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

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Management
Responsibility

Measurement,
Analysis,
Improvement

Resource
Management

Input

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Product
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Model of a process-based quality

management system
ISO 2000

Presentation on PPAP
Production Part Approval Process Objectives:
UnderstandwhenPPAPsubmissionsarerequired
UnderstandrequirementsforPPAPsubmissions
UnderstandthedifferentPPAPsubmissionlevels
UnderstandingoftheformsusedforPPAPsubmissions
UnderstandingwherethePPAPsubmissionfitsintothe
APQPcycle

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)

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)
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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 &
equipment
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Presentation on PPAP

WHEN A PPAP IS REQUIRED ?

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

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.

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

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
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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.

Production process tooling and/or

equipment
transferred
between
buildings or facilities in one or more
locations.

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.

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
Any change after, which affects
changes related to
customer requirements for fit,
components of the production form,
function,
performance,
and/or
durability
requires
product manufactured
notification to the customer.
internally or manufactured
by subcontractors that
NOTE: The fit, form, function,
impact fit, form, function ,
performance,
and/or
durability
performance, and /or
requirements should be part of
durability of the salable
customer specifications as agreed
product. Additionally, the
on during contract review.
supplier shall concur with any
requests by a subcontractor
before submission to the
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customer.

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

Approver determine
part submission status
Approver evaluates
PPAP package
Notify supplier and
manufacturing of
status

Supplier submits PPAP

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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
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data available for review at the suppliers manufacturing location.

Presentation on PPAP
PPAP Process Requirements
SUBMISSION TO CUSTOMER LEVELS OF EVIDENCE

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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Presentation on PPAP

PPAP Process Requirements

Requirement

Submission Level
Level 1

1. Design Records of Saleable

Product
-for proprietary components/
Details
- for all other component/details
2. Engineering change documents,
If any
3. Customer Eng. Approval, if required

Level 2

Level 3

Level 4

Level 5

R
R

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

10.Measurement System Analysis Studies R

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R
R

Presentation on PPAP
PPAP Process Requirements
11. Qualified Lab. Documentation
12. Control Plan

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

19. Records of compliance

R
With Customer-Specific Requirements

13. Part Submission Warrant (PSW)

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.
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*

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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