Core Tools

PPAP

TÜV SÜD South Asia 23 July 2018 Core Tools - PPAP - Ed 2018 Rev 0 Slide 1

Welcome to training programme on

Production Part Approval Process
(PPAP Reference Manual,
Fourth Edition, March 2006)

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Core Tools – PPAP – PPT 02 1

 Production Part Approval Process

PURPOSE

§ The purpose of PPAP is to determine if all customer engineering design record and
specification requirements are properly understood by the organization .
§ Manufacturing process has the potential to produce consistently meeting these requirements
during an actual production run at the quoted production rate.

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Production Part Approval Process

IATF 16949:2016 REQUIREMENTS

§ Comply with a Part Approval Process as recognized by the Customer.

§ If an Organization decides to comply with PPAP Manual, all requirements in PPAP manual
must be complied.
§ All Suppliers must be covered under Part Approval Process. (PPAP shall be extended to
Suppliers.)
§ All changes affecting production process environment are to be validated properly and records
shall be maintained
§ PPAP Policies & Procedures must be in place, whether customer requires it or not.

Continued……..

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 Production Part Approval Process

IATF 16949:2016 REQUIREMENTS

§ PPAP documentation must be available for all active parts or Corrective action plan for PPAP
going forward (intended).
§ For Bulk Materials, PPAP is not required unless requested by customer
§ PPAP records shall be maintained till the part is active + 1 calendar year.

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Production Part Approval Process

SIGNIFICANT PRODUCTION RUN

§ This is carried out as per product/process design & development (APQP) timing plan.
§ This run shall be from 1 hr to 8 hrs. of production, and with the production quantity to total a
min. of 300 consecutive parts, unless otherwise specified by the authorized customer
representative
§ Produced from production site using tooling, gauging, process , material, operators from the
production environment.
§ Parts from unique tools, lines, cavity, mould, pattern are measured and representative Parts
tested.

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 Production Part Approval Process

REQUIREMENTS FOR PART APPROVAL

1. Design Record
2. Engineering Change Documents, if any
3. Customer Engineering Approval, if required
4. Design FMEA
5. Process Flow Diagrams
6. Process FMEA
7. Control Plan
8. Measurement System Analysis Studies
9. Dimensional Results
Continued…….

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Production Part Approval Process

REQUIREMENTS FOR PART APPROVAL

10. Records of Material / Performance Test results

11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW)

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 Production Part Approval Process

1. DESIGN RECORDS
§ Part drawings, specifications, CAD data or any documents referenced.
§ A single design record can represent multiple part or assembly configurations.

2. AUTHORISED ENGINEERING CHANGE DOCUMENTs

§ Authorized change documents provided by customer for the changes incorporated in the
part not incorporated in the drawing

3. CUSTOMER ENGINEERING APPROVAL

§ Where specified by the customer, the organization shall have evidence of customer
engineering approval

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Production Part Approval Process

4. DESIGN FMEA
§ Applicable to product design responsible suppliers.
§ Single Design FMEA may be applied to a family of similar parts or materials.

5. PROCESS FLOW DIAGRAM

§ In an organization specified format that clearly describes the production process steps and
sequence as per customer requirements. (As per APQP)
§ Family concept is acceptable.

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 Production Part Approval Process

6. PROCESS FMEA
§ Compliance to customer requirements (Use current version of FMEA Manual)
§ Family concept is acceptable.

7. CONTROL PLAN
§ As per APQP manual & IATF requirement and Customer specific requirement.
§ Family Control Plans are acceptable if the new parts have been reviewed for commonality
by the Organization.
§ Control Plan approval may be required by some Customers.

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Production Part Approval Process

8. MEASUREMENT SYSTEMS ANALYSIS STUDIES

§ Compliance to MSA studies as per current version of the reference Manual or as required
by Customer.
§ Required for all new or modified gages, measurement and test equipment.

9. DIMENSIONAL RESULTS
§ Compliance to control plan & Design Record and all characteristics (Except Reference
Dimensions)
§ Dimensional results for each production lines, each cavities, molds, patterns, dies
§ Indicate design record, change level, authorized Engineering Change document ref. on all
reports
§ Identify master sample which is measured
§ Tracing is required when optical comparator is required

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 Production Part Approval Process

10. RECORDS OF MATERIAL / PERFORMANCE TEST RESULTS

§ Compliance to design record / control plan
§ Record of quantity tested on each tests
§ Engineering Change level or authorized Engineering Change
§ Date of testing
§ Material supplier’s name and their code (from customer approved list)

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Production Part Approval Process

11. INITIAL PROCESS STUDIES

§ Prior to submission, acceptable level of initial process capability or performance shall be
determined with customer.
§ MSA prior to initial process studies.
§ For special Characteristics of variable data.
§ Where there are no special characteristics identified, the Customer reserves the right to
require demonstration of initial process capability on other characteristics.
§ Cpk or Ppk can be as per customer agreement.
§ Control charts are preferred, if X bar – R charts used, Min. 25 sub groups, min 100 nos.
from significant production run.
Continued………….

