HMCL SUPPLIER PPAP CHECKLIST

S.No Bullet Point Requirements

1 Availability of latest Drawing Revision Level

01 Design Records
2 Ballooned & Labeled Drawing for Inspection Recording

02 Substance of Concern 1 Not required in current situation

03 Design FMEA 1 Not required in current situation

1 Ensure coverage of all process from Receiving to Dispatch from supplier

2 Identification of Process / stage at which Quality Gate is displayed.

04 Process Flow Diagram
3 Ensure Inclusion of Rework Station & Rework Flow in PFD

4 Identification for Vendor process like Plating / Surface / Heat Treatment in the correct seque

1 Ensure FMEA is done for all process steps from Receiving to Dispatch
Process FMEA
05 2 Ensure High Severity Items have both Preventive & Detective Control(Poke Yokes for custom
(PFMEA)
3 Review PFMEA of processes, where rejection / Rework is high

1 Ensure coverage of all processes from Receiving to Despatch from supplier (All Conversion P

2 Identify critical to quality ( CTQs ) and critical to Process ( CTPs ) and Ensure 100% control fo

3 Identify Fit, Functional & Performance Characteristics

06 PQCS (Control Plan) 4 Inspection & checking Aids should be identified

5 Reaction Plan should be documented

6 References should be provided for Machines, Fixture preventive maintenance & Rework Sop'

7 Ensure due verification details of Raw Materials

1 Availability of duly calibrated gauges , Instruments , Test rigs

2 INSPECTION METHOD / MEANS COMPATIBILITY BETWEEN HMCL & SUPPLIER

Measurement System
07 3 Availability of Calibration/Inspection Status on Gauges.
Analysis (MSA)
4 Attribute gauge study to ensure usage of Known OK & bad samples

5 Inspector's Identification on parts for traceability ( wherever mutually agreed with HMCL)

1 Ensure Critical as well as Related Dimensions are included in Inspection Report

Dimensional Inspection
08 2 Ensure addressal of parameters in case of multiple dies, cavities, moulds & fixtures.
Report
3 Ensure OK / NG Status against all Measured Data's

1 Ensure reports of raw material from the same batch for which samples are submitted.
Material & Performance
09 2 Ensure all Performance test results are recorded in the reports.
Test Results
3 Ensure weld length & Weld penetration reports as applicable ( in welding process )
 HMCL SUPPLIER PPAP CHECKLIST
S.No Bullet Point Requirements

1 Ensure process qualification & validation reports

2 Ensure & Document sequence of part loading / clamping on fixture
3 Ensure & Document sequence of Gauging
4 Ensure recording of Initial Trials reports with corrective actions
5 Ensure straight pass data & cycle time is recorded during trials
10 Initial Process Studies
6 Compare Each process cycle time w.r.t Tact Time & submit Action Plan in case of Gaps

7 List of Problems observed with CAPA & Why-Why analysis during samples preparation.

8 Availability of work instructions, capturing fit & functions.

9 Disposition of Trial Material

Shall consist of dimensional,Metallurgical,Metal finishing, Performance & Endurance report (

1
Sample Approval applicable)
11 2 Action Plan for the Non conformances highlighted in sample inspection report.
Report
3 Approved BOP's Offloaded Processes & Raw material suppliers report.

1 List of All BOP suppliers, offloaded processes / special processes with part description.
2 Status of Supplier Audits at Tier-II suppliers.
12 BOP's PPAP Status
3 Verify as per PPAP checklist at BOP suppliers
4 Raw Material Source list of BOP suppliers.

1 lab test report for Raw material, Special processes e.g.- Heat treatment, Plating & painting e
13 Qualified Lab Reports
2 Conformance of lab test results at certified lab.

