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Supplier Production Part Approval Process (PPAP)Training
*PLEASE MUTE YOUR PHONE FOR THIS TRAINING*
Why we are here
• This presentation has been put together to assist and answer questions that you may have understanding the ADAC Supplier PPAP Requirements.
• ADAC has tried to simplify and combine all requirements into this package.
Key Contacts @ ADAC Automotive Main Line - 616-957-3800
– PPAP-Nancy Soltys [email protected]– SPCR (Supplier Process Change Request)
-Charity Jimenez [email protected]– SPCR (Supplier Process Change Request)
-Kurt Meldrum [email protected]– SPCR (Supplier Process Change Request)
-Chris Hill [email protected]– SPCR (Supplier Process Change Request)
-Keith Scheiern [email protected]– Quality Engineer/Program Manager as designated per project– Buyer as designated per project commodity– Quality and Reliability Manager Mark Tegrootenhuis
Supplier PPAP Information
• You will be sent the following document when a supplier PPAP is requested.
• Follow all requests and if you have questions please refer back to the key contact.
Supplier PPAP Information PageDAIMLERCHRYSLER Part Submission Warrant
Part Name Cust. Part Number
Show n on Draw ing No. Org. Part Number
Engineering Change Level Dated
Additional Engineering Changes Dated
Safety and/or Government Regulation Purchase Order No. Weight (kg)
Checking Aid No. Checking Aid Engineering Change Level Dated
ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION
Supplier Name &Supplier/Vendor Code Customer Name / Division
Street Address Buyer / Buyer Code
City Region Postal Code Country Application
MATERIALS REPORTINGHas customer-required Substances of Concern information been reported?.
Submitted by IMDS or other customer format:
Are polymeric parts idenfied w ith appropriate ISO marking codes?
REASON FOR SUBMISSION (Check at least one)Initial submission Change to Optional Construction or MaterialEngineering Change(s) 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 w ith product samples and limited supporting data submitted to customer.Level 3 - Warrant w ith product samples and complete supporting data submitted to customer.Level 4 - Warrant and other requirements as defined by customer.Level 5 - Warrant w ith product samples and complete supporting data review ed at organization's manufacturing location.
SUBMISSION RESULTSThe results for dimensional measurements material and functional tests appearance criteria statistical process packageThese results meet all design record requirements: (If "NO" - Explanation Required)Mold / Cavity / Production Process
DECLARATIONI aff irm that the samples represented by this w arrant are representative of our parts, w hich w ere made by a process that meets all Product PartApproval Process Manual 4th Edition Requirements. I further aff irm that these samples w ere produced a the production rate of / hours.I also cerify that documented evidence of such compliance is on f ile and available for review . I have noted any deviations from this declaration be
EXPLANATION/COMMENTS:
Is each Customer Tool properly tagged and numbered?
Organization Authorized Signature Date
Print Name FAX No.
Title E-mail
FOR CUSTOMER USE ONLY (IF APPLICABLE)PPAP Warrant Disposition:
Customer Signature Date
Print Name Customer Tracking Number (optional)March
2006
Phone No.
CFG-1001
YES NO
Yes No
Yes No
Approved Rejected Other
n/a
Yes No n/a
YES NO n/a
Submit All PPAP's to Attn of:
Date:
Supplier: Supplier Code:
Attention:
Submission Level: ADAC IMDS Code:
Submission Due Date:
*New Part #:
Previous Part #:
Reference Print #: Print Date:
*New Rev.: Previous Rev.:
CN #:
Part Description:
Program:
Reason for PPAP:
Quality Engineer:
QE E-mail:
Chief Engineer:
Buyer: Buyer Code:
Feasibility Commintment Due Date:
Subcomponents Revision:
1086
(to be used on PSW - Buyer infomration section)
(616) 957-3800
Old Part Number:0
Print Date: Current Rev. Level: Current Part Number: Old Rev. Level:1/0/1900 0 0 0
616-957-3800 ext. 5508
Nancy Soltys
Information Sheet
(616) 957-3800
Submit PPAP To: Attn: Nancy Soltys5670 Eagle Drive.Grand Rapids, MI 49512
Supplier Feasibility CommitmentSupplier Code: Feasibility Commitment
Date: Part Number:Supplier: Current Eng. Rev. Level:Part Name: Print Number:
Print Date:Program: CAD file#:
Previous Part#:Part Submission Due Date: Previous Eng Rev. Level:
Feasibility Considerations:
All "No" answers shall be supported with attached comments/documents identifying concerns and/or proposed changes.
