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Dipl.-Ing.

Ralf Glner

PPAP

Production Part Approval Process 4th Edition

2007 by R.Glner, D-85221 Dachau,

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Dipl.-Ing. Ralf Glner

PPAP_engl.PPT vom

13.01.2007

Seite 1

PPAP

Its the goal of this lecture to


to show you the basic content and the rules of the

Production Part Approval Process


and to explain the purpose and the background
but this lecture will not save you from learning
how to practically use this system
2007 by R.Glner, D-85221 Dachau,

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PPAP_engl.PPT vom 13.01.2007

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Dipl.-Ing. Ralf Glner

PPAP

Notes to This Lecture


this lecture was created for training purposes only;
it is not an extensive description, but a
help for getting started
view of contents, basic idea and goals

The content of this lecture shall not be used as a reference for daily work
Please make sure that you are working only with original latest level documents

Creating this lecture, the valid standards of Dec 2006 were used
This lecture does not refer to customer specific requirements, nor to special PPAP
rules/requirements for bulk materials, tires, nor truck industry!
Standards mentioned in this lecture can be obtained from the institutions listed in
section 6. Internet Links

2007 by R.Glner, D-85221 Dachau,

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Dipl.-Ing. Ralf Glner

PPAP_engl.PPT vom 13.01.2007

Seite 3

PPAP

Contents
1.

Introduction

2.

Content of the QS-9000


1.
2.
3.
4.
5.
6.

PPAP

General
PPAP Process Requirements
Customer Notification and Submission Requirements
Submission to Customer - Levels of Evidence
Part Submission Status
Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

6.

Internet Links

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PPAP

Dipl.-Ing. Ralf Glner

1. Introduction
it is the purpose of advanced quality management
to prevent that unreliable designs or processes
are used in serial production

therefore it is necessary to have one


extensive, strict approval process for new
or changed designs or processes
inevitably this process causes some
administration work

but its worth while because it reduces the


production of muda!
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PPAP

Dipl.-Ing. Ralf Glner

Saving by taking advantage of the Rule Of The 10:


The cost of the remedy of a defect increases
tenfold with every step, the project advances!

EXPENSES

Early identification of a defect

...saves the
major part of
the cost!

PROJECT TIME

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PPAP

Dipl.-Ing. Ralf Glner

Savings by avoiding the 7+1 muda

errors

over
production

stock

muda
in the process

muda

unnecessary unnecessary waiting


movement
transport
time

2007 by R.Glner, D-85221 Dachau,

Design ignoring
the customers
expectations

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PPAP_engl.PPT vom 13.01.2007

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PPAP

Too high stocks...


take space
raise assets employed
require additional searching
require additional administration
require additional transport
are a risk, because parts might exceed expiration date or become
unsaleable
are a risk, because parts might be damaged
complicate the overview
are often a consequence of a weak process
cover weak process
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PPAP

Dipl.-Ing. Ralf Glner

Requirement for low stocks...


are controlled and capable processes
and Total Productive Maintenance
since all kind of process problems will cause delivery stops,
if the stocks are low!

lower
stocks

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PPAP_engl.PPT vom 13.01.2007

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PPAP

Advantages of controlled & capable production processes


satisfied customers
by good quality and avoided muda

no scrap, no rework

constant flow of material

low stocks possible

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Dipl.-Ing. Ralf Glner

PPAP

According to QS-9000...
such an extensive and strict process is an obligatory requirement
(cp.
QS-9000, main section I)
the name of this process is

Production Part Approval Process

its explanation is one QS-9000 reference manual

QS-9000
2007 by R.Glner, D-85221 Dachau,

PPAP

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Dipl.-Ing. Ralf Glner

PPAP_engl.PPT vom 13.01.2007

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PPAP

Contents
1.

Introduction

2.

Content of the QS-9000

PPAP

1.

General

2.

PPAP Process Requirements

3.

Customer Notification and Submission Requirements

4.

Submission to Customer - Levels of Evidence

5.

Part Submission Status

6.

Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

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Dipl.-Ing. Ralf Glner

2.

PPAP

Content of the QS-9000

PPAP

Introduction
Section 1

General

Section 2

PPAP Process Requirements

Section 3

Customer Notification and Submission Requirements

Section 4

Submission Levels

Section 5

Part Submission Status

Section 6

Record Retention

Manufacturer Specific Requirements


Will not be discussed here!
are to be found in internet
OEM Homepages or
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PPAP_engl.PPT vom 13.01.2007

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PPAP

Appendicies
Appendix A

Completion of the Part Submission Warrant

Appendix B

Completion of the Appearance Approval Report

Appendix C

PPAP, Dimensional Results

Appendix D

PPAP, Material Test Results

Appendix E

PPAP, Performance Test Results

Appendix F

Bulk Material - Specific Requirements

Appendix G

Tires - Specific Requirements

Appendix H

Truck Industry - Specific Requirements

Glossary

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Dipl.-Ing. Ralf Glner

PPAP

Contents
1.

