Production Part Approval Process 4 · PDF fileProduction Part Approval Process 4th Edition ... Production Part Approval Process ... (cp. QS-9000, main section I)

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PPAP

13.01.2007PPAP_engl.PPT vom© 2007 by R.Gläßner, D-85221 Dachau, +49-8131-53595, www.glaessner.de

Dipl.-Ing. Ralf Gläßner

Production Part Approval Process 4th Edition

PPAPDipl.-Ing. Ralf Gläßner

13.01.2007 Seite 2PPAP_engl.PPT vom© 2007 by R.Gläßner, D-85221 Dachau, +49-8131-53595, www.glaessner.de

to show you the basic content and the rules of the

Production Part Approval Processand to explain the purpose and the background

but this lecture will not save you from learninghow to practically use this system

It‘s the goal of this lecture to



Notes to This Lecturethis lecture was created for training purposes only;

it is not an extensive description, but a

help for getting started

view of contents, basic idea and goals

The content of this lecture shall not be used as a reference for daily work

Please make sure that you are working only with original latest level documents

Creating this lecture, the valid standards of Dec 2006 were used

This lecture does not refer to customer specific requirements, nor to special PPAP

rules/requirements for bulk materials, tires, nor truck industry!

Standards mentioned in this lecture can be obtained from the institutions listed in

section 6. Internet Links



Contents1. Introduction2. Content of the QS-9000 „PPAP“

1. General2. PPAP Process Requirements3. Customer Notification and Submission Requirements4. Submission to Customer - Levels of Evidence5. Part Submission Status6. Record Retention

3. Summary of the Process4. The Documentation and its Preparation5. Summary6. Internet Links



1. Introductionit is the purpose of advanced quality managementto prevent that unreliable designs or processesare used in serial production

therefore it is necessary to have oneextensive, strict approval process for newor changed designs or processes

inevitably this process causes someadministration work

but its worth while because it reduces theproduction of muda!



PROJECT TIME

EXPE

NSE

S

Saving by taking advantage of the “Rule Of The 10”:“The cost of the remedy of a defect increases

tenfold with every step, the project advances!”

Early identification of a defect

...saves themajor part of

the cost!



Savings by avoiding the “7+1 muda”

unnecessarymovement

overproduction

waitingtime

stock

unnecessarytransport

mudain the processerrors

Design ignoringthe customer‘sexpectations

muda



Too high stocks...take space

raise assets employed

require additional searching

require additional administration

require additional transport

are a risk, because parts might exceed expiration date or becomeunsaleable

are a risk, because parts might be damaged

complicate the overvieware often a consequence of a weak processcover weak process



Requirement for low stocks...

lowerstocks

are controlled and capable processes

and Total Productive Maintenance

since all kind of process problems will cause delivery stops,if the stocks are low!



Advantages of controlled & capable production processes

satisfied customersby good quality and avoided muda

no scrap, no rework

constant flow of material

low stocks possible



According to QS-9000...such an extensive and strict process is an obligatory requirement(cp. QS-9000, main section I)

the name of this process is

Production Part Approval Process

its explanation is one QS-9000 reference manual

QS-9000 “PPAP”





3. Summary of the Process4. The Documentation and its Preparation5. Summary



2. Content of the QS-9000 „PPAP“Introduction

Section 1 General

Section 2 PPAP Process Requirements

Section 3 Customer Notification and Submission Requirements

Section 4 Submission Levels

Section 5 Part Submission Status

Section 6 Record Retention

Manufacturer Specific Requirements

• Will not be discussed here!

• are to be found in internetOEM Homepages or



Appendicies

Appendix A Completion of the “Part Submission Warrant”

Appendix B Completion of the “Appearance Approval Report”

Appendix C PPAP, Dimensional Results

Appendix D PPAP, Material Test Results

Appendix E PPAP, Performance Test Results

Appendix F Bulk Material - Specific Requirements

Appendix G Tires - Specific Requirements

Appendix H Truck Industry - Specific Requirements

Glossary








PPAP is, so to speak, „the goal” of APQP...

