AUTOMOTIVE CONTROLS

SUPPLIER PRODUCTION PART APPROVAL PROCESS (PPAP)

REQUIREMENTS
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INTRODUCTION
• Production Part Approval Process (PPAP) is used in the automotive supply chain for establishing confidence in
suppliers and their production processes.

• The PPAP process is designed to demonstrate that a supplier has developed their design and production process to
meet the client's requirements.

• PPAP is a series of documents gathered in one specific location (a binder or electronically) called the "PPAP
Package". The PPAP package is a series of documents which need a formal certification / sign-off by the supplier.

• There is two type of Production Part Approval Process standards:

1. The Automotive Industry Action Group (AIAG) standard. In this case is called PPAP.
2. The VDA QMC Standard. In this case is called PPF (mostly required by the German companies)

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 I. PURPOSE
The purpose of the PPAP(AIAG) respectively PPF(VDA) is:

 To provide the evidence that all engineering designs and specification requirements are properly understood and
fulfilled by the Supplier.

 To demonstrate that the Supplier’s manufacturing process has the potential to produce product that consistently
meets all requirements during an actual production run at the quoted production rate.

II. WHEN IS PPAP/PPF SUBMISSION REQUIRED?

A PPAP/PPF is required anytime a new part or a change to an existing part or process is being planned.

The customer has the right to determine when and if a PPAP submission will be required.

The request of a PPAP submission could be for a variety of reasons. It can include the following ones:

• New part or product

• New supplier

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• New process or technology

• Change to existing product/ material or component

• Change to design including material, construction, or component

• New, additional or modified tools

• Upgrade of existing tools

• Tooling, production, or equipment transferred to a different site

• Product when tooling has been inactive for 12 months

• Product or process changes on the components of the product

• Change in test or inspection method

• Bulk material: New source of raw material

• Change in product appearance attributes

• Change of sub-Supplier or material source

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 III. SUBMISSION LEVEL
1. Submission of initial sample according to VDA
• According to VDA QMC standard there is 4 submission Levels:

- Level 0
- Level 1
- Level 2
- Level 3
• Within Eberspächer factories the initial sample is ordered according to
VDA and it must be a Level 1 submission.

• The table on the right shows the correspondent documents to each

Level according to PPF process (VDA).

• The form that summarizes this PPA package is called Cover Sheet.

The supplier must execute a complete PPF process

undependably from the required submission level from customer.

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2. Submission of initial sample according to PPAP (AIAG)
• The table on the right shows the correspondent documents to each Level
according to PPAP process (AIAG).

• Customer can require a PPAP according to a AIAG process with a

defined level (Level 3 for the most of external customers).

• The PPAP package is a series of documents which need a formal

certification/sign-off by the supplier and approval/sign-off by the
customer.

• The form that summarizes this package is called PSW (Part Submission
Warrant): Element number 18.

• PPAP requirements are typically distinguished by level as follows:

Level 1 – Part Submission Warrant (PSW) only submitted to the customer.

Level 2 – PSW with product samples and limited supporting data.
Level 3 – PSW with product samples and complete supporting data.
Level 4 – PSW and other requirements as defined by the customer.
Level 5 – PSW with product samples and complete supporting data
The supplier must execute a complete PPF process
available.
undependably from the required submission level from customer.

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 INTERSECTION PPF  PPAP

• The Table shows the intersection between the PPF and the
PPAP.
• PPAP and PPF have same concept but they have some
differences which it needs to be taken into consideration.

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 IV. PPF ELEMENTS
1. Cover Sheet
a. Cover sheet according to VDA

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 2. Test result for product
• A summary of every test performed on the part for product release.

• We can take as examples: Geometry, dimensions, function, weight, acoustic, electrical tests, Material tests, appearance,
security tests, ESD-Test, Mechanical tests, Solderability Test Report, Reliability Test…

• If the test is made externally, a copy of all laboratory certifications must be saved.

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 Dimensional results
• Supplier should be able to provide evidence that all measurements/test have been done in accordance with Control Plan
and results indicate compliance with specified requirements.

• Usually a minimum of 5 pieces is reported per product / process combination.

• Elements to be checked:

1. The Dimensional Results must correlate with ballooned drawing including all characteristics and notes.
2. Each data point must indicate: “in spec/out of spec”, „ok/nok” and/or “pass/fail”.
3. The report could include measured values or visual inspected.
4. Base for the measurements is 2D drawing.
5. The measured parts are the parts which were submitted as PPF/PPAP Sample Parts.