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 Production Part Approval Process

11. INITIAL PROCESS STUDIES - QUALITY INDICES

a) Use Cpk or Ppk
b) Where historical Cpk data is available for similar parts of same process, Cpk can be
captured.
c) For chronically unstable processes (within specification) use Ppk.
d) Index value ≥ 1.67, Else CA plan is reqd.
e) For unstable processes, notify customer & submit CA plan.
f) Modify Control Plan, normally providing for 100% inspection. 100% inspection
methodologies are subject to review and concurrence by the customer.
g) One sided specification or non normal data. E.g. R/O, concentricity, twist, effort, surface
finish, uniformity, etc.. Alternate method of calculation & acceptance criteria with customer
agreement.

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Production Part Approval Process

12. QUALIFIED LABORATORY DOCUMENTATION

§ If in-house laboratory is only used for testing / calibration, add laboratory scope
§ If outside laboratory is used for testing / calibration, add NABL certificate or equivalent of
that laboratory
§ Add scope of accreditation of that lab
§ Qualified outside laboratory must be as defined by the Customer.

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 Production Part Approval Process

13. APPEARANCE APPROVAL REPORT (AAR)

§ Separate report for each part or series of parts, if part has the appearance requirements on
design record.
§ Record of AAR with complete information.
§ AAR applies only for parts with color, grain, or surface appearance requirements.
§ Certain customers may not require entries in all AAR fields.

14. SAMPLE PRODUCTION PARTS

§ As per customer request.

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Production Part Approval Process

15. MASTER SAMPLE

§ Retain till new master sample is produced or as per design record requirement for
inspection criteria.
§ For each position of a multiple cavity, die, tool, mould or pattern, line.
§ Retention period can be waived or modified by customer

16. CHECKING AIDS

§ Inspection Fixtures, gages, models, templates, etc. specific to the part
§ If more than one, prepare & refer the list in PSW including its change level.
§ Submit if required by customer
§ Certification of checking aid w.r.t part dimensions
§ Demonstration of engineering change in gauge change
§ Appropriate MSA studies

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 Production Part Approval Process

17. CUSTOMER SPECIFIC REQUIREMENTS

§ Compliance records to all specific requirements of customer.

18. PART SUBMISSION WARRANT

§ Separate PSW for each part no.
§ Identify Mould / cavity / line no. in PSW
§ Part weight shall be rounded off to four decimals derived out of 10 randomly selected parts
§ 10 parts represent all moulds, cavities, lines as appropriate.

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Production Part
Production Approval
Part Process
Approval Process

SITUATIONS WHEN PPAP VALIDATION, CUSTOMER NOTIFICATION AND SUBMISSION ARE

REQUIRED

The Organization shall notify the Customer of any planned changes to the design, process or site.
Upon notification and approval of the proposed change by the Customer representative, and after
change implementation, PPAP submission is required, unless specified.

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 Production Part Approval Process

SITUATIONS WHERE NOTIFICATION TO CUSTOMER AND SUBMISSION IS REQUIRED

(Unless waived by customer)

# Requirements
01 Use of construction or material other than what was used in the previously approved part
or product (e.g. under deviation permit cases)
02 Production from new or modified tools , dies, moulds, patterns, etc.

03 Production following upgrade or rearrangement of existing tooling or equipment

04 Production from Tooling and Equipment transferred to a different plant site or from an
additional plant site
05 Change of Supplier for parts, non-equivalent materials, or services
(Example: Heat Treatment, Plating)

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Production Part Approval Process

SITUATIONS WHERE NOTIFICATION TO CUSTOMER IS REQUIRED

(Unless waived by customer)

# Requirements
06 Product produced after the tooling has been inactive for volume production for 12 months
or more
07 Product and Process related changes to components of the production product
manufactured internally or by Suppliers
08 Change in test / inspection method – new technique (no effect on acceptance criteria)

09 For bulk materials, new source of raw material from new or existing supplier

10 Change in Product appearance attributes

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 Production Part Approval Process

SITUATIONS WHERE SUBMISSION TO CUSTOMER IS REQUIRED

# Requirements
01 A new part or product (Ex: a specific part, material, or colour not previously supplied to
Customer)
02 Correction of a discrepancy on a previously submitted part

03 Engineering Change to design records, specifications, or materials production product /

part numbers(s)
04 For bulk materials, Process technology new to the supplier, not previously used for this
product

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Production Part Approval Process

SUBMISSION TO CUSTOMER – LEVELS OF EVIDENCE

Level 1 Warrant only (and for designated appearance items, an AAR) submitted to the
customer.
Level 2 Warrant with product samples and limited supporting data submitted to the
customer.
Level 3 Warrant with product samples and complete supporting data submitted to the
customer
Level 4 Warrant and other requirements as defined by the customer.

Level 5 Warrant with product samples and complete supporting data reviewed at the
organization’s manufacturing location.

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 PSW Format as an Overview

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PSW Format Details

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 PSW Format Details

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PSW Format Details

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 Any Questions?

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Thank you for your

time.
www.tuv-sud.in
info@tuv-sud.in

TÜV
TÜVSÜD
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