Production Part Approval Process 4 Edition: It S The Goal of This Lecture To

Dipl.-Ing.
Ralf Glner PPAP
Production Part Approval Process 4th Edition
2007 by R.Glner, D-85221 Dachau, +49-8131-53595, www.glaessner.de PPAP_engl.PPT vom 13.01.2007 Seite 1
Dipl.-Ing. Ralf Glner 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
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
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
6. Internet Links
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!

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!
Early identification of a defect

EXPENSES
...saves the
major part of
the cost!
PROJECT TIME
Savings by avoiding the 7+1 muda
over muda
errors production stock in the process
muda
unnecessary unnecessary waiting Design ignoring

movement transport time the customers
expectations
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
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
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
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 PPAP
Contents
1. Introduction
1. General
6. Record Retention
5. Summary

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
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
Contents
1. Introduction
1. General
6. Record Retention
5. Summary
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
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
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.
Contents
1. Introduction
1. General
6. Record Retention
5. Summary
(2.) 2. PPAP Process Requirements

2.1 Significant Production Run
2.2 PPAP Requirements
2.2.1
Requirements describing the details
2.2.2 of documentation to be attached
Will be discussed
in chapter 4 of this presentation!
2.2.18
(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
(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.
View over the documentations to be created

(see chapter 4 of this presentation for details)
Warrant
Content of the documentation to be created

1. Design Record 10. Records of Material/
2. Authorized Engineering Change Performance Test Results
Documents 11. Initial Process Studies
3. Customer Engineering Approval 12. Qualified Laboratory
4. Design-FMEA 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 16. Checking Aids
Studies 17. Customer-Specific
9. Dimensional Results Requirements
18. Part Submission Warrant
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
Contents
1. Introduction
1. General
6. Record Retention
5. Summary
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.
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
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
Contents
1. Introduction
1. General
6. Record Retention
5. Summary
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!
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
The customer decides about the submission level
I want ...looking at:

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
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
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!
Contents
1. Introduction
1. General
2. PPAP Requirements
4. Submission Levels
6. Record Retention
5. Summary
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
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.
Part Submission Status:
A B C
Approved Interim Approval Rejected
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
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.
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.
Contents
1. Introduction
1. General
6. Record Retention
5. Summary
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
Contents
1. Introduction
1. General
6. Record Retention
5. Summary

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
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.
Contents
1. Introduction
1. General
6. Record Retention
5. Summary
Warrant
Only English report forms

have to be filled out and
submitted to the
customer!
Content of the documentation to be created

1. Design Record 10. Records of Material/
2. Authorized Engineering Change Performance Test Results
Documents 11. Initial Process Studies
3. Customer Engineering Approval 12. Qualified Laboratory
4. Design-FMEA 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 16. Checking Aids
Studies 17. Customer-Specific
9. Dimensional Results Requirements
18. Part Submission Warrant
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
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
4.3 Customer Engineering Approval
where specified by the customer, the

organization shall have evidence of
customer engineering approval
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)
4.5 Process Flow Diagrams
see QS-9000 APQP
4.6 Process-FMEA
according to the customer-specific requirements

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

QM-Plan
The Organization shall have control plan that
according to
defines all controls used for process
QS-9000
control and complies with the customer-
specified requirements,
APQP
e.g. 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.
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.
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.
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).
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.
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
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.
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.
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.
4.11 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
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 SPC (Statistical
Process Control manual)
Turning
Point
Standard Deviation s
Mean Value x
Gau Normal Distribution

Definitions Process under Control / Capable Process

not capable capable
not under control

under control

Process
The Capable Process Example Capability

Index
Comment
Cp = Process Capability Index

No capability
High amount of
scrap
Shows proportion of the permissible

No capability
tolerance interval to the scatter 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 Statistically no scrap
tolerance, then Cp=1

No capability
Not centered
Cpk = Critical Process Capability Scrap
Index Good capability

Process is centered
enough
Supplementary considers the mean Little scrap
of the process not being equal to the Process adjusted

Example 1 to 3 exactly to center
middle of the tolerance interval of tolerance
interval
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.
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.
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.

Examination of the stability
(Process control)
process seems stable process seems instable
examine capability Process may not meet

customer requirements
continue with 4.11.3 continue with 4.11.4
4.11.3 Acceptance Criteria for Initial Study
Capability Index for stable process
Index > 1.67 1.33 Index 1.67 Index < 1.33
the process currently the process may be the process does not
meets the acceptable currently meet the
acceptance criteria contact the acceptance criteria
after approval, begin authorized customer contact the authorized
production and representative for a customer representative
follow control plan review of the study for a review of the study
results results
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.
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 non-
normality (e.g., is it stable over time?) and managing variation.
Refer to the Statistical Process Control reference manual for
further guidance.
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.
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.
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
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
4.14 Sample Production Parts
The organization shall provide sample products as

specified by the customer.
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.
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).
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.
4.18. Production Part Submission Warrant
Upon completion of all PPAP requirements, Warrant
the organization shall complete the

Part Submission Warrant (PSW).
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.
4.18. Production Part Submission Warrant/
The organization shall verify that all of the Warrant
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.
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)
Detail of Part Submission Warrant
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.
Contents
1. Introduction
1. General
6. Record Retention
5. Summary
The Attempt to Run PPAP without APQP!
The Production Part Approval Process is an

extensive strict approval process for new
or changed designs or processes.
It is very formalized, so it inevitably causes
Summary
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.
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

Production Part Approval Process 4 Edition: It S The Goal of This Lecture To

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Production Part Approval Process 4 Edition: It S The Goal of This Lecture To

Uploaded by

Copyright:

Available Formats

Dipl.-Ing.

Ralf Glner PPAP

Production Part Approval Process 4th Edition

Dipl.-Ing. Ralf Glner PPAP

Its the goal of this lecture to

Notes to This Lecture

it is not an extensive description, but a

view of contents, basic idea and goals

Dipl.-Ing. Ralf Glner PPAP

therefore it is necessary to have one

inevitably this process causes some

but its worth while because it reduces the

Dipl.-Ing. Ralf Glner PPAP

Early identification of a defect

Savings by avoiding the 7+1 muda

unnecessary unnecessary waiting Design ignoring

Dipl.-Ing. Ralf Glner PPAP

Too high stocks...

Requirement for low stocks...

Dipl.-Ing. Ralf Glner PPAP

Advantages of controlled & capable production processes

constant flow of material

low stocks possible