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 EXAMPLE

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 3. Sample
• The number of samples must be agreed with the customer.
(Normally 5 samples)

4. Technical specifications
• Technical specifications (e.g. customer drawings, CAD
data, specifications, approved design changes, Short-
circuit strength, voltage protection, functional Security
(FuSI)

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 5. Product FMEA (D-FMEA)
• The FMEA is a design tool used to systematically analyze postulated component failures and identify the resultant
effects on system operation.

• A copy of the Design Failure Mode and Effect Analysis (DFMEA), reviewed and signed off by supplier and
customer.

• The FMEA must be issued according to AIAG/VDA Standard (please refer to the FMEA Manual AIAG/VDA).

• The following evaluation criteria based on VDA must be used:

 B= Bedeutung = Severity
 A= Auftreten = Occurrence
 E= Entdeckung= Detection

RPN=Risk Priority Number (S x O x D)

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 The DFMEA will help us to identify the high risks in our design. This high risks will be converted into special
characteristics.

• The Special characteristics could be defined as follow:

 YC = Yes - could be - Critical (Produkt-FMEA)

 BM S= Security relevance.
 YS = Yes - could be - Special (Produkt-FMEA) acc. to
 BM F= Legal and regulatory requirements. acc. to
 CC = Critical Characteristic (Prozess-FMEA) AIAG VDA
 BM Z= Functions /technical requirements
 SC = Special Characteristic (Prozess-FMEA)

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 EXEMPLE

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 6. Design Record
• A printed copy of drawing needs to be provided.

• If the customer is responsible for designing, a copy of drawing must be sent together with the Purchase Order (PO).

• If supplier is responsible for designing this is a released drawing in supplier's release system.

• Fully “ballooned” drawing (all dimensions, notes, specs) must be submitted as part of a PPAP for every submission level
where Dimensional Results are required.

• All balloons must match with numbers used in Dimensional Results report.

• Check if drawing number and revision level are the latest available.

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 Leiterplatte design record

• The blue framed part: shows the PCB

with the mounted components which is
done in the AAE production in Tianjin.
For this part a measurements report
must be issued and the production
process capability must be evaluated.

• The Red framed part: shows the PCB

without the mounted components which
we supply from CML.

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 Leiterplatte design record

• The blue framed part: shows the PCB

with the mounted components which is
done in the AAE production in Tianjin.
For this part a measurements report
must be issued and the production
process capability must be evaluated.

• The Red framed part: shows the PCB

without the mounted components which
we supply from CML.

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7. Proof of compliance with legal requirements

• This section of the PPAP documentation lists the requirements of specific industries and the
individual requirements of the customer.

• Proof of compliance with legal requirements, if agreed with the customer (e.g. environment, safety,
recycling, country-specific certificates)

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 8. Material specification sheet (IMDS)
• The International Material Data System (IMDS) is a global data repository that contains information on materials
used by the automotive industry.

• All substances must be declared in the material data sheet (MDS) of the IMDS to a resolution of 1  gram or better –
not just declarable and prohibited substances (e.g. Cr VI / Hg / Pb / Cd).

• The information about the content of the Material must be document in a Material data sheet (MBD) like the one
below:

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 9. Sofware test report
• The software must be tested and validated before the release.

• The Software must meet the customer requirements.

• Example:

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 10.Process FMEA (PFMEA)
•  A copy of the Process Failure Mode and Effect Analysis (PFMEA), reviewed and signed off by supplier and
customer.

• The PFMEA follows the Process Flow steps, and indicates "what could go wrong" during the fabrication and
assembly of each component.

• PFMEA must be done according to AIAG FMEA handbook in terms of severity, detection and occurrence ratings.

• Special characteristics CC/SC(AIAG) or BM F/BM S/ BM Z (VDA) identified in the DFMEA must be taken into
consideration in the PFEMA .

• PFMEA can generate other special characteristics than the ones in the DFMEA.

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The link between PFMEA and DFMEA
•  The primary link between the DFMEA and PFMEA is the special characteristic.

• The special characteristic is a conversion of a cause of failure the design team has determined to be at risk.

• The special controls necessary to address the risk should be discussed between manufacturing and product design.
THE PFMEA should address the risk through analysis.

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 11. Process chart (Process Flow Diagram)
• A copy of the Process Flow, indicating all steps and sequence in the fabrication process, including incoming
components.

• The supplier can chose the way he wants to represent his Process Flow Diagram.

The order of the Process Flow Diagram steps

must be kept the same in the PFMEA.

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 12. Control Plan
• The Control Plan is a document that describes the actions required at each phase of a process to assure the
process outputs will conform to pre-determined requirements.