Conclusion Feasible - Product can be produced as specified with no revisions. Not Feasible - Design review/changes required to produce product within the specified requirements - (explanation attached).
Comments/Concerns:
(Sign-off by Supplier Personnel)
Team Member/Title/Date:Please complete, sign and return to: Nancy Soltys
Note: 4.0 Advanced Product Quality Planning (APQP)See ADAC Automotive Supplier Manual Email: [email protected] Phone: 616-957-3800 ext. 5508
Is statistical process control required on the product?
1/0/1900Return Date:
Where statistical process control is used on similar products, are the processes in control and stable? And are the Cpk's greater than 1.67?
Is statistical process control presently used on similar products?
Does the design allow the use of efficient material handling techniques?Can Product be manufactured with Cpk's that meet requirements?
Is the product adequately defined (cosmetic, dimensional, performance, application, requirements, etc) to enable a feasibility evaluation?Can Product be manufactured to tolerances specified on drawing?
CONSIDERATION:
0
Can Engineering Performance Specifications be met as written?YES NO
00
0
1/0/1900
Our quality team has considered the following questions, which are not intended to be all-inclusive in performing a feasibility evaluation. The drawings and/or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All "No" answers shall be supported with attached comments identifying concerns and/or proposed changes to enable us to meet the specified requirements. Please work with ADAC Engineering to resolve any issues of concerns that prevents the product from being feasible. Production parts may not be shipped without PPAP approval or written deviation. Failure to return this form to ADAC on or before the "Return Date" (listed below) is an automatic acceptance of the part being "Feasible".
ADAC Supplier PPAP Request and Requirements
00
Return Date: 1/0/190001/0/1900 1/0/1900
1/0/19001/0/1900
0
Supplier PPAP Request and Requirements Page
Date: Submit All PPAP's To:
Requested By: Nancy Soltys Nancy Soltys Senior Buyer 5670 Eagle Drive616-957-3800 ext. 5508 Grand Rapids, MI 49512
4.5 PPAP RequirementsPPAP’s are requested by and submitted to ADAC Purchasing. Final PPAP date will be established after delivery of ADAC
controlled documents. ADAC uses a default of level (3) AIAG format – for all PPAP submissions (See Page 17 PPAP 4th Edition). Use current AIAG reference manuals for appropriate documentation and guidance.
(ADAC may require suppliers to use “End Customer Specific” documentation when available/requested).
QE:
4.5.1 ADAC PPAP Requirements/Checklists ( 18 PPAP sections required/organized as follows)
(Check box X as Completed/Submitted) (Submit this completed checklist with PPAP)1) Design Records:
The organization shall have the design record for the saleale product/part, including design records for components or details of the saleable product/print.
CN#:2) Engineering Change Documents (if applicable)
Supplier Internal Change Notices, Supplier Eng. Change Notices, Etc. o Supplier related documents that pertain to product/program changes.
3) Customer Engineering Approval: PPAP must include a signed “Request for Functional Approval”. (See Tab – "Functional Approval")……………
o "MUST BE SIGNED" by ADAC Engineering prior to and submitted with PPAP Package.* Please submit request to ADAC engineering along with sample product for functional evaluation.
