PPAP Workbook

Separate tabs are included for each section of the PPAP (as shown in the AIAG PPAP Manual, Fourth Edition).

For Ease of Use with the forms, you should enter all relevant information in the "Data" tab to avoid having to retype it.

The "Submission Plan" defines what sections are applicable for each level of PPAP.

Supplier shall fill in areas shaded "yellow". JVS uses sections shaded "blue".

Workbook Rev: 23-MAY-12

This workbook is to be used for Production Part Approval Process (PPAP) submissions to Jacobs Vehicle Systems (JVS).

Supplier shall complete each tab. Included are check boxes to be used if the tab is "not applicable". If a document cannot be attached into the designated tab, please indicate in the designated tab and add a separate tab or submit as a separate .pdf document.

On tab #18 (Part Submission Warrant), be sure to check off applicable boxes. "Data" information auto fills, but other information requires your input, including reportable substances, for example. The JVS Reportable substance list is available in the Supplier section at http://www.jacobsvehiclesystems.com/suppliers/jvs-ppap-workbook/.

Upon completion, please submit your PPAP to JVS_PPAP@jakebrake.com or as requested in the PPAP purchase order or instruction from JVS Purchasing or Quality.

Part InformationPart NamePart NumberRevisionSupplier Part Number (if applicable)Supplier Part Rev or Date (if applicable)Additional engineering changesAdditional engineering change rev/dateShown on drawing numberDeviationDeviation Approval DateWeightApplicationPurchase Order NoTooling Purchase OrderJVS Buyer Name

Submission InformationSubmission DateSubmission Level (see submission plan)

Reason for PPAP submission

Supplier InformationSupplier NameStreet AddressCityStatePostal CodePerson responsible for PPAP submissionTitlePhone Faxe-mail

PPAP Submission PlanSupplier 0 Part Name 0 Date of Submission 0

Part Number 0 Revision 0 PPAP Level 0

Reason for submission 0

RequirementPPAP Level

Supplier Comments JVS Comments1 2 3 4 4* 51 R S S * S R

Com

men

ts

2S S S * S R

3 S S S * S R

App

rove

d

Rej

ecte

d

4 R R S * W R

5 Process Flow Diagram R R S * W R

6 Process FMEA R R S * W R

7 Control Plan R R S * W R

8R R S * W R

9R S S * S R

Dat

e

Dat

e

Dat

e

Dat

e

10

R S S * S R

11

R R S * W R

12R S S * S R

13 W W W W W W N/A Waived Waived N/A

14

R S S * S R

15

R R R * R R N/A To be retained at supplier To be retained at supplier N/A

16R R R * W R

Pro

duct

Eng

inee

r

Pro

cess

Qua

lity

Eng

inee

r

Com

mod

ity M

gr/B

uyer

Pla

nner

Sup

plie

r Qua

lity

Eng

inee

r17

S S S S S R

18 Part Submission Warrant S S S S S R

19 W W W W W W N/A Waived Waived N/A

JVS normally requires PPAP level 3, unless otherwise specified. The PPAP P.O. takes precedence.JVS requires PPAP level 4* (see below) for commercially available product such as fasteners. Item 10 should include material certs, grade certs, mechanical properties, unless otherwise specified. The PPAP P.O. takes precedence.

This form represents a plan for the submission of requirements. Not all requirements may be applicable in every case.Key: R - Retain at Supplier S - Submit to JVS W - WaivedRefer to AIAG PPAP Manual, Fourth Edition, for further clarification.

SubmittedY/N

AcceptableY/N

Design RecordBallooned JVS Part PrintEngineering Change Documents, if anyJVS Supplier Change Request or evidence of engineering approval (e.g. e-mail)

Customer Engineering ApprovalJVS Supplier Deviation Request

Inte

rim/

Con

ditio

nal

Design FMEARequired, if design responsible.

Measurement System Analysis StudiesRequired for measurement devices used for special characteristics.

Dimensional ResultsClearly identify dimensional data to the part(s) submitted in # 14. JVS Layout -

Material, Performance, Test ResultsTransfer data to form from certifications, including the specification limits, and attach copy of material and test certifications.

Met Review - Other Testing -

Initial Process StudyRequired for all special characteristics.Include raw data, histogram, control chart and capability indices (PpK and CpK).

Qualified Laboratory DocumentationInclude copies of certifications (e.g. ISO9000, TS16949, A2LA), as appropriate

Appearance Approval ReportNot applicable to JVS productSample ProductClearly identify part(s) used for the results submitted in # 9. A minimum of 2 parts to be submitted (one for dimensional analysis and one for possible destructive testing), unless otherwise specified.

Master SamplesSample must be retained at the supplier. Dimensional data for this piece should also be included in #9.

Checking AidsList the checking aids with calibration status, as appropriate.

JVS Specific RequirementsPackaging & PreservationCoatings (MSDS)Process ChemicalsOutside processes

Bulk Material ChecklistNot applicable to JVS product

Design RecordBallooned JVS print (required for PPAP level 2, 3, 4, and 4*)

Attached below

Supplier printSubmitted under separate cover

Attached belowSubmitted under separate cover

Engineering Change Document(Supplier Change Request)

Identify approved change(s) not yet recorded on the design drawing, but which are incorporated in the product.

