Presentation on PPAP

PRODUCTION PART APPROVAL PROCESS (PPAP)

Presentation on PPAP Production Part Approval Process

Understanding ISO/TS 16949:2002 Basic requirements Overview of PPAP requirements Understanding of
Submission Level Process Flow Process FMEA Capability Study MSA
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Presentation on PPAP
Continual Improvement of the Quality Management System
C U S T O M E R FIGURE 1 R E Q U I R E M E N T S
Management Responsibility

C S A T I S F A C T I O N U S T O M E R

Resource Management

Measurement, Analysis, Improvement

Input

Product Realization

Output Product

Model of a process-based quality management system

ISO 2000

Presentation on PPAP
Production Part Approval Process Objectives: Understand when PPAP submissions are required Understand requirements for PPAP submissions Understand the different PPAP submission levels Understanding of the forms used for PPAP submissions Understanding where the PPAP submission fits into the APQP cycle

Presentation on PPAP
The Purpose of PPAP
is to determine A) If all customer engineering design records and specification requirements are properly understood by the supplier (Customer and Supplier have a common understanding of Customer requirements) B)The process has potential to produce parts consistently meeting the requirements during an actual production run at the quoted production rate (Is the process capable of meeting customer requirements during on going production process)
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Presentation on PPAP
Applicability of PPAP
PPAP shall apply to External and internal suppliers sites of: Bulk Material Production Material Production Parts Service Parts For Bulk material PPAP is not required unless asked by the customer. A supplier of production parts / service parts shall comply with the PPAP requirements unless the same is formally waived by the Customer (documented evidences should be available) 6

Presentation on PPAP Application

AIAG PPAP manual defines when PPAP submission is required

Something
Changed

New part Correction to discrepancy in previous submission Design or process change Change in source of subcontracted materials or services transfer or rearrangement of tooling 7 & equipment

WHEN A PPAP IS REQUIRED ?

Requirement 1. Use of other construction or material than was used in the previously approved part or product 2. Production from new or modified tools (except perishable tools), dies, molds, patterns, etc., including additional or replacement tooling.

Presentation on PPAP
For example, other construction as documented on a deviation (permit) or included as a note on the design record and not covered by an engineering change

A PPAP is required to be submitted in the following conditions also :

only applies to tools which due to their unique form or function, can be expected to influence the integrity of the final product. It is not meant to describe standard tools (new or repaired)., such as standard measuring devices, drivers (manual or power), etc.

Presentation on PPAP
WHEN A PPAP IS REQUIRED ?
3. Production following refurbishment or rearrangement of existing tooling or equipment
Refurbishment means the reconstruction and/or modification of a tool or machine or to increase the capacity, performance, or change its existing function (Not normal maintenance, repair etc..)
Rearrangement is defined as activity which changes the sequence of product/process flow from that documented in the process flow diagram (including the addition of a new process). minor changes to add to safety requirements can be made with out customer approval, provided these changes does not lead to a change in the process flow sequence 9

Presentation on PPAP
WHEN A PPAP IS REQUIRED ?
4. Production from tooling and equipment transferred to a different plant location or from an additional plant location.
5. Change of subcontractor for parts, non-equivalent materials, or services (e.g.: heat-treating, plating) that affect customer fit, form, function, durability, or performance requirements.

Production process tooling and/or equipment transferred between buildings or facilities in one or more locations. Suppliers are responsible for approval of subcontracted material and services that do not affect customer fit, form, function, durability, or performance requirements.
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Presentation on PPAP
WHEN A PPAP IS REQUIRED ?
6. Product produced after the tooling has been inactive for volume production for twelve months or more
For product that has been produced after tooling has been inactive for twelve months or more, Notification is required when the part has had no active purchase order and the existing tooling has been inactive for volume production for twelve months or more. The only exception is when the part has low volume e.g. service or specialty vehicles. However, a customer may specify certain PPAP requirements for service parts.
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Presentation on PPAP
WHEN A PPAP IS REQUIRED ?
7. Product and process changes related to components of the production product manufactured internally or manufactured by subcontractors that impact fit, form, function , performance, and /or durability of the salable product. Additionally, the supplier shall concur with any requests by a subcontractor before submission to the customer.

