PPAP Guidelines

GKN Rockford Supplier:

To assure our customers they are receiving products of the highest quality and reliability GKN Rockford follows a formal Production Part Approval Process (PPAP). All products with unique part numbers require that you, as a supplier, secure approval prior to supplying production quantities of product. A Part Submission Warrant (PSW), signed by GKN Rockford Quality and returned to you, is your evidence of PPAP approval. GKN Rockford urges suppliers to utilize electronic communication in supplying PPAP documents prior to receipt at Rockford. Realizing that pre-approval may not always be economical or support GKN production schedules, GKN Quality allows PPAP submittal with the first production order. You, as Supplier, must assure compliance to GKN Rockford print requirements and you assume risk of rejection should GKN find your samples nonconforming to our requirements.

If you are a new supplier to GKN Rockford:

You need to submit a level 4 PPAP with the parts or a level 5 PPAP may be done at your facility, if possible. This will be indicated by a PAP4 or PAP5 designation on your Purchase Order.

If you are an existing supplier:

If the part you will make is part of a family and utilizes similar processes as parts you already make for GKN Rockford a level 2 PPAP is required with the first production part receipt. This will be indicated by a PAP2 designation on your Purchase Order and requires limited supporting documentation. The Process FMEA and Control Plan need not be resubmitted. Indicate on the PSW which part number the original PFMEA and CP were submitted and approved on. If the part you will make is not part of a family or utilizes processes different than parts you already make for GKN Rockford a level 3 PPAP is required with the first production part receipt. This will be indicated by a PAP3 designation on your Purchase Order.

If you supply standard off the shelf items:

If the part being purchased is a made to industry standards, such as a bolt, then a Level 1 PPAP is required along with a certificate of conformance. This will be indicated by a PAP1 designation on your Purchase Order.

PPAP quantities:
A minimum run of 300 production pieces is the standard requirement for PPAP evaluation. This allows you to statistically monitor your process and determine your capability to meet GKN product requirements long term. Dimensional verification, in the form of an Initial Sample Inspection Report (ISIR), is required on an agreed upon quantity of sample parts. A six piece layout is preferred but a lesser quantity may be designated by GKN. These numbered layout samples are supplied to GKN Quality for verification and referenced on the ISIR with corresponding dimensional results, following a numbered print.

Form # 6190

REV. 03

Date: 2/18/09

DAF # 1784

PPAP Guidelines
Due to lower volume requirements a PPAP can be performed on production orders of less then 300 pieces. Orders of 10 pieces or less require no PPAP but you must verify compliance to GKN requirements.

Family of parts:
If you are making several parts for GKN Rockford and the process for producing these parts is similar then you submit the process Flow Diagram, FMEA, Control Plan, SPC data, and gage R&R once to cover all of the parts within the family. You must still submit to GKN a level 2 PPAP for each unique part number. Please indicate for which previous family part number the initial Level 3 PPAP documentation was submitted on the Part Submission Warrant (PSW).

After a PPAP has been approved:

After successful product verification GKN Rockford will approve and sign your PSW and return a copy to you. You must have an approved PSW for each part number you supply to GKN Rockford. You must provide a certificate of conformance and a material certification, if requested, with each subsequent production order. Process capability data (Cpk) on significant characteristics may be requested on a quarterly basis. To avoid possibility of nonconforming product, if you have any significant change in processing, including different location, equipment, material or processes, GKN Rockford must be informed. An additional PPAP may be requested by GKN Rockford if the changes are deemed significant.

Interim PPAP approval:

If one or more product requirements are found to violate GKN Rockford specifications, but GKN product engineering approves the parts to be used, an interim PPAP approval is given. When you run the next production order of parts you must document corrective actions to correct the discrepancies and submit another PPAP. A Level 2 PPAP, with appropriate verification data on the corrected discrepancies, is submitted to GKN Rockfords inspection department for verification. If they have been corrected then the PPAP will be approved.

Exceptions to GKN Requirements:

If you cannot meet any GKN Rockford part requirement you must state why you cannot correct the discrepancy and GKN Product Engineering must determine if the requirements can be revised to allow acceptance. Before submitting PPAP samples contact your buyer for a Suppliers Request for Material Review Board Action form. This will allow review by GKN and may result in a temporary deviation or a specification change. Failure to request this review prior to PPAP submittal will have a negative impact on your Supplier Rating if your PPAP is rejected.

Form # 6190

REV. 03

Date: 2/18/09

DAF # 1784

PPAP Guidelines
Levels of PPAP submission as indicated on your PO:
PAP1
Level 1 PPAP consists of the following documentation being supplied before or with the initial sample parts: Part Submission Warrant (PSW) and Material Certification (if applicable). This level is used when changes are made that have minimal effect on the supplier but to assure you have the most recent drawings and documentation from GKN. The submission warrant will show you have received and acknowledge the changes.

PAP2
Level 2 PPAP consists of the following documentation being supplied before or with the initial sample parts: PSW, I.S.I.R. and Material Certification (if applicable). NOTE: You must indicate on the PSW under Level 2 which previously approved family part number the additional Level 3 supporting documents were submitted on and approved.

PAP 3
Level 3 PPAP consists of the following documentation being supplied before or with the initial sample parts: PSW, I.S.I.R., Material Certification (if applicable), Process Flow Diagram, Control Plan, Process FMEA, Process Capability Analysis, gage R&R study.

PAP4
Level 4 PPAP consists of the same documentation as a level 3 as well as additional requirements as defined by GKN Rockford being supplied before or with the initial sample parts.

PAP5
Level 5 PPAP uses the same documentation as a level 3 but is reviewed at your facility. The processing of the part is reviewed while the supplier is performing their I.S.I.R. The GKN representative verifies that the parts are being measured with proper inspection equipment and verifies the dimensions to GKNs drawing. If the parts conform to requirements and the process is deemed capable then the PSW can be signed off approving the PPAP. When the parts are received at GKN Rockford a short inspection (appearance and documentation) is performed and the parts sent to stock.

Form # 6190

REV. 03

Date: 2/18/09

DAF # 1784

PPAP Guidelines
Description of required documentation:
DOCUMENT Process Flow Diagram DESCRIPTION Representation of all process elements required to make the part. Analytical spreadsheet detailing potential process failure points with numerical rankings, current controls and reaction plans. High risk (RPN) items must have proposed alternative action/controls. Using the FMEA, detail of all significant process elements with inspection features, responsibilities, frequencies, sample sizes, gages and reaction plans. Initial capability analysis of significant product characteristics with 2.00 Ppk minimum requirement. Long term capability analysis of significant product characteristics require 1.66 Cpk minimum requirement Analysis of gaging error by isolating operator error from equipment error.

Process Failure Mode and Effects Analysis (FMEA)

Control Plan

Capability Studies

Gage Repeatability and Reproducibility Analysis (GR&R) Material Certification

Detailed chemical and physical properties of material traceable to a lot or heat number, including heat treating requirements. Items on GKN part drawing identified by number for reference on the ISIR. Detailed results of at least two samples from first production lot for (numbered) drawing requirements (including notes). 6 identified parts of a minimum 300 piece run on production processes (unless otherwise agreed upon). Warrant form used to identify the part number, revision level, PPAP level, reason for submission, warranted results
Date: 2/18/09 DAF # 1784 4

Numbered Part Print Initial Sample Inspection Report (ISIR) Sample Parts

Part Submission Warrant (PSW)

Form # 6190 REV. 03

PPAP Guidelines
and authorized signature. GKN signed copy is evidence of production part approval.

Form # 6190

REV. 03

Date: 2/18/09

DAF # 1784