Not Applicable

Other evidence of engineering approval (e.g. e-mail)

Attached belowSubmitted under separate cover

Supplier Change Request included (form available at www.jakebrake.com)

Approved Supplier Change RequestAttached belowSubmitted under separate cover

Attached belowSubmitted under separate cover

Engineering Approval(Supplier Deviation Request)

Identify any deviation(s) from the design drawing (characteristics which do not meet the design requirement).

Not Applicable

Other evidence of engineering approval (e.g. e-mail)

Attached belowSubmitted under separate cover

Supplier Deviation Request included (form available at www.jakebrake.com)

Approved Supplier DeviationAttached belowSubmitted under separate cover

Attached belowSubmitted under separate cover

Design Failure Mode & Effects Analysis(DFMEA)

Not Applicable per Submission PlanNot Applicable - Not design responsibleDFMEA attached belowDFMEA submitted under separate coverDFMEA included as separate tab in this workbook

DFMEA included as separate tab in this workbook

Process Flow DiagramNot Applicable per Submission PlanProcess Flow attached belowProcess Flow submitted under separate coverProcess Flow included as separate tab in this workbook

Process Failure Mode & Effects Analysis(PFMEA)

Not Applicable per Submission Plan

PFMEA attached belowOther (Explain)

PFMEA submitted under separate coverPFMEA included as separate tab in this workbook

PROCESSFAILURE MODE AND EFFECTS ANALYSIS

00-039626 PFMEA Rev 11/6/11 Page 11 of 27

Item

Potential Failure Mode Recommended Action(s)

Action Results

Actions Taken

Potential Effect(s) of Failure

Sev

Class

Potential Cause(s)/ Mechanism(s) of Failure

Occur

Current Process Controls

Prevention

Current Process ControlsDetection

Detect

RPN

Responsibility & Target Completion DateProcess Function/

RequirementsSev

Occ

Det

RPN

Control PlanNot Applicable per Submission PlanControl Plan attached belowControl Plan submitted under separate coverControl Plan included as separate tab in this workbook

CONTROL PLAN

00-039626 Control Plan Rev 11/6/11 Page 13 of 27

Control Plan Control Plan Number:

Key Contact / Phone: Part Number / Latest Change:Prepared By: Orig Date:

Revised by: Rev Date:

Characteristics Methods

Reaction PlanNo. Product Process Sample Size Control Method

Part / Process Number

Process Name/Operation

DescriptionMachine, Device, Jig,

Tools for Mfg.Special Char. Class

Specification / Tolerance

Evaluation / Measurement Technique

Sample Frequency

Measurement System Analysis StudiesNot Applicable per Submission PlanNot Applicable - No Special CharacteristicsMSA evaluated

Total GRR < 10% 10% < Total GRR < 30%Total GRR > 30% - Action plan attached

MSA submitted under separate coverMSA included as separate tab(s) in this workbook

MSA attached below

Page 15 of 27

Dimensional ResultsPART NAME PART NUMBER PART REV

0 0 0SUPPLIER NAME OF SUPPLIER INSPECTOR DATE OF SUPPLIER INSP

0PURCHASE ORDER NAME OF JVS INSPECTOR DATE OF JVS INSP

0

Item

Supplier JacobsResults

A/R Results A/RPc. 1 Pc. 2

Inspection MethodC=Calipers, DI=Drop Indicator, G=Gage Pins, I=Indicator, M=Micrometer, P=Profilometer, R=Rockwell Hardness Tester, S=Shadowgraph

Dimension / Specification

Inspection Method

Inspection Method

Pc. 3 (Retained at Supplier)

Page 16 of 27

Item

Supplier JacobsResults

A/R Results A/RPc. 1 Pc. 2Dimension /

SpecificationInspection

MethodInspection

MethodPc. 3

(Retained at Supplier)

Material Test Results

SUPPLIER PART NAME PART NUMBER REV0 0 0 0

MATERIAL SUPPLIER QTY TESTED OKSAMPLE DATA

METAL CO METAL CO. 0.38 - 0.45 6/6/10 0.44 OKHT SUPPLIER HT SUPPLIER Core Hardness 56 - 60 HRC 6/10/10 1 57.70 OK

Complete form and attach material certification below. Blanket statements of conformance are unacceptable for any test results.

NAME OF LABORATORY

MATERIAL SPEC./ CHARACTERISTIC

SPECIFICATION LIMITS

TEST DATE

SUPPLIER TEST RESULTS (DATA)

NOT OK

42CrMoS4% C

Heat 425880 (2000 lbs)

Not Applicable

Performance Test Results

SUPPLIER PART NAME PART NUMBER REV0 0 0 0

TEST LABORATORY QTY TESTED OKSAMPLE DATA

AAA TEST LAB 6/6/10 3 OK

Applies to performance tests such as fatigue testing, breakaway torque and mechanical properties.Complete form and attach test certification below (if applicable). Blanket statements of conformance are unacceptable for any test results.