Introduction

2.

Content of the QS-9000


1.
2.
3.
4.
5.
6.

PPAP

General
PPAP Process Requirements
Customer Notification and Submission Requirements
Submission to Customer - Levels of Evidence
Part Submission Status
Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

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PPAP_engl.PPT vom 13.01.2007

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PPAP

PPAP is, so to speak, the goal of APQP...


APQP makes sure
that all requirements are recognized before the Product
Development is started
that those special characteristics of the product are specified
which influence these requirements
that it is verified again and again that the planed design can safely
meet these requirements, if the special characteristics are within
tolerance
that only those production processes are specified, which are
controlled and capable according to SPC regarding these
characteristics
A test production and PPAP are used to validate that
all processes are under control and capable
the produced parts fulfil all requirements
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PPAP

Dipl.-Ing. Ralf Glner

Purpose and Applicability


It is the purpose of PPAP to
define generic requirements for production part approval
determine if all customer engineering design record and specification
requirements are properly understood by the organization
determine that the manufacturing process has the potential to produce
the product consistently meeting these requirements during an actual
production run at the quoted production rate

Applicability (

PPAP, Introduction)

PPAP shall apply to internal and external organization sites supplying


production or service parts, production materials or bulk materials.
For bulk material PPAP is not required unless specified by the customer

a supplier of standard catalogue production or service parts shall


comply with PPAP unless formally waived by the customer
2007 by R.Glner, D-85221 Dachau,

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PPAP_engl.PPT vom 13.01.2007

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PPAP

Submission of PPAP
The organization shall obtain full approval from the
authorized customer product approval activity for:
1. a new part or product
2. correction of a discrepancy on a previously submitted part
3. product modified by an engineering change to
design records
specifications
materials

4. any situations required by section 3


Note: If there is any question concerning the need for PPAP,
contact the authorized customer representative.
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PPAP

Dipl.-Ing. Ralf Glner

Contents
1.

Introduction

2.

Content of the QS-9000

PPAP

1.

General

2.

PPAP Process Requirements

3.

Customer Notification and Submission Requirements

4.

Submission to Customer - Levels of Evidence

5.

Part Submission Status

6.

Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

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PPAP

Dipl.-Ing. Ralf Glner

(2.) 2.

PPAP_engl.PPT vom 13.01.2007

PPAP Process Requirements

2.1

Significant Production Run

2.2

PPAP Requirements
2.2.1
2.2.2

Requirements describing the details


of documentation to be attached
Will be discussed
in chapter 4 of this presentation!

2.2.18

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Dipl.-Ing. Ralf Glner

PPAP

(2.)2.1 Significant Production Run


Products for PPAP shall be taken from a significant production run
This production run shall be from one hour to eight hours of
production, and with the specific production quantity to total a
minimum of 300 consecutive parts, unless otherwise specified by
the authorized customer representative
This significant production run shall be conducted at the
production, at the production rate, using the production tooling,
production gaging, production process, production materials, and
production operators.
Parts from each unique production process, e.g. duplicate
assembly line and/or work cell, each position of a multiple cavity
die, mold, tool or pattern, shall be measured and representative
parts tested
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PPAP

(2.)2.2 PPAP Requirements


the supplier shall meet all specified requirements
as listed in this handbook
and all customer-specific requirements

Production parts shall meet all customer engineering design


record and specification requirements
including safety and regulatory requirements

If any part specification cannot be met, the organization shall


document their problem-solving efforts and shall contact the
authorized customer representative for concurrence in
determination of appropriate corrective action.

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Dipl.-Ing. Ralf Glner

PPAP

View over the documentations to be created


(see chapter 4 of this presentation for details)

Warrant

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Dipl.-Ing. Ralf Glner

PPAP_engl.PPT vom 13.01.2007

Seite 23

PPAP

Content of the documentation to be created


1. Design Record
2. Authorized Engineering Change
Documents
3. Customer Engineering Approval

10. Records of Material/


Performance Test Results
11. Initial Process Studies

4. Design-FMEA

12. Qualified Laboratory


Documentation

5. Process Flow Diagram(s)

13. Appearance Approval Report

6. Process-FMEA

14. Sample Production Parts

7. Control Plan

15. Master Sample

8. Measurement System Analysis


Studies

16. Checking Aids

9. Dimensional Results

17. Customer-Specific
Requirements
18. Part Submission Warrant

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Dipl.-Ing. Ralf Glner

PPAP

Paperwork or EDP?