1 All Visual Appearance areas are identified with well defined Limit Samples
Appearance Approval
14
Report
2 Availability of HMCL approved limit samples & Master samples

1 Is the packaging Design and Standard available for Bops' & Finished Goods and is in consens
Packaging / Trolleys
15
Approval 2 Is the calculation done for adequacy of Bins / Trolleys as per customer requirements

1 List of All Guages, Instruments,Testing/Endurance & Performance Testing Facility available w

16 Checking Aid List
2 List of trained workforce for operating the checking aids

1 Ensure Correct part number & drawing revision level

Part Submission
17 2 Correct weight information should be available
Warrant
3 Ensure capacity declaration information with Run @ Rate Study.
R PPAP CHECKLIST
Status to be filled by
ements HMCL
Supplier

YES Yes

No

No

ch from supplier

displayed.
YES Yes
D

Heat Treatment in the correct sequence

g to Dispatch

ective Control(Poke Yokes for customer centric parameters ) YES Yes

s high

patch from supplier (All Conversion Processes)

( CTPs ) and Ensure 100% control for Key Characteristics

YES Yes

eventive maintenance & Rework Sop's

t rigs

N HMCL & SUPPLIER

YES Yes

bad samples

ever mutually agreed with HMCL)

ed in Inspection Report

, cavities, moulds & fixtures. Yes Yes

which samples are submitted.

Yes Yes
eports.
cable ( in welding process )
R PPAP CHECKLIST
Status to be filled by
ements HMCL
Supplier

g on fixture

actions
g trials YES Yes
mit Action Plan in case of Gaps

sis during samples preparation.

s.

g, Performance & Endurance report (whichever is

mple inspection report. YES Yes

ppliers report.

rocesses with part description.

Yes Yes

Heat treatment, Plating & painting etc.

Yes Yes

ned Limit Samples

Pending Yes
amples

s' & Finished Goods and is in consensus with Customer

Yes Yes
per customer requirements

formance Testing Facility available with calibration Status

Yes Yes

Yes Yes
e Study.
 HMCL SUPPLIER PPAP CHECKLIST
Status to be filled by
S.No Bullet Point Requirements HMCL
Supplier
1 Availability of latest Drawing Revision Level
01 Design Records Yes
2 Ballooned & Labelled Drawing for Inspection Recording

02 Substance of Concern 1 Not required in current situation No

03 Design FMEA 1 Not required in current situation No

1 Ensure coverage of all process from Receiving to Dispatch from supplier

2 Identification of Process / stage at which QG is displayed.

3 Proper location of FI to ensure a smooth material flow which avoids double handling & prevent damages

4 Clearly demonstrated floor space for material ( Under Inspection , Ok & Reject )

5 Part Movement & Storage between process identified

6 Identify Key Processess ( CTPs) responsible for Key Product Characteristics ( CTQs)
04 Process Flow Diagram Yes
7 Ensure Inclusion of Rework Station & Rework Flow in PFD

8 Availability of SPACE ( OK / REJ. / HOLD MATERIAL) - NO CHANCES OF MIX-UP OF MATERIAL

9 Data recording & Monitoring points

10 Identify the Straight Pass Data Collection Points

11 Identify Processes where Capability Stude would be conducted

12 Identification for Vendor Our process like Plating / Surface / Heat Treatment in the correct sequence

1 Ensure FMEA is done for all process steps from Receiving to Dispatch

Process FMEA 2 Ensure High Severity Items have both Preventive & Detective Control
05 Yes
(PFMEA) 3 Poka Yokes for custmer centric parameters

