Supplier PPAP Level - Detail Required: Qualified Laboratory Documentation

Supplier PPAP Level - Detail Required
PPAP Level
Click on the selected section to go directly to its tab. 1 2 3 4* 5
1 Design Record R R S R
2 Engineering Change Documents R S R
3 Customer Engineering Approval R S R
4 Design FMEA R S R
5 Process Flow Diagram R S R
6 Process FMEA R S R
7 Control Plan R S R
8 Measurement System Analysis Studies R S R
9 Dimensional Results R R S R
10 Material, Performance Test Results R R S R
11 Initial Process Capability Studies R S R
12 Qualified Laboratory Documentation R R S R
13 Appearance Approval Report (AAR) R R S R
14 Sample Product R R S R
15 Master Sample S
16 Checking Aids S R S R
17 Records of Compliance (Substance of Concern & Conflict Minerals) R R R R
18 Part Submission Warrant R R R R R
Other Specific Requirements
19 Packaging Data Sheet R SR
20 Capacity Checklist R R
21 Capacity Worksheet R R
22 Castings Checklist: Evidence of Qualification (Photos, R-Ray pictures, …) S R R
23 Safe Launch Plan S S S
24 SAS and/or PSR audit rquired R
R = Required (unless not applicable)
S = Submit upon request from RBC
*Level 4 PPAP: get guidance from SDE
RBC PPAP info and forms: http://www.regalbeloit.com/suppliers
SUPPLIER PPAP GUIDELIN
PPAP LEVELS
Level Documentation Inspection Data
1 Part Submission Warrant (PSW) only No
2 PSW + limited documentations Yes, (5) pcs full layout
3 PSW + full documentations Yes, (5) pcs full layout + Capability Data on C
4 PSW + as required docs and samples (a la carte) as required
Level 3 plus SAS or PSR before PPAP or Start of
Production at Regal for New Supplier or Supplier Site
5 Change Yes, (5) pcs full layout + Capability Data on C
COMMON PPAP TYPES
(Ref. PPAP Change Management Mat
New Products and Changes PPAP Level
Brand New Part (entire product) from Current Supplier Level 3 PPAP
Product from New Supplier Level 3 PPAP
Design / Feature / Spec Change to an Existing Baseline Product Level 2 PPAP (if non-CTQ change)
Level 3 PPAP (if CTQ change)
Catalogue Products Level 1
PPAP by PART FAMILY
If PPAP is needed on multiple, similar part numbers, PPAP can be done as a family of parts. PPAP to the 'Parent'
PPAP.
LOW VOLUME PPAP
For PPAP Level 2 and Level 3, full layout on 5 samples (or fewer samples depending on the volume of the project
if the project volume or the supplier production run size does not support 30 pc capability study. For normal pro
period of multiple production runs, supplier can aggregate the CTQ data (with same sub-group size) to run the 30
provide waiver to supplier the suspension of collecting CTQ data.
URGENT PPAPs
In situations where an urgent PPAP approval is needed , SDE can support the PPAP as needed (if notified in adva
PPAP PROCESS FLOW
REGAL- SUPPLIER: SUPPLIER: REGAL-SDE:

Sourcing PPAP Preparation - New Submit PPAP Review PPAP
(CM): Tool (or Revised Tool) / to SDE Documentation
PPAP Request Manufacturing Process Set
INitiated & up / Run Parts / Collect
Sent to Data
Supplier
FAQ
Who determines PPAP level?
Supplier Development Engineer (SDE). SDE will assign PPAP level based on information provided & available. Howe
needs to know additional information to correctly assign PPAP level.
What happens to PPAP approval if the supplier inspection data is out of spec?
SDE should review the data with Product Eng if the supplier out-of-spec data is acceptable. If acceptable, supplier
followed by granting an Interim PPAP approval. Product Eng will need to update the print to match the deviation
spec data is not acceptable to Product Eng, supplier will need to resubmit PPAP with in-spec data.
Who determines PPAP level?
Supplier Development Engineer (SDE). SDE will assign PPAP level based on information provided & available. Howe
needs to know additional information to correctly assign PPAP level.
What happens to PPAP approval if the supplier inspection data is out of spec?
SDE should review the data with Product Eng if the supplier out-of-spec data is acceptable. If acceptable, supplier
followed by granting an Interim PPAP approval. Product Eng will need to update the print to match the deviation
spec data is not acceptable to Product Eng, supplier will need to resubmit PPAP with in-spec data.
If an existing part is sourced to another plant, does the supplier have to PPAP to the new plant?
Assuming the PPAP exists to the current consuming plant, supplier will need to submit Level 1 PPAP. If PPAP does n
If the part to be PPAP's is used at multiple Regal plants, do all of those plants need to approved the PPAP?
No. Pick one plant to be the lead or primary plant (based on volume usage) for plant quality approval of supplier P
If I have questions on supplier PPAP process or requirements, who should I contact?
Contact regional SDE Manager for guidance. Located Regal Inside/Global Supply Chain/
PLIER PPAP GUIDELINES
PPAP LEVELS
a Samples to Plant Quality Samples to Product Eng
No No
l layout Yes as needed
l layout + Capability Data on CTQs Yes as needed
as needed as needed
l layout + Capability Data on CTQs Yes as needed

