Production Part Approval Process (PPAP
Production Part Approval Process (PPAP)
( b) Authorized Engineering Change (note) Documents This is the supplier request for a change in design record A document that shows the detailed description of the change. Usually this document is called "Engineering Change Notice", but it may be covered by the customer PO or any other engineering authorization. This documentation must include the part numbers affected, the description of the change, the reason(s) for the change, the requested timing for the change, and the supplier representative's contact information, signature and date.
(d) DFMEA DESIGN-POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS . Applicable only when the supplier has design responsibility . A tool used when designing a component, system, process, etc. to ensure, to the extent possible, that all potential failure modes (design related) and their associated causes/mechanisms have been considered and addressed. A copy of the (DFMEA), reviewed and signed-off by supplier and customer. If customer is design responsible, usually customer may not share this document with the supplier. However, the list of all critical or high impact product characteristics should be shared with the supplier, so they can be addressed on the PFMEA and Control Plan.
( e) Process Flow Diagram This record is used to verify that the supplier has thoroughly evaluated and analyzed the total manufacturing or assembly process, from start to finish, for all possible causes of variation (i.e. machines, materials, methods, etc.) and has organized the process in such a way as to reduce or eliminate the effect these variations will have on the overall quality system. A copy of the Process Flow, indicating all steps and sequence in the fabrication process, including Incoming components. This document shall flow smoothly into the supplier Control Plan and FMEA. Part/Process Numbers nd Process Name/Operation Descriptions should carry over and be consistent on all three documents.
( f) PFMEA To ensure that all potential failure modes and the effects they have on a process have been considered, addressed and/or eliminated. A copy of the Process Failure Mode and Effect Analysis reviewed and signed-off by supplier and customer. The PFMEA follows the Process Flow steps, and indicate "what could go wrong" during the fabrication and assembly of each component. The PFMEA is a living document that should be used and updated for the life of the product
( g) Control Plan PROCESS/PRODUCT CONTROL PLAN (CP) To aid in the manufacture of quality products according to customer requirements, a structured approach must be used for the design, selection, and implementation of value-added control methods for the total system. It provides a written summary description of the systems used in minimizing process and product variation. A copy of the Control Plan, reviewed and signed-off by supplier and customer. The Control Plan follows the PFMEA steps, and provides more details on how the "potential issues" are checked in the incoming quality, assembly process or during inspections of finished products. All Special Characteristics (e.g., critical, key, significant, etc.) must be indentified and addressed on the CP
( h) Measurement System Analysis Studies The purpose of this record is to verify that the gauge (U.S. gage) or measurement system is capable of accurately assessing the quality of the parts. MSA usually contains for the critical or high impact characteristics, and a confirmation that gauges used to measure these characteristics are calibrated. Measurement System Analysis Studies must be submitted with ALL Initial Process Studies.Gage R&R, Bias, Linearity, & Stability must be submitted when applicable
( j) Dimensional Results This record is used to verify that the parts meet all of the dimensional requirements called out on the Drawing and Control Plan. A list of every dimension noted on the ballooned drawing. This list shows the product characteristic, specification, the measurement results and the assessment showing if this dimension is "ok" or "not ok". Usually a minimum of 6 pieces is reported per product/process combination. All dimensions, characteristics, and specifications noted on the Drawing and Control Plan should be listed in a convenient and organized format with the actual results recorded..
( l) Initial Process Studies The purpose of this record is to determine if the production process will produce product that meets the Customer's requirements. This includes both the raw data (data points) and the results (e.g. CPK, PPK, CP). Usually this section shows all Statistical Process Control charts affecting the most critical characteristics. The intent is to demonstrate that critical processes have stable variability and that is running near the intended nominal value. When performing the initial process study, data shall be plotted from consecutive parts taken from the production trial run. These studies could be augmented or replaced by long term results from the same or similar process run on the same equipment with prior customer concurrence. Study data shall be submitted in a format agreed to by the custome
( m) Qualified Laboratory Documentation The purpose of this record is to verify that the supplier has used an Accredited Laboratory or Testing Facility to perform all Material, Functional, and Performance testing called out on the Drawing and Control Plan. This Record must be submitted with ALL testing data. This includes ALL standards and specifications called out on the Drawing and CP Copy of all laboratory certifications (e.g. A2LA, TS) of the laboratories that performed the tests reported
( n) Appearance Approval Report Submitted with PPAP and sample parts for the customer to sign, verifying the parts meet all aesthetic criteria. A copy of the AAI (Appearance Approval Inspection) form signed by the customer. Applicable for components affecting appearance only.
