Introducing a New Product

Toyota Part Approval (PA) Process

Rahul Laxman Iyer, ASQ Certified Quality Engineer

Mesa AZ USANovember 2015

Introduction

Unlike the standard automotive companies (Detroit Big 3 & others), Toyota has a different procedure for approval of production parts. It is not the standard AIAG approach to a PPAP. This presentation aims to explain and show the required process for Toyota submissions.

Description of Toyota Part Approval (PA) Process

The following are the standard forms used for the Part Approval (PA) Process regarding Toyota. These forms are different from the standard AIAG PPAP.A) Request for Part Approval (PA) / Approval Request (AR) form

B) Qualified sample parts produced from off tool and mass production must have been previously submitted

C) Supplier Part Master Plan (SPMP) previously submitted and on record

D) Manufacturing Quality Plan (MQC) previously submitted and on record

E) Process FMEA (P-FMEA) previously submitted and on record

F) Process Capability Studies (Cpk) previously submitted and on record

G) Toyota Part Inspection Standard (TIS) must have been previously submitted and approved

H) Raw Material Certifications / Addition Certifications (as required)

I) Part Evaluation Plan (PEP)

J) Sample Data Sheets (SDS)

Part Approval (PA) / Approval Request (AR)

Supplier Part Master Plan (SPMP)--Gantt Chart

Manufacturing Quality Plan (MQC)--Process Control Plan (PCP)

Manufacturing Quality Plan (MQC)--Process Control Plan (PCP)--continued

Process FMEA

Reference the following Slideshare for developing a Process FMEA

http://www.slideshare.net/anandsubramaniam/process-failure-modes-effects-analysis-pfmea

Process Capability Studies (Cpk)

Reference the following presentation in Slideshare for conducting a Process Capability Study

http://www.slideshare.net/JGarcaVerdugo/process-capability-cp-cpk-pp-ppk

Toyota Part Inspection Standard (TIS)

Toyota Part Inspection Standard (TIS)--continued

Toyota Part Inspection Standard (TIS)--continued

Additional Certifications (G R&R)

Additional Certifications (G R&R)

Additional Certifications (G R&R)

Additional Certifications

Additional Certifications (Mating Part Component Request)

Additional Certifications (Color/Grain Matching Follow Sheet)

Part Evaluation Plan (PEP)

Part Evaluation Plan (PEP)--continued

Sample Data Sheets (SDS)

Results of Part Approval (PA) Process

Review of the submission packet by Toyota will result in one of the following outcomes:Part Approval (PA) will be granted, with a notification of the requirements for Final Approval (FA)

Part Approval (PA) will be rejected, requiring corrective action and resubmission for Part Approval (PA)

If Part Approval (PA) is granted, mass production can start, and the requirements of Final Approval (FA) can be prepared.

FINAL APPROVAL (FA)

Final Approval (FA) may be as simple a resubmission of the cover page after 90 days of production.Resubmission of a dossier similar to what occurred for Part Approval (PA)

Toyota may opt to not require a Final Approval (FA), and Final Approval (FA) is automatic after a set period of time, or after a certain quantity of parts produced (usually 90 days after start of production).

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