COMMON PPAP TYPES
PAP Change Management Matrix)
Notes
if non-CTQ change) if baseline PPAP exists, only PPAP the variant

if CTQ change) if baseline PPAP exists, only PPAP the variant
PPAP by PART FAMILY

of parts. PPAP to the 'Parent' (most complex or largest volume), and include 'Children' part numbers in
LOW VOLUME PPAP

g on the volume of the project or product) is required. Capability study will not be required for Level 3 PPAP
pability study. For normal production runs, supplier needs to measure and document CTQ data. Over a
e sub-group size) to run the 30 pc capability analysis. If supplier capability data is acceptable, then Regal will
URGENT PPAPs
as needed (if notified in advance), working with requester and supplier.
PPAP PROCESS FLOW
REGAL-SDE: REGAL-Plant REGAL-Product REGAL-SDE:

Review PPAP Quality Eng: Eng: PPAP
Documentation Plant quality Product Approved,
reviews samples engineering Sent to
reviews samples & Supplier,
data Stored in
Depository
FAQ
on provided & available. However, the PPAP requester or Product Eng may and should contact SDE if SDE
ptable. If acceptable, supplier will need to submit Deviation Request form, and Prod Eng will approve,
e print to match the deviation request, after which the full PPAP approval will be granted to supplier. If out-of-
in-spec data.
on provided & available. However, the PPAP requester or Product Eng may and should contact SDE if SDE
ptable. If acceptable, supplier will need to submit Deviation Request form, and Prod Eng will approve,
e print to match the deviation request, after which the full PPAP approval will be granted to supplier. If out-of-
in-spec data.
e new plant?
mit Level 1 PPAP. If PPAP does not exist, PPAP request should be initiated.
to approved the PPAP?
t quality approval of supplier PPAP.
t?
ain/
Version 10.0 PPAP Change Management Matrix Requirements
Level 1 - Warrant only.
(1-2 Business Days)
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Level 2 - Warrant with (5) product samples and limited supporting data.
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(10-15 Business Days from initial production run unless engineering test are required, timing depending on tests)
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Level 5 - PPAP Level 3 with SAS and/or PSR required before PPAP or before start of production at Regal. For
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Supplier Development Engineer (SDE) has the responsibility of defining PPAP Level. Always contact SDE for PPAP requirements.
Supplier Quality Development has overall coordination responsibility for the PSW signoff.
SDE has responsibility on PPAP Package review and readiness sign off for distribution to Quality and Engineering for sign off. (R1)
Quality has sign off responsibility for manufacturing (R2)
Engineering has sign off responsibility for technical evaluation as required. (R3)
SOURCED COMPLETE/BRANDED PRODUCTS/PROCESSES
3 5 5 4 4 4 4 4
Motors, Generators, Gear Boxes, Gear Reducer, Controls, Outsourced Processes, etc.
METAL COMPONENTS
3 5 5 4 4 4 4 4
Die-Castings, Sand Castings, Extrusions, Forgings, Bearings, Gears, Powder Metal, Stampings, Springs, Shafts,
Sheaves, Sprockets, Chains, Finished Shells, Castings, Machined Parts and Contacts
ELECTRONICS/ELECTRO-MECHANICAL
3 5 5 4 4 4 4 4
ECM Controls, PCB, DVR/AVR, Power Modules, Miscellaneous Electronics, Capacitors, Switches, Terminals,
Terminal Blocks and Capacitor Film
STEEL
3 5 5 4 4 4 2 4
Lam Steel, Service Centers, Bar Steel, Steel Tubing and Shell Steel
MAGNET WIRE & NON-FERROUS RAW

3 5 5 4 4 4 4 4
Copper Wire, Shading Bands, Sheet and Coils. Aluminum Wire, Aluminum Ingots (Prime and Secondary), Zinc, and
Lead Wire
ENGINEERED COMPONENTS
3 5 5 4 4 4 2 4
Protectors, Plastic Parts, Plastic Resins, Cord set and Plugs, Rubber/Felt/Fiber, Nameplates, Blowers/Fans,
Magnets, Brakes/Clutches/Valves, Brushing, Commutators and Heating Elements
LAMINATIONS AND DIE CAST ROTORS

3 5 5 4 4 4 2 4
Laminations, Die cast Rotors
FASTENERS
3 5 5 4 2 2 2 4
Engineered fasteners
CATALOGUE / STANDARD PARTS / STANDARD TO ASTM, SAE, OR OTHER INDUSTRY STANDARDS

1 1 1 1 1 1 1 1
Parts that can be ordered through supplier catalogue or made to industry common standards specs (i.e. ASTM,
SAE). For this category, supplier provides same parts all of their clients.
PACKAGING, LABELS, FABRICATION, and ADHESIVES

4 4 4 4 4 4 4 4
Tie Cord, Tapes, Insulation Systems, Corrugated
1 PIECE ORDERS / LOW VOLUME

4 4 4 4 4 4 4 4
FLUIDS
4 4 4 4 4 4 4 4
Oils, Greases, Varnish, Paints, Chemicals and Lubricants
02/28/2022 file:///conversion/tmp/activity_task_scratch/579461348.xls Page 6 of 56