4) Design FMEA (when applicable): All Components/Assemblies/Systems must be included/covered in a Design FMEA. DFMEA will be detailed with specifics (In general FMEA’s are usually longer than 1 page). YC, ACC, YS, and other critical/special characteristics will be identified in the “Class” column. Shall use consistant Severity, Occurrence and Detection Rankings. (See S.O.D.Rankings Tab)……………
5) Process Flow Diagram: CC, ACC, SC, etc will be identified in the Flow Diagram. Header will include current Print Date/Revision Level. List all sub-suppliers on the Flow Diagram.
6) Process FMEA: PFMEA will be detailed with specifics (In general FMEA’s are usually longer than 1 page). CC, ACC, SC, and other critical/special characteristics will be identified in the “Class” column. Shall use consistant Severity, Occurrence and Detection Rankings. (See S.O.D.Rankings Tab)……………
o Root cause shall be identified when Severity is 9 or 10.7) Control Plan:
Control Plans will be detailed with specifics and are linked to the PFMEA & Flow Diagram. CC, ACC, Etc will be identified in the “Special Char. Class” column. Header will include current Print Date/Revision Level. DVP&R requirements must be included on Control Plan.
o Including: Submission Time intervals (Must state specific date of last Submittal).8) Measurement Systems Analysis Studies:
Complete MSA Studies including: R&R, Linearity, Bias and Stability are required for all new or modified gages, measurement, and test equipment (See MSA reference manual). Checking aids/Gages/Documentation will address each CC, ACC, SC, etc. designated on the print. Gage R&R’s shall be documented/submitted for all checking aids that are relative to the design record/control plan.
o Variable Studies shall utilize 10 parts, 3 operators and 3 trials,o Attribute Studies shall utilize 50 parts (pre measured), 3 operators and 3 trials,
The Gage's % R&R shall be 10% or below & NDC (Number of Distinct Categories) must be 5 or greatero Ford Specific Variable R&R's must be reported in ANOVA method.
9) Dimensional Results: Dimensional results (5 pcs per cav.) shall be submitted to the current print revision level for PPAP. Dimensional results shall include all dimensions (except reference dim.), characteristics, and specifications as noted on the design record and Control Plan.
10) Records of Material / Performance Test (DVP&R): The organization shall include records of material and performance test results for tests specified on the Design Record or Control Plan. Submit these results on a collection sheet (ie: DVP&R, CFG-1004, CFG-1005). All Material Certification will be for current production lot. (Shall be less than 1 year old at PPAP date) Supplier will have a copy of all applicable specification requirements available for review. Plastic Molder/Regrind Certification Letter must be submitted with each PPAP. (See Regrind Certification Tab)………… * GM Specific - A copy of the Trim Transmittal Form must be included for each "Class A" Resin component.
11) Initial Process Studies: Capability studies shall be performed on a minimum of 100 pieces per cav. (Out of the 300 pc min. production run)
o Ppk and/or Cpk must exceed 1.67. (see attachment for details)o Ford specific capability studies shall be performed on a minimum of 125 pieces per cav. (Out of the 300 pc min. run)
Capability studies shall be performed and identified for all special characteristic designated by the customer or organization. Where no Special Characteristics have been identified, contact the Program QE for verification on what characteristics require data.
12) Qualified Laboratory Documentation: Lab certifications shall be current. Labs shall be accredited to ISO/IEC 17025 or national equivalent (A2LA, NVAP and ICBO ES) Complete Lab Scope must be included for each lab used.
13) Appearance Approval Report (AAR): (when applicable) AAR’s shall be signed prior to and submitted with PPAP Package.
14) Sample Production Product: 3 samples (per production cavity) shall be submitted with PPAP (use dimensional parts)[Sec 9].
15) Master Samples: Supplier shall identify one of the parts (Layout) measured as the master sample. Shall be representative of PPAP run. One sample for each cavity, mold, tool or pattern, or production process.
16) Checking Aids: ADAC owned gages shall meet the “ADAC Plastics Inc, Gage & Check Fixture Guidelines” (latest revision). Gage Designs must be approved by ADAC personnel prior to kick-off of ADAC/Customer owned gages. Gages layouts, certification, and instructions shall be in this section.