APQP makes surethat all requirements are recognized before the ProductDevelopment is startedthat those “special characteristics” of the product are specifiedwhich influence these requirementsthat it is verified again and again that the planed design can safelymeet these requirements, if the special characteristics are withintolerancethat only those production processes are specified, which arecontrolled and capable according to SPC regarding thesecharacteristics

A test production and PPAP are used to validate thatall processes are under control and capablethe produced parts fulfil all requirements



Purpose and Applicability

It is the purpose of PPAP todefine generic requirements for production part approvaldetermine if all customer engineering design record and specificationrequirements are properly understood by the organizationdetermine that the manufacturing process has the potential to producethe product consistently meeting these requirements during an actualproduction run at the quoted production rate

Applicability ( “PPAP”, Introduction)

PPAP shall apply to internal and external organization sites supplyingproduction or service parts, production materials or bulk materials.

For bulk material PPAP is not required unless specified by the customer

a supplier of standard catalogue production or service parts shallcomply with PPAP unless formally waived by the customer



Submission of PPAP

The organization shall obtain full approval from theauthorized customer product approval activity for:

1. a new part or product2. correction of a discrepancy on a previously submitted part3. product modified by an engineering change to

design recordsspecificationsmaterials

4. any situations required by section 3

Note: If there is any question concerning the need for PPAP,contact the authorized customer representative.








(2.) 2. PPAP Process Requirements

2.1 Significant Production Run

2.2 PPAP Requirements

2.2.1

2.2.2

…

2.2.18

Requirements describing the detailsof documentation to be attached

Will be discussedin chapter 4 of this presentation!



(2.)2.1 Significant Production Run

Products for PPAP shall be taken from a significant production run

This production run shall be from one hour to eight hours ofproduction, and with the specific production quantity to total aminimum of 300 consecutive parts, unless otherwise specified bythe authorized customer representative

This significant production run shall be conducted at theproduction, at the production rate, using the production tooling,production gaging, production process, production materials, andproduction operators.

Parts from each unique production process, e.g. duplicateassembly line and/or work cell, each position of a multiple cavitydie, mold, tool or pattern, shall be measured and representativeparts tested



(2.)2.2 PPAP Requirements

the supplier shall meet all specified requirementsas listed in this handbookand all customer-specific requirements

Production parts shall meet all customer engineering designrecord and specification requirements

including safety and regulatory requirements

If any part specification cannot be met, the organization shalldocument their problem-solving efforts and shall contact theauthorized customer representative for concurrence indetermination of appropriate corrective action.



View over the documentations to be created(see chapter 4 of this presentation for details)

Warrant



Content of the documentation to be created

1. Design Record

2. Authorized Engineering ChangeDocuments

3. Customer Engineering Approval

4. Design-FMEA

5. Process Flow Diagram(s)

6. Process-FMEA

7. Control Plan

8. Measurement System AnalysisStudies

9. Dimensional Results

10. Records of Material/ Performance Test Results

11. Initial Process Studies

12. Qualified LaboratoryDocumentation

13. Appearance Approval Report

14. Sample Production Parts

15. Master Sample

16. Checking Aids

17. Customer-SpecificRequirements

18. Part Submission Warrant



Paperwork or EDP?

all forms mentioned in this documentmay be replaced by identical computergenerated forms

these documents have to be approvedby the customer product approvalactivity before first submission

at Adare Carwin a floppy with all formscan be obtained

PPAP?








2.3. Customer Notification and SubmissionRequirements( “PPAP”, Section 3)1. Customer Notification

The organization shall notify the authorized customer representative of anyplanned changes to the design, process or site.Examples are indicated in Table 3.1

Notification of all changes to desing nad process is the the organization´s resonsibility.Upon notification and approval of the proposed change by the authorizedcustomer representative, and after change implementation, PPAP submissionis required unless otherwise specified

2. Submission to CustomerThe organization shall submit for PPAP approval prior to the first productionshipment in the following situations (see Table I.3.2) unless the authorizedcustomer representative has waived this requirement.The organization shall review and update all applicable items in the PPAP file toreflect the production process,

regardless of whether or not the customer requests a formal submission.

The PPAP file shall contain the name of the authorized customer representativegranting the waiver and the date.



Table 3.1: Customer Notification Required1. use of other construction or material than was used in the previously

approved part or product

2. production from new or modified tools (except perishable tools), dies, molds,patterns, etc., including additional or replacement tooling

3. production following refurbishment or rearrangement of existing tooling orequipment

4. production from tooling and equipment transferred to a different plantlocation or from a additional plant location.