PPAP?

all forms mentioned in this document


may be replaced by identical computer
generated forms
these documents have to be approved
by the customer product approval
activity before first submission
at Adare Carwin a floppy with all forms
can be obtained

2007 by R.Glner, D-85221 Dachau,

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Dipl.-Ing. Ralf Glner

PPAP_engl.PPT vom 13.01.2007

Seite 25

PPAP

Contents
1.

Introduction

2.

Content of the QS-9000

PPAP

1.

General

2.

PPAP Process Requirements

3.

Customer Notification and Submission Requirements

4.

Submission to Customer - Levels of Evidence

5.

Part Submission Status

6.

Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

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Dipl.-Ing. Ralf Glner

PPAP

2.3. Customer Notification and Submission


Requirements( PPAP, Section 3)
1. Customer Notification
The organization shall notify the authorized customer representative of any
planned changes to the design, process or site.
Examples are indicated in Table 3.1
Notification of all changes to desing nad process is the the organizations resonsibility.

Upon notification and approval of the proposed change by the authorized


customer representative, and after change implementation, PPAP submission
is required unless otherwise specified

2. Submission to Customer
The organization shall submit for PPAP approval prior to the first production
shipment in the following situations (see Table I.3.2) unless the authorized
customer representative has waived this requirement.
The organization shall review and update all applicable items in the PPAP file to
reflect the production process,
regardless of whether or not the customer requests a formal submission.

The PPAP file shall contain the name of the authorized customer representative
granting the waiver and the date.

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PPAP_engl.PPT vom 13.01.2007

Seite 27

PPAP

Table 3.1: Customer Notification Required


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

3.

production following refurbishment or rearrangement of existing tooling or


equipment

4.

production from tooling and equipment transferred to a different plant


location or from a 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

6.

product produced after tooling has been inactive for volume production for
twelve months or more

7.

product and process changes that impact fit, form, function, performance,
and/or durability of the salable product

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Dipl.-Ing. Ralf Glner

PPAP

Table 3.2: Submission to Customer


1.

a new part or product (i.e.: a specific part, material, or color not


previously supplied to this specific customer)

2.

correction of a discrepancy on a previously submitted part

3.

engineering changes to design records, specifications, or


materials for production product/part number(s)

4.

bulk material only: process technology new to the supplier, not


previously used for this product

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PPAP_engl.PPT vom 13.01.2007

Seite 29

PPAP

Contents
1.

Introduction

2.

Content of the QS-9000

PPAP

1.

General

2.

PPAP Process Requirements

3.

Customer Notification and Submission Requirements

4.

Submission to Customer - Levels of Evidence

5.

Part Submission Status

6.

Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

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PPAP

Dipl.-Ing. Ralf Glner

2.4. Submission Levels


Note:

The content of the documentation to be generated


is always the same!
The supplier has to retain everything (e.g.. as a copy)!
the Submission Level just indicates what has to be submitted to
the customer!
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PPAP_engl.PPT vom 13.01.2007

Seite 31

PPAP

There are five Submission Levels:


1. warrant only (and if applicable an Appearance Approval Report)
2. warrant with product samples and limited supporting data
3. warrant with product samples and complete supporting data
4. warrant with other requirements as defined by the customer
5. warrant with product samples and complete supporting data available
for review at the organizations manufacturing location

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Dipl.-Ing. Ralf Glner

PPAP

The customer decides about the submission level


...looking at:

I want
I need
I wish

the status of the supplier


(Ford Q1, ...)
his experience with earlier
approval processes
the know-how of the supplier
concerning this product
the importance of the part
so the submission level might
be different for every product
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PPAP_engl.PPT vom 13.01.2007

Seite 33

PPAP

S = submit
retain a copy at an
appropriate
location, (including
manufacturing)

R = retain at
appropriate locations
(including manufacturing)

has to be made
readily available to
the customer
representative upon
request

* = retain at
appropriate locations
submit upon
request

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Dipl.-Ing. Ralf Glner

PPAP

LEVEL 3 IS THE STANDARD LEVEL"


IT SHALL BE USED FOR ALL SUBMISSIONS UNLESS
SPECIFIED OTHERWISE BY THE RESPONSIPLE CUSTOMER
PRODUCT APPROVAL ACTIVITY
Level 1 = just warrant
and (if applicable) Appearance Approval Report
Level 2 = standard minus process description
and background information
Level 3 = standard
Level 4 = warrant, other requirements as defined by the customer
Level 5 = the complete list,
and everything will be checked at the suppliers site!
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PPAP_engl.PPT vom 13.01.2007

Seite 35

PPAP

Contents
1.

Introduction

2.

Content of the QS-9000


1.
2.
3.
4.
5.
6.