17) Customer Specification Requirements / Records of Compliance: IMDS Data shall be completed for each component/sub-component or assembly associated with a PPAP request.
o IMDS must be submitted and approved each time the product is PPAP’d.o IMDS shall be submitted within 1 week of receipt of PPAP request and Print to (ADAC's) Customer Code # 1086o Suppliers shall submit a printed copy of the "APPROVED" IMDS submission with PPAP.
Please submit ISO/TS certifications for all suppliers& Sub-suppliers that pertain to each program. (Current, Non-Expired) PPAP should include a "Component Information Sheet" . (See Tab – "Comp Info")…………… Supplier shall submit a copy of the Production Label with PPAP.
o See http://www.adacautomotive.com website for detailed instructions & latest revision.18) Part Submission Warrant (PSW): ALL lines shall be filled in (no blank spaces).
A PPAP/PSW is required for each component, assembly and sub-assembly as listed on the Print BOM. Purchase Order must be filled in. Checking Aid Number must be filled in. (If various, please attach list) Weight (kg) = Enter the actual weight in kilograms to four decimal places. Suppler & Buyer codes must be filled in. Production Rate must be filled in. Mold/Cavity/Production Process must be filled in. (If various, please attach list)
Bulk Material Requirements / Checklist: For bulk material. Review PPAP 4th edition for each sections requirements.
Comments / Remarks:
0
01/0/1900
00*New Re
Previous Rev
*New Part #:1/0/1900
Previous Part #:1/0/1900
CN #:
ADAC Supplier PPAP Request and Requirements
Submission Level
Submission Due Date:1/0/1900
Submit All PPAP's To:
(616) 957-3800
0 Attention:
Supplier:
0
* Any deviation to these requirements will result in a rejection of PPAP unless approved by appropriate ADAC personnel prior to submission.
0 0
January 0, 1900
Program:
Description:0 1/0/19001/0/1900
0
Reason for PPAP:
Attn: Nancy Soltys5670 Eagle Drive
Grand Rapids, MI. 49512
0
Print Date:
Ref. Print:01/0/1900
1) Design Records:AIAG-PPAP 4th Edition - Page 4. Sec. 2.2.1 (Note 1)
2) Engineering Change Documents (if applicable)AIAG-PPAP 4th Edition - Page 5. Sec. 2.2.2
3) Customer Engineering Approval:AIAG-PPAP 4th Edition - Page 5. Sec. 2.2.3 & FORD Specifics for ISO/TS 16949:2002, 2nd Edition - Page16. Sec. 4.29 (Note) AIAG-PPAP 4th Edition - Page 5. Sec. 2.2.3 & FORD Specifics for ISO/TS 16949:2002, 2nd Edition - Page16. Sec. 4.29 (Note)
4) Design FMEA (when applicable): AIAG-FMEA 4th Edition - Page 10.AIAG-FMEA 4th Edition - Page 10.AIAG-FMEA 4th Edition - Page 39AIAG-FMEA 4th Edition - Page 37, 46 and 54
5) Process Flow Diagram:ISO/TS 16949 Second Edition - Page 16. Sec 7.3.2.3.AIAG-APQP - Page 77. A-6 Process Flow Chart ChecklistAIAG-APQP - Page 10. Sec. 1.10. & Page 84.
6) Process FMEA:AIAG-FMEA 4th Edition - Page 70.AIAG-FMEA 4th Edition - Page 91.AIAG-FMEA 4th Edition - Page 88, 93 and 100.
7) Control Plan:AIAG-APQP 1st Edition - Page 31, 44. -Control Plan MethodologyAIAG-APQP 1st Edition - Page 41. Sec. 21.AIAG-APQP 1st Edition - Page 36 - 39.AIAG-APQP 1st Edition - Page 31, 44.
8) Measurement Systems Analysis Studies:AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8 & MSA 3rd Edition - Page 83-123.
AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8.AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8 & MSA 3rd Edition - Page 83-123.AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8 & MSA 3rd Edition - Page 83-123.AIAG-PPAP 4th Edition - Page 6. Sec..2.2.8 & MSA 3rd Edition - Page 125-140.AIAG-MSA 3rd Edition - Page 77. Ford Specific Requirements (3/31/06) page 3, sec 9. & AIAG-MSA 3rd Edition - Pages 177 & 125.
9) Dimensional Results: AIAG-PPAP 4th Edition - Page 6. Sec. 2.2.9 & Page 9. Sec. I.2.2.13. Ford & Chrysler requirements are 3pcs per cav.AIAG-PPAP 4th Edition - Page 6. Sec. 2.2.9
10) Records of Material / Performance Test (DVP&R):AIAG-PPAP 4th Edition - Page 6. Sec. 2.2.10.AIAG-PPAP 4th Edition - Page 31 & 32.ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3GM Specific Lab Approval Requirement/ ADAC to validate the Material Spec Requirements for RegrindGM Specific Lab Approval Requirement
11) Initial Process Studies:AIAG-PPAP 4th Edition - Page 7. Sec. 2.2.11.1 (Note 5).AIAG-PPAP 4th Edition - Page 7, 8 & 9. Sec. 2.2.11. Ford Specific Requirements (3/31/06) page 4, sec 11. AIAG-PPAP 4th Edition - Page 7. Sec. 2.2.11.1.AIAG-PPAP 4th Edition - Page 7. Sec. 2.2.11.1 (Note 1).
12) Qualified Laboratory Documentation: ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3.2 ISO/TS 16949:2002, 2nd Edition - Page25-26. Sec. 7.6.3.1 & 7.6.3.2
13) Appearance Approval Report (AAR): (when applicable)AIAG-PPAP 4th Edition - Page 10. Sec. 2.2.13
14) Sample Production Product:AIAG-PPAP 4th Edition - Page 10. Sec. 2.2.14
15) Master Samples:AIAG-PPAP 4th Edition - Page 10. Sec. 2.2.15AIAG-PPAP 4th Edition - Page 10. Sec. 2.2.15
16) Checking Aids:ADAC RequirementADAC RequirementAIAG-PPAP 4th Edition - Page 11. Sec. 2.2.16
17) Customer Specification Requirements / Records of Compliance:International Requirement for PPAP ApprovalAIAG-PPAP 4th Edition - Page 22/23.ADAC Requirement (Customers want these numbers registered for early builds)ADAC Requirement (Supplier issues with correct IMDS to Part/Rev)ISO/TS 16949:2002 Requirement for business with OEM'sADAC RequirementADAC Requirement (See: http://www.adacautomotive.com)
18) Part Submission Warrant (PSW): ALL lines shall be filled in (no blank spaces).AIAG-PPAP 4th Edition - Page 11. Sec. 2.2.18AIAG-PPAP 4th Edition - Page 22/23. / ADACAIAG-PPAP 4th Edition - Page 12. Sec. 2.2.18.1 & Page 22/23.AIAG-PPAP 4th Edition - Page 22/23.AIAG-PPAP 4th Edition - Page 11. Sec. 2.2.18 & Page 22/23. / ADAC
Bulk Material Requirements / Checklist:AIAG-PPAP 4th Edition
Request for Functional ApprovalREQUEST FOR FUNCTIONAL APPROVAL
(PER SECTION 3 OF PPAP CHECKSHEET)
SUPPLIER TO COMPLETE:SUPPLER NAME: SUPPLIER MFG. CODE:
ADDRESS:PHONE:
FAX:
DESCRIPTION OF CHANGE: DESIGN PROCESS
PART NUMBER(S) AFFECTED: REV. LEVEL: REV. DATE: PLANT(S) AFFECTED:
ADAC ENGINEERING TO COMPLETE:A PLANT TRYOUT IS: REQUIRED NOT REQUIRED
NAME: DATE:
TRYOUT MATERIAL SHIPPING INSTRUCTIONS: TRYOUT QUANTITY:
TRYOUT RESULTS:
CHANGE IS APPROVED FOR PRODUCTION: Approved by:
CHANGE IS NOT APPROVED FOR PRODUCTION: Rejected by:
COMMENTS/RATIONALE:
* A completed/approved Functional Approval Form is a requirement for each PPAP prior to submission.
