dimensional data to the part(s)
submitted in # 14.

10 Material, Performance, Test Results

Transfer data to form from certifications,
including the specification limits, and attach
copy of material and test certifications.

11 Initial Process Study

Required for all special characteristics.
Include raw data, histogram, control chart and
capability indices (PpK and CpK).

12 Qualified Laboratory Documentation

Include copies of certifications (e.g. ISO9000,
TS16949, A2LA), as appropriate

13 Appearance Approval Report

Not applicable to JVS product

14 Sample Product
Clearly identify part(s) used for the results
submitted in # 9. A minimum of 2 parts to be
submitted (one for dimensional analysis and
one for possible destructive testing), unless
otherwise specified.

15 Master Samples
Sample must be retained at the supplier.
Dimensional data for this piece should also be
included in #9.

16 Checking Aids
List the checking aids with calibration status,
as appropriate.

17 JVS Specific Requirements

Coatings (MSDS)
Process Chemicals
Outside processes

18 Part Submission Warrant

19 Bulk Material Checklist
Not applicable to JVS product

FAI -

Date

Supplier Quality Engineer

Engineering Change Documents, if any

JVS Supplier Change Request or evidence of
engineering approval (e.g. e-mail)

Acceptable
Y/N

Interim/
Conditional

JVS Comments

Date

Design Record
Ballooned JVS Part Print

Supplier Comments

Commodity Mgr/Buyer Planner

Submitted
Y/N

Rejected

Date

4*

Process Quality Engineer

Comments

Approved

Date

PPAP Level
1

Product Engineer

Requirement

Met Review -

N/A

Waived

Waived

N/A

N/A

To be retained at supplier

To be retained at supplier

N/A

N/A

Waived

Waived

N/A

Design Record

Ballooned JVS print (required for PPAP level 2, 3, 4, and 4*)

Attached below
Submitted under separate cover

Supplier print

Attached below
Submitted under separate cover

Engineering Change Document

(Supplier Change Request)
Identify approved change(s) not yet recorded on the design drawing, but which are
incorporated in the product.
Not Applicable
Approved Supplier Change Request

Attached below

Submitted under separate cover

Other evidence of engineering approval (e.g. e-mail)

Attached below

Submitted under separate cover

Supplier Change Request included (form available at www.jakebrake.com)

Attached below
Submitted under separate cover

Engineering Approval
(Supplier Deviation Request)
Identify any deviation(s) from the design drawing (characteristics which do not meet the
design requirement).
Not Applicable

Approved Supplier Deviation

Attached below
Submitted under separate cover

Other evidence of engineering approval (e.g. e-mail)

Attached below
Submitted under separate cover
Supplier Deviation Request included (form available at www.jakebrake.com)
Attached below
Submitted under separate cover

Design Failure Mode & Effects Analysis

(DFMEA)
Not Applicable per Submission Plan

Not Applicable - Not design responsible

DFMEA attached below

DFMEA submitted under separate cover

DFMEA included as separate tab in this workbook

Process Flow Diagram

Not Applicable per Submission Plan

Process Flow attached below

Process Flow submitted under separate cover

Process Flow included as separate tab in this workbook

Process Failure Mode & Effects Analysis

(PFMEA)
Not Applicable per Submission Plan

Other (Explain)

PFMEA attached below

PFMEA submitted under separate cover

PFMEA included as separate tab in this workbook

Control Plan
Not Applicable per Submission Plan
Control Plan attached below
Control Plan submitted under separate cover
Control Plan included as separate tab in this workbook

Measurement System Analysis Studies

Not Applicable per Submission Plan
Not Applicable - No Special Characteristics
MSA evaluated
Total GRR < 10%
10% < Total GRR < 30%
Total GRR > 30% - Action plan attached
MSA attached below
MSA submitted under separate cover
MSA included as separate tab(s) in this workbook

Dimensional Results
PART NAME

PART NUMBER

PART REV

SUPPLIER

NAME OF SUPPLIER INSPECTOR

DATE OF SUPPLIER INSP

NAME OF JVS INSPECTOR

DATE OF JVS INSP

0
PURCHASE ORDER

Inspection Method
C=Calipers, DI=Drop Indicator, G=Gage Pins, I=Indicator, M=Micrometer, P=Profilometer, R=Rockwell Hardness Tester, S=Shadowgraph

Supplier
Item

Dimension /
Specification

Inspection
Method

Jacobs

Results
Pc. 1

Pc. 2

Pc. 3
(Retained at Supplier)

A/R

Inspection
Method

Results

Page 13 of 24

A/R

Supplier
Item

Dimension /
Specification

Inspection
Method

Jacobs

Results
Pc. 1

Pc. 2

Pc. 3
(Retained at Supplier)

A/R

Inspection
Method

Results

Page 14 of 24

A/R

Material Test Results

Not Applicable

Complete form and attach material certification below. Blanket statements of conformance are unacceptable for any test results.
SUPPLIER

PART NAME

PART NUMBER

REV

MATERIAL SUPPLIER

NAME OF
LABORATORY

MATERIAL SPEC./
CHARACTERISTIC

SPECIFICATION
LIMITS
TEST DATE QTY TESTED

SUPPLIER TEST
RESULTS (DATA)