PPAP

General
PPAP Requirements
Customer Notification and Submission Requirements
Submission Levels
Part Submission Status
Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

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PPAP_engl.PPT vom 13.01.2007

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PPAP

Dipl.-Ing. Ralf Glner

After everything is ready, it will be


submitted to the customer!

namely at the responsible product approval activity


the customer will inspect everything and notify the
organization of the result using the Part Submission Status

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PPAP

Dipl.-Ing. Ralf Glner

Part Submission Status


ORGANIZATIONS MAY NEVER
SHIP PRODUCTION QUANTITIES
BEFORE CUSTOMER APPROVAL!

Upon approval of the submission, the organization shall assure


that future production continues to meet all customer requirements
For those organizations that have been classified as self-certifying
by a specific customer (PPAP Submission Level 1), submission of
the required organization-approved documentation will be
considered as customer approval unless the organization is
advised otherwise.
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PPAP

Dipl.-Ing. Ralf Glner

Part Submission Status:

Approved

Interim Approval

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Dipl.-Ing. Ralf Glner

Rejected

PPAP_engl.PPT vom 13.01.2007

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PPAP

Part Submission Status A = Approved


indicates that the part or material meets all customer specifications
and requirements
the organization therefore is authorized to ship production quantities
of the product subject to releases from the customer scheduling
activity

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Dipl.-Ing. Ralf Glner

PPAP

Part Submission Status B = Interim Approval


Permits shipment of material for production requirements
on a limited time or piece quantity basis. Interim Approval
will only be granted when the organization has:
clearly defined the non-compliances preventing approval; and,
prepared an interim approval action plan agreed upon by the customer

The organization is responsible for implementing containment


actions to ensure that only acceptable material is beeing shipped to
the customer.
PPAP re-submission is required to obtain a status of Approved
material covered by an interim approval that fails to meet the
agreed-upon action plan either by the expiration date or the
shipment of the authorized quantity will be rejected. No additional
shipments are authorized unless an extention of the interim approval
is granted.
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PPAP_engl.PPT vom 13.01.2007

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PPAP

Part Submission Status C = Rejected

Means that the PPAP submission does not meet the customer
requirements, based on
the production lot from which it was taken,
and/or accompanying documentation

In such cases, the submission and/or process (as appropriate)


shall be corrected to meet the customer requirements.
The submission shall be approved before production quantities
may be shipped.

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Dipl.-Ing. Ralf Glner

PPAP

Contents
1.

Introduction

2.

Content of the QS-9000

PPAP

1.

General

2.

PPAP Process Requirements

3.

Customer Notification and Submission Requirements

4.

Submission to Customer - Levels of Evidence

5.
6.

Part Submission Status


Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

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PPAP_engl.PPT vom 13.01.2007

Seite 43

PPAP

Record Retention and Sampling


PPAP records, regardless of submission level,
shall be maintained for the length of the time
the part is active (in production or service)
plus one calendar year
the supplier shall ensure that the appropriate PPAP records from a
superseded part PPAP file are included, or referenced in the new
part PPAP file

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Dipl.-Ing. Ralf Glner

PPAP

Contents
1.

Introduction

2.

Content of the QS-9000


1.
2.
3.
4.
5.
6.

PPAP

General
PPAP Requirements
Customer Notification and Submission Requirements
Submission Levels
Part Submission Status
Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

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PPAP_engl.PPT vom 13.01.2007

Seite 45

PPAP

3. Summary of the Process


before delivering new or changed parts or changing the production
processes the supplier has to document that he has successfully
finalized all activities of to ensure
that the product will meet all requirements
that the processes are under control and capable
These activities are mostly described in QS 9000
APQP

the documentation consist of the Part Submission Certificate and


the required attachments
according to his Submission Level the supplier has to submit
everything or just parts of it to the customer
the customer checks the documentation and sets the Part
Submission Status
depending on that the supplier can start delivery or not
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Seite 46

PPAP

Dipl.-Ing. Ralf Glner

Teamwork: How to judge about PPAP?


Task:
Assume you have received a PPAP
Submission Level 3 from your supplier.
Supplier has design responsibility.
How to make sure whether or not the supplier
worked carefully?
but without leaving your desk!

Time frame:
Preparation 15 min.
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Dipl.-Ing. Ralf Glner

PPAP_engl.PPT vom 13.01.2007

Seite 47

PPAP

Contents
1.

Introduction

2.

Content of the QS-9000


1.
2.
3.
4.
5.
6.

PPAP

General
PPAP Requirements
Customer Notification and Submission Requirements
Submission Levels
Part Submission Status
Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

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Dipl.-Ing. Ralf Glner

PPAP

4. The Documentation and its Preparation

Warrant

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PPAP_engl.PPT vom 13.01.2007

Seite 49

PPAP

Only English report forms


have to be filled out and
submitted to the
customer!

