VOLVO CAR

-
PPAP REQUIREMENTS
HANDBOOK
V3
2015-11-05

Supplier Quality Management - Hans Pettersson, hpetter2

Proprietary

VOLVO CAR CORPORATION

Volvo_Car_PPAP_Requirements_Handbook_v3
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Instruction Proprietary V3 2015-11-05
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Supplier Quality Management - Hans Pettersson,
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IMPORTANT
This process is derived from, but not equal to, the Ford process.
It is important to ensure that the Volvo Car version is always used for Volvo Car business as they are NOT
interchangeable.

For any queries regarding the process described in this document, please contact your Volvo Car Site SQM.

Volvo Car PPAP Introduction

In order to improve launch performance the Volvo Car Production Part Approval Process (PPAP) is
structured into a delivery approach that will require an organisation to demonstrate manufacturing
capability, product quality and production capacity prior to Job #1.

Volvo Car PPAP will provide Volvo Car and the Supplier with an improved understanding of Supplier
manufacturing process and part readiness.Volvo Car PPAP organizes the Production Part Approval
Process into four deliveries:

• Process (Phase 0+)

• TR Testing (Phase 1)
• Production (Phase 2)
• Capacity (Phase 3)

Benefits of Delivery Approach PPAP

• Dividing PPAP activities into more manageable segments.
• Providing a structured approach aligned with manufacturing process development.
• Providing earlier and additional measures to forecast program/product readiness.
• Providing a consistent mechanism to demonstrate ability to support volume
requirements/capacity.

Teamwork
Volvo Car and its Suppliers must work together to deliver a quality part, produced on-time, that meets
all Volvo Car requirements.
To drive flawless execution in launching and delivering products that surpass customer expectations,
Volvo Car and its Suppliers must place trust, integrity and accuracy above all else in the Production
Part Approval Process.

Successful completion of Delivery Approach PPAP:

• Confirms that ALL production streams have the potential to produce product consistently
meeting all customer engineering design records and specification requirements.
• Verifies that the Supplier's production system can support the Invested NWC (NormalWeekly
Capacity) declared by the customer.

Scope
PPAP must be completed for any of the situations already specified by the current edition AIAG PPAP
Manual. In addition, any increase in the Invested Normal weekly Capacity (NWC) declared by the
customer above the verified declared NWC will require the Supplier to re-complete any affected PPAP
deliveries.
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PPAP Objectives
Trial Runs
Objectives:
• To trim the process until Requirements are met to support a Run-at-Rate.
• Trial’s must be planned to support Run-at-Rate timing.

Run-at-Rate
Objectives:
• To provide an indicator that the process/tool/facility design has the potential to produce
acceptable parts at the planned ideal cycle time.

Required Inputs see Table A

Process Verification (Phase 0+)

Objectives:
• To show that production preparations (for at least one production stream) are complete with all
planned quality assurance documents and activities and that the process is stable without
major interuptions.
• Dimensional & Capability requirements are met and accepted by customer.
• To identify process actual cycle time and demonstrated OEE as shown in Capacity Analysis
Report (CAR). This will give an indication wheather it will later on be possible to verify the
Invested Normal Weekly Capacity NWC.
• To provide an indicator that the produced parts are ready for TR testing and that the design of
the process/tool/facility has the potential to produce product consistently meeting these
requirements.

Required Inputs see Table A

Required Output see Table B

Important notes:
R@R is a limited production run of parts for at least one production stream, and is not a demonstration
that all PPAP requirements have been met for that production stream.

Product Verification (TR Testing) (Phase 1)

Utilizes parts produced during R@R and having achieved Phase 0+ approval status.

Objectives:
• To verify that the process/tool/facility has the potential to produce product consistently meeting
all customer design records and specification requirements (Part Folder For Supplier) by
operating a minimum of one selected production stream.