• These actions could be: measurements, inspections, quality checks or monitoring of process parameters.

• The Control Plan provides the operator or inspector with the information required to properly control the process and
produce quality parts or assemblies.

• The control Plans are living documents that should be periodically updated as the measurement methods and
controls are improved throughout the life cycle of the product.

How to create
a control plan?

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• The Control Plan should be developed by a Cross Functional Team (CFT) that has an understanding of the process being
controlled or improved.

• The plan developed by the team to control the process and ensure the process produces quality parts that meet the customer
requirements.

• Information contained in the control plan can originate from several sources, including but not limited to the following:

 The Process Flow Diagram

 Design Failure Mode and Effects Analysis (DFMEA)
 Process Failure Mode and Effects Analysis (PFMEA)
 Special Characteristics Matrix
 Lessons Learned from similar parts
 Design Reviews
 Team knowledge about the process
 Field or warranty issues

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 13. Process capability plan
• In this phase of the project we have to make an initial process study to check if our process is capable to meet the
technical requirements of customer.

• A capability analysis must be executed to calculate the Ppk,Cmk and the Cpk.

• To calculate the process capability we can use the SPC (statistic process control) method.

• The process capability must be verified for the all special characteristics(SC; CC; BM F; BM S; BM F) previously.

• Acceptance criteria:

 If process acceptance criteria are not meet for one or more special characteristics, a containment action plan is
required (Ex:100% inspection).

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Example of capability study generated

The machine
is capable

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 14. Proof protection of specific character.
• In the plan for safeguarding SC/CC features, all special characteristics must be recorded and adequately safeguarded.

• The special characteristics could be listed in a document with their tolerance conditions.

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 15. Inspection equipment (specific to product)
• The Measuring device used to measure and evaluate these
characteristics must be listed in the same document too.

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 16. Measurement System Analysis (MSA)
• Measurement system analysis (MSA) uses scientific tools to determine the amount of variation contributed
by the measurement system.

• MSA is used to certify the measurement system for use by evaluating the system’s accuracy, precision and
stability:
How to make
• A measurement systems analysis considers the following: MSA?

 Selecting the correct measurement and approach.

 Assessing the measuring device.
 Assessing procedures and operators.
 Assessing any measurement interactions.
 Calculating the measurement uncertainty of individual measurement devices and/or measurement systems

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• The first objective of the MSA is to validate the measurement system used to collect the data before moving onto the
ANALYZE phase and running statistical tests.

• The total measurement system variation could be represented as follow:

Total measurement system variation= Process variation Appraiser + (device)

variation

• There is a different methods to calculate this variation but we will only retain this Gage R&R Method according to AIAG.

• The execution of the AIAG method:

1. The test is carried out with 3 appraisers and by taking a sample of 10 different numbered parts representative of the
tolerance interval.

2. Each operator must measure the same part 3 times, for all 10 parts using the same measurement system. z
3. All the measurements will be collected in order to make an estimation of the Gage R&R variable.
• The acceptance criteria:

 The measurement system is accepted only when the Gage %R&R< 10%

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• To calculate the %GRR you need to determine the Repeatability and the reproducibility:

 Repeatability called equipment variation (EV): EV  R  K1  % AV  100  ( AV / TV )

X  K 2   EV 2 / nr 
2
 Reproducibility called appraiser variation (AV): AV  DIFF
 % R & R  100  ( R & R / TV )

R & R  EV 2  AV 2  % R & R  100  ( R & R / TV )

• The measurement quality of the measurement system could be judged based on the Gage R&R variable:

 NB: To facilitate the calculation of the the Gage R&R variable we can use Excel to program the equations above.
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 Example

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17. Tool overview
• Does the supplier use tools that are specifically designed for customer that were built and paid for by the
customer, is an overview with a photo of the test report to be enclosed.

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18. Evidence that the agreed capacity
• The supplier must explain the output of good parts in pieces per week or pieces per day with normal production capacity.

• Only the bottleneck process is considered here.

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19. Written self assesment
• A written self assessment for product and process needs to be issued.

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 20. Maintenance history/ Teilelebenslauf
• All the Engineering changes must be documented during the sampling process.

• The technical changes must be defined and clearly described.

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 21. Archiving duty
• The obligation to archive specification and evidence documents with data that is subject to special archiving duties is 15
years from EOP (End of Production) according to VDA.

• Proof documents and data relating to critical features must be kept for at least 15 years after they have been used.

• If so requested, the Supplier shall allow customer to view these documents .

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 Thank you for your attention

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