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Dipl.-Ing. Ralf Glner

PPAP

Content of the documentation to be created


1. Design Record
2. Authorized Engineering Change
Documents
3. Customer Engineering Approval

10. Records of Material/


Performance Test Results
11. Initial Process Studies

4. Design-FMEA

12. Qualified Laboratory


Documentation

5. Process Flow Diagram(s)

13. Appearance Approval Report

6. Process-FMEA

14. Sample Production Parts

7. Control Plan

15. Master Sample

8. Measurement System Analysis


Studies

16. Checking Aids

9. Dimensional Results

17. Customer-Specific
Requirements
18. Part Submission Warrant

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PPAP_engl.PPT vom 13.01.2007

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PPAP

4.1 Design Records


all design records for the saleable product e.g.
CAD/CAM Data
part drawings
specifications

including component drawings


For parts identified as black box the design record specifies the
interface and performance requirements
The organization shall provide evidence that the
Material/Substance Composition reporting has been completed
and that reported data complies with all requirements
Reporting and requirements as prescribed by the customer
Reporting may be entered into International Materials Data System
(IMDS), www.mdsystem.com/index.jsp

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Dipl.-Ing. Ralf Glner

PPAP

4.1 Design Records /


Where applicable, the Organization shall identify polymeric parts
with the ISO symbols
for plastics: 100g, see ISO 11469 / 1043-1
for elastomers: 100g, see ISO 11469 /1629

4.2 Authorized Engineering Change Documents


all authorized engineering change documents, which are
not yet recorded in the design record
but incorporated in the product, part or tooling

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PPAP_engl.PPT vom 13.01.2007

Seite 54

PPAP

4.3 Customer Engineering Approval

where specified by the customer, the


organization shall have evidence of
customer engineering approval

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PPAP

Dipl.-Ing. Ralf Glner

4.4

Design-FMEA

If the supplier is design responsible a Design-FMEA


is required
according to the customer-specific requirements
e.g. QS-9000
FMEA
(Potential Failure Mode and Effect Analysis)

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PPAP

Dipl.-Ing. Ralf Glner

4.5 Process Flow Diagrams

see QS-9000

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4.6

PPAP

Process-FMEA

according to the customer-specific requirements


e.g. QS-9000
FMEA
(Potential Failure Mode and Effect Analysis)

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4.7

PPAP_engl.PPT vom 13.01.2007

Seite 57

PPAP

Control Plan
The Organization shall have control plan that
defines all controls used for process
control and complies with the customerspecified requirements,
e.g. QS-9000
APQP

QM-Plan
according to
QS-9000

APQP

control plans for families of similar


parts are acceptable if the new parts
have been reviewed for commonality
Note: Certain customers require control plan approval e.g.
customer signature on the control plan, prior to submission.

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Dipl.-Ing. Ralf Glner

PPAP

4.8 Measurement
System Analysis
Studies
the organization shall have applicable Measurement System
Analysis Studies (e.g. Gage R & R) for all new or modified
gages, measurement, and test equipment
See QS-9000
MSA (Measurement System Analysis
reference manual.

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PPAP

4.9 Dimensional Results


The organization shall provide evidence that
dimensional verifications required by die design record
and the Control Plan have been completed and
results indicate compliance with specified
requirements.
The organization shall have dirnensional results for each unique
manufacturing process, e.g. cells or production limes and all
cavities, molds, patterns or dies
The organization shall record, with the actual results: all
dimensions (except reference dimensions), characteristics, and
specifications as noted an the design record and Control Plan.

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Dipl.-Ing. Ralf Glner

PPAP

4.9 Dimensional Results /


The organization shall indicate
the date of the design record,
change level, and
any authorized engineering change document not yet incorporated in
the design record to which the part was made.

The organization shall record


the change level,
drawing date,
organization name and
part number

on all auxiliary documents (e.g. supplementary layout results


sheets, sketches, tracings, cross sections, CMM inspection point
results, geometric dimensioning and tolerancing sheets, or other
auxiliary drawings used in conjunction with the part drawing).
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Seite 61

PPAP

4.9 Dimensional Results /


Copies of these auxiliary materials shall accompany the
dimensional results according to the Retention/Submission
Requirements Table.
A tracing shall be included when an optical comparator is
necessary for inspection.
The organization shall identify one of the parts measured as the
master sample
NOTE 1: The Dimensional Results form in Appendix C,
a pictorial, geometrie dimensioning & tolerancing [GD&T] sheets,
or a checked print where the results are legibly written on a part
drawing including cross sections, tracings, or sketches as applicable
may be utilized for this purpose.
NOTE 2: Dimensional results typically do not apply to bulk materials.

