PRODUCTION PART

APPROVAL PROCESS
(PPAP)

Production Part Approval Process (PPAP)

First Edition Issued February, 1993
Second Edition, 1st Printing, February, 1995, 2nd Printing, July, 1995
Third Edition, September, 1999, 2nd Printing, August, 2000
Copyright 1993, 1995, 1997, 1999, 2000
DaimlerChrysler Corporation, Ford Motor Company, General Motors Corporation

Production Part Approval Process (PPAP)

First Edition Issued February, 1993
Second Edition, 1st Printing, February, 1995, 2nd Printing, July, 1995
Third Edition, September, 1999, 2nd Printing, August, 2000
Copyright 1993, 1995, 1997, 1999, 2000
DaimlerChrysler Corporation, Ford Motor Company, General Motors Corporation
The Second Edition, 2nd Printing, July, 1995 edition is obsolete February 1, 2000
unless otherwise specified by your customer

Further copies are obtainable from AIAG at 01-248-358-3003 or

Carwin Continuous (UK) in Europe 44-1-708-861333

FOREWORD TO THE THIRD EDITION

The Production Part Approval Process (PPAP) Third Edition was issued to incorporate a number of revisions
which include:

Use of auditable language and a format consistent with QS-9000 to support third party auditing;

A reordering of the PPAP requirements aligned with the typical process flow;

Revision of Preliminary Process Capability Requirements, now called Initial Process Studies, to
provide for the use of either Cpk or Ppk, depending on the amount and type of data available, consistent
with our Statistical Process Control reference manual;

Clarification of when customer notification and/or submission is required;

The prior IASG QS-9000 Sanctioned Interpretations specific to PPAP;

A Truck OEM-Specific Instructions;

Requirements for bulk material, including a Bulk Material-Specific Appendix;

Tire Industry-Specific Appendix;

An enhanced glossary of terms.

The actual changes of the previous PPAP text are minimal, and evolutionary. While the additions have
increased the size of the document, they provide greater clarification of PPAP requirements and allow
application of PPAP requirements to a broader community of users.
Current training modules sanctioned by DaimlerChrysler, Ford and General Motors have been revised to
incorporate these changes.
Acknowledgments are due to the DaimlerChrysler, Ford and GM Supplier Quality Requirements Task Force
(Hank Gryn, Dan Reid and Steve Walsh), Michael Schons from DaimlerChrysler, Carol Myers and Rudy
Pomper from General Motors, Paul Norkevicius from Ford, Patricia Messenger from the Chemical
Manufacturers Association, Joseph Muscedere from the AIAG Truck and Heavy Equipment Group, and
Steve Butcher from the Rubber Manufacturers Association.
The PPAP Third Edition obsoletes the Second Edition effective February 1, 2000 unless otherwise specified
by your customer.

September, 1999

ii

FOREWORD TO THE SECOND EDITION

This document is the second edition of the Chrysler, Ford and General Motors Production Part Approval
Process (PPAP) procedure. It represents a refinement of the original PPAP procedure based on input from
representatives at each of these companies. In particular, it includes recommendations by the companies
European affiliates that will facilitate implementation of PPAP and QS-9000 in Europe.
The second edition of PPAP, February 1995, does not revise the production parts approval process. A
change summary has been provided as Appendix E. Document control requirements mandate that the
February, 1993, edition of PPAP is obsolete effective September 1, 1995.
While this procedure is intended to cover all situations normally occurring during the part approval
process, there may be questions that arise during implementation. These questions should be directed to
your customers part approval activity. If you are uncertain how to contact the parts approval activity, the
buyer in your customers Purchasing activity can assist you.
As an aid to suppliers in implementing PPAP, all of the forms required by the procedure are available on
diskette and permit entry of all necessary data. Diskettes are available from AIAG at (248) 358-3003.
Please note the customer-specific information in Appendices B, C, and D. These appendices clarify each
customers individual requirements.
The PPAP document represents the efforts of the Chrysler, Ford and General Motors subcommittee
members, B. Ray Daugherty and Robert Panczyk (Chrysler), Stephen Walsh (Ford), and Timothy OBrien
and Dennis Whitman (General Motors). The subcommittee gratefully acknowledges the contributions of
many employees in their respective companies, without whose assistance and continuing support the
procedure could not be effectively implemented.

February, 1995

iii

iv

FOREWORD TO THE FIRST EDITION

This Procedure was developed by the Quality and Part Approval staffs at Chrysler, Ford, and General Motors, working under the auspices of the Automotive Division of the American Society for Quality Control
(ASQC) and the Automotive Industry Action Group (AIAG).
The ASQC/AIAG Task Force charter is to standardize the reference manuals, procedures, reporting formats, and technical nomenclature used by Chrysler, Ford, and General Motors in their respective supplier
quality systems. Accordingly, this Procedure should be used by suppliers in the submission of production
parts for approval to any of these companies.
In the past, Chrysler, Ford, and General Motors each had their own procedures for reviewing supplier submissions of production parts for customer approval (initial samples). Differences between these three
processes resulted in additional demands on supplier resources. To improve upon this situation, Chrysler,
Ford, and General Motors agreed to develop, and, through AIAG, distribute this Procedure. The work
group responsible for the Procedure was led by Rad Smith of Fords Corporate Quality Office.
While this Procedure is intended to cover all situations normally occurring during the sample submission
process, there will be questions that arise during this process. These questions should be directed to your
customers part approval activities. If you are uncertain as to how to contact the parts approval activity,
the buyer in your customers Purchasing office can help.
Please note the customer-specific information in Appendices B, C, and D. These appendices clarify each
customers individual requirements.
The Task Force gratefully acknowledges: the leadership and commitment of Vice Presidents Thomas T.
Stallkamp at Chrysler, Norman F. Ehlers at Ford, and J. Ignasio Lopez de Arriortua of General Motors;
the assistance of the AIAG in the development, production, and distribution of the Procedure; and the
guidance of the Task Force principals Russ Jacobs (Chrysler), Steve Walsh (Ford) and Dan Reid (General
Motors), Radley Smith and the assistance of the ASQC Automotive Reading Team. This team, led by
Tripp Martin (Peterson Spring), reviewed the Manual for technical content and accuracy and made valuable contributions to the form and content. Since the Manual was developed to meet specific needs of the
automotive industry, the ASQC voluntary standards process defined by ASQC policies and procedures
was not used in its development.

February, 1993

TABLE OF CONTENTS
Introduction................................................................................................................................... 1
Section I
I.1 General ................................................................................................................................................................... 2
I.2 PPAP Process Requirements ................................................................................................................................. 2
I.2.1
Significant Production Run ..................................................................................................................... 2
I.2.2
PPAP Requirements ................................................................................................................................. 2
I.2.2.1
Design Records ............................................................................................................................ 3
I.2.2.2
Engineering Change Documents ................................................................................................. 3
I.2.2.3
Engineering Approval .................................................................................................................. 3
I.2.2.4
Design Failure Mode and Effects Analysis (Design FMEA) ........................................................ 4
I.2.2.5
Process Flow Diagrams ............................................................................................................... 4
I.2.2.6
Process Failure Mode And Effects Analysis (Process FMEA) ..................................................... 4
I.2.2.7
Dimensional Results .................................................................................................................... 4
I.2.2.8
Records of Material/Performance Test Results ............................................................................ 5
I.2.2.8.1 Material Test Records .......................................................................................................... 5
I.2.2.8.2 Performance Test Records ................................................................................................... 5
I.2.2.9
Initial Process Studies .................................................................................................................. 6
I.2.2.9.1 General ................................................................................................................................ 6
I.2.2.9.2 Quality Indices ..................................................................................................................... 6
I.2.2.9.3 Acceptance Criteria ............................................................................................................. 7
I.2.2.9.4 Unstable Processes .............................................................................................................. 7
I.2.2.9.5 Processes With One-Sided Specifications or Non-Normal Distributions ........................... 7
I.2.2.9.6 Strategy When Acceptance Criteria Are Not Satisfied ........................................................ 8
I.2.2.10
Measurement System Analysis Studies ......................................................................................... 8
I.2.2.11
Qualified Laboratory Documentation .......................................................................................... 8
I.2.2.12
Control Plan ................................................................................................................................. 8
I.2.2.13
Part Submission Warrant (PSW) .................................................................................................. 9
I.2.2.13.1 Part Weight (Mass) .............................................................................................................. 9
I.2.2.14
Appearance Approval Report ....................................................................................................... 9
I.2.2.15
Bulk Material Requirements Checklist ....................................................................................... 10
I.2.2.16
Sample Production Parts ............................................................................................................ 10
I.2.2.17
Master Sample ........................................................................................................................... 10
I.2.2.18
Checking Aids ............................................................................................................................. 10
I.2.2.19
Customer-Specific Requirements ............................................................................................... 10
I.3 Customer Notification and Submission Requirements ...................................................................................... 11
I.3.1
Customer Notification ........................................................................................................................... 11
I.3.2
Submission to Customer ........................................................................................................................ 12
I.3.3
Situations Where Customer Notification Is Not Required .................................................................... 13
I.4 Submission To Customer - Levels Of Evidence .................................................................................................. 15
I.4.1
Submission Levels ................................................................................................................................ 15
I.5 Part Submission Status ........................................................................................................................................ 17
I.5.1
General ................................................................................................................................................... 17
I.5.2
Customer PPAP Status ........................................................................................................................... 17
I.5.2.1
Full Approval ............................................................................................................................. 17
I.5.2.2
Interim Approval ........................................................................................................................ 17
I.5.2.3
Rejected ..................................................................................................................................... 17
vi

Table of Contents (Continued)

I.6 Record Retention ................................................................................................................................................. 17