5. change of subcontractor for parts, non-equivalent materials or services (e.g.:heat-treating, plating) that affect customer fit, form, function, durability, orperformance requirements

6. product produced after tooling has been inactive for volume production fortwelve months or more

7. product and process changes that impact fit, form, function, performance, and/or durability of the salable product



Table 3.2: Submission to Customer

1. a new part or product (i.e.: a specific part, material, or color notpreviously supplied to this specific customer)

2. correction of a discrepancy on a previously submitted part

3. engineering changes to design records, specifications, ormaterials for production product/part number(s)

4. bulk material only: process technology new to the supplier, notpreviously used for this product








2.4. Submission Levels

Note:

The content of the documentation to be generatedis always the same!

The supplier has to retain everything (e.g.. as a copy)!

the Submission Level just indicates what has to be submitted tothe customer!



There are five Submission Levels:

1. warrant only (and if applicable an Appearance Approval Report)

2. warrant with product samples and limited supporting data

3. warrant with product samples and complete supporting data

4. warrant with other requirements as defined by the customer

5. warrant with product samples and complete supporting data availablefor review at the organization’s manufacturing location



The customer decides about the submission level…

I wantI needI wish

...looking at:

the status of the supplier(Ford Q1, ...)

his experience with earlierapproval processes

the know-how of the supplierconcerning this product

the importance of the part

so the submission level mightbe different for every product



S = submitretain a copy at anappropriatelocation, (includingmanufacturing)

R = retain at appropriate locations(including manufacturing)

has to be madereadily available tothe customerrepresentative uponrequest

* = retain atappropriate locations

submit uponrequest



LEVEL 3 IS THE “STANDARD LEVEL"

IT SHALL BE USED FOR ALL SUBMISSIONS UNLESSSPECIFIED OTHERWISE BY THE RESPONSIPLE CUSTOMERPRODUCT APPROVAL ACTIVITY

Level 1 = just warrantand (if applicable) Appearance Approval Report

Level 2 = standard minus process descriptionand background information

Level 3 = standardLevel 4 = warrant, other requirements as defined by the customerLevel 5 = the complete list,

and everything will be checked at the supplier´s site!




1. General2. PPAP Requirements3. Customer Notification and Submission Requirements4. Submission Levels5. Part Submission Status6. Record Retention




After everything is ready, it will besubmitted to the customer!

namely at the responsible product approval activity

the customer will inspect everything and notify theorganization of the result using the Part Submission Status



Part Submission Status

Upon approval of the submission, the organization shall assurethat future production continues to meet all customer requirements

For those organizations that have been classified as self-certifyingby a specific customer (PPAP Submission Level 1), submission ofthe required organization-approved documentation will beconsidered as customer approval unless the organization isadvised otherwise.

ORGANIZATIONS MAY NEVERSHIP PRODUCTION QUANTITIESBEFORE CUSTOMER APPROVAL!



Part Submission Status:

“A” “B” “C”Approved Interim Approval Rejected



Part Submission Status “A” = Approved

indicates that the part or material meets all customer specificationsand requirements

the organization therefore is authorized to ship production quantitiesof the product subject to releases from the customer schedulingactivity



Part Submission Status “B” = Interim ApprovalPermits shipment of material for production requirements on a limited time or piece quantity basis. Interim Approval will only be granted when the organization has:

clearly defined the non-compliances preventing approval; and,prepared an interim approval action plan agreed upon by the customer

The organization is responsible for implementing containmentactions to ensure that only acceptable material is beeing shipped tothe customer.PPAP re-submission is required to obtain a status of “Approved”material covered by an interim approval that fails to meet theagreed-upon action plan either by the expiration date or theshipment of the authorized quantity will be rejected. No additionalshipments are authorized unless an extention of the interim approvalis granted.



Part Submission Status “C” = Rejected

Means that the PPAP submission does not meet the customerrequirements, based on

the production lot from which it was taken,and/or accompanying documentation

In such cases, the submission and/or process (as appropriate)shall be corrected to meet the customer requirements.

The submission shall be approved before production quantitiesmay be shipped.