PPAP Requirements Checklist
(SUPPLIER)
APPROVED
INCLUDED
IN PPAP
REGAL
Element
Requirement Required Detail
YES
YES
N/A
NO
NO
Latest detailed print and/or material spec reflecting part-number and rev level. For
1 Design Record complicated assemblies an iso-plot will be accepted. Element also needs to include a
Bill of Materials (BOM).
Engineering Change Any ECN not yet recorded in latest print and/or material spec or ISO-plot referenced in
2
Documents Element 1.
If required by RBC a written statement that approves the component/material to be
3 Customer Engineering Approval
PPAP’d by RBC Engineering.
4 Design FMEA If supplier is design responsible, a DFMEA will be required.
Process map of the manufacturing process from receiving raw/sub- components to
5 Process Flow Diagrams
shipping finished product.
Process FMEA identifying all critical process Failure Modes as well as critical to Quality
6 Process FMEA
(CTQ) characteristics. Format expected is per AIAG-FMEA.
Process Control Plan identifying all critical process controls per pFMEA as well as
7 Control Plan
critical to Quality (CTQ) characteristics. Format expected per AIAG-APQP.
Measurement System Analysis MSA studies (at a minimum Gage R&R) for all gages associated with measuring CTQ’s
8
Studies or supplier identified critical characteristics.
Full lay-out of the component to be PPAP’d relative to all print dimensions on a
9 Dimensional Results
minimum of 5 samples (per tool or cavity).
Data submitted needs to prove that component/material meets all material, performance
Material, Performance Test
10 and test requirements identified by RBC and Supplier (internal). A minimum data set of
Results
5 samples is required.
At a minimum all CTQ’s will have to demonstrate a process capability with a Cpk ≥ 1.33
Initial Process Capability
11 (minimum 10 sub-groups of 3 - (beginning of process / middle of process / end of
Studies (Ref 11a, 11b, 11c)
process) based on a stable process.
If using in-house lab for material and/or performance test results, insert the lab’s testing
Qualified Laboratory
12 scope and cerification in this section. If using an outside lab, include lab certification and
Documentation
scope.
Is waived unless specifically requested by RBC. Enclose approved Appearance
13 Appearance Approval Report
Approval Report (AAR).
Product samples to be submitted with the PPAP are the same samples used for part
14 Sample Product layout (element 9). Parts will have to be identified so that the data reported in element 9
can be verified (default 5 parts).
15 Master Sample Supplier to keep a PPAP Master sample.
In order to avoid different measurement techniques on key-product features (CTQ's),
16 Checking Aids document the method of measurement (i.e. pin-gage, micrometer, height-gage, special
gage) by feature.
Records of Compliance Mandatory Requirements to be submitted via the Regal compliance portal. Use the
17 (Substance of Concern & PSW to identify if declarations are included in PPAP (as required). If 'No', contact
Conflict Minerals) Regal.Materials.Compliance@regalbeloit.com
A completed RBC-PSW warranting the product/material meeting all applicable
Part Submission Warrant
18 specifications and standards. No product and/or process changes are allowed unless
(PSW)
RBC has given approval to do so per AIAG-PPAP latest edition section 3.
19 Packaging Data Sheet Include the details about the packaging standards to be used.
Use capacty checklist & worksheet to demonstrate that the supplier has the required
20 Capacity Checklist
equipment capacity to meet customer demand (Quoted capacity).
Use capacty checklist & worksheet to demonstrate that the supplier has the required
21 Capacity Worksheet
equipment capacity to meet customer demand (Quoted capacity).
Evidence of part validation. Documentation includes pictures of cross-sections and/or X-
22 Castings Checklist ray pictures to demonstrate that the casting process is capable of producing quality
parts (i.e. internal integrity/porosity, …).
Enhanced process and product controls during new process / new product launch. As
23 Safe Launch Plan
required by SDE.
Part Submission Warrant
Part Name Cust. Part Number
Shown on Drawing No. Org. Part Number
Engineering Change Level Dated
Additional Engineering Changes Dated

Safety and/or Government Regulation Yes No Purchase Order No. Weight (kg)
Checking Aid No. Checking Aid Engineering Change Level Dated
ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION
Organization Name & Supplier/Vendor Code Customer Name/Division
Street Address Requester / Commodity Manger
City Region Postal Code Country Plant
MATERIALS COMPLIANCE REPORTING
Has the substance of concern information for the part being warranted been submitted via Yes No
the Regal compliance portal?
Is the Substance of Concern declaration included in the PPAP package? ✘ Yes No

Has the conflict minerals information for the part being warranted been
submitted via the Regal compliance portal? Yes No
Is the Conflict Minerals declaration included in the PPAP package? ✘ Yes No
Casting components: Is evidence of part qualification included? Yes No N/A
REASON FOR SUBMISSION (Check at least one)

Initial Submission Change to Optional Construction or Material
Engineering Change(s) Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts Produced at Additional Location
Tooling Inactive > than 1 year Other - please specify below
REQUESTED SUBMISSION LEVEL (Check one)
Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location.
SUBMISSION RESULTS
The results for dimensional measurements
material and functional tests
appearance criteria statistical process package
Yes
These results meet all drawing and specification requirements: No (If "NO" - Explanation Required)
Mold / Cavity / Production Process
DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts which were made by a process that meets all Production Part
Approval Process Manual 4th Edition Requirements. I further affirm that the designated process to produce this part have the minimum capacity
of 120% of the quoted volume with production tools and equipment in the quoted work patterns. Any deviations from the declaration are noted below.
EXPLANATION/COMMENTS:
Is each CUSTOMER owned tool properly tagged and numbered?