Section II
II.1 DaimlerChrysler Corporation-Specific Instructions ......................................................................................... 19
II.2 Ford-Specific Instructions ................................................................................................................................... 24
II.3 General Motors-Specific Instructions ................................................................................................................ 34
II.4 Truck OEM-Specific Instructions ....................................................................................................................... 46

Appendices
Appendix A: Completion of the Part Submission Warrant ....................................................................................... 52
Part Submission Warrant ..................................................................................................................... 53
- Indexed Form ................................................................................................................................ 53
- Blank Form ................................................................................................................................... 54
Appendix B: Completion of the Appearance Approval Report ................................................................................. 56
Appearance Approval Report .............................................................................................................. 57
- Indexed Form ................................................................................................................................ 57
- Blank Form ................................................................................................................................... 58
Appendix C: Dimensional Report ............................................................................................................................. 61
Appendix D: Material Test Report ............................................................................................................................ 63
Appendix E: Performance Test Report ..................................................................................................................... 65
Appendix F: Bulk Material - Specific Requirements ............................................................................................... 67
Appendix G: Tire Industry - Specific Requirements ................................................................................................ 85
Glossary ....................................................................................................................................................................... 87

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viii

Introduction

INTRODUCTION
PURPOSE
Production Part Approval Process (PPAP) defines generic requirements for production part approval, including
production and bulk materials (See Glossary). The purpose of PPAP is to determine if all customer engineering
design record and specification requirements are properly understood by the supplier and that the process has the
potential to produce product consistently meeting these requirements during an actual production run at the
quoted production rate.

APPLICABILITY
PPAP shall apply to internal and external supplier sites (See Glossary) of bulk materials, production materials,
production or service parts. For bulk materials, PPAP is not required unless requested by your customer.
A supplier of standard catalogue production or service parts shall comply with PPAP unless formally waived by
the customer. Tooling shall be maintained for standard catalogue items as long as the items are offered or stated
as being available.
NOTE 1: See the customer-specific instructions in Section II for additional information. All questions
about PPAP should be addressed to the customer product approval activity (See Glossary).
NOTE 2: A customer can formally waive PPAP requirements for a supplier. Waivers for applicable items
will be documented by the customer.

APPROACH
The word shall indicates mandatory requirements. The word should indicates a mandatory requirement with
some flexibility allowed in compliance methodology.
Paragraphs marked NOTE are for guidance in understanding or clarifying the associated requirement. The
word should appearing in a NOTE is for guidance only.
The Glossary contains information that should be used for purposes of compliance to PPAP requirements.

SECTION I
I. 1

GENERAL
The supplier shall obtain full approval (See I.5.2.1) from the customer product approval activity for:
1. a new part or product (i.e., a specific part, material, or color not previously supplied to the specific customer).
2. correction of a discrepancy on a previously submitted part.
3. product modified by an engineering change to design records, specifications, or materials.
4. any situations required by Section I.3.
NOTE: If there is any question concerning the need for production part approval, contact the responsible customer
product approval activity.

I.2
I.2.1

PPAP PROCESS REQUIREMENTS

Significant Production Run

For production parts, product for PPAP shall be taken from a significant production run. This production run shall be
from one hour to eight hours of production, and with the specific production quantity to total a minimum of 300
consecutive parts, unless otherwise specified by the authorized customer quality representative.
This run shall be manufactured at the production site using the tooling, gaging, process, materials, and operators from
the production environment. Parts from each unique production process, e.g. duplicate assembly line and/or work cell,
each position of a multiple cavity die, mold, tool or pattern, shall be measured and representative parts tested.
For bulk materials: No specific number of parts is required. If a sample is required to be submitted, it shall be taken
in a manner as to assure that it represents steady-state operation of the process.
NOTE: For bulk material, production histories of current products may often be used to estimate the initial
process capability or performance of new and similar products. In cases where no production history of a similar
bulk material product or technology exists, a containment plan may be put into effect until sufficient production
has demonstrated capability or performance.

I.2.2

PPAP Requirements

The supplier shall meet all specified requirements, e.g. design record, specifications, and for bulk material, the Bulk
Material Requirements Checklist (see I.2.2.15 and Appendix F). Any results that are outside specification are cause for
the supplier not to submit the parts, documentation and/or records. Every effort shall be made to correct the process so
that all design record requirements are met. If the supplier is unable to meet any of these requirements, the customer
shall be contacted for determination of appropriate corrective action.

Section I

Inspection and testing for PPAP shall be performed by a qualified laboratory (See QS-9000, Third Edition, cl. 4.10.6).
Commercial/independent test laboratories used shall be accredited facilities (see QS-9000, Third Edition, cl. 4.10.7,
and 4.11.2.b.1). When a commercial laboratory is used, the supplier shall submit the test results on the laboratory
letterhead, or the normal laboratory report format. The name of the laboratory that performed the tests, and the date (s)
of the tests, and the standards used to run the tests shall be indicated. Blanket statements of conformance are
unacceptable for any test results.
The supplier shall have the applicable items and records (See QS-9000, Third Edition, cl. 4.16), listed below, for each
part, or family of parts, regardless of the part submission level. These records (I.2.2.1 15 and 19 if any) shall be in a
PPAP part file, or referenced in such file and be readily available. The items below (I.2.2.16 - 18) shall be readily
available for customer use in PPAP.
The supplier shall obtain prior approval (see QS-9000, Third Edition, cl. 4.16) from the customer product approval
activity for exceptions or deviations to PPAP requirements.
NOTE 1: The supplier may, upon special arrangement, have tests performed by the customers laboratories.
NOTE 2: All I.2.2 items or records may not necessarily apply to every customer part number from every
supplier. For example, some parts do not have appearance requirements, and others do not have color
requirements. In order to determine with certainty which items must be included, consult the design record,
e.g. part print, the relevant Engineering documents or specifications, and your customer responsible part
approval activity.

I.2.2.1 Design Records

The supplier shall have all design records for the saleable product, including design records for components or details
of the saleable product. Where the design record, e.g. CAD/CAM math data, part drawings, specifications, is in
electronic format, e.g. math data, the supplier shall produce a hard copy (e.g. pictorial, geometric dimensioning &
tolerancing [GD&T] sheets, drawing) to identify measurements taken.
NOTE 1: For any saleable product, part or component, there will only be one design record, regardless of who
has design-responsibility. The design record may reference other documents making them part of the design
record.
NOTE 2: For bulk materials, the design records may include identification of raw materials, formulations,
processing steps and parameters, and final product specifications or acceptance criteria. If dimensional results
do not apply, then CAD/CAM requirements are also not applicable.

I.2.2.2 Any authorized Engineering Change documents

The supplier shall have any authorized engineering change documents not yet recorded in the design record but
incorporated in the product, part or tooling.

I.2.2.3 Engineering Approval, when required

Where specified by the design record, the supplier shall have evidence of customer engineering approval.
NOTE: For bulk materials, this requirement is satisfied by a signed Engineering Approval line item on the
Bulk Material Requirements Checklist (Appendix F) and/or inclusion on a customer maintained list of approved
materials.

I.2.2.4 Design Failure Mode and Effects Analysis (Design FMEA), if the supplier is design responsible. See
Potential Failure Mode and Effects Analysis reference manual.
The supplier shall have a Design FMEA developed in accordance with, and compliant to, QS-9000 Third Edition
requirements for parts or materials for which they are design-responsible. For bulk materials, a Design Matrix (See
Appendix F), when required by the Bulk Material Requirements Checklist (see I.2.2.15), shall be prepared prior to
developing the Design FMEA.
NOTE: For bulk materials, Design FMEA rankings (Severity, Occurrence, Detection) as discussed in Appendix
F, may be utilized to provide proper differentiation of risk factors.

I.2.2.5 Process flow diagrams

The supplier shall have a process flow diagram in supplier-specified format that clearly describes the production process
steps and sequence, as appropriate and meets the specified customer needs, requirements and expectations (see Advanced
Product Quality Planning and Control Plan reference manual). For bulk materials, an equivalent to a Process Flow
Diagram is a Process Flow Description.
NOTE: Process flow diagrams for families of similar parts are acceptable if the new parts have been reviewed
for commonality.

I.2.2.6

Process Failure Mode and Effects Analysis (Process FMEA). See Potential Failure Mode and Effects
Analysis reference manual.

The supplier shall have a Process FMEA developed in accordance with, and compliant with QS-9000 Third Edition
requirements.
NOTE: A single Design or Process FMEA may be applied to a process manufacturing a family of similar parts
or materials. For bulk materials, see Appendix F for a severity, occurrence, and detection ranking system to
provide proper differentiation of risk factors.

I.2.2.7 Dimensional results

The supplier shall provide evidence that dimensional verifications required by the design record and the Control Plan
have been completed and results indicate compliance with specified requirements. The supplier shall have dimensional
results for each unique manufacturing process, e.g. cells or production lines and all cavities, molds, patterns or dies (see
I.2.2.13).
The supplier shall indicate the date of the design record, change level, and any authorized engineering change document
not yet incorporated in the design record to which the part was made.
The supplier shall identify one of the parts measured as the master sample (See I.2.2.17).
The supplier shall record the change level, drawing date, supplier name and part number on all auxiliary documents
(e.g. supplementary layout results sheets, sketches, tracings, cross sections, CMM inspection point results, geometric
dimensioning and tolerance sheets, or other auxiliary drawings used in conjunction with the part drawing). Copies of
these auxiliary materials shall accompany the dimensional results according to the Retention/Submission Requirements
Table. A tracing shall be included when an optical comparator is necessary for inspection.