OK

0.44
57.70

OK
OK

SAMPLE DATA

METAL CO
HT SUPPLIER

METAL CO.
HT SUPPLIER

42CrMoS4
%C
Core Hardness

0.38 - 0.45
56 - 60 HRC

6/6/10
6/10/10

Heat 425880
(2000 lbs)
1

NOT
OK

Performance Test Results

Not Applicable

Applies to performance tests such as fatigue testing, breakaway torque and mechanical properties.
Complete form and attach test certification below (if applicable). Blanket statements of conformance are unacceptable for any test results.
SUPPLIER

PART NAME

PART NUMBER

REV

TEST LABORATORY

TEST SPEC./
CHARACTERISTIC

SPECIFICATION
LIMITS
TEST DATE QTY TESTED

SUPPLIER TEST
RESULTS (DATA)

OK

1 pc broke at 214,000
cycles, 2 pcs test
stopped at 250,000
cycles without failure

OK

SAMPLE DATA

AAA TEST LAB

Cycle test per ABC

SPEC 1234

100,000 cycles
without failure

6/6/10

NOT
OK

Initial Process Studies

Process Studies are required for all special (Critical and Major) characteristics. Process
Studies should be included, if possible, for all KCC/KPC
Include raw data, histogram, control chart and capability indices (PpK and CpK)
Not Applicable per Submission Plan
Not Applicable - No Special Characteristics
Process Studies conducted
Min Capability Requirements met (Critical 1.67 CpK and Major 1.33 CpK)
Min Capability Requirements not met - Action plan attached
Process Studies attached below
Process Studies submitted under separate cover
Process Studies included as separate tab(s) in this workbook

Qualified Laboratory Documentation

Not Applicable
Certificate(s) previously submitted (no changes)
Certificate(s) attached
Certificate(s) submitted under separate cover
TS 16949 Certification
ISO 9001 Certification
ISO 14000 Certification
A2LA Certification
ISO/IEC17025 Certification
Other Certification (Please specify)

Issue Date
Issue Date
Issue Date
Issue Date
Issue Date

Expiration Date
Expiration Date
Expiration Date
Expiration Date
Expiration Date

Checking Aids
Not Applicable

SUPPLIER

PART NAME

Checking aid
number

PART NUMBER

Description of checking aid

REV

0
Complies with
revision above?
Y/N

0
Date of last
calibration /
verification

Coating MSDS
List any coatings on the product and attach MSDS
Not Applicable
MSDS(s) previously submitted (no changes)
MSDS(s) attached
MSDS(s) submitted under separate cover
Oil (Please specify type and include MSDS)
Rust Preventative (Please specify type and include MSDS)
Black Oxide (Please include MSDS)
Plating (Please specify type and include MSDS)
Loctite or similar (Please specify type and include MSDS)
Other (Please specify and include MSDS)

Process Chemicals
List any chemicals used for cleaning, degreasing, descaling, etching, acids or bases used in vibratory finishing, etc..
Attach manufacturer's chemical specification for any such chemicals, as appropriate.
Not Applicable

Brand Name and Manufacturer of Chemical

Process where chemical is used

Outside Services
Identify supplier for any outside processes or services (e.g. coating application, shot peen, grinding)
Not Applicable

Outside Service /
Operation

Supplier Name

Supplier Location

Certifications and expiration

dates
(e.g. ISO 9001, TS16949,
A2LA, ISO/IEC 7025)

Part Submission Warrant

0

Part Name

JVS Part Number

Rev.

Supplier Part Number

Rev.

Additional Engineering Changes

Rev. / Date

Tooling P.O. Number

Purchase Order No.

Weight (kg)

ORGANIZATION MANUFACTURING INFORMATION

SUBMISSION INFORMATION

JACOBS VEHICLE SYSTEMS

0.0000

Supplier Name

Street Address

JVS Purchasing or Buyer/Planner Contact

City

State

Note:

Zip

Application

Does this part contain any restricted or reportable substances?

Yes

No

Are plastic parts identified with appropriate ISO marking codes?

Yes

No

REASON FOR SUBMISSION

Initial submission

Change to Optional Construction or Material

Engineering Change(s)

Sub-Supplier or Material Source Change

Tooling: Transfer, Replacement, Refurbishment, or Additional

Change in Part Processing

Correction of Discrepancy

Parts produced at Additional Location

Tooling inactive > than 1 year

Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.

9 10 11 12 13 14 15 16 17 18 19

(check)
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
DECLARATION
I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer drawings and
specifications and are made from specified materials on regular production tooling with no operations other than the regular production process. I
also certify that documented evidence of such compliance is on file and available for review.

EXPLANATION/COMMENTS:

List Molds / Cavities / Production Processes

Organization Authorized Signature
Print Name
Title

Date
0

Phone No.

Fax No.

E-Mail
FOR JVS USE ONLY

PPAP Warrant Disposition

Approved

Interim Approval

Customer Signature
Print Name

Date

Rejected

Comments

0
0

Dispositioned PSW
For JVS use only