4 FMEA should be done for rework process

1 Ensure coverage of all process from Receiving to Dispatch from supplier

2 Identify critical to quality ( CTQs ) and critical to Process ( CTPs ) and Ensure 100% control for Key Characteristics

3 Identify Fit Functional & Performance Characteristics

4 Inspection & checking Aids should be identified

5 Reaction Plan should be documented

6 Preventive Maintenance SOP should be referred

06 PQCS 7 All Visual Inspections should have limit Samples availability duly Yes

8 Ensure due verification of Raw Materials

9 Fixture wear part review & replacement frequency identified , CRITICAL SPARES PARTS LIST AVAILABLE

10 Fixtures are numbered as per Design Records & Fixtures drawings & inspection reports are available

11 Rework Instructions are Available , Rework Authorization & trained operators listed

12 Implementation of controls to ensure deployment of trained manpower at FI stages / Quality Gates

13 Daily internal audit of QG / FI by Quality custodian.

1 Availability of duly caliberated gauges , Instruments , Test rigs which are compatible with HMCL requirements

2 INSPECTION METHOD COMPATIBILITY BETWEEN HMCL & SUPPLIER

3 INSTRUMENT / GAUGE COMPATIBILITY BETWEEN HMCL & SUPPLIER

4 SUPPLIERS' INSPECTOR SKILL / FREEZING OF MANPOWER

Measurement System
07 5 ACCEPTANCE CRITERIA BETWEEN HMCL & SUPPLIER ( LIMIT SAMPLE + STD.) Yes
Analysis (MSA)
6 Calibration Status available on Gages

7 Attribute gage study ensure usage of Known OK & bad samples

8 Inspection Report all gages should be available

9 Inspector's Identification on parts for traceability ( wherever mutually agrred with HMCL)

1 Ensure all Drawing Dimensions are included in Inspection Report

Dimensional Inspection
08 2 Ensure Inspection Report for each process incase of Multiple Fixtures Yes
Report
3 Ensure OK / NG Status against all Measured Data's

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 HMCL SUPPLIER PPAP CHECKLIST
Status to be filled by
S.No Bullet Point Requirements HMCL
Supplier
1 Ensure that all Raw Material test reports are recents
Material & Performance 2 Ensure due identification of Raw Material into the process Yes
09
Tets Results 3 Ensure all Performance test results are enclosed
4 Ensure weld length & Weld penetration reports as applicable ( in welding process )

1 Ensure process qualification & validation reports

2 Ensure process for training of Operators
3 Ensure & Document sequence of part loading on fixture
4 Ensure & Document of part clamping on fixture
5 Ensure & Document sequence of Gaging
6 Ensure recording of Initial Trials reports with corrective actions

7 Ensure that final process status after due process trials is adequately captured & recorded

8 Ensure straight pass data is recorded & benchmark against target

9 Ensure that well defined parts are processed during process trials as per process requirements
10 Initial Process Studies Yes
10 All trial issues are captured & actions taken
11 Calculate Takt Time based on Customer Forecast Requirment

12 Calculate & Compare Each process cycle time wrt Takt Time & Action Plan incase of Gaps

13 Calculate the Hourly Production Rates & Daily Production Capacity

14 Work Instructions available & capturing Fit Function Dimensions

15 List of Hinanyo's / Problems observed with due analysis CAPA , 5 Why? during sample build

16 Work Instructions available & capturing Fit Function Dimensions

17 Disposition of Trial Material

1 List of All BOP suppliers with part decription available

2 Status of Supplier Audits at BOP Tier-II suppliers
12 BOP parts PPAP Status Yes
3 Same PPAP Checklist verified for all BOP suppliers
4 Raw Material Source list for Tier II BOP supplier

1 Status of Quality Certification

13 Qualified Lab Reports No
2 Approved Laboratory certification for Lab & test results

1 All Visual Appearance areas are identified with well defined Limit Samples
Appearance Approval
14 Yes
Report
2 Availability of HMCL approved limit samples & Master samples

1 Is the packaging Std available for Finished Goods , Is the Customer approval taken

Packaging / Trolleys
15 2 Is the packaging Std available for BOP's & Finished Goods Yes
Approval

3 Is the calculation done for adequancy of Bins / Trolleys as per customer requirements

1 List of All Checking Aid with calibration Status

16 Checking Aid List Yes
2 List of trained workforce for operating the checking aids

1 Ensure Correct part number & drawing revision level

Part Submission
17 2 Correct weight information should be available Yes
Warrant
3 Ensure capacity decalaration information is dully filled

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