Section I

NOTE 1: All dimensions (except reference dimensions), characteristics, and specifications as noted on the
design record and Control Plan should be listed in a convenient format with the actual results recorded. The
Dimensional Results form in Appendix C, or a checked print where the results are legibly written on a part
drawing including cross-sections, tracings, or sketches as applicable may be utilized for this purpose.
NOTE 2: Dimensional results typically do not apply to bulk materials.

I.2.2.8 Records of material / performance test results

The supplier shall have records of material and/or performance test results for tests specified on the design record or
Control Plan.

I.2.2.8.1 Material Test Results

The supplier shall perform tests for all part(s) and product material(s) when chemical, physical, or metallurgical
requirements are specified by the design record or Control Plan.
All tests required by the design record and related specifications should be listed in a convenient format along
with the quantity tested and the actual results of each test. Also indicate any authorized engineering change
documents that have not yet been incorporated in the design record.
The material test report (See Appendix D) shall indicate the:
design record change level of the parts tested, and the number, date, and change level of the specifications
to which the part was tested;
date on which the testing took place;
material subcontractors name and, when required by your customer, their supplier code number for the
material from the customer-approved subcontractor list.
For products with customer-developed material specifications and a customer-approved subcontractor list, the
supplier shall procure materials and/or services (e.g. painting, plating, heat-treating) from subcontractors on that
list.

I.2.2.8.2 Performance Test Results

The supplier shall perform tests for all part(s) or product material(s) when performance or functional requirements
are specified by the design record or Control Plan.
The test report shall indicate:
the design record change level of the parts tested, the number, date, and change level of the specifications
to which the part was tested;
any authorized engineering change documents that have not yet been incorporated in the design record;
the date on which the testing took place.
NOTE: Results for all tests required by the design record or related specifications should be listed in an
understandable format and include the quantity tested. The Performance Test Results form in Appendix E
may be used for this purpose.

I.2.2.9 Initial Process Studies

I.2.2.9.1

General

The 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 supplier.
The supplier shall perform measurement system analysis to understand how measurement error is affecting the
study measurements. (See I.2.2.10 and Measurement Systems Analysis reference manual )
NOTE 1: The purpose of this requirement is to determine if the production process is likely to produce
product that will meet the customers requirements. The initial process study is focused on variables not
attributes data. Assembly errors, test failures, surface defects are examples of count time data, which is
important to understand, but is not covered in this initial study. To understand the performance of
characteristics monitored by attribute data will require more data collected over time.
NOTE 2: The index for estimating process capability or performance will be agreed upon by the customer
and supplier. Cpk and Ppk are described below. Other methods more appropriate for certain processes or
products may be substituted with prior customer approval.
NOTE 3: Initial process studies are short-term and will not predict the effects of time and variation in
people, materials, methods, equipment, measurement systems, and environment. Even for these short-term
studies, it is important to collect and analyze the data in the order produced using control charts.
NOTE 4: For those characteristics that can be studied using X-bar and R charts, a short term study should
be based on a minimum of 25 subgroups containing at least 100 readings from consecutive parts of the
significant production run (See I.2.1). The initial data requirements may be replaced by longer-term results
from the same or similar processes, with customer concurrence. For certain processes, alternative analytical
tools such as individual and moving range charts may be appropriate and permitted with prior customer
approval.

I.2.2.9.2 Quality Indices

Initial process studies should be summarized with capability or performance indices, if applicable.
NOTE 1: The initial process study results are dependent on the purpose of the study, data normality
(assumption is normality and two sided specifications), method of data acquisition, sampling, amount of
data, demonstration of statistical control, etc. It is assumed that anyone trying to apply the principles listed
below has reviewed the capability section in the Statistical Process Control reference manual and
understands basic principles of stability from an average and range chart perspective. For guidance on
items listed below, contact the customer responsible part approval activity. See Statistical Process Control
reference manual, Chapter 2, Section 5, D: Suggested Use of Process Measures.
Cpk- The capability index for a stable process. The estimate of sigma is based on within subgroup
variation (R-bar/d2 or S-bar/c4).
Ppk- The performance index. The estimate of sigma is based on total variation (all of individual sample
data using the standard deviation [root mean square equation], s).
Short-term studies. The purpose of the initial process study is to understand the process variation, not just
to achieve a specific index value. When historical data is available or enough initial data exist to plot a
control chart (at least 100 individual samples), Cpk can be calculated when the process is stable. For
6

Section I

chronically unstable processes with output meeting specifications and a predictable pattern, Ppk should be
used. When not enough data is available ( <100 samples) contact the customer responsible part approval
activity to develop a suitable plan.
Refer to the Statistical Process Control reference manual for information on evaluating stability and a
detailed description of Ppk and Cpk.
NOTE 2: For bulk material, the supplier should obtain customer agreement regarding the appropriate
techniques for initial process studies, if required, in order to determine an effective estimate of capability.

I.2.2.9.3 Acceptance Criteria For Initial Study

The supplier shall use the following as acceptance criteria for evaluating initial process study results for processes
that appear stable:
Results

Interpretation

Index Value > 1.67

The process currently meets customer requirements. After

approval, begin production and follow Control Plan.

1.33 (Index Value) 1.67

The process is currently acceptable, but may require some

improvement. Contact your customer and review results of the
study. This will require changes to the Control Plan, if not
improved prior to start of volume production.

Index Value < 1.33

The process does not currently meet the acceptance criteria.

Contact the appropriate customer representative for a review of
the study results.

NOTE: Cpk can only be used for stable processes.

I.2.2.9.4

Unstable Processes

Depending on the nature of the instability, an unstable process may not meet customer requirements. The supplier
shall identify, evaluate and, wherever possible, eliminate special causes of variation prior to PPAP submission.
The supplier shall notify the customer of any unstable processes that exist and shall submit a corrective action
plan to the customer prior to any submission.
NOTE: For bulk materials, if historical data shows that similar processes are chronically unstable, and
previous actions have been unable to achieve stability, corrective action plans may not be warranted.

I.2.2.9.5 Processes With One-Sided Specifications or Non-Normal Distributions

The supplier shall determine with the customer an alternative acceptance criteria for processes with one-sided
specifications or non-normal distributions.
NOTE 1: The above mentioned acceptance criteria (I.2.2.9.3) assumes normality and a two-sided
specification (target in the center). When this is not true, using this analysis may result in unreliable
information. This alternate acceptance criteria could require a different type of index 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.
7

NOTE 2: For bulk materials, non-normal distributions are generally found after routine plotting of
histograms of process data. Quality indices should not be computed because the values obtained may be
misleading.

I.2.2.9.6 Strategy When Acceptance Criteria Are Not Satisfied

The supplier shall contact the customer if the process cannot be improved.
If acceptance criteria cannot be attained by the PPAP submission promise date, the supplier shall submit to the
customer for approval a corrective action plan and a modified Control Plan normally providing for 100% inspection
(see QS-9000, Third Edition, cl. 4.2.3.7). See QS-9000, Third Edition, cl. 4.2.5, Continuous Improvement for
additional techniques. Continue variation reduction efforts until a Ppk or Cpk of 1.33 or greater is achieved, or
until customer full approval is received.
NOTE: For bulk materials, a product that does not meet the capability requirements as defined by the
customer may be allowed to go forward into production. For example, if the supplier relies on 100%
inspection, using a test method as agreed to by the customer, then approval may be granted. 100% inspection
for bulk material means an evaluation of a sample(s) of product from a continuous process or
homogeneous batch which is representative of the entire production run. If historical data show that
similar processes do not meet the acceptance criteria, corrective action plans may not be warranted.

I.2.2.10 Measurement System Analysis Studies

The supplier shall have applicable Measurement System Analysis studies, e.g. gage R&R, bias, linearity, stability
studies, for all equipment used for new or modified gages, measurement, and test equipment. (See I.2.2.9.1 and
Measurement Systems Analysis reference manual)
NOTE: For bulk materials, Measurement System Analysis may not apply. Customer agreement on actual
requirements should be obtained during the planning phase.

I.2.2.11 Qualified Laboratory Documentation

The supplier shall have a laboratory scope and documentation showing that laboratories used comply with QS-9000,
Third Edition, cl. 4.10.6 and/or 4.10.7.

I.2.2.12 Control Plan (See Advance Product Quality Planning and Control Plan reference manual and QS-9000,
Third Edition, cl. 4.2.3.7)
The supplier shall have a Control Plan that defines all controls used for process control and complies with QS-9000
(See QS-9000, Third Edition cl. 4.9).
NOTE 1: Control Plans for families of similar parts are acceptable if the new parts have been reviewed for
commonality.
NOTE 2: Certain customers require Control Plan approval, e.g. customer signature on the Control Plan, prior to
submission. See QS-9000, Third Edition, Section II, Customer-specific appendices.

Section I

I.2.2.13 Part Submission Warrant (PSW)

Upon satisfactory completion of all required measurements and tests, the supplier shall record the required information
on the Part Submission Warrant (PSW).
A separate PSW shall be completed for each customer part number unless otherwise agreed to by the customer.
If production parts will be produced from more than one cavity, mold, tool, die, pattern, or production process, e.g. line
or cell, the supplier shall complete a dimensional evaluation (see I.2.2.7) on one part from each. The specific cavities,
molds, line, etc., shall then be identified in the Mold/Cavity/Production Process line on a PSW, or in a PSW attachment.
The supplier shall verify that all of the measurement and test results show conformance with customer requirements
and that all required documentation is available (or, for Level 2, 3, and 4, is included in the submission). A responsible
supplier official shall approve the PSW and provide date, title, and telephone number.
NOTE 1: One warrant per customer part number can be used to summarize many changes providing that the
changes are adequately documented, and the submission is in compliance with customer program timing
requirements.
NOTE 2: PSWs may be submitted electronically in compliance with customer requirements, if any.