Yes No N/A
Organization Authorized Signature Date
Print Name Phone No. Fax No.
Title E-mail
FOR CUSTOMER USE ONLY
Part Warrant Disposition: Approved Rejected Other
Plant Quality SDE

Is PPAP required to Regal customer? Yes No
Engineering Other
Note: Customer sign-off = Sign, print name and date
Oct-16
Add here or attach the Design Records (Drawings and Specifications)
being PPAP'd to:
Add here or attach any document related to an Engineering Change
(ECR/ECO) as applicable for PPAP
(Refer to PPAP Checklist)
Add here or attach any approval from Regal Engineering related to
documents such as drawings and specifications
If Design responsible, add here or attach the DFMEA
Add here or attach the Process Flow Diagram (Using an AIAG approved
format)
SAMPLES
P L E
SA M
L E
P L E
SA M
Process Flow Chart
24
P L E
4
M
M P
4
5
SA
6
25
9
13
10 14
NO
ACCEPTED?
NO
NO
11 20
12
11 20
12
YES
ACCEPTED?
YES
15 16 17
OPERATIONS
1.- Wip Material
2.- Solder
3.- Put bottom insulator
4.- Put top insulator
5.- Put mylar
6.- Put roll
7.- Welding
8.- Oil
9.- Seaming
10.- Electrical test
11.- Labeling
E
12.- Repair area
L
13.- Scrap area
14.- Scrap area
15.- Label
P
16.- Waiting for process
17.- Oven
18.- Waiting test
19.- Final electrical test
20.- Repair area
21.- Waiting
22.- Packaging
23.- Storage
P 24.- Subassy area
25.- Subassy area
23
22
21
YES
NO
20
19 ACCEPTED?
20
19
18
POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (FMEA)
(PROCESS FMEA)
FMEA Number:
PRODUCT Name PROCESS RESPONSIBILITY: PREPARED BY:
Part number: Eng Rev Level ORIGINAL DATE:
CORE TEAM REVISION DATE:
Process Function Action Results
C O O
S l c D R Responsibility & S c D R
Process Potential cause(s)/ Current Process Current Process Controls Recommended
Requirements Potential Failure Mode Potential Effect(s) of Failure e a c e P Target Completion Actions Taken e c e P
Number s Mechanism of Failure Controls Prevention Detection Actions
v u t N Date v u t N
s
r r
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
02/28/2022 FO-0022-PEP PFMEA Rev. A 22 of 56

(PROCESS FMEA)
FMEA Number:
C O O
s
r r
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0

(PROCESS FMEA)
FMEA Number:
C O O
s
r r
0 0

Rank Description Severity Criteria
10 Hazardous without warning Potential failure mode affects safety and/or involves noncompliance with agency listing without warning
9 Hazardous with warning Potential failure mode affects safety and/or involves noncompliance with agency listing with warning
8 Very High Product is inoperable and has lost primary function
7 High Product has overall reduced level of performance. Customer very dissatisfied
6 Moderate Some aspect of product inoperable. Customer dissatisfied
5 Low Some aspect of product inoperable. Customer somewhat dissatisfied
4 Very Low Defect noticed by discriminating customers (greater than 75%). Fit & finish issues
3 Minor Defect noticed by discriminating customers (50%). Fit & finish issues
2 Very Minor Defect noticed by discriminating customers (less than 25%). Fit & finish issues
1 None No discernible effect
Rank Description Occurrence Criteria

10 Very High: persistent failures > 100 per thousand products
9 Very High: persistent failures 50 per thousand products
8 High: frequent failures 20 per thousand products
7 High: frequent failures 10 per thousand products
6 Moderate occasional failures 5 per thousand products
3 Low: relatively few failures .5 per thousand products
2 Low: relatively few failures .1 per thousand products
1 Remote: failure is unlikely <.01 per thousand products
Rank Description Detection Evaluation Criteria

10 Almost Impossible Absolute certainty of non-detection. Cannot detect error or is not checked.
9 Very Remote Controls will probably not detect. Control is achieved with indirect or random checks only.
8 Remote Controls have poor chance of detection. Control is achieved with visual inspection only.
7 Very Low Controls have poor chance of detection. Control is achieved with double visual inspection only.
6 Low Controls may detect. Control is achieved with charting methods, such as SPC (Statistical Process Control).
5 Moderate Controls may detect. Control is based on variable gauging after parts have left the station, or Go/No Go gauging performed
on 100% of the parts after leaving the station.
4 Moderately High Controls have a good chance to detect. Error detection in subsequent operations, Or Gauging performed on setup and
first-piece check (for setup causes only).
3 High Controls have a good chance to detect. Error detection in-station, or error detection in subsequent operations by multiple
layers of acceptance: supply, select, install,
2 Very High Controls almost certain to detect. Error detection in-station (automatic gauging with automatic stop feature).
Cannot pass discrepant part.
1 Very High Controls certain to detect. Discrepant parts cannot be made because item has been error-proofed by process/product design.
CONTROL PLAN
Prototype Prelaunch Production
Control Plan Number Key Contac Phone Date (Original) Date (Rev)
Part Number / Latest Change Level Core Team Customer Engineering Approvals (if required)
Part Number / Description Supplier / Plant Approval / Date Customer Quality Approval (if required)
Supplier / Plant Supplier Code Other Approval / Date (if required) Other Approval / Date (if required)
CHARACTERISTIC METHODS
SAMPLE
PART / PROCESS NAME / MACHINE, SPECIAL PRODUCT / PROCESS EVALUATION /

CHARACTERI ERROR REACTION PLAN & CORRECTIVE
PROCESS OPERATION DEVICE, JIG, No. NAME PRODUCT PROCESS SPECIFICATION / Measurement SIZE FREQ. CONTROL METHOD
STICS PROOFING ACTIONS
NUMBER DESCRIPTION TOOLS FOR MFG CLASS. TOLERANCE Technique
02/28/2022 FO-0021-PEP Control Plan Rev. A 26 of 56