( p) Master Sample A sample signed off by customer and supplier, that usually is used to train operators on subjective inspections such as visual or for noise. The supplier shall retain a master sample for the same period as the production part approval records or until a new master sample is produced for the same customer part number for customer approval, or where a master sample is required by the design record, Control Plan or inspection criteria, as a reference or standard. The supplier shall retain a master sample for each position of a multiple cavity die, mould, tool or pattern, or production process
( q) Checking Aids When there are special tools for checking parts, this section shows a picture of the tool and calibration records, including dimensional report of the tool. The supplier shall certify that all aspects of the checking aid agree with part dimensional requirements. The supplier shall document all released engineering design changes that have been incorporated in the checking aid at the time of submission. The supplier shall provide for preventive maintenance of any checking aids for the life of the part.
( s) Part Submission Warrant (PSW) This is the form that summarizes the whole PPAP package. This form shows the reason for submission (design change, annual revalidation, etc.) and the level of documents submitted to the customer. There is a section that asks for "results meeting all drawing and specification requirements: yes/no" refers to the whole package. If there is any deviations the supplier should note on the warrant or inform that PPAP cannot be submitted.
(a) Design Records A copy of the drawing. Suppliers MUST submit a ballooned copy of the Drawing that corresponds to the Dimensional, Material, and Performance Results If the customer is design responsible this is a copy of customer drawing that is sent together with the Purchase Order (PO). If supplier is design responsible this is a released drawing in supplier's release system. When the design records, e.g. CAD/CAM math data, part Drawings, specifications, are in electronic format, e.g. math data, the supplier shall produce and submit a hard copy (e.g. pictorial, GD&T sheets, Drawing, specification pages, etc.) to identify measurements taken.
( b) Authorized Engineering Change (note) Documents This is the supplier request for a change in design record A document that shows the detailed description of the change. Usually this document is called "Engineering Change Notice", but it may be covered by the customer PO or any other engineering authorization. This documentation must include the part numbers affected, the description of the change, the reason(s) for the change, the requested timing for the change, and the supplier representative's contact information, signature and date.
( c ) Customer Engineering Approval This approval is usually the Engineering trial with production parts performed at the customer plant. A "temporary deviation" usually is required to send parts to customer before PPAP. Customer may require other "Engineering Approvals". The organization have evidence of customer engineering approval including approval for parts, tooling, product or processe
(d) DFMEA DESIGN-POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS . Applicable only when the supplier has design responsibility . A tool used when designing a component, system, process, etc. to ensure, to the extent possible, that all potential failure modes (design related) and their associated causes/mechanisms have been considered and addressed. A copy of the (DFMEA), reviewed and signed-off by supplier and customer. If customer is design responsible, usually customer may not share this document with the supplier. However, the list of all critical or high impact product characteristics should be shared with the supplier, so they can be addressed on the PFMEA and Control Plan.
( e) Process Flow Diagram This record is used to verify that the supplier has thoroughly evaluated and analyzed the total manufacturing or assembly process, from start to finish, for all possible causes of variation (i.e. machines, materials, methods, etc.) and has organized the process in such a way as to reduce or eliminate the effect these variations will have on the overall quality system. A copy of the Process Flow, indicating all steps and sequence in the fabrication process, including Incoming components. This document shall flow smoothly into the supplier Control Plan and FMEA. Part/Process Numbers nd Process Name/Operation Descriptions should carry over and be consistent on all three documents.
( f) PFMEA To ensure that all potential failure modes and the effects they have on a process have been considered, addressed and/or eliminated. A copy of the Process Failure Mode and Effect Analysis reviewed and signed-off by supplier and customer. The PFMEA follows the Process Flow steps, and indicate "what could go wrong" during the fabrication and assembly of each component. The PFMEA is a living document that should be used and updated for the life of the product
( g) Control Plan PROCESS/PRODUCT CONTROL PLAN (CP) To aid in the manufacture of quality products according to customer requirements, a structured approach must be used for the design, selection, and implementation of value-added control methods for the total system. It provides a written summary description of the systems used in minimizing process and product variation. A copy of the Control Plan, reviewed and signed-off by supplier and customer. The Control Plan follows the PFMEA steps, and provides more details on how the "potential issues" are checked in the incoming quality, assembly process or during inspections of finished products. All Special Characteristics (e.g., critical, key, significant, etc.) must be indentified and addressed on the CP
( h) Measurement System Analysis Studies The purpose of this record is to verify that the gauge (U.S. gage) or measurement system is capable of accurately assessing the quality of the parts. MSA usually contains for the critical or high impact characteristics, and a confirmation that gauges used to measure these characteristics are calibrated. Measurement System Analysis Studies must be submitted with ALL Initial Process Studies.Gage R&R, Bias, Linearity, & Stability must be submitted when applicable
( j) Dimensional Results This record is used to verify that the parts meet all of the dimensional requirements called out on the Drawing and Control Plan. A list of every dimension noted on the ballooned drawing. This list shows the product characteristic, specification, the measurement results and the assessment showing if this dimension is "ok" or "not ok". Usually a minimum of 6 pieces is reported per product/process combination. All dimensions, characteristics, and specifications noted on the Drawing and Control Plan should be listed in a convenient and organized format with the actual results recorded..