I.2.2.13.1 Part Weight (Mass)

The supplier shall record the part weight of the part as shipped on the PSW, measured and expressed in kilograms
to four significant decimal places (0.0000) unless otherwise specified by the customer. The weight shall not
include shipping protectors, assembly aides, or packaging materials. To determine part weight, the supplier
shall individually weigh ten randomly selected parts, calculate and report the average weight. At least one part
shall be measured from each cavity, tool, line or process to be used in product realization.
NOTE: This weight is used for vehicle weight analysis only and does not affect the approval process.
Where there is no production or service requirement for at least ten parts, the supplier should use the
required number for calculation of the average part weight. For bulk materials, the part weight field is not
applicable.

I.2.2.14 Appearance Approval Report (AAR)

A separate Appearance Approval Report (AAR) shall be completed for each part or series of parts for which a submission
is required if the product/part has appearance requirements on the design record.
Upon satisfactory completion of all required criteria, the supplier shall record the required information on the AAR.
The completed AAR and representative production products/parts shall be submitted to the location specified by your
customer to receive disposition. AARs (complete with part disposition and customer signature) shall then accompany
the PSW at the time of final submission based upon the submission level requested. Additional requirements may be
recorded in customer-specific requirements.
NOTE 1: AAR typically applies only for parts with color, grain, or surface appearance requirements.
NOTE 2: Certain customers may not require entries in all AAR fields. See Appendix B for detailed instructions
on completing the AAR.

I.2.2.15 Bulk Material Requirements Checklist (applies only to bulk material PPAP)
For bulk material, the Bulk Material Requirements Checklist (see Glossary) shall be jointly agreed upon by the customer
and supplier. All specified requirements shall be completed unless specifically indicated as Not Required (NR) on
the checklist.
NOTE: Additional requirements may be specified on the checklist.

I.2.2.16 Sample Production Parts

The supplier shall provide sample product as requested by the customer and as defined by the submission request.

I.2.2.17 Master Sample

The supplier shall retain a master sample for the same period as the production part approval records, or a) until a new
master sample is produced for the same customer part number for customer approval, or b) where a master sample is
required by the design record, Control Plan or inspection criteria, as a reference or standard to be used. The master
sample shall be identified as such, and shall show the customer approval date on the sample. The supplier shall retain
a master sample for each position of a multiple cavity die, mold, tool or pattern, or production process unless otherwise
specified by the customer.
NOTE 1: When part size, sheer volume of parts, etc. makes storage of a master sample difficult, the sample
retention requirements may be modified or waived in writing by the responsible customer product approval
activity. The purpose of the master sample is to assist in defining the production standard, especially where data
is ambiguous or in insufficient detail to fully replicate the part to its original approved state.
NOTE 2: Many bulk material properties are by their nature time dependent, and if a master sample is required,
it may consist of the manufacturing record, test results, and certificate of analysis of key ingredients, for the
approved submission sample. (see Appendix F).

I.2.2.18 Checking Aids

If requested by the customer, the supplier shall submit with the PPAP submission any part-specific assembly or component
checking aid.
The supplier shall certify that all aspects of the checking aid agree with part dimensional requirements. The supplier
shall document all released engineering design changes that have been incorporated in the checking aid at the time of
submission. The supplier shall provide for preventive maintenance of any checking aids for the life of the part (see
Glossary - Active Part).
Measurement system analysis studies, e.g. gage R & R, accuracy, bias, linearity, stability studies, shall be conducted in
compliance with customer requirements. (See I.2.2.10 and Measurement Systems Analysis reference manual).
NOTE: Checking aids can include fixtures, gages, models, templates, mylars specific to the product being
submitted. Checking aids, etc. typically do not apply to Bulk Materials.

I.2.2.19 Customer-Specific Requirements

The supplier shall have records of compliance to all applicable customer specific requirements. (See Section II). For
bulk materials, any customer-specific requirements shall be documented on the Bulk Material Requirements Checklist.
10

Section I

I.3

CUSTOMER NOTIFICATION AND SUBMISSION REQUIREMENTS

I.3.1

Customer Notification

The supplier shall notify the responsible customer product approval activity of any design and process changes as
indicated in the table below. The customer may subsequently elect to require a submission for PPAP approval. (see
Table I.3.1)

Table I.3.1
Requirement

Clarification or examples

1. Use of other construction or material than was

used in the previously approved part or product.

For example, other construction as documented on a

deviation (permit) or included as a note on the design
record and not covered by an engineering change as
described in Table I.3.2 #3.

2. Production from new or modified tools (except

perishable tools), dies, molds, patterns, etc.,
including additional or replacement tooling.

This requirement only applies to tools which due to

their unique form or function, can be expected to
influence the integrity of the final product. It is not
meant to describe standard tools (new or repaired),
such as standard measuring devices, drivers (manual
or power), etc.

3. Production following refurbishment or

rearrangement of existing tooling or equipment.

Refurbishment means the reconstruction and/or

modification of a tool or machine or to increase the
capacity, performance, or change its existing function.
This is not meant to be confused with normal
maintenance, repair or replacement of parts, etc., for
which no change in performance is to be expected and
post repair verification methods have been established.
Rearrangement is defined as activity which changes
the sequence of product/process flow from that
documented in the process flow diagram (including the
addition of a new process).
Minor adjustments of production equipment may be
required to meet safety requirements such as,
installation of protective covers, elimination of potential
ESD risks, etc. These changes can be made without
customer approval unless the process flow is changed
as a result of this adjustment.

4. Production from tooling and equipment

transferred to a different plant location or from an
additional plant location.

Production process tooling and/or equipment

transferred between buildings or facilities in one or
more locations.

5. Change of subcontractor for parts, non-equivalent

materials, or services (e.g.: heat-treating, plating)
that affect customer fit, form, function, durability,
or performance requirements.

Suppliers are responsible for approval of

subcontracted material and services that do not affect
customer fit, form, function, durability, or
performance requirements.

11

Requirement

Clarification or examples

6. Product produced after the tooling has been

inactive for volume production for twelve months
or more.

For product that has been produced after tooling has

been inactive for twelve months or more:
Notification is required when the part has had no
active purchase order and the existing tooling has
been inactive for volume production for twelve
months or more. The only exception is when the part
has low volume, e.g. service or specialty vehicles.
However, a customer may specify certain PPAP
requirements for service parts.

7. Product and process changes related to

components of the production product
manufactured internally or manufactured by
subcontractors that impact fit, form, function,
performance, and/or durability of the salable
product. Additionally, the supplier shall concur
with any requests by a subcontractor before
submission to the customer.

Any change that affects customer requirements for

fit, form, function, performance, and/or durability
requires notification to the customer.

8. For bulk materials only:

These changes would normally be expected to have

an effect on the performance of the product.

NOTE: The fit, form, function, performance,

and/or durability requirements should be part
of customer specifications as agreed on during
contract review.

New source of raw material with special

characteristics from new or existing subcontractor.
Change in product appearance attributes where
there is no appearance specification.
Revised parameters in the same process (outside
PFMEA parameters of the approved product,
includes packaging).
Change outside of DFMEA (product composition,
ingredient levels) of the approved product.
9. Change in test/inspection method new technique
(no effect on acceptance criteria)

I.3.2

For change in test method, supplier should have

evidence that the new method provides results
equivalent to the old method.

Submission to Customer

The supplier shall submit for PPAP approval prior to the first production shipment in the following situations unless the
responsible product approval activity has waived this requirement (see Table I.3.2).
The supplier shall review and update, as necessary, all applicable items in the PPAP file to reflect the production
process, regardless of whether or not the customer requests a formal submission. The PPAP file shall contain the name
of the responsible customer product approval activity person granting the waiver and the date.

12

Section I

Table I.3.2
Requirement

Clarification or examples

1. A new part or product (i.e. a specific part,

material, or color not previously supplied to the
specific customer.)

Submission is required for a new product (initial

release) or a previously approved product which has a
new or revised (e.g. suffix) product/part number
assigned to it. A new part/product or material added
to a family may use appropriate PPAP documentation
from a previously fully approved part within the same
product family.

2. Correction of a discrepancy on a previously

submitted part.

Submission is required to correct any discrepancies

on previously submitted part.
A discrepancy can be related to:
The product performance against the
customer requirement
Dimensional or capability issues
Subcontractor issues
Full Approval of a part replacing an interim
approval
Testing, including material, performance,
engineering validation issues

3. Engineering change to design records,

specifications, or materials for production product/
part number(s).

Submission is required on any engineering change to

production product/part design records,
specifications or materials.

4. For Bulk Materials only:

Process technology new to the supplier, not
previously used for this product.

I.3.3

Situations Where Customer Notification Is Not Required

Customer notification and submission (e.g. PSW) is not required for the situations described in the below table. The
supplier is responsible to track the changes and/or improvements and update any affected PPAP documentation. The
following examples are of manufacturing and quality systems situations and/or improvements.
NOTE: Customer notification is required any time customer product requirements for fit, form, function, durability
and performance are affected.

13

Table I.3.3
Requirement

Clarification or examples

1. Changes to component level drawings,

manufactured internally or manufactured by subcontractors, that do not impact the design record
for the product supplied to the customer.

Changes do not affect customer fit, form, function,

durability or performance requirements.

2. Tool movement within the same plant (used in

equivalent equipment, no change in process flow,
no disassembly of the tool) or equipment
movement within the same plant (same equipment,
no change in process flow).

Based on lean manufacturing initiatives, some

equipment is designed for mobility, i.e. on wheels
with quick disconnects. Cell configurations or
location within a department may be changed
without affecting process flow. No change made to
process flow or control plan.

3. Changes in equipment (same process flow with

same basic technology or methodology).