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Dipl.-Ing. Ralf Glner

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PPAP

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PPAP_engl.PPT vom 13.01.2007

Seite 63

PPAP

4.10 Records of Material/Performance Test Results

The organization shall have records of test results for


material tests
performance tests

for tests specified


in the design record
in the control plan

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PPAP

4.10.1 Material Test Results


The organization shall perform tests for all parts and product
materials when chemical, physical, or metallurgical requirements
are specified by the design record or control plan
Material test results shall indicate and include:
the design record change level of the parts tested;
any authorized engineering change documents that have not yet
been incorporated in the design record;
the number, date, and change level of the specifications to which the
part was tested;
the date on which the testing took place;
the quantity tested;
the actual results;
the material suppliers name and, when required by the customer, the
customer-assigned supplier/vendor code.

NOTE: Material test results may be presented in any convenient


format. An example is shown in Appendix D.
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PPAP

Dipl.-Ing. Ralf Glner

PPAP

4.10.1 Material Test Results /


For products with customer-developed material specifications and
a customer-approved supplier list, the organization shall procure
materials and/or services (e.g., painting, plating, heat-treating,
welding) from suppliers on that list.

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PPAP

4.10.2 Performance Test Results


The organization shall perform tests for all part(s) or product
material(s) when performance or functional requirements are
specified by the design record or Control Plan.
Performance test results shall indicate and include:
die design record change level of the parts tested;
any authorized engineering change documents that have not yet
been incorporated in the design record;
the number, date, and change level of the specifications to which the
part was tested;
the date on which the testing took place;
the quantity tested;
the actual results.

NOTE:
Performance test results may be presented in any convenient
format.
An example is shown in Appendix E.
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4.11

PPAP

PPAP_engl.PPT vom 13.01.2007

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PPAP

Initial Process Studies

4.11.1 General
4.11.2 Quality Indices
4.11.3 Acceptance Criteria for Initial Study
4.11.4 Unstable Processes
4.11.5 Processes With One-Sided Specifications
or Non-Normal Distributions
4.11.6 Actions To Be Taken When Acceptance Criteria Are Not Satisfied

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PPAP

Dipl.-Ing. Ralf Glner

4.11.1 General
the level of initial process capability or
performance shall be determined to be
acceptable prior to submission for all
special characteristics designated by the
customer or the organization (sc,cc)
the organization shall perform measurement analysis
to understand how measurement error is affecting
the study measurements
(see
Measurement System Analysis reference manual)
for explanations about Cpk or Ppk see
Process Control manual)

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PPAP

Dipl.-Ing. Ralf Glner

Turning
Point

Mean Value x

Standard Deviation s

Gau Normal Distribution


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PPAP

Dipl.-Ing. Ralf Glner

Definitions Process under Control / Capable Process


not capable

under control

not under control

capable

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PPAP_engl.PPT vom 13.01.2007

PPAP

The Capable Process

Example

Cp = Process Capability Index

Process
Capability
Index

Comment

No capability
High amount of
scrap

Shows proportion of the permissible


tolerance interval to the scatter

No capability
If centered pretty
exact, just about no
scrap

Scatter is measured in multiples of


the standard deviation s

Very good capability

If the scatter is with +/- 3 s within the


tolerance, then Cp=1

Statistically no scrap

No capability
Not centered

Cpk = Critical Process Capability

Scrap

Index

Good capability

Supplementary considers the mean


of the process not being equal to the
middle of the tolerance interval
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Process is centered
enough
Little scrap

Example 1 to 3

Process adjusted
exactly to center
of tolerance
interval

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Dipl.-Ing. Ralf Glner

PPAP

4.11.2 Quality Indices


Initial process studies shall be summarized with capability or
performance indices, if applicable.
NOTE 1: The initial process study results are dependent on the
purpose of the study, method of data acquisition, sampling,
amount of data, demonstration of statistical control. etc.
See the QS-9000
Statistical Process Control reference manual
for additional information in understanding the basic principles of
statistical stability and process measures (indices).
For guidance on items listed below, contact the authorized
customer representative.

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PPAP

Cpk and Ppk


Cpk - The capability Index for a stable process.

The estimate of sigma is based on within subgroup variation .


Cpk is an indicator of process capability based on process variation within
each subgroup of a set of data.
Cpk does not include the effect of process variability between the subgroups.
Cpk is an indicator of how good a process could be if all process variation
between subgroups was to be eliminated.
Therefore, use of Cpk alone may be an incomplete indicator of process
performance.

Ppk - The performance index.

The estimate of sigma is based on total variation (all of individual sample data
using the standard deviation.
Ppk is an indicator of process performance based on process variation
throughout the full Set of data.
Unlike Cpk, Ppk is not limited to the variation within subgroups.
However, Ppk cannot isolate within subgroup variation from between subgroup
variation.

When calculated from the same data set, Cpk and Ppk can be compared to
analyze the sources of process variation.
For more information, see QS-9000
Statistical Process Control.
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PPAP

Purpose of Initial Process Studies


The purpose of the initial process study is to understand the
process variation, not just to achieve a specific index value.
When historical data are available or enough initial data exist to
plot a control chart (at least 100 individual sarnples), Cpk can be
calculated when the process is stable.
Otherwise, for processes with known and predictable special
causes and output meeting specifications, Ppk should be used.
When not enough data are available (< 100 samples) or there are
unknown sources of variation, contact the authorized customer
representative to develop a suitable plan.