Record Retention and Sampling

PPAP records, regardless of submission level,shall be maintained for the length of the timethe part is active (in production or service)plus one calendar yearthe supplier shall ensure that the appropriate PPAP records from asuperseded part PPAP file are included, or referenced in the newpart PPAP file








3. Summary of the Processbefore delivering new or changed parts or changing the productionprocesses the supplier has to document that he has successfullyfinalized all activities of to ensure

that the product will meet all requirementsthat the processes are under control and capable

These activities are mostly described in QS 9000 APQP

the documentation consist of the Part Submission Certificate andthe required attachments

according to his Submission Level the supplier has to submiteverything or just parts of it to the customer

the customer checks the documentation and sets the “PartSubmission Status”

depending on that the supplier can start delivery – or not…



Task:

Assume you have received a PPAPSubmission Level 3 from your supplier.Supplier has design responsibility.How to make sure whether or not the supplierworked carefully?

…but without leaving your desk!

Time frame:Preparation 15 min.

Teamwork: How to judge about PPAP?








4. The Documentation and its Preparation

Warrant



Only English report formshave to be filled out andsubmitted to thecustomer!



Content of the documentation to be created

1. Design Record

2. Authorized Engineering ChangeDocuments

3. Customer Engineering Approval

4. Design-FMEA

5. Process Flow Diagram(s)

6. Process-FMEA

7. Control Plan

8. Measurement System AnalysisStudies

9. Dimensional Results

10. Records of Material/ Performance Test Results

11. Initial Process Studies

12. Qualified LaboratoryDocumentation

13. Appearance Approval Report

14. Sample Production Parts

15. Master Sample

16. Checking Aids

17. Customer-SpecificRequirements

18. Part Submission Warrant



4.1 Design Recordsall design records for the saleable product e.g.

CAD/CAM Datapart drawingsspecifications

including component drawings

For parts identified as “black box” the design record specifies theinterface and performance requirements

The organization shall provide evidence that theMaterial/Substance Composition reporting has been completedand that reported data complies with all requirements

Reporting and requirements as prescribed by the customerReporting may be entered into International Materials Data System(IMDS), www.mdsystem.com/index.jsp



4.1 Design Records / …Where applicable, the Organization shall identify polymeric partswith the ISO symbols

for plastics: ≥ 100g, see ISO 11469 / 1043-1for elastomers: ≥ 100g, see ISO 11469 /1629

4.2 Authorized Engineering Change Documents

all authorized engineering change documents, which are

not yet recorded in the design record

but incorporated in the product, part or tooling



4.3 Customer Engineering Approval

where specified by the customer, theorganization shall have evidence ofcustomer engineering approval



4.4 Design-FMEA

If the supplier is design responsible a Design-FMEA is required

according to the customer-specific requirements

e.g. QS-9000 “FMEA”(Potential Failure Mode and Effect Analysis)



4.5 Process Flow Diagrams

see QS-9000 “APQP”



4.6 Process-FMEA

according to the customer-specific requirements

e.g. QS-9000 “FMEA”(Potential Failure Mode and Effect Analysis)



4.7 Control PlanThe Organization shall have control plan that defines all controls used for process control and complies with the customer-specified requirements,e.g. QS-9000 “APQP”

control plans for “families” of similar parts are acceptable if the new parts have been reviewed for commonality

Note: Certain customers require control plan approval e.g.customer signature on the control plan, prior to submission.

QM-Plan

according to

QS-9000

“APQP”



4.8 MeasurementSystem AnalysisStudies

the organization shall have applicable Measurement SystemAnalysis Studies (e.g. Gage R & R…) for all new or modifiedgages, measurement, and test equipment

See QS-9000 “MSA” (Measurement System Analysisreference manual.



4.9 Dimensional Results

The organization shall provide evidence thatdimensional verifications required by die design recordand the Control Plan have been completed andresults indicate compliance with specifiedrequirements.

The organization shall have dirnensional results for each uniquemanufacturing process, e.g. cells or production limes and allcavities, molds, patterns or dies

The organization shall record, with the actual results: alldimensions (except reference dimensions), characteristics, andspecifications as noted an the design record and Control Plan.



4.9 Dimensional Results / …The organization shall indicate

the date of the design record,change level, andany authorized engineering change document not yet incorporated inthe design record to which the part was made.