Examples are new equipment, additional equipment,

replacement, or change in equipment size.

4. Identical gage replacement.

Gages replaced as a part of a gage maintenance or

calibration system.

5. Rebalance of operator job content with no change

in process flow.

Lean manufacturing allows for rebalancing job

content to eliminate bottleneck issues.

6. Changes resulting in reduced RPN on PFMEA

(with no change to process flow).

Examples include added controls, increased sample

size and frequency, and error-proofing installation.

7. For Bulk Materials only:

These changes are within the product/process

parameters previously defined and/or approved.
Tracking by supplier is sufficient to assure
continuous product performance in the defined
application.

Changes within the DFMEA (formulation range,

packaging design) of the approved product.
Changes within PFMEA (process parameters).
Changes which do not significantly affect a
Special Characteristic (including shift in target
point within approved specification limits).
Changes in approved commodity ingredient (no
change in Chemical Abstract Service [CAS]
number within CAS family) and/or change in
approved subcontractors.
Change in subcontractor producing location of a
raw material that has no Special Characteristics.
New source of raw material that has no Special
Characteristics.
Tightening of Customer/Sales acceptance
tolerance limits.

14

Section I

I.4

SUBMISSION TO CUSTOMER - LEVELS OF EVIDENCE

I.4.1 Submission Levels

The supplier shall submit the items and/or records specified by the level as requested by the customer:
Level 1 -

Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to the
customer.

Level 2 -

Warrant with product samples and limited supporting data submitted to the customer.

Level 3 -

Warrant with product samples and complete supporting data submitted to the
customer.

Level 4 -

Warrant and other requirements as defined by the customer.

Level 5 -

Warrant with product samples and complete supporting data available for review at the suppliers
manufacturing location.

See Retention/Submission Requirements Table I.4.1 for exact requirements for each level.
The supplier shall use level 3 as the default level for all submissions unless specified otherwise by the responsible
customer product approval activity. A supplier of bulk material only shall use level 1 as the default level for all bulk
material PPAP submissions unless specified otherwise by the responsible customer product approval activity.
NOTE 1: The customer will identify the submission level that will be used with each supplier, or supplier and
customer part number combination. Different customer locations may assign different submission levels to the
same supplier manufacturing location.
NOTE 2: All of the forms referenced in this document may be replaced by computer-generated facsimiles.
Acceptability of these facsimiles is to be confirmed with the responsible part approval activity prior to the first
submission. The Automotive Industry Action Group (AIAG) offers for sale a diskette with the PPAP/APQP/
FMEA forms.

15

Retention/Submission Requirements Table I.4.1

(Normative - See I.2.2 Note 2)
Submission Level
Requirement

Level 1

Level 2

Level 3

Level 4

Level 5

Design Records of Saleable Product

- for proprietary components /details

- for all other components/details

2.

Engineering Change Documents, if any

3.

Customer Engineering approval, if required

4.

Design FMEA (See I.2.2.4)

5.

Process Flow Diagrams

6.

Process FMEA

7.

Dimensional Results

8.

Material, Performance
Test Results

9.

Initial Process Study

10.

Measurement System Analysis Studies

11.

Qualified Laboratory Documentation

12.

Control Plan

13.

Part Submission Warrant (PSW)

14.

Appearance Approval Report, (AAR)

if applicable

1.

15.

Bulk Material Requirements Checklist

(for bulk material PPAP only)

16.

Sample Product

17.

Master Sample (See I.2.2.17)

18.

Checking Aids

19.

Records of Compliance
With Customer-Specific Requirements

S = The supplier shall submit to designated customer product approval activity and retain a copy of records or documentation items at
appropriate locations, including manufacturing.
R = The supplier shall retain at appropriate locations, including manufacturing, and make readily available to the customer representative
upon request.
*

= The supplier shall retain at appropriate locations, and submit to customer upon request.

16

Section I

I.5

PART SUBMISSION STATUS

I.5.1

General

The supplier shall be notified by the customer of the disposition of the submission. After production part approval,
suppliers shall assure that future production continues to meet all customer requirements.
NOTE: For those suppliers that have been classified as self certifying by a specific customer, submission of
the required documentation showing supplier approval will be considered as customer approval unless the supplier
is advised otherwise.

I.5.2

Customer PPAP Status

I.5.2.1 Full Approval indicates that the part or material meets all customer specifications and requirements. The
supplier is therefore authorized to ship production quantities of the product subject to releases from the customer
scheduling activity.
I.5.2.2 Interim Approval permits shipment of material for production requirements on a limited time or piece quantity
basis. Interim Approval will only be granted when the supplier has:
- clearly defined the root cause of the non-conformities preventing production approval; and,
- prepared an interim approval action plan agreed upon by the customer. Re-submission to obtain full
approval is required.
Material covered by an interim approval that fails to meet the agreed-upon action plan either by the expiration date or
the shipment of the authorized quantity will be rejected. No additional shipments are authorized unless an extension of
the interim approval is granted.
For bulk materials, the supplier shall use the Bulk Material Interim Approval form, or its equivalent (See Appendix
F).
I.5.2.3 Rejected means that the submission, the production lot from which it was taken, and accompanying
documentation do not meet customer requirements. Corrected product and documentation shall be submitted and
approved before production quantities may be shipped.

I.6

RECORD RETENTION

Production part approval records (see I.2.2), regardless of submission level, shall be maintained for the length of time
that the part is active (See Glossary) plus one calendar year.
The supplier shall ensure that the appropriate PPAP records from a superseded part PPAP file are included, or referenced
in the new part PPAP file.
NOTE: An example of an appropriate document/record that should be carried forward from the old file to the
new part file would be a material certification from a raw material supplier for a new part that represents only a
dimensional change from the old part number. This should be identified by conducting a PPAP gap analysis
between the old and new part numbers.

17

18

Section II - DaimlerChrysler Specific Instructions

SECTION II
II.1

DaimlerChrysler Corporation-Specific Instructions

Unless superseded by specific written direction from the DaimlerChrysler Corporation Procurement and Supply
representative or by engineering drawing and specification requirements the following instructions apply.
II.1.1

SUBMISSION LEVELS

Suppliers designated by DaimlerChrysler Corporation as self-certified are to follow the guidelines for Submission
Level 1. All others are to follow the guidelines for Submission Level 2 unless otherwise instructed by your Component
Procurement and Supplier Quality representative. When conducting a bulk material PPAP, use conventions as detailed
in Section I in this manual.
II.1.2 SUBMISSION
All suppliers submitting their PSWs for PRODUCTION PARTS designated for use at all DaimlerChrysler Corporation
facilities must follow the directions as found on the DaimlerChrysler Corporation Supply Partner Information Network,
(SPIN), on the World Wide Web. This information can be accessed from the PRISM Home Page. Click on PPAP
Business Processes.

II.1.3

All suppliers providing material for any DaimlerChrysler PILOT build must submit a PSW utilizing the directions
found in the DaimlerChrysler Corporation Supply Partner Information Network, (SPIN), on the World Wide
Web. This information can be accessed from the PRISM Home Page. Click on PPAP Business Processes.
Suppliers must submit their PSWs per table I.3.1 in this manual as required by DaimlerChryslers Forever
Requirements as well as PSWs for new and modified parts.
CHECKING AIDS

Checking aids must be submitted when required to perform the dimensional inspection of the part being submitted.
Contact your DaimlerChrysler Corporation part approval representative to determine if this requirement can be waived.
II.1.4

APPEARANCE APPROVAL REQUIREMENTS

The supplier must complete the Appearance Approval Report if the design records include any appearance features
(e.g.. Color, Grain, Finish, Appearance Standards, or Mastering Standards). Prior to submission with the Warrant, the
supplier must obtain a DaimlerChrysler Corporation Design Office approval signature on the Appearance Approval
Report.
NOTE: Both Interior and Exterior parts are included in the Appearance Approval Report procedure.
Suppliers of external sheet metal body panels must follow DaimlerChrysler Corporate Procedure 90-57 for surface
appearance review.

19

COMPLETION OF THE APPEARANCE APPROVAL REPORT

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

17)

18)
19)
20)
21)
22)

23)
24)
25)
26)
27)
28)