Required Inputs see Table A

Required Output see Table B

Important notes:
For suppliers with only one production stream completion of TR Testing & Product Approval (Ph1&2)
occur at the same time. It is required that prior to TR Testing (Ph1) submission that sub-supplier(s)
material status from Tierx has also achieved TR Testing Approval (Ph1).
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Production Verification (Phase 2)

Objectives:
• To verify that ALL production lines have the potential to produce product consistently meeting
all customer design records and specification requirements (Part Folder For Supplier)

Required Inputs see Table A

Required Output see Table B

Important notes:
• The approach adopted for PPAP of multiple production streams is scenario-specific and must
be agreed between the Supplier and SQM.
• Production & Capacity Approval (Ph2 and Ph3) can happen concurrently if requirements for
both deliveries are fulfilled.

Capacity Verification (Phase 3)

Objective:
• Verify the Supplier's production system can support invested NWC requirements while
meeting Phase 2 requirements.

PPAP Approval
Process Approval (Ph0+) require a PPAP Submission Warrant (PSW), however a Capacity
Analysis Report Report (CAR) and supporting documentation must be submitted with the Part
Submission Warrant and signed by the Supplier.
• In addition, the Supplier should have results from Run-at-Rate readily available for Site SQM
review and approval when required
• All PPAP delivery timings require a Part Submission Warrant (PSW) and customer approval in
line with the AIAG PPAP submission level.
• Capacity Approval (Ph3) requires Suppliers to complete the Capacity Analysis Report in
addition to the Part Submission Warrant.
• Suppliers to Volvo Car and its affiliates utilize the Volvo Car Part Submission Warrant (PSW).
SQM will review and either Approve, Reject or Interim Approve (TPD required) the Part
Submission Warrant (PSW).
• Any temporary exception due to non-compliance with a PPAP element or build timing
requirement is handled in line with the Handling Part Deviation Process.
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Expectations

PPAP Achievement by Build Milestone

• Required Inputs see Table A
• Exceptions are to be approved by SQM Program & Site.

PPAP Reporting Expectations

• Volvo Car PPAP requires Suppliers report on multiple promise dates.
• Tier 1 Suppliers shipping to Volvo Car must use a production part approval process for their
sub-suppliers.
• Additionally, Suppliers are required to verify their sub-supplier can meet required volumes at
the required time; Suppliers and/or subsuppliers may use the Volvo Car Capacity Analysis
Report (CAR) and Part Submission Warrant (PSW)
• SQM will disposition the Supplier PPAPsubmission and provide a copy of the signed Warrant
to the Supplier.
• Once the Supplier has received the SQM signed Warrant, the supplier shall send a copy of the
approved PSW to the defined mailbox for update of the status into the Volvo Car Systems

PPAP Deviation
It is the responsibility of the Supplier to complete the 18 requirements of PPAP and get an Approved
or Interim PSW using the latest Partfolder prior to the date when approved material is required to
support customer manufacturing.

PPAP Review Requirements

Site VQE Part Status PPAP PPAP Status PPAP Status PPAP Status PPAP Status
Status Submission Process TR Testing Production Capacity
Level (Ph0+) (Ph1) (Ph2) (Ph3)
VQE Non-Priority 1 Supplier Site self-certifies to Volvo Car PPAP Requirements
No VQE Non-Priority 3 SQM desktop review of PPAP submission and accompanying
documentation
Regardless of Priority 5 SQM On-Site review of Supplier Site PPAP submission and
VQE Status accompanying documentation
Documentation PSW PSW PSW PSW
Support Doc. Support Doc. Support Doc.
CAR CAR
Sample parts Sample parts
if requested. if requested.
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Definitions
Production Stream:
A single production stream is a sequence of a minimum of one line, machine, tool,
cavity, facility, equipment, gauge, operator and other required items at the intended
location and with the intended layout that will be used to produce parts that meet
Volvo Car specifications.
All production streams must include any additional items not included in the single
production stream that are required to meet the Invested Normal Weekly Capacity (NWC)
requirements for all parts produced in the line (e.g. additional tools,cavities, lines, conveyors,
machines).