The organization shall recordthe change level,drawing date,organization name andpart number

on all auxiliary documents (e.g. supplementary layout resultssheets, sketches, tracings, cross sections, CMM inspection pointresults, geometric dimensioning and tolerancing sheets, or otherauxiliary drawings used in conjunction with the part drawing).



4.9 Dimensional Results / …Copies of these auxiliary materials shall accompany thedimensional results according to the Retention/SubmissionRequirements Table.

A tracing shall be included when an optical comparator isnecessary for inspection.

The organization shall identify one of the parts measured as themaster sample

NOTE 1: The Dimensional Results form in Appendix C,a pictorial, geometrie dimensioning & tolerancing [GD&T] sheets,or a checked print where the results are legibly written on a partdrawing including cross sections, tracings, or sketches as applicablemay be utilized for this purpose.NOTE 2: Dimensional results typically do not apply to bulk materials.





4.10 Records of Material/Performance Test Results

The organization shall have records of test results formaterial tests

performance tests

for tests specifiedin the design record

in the control plan



4.10.1 Material Test ResultsThe organization shall perform tests for all parts and productmaterials when chemical, physical, or metallurgical requirementsare specified by the design record or control planMaterial test results shall indicate and include:

the design record change level of the parts tested;any authorized engineering change documents that have not yetbeen incorporated in the design record;the number, date, and change level of the specifications to which thepart was tested;the date on which the testing took place;the quantity tested;the actual results;the material supplier‘s name and, when required by the customer, thecustomer-assigned supplier/vendor code.

NOTE: Material test results may be presented in any convenientformat. An example is shown in Appendix D.





4.10.1 Material Test Results / …For products with customer-developed material specifications anda customer-approved supplier list, the organization shall procurematerials and/or services (e.g., painting, plating, heat-treating,welding) from suppliers on that list.



4.10.2 Performance Test ResultsThe organization shall perform tests for all part(s) or productmaterial(s) when performance or functional requirements arespecified by the design record or Control Plan.Performance test results shall indicate and include:die design record change level of the parts tested;

any authorized engineering change documents that have not yetbeen incorporated in the design record;the number, date, and change level of the specifications to which thepart was tested;the date on which the testing took place;the quantity tested;the actual results.

NOTE:Performance test results may be presented in any convenientformat.An example is shown in Appendix E.





4.11 Initial Process Studies

4.11.1 General

4.11.2 Quality Indices

4.11.3 Acceptance Criteria for Initial Study

4.11.4 Unstable Processes

4.11.5 Processes With One-Sided Specificationsor Non-Normal Distributions

4.11.6 Actions To Be Taken When Acceptance Criteria Are Not Satisfied



4.11.1 Generalthe level of initial process capability or performance shall be determined to be acceptable prior to submission for all special characteristics designated by the customer or the organization (sc,cc)

the organization shall perform measurement analysis to understand how measurement error is affecting the study measurements (see Measurement System Analysis reference manual)

for explanations about Cpk or Ppk see “SPC” (StatisticalProcess Control manual)



Gauß Normal Distribution

Standard Deviation sMean Value x

TurningPoint



Definitions “Process under Control” / “Capable Process”capablenot capable

notu

nder

cont

rol

unde

rcon

trol



The Capable Process

Cp = Process Capability IndexShows proportion of the permissibletolerance interval to the scatterScatter is measured in multiples ofthe standard deviation sIf the scatter is with +/- 3 s within thetolerance, then Cp=1

Cpk = Critical Process CapabilityIndex

Supplementary considers the meanof the process not being equal to themiddle of the tolerance interval

ProcessCapability

IndexExample Comment

No capability

High amount ofscrap

No capability

If centered prettyexact, just about noscrap

Very good capability

Statistically no scrap

No capability

Not centered

Scrap

Good capability

Process is centeredenough

Little scrap

Example 1 to 3Process adjustedexactly to centerof toleranceinterval



4.11.2 Quality Indices

Initial process studies shall be summarized with capability orperformance indices, if applicable.

NOTE 1: The initial process study results are dependent on thepurpose of the study, method of data acquisition, sampling,amount of data, demonstration of statistical control. etc.

See the QS-9000 Statistical Process Control reference manualfor additional information in understanding the basic principles ofstatistical stability and process measures (indices).

For guidance on items listed below, contact the authorizedcustomer representative.