End Item Number: Engineering released part number and engineering change level.
Supplier Name: Enter component and end item suppler.
Manufacturing Location: Location where part was manufactured or assembled.
Date: Date of submission.
Component Part Number: Engineering released component part number.
Supplier Contact: Supplier representative responsible for submission.
Supplier Phone Number: Supplier contact phone number.
Application (Vehicle): List model year(s) and vehicles in which part is used.
Component Name: Enter the component part name.
Supplier Code: DaimlerChrysler assigned code for supplier location where the part was manufactured or assembled.
Buyer Code: Enter the code for specific buyer of end item.
Customer Engineer: Enter the name of the DaimlerChrysler Release Engineer responsible for the part being submitted.
Texture ID: Enter DaimlerChrysler identification number of texture (when applicable).
Texture Source: Enter name and location of texturing source (when applicable).
Texture Location on Part: Enter area(s) of grain(s) delineation (when applicable).
Surface and Texture Evaluation (when applicable):
a) DaimlerChrysler Design Office manager (or designated representative) approval of pre-textured surface.
b) DaimlerChrysler Release / Product Engineer authorization to proceed with texture.
c) DaimlerChrysler Design Office mastering studios designated representative authorization to proceed, including a
signed part.
d) DaimlerChrysler Design Office mastering studios designated representative post texture approval
Note: Texturing can not proceed without authorized signatures in 16a, 16b, and 16c.
e) DaimlerChrysler Design Office manager (or designated rep.) decision as to ornamentation and graphics approval
requirements.
Base or Raw Material DaimlerChrysler Spec. # and Supplier / Supplier # / Lot # : Enter DaimlerChrysler material
specification code, supplier name, supplier product code, and lot number of the material used to make the submitted
part.
Paint or Colorant DaimlerChrysler Spec. # and Supplier / Supplier # / Lot # : Enter DaimlerChrysler Paint or
Colorant Spec. #, supplier name, supplier product code, and lot number of the material used to make the submitted part.
Master # and Color: Enter full master identification and color number as released by DaimlerChrysler. (Refer to Trim
Release).
Ref. Master Type and Date: Enter reference master type and date as supplied by DaimlerChrysler for visual direction.
Tristimulus and Gloss Part Data: List numerical (colorimeter) data of submission part as compared to the customerauthorized master. Enter gloss data using 60-degree geometry measuring equipment.
Customer Comments / Approval Status / Initials / Date: Customer comments regarding color and gloss disposition
and/or color direction. Customer will indicate whether the color and gloss are accepted (A) or rejected (R), initial and
date the form. Note: Final approval signature is still required.
Supplier Signature, Phone Number & Date: Supplier designated representative accountable for the certification that
the submitted parts and document information is accurate and meets all the requirements specified.
Type of Ornamentation, Graphics Required and Surface Tactility: Name / process type cluster graphics, badges,
labels, etc. / pad transfer, hot stamp, lithograph, heat transfer, silk screen, laser etch, soft touch feel, etc.
Customer Approval Signature & Date: Design Office designated rep. Approval of identified ornamentation, graphics
and surface tactility.
Comments: General comments of importance to be initialed and dated.
Customer Interim Approval Signature: DaimlerChrysler Design Office Interim approval of end item or component
part. Allows IAA usage at this submission level.
Customer Final Approval Signature: DaimlerChrysler Design Office Final approval of end item or component part.
ALL SIGNATURES AND DATES (areas 16 (if applicable), 22, 25 (if applicable) & 27)
MUST BE COMPLETED FOR FULL AAR APPROVAL.
THE AREAS INSIDE THE BOLD LINES ARE FOR CUSTOMER USE ONLY

20

13

TEXTURE
SOURCE

E/C
LEVEL
E/C
LEVEL

14

TEXTURE LOCATION
ON PART

21

January 1, 1999
AAR.doc

26

DL*

17

APPROVALS

16

MASTERING STUDIO TEXTURE

ORIENTATION
MASTERING STUDIO
POST TEXTURE
ORNAMENTATION AND GRAPHICS

ENGINEERING PRE-TEXTURE
CONCURRENCE

DESIGN STUDIO
PRE-TEXTURE SURFACE

Da*
Db*
De*
CMC

TRISTIMULUS & GLOSS PART DATA

18

GLS

21

PHONE

b.
c.
d.

CUSTOMER COMMENTS

27

28

CUSTOMER FINAL APPROVAL

SIGNATURE

25

CUSTOMER INTERIM APPROVAL

SIGNATURE

CUSTOMER APPROVAL
SIGNATURE

DATE
APPLICATION
(VEHICLE)
CUSTOMER
ENGINEER
12

4
8

22

REQD

APPROVAL
STATUS

e.

DATE

DATE

DATE

DATE

CUSTOMER
INITIALS / DATE

CUSTOMER REPRESENTATIVE SIGNATURE AND DATE

a.

NOT REQD

ORNAMENTATION, GRAPHICS AND SURFACE TACTILITY

BOLD BOXED AREAS FOR CUSTOMER USE ONLY

COMMENTS:

24

DATE

TYPE OF ORNAMENTATION
AND GRAPHICS REQUIRED

TYPE

20

23

COLOR

REF. MASTER

SUPPLIER APPROVAL
SIGNATURE

19

15

11

MATERIAL, COLOR, AND GLOSS EVALUATION

PAINT OR COLORANT DAIMLERCHRYSLER SPEC. # AND SUPPLIER / SUPPLIER # / LOT #

MASTER

MANUFACTURING
LOCATION
SUPPLIER
PHONE
BUYER
CODE

SURFACE AND TEXTURE EVALUATION

10

APPEARANCE APPROVAL REPORT

SUPPLIER
NAME
SUPPLIER
CONTACT
SUPPLIER
CODE

BASE OR RAW MATERIAL DAIMLERCHRYSLER SPEC. # AND SUPPLIER / SUPPLIER # / LOT #

TEXTURE
ID

END ITEM
NUMBER
COMPONENT
PART NUMBER
COMPONENT
NAME

DaimlerChrysler

Section II - DaimlerChrysler Specific Instructions

22

TEXTURE
SOURCE

E/C
LEVEL
E/C
LEVEL

TEXTURE LOCATION
ON PART

COLOR

January 1, 1999
AAR.doc

TYPE
DATE

REF. MASTER
DL*
Da*
Db*
De*
CMC

TRISTIMULUS & GLOSS PART DATA

GLS

PHONE

CUSTOMER COMMENTS

NOT REQD

DATE

DATE

DATE

CUSTOMER
INITIALS / DATE

CUSTOMER FINAL APPROVAL

SIGNATURE

APPROVAL
STATUS

DATE

REQD

CUSTOMER INTERIM APPROVAL

SIGNATURE

CUSTOMER APPROVAL
SIGNATURE

DATE
APPLICATION
(VEHICLE)
CUSTOMER
ENGINEER

CUSTOMER REPRESENTATIVE SIGNATURE AND DATE

ORNAMENTATION, GRAPHICS AND SURFACE TACTILITY

BOLD BOXED AREAS FOR CUSTOMER USE ONLY

COMMENTS:

TYPE OF ORNAMENTATION
AND GRAPHICS REQUIRED

SUPPLIER APPROVAL
SIGNATURE

MASTER

PAINT OR COLORANT DAIMLERCHRYSLER SPEC. # AND SUPPLIER / SUPPLIER # / LOT #

MATERIAL, COLOR, AND GLOSS EVALUATION

MASTERING STUDIO TEXTURE

ORIENTATION
MASTERING STUDIO
POST TEXTURE
ORNAMENTATION AND GRAPHICS

DESIGN STUDIO
PRE-TEXTURE SURFACE
ENGINEERING PRE-TEXTURE
CONCURRENCE

APPROVALS

SURFACE AND TEXTURE EVALUATION

MANUFACTURING
LOCATION
SUPPLIER
PHONE
BUYER
CODE

APPEARANCE APPROVAL REPORT

SUPPLIER
NAME
SUPPLIER
CONTACT
SUPPLIER
CODE

BASE OR RAW MATERIAL DAIMLERCHRYSLER SPEC. # AND SUPPLIER / SUPPLIER # / LOT #

TEXTURE
ID

END ITEM
NUMBER
COMPONENT
PART NUMBER
COMPONENT
NAME

DaimlerChrysler

Section II - DaimlerChrysler Specific Instructions

II.1.5

SUPPLIER REQUEST FOR PRODUCT CHANGE

The Supplier Request for Product Change (SRPC) provides suppliers the opportunity to obtain specification relief for
minor dimensional and/or standard variations that do not affect performance, assembly, quality, durability, warranty,
customer satisfaction or cost.
The SRPC is not a means to avoid making the parts to print. The supplier is expected to make every effort to resolve
discrepancies before resorting to an SRPC. All SRPCs should be written and approved prior to presenting the Warrant.
Contact the respective DaimlerChrysler Corporation part approval activity for copies of the SRPC form and complete
instructions on its use. Identify the approved SRPC (as SRPC#XXXX) in the Additional Engineering Change line of
the Warrant.

II.1.6 INTERIM APPROVAL

II.1.6.1 INTERIM APPROVAL AUTHORIZATIONS
The Interim Approval Authorization (IAA) is a procedure to enable suppliers to meet production part submission dates
and plant production requirements for late design changes. In these cases, the supplier will receive authorization from
DaimlerChrysler Corporation through the Interim Approval Authorization (IAA) document. Parts to specification are
supplied through the use of the IAA process until permanent tool/process parts are approved and available to meet
production requirements.
Once parts are available from the permanent tooling/process, a new submission is required.
II.1.7

DaimlerChrysler Corporation Procurement and Supply Representative

All references to customer pertain to the DaimlerChrysler Procurement and Supply representative. The customer
product approval activity pertains to DaimlerChrysler Corporation Powertrain, Stamping, and Component operation
receiving facilities.
II.1.8

Third Party Laboratories

When DaimlerChrysler Corporation specifies the use of a third party laboratory, that laboratory must be approved by
DaimlerChrysler Corporation or accredited through either an ILAC or APLAC member, e.g. American Association for
Laboratory Accreditation (A2LA), the Standards Council of Canada (SCC) or the Laboratory Accreditation Bureau (LA-B).

23

II.2 Ford-Specific Instructions

II.2.1

Part Approval Activity - For external suppliers this refers to the Ford Supplier Technical Assistance
Office (STA) of, or representing, the customer. Internal operations should contact their responsible approval activity or the FAO Quality Office.

II.2.2

ES (Engineering Specification) - This is the Ford designation for the performance tests referred to in the
body of this document.

II.2.3

Substance Use Restrictions - A statement indicating conformance with Ford Engineering Material Specification WSS-M99P9999-A1 is required on the material test report. (This specification is available from
Materials Engineering). This specification results from regulations of the countries where Ford does business. These regulations apply equally to Ford and its suppliers. Therefore, this specification does not add
any requirements, but does require the supplier to verify conformance with the specification and with
relevant regulations in the country of manufacture and the country of the Ford receiving location.
Suppliers self-certify conformance to this specification and are not required to provide supporting test
data.
NOTE: Plastic Parts Marking - suppliers of plastic parts are encourage to mark plastic (polymeric) parts
with the appropriate ISO symbols to designate the type of polymer and filler/reinforcer used to fabricate
the part (further information is provided in Ford material specification E-4 available on-line at https://
web.keyinfo.ford.com/manuals/index.html and https://web.keyinfo.ford.com/supply/docs/e4.pdf). Affected
suppliers are requested to indicate compliance on the PSW form, as appropriate.