1/0/1900
000
1/0/19001/0/1900
0000
1/0/19001/0/19001/0/19001/0/1900
ADAC Supplier PPAP Request and Requirements
ADAC
0
0
000
0000
0
Molder Regrind Certification(PER SECTION 10 OF PPAP CHECKSHEET)
DATE:
SUPPLER NAME: SUPPLIER MFG. CODE:
PHONE:
FAX:
E MAIL:
CUSTOMER NAME:
PART NAME:
PART NUMBER:
MATERIAL SUPPLIER:
PRODUCT CODE:
COLOR:
We certify that the above parts provided to your company for PPAP and Product ValidationTesting were produced with % regrind.
Our production parts will be provided at the above stated regrind % or less.We will submit a supplier request for change to ADAC if we require a need to produce product made with higher levels of regrind.
Print Name: Signature:
Title:
Note: This form is to be filled out by the plastic molder.
MOLDER/REGRIND CERTIFICATION LETTER
0-
ADAC Automotive
-
-
Component InformationADAC P/N: DATE:
1/0/1900
PACKAGING P/N #/CTN Rev. Level:
0
0
0
0
0
PICTURE # 3 - PALLET/STACK
Pkg. Tare WT:Part Weight:
Carton Gross WT:Pcs. per Carton:
0Part Name:
ADAC AutomotiveCustomer:
Carton Dimensions:
Pcs. Per Pallet:
Layers per Carton: Cartons per Layer:
PICTURE # 1 - PART
* Note: The responsibility for ensuring 100% component quality from supplier to ADAC Automotive remains with the Supplier.
APPROVED BY: (Name/Title/Date)
Layers per Pallet: Cartons per Pallet:
Pallet Tare WT: Pallet Gross WT:
0 0
SUBMITTED BY: (Name/Title/Date)
PICTURE # 2 - PACKAGE
INSTRUCTIONS: Pcs. per Cell:
Component Information
Pallet Dimensions:
PACKAGING BOM (Components for one carton consist of:)
0 Issue DateDESCRIPTION #/PC
Information Only
• All of the remaining sheets that are included in the PPAP package you receive from ADAC are for your information; you are not obligated to send this information with your PPAP submission.
• Pages include FMEA ranking criteria, classification description guidelines, Retention/submission level requirements and revision history.
ADAC ApprovalPPAP Request
Sent to Supplier
Feasibility Commitment Returned to
Nancy
Supplier submits submission to
Nancy.
Nancy Checks for content-then submits to ADAC
QE for Review
ADAC QE dispositions
PPAP and returns to Nancy
Nancy Email PSW to supplier once approved.
Product ready for production.
ADAC SPCR
• SPCR = Supplier Process Change Request
• This form is used anytime there is a change in the suppliers process.
• It MUST be submitted and ADAC approved prior to any change.
• ADAC will communicate any specific requests with the approved SPCR.
Q & A
• Functional ApprovalQ:How do suppliers know the function of the component being sent to ADAC?
A:Work with the program manager to know the function of the part; suppliers are only to fill out the top portion of the request. The ADAC engineer is responsible for the function of the product and will approve this document.
• Submission FormatQ:How should the PPAP documents be submitted?
A:Documents should be sent via email one PDF copy. NO ZIP files. Parts should be mailed separately to Nancy.
Q & A
• IMDS Q:Do I have to supply an acceptance printout with my submission?
A:Yes-if there are extenuating circumstances please communicate with Nancy prior to due date submission.
• PPAP Requirements ChecklistQ:Does the PPAP Requirements Checklist need to be completed and included with the submission.
A:Yes-both the supplier and ADAC should use this as an index for the PPAP.