CONTROL PLAN
SAMPLE


CONTROL PLAN
SAMPLE


CONTROL PLAN
SAMPLE


CONTROL PLAN
SAMPLE


Gauge R&R Report
Supplier:
Date:
Gage No. Part Number Trials

Gage Desc. Part Desc. Operators
Cal. Date Characteristic
Coding 0 = Tolerance
Units 1= Performed By:
A Name B Name C Name

No. 1st 2nd 3rd Range 1st 2nd 3rd Range 1st 2nd 3rd Range
1
2
3
4
5
6
7
8
9
10
X1A X2A X3A RA X1B X2B X3B RB X1C X2C X3C RC

Avg.
XA = (X1A+X2A+X3A) / Trials XB = (X1B+X2B+X2B) / Trials XC = (X1C+X2C+X3C) / Trials

XA XB XC
Calculations
R1 = (RA+RB+RC) / Operators UCLR = D4 * R1

R1 UCLR
Repeatability (Gauge Variation)

Gauge Variation SGV = R1 / d2
Gauge Repeatability Capability CGV = 6*SGV
Percent Tolerance Consumed (100*CGV) / Tolerance
Reproducibility (Operator Variation)

R2 Calculation R2 = XLargest of ABC - XSmallest of ABC
Operator Variation SOV = R2/dO
Gauge Capability COV = 6*SOV
Percent Tolerance Consumed (100*COV)/Tolerance
Repeatability & Reproducibility (Measurement Variation)
Measurement Variation SMV = Square Root (SGV + SOV ) 2 2
Gauge Capability CMV = 6*SMV

Percent Tolerance Consumed (100*CMV)/Tolerance
n D4 d2 dO
Factors
2 3.268 1.128 1.41

3 2.574 1.693 1.908
Print Date Document Page

Attribute Gage R&R
Measurement Characteristic Measurement System Details

Drawing: Description: A
Specification: Date: Operator B
Tolerance (if any): Gage #: C
Operator ID A B C
Sample # Standard Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3 Trial 1 Trial 2 Trial 3
1
2
3
4
5
6
7
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9
10
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Calculated Score % Effective: Action Plan for Improvement (if required):
Results Calculated Score % Effective vs. Attribute:

Results Meet Acceptance Criteria?: Yes No
Revision A
Production Part Approval
Dimensional Test Results
ORGANIZATION: PART NUMBER:
SUPPLIER CODE: PART NAME:
NAME OF INSPECTION FACILITY: DESIGN RECORD CHANGE LEVEL:
ENGINEERING CHANGE DOCUMENTS:
DIMENSION SPECIFICATION TOLERANCE TEST QTY. MEASUREMENT RESULTS (DATA) MEASUREMENT GAGE NOT
ITEM OK
(Nominal) DESCRITPION (-) (+) DATE TESTED (Minimum 5 pieces) TYPE OK
Mark inspected parts #1 - #5. The inspected parts are to be
shipped to Regal for PAPP samples.
Sample #1 Sample #2 Sample #3 Sample #4 Sample #5
Note: If the characteristic is considered a 'REFERENCE' or 'BASIC' dimension, add 'Reference' in the Specification Description column
42644 Blanket statements of conformance are unacceptable for any test results.
SIGNATURE TITLE DATE
Material Test Results
SUPPLIER/VENDOR CODE: PART NAME:
MATERIAL SUPPLIER: DESIGN RECORD CHANGE LEVEL:
*CUSTOMER SPECIFIED SUPPLIER/VENDOR CODE ENGINEERING CHANGE DOCUMENTS:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code. NAME of LABORATORY:
MEASUREMENT RESULTS (DATA)

SPECIFICATION / TEST QTY. MEASUREMENT GAGE NOT
MATERIAL SPEC. NO. / REV / DATE Mark inspected parts #1 - #5. The inspected parts are OK
LIMITS DATE TESTED TYPE OK
to be shipped to Regal for PAPP samples.
Sample #1 Sample #2 Sample #3 Sample #4 Sample #5
Performance Test Results
SUPPLIER/VENDOR CODE: PART NAME:
MATERIAL SUPPLIER: DESIGN RECORD CHANGE LEVEL:
*CUSTOMER SPECIFIED SUPPLIER/VENDOR CODE ENGINEERING CHANGE DOCUMENTS:
*If source approval is req'd, include the Supplier (Source) & Customer assigned code.
SPECIFICATION / TEST QTY. TEST RESULTS MEASUREMENT GAGE NOT

TEST SPECIFICATION / REV / DATE LIMITS DATE TESTED (DATA) TYPE OK OK
30 Piece Capability Study
Supplier Name:
No. Data Part Number: Engineering Release #:
1 Drawing Number: Drawing Rev:
2 Part Description: Asset/Tool #:
3 Characteristic: Gage Type:
4 Specification: Date:
5
6 Specification Process Capability Calculations
7 USL 0.0000 + 3 Sigma #DIV/0! Standard Deviation (Sigma) #DIV/0!
8 + 2 Sigma #DIV/0! Total Specification Tolerance 0.00000
9 + Tol. + 1 Sigma #DIV/0! Process Spread (6*Sigma) #DIV/0!
10 Target Dim. MEAN #DIV/0! Capability Ratio (Cr) #DIV/0!
11 -Tol. - 1 Sigma #DIV/0! Process Potential (Cp) #DIV/0!
12 - 2 Sigma #DIV/0!
13 LSL 0.0000 - 3 Sigma #DIV/0!
Process Capability (Cpk) #DIV/0!
14 3 Sig. Process Tolerance = +/- #DIV/0!
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29 COMMENTS:
30
Comments:
HIGH 0.0000
LOW 0.0000
Range 0.0000
#DIV/0!
Capabilty Study on Low Volume Products - 100% Inspection on CTQs on ALL (100%) Parts
Low Volume = Less than 30 pcs for a single run / batch run / PPAP run due to low annual volume usage
SUPPLIER CODE: PART NAME:
NAME OF INSPECTION FACILITY: DESIGN RECORD CHANGE LEVEL:
ENGINEERING CHANGE DOCUMENTS:
DIMENSION SPECIFICATION TOLERANCE NOT