II.2.4

Interim Approvals - When non-conformances on a production part submission are identified, the STA
engineer shall contact the buyer and product engineer following local procedures. If the product engineer
allows use of product affected by the non-conformance, product engineering shall initiate (and approve) an
alert in the WERS system, specifying the time period or quantity for which the non-conforming product
can be used. The supplier shall enter the alert number on the PSW form under Additional Engineering
Changes. Once parts are available from the permanent tooling/process, a new part submission warrant (PSW) is required. Should incomplete or in-process test data result in an alert, a new PSW is
required upon availability of completed test data.

II.2.5

Control Plans - Shall be developed by the supplier and be available for review by the customer as early as
possible and in any case prior to the production part submission date. Control Plans must include all
Critical and Significant characteristics. Product Engineering and Part approval activity signatory approval
is required on Control Plans for Control Item ( ) products and for products so designated by Product
Engineering (e.g., with an ES specifically requiring this approval). Some Ford quality activities may request that a copy of the approved Control Plan be attached to the Part Submission Warrant and forwarded
to the customer part approval activity.

II.2.6

Appearance Item Approvals - All parts having appearance criteria (*) shall be reviewed by the Ford
Design Quality Office. The completed Appearance Approval Report (form CFG01002) shall accompany
this submission. After approval signatures have been obtained from the designated Ford Design Quality
representative, the form shall be included with Warrant.

(*) NOTE: All interior, exterior, luggage compartment, and select underhood components which are
visible to the customer. Appearance approval included but is not limited to overall appearance, color,
texture, and gloss.
Refer to the Corporate Design Decorative Component Approval Process manual for detailed instructions.

24

Section II - Ford Specific Instructions

For additional information, contact: Ford Design Quality, Ford Motor Company, Product Development
Center, Mail Drop 533, PO Box 2110, Dearborn, MI, 48123; fax: 313-594-7705.
II.2.7

Part Submission Level - For external suppliers, PPAP submission level is controlled by the Ford STA
Commodity Engineer based on Q1 status, correct PPAP usage/submittal, critical nature of components and
product concerns. When conducting a bulk material PPAP, use conventions as detailed in Section I in this
manual.
NOTE: It is important that suppliers designated as Level 2-5 account for any additional time that may
be required to obtain STA approval, when providing PSW promise date (If the STA Engineer is unavailable to approve the PPAP in a timely manner, the supplier should contact the STA Program Manager who may assign another engineer to disposition the PSW; for bulk materials, contact the Raw
Materials STA Manager).
Internal operations should contact their responsible approval activity or the FAO Quality Office regarding
PPAP submission level.

II.2.8

Manage the Change - The supplier shall develop and implement a process to manage change to ensure
that any product (either revised or new) affected by revisions in design and process shall continue to meet
all applicable specifications. A copy of the Supplier Checklist/Approval for Managing Change is provided
for guidance on page 30.
All design changes shall be clearly described and reference the WERS Engineering Notice number under
the Additional Engineering Changes on the PSW form. Questions regarding this requirement should be
reviewed with the using Ford facility.
The customer using facility may request full or partial PPAP documentation from the supplier in addressing specific product related concerns - supplier data shall be readily available upon request.
All post Job #1 changes (e.g., running changes, new supplier sourcing, revised supplier manufacturing
location, etc.) shall obtain functional approval from the customer using facility prior to shipping of production quantities.
NOTE: At Vehicle Operation facilities contact the Plant Vehicle Team (PVT) for functional approval.
If the component is used at multiple Ford facilities, then all using facilities must provide functional approval (a using facility may opt to waive functional approval in certain cases). Functional approval is
provided at the bottom of the PSW form under For Customer Use Only. Questions concerning the need
for functional approval should be directed to the using Ford facilities.

II.2.9

Family of Parts - Suppliers are permitted to submit multiple part numbers (same family of parts) on a
single PSW with all part specifics (e.g., prefix, base, suffix) clearly noted on the PSW.

II.2.10

Labeling Requirement - Suppliers to Ford European facilities are required to affix orange labels (Form
EU 3441, minimum A5 size) on all four sides of the packaging for all shipments of new or changed product
to each using Ford facility. Powertrain suppliers are required to include their unique supplier generated
PSW number on each label of the PSW shipment (ongoing shipments are excluded from this requirement).

II.2.11

Run at Rate - Run at rate is an integral part of the sample submission (PSW) for suppliers and which
provides the basis to extract capability data and inspection layout data. All production tooling shall be in
place and running at full production feeds and speeds, using all regular production direct and indirect
personnel and support systems (QS-9000, Section II, Ford-Specific Requirements)

25

II.2.12

Qualified Laboratory Documentation - Laboratory scope and documentation requirements (PPAP,

Section I.2.2.11) are not applicable to Ford suppliers.

II.2.13

Supplier Request for Engineering Approval (SREA) - The SREA procedure applies to all internal and
external suppliers without on-line WERS capability. Ford product engineering approval of a SREA is
required prior to implementing the change. Once Ford product engineering determines that the change is
feasible and a SREA is required, the supplier will complete and submit the SREA, Form 1638, to the
responsible product engineer.
Once approval is granted, a copy of the approved SREA shall be included in the PSW submission; powertrain
suppliers shall also provide a copy of the approved SREA to the using customer facility.
Process Changes
The supplier is empowered to implement process changes without issuing and obtaining SREA approval with the following exceptions:
- Change in heat treat, plating/coating and solderability.
- Changes to the manufacture of supplier-designed electronic components (capacitors, resistors, integrated circuits and similar components).
- Re-location of product to a different manufacturing location.
These exceptions will be waived once a supplier achieves Full Service Supplier status or is released
from the SREA requirement by the responsible design activity.

Changes to the process of control item ( ) parts or emission components always require issuance of
a SREA. No waivers apply for these components.
Ford reserves the right to require that additional process changes be subject to SREA submission based
on each suppliers performance in managing the change process. Suppliers are responsible for implementing this procedure with subcontractors.
Refer to the following flow diagram for the elements of the SREA process.

26

Section II - Ford Specific Instructions

SUPPLIER REQUEST FOR ENGINEERING APPROVAL (SREA)

PROCESS

SUPPLIER WANTS TO
MAKE A DESIGN OR
PROCESS CHANGE

YES

PREDESIGNATED
PROCESS*
?

YES

NO

NO

SREA
WAIVED
?

NO

REVIEW WITH
ENGINEERING
FOR
APPROVAL IN
WERS

YES

YES

FULL
SERVICE
SUPPLIER
?

NO

SUPPLIER TO
MANAGE THE
CHANGE
ACCORDING TO
PPAP AND
ISSUE PSW
OBTAIN
FUNCTIONAL
APPROVAL

BLACK
BOX
DESIGN
?

FULL
SERVICE
SUPPLIER
?

NO

DESIGN

YES

(REQUIREMENT GUIDELINES)
CONTROL
ITEM OR
EMISSION
COMPONENT
?

YES

NO

SREA
WAIVED ?

YES

NO

(SREA APPROVAL PROCESS)

SREA REQUIRED

*CHANGE IN HEAT TREAT, PLATING/COATING, SOLDERABILITY

CHANGE IN MANUFACTURE OF ELECTRONIC COMPONENTS
RELOCATION OF PRODUCT TO ALTERNATE MANUFACTURING LOCATION

SUPPLIER CONTACTS
FORD ENGINEERING TO
OBTAIN PRELIMINARY
FEASIBILITY APPROVAL

NO

FEASIBLE
?

YES

SUPPLIER SUBMITS SREA TO

RESPONSIBLE FORD
ENGINEER FOR DISPOSITION
(15 DAY TURN-AROUND)

YES

ADDITIONAL
INFORMATION
REQUIRED
?

NO
YES

NO

SREA
APPROVED
?

27

YES

DO NOT IMPLEMENT
CHANGE

DISTRIBUTE TO
AFFECTED ACTIVITIES
AND SUPPLIER

II.2.14

PSW Submission Process - The following table sumarizes submission practices and methods for notifying the appropriate Ford system of completion of the PSW:
Suppliers on DDL (Direct Data Link) shall enter their PSW approval into appropriate Ford PSW
tracking system (EASI, CMMS Parts Progress, ELECT) per table below. Non-DDL suppliers shall
follow local practices required to accommodate differing Ford systems to facilitate proper entry.

PPAP
Level
Level 1
DDL

SUPPLIER
- Prepare PPAP data package/self
approve.
- Assign unique number to each PSW *
- Provide sample parts/PSW to using
Ford facilities for functional approval/
waiver.
- Fax copy of PSW to using powertrain
plant when parts are shipped *
- Enter approval in Ford System.
- Maintain the completed PPAP data
package on file.

Non-DDL - Prepare PPAP data package/self

approve.
- Assign unique number to each PSW *
- Provide sample parts/PSW to using
Ford facilities for functional approval/
waiver.
- Fax copy of PSW to using powertrain
plant when parts are shipped *
- Contact FAO Production Purchasing
and report PPAP data package
approval status.
- Maintain the completed PPAP data
package on file.

Level 2-5
DDL

STA ENGINEER APPROVAL

OF PSW DATA PACKAGE

DATA ENTRY OF
APPROVAL

STA approval of PSW data

Supplier enters in Ford
package is not required. Supplier system.
self certifies (supplier submission
not required)

STA approval of PSW data

package is not required. Supplier
self certifies (supplier submission
not required)

- Prepare PPAP data package.