TEST SPEC./ CHARACTERISTIC

SPECIFICATION LIMITS

TEST DATE

SUPPLIER TEST RESULTS (DATA)

NOT OK

Cycle test per ABC SPEC 1234

100,000 cycles without failure

1 pc broke at 214,000 cycles, 2 pcs test

stopped at 250,000 cycles without failure

Not Applicable

Initial Process StudiesProcess Studies are required for all special (Critical and Major) characteristics. Process Studies should be included, if possible, for all KCC/KPCInclude raw data, histogram, control chart and capability indices (PpK and CpK)

Not Applicable per Submission PlanNot Applicable - No Special Characteristics

Process Studies attached below

Min Capability Requirements met (Critical 1.67 CpK and Major 1.33 CpK)Min Capability Requirements not met - Action plan attached

Process Studies submitted under separate coverProcess Studies included as separate tab(s) in this workbook

Process Studies conducted

Qualified Laboratory Documentation

Issue Date Expiration DateIssue Date Expiration DateIssue Date Expiration DateIssue Date Expiration DateIssue Date Expiration Date

Not Applicable

TS 16949 Certification

ISO 14000 CertificationA2LA CertificationISO/IEC17025 CertificationOther Certification (Please specify)

ISO 9001 Certification

Certificate(s) previously submitted (no changes)Certificate(s) attachedCertificate(s) submitted under separate cover

Checking Aids

SUPPLIER PART NAME PART NUMBER REV

0 0 0 0

Description of checking aidChecking aid

number

Complies with revision above?

Y/N

Date of last calibration / verification

Not Applicable

Packaging and PreservationQuantity per individual package/box

Weight per individual package/box NOTE: Over 25 pounds requires formal JVS approval

Packaging Material Type

Outer packaging

Inner packaging (Idenfify all applicable)

Returnable bin or crate (Specify type)

Other (Please specify)

Gaylord container (Specify size)Cardboard box (Specify size and test rating) Other (Please specify)

Plastic or other dividers (Please describe)

Dessicant Bag

Cardboard dividers

Plastic Bag (Non-VCI)VCI Bag

Bubblewrap

Plastic Sheet (Non-VCI)VCI Sheet

Wooden bin or crate (Specify type)

RP applied (Specify type; complete separate tab)VCI Chip

Coating MSDSList any coatings on the product and attach MSDS

Oil (Please specify type and include MSDS)

Black Oxide (Please include MSDS)

Other (Please specify and include MSDS)

Plating (Please specify type and include MSDS)Loctite or similar (Please specify type and include MSDS)

Rust Preventative (Please specify type and include MSDS)

Not ApplicableMSDS(s) previously submitted (no changes)MSDS(s) attachedMSDS(s) submitted under separate cover

Process Chemicals

Brand Name and Manufacturer of Chemical Process where chemical is used

List any chemicals used for cleaning, degreasing, descaling, etching, acids or bases used in vibratory finishing, etc..Attach manufacturer's chemical specification for any such chemicals, as appropriate.

Not Applicable

Outside ServicesIdentify supplier for any outside processes or services (e.g. coating application, shot peen, grinding)

Supplier Name Supplier LocationOutside Service / Operation

Certifications and expiration dates

(e.g. ISO 9001, TS16949, A2LA, ISO/IEC 7025)

Not Applicable

Part Submission WarrantPart Name 0 JVS Part Number 0 Rev. 0

Supplier Part Number 0 Rev. 0

Additional Engineering Changes 0 Rev. / Date 0

Tooling P.O. Number 0 Purchase Order No. 0 Weight (kg) 0.0000

ORGANIZATION MANUFACTURING INFORMATION SUBMISSION INFORMATION

0 JACOBS VEHICLE SYSTEMSSupplier Name

0 0Street Address JVS Purchasing or Buyer/Planner Contact

0 0 0 0City State Zip Application

Does this part contain any restricted or reportable substances?Verified by:

Explanation

Are plastic parts identified with appropriate ISO marking codes?

REASON FOR SUBMISSIONInitial submission Change to Optional Construction or MaterialEngineering Change(s) Sub-Supplier or Material Source ChangeTooling: Transfer, Replacement, Refurbishment, or Additional Change in Part ProcessingCorrection of Discrepancy Parts produced at Additional LocationTooling inactive > than 1 year Other - please specify

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.

(check)Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

DECLARATION

EXPLANATION/COMMENTS: 0

List Molds / Cavities / Production Processes

Organization Authorized Signature Date 0

Print Name 0 Phone No. 0 Fax No. 0

Title 0 E-Mail 0

FOR JVS USE ONLY

PPAP Warrant Disposition Comments

Customer Signature

Print Name Date

I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer drawings and specifications and are made from specified materials on regular production tooling with no operations other than the regular production process. I also certify that documented evidence of such compliance is on file and available for review.

Approved RejectedInterim Approval

Yes (explain below) No

Yes No

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

JVS Restricted and Declarable Substance List (available at www.jacobsvehiclesystems.com)GADSL

IMDS (provide number below)

N/A

REACH Chemicals including Candidate ListEPA List of Lists

Other (explain below)

Dispositioned PSWFor JVS use only