SAMPLE # CTQ ITEM # MEASUREMENT RESULTS (DATA) MEASUREMENT GAGE TYPE OK
(Nominal) DESCRITPION (-) (+) OK
X
X
X
Samples and data from multiple runs, over a period of time, can be grouped together with the same sub-group size, to run normal Capability Study. At which time, if the capabilty analysis
demonstrates Cpk>1.3, then 100% inspection on CTQs will be waived.
Note: If the characteristic is considered a 'REFERENCE' or 'BASIC' dimension, add 'Reference' in the Specification Description column

How to Run Capabilty Study on Unilateral Toleranced Feature
TYPE 1
If the unilateral tolerance is NOT BOUNDED, meaning the feature can physically go outside of MIN and MAX;
For capability study, reset; Ex: Unilateral Tol = 5 -0 / +1
NOM = (MIN + MAX)/2 New NOM: (5 + 6) / 2 = 5.5

MIN = [(new NOM) - (Range/2)] New MIN: [(5.5) - (1/2)] = 5
MAX = [(new NOM) + (Range/2)] New MAX: [(5.5) + (1/2)] = 6
TYPE 2
If the unilateral tolerance is BOUNDED, meaning the feature CANNOT physically go outside of MIN and/or MAX;
Normal capability study model does not work

One can run capability study without setting MIN and MAX and evaluate the range and tightness of data for subjecti
In Minitab, there's a check box for cahecking 'Bounded' for tolerance limits
ced Feature
MIN and MAX;
MIN and/or MAX;
nd tightness of data for subjective evaluation

Add here or attach the Qualified Laboratory Documentation
APPEARANCE APPROVAL REPORT
PART DRAWING APPLICATION
NUMBER NUMBER (PRODUCT LINES)
PART BUYER E/C LEVEL DATE
NAME CODE
SUPPLIER MANUFACTURING SUPPLIER
NAME LOCATION CODE
REASON FOR PART SUBMISSION WARRANT SPECIAL SAMPLE RE-SUBMISSION OTHER
SUBMISSION PRE TEXTURE FIRST PRODUCTION SHIPMENT ENGINEERING CHANGE
BOUNDRY SAMPLES
BOUNDRY SAMPLES SUPPPLIER REGAL REPRESENTATIVE
Include with PPAP, Go (acceptable) / No-Go (not accpetable) boundry samples. Parts to be signed REPRESENTATIVE
and dated by supplier. Duplicate set to be retained at supplier location. SIGNATURE AND DATE SIGNATURE AND DATE
APPEARANCE EVALUATION
AUTHORIZED RBC
ORGANIZATION SOURCING AND TEXTURE INFORMATION PRE-TEXTURE REPRESENTATIVE
EVALUATION SIGNATURE AND DATE
CORRECT AND
PROCEED
CORRECT AND
RESUBMIT
APPROVED TO
ETCH/TOOL/EDM
COLOR EVALUATION
COLOR
COLOR TRISTIMULUS DATA MASTER MASTER MATERIAL MATERIAL HUE VALUE CHROMA GLOSS METALLIC SHIPPING PART
SUFFIX NUMBER DATE TYPE SOURCE BRILLIANCE SUFFIX DISPOSITION
DL* Da* Db.* DE* CMC RED YEL GRN BLU LIGHT DARK GRAY CLEAN HIGH LOW HIGH LOW
COMMENTS
ORGANIZATION PHONE NO. DATE AUTHORIZED CUSTOMER DATE

SIGNATURE REPRESENTATIVE SIGNATUR
42644
Brief description about shipment of PPAP samples sent to Regal for
evaluation: Quantity, Part Number, Where to, ...
Shipping Tag Requirements for PPAP Samples (link below)
SOP for Supplier Special Shipment Tag
Label Tag Template

Brief description about PPAP samples kept for future reference: Quantity,
Part Number, Date ...
Add or attach supporting Checking Aids information / documents
(Measurement Methods for CTQ's)
Examples of Information to include:
- description of checking aid
- precision level, if applicable
- pictures of checking aid
COPY / PASTE THE DECLARATION OF
SUBSTANCE OF CONCERN AND CONFLICT
MINERALS HERE
DOCUMENTATION
REQUIREMENTS FOR
REACH AND RoHS
DOCUMENTATION
REQUIREMENTS FOR
REACH AND RoHS
REGAL BELOIT
(Reference Regal - Supplier Packaging/Labeling Standards)
Regal Part Number PART NAME: PRODUCT DESCRIPTION: DATE:
Regal Beloit Contacts EMAIL: PHONE: FAX: AUTHORIZATION TO SHIP

PURCHASING/SOURCING
SUPPLIER DEVELOPMENT R
E
G
MATERIALS / PLANNING A
L
PRODUCT ENGINEER
I
N
PLANT QUALITY
P
U
Expected Delivery Frequency: (Weekly, Daily, Etc.) Expected Volume of Parts per Delivery: T
Specific-Special Packaging/Labeling Requirements:
COMPANY NAME: ADDRESS: Regal SUPPLIER NO.:
SUPPLIER'S PACKAGING CONTACT: EMAIL: PHONE: FAX:
PART(S) PACKAGED IN SUBPACK OR INTERNAL DUNNAGE SHIPPING PACK