Cpk and PpkCpk - The capability Index for a stable process.

The estimate of sigma is based on within subgroup variation .Cpk is an indicator of process capability based on process variation withineach subgroup of a set of data.Cpk does not include the effect of process variability between the subgroups.Cpk is an indicator of how good a process could be if all process variationbetween subgroups was to be eliminated.Therefore, use of Cpk alone may be an incomplete indicator of processperformance.

Ppk - The performance index.The estimate of sigma is based on total variation (all of individual sample datausing the standard deviation.Ppk is an indicator of process performance based on process variationthroughout the full Set of data.Unlike Cpk, Ppk is not limited to the variation within subgroups.However, Ppk cannot isolate within subgroup variation from between subgroupvariation.

When calculated from the same data set, Cpk and Ppk can be compared toanalyze the sources of process variation.For more information, see QS-9000 Statistical Process Control.



Purpose of Initial Process Studies

The purpose of the initial process study is to understand theprocess variation, not just to achieve a specific index value.

When historical data are available or enough initial data exist toplot a control chart (at least 100 individual sarnples), Cpk can becalculated when the process is stable.

Otherwise, for processes with known and predictable specialcauses and output meeting specifications, Ppk should be used.

When not enough data are available (< 100 samples) or there areunknown sources of variation, contact the authorized customerrepresentative to develop a suitable plan.



Examination of the stability (Process control)

examine capability

continue with 4.11.3

process seems instableprocess seems stable

Process may not meetcustomer requirements

continue with 4.11.4



4.11.3 Acceptance Criteria for Initial Study

Index > 1.67

the process currentlymeets theacceptance criteriaafter approval, beginproduction andfollow control plan

Index < 1.33

the process does notcurrently meet theacceptance criteriacontact the authorizedcustomer representativefor a review of the studyresults

1.33 ≤ Index ≤ 1.67

the process may beacceptablecontact theauthorized customerrepresentative for areview of the studyresults

Capability Index for stable process



4.11.4 Unstable Processes

Depending on the nature of the instability, an unstable processmay not meet customer requirements.

The organization shall identify, evaluate and, wherever possible,eliminate special causes of variation prior to PPAP submission.

The organization shall notify the authorized customerrepresentative of any unstable processes that exist and shallsubmit a corrective action plan to the customer prior to anysubmission.

NOTE: For bulk materials, for processes with known andpredictable special causes and output meeting specifications,corrective action plans may not be required by the customer.



4.11.5 Processes With One-Sided Specificationsor Non-Normal Distributions

The organization shall determine with the authorized customerrepresentative alternative acceptance criteria for processes withone-sided specifications or nonenormal distributions.NOTE: The above mentioned acceptance criteria assumenormality and a two-sided specification (target in the center).When this is not true, using this analysis may result in unreliableinformation.These alternate acceptance criteria could require a different type ofindex or some method of transformation of the data.The focus should be on understanding the reasons for the non-normality (e.g., is it stable over time?) and managing variation.Refer to the Statistical Process Control reference manual forfurther guidance.



4.11.6 Actions To Be Taken WhenAcceptance Criteria Are Not Satisfied

The organization shall contact the authorized customerrepresentative if the acceptance criteria cannot be attained by therequired PPAP submission date.

The organization shall submit to the authorized customerrepresentative for approval a corrective action plan and a modifiedControl Plan normally providing for 100% inspection.

Variation reduction efforts shall continue until the acceptancecriteria are met, or until customer approval is received.

NOTE: 100% inspection methodologies are subject to review andconcurrence by the customer.



4.12 Qualified Laboratory Documentation

Inspection and testing for PPAP shall beperformed by a qualified laboratory as definedby customer requirements(e.g., an accredited laboratory).

The qualified laboratory (internal or external to the organization)shall have a laboratory scope and documentation showing that thelaboratory is qualified for the type of measurements or testsconducted.

When an external/commercial laboratory is used, the organizationshall submit the test results on the laboratory letterhead or thenormal laboratory report format. The name of the laboratory thatperformed the tests, the date (s) of the tests, and the standardsused to run the tests shall be identified.