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PPAP

Examination of the stability


(Process control)

process seems stable

examine capability
continue with 4.11.3

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process seems instable

Process may not meet


customer requirements
continue with 4.11.4

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PPAP

Dipl.-Ing. Ralf Glner

4.11.3 Acceptance Criteria for Initial Study


Capability Index for stable process

Index > 1.67

1.33 Index 1.67

the process currently


meets the
acceptance criteria
after approval, begin
production and
follow control plan

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the process may be


acceptable
contact the
authorized customer
representative for a
review of the study
results

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Dipl.-Ing. Ralf Glner

Index < 1.33


the process does not
currently meet the
acceptance criteria
contact the authorized
customer representative
for a review of the study
results
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PPAP

4.11.4 Unstable Processes


Depending on the nature of the instability, an unstable process
may not meet customer requirements.
The organization shall identify, evaluate and, wherever possible,
eliminate special causes of variation prior to PPAP submission.
The organization shall notify the authorized customer
representative of any unstable processes that exist and shall
submit a corrective action plan to the customer prior to any
submission.
NOTE: For bulk materials, for processes with known and
predictable special causes and output meeting specifications,
corrective action plans may not be required by the customer.

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PPAP

4.11.5 Processes With One-Sided Specifications


or Non-Normal Distributions
The organization shall determine with the authorized customer
representative alternative acceptance criteria for processes with
one-sided specifications or nonenormal distributions.
NOTE: The above mentioned acceptance criteria assume
normality and a two-sided specification (target in the center).
When this is not true, using this analysis may result in unreliable
information.
These alternate acceptance criteria could require a different type of
index or some method of transformation of the data.
The focus should be on understanding the reasons for the nonnormality (e.g., is it stable over time?) and managing variation.
Refer to the Statistical Process Control reference manual for
further guidance.
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PPAP_engl.PPT vom 13.01.2007

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PPAP

4.11.6 Actions To Be Taken When


Acceptance Criteria Are Not Satisfied
The organization shall contact the authorized customer
representative if the acceptance criteria cannot be attained by the
required PPAP submission date.
The organization shall submit to the authorized customer
representative for approval a corrective action plan and a modified
Control Plan normally providing for 100% inspection.
Variation reduction efforts shall continue until the acceptance
criteria are met, or until customer approval is received.
NOTE: 100% inspection methodologies are subject to review and
concurrence by the customer.

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Dipl.-Ing. Ralf Glner

PPAP

4.12 Qualified Laboratory Documentation


Inspection and testing for PPAP shall be
performed by a qualified laboratory as defined
by customer requirements
(e.g., an accredited laboratory).
The qualified laboratory (internal or external to the organization)
shall have a laboratory scope and documentation showing that the
laboratory is qualified for the type of measurements or tests
conducted.
When an external/commercial laboratory is used, the organization
shall submit the test results on the laboratory letterhead or the
normal laboratory report format. The name of the laboratory that
performed the tests, the date (s) of the tests, and the standards
used to run the tests shall be identified.
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PPAP_engl.PPT vom 13.01.2007

Seite 83

PPAP

4.13 Appearance Approval Report (AAR)


AAR = approval report for the appearance of
appearance items concerning requirements
on color, structure, or surface
For completion of AAR, see instruction in

PPAP, appendix B

A separate AAR shall be completed for each part or series of parts


for which a submission is required if the product/part has
appearance requirements on the design record
Upon satisfactory completion of all required criteria, the supplier
shall record the information on the AAR
since the Appearance Approval Report is a industry wide used form
not all customers will require entries in every position

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Dipl.-Ing. Ralf Glner

PPAP

4.13 Appearance Approval Report (AAR) /


The completed AAR and representative
production products/parts shall be submitted to the location
specified by your customer to receive disposition
AARs (complete with part disposition and customer signature)
shall then accompany the PSW at the time of final submission
based upon the submission level requested

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PPAP

Dipl.-Ing. Ralf Glner

PPAP

4.14 Sample Production Parts


The organization shall provide sample products as
specified by the customer.

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PPAP

4.15 Master Sample


The organization shall retain a master sample for
the same period as the production part approval
records, or
a) until a new master sample is produced for the same customer part
number for customer approval, or
b) where a master sample is required by the design record, Control Plan
or inspection criteria. as a reference or standard.

The master sample shall be identified as such, and shall show the
customer approval date on the sample.
The organization shall retain a master sample for each position of
a multiple cavity die, mold, tool or pattern, or production process
unless otherwise specified by the customer.