DIGITAL PHOTOS
S
U
P
P
L
I
E
PALLET INFORMATION Material: Wood HT Other: ESD Material YES NO R
Size:48" x 48" Other: IF YES, GIVE DETAILS OF PROTECTION USED AND PRECAUTION LABEL
TO BE IN CONTAINERS I
N
P
PACKAGING PROPOSAL: NEW: YES NO IF NO, REVISION # PLASTIC BAGS CORROSION PROTECTION
U
RETURNABLE OR EXPENDABLE TOTAL GROSS WEIGHT (INCHES or MM ) NO. OF USED? NEEDED? T
PACKAGING? (US LBS or KG) LENGTH WIDTH HEIGHT PARTS YES NO YES NO
SHIPPING PACK: Ret Exp IF YES, QUANTITY IF YES, WHAT TYPE OF
SUB-PACK: Ret Exp PER BAG? PROTECTION IS USED.
SINGLE PART: DIMENSIONS________
Packaging description Supplier Checklist:
1.Fiberboard compression strength (ECT, Mullen, or VDW)
2.Stackup height of shipping pack (st 1. This packaging/labeling data form shall be filled out completely.
3 2. All data shall conform to the Regal Beloit Supplier Packaging/Labeling
4 Standards.
BAR CODE ASSIGNED ID: Sample 3. Submit this form via email.
4. Mail actual shipping label samples.
SUPPLIER SIGNATURE: DATE: 5. Supplier shall be responsible for cleanliness of returnable packaging
containers.
(Note: Individual Regal plants use small variations of this form)

PRODUCTION CAPACITY VERIFICATION CHECKLIST
Supplier Name: Part Number(s):
A. MANUFACTURING CAPACITY RESULTS

The following will be verified while the process is running.
1. Can net output from each operation support quoted capacity? Yes No
Comments:
Operation Quoted Capacity Rate
2. Can all line changeovers, if any, be performed within the quoted tooling capacity requirements?
Yes No Comments:
3. Does the net through-put of good pieces (scrap taken out, ant allowable rework) meet daily/yearly quoted capacity?
Yes No Comments:
4. Is the acceleration plan sufficient to meet requirements? Yes No
Comments:
B. SUBCONTRACTOR REQUIREMENTS
1. Were subcontractors' abilities to meet the customer's quality and capacity requirements confirmed by the supplier?
Yes No Comments:
COMMENTS:
PASS
PASS OPEN
OPEN FAIL
FAIL
Page 50 of 56
II. Capacity Planning
Operating pattern for the specific part Process 1 Process 2 Process 3
Process description (ID batch or continuous process)
Identify asset ID # or code
Dedicated or Shared process (for shared process,
show only the operating pattern for the specific part/part
family)
If shared process - shared with other Regal parts or
other Customer parts
A Shifts/day
B Total hours/shift
B1 Hours/shift used for this part number (shared prod)
C1 Personal breaks: lunch, breaks (minutes/shift)
C2 Planned Maintenance (minutes/shift)
D Days/week
E Net available time (production hours/week)
[A*(B1-(B1/B)*((C1+C2)/60))*D]
- - -
II. Capacity Planning SHARED
Operating pattern for the specific part/part family Process 1 Process 2 Process 3 Process 4
Process description (ID batch or continuous process) Identify asset Bore #1
Turning #1 (batch) Drill #1 (batch) Washing (batch)
ID # or code (batch)
Dedicated or Shared process (for shared process,
SHARED
show only the operating pattern for the specific part/part family)
If shared process - shared with other Regal parts or other
OTHER CUSTOMERS
Customer parts
A. Shifts/day 1.00 2.00 1.00 1.00
B. Total hours/shift 8.00 8.00 8.00 3.00
B1 Hours/shift used for this part number (shared prod) 5.00 4.00 4.00 4.00
C1 Personal breaks: lunch, breaks (minutes/shift) 30.00 30.00 30.00 30.00
C2 Planned Maintenance (minutes/shift) 30.00 30.00 30.00 30.00
D Days/week 1.00 5.00 4.00 5.00
E
Net available time (production hours/week)
[A*(B1-(B1/B)*((C1+C2)/60))*D]
4.38 35.00 14.00 16.67
Castings Qualification & Validation Checklist
Add or attach evidence - documents and/or pictures
Casting Development Requirements

D1). Has supplier used modeling software for casting development?
Yes No Comments:
If software modeling used, which one(s);

Die / Pattern Design
Tool Gating and Runner System
Tool Cooling / Heating Design
Part Solidification
D2). Has supplier sectioned (cut) during a development run to review and document for internal porosity/inclusions?
Yes No Comments:
D3). Has supplier utilized destructive testing (sectioning & trial machining) to validate internal integrity of casting?
Yes No Comments:
D4). Has supplier utilized non-destructive testing (such as x-ray, ultrasound) to validate internal integrity of casting?
Yes No List method:
1st Production Run and PPAP

P1). Has supplier sectioned samples from beginning of run, middle of run, and end of run to validate & document process and samples?
Yes No Comments:
P2). Are the data from P1 included in the PPAP?