Normal Weekly Capacity (NWC)

• Ref: Global Terms and Conditions Capacity Planning Web Guide
• Contracted NWC are the volumes for which Volvo Car and Suppliers has an agreement on.
This Agreement could be on multi year basis.
• Invested NWC are the volumes for which Volvo Car requires Suppliers to facilitate and tool-up
for and is based on a Volvo Car tool order when Volvo Car owns the tools.
• NWC volumes is available from the buyer.
• Suppliers are expected to satisfy the production weekly demand based on a 120h Total
Scheduled Time manufacturing operating pattern. If the process deviates from the Contracted
NWC definition an NWC Deviation form needs to be approved by Volvo Car.

Interim Acceptance
• Part deviates from Partfolder specifications but meets customer specifications by a valid
Temporary Part Deviation(TPD).
• Process deviates from Customer Process Requirements (e.g. poka-yoke) but meets customer
expectations by a valid Temporary Part Deviation(TPD).

Temporary Part Deviation (TPD)

• Ref: Volvo Car Customer Specific Requirements item 2.2.2
• Temporary Specification provided by Volvo Engineering
• Required if part deviates from Specification (Partfolder) or Process expectations.

Approved PSW
• Part meets all customer specifications and requirements.

Significant Production Run

• Ref: Volvo Car Customer Specific Requirements (PPAP) item 2.1
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Tables

Table A – Required Input

Run-at-Rate TT PP MP1
Process TR Testing & Production Capacity
(Ph0+) (Ph1 and Ph2) (Ph3)
Parts from R@R. Parts from R@R.
Partfolder for Suppliers Partfolder for Suppliers Partfolder for Suppliers
IMDS Submitted IMDS Approved
Invested and contracted Invested and contracted Invested and contracted
NWC NWC NWC
• Tier-x Ph0+ Approved • Tier-x Ph0+ Approved • Tier-x Ph1 Approved • Tier-x Ph3 Approved

• Hard Tools • Hard Tools • Hard Tools - Grained • Hard Tools - Grained
(Graining not required if (Graining not required if
agreed with Site SQM). agreed with Site SQM).

• Quantity of parts • Quantity of parts

required as defined by required as defined by
Customer (default 300 Customer (default one
consecutive parts). shift production).

Min 1 production stream Min 1 production stream All production streams

• Job 1 location (final site & line).
• All planned handling equipment (e.g. Robots, Conveyers etc.)Installed.
• Trained Supplier production Operators.
• Production cycle times required to support Invested NWC.
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Table B – Required Output

TT PP PP MP1
Process (Ph0+) TR Testing (Ph1) Production (Ph2) Capacity (Ph3)
1 Design Record All 18 PPAP All 18 PPAP All 18 PPAP requirements
2 Engineering requirements have been requirements have have been met for all
Change Documents met for 1 production been met for all production streams
4 Design FMEA stream production streams
5 Process Flow
Diagrams
6 Process FMEA
7 Control Plan
8 Measure System
Analysis
9 Dimensional Results
11 Initial Process Studies
18 PPAP Warrant
Doc. to Site SQM Doc. to Site SQM Doc. to Site SQM Doc. to Site SQM
Part Submission Warrant Part Submission Warrant Part Submission Part Submission Warrant
Supporting Doc. Supporting Doc. Warrant Supporting Doc.
Capacity Analysis Report Supporting Doc. Capacity Analysis Report
Doc. to PSW mailbox Doc. to PSW mailbox Doc. to PSW mailbox Doc. to PSW mailbox
• PSW front sheet • PSW front sheet • PSW front sheet • PSW front sheet
• CAR front sheet • CAR front sheet
• CAR line pno sheet • CAR line pno sheet
CM4D data CM4D data CM4D data CM4D data

Important notes:
When a TR Testing verification (Ph1) has been approved for ALL production streams a Production
Warrant (Ph2) can be issued. Tool payment Requires an approved Production PSW (Ph2).