(k) Records of Material / Performance Tests This record is used to verify that the parts meet all of the Material and/or Performance requirements/specifications called out on the Drawing and Control Plan. A summary of every test performed on the part. This summary is usually on a form of DVP&R (Design Verification Plan and Report), which lists each individual test, when it was performed, the specification, results and the assessment pass/fail. If there is an Engineering Specification, usually it is noted on the print. The DVP&R shall be reviewed and signed off by both customer and supplier engineering groups. The quality engineer will look for a customer signature on this document.
In addition, this section lists all material certifications (steel, plastics, plating, etc.), as specified on the print. The material certification shall show compliance to the specific call on the print.
In addition, this section lists all material certifications (steel, plastics, plating, etc.), as specified on the print. The material certification shall show compliance to the specific call on the print.
( l) Initial Process Studies The purpose of this record is to determine if the production process will produce product that meets the Customer's requirements. This includes both the raw data (data points) and the results (e.g. CPK, PPK, CP). Usually this section shows all Statistical Process Control charts affecting the most critical characteristics. The intent is to demonstrate that critical processes have stable variability and that is running near the intended nominal value. When performing the initial process study, data shall be plotted from consecutive parts taken from the production trial run. These studies could be augmented or replaced by long term results from the same or similar process run on the same equipment with prior customer concurrence. Study data shall be submitted in a format agreed to by the custome
( m) Qualified Laboratory Documentation The purpose of this record is to verify that the supplier has used an Accredited Laboratory or Testing Facility to perform all Material, Functional, and Performance testing called out on the Drawing and Control Plan. This Record must be submitted with ALL testing data. This includes ALL standards and specifications called out on the Drawing and CP Copy of all laboratory certifications (e.g. A2LA, TS) of the laboratories that performed the tests reported
( n) Appearance Approval Report Submitted with PPAP and sample parts for the customer to sign, verifying the parts meet all aesthetic criteria. A copy of the AAI (Appearance Approval Inspection) form signed by the customer. Applicable for components affecting appearance only.
(o) Sample Production Parts Sample parts are submitted for appearance and functional evaluation. A sample from the same lot of initial production run. The PPAP package usually shows a picture of the sample and where it is kept (customer or supplier). A few of the parts used for dimensional verification shall be submitted. These shall be labelled with part number, cavity, revision ,tool number, etc. and include a sample number that corresponds to the Dimensional Report. Suppliers shall submit samples that represent each unique cavity, mould, line, etc.
( p) Master Sample A sample signed off by customer and supplier, that usually is used to train operators on subjective inspections such as visual or for noise. The supplier shall retain a master sample for the same period as the production part approval records or until a new master sample is produced for the same customer part number for customer approval, or where a master sample is required by the design record, Control Plan or inspection criteria, as a reference or standard. The supplier shall retain a master sample for each position of a multiple cavity die, mould, tool or pattern, or production process
( q) Checking Aids When there are special tools for checking parts, this section shows a picture of the tool and calibration records, including dimensional report of the tool. The supplier shall certify that all aspects of the checking aid agree with part dimensional requirements. The supplier shall document all released engineering design changes that have been incorporated in the checking aid at the time of submission. The supplier shall provide for preventive maintenance of any checking aids for the life of the part.
( r) Customer-Specific Requirements Each customer may have specific requirements to be included on the PPAP package. It is a good practice to ask the customer for PPAP expectations before even quoting for a job..
( s) Part Submission Warrant (PSW) This is the form that summarizes the whole PPAP package. This form shows the reason for submission (design change, annual revalidation, etc.) and the level of documents submitted to the customer. There is a section that asks for "results meeting all drawing and specification requirements: yes/no" refers to the whole package. If there is any deviations the supplier should note on the warrant or inform that PPAP cannot be submitted.