4.13 Appearance Approval Report (AAR)AAR = approval report for the appearance of appearance items concerning requirements on color, structure, or surface

For completion of AAR, see instruction in “PPAP”, appendix B

A separate AAR shall be completed for each part or series of partsfor which a submission is required if the product/part hasappearance requirements on the design record

Upon satisfactory completion of all required criteria, the suppliershall record the information on the AAR

since the Appearance Approval Report is a industry wide used formnot all customers will require entries in every position



4.13 Appearance Approval Report (AAR) / …

The completed AAR and representative production products/parts shall be submitted to the locationspecified by your customer to receive disposition

AARs (complete with part disposition and customer signature)shall then accompany the PSW at the time of final submissionbased upon the submission level requested





4.14 Sample Production Parts

The organization shall provide sample products as specified by the customer.



4.15 Master Sample

The organization shall retain a master sample forthe same period as the production part approvalrecords, or

a) until a new master sample is produced for the same customer partnumber for customer approval, or

b) where a master sample is required by the design record, Control Planor inspection criteria. as a reference or standard.

The master sample shall be identified as such, and shall show thecustomer approval date on the sample.

The organization shall retain a master sample for each position ofa multiple cavity die, mold, tool or pattern, or production processunless otherwise specified by the customer.



4.16 Checking AidsIf requested by the customer, the organizationshall submit with the PPAP submission anypart-specific assembly or component checking aid.The organization shall certify that all aspects of the checking aid agreewith part dimensional requirements.The organization shall document all released engineering designchanges that have been incorporated in the checking aid at the time ofsubmission.The organization shall provide for preventive maintenance of anychecking aids for the life of the part.measurement system analysis studies, e.g. gage R&R, accuracy, bias,linearity, stability studies, shall be conducted in compliance with thecustomer requirements. See “MSA” (Measurement SystemsAnalysis reference manual).



4.17 Customer-Specific Requirements

The organization shall have records of compliance to all applicablecustomer-specific requirements.

For bulk materials, applicable customer-specific requi rementsshall be documented on the Bulk Material Requirements Checklist.



4.18. Production Part Submission Warrant

Upon completion of all PPAP requirements,the organization shall complete thePart Submission Warrant (PSW).

A separate PSW shall be completed for each customer part numberunless otherwise agreed to by the authorized customerrepresentative.

If production parts will be produced from more than one cavity, mold,tool, die, pattern, or production process. e.g., line or cell, theorganization shall complete a dimensional evaluation on one partfrom each.

The specific cavities, molds, line, etc., shall then be identified in the“Mold/Cavity/Production Process“ line on a PSW, or in a PSWattachment.

Warrant



4.18. Production Part Submission Warrant/…

The organization shall verify that all of themeasurement and test results show conformancewith customer requirements and that allrequired documentation is available and, for Level 2, 3, and 4,is included in the submission as appropriate.

A responsible official of the organization shall approve the PSW andprovide contact information.

Warrant



Part Submission Warrant

consists of:Information about the part

Some formal information

Materials reporting

Reason of the submission

Requested submission level

Result of the submission

Declaration

For customer use (result)



Detail of Part Submission Warrant



Dimension Results / Part Weight (Mass)The organization shall record on the PSW the part weightof the part as shipped, measured and expressed inkilograms to four decimal places (0.0000) unless otherwisespecified by the customer.

The weight shall not include shipping protectors, assembly aides, orpackaging materials.

To determine part weight, the organization shall individually weigh tenrandomly selected parts, calculate and report the average weight.

At least one part shall be measured from each cavity, tool, line or processto be used in product realization.

NOTE: This weight is used for vehicle weight analysis only and does notaffect the approval process. Where there is no production or servicerequirement for at least ten parts, the organization should use the requirednumber for calculation of the average part weight.








The Attempt to Run PPAP without APQP!



Summary

The Production Part Approval Process is anextensive strict approval process for newor changed designs or processes.It is very formalized, so it inevitably causessome administration work,

but it doesn’t demand anything thatmakes no sense from an engineer´s pointof view!Later changes of the product or the processare expensive and take a lot of time.

The prerequisite to fulfill PPAP demands is acarefully done quality planning according toQS-9000 ”APQP”.



6. Internet Links

http://www.din.de

http://www.iso.ch

http://www.cenorm.be

https://www.carwin.co.uk/qs/qs9000default.htm

http://www.aiag.org

http://www.iaob.org

http:// www.vda-qmc.de