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PPAP

4.16 Checking Aids


If requested by the customer, the organization
shall submit with the PPAP submission any
part-specific assembly or component checking aid.
The organization shall certify that all aspects of the checking aid agree
with part dimensional requirements.
The organization shall document all released engineering design
changes that have been incorporated in the checking aid at the time of
submission.
The organization shall provide for preventive maintenance of any
checking aids for the life of the part.
measurement system analysis studies, e.g. gage R&R, accuracy, bias,
linearity, stability studies, shall be conducted in compliance with the
customer requirements. See
MSA (Measurement Systems
Analysis reference manual).
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PPAP_engl.PPT vom 13.01.2007

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PPAP

4.17 Customer-Specific Requirements


The organization shall have records of compliance to all applicable
customer-specific requirements.
For bulk materials, applicable customer-specific requi rements
shall be documented on the Bulk Material Requirements Checklist.

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Dipl.-Ing. Ralf Glner

PPAP

4.18. Production Part Submission Warrant


Upon completion of all PPAP requirements,
the organization shall complete the
Part Submission Warrant (PSW).

Warrant

A separate PSW shall be completed for each customer part number


unless otherwise agreed to by the authorized customer
representative.
If production parts will be produced from more than one cavity, mold,
tool, die, pattern, or production process. e.g., line or cell, the
organization shall complete a dimensional evaluation on one part
from each.
The specific cavities, molds, line, etc., shall then be identified in the
Mold/Cavity/Production Process line on a PSW, or in a PSW
attachment.
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PPAP_engl.PPT vom 13.01.2007

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PPAP

4.18. Production Part Submission Warrant/


Warrant
The organization shall verify that all of the
measurement and test results show conformance
with customer requirements and that all
required documentation is available and, for Level 2, 3, and 4,
is included in the submission as appropriate.

A responsible official of the organization shall approve the PSW and


provide contact information.

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PPAP

Part Submission Warrant


consists of:
Information about the part
Some formal information
Materials reporting
Reason of the submission
Requested submission level
Result of the submission
Declaration
For customer use (result)

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PPAP

Detail of Part Submission Warrant

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PPAP

Dimension Results / Part Weight (Mass)


The organization shall record on the PSW the part weight
of the part as shipped, measured and expressed in
kilograms to four decimal places (0.0000) unless otherwise
specified by the customer.
The weight shall not include shipping protectors, assembly aides, or
packaging materials.
To determine part weight, the organization shall individually weigh ten
randomly selected parts, calculate and report the average weight.
At least one part shall be measured from each cavity, tool, line or process
to be used in product realization.
NOTE: This weight is used for vehicle weight analysis only and does not
affect the approval process. Where there is no production or service
requirement for at least ten parts, the organization should use the required
number for calculation of the average part weight.
2007 by R.Glner, D-85221 Dachau,

+49-8131-53595, www.glaessner.de

Dipl.-Ing. Ralf Glner

PPAP_engl.PPT vom 13.01.2007

Seite 95

PPAP

Contents
1.

Introduction

2.

Content of the QS-9000


1.
2.
3.
4.
5.
6.

PPAP

General
PPAP Requirements
Customer Notification and Submission Requirements
Submission Levels
Part Submission Status
Record Retention

3.

Summary of the Process

4.

The Documentation and its Preparation

5.

Summary

2007 by R.Glner, D-85221 Dachau,

+49-8131-53595, www.glaessner.de

PPAP_engl.PPT vom 13.01.2007

Seite 96

PPAP

Dipl.-Ing. Ralf Glner

The Attempt to Run PPAP without APQP!

2007 by R.Glner, D-85221 Dachau,

+49-8131-53595, www.glaessner.de

PPAP_engl.PPT vom 13.01.2007

Seite 97

PPAP

Dipl.-Ing. Ralf Glner

The Production Part Approval Process is an


extensive strict approval process for new
or changed designs or processes.

Summary

It is very formalized, so it inevitably causes


some administration work,
but it doesnt demand anything that
makes no sense from an engineers point
of view!
Later changes of the product or the process
are expensive and take a lot of time.
The prerequisite to fulfill PPAP demands is a
carefully done quality planning according to
QS-9000 APQP.

2007 by R.Glner, D-85221 Dachau,

+49-8131-53595, www.glaessner.de

PPAP_engl.PPT vom 13.01.2007

Seite 98

PPAP

Dipl.-Ing. Ralf Glner

6.

Internet Links
http://www.din.de
http://www.iso.ch
http://www.cenorm.be
https://www.carwin.co.uk/qs/qs9000default.htm
http://www.aiag.org
http://www.iaob.org
http:// www.vda-qmc.de

2007 by R.Glner, D-85221 Dachau,

+49-8131-53595, www.glaessner.de

PPAP_engl.PPT vom 13.01.2007

Seite 99

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