Yes No Comments:
P3). Will supplier ship one of the samples from 1st production run as PAPP samples?
Yes No Comments:
P4). Does supplier Control Plan include an on-going process integrity checks, including checks at a minimum from the beginning, middle and end of
each production run?
Yes No Comments:
P5). If there are current Regal casting quality issues, has the supplier revalidated process and casting integrity as outlined in the above Casting
Development?
Yes No Comments:
Add or attach details about the Safe Launch Plan (Enhanced Control Plan)
Tab: 23. Safe Launch Plan

File: 579461348.xls Document Printed on:
Page 54 of 56
02/28/2022
ontrol Plan)
Tab: 23. Safe Launch Plan

File: 579461348.xls Document Printed on:
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02/28/2022
Revisions History
File Name Master Supplier Development Support Team Matrix

Date of revision Rev Tab Change Approved by:
4/29/2014 00 All File reviewed, improved and updated Alfredo Heredia
5/23/2014 00 All File reviewed, improved and updated Alfredo Heredia
6/16/2014 00 PPAP Level & PSW PPAP Level: Level 1 requirements updated; PSW: Sign off section updated Alfredo Heredia
Changed to R=Required & S=Submit upon request. Removed "Annual PPAP
11/10/2014 00 PPAP Level & Checklist Recertification" requirement Alfredo Heredia
Revision: 9 ; New Fluids Category, PPAP level updates, PTS specific
Requirements Matrix commodities added & corrected some errors (1/26/2016) & add samples and
1/26/2016 00 & Dimensional remove shading on all tabs Mike Watkins
- Added Yes/No boxes and “Is PPAP required to Regal customer?” for Plant
Quality to identity
11/4/2016 00 PSW - Moved SDE to the right side Hilda Flores
2/13/2017 0 PSW Reorginze signature spaces Hilda Flores
Document Printed on: Tab: Rev

File: 579461348.xls
02/28/2022 Page 56 of 56

Supplier PPAP Level - Detail Required: Qualified Laboratory Documentation

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Supplier PPAP Level - Detail Required

PPAP PROCESS FLOW

REGAL- SUPPLIER: SUPPLIER: REGAL-SDE:

l layout + Capability Data on CTQs Yes as needed

if non-CTQ change) if baseline PPAP exists, only PPAP the variant

PPAP by PART FAMILY

LOW VOLUME PPAP

PPAP PROCESS FLOW

REGAL-SDE: REGAL-Plant REGAL-Product REGAL-SDE:

MAGNET WIRE & NON-FERROUS RAW

LAMINATIONS AND DIE CAST ROTORS

Laminations, Die cast Rotors

CATALOGUE / STANDARD PARTS / STANDARD TO ASTM, SAE, OR OTHER INDUSTRY STANDARDS

PACKAGING, LABELS, FABRICATION, and ADHESIVES

Tie Cord, Tapes, Insulation Systems, Corrugated

1 PIECE ORDERS / LOW VOLUME

Oils, Greases, Varnish, Paints, Chemicals and Lubricants

02/28/2022 file:///conversion/tmp/activity_task_scratch/579461348.xls Page 6 of 56

Requirement Required Detail

Engineering Change Level Dated

Additional Engineering Changes Dated

Checking Aid No. Checking Aid Engineering Change Level Dated

ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION

Organization Name & Supplier/Vendor Code Customer Name/Division

Street Address Requester / Commodity Manger

City Region Postal Code Country Plant

MATERIALS COMPLIANCE REPORTING

Is the Substance of Concern declaration included in the PPAP package? ✘ Yes No

REASON FOR SUBMISSION (Check at least one)

REQUESTED SUBMISSION LEVEL (Check one)

Is each CUSTOMER owned tool properly tagged and numbered?

Organization Authorized Signature Date

Print Name Phone No. Fax No.

FOR CUSTOMER USE ONLY

Part Warrant Disposition: Approved Rejected Other

Plant Quality SDE

Note: Customer sign-off = Sign, print name and date

Process Flow Chart

Process Function Action Results

02/28/2022 FO-0022-PEP PFMEA Rev. A 22 of 56

Process Function Action Results

02/28/2022 FO-0022-PEP PFMEA Rev. A 23 of 56

Process Function Action Results

02/28/2022 FO-0022-PEP PFMEA Rev. A 24 of 56

Rank Description Occurrence Criteria

Rank Description Detection Evaluation Criteria

PART / PROCESS NAME / MACHINE, SPECIAL PRODUCT / PROCESS EVALUATION /

02/28/2022 FO-0021-PEP Control Plan Rev. A 26 of 56

PART / PROCESS NAME / MACHINE, SPECIAL PRODUCT / PROCESS EVALUATION /

02/28/2022 FO-0021-PEP Control Plan Rev. A 27 of 56

PART / PROCESS NAME / MACHINE, SPECIAL PRODUCT / PROCESS EVALUATION /

02/28/2022 FO-0021-PEP Control Plan Rev. A 28 of 56

PART / PROCESS NAME / MACHINE, SPECIAL PRODUCT / PROCESS EVALUATION /

02/28/2022 FO-0021-PEP Control Plan Rev. A 29 of 56

PART / PROCESS NAME / MACHINE, SPECIAL PRODUCT / PROCESS EVALUATION /

02/28/2022 FO-0021-PEP Control Plan Rev. A 30 of 56

Gage No. Part Number Trials

A Name B Name C Name

X1A X2A X3A RA X1B X2B X3B RB X1C X2C X3C RC

XA = (X1A+X2A+X3A) / Trials XB = (X1B+X2B+X2B) / Trials XC = (X1C+X2C+X3C) / Trials

R1 = (RA+RB+RC) / Operators UCLR = D4 * R1

Repeatability (Gauge Variation)

Reproducibility (Operator Variation)