Any change after, which affects customer requirements for fit, form, function, performance, and/or durability requires notification to the customer.
NOTE: The fit, form, function, performance, and/or durability requirements should be part of customer specifications as agreed on during contract review.

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Presentation on PPAP
WHEN A PPAP IS REQUIRED ?
8. For bulk materials only: New source of raw material with special characteristics from new or existing subcontractor. Change in product appearance attributes where there is no appearance specification. Revised parameters in the same process (outside PFEA parameters of the approved product, includes packaging). Change outside of DFEA (product composition, ingredient levels) of the approved product.

These changes would normally be expected to have an effect on the performance of the product.

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Presentation on PPAP
WHEN A PPAP IS REQUIRED ?

9. Change in test/inspection method new technique (no effect on acceptance criteria).

For change in test method, supplier should have evidence that the new method provides results equivalent to the old method.

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Presentation on PPAP
Methodology
Buyer enters PPAP submission date on purchase order Approver determines submission level default level 3 Supplier submits PPAP Approver determine part submission status Approver evaluates PPAP package Notify supplier and manufacturing of status

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Presentation on PPAP
PPAP Process Requirements
SUBMISSION TO CUSTOMER LEVELS OF EVIDENCE
Submission Levels The supplier shall submit the items and/or records specified by the level as requested by the customer. Level 1 Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to the customer. Level 2 - Warrant with product samples and limited supporting data submitted to the customer. Level 3 Warrant with product samples and complete supporting data submitted to the customer. Level 4 Warrant and other requirements as defined by the customer. Level 5 - Warrant with product samples and complete supporting 16 data available for review at the suppliers manufacturing location.

Presentation on PPAP
PPAP Process Requirements
Submission Levels The supplier shall use level 3 as the default level for all submissions unless specified otherwise by the responsible customer product approval activity. A supplier of bulk material only shall use level 1 as the default level for all bulk material PPAP submissions unless specified otherwise by the responsible customer product approval activity. The customer will identify the submission level that will be used with each supplier, or supplier and customer part number combination. Different customer locations may assign different submission levels to the same supplier manufacturing location. All of the forms referenced in this document may be replaced by computer-generated facsimiles is to be confirmed with the responsible part approval activity prior to the first submission.
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SUBMISSION TO CUSTOMER LEVELS OF EVIDENCE

PPAP Process Requirements

Requirement
Level 1 1. Design Records of Saleable Product -for proprietary components/ Details - for all other component/details Engineering change documents, If any R R R

Presentation on PPAP
Submission Level
Level 2 S R S Level 3 S R S

Level 4 * * *

Level 5 R R R

2.

R R R R R R R R

S R R R R S S R R

S S S S S S S S S

* * * * * * * * *

R R R R R R R

3. Customer Eng. Approval, if required 4. Design FMEA (See 1.2.2.4) 5. Process Flow Diagrams 6. Process FMEA 7. Dimensional Results 8. Material, Performance Test results 9. Initial Process Study

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R R

10.Measurement System Analysis Studies R

Presentation on PPAP
PPAP Process Requirements
11. Qualified Lab. Documentation 12. Control Plan 13. Part Submission Warrant (PSW) R R S S R S S R R R R R S S S S R R R R S * * * * * * * * * R R R R R R R R R

14. Appearance Approval Report (AAR) S 15. Bulk Material Requirement Checklist R 16. Sample Product 17. aster Sample (See 1.2.2.17) 18. Checking Aids R R R

19. Records of compliance R With Customer-Specific Requirements

S = The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items at appropriate locations, including manufacturing. R = The supplier shall retain at appropriate locations, including manufacturing, and make readily available to the customer representative upon request. 19 * = The supplier shall retain at appropriate locations, ad submit to customer upon request.

Presentation on PPAP
Supplier Data Received
Warrant Appearance Approval Report (AAR), as required Sample Parts Print/Design Record Engineering Change Documents Check fixtures/aids Process Flow Diagram PFMEA DFMEA Control Plan Early Production Containment Plan (Pre-Launch Control Plan) Process capability studies Gage Measurement System Analysis Lab Accreditation & scope Restricted & Reportable Materials form Interim Worksheet, if required
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