- STA approves PPAP data
- Get STA approval.
package/sign warrant.
- Assign unique number to each PSW * - STA returns PPAP data
- Provide sample parts/PSW to using package to supplier.
Ford facilities for functional approval/
waiver.
- Fax copy of PSW to using powertrain
plant when parts are shipped *
- Enter approval in Ford system after STA
approval of PPAP data package.
- Maintain the completed PPAP data
package on file.

28

FAO Production
Purchasing enters
approval, per local
practice.

Supplier enters in Ford

system after STA
approval of PPAP data
package.

Section II - Ford Specific Instructions

PPAP
Level

STA ENGINEER APPROVAL

OF PSW DATA PACKAGE

DATA ENTRY OF
APPROVAL

Non-DDL - Prepare PPAP data package.

- STA approves PPAP data
- Get STA approval.
package/sign warrant.
- Assign unique number to each PSW * - STA returns PPAP data package
- Provide sample parts/PSW to using to supplier.
Ford facilities for functional
approval/waiver.
- Fax copy of PSW to using powertrain
plant when parts are shipped *
- Contact FOA Production Purchasing
and report PPAP data package approval
status.
- Maintain the completed PPAP data
package on file.

FAO Production
Purchasing enters
approval, per local
practice after STA
approval of PPAP data
package.

SUPPLIER

* applies only to suppliers to powertrain operations

NOTE: JAGUAR IS EXEMPTED FROM THIS PROCESS.

PSW SUBMISSION LOCAL PRACTICES

Supplier or STA Engineer will handle approved warrant per local practices below:

Purchase Orders Issued in North America

Purchase Orders Issued in

Europe

PTO

Vehicle Operations

All Operations

NON-DDL SUPPLIERS:
- Fax (or hand deliver to onsite drop box)
copy of the approved warrant to Timing
Analyst.

NON-DDL SUPPLIERS:
- Notify Material Follow-up Analyst when
PPAP data package is approved.

- Send copy of Approved

Warrant to Buyer.

- Analyst enters approval.

- Analyst will enter approval in the Ford

PPAP tracking software.

- Buyer enters PPAP data

package approval.
- Buyer files copy of Warrant.

NOTE: Supplier must allow for STA

approval timing, where required, in Sample
Promise Date.

29

SUPPLIER CHECKLIST/APPROVAL for MANAGING CHANGE

Supplier Name

Part Name

Part Number

Mfg. Location Code

Vehicle Lines Affected

Ford Plants Affected

Change Description
ANY ITEMS NOT REQUIRED, PLEASE EXPLAIN:

Reqd.

Complete

Date

Comments

1. Engineering and Manufacturing Disciplines:

Layout/Detail/Assy Drawings
Tolerance Stack-Up
Installation Drawings
Reliability Methods
Process Sheets
Engineering Specification
Material Specification
Supplier Component DFMEA
Supplier System DFMEA
Ford Component DFMEA
Ford System DFMEA
Process Flow Chart
Supplier Component PFMEA
Supplier System PFMEA
Ford Component PFMEA
Ford System PFMEA
Ford SDS Update
DV/PV/IP Test
Vehicle Test
Operator Instruction Sheets
Tool & Gage Revisions
Gage R&R Study
Control Plan
Production Trial Run
Sub-Supplier Affect
Service Parts
2. Ford Feasibility Review
Ford Design Engineer Approval
SREA
CR/CR
Alert
PSW
Ford Plant Functional Approval
Use Part Submission Warrant (PSW) under Customer Use Only
Purchase Order
3. Approvals
Engineering Manager:
Quality Manager:
Production Manager:
Plant Manager:

30

Section II - Ford Specific Instructions

SUPPLIER REQUEST FOR ENGINEERING APPROVAL

DATE ___________________________________ 19 ________

SUPPLIER TO COMPLETE
SUPPLIER NAME AND ADDRESS

FORD AND/OR SUPPLIER PART NAME AND PART NUMBER OF ASSEMBLY AND ITS COMPONENTS

EMISSION CONTROL
CODE NUMBER

(SEE FORM
74-107)
CONTROL ITEM
AFFECTED

YES
DESIGN

DESCRIPTION OF CHANGE:

COMPOSITION

WEIGHT

NO

PROCESSING

EFFECT OF CHANGE:

INTERCHANGEABILITY AFFECTED
ASSEMBLY

YES

NO

COMPONENTS

YES

NO

WILL INCORPORATION OF CHANGE

AFFECT SHIPPING SCHEDULE?
YES

TIME REQD TO INCORPORATE CHANGE

AFTER APPROVAL

TOOLING OR FACILITY CHANGES REQUIRED

YES

NO

YES

NO

IF YES, COST EFFECT $

PIECE COST AFFECTED
SIGNATURE _____________________________

NO

SUPPLIER REPRESENTATIVE

IF YES, COST EFFECT $

PRODUCT ENGINEERING TO COMPLETE

APPROVED*

RELEASE ACTION REQD, NOTICE # __________________________________________________________________

BY

DATE

CONCURRED BY
SIGNATURE__________________________________

SIGNATURE __________________________________
BLANKET APPROVAL GRANTED FOR SUBSEQUENT CHANGES
WHICH ARE SAME AS DESCRIBED ABOVE

YES

SUPPLIER CHECKLIST ATTACHED?

YES

NO

REJECTED

DATE

SAMPLE OF CHANGED COMPONENT REQUIRED

NO

YES

NO

REASON FOR REJECTION OR QUALIFYING CONDITIONS OF ACCEPTANCE:

REVIEWED BY:
SQA ____________________________________ DATE ________________ PURCHASING____________________________________DATE __________________________

* This approval is granted upon the understanding that it is advisory in nature and in no manner changes the Sellers
original responsibility for insuring that all characteristics, designated in the applicable engineering specifications and/or
inherent in the samples as originally tested and approved, are maintained. Seller accepts full responsibility for the changes
or types of changes listed above; and should such changes result in less satisfactory performance than experienced with
the originally approved item, Seller will fully reimburse the Buyer for all expenses incurred to correct the deficiency.
CEG
JUL 92

1638 (Previous editions may NOT be used)

31

FORD GLOSSARY
Critical ( )
Characteristics

Critical ( ) characteristics are those product requirements (dimensions, performance tests)

or process parameters that can affect compliance with government regulations or safe vehicle/
product function, and which require specific supplier, assembly, shipping, or monitoring
and are included on Control Plans.

SREA

The process that provides for two-way communication between the component supplier and
the responsible Ford product engineering activity through which the supplier requests
concurrence for certain process related changes.

32

Section II - Ford Specific Instructions

33

GM

II.3

General Motors Specific Instructions

II.3.1

Applicability

This procedure is applicable to production, service, and unitized service parts, raw materials purchased by or contracted
to GM. It also applies to all commodities supplied by external independent suppliers, GM Allied and Affiliated suppliers,
plus all commodities supplied to these suppliers (e.g., subcontractors and third tier suppliers). Please note that for bulk,
raw, or indirect material, it is the Procuring Divisions decision whether PPAP is required. When conducting a bulk
material PPAP, use conventions as detailed in Section I in this manual.

II.3.2 Requirements For Part Approval

II.3.2.1
1.
2.
3
4.
5.

6.

The supplier shall use one warrant per customer part number.
GM does not require the purchase order number (item #7).
Enter Buyer name, and/or Buyer Code, if known (item #15).
The Supplier Code referred to on the PSW and on the Appearance Approval Report is the full code assigned to the
manufacturing location on the purchasing order.
The PSW shall be complete, legible and accurate. Warrants will not be accepted that have the following fields in
error:
Part Number
item 2
Engineering Drawing Change Level
item 4
Weight
item 8
Supplier Code
item 11
Supplier Address
item 12
Reason for Submission
item 17
Supplier Authorized Signature
item 22
The supplier should include an EWO number with the engineering change level on the warrant.

II.3.2.2
1.

PSW Form (CFG-1001) (see I.2.2.13)

Appearance Approval Report (see I.2.2.14)

Appearance Approval Report (AAR) (CFG-1002) for parts with color, grain, gloss or textiles
NOTE: AAR is not required for surface quality of body in white (BIW) parts. Refer to the General Motors
North America Surface Buyoff Procedure for Surface Requirements of BIW parts.

2.

Appearance Approval may occur concurrently with part inspection and testing.

II.3.2.3

Sample Product (see I.2.2.16)

If submitting for Level 2 or 3, the supplier shall submit two sample parts unless otherwise specified by the procuring
Division. For multiple processes, two sample parts per process e.g. two parts per cavity, tool, cells, assembly lines are
required unless otherwise specified by the procuring division. The sample parts do not have to be the same part(s) that

34

Section II - GM Specific Instructions

were dimensionally measured and documented on the marked drawing or check sheet. All sample parts should be
labeled with part number, change level, and supplier name.

II.3.2.4 Design Records (see I.2.2.1)

1.
2.
3.
4.

A marked drawing can be used for a full PPAP submission provided the drawing is signed by the product engineer,
has an EWO number and is dated.
All Supplier design records shall be GM approved.
The supplier shall furnish evidence of conformance to print specifications of each detail component when requested.
For CAD parts that are databanked, the current level in the GM design databank is the inspection referee. The
source of the data shall be provided with change level and date.

II.3.2.5 Material, Performance and Durability test results (see I.2.2.8)

1.

2.

3.

When Material, Validation, Performance, Durability, Reliability, or other engineering requirements are on the
design record, approval can occur in two ways.
a) The supplier gets approval prior to PPAP and submits evidence of approval.
b) The supplier submits the test data or results with the PPAP submission. Note that an additional drawing may
be required by the procuring division.
All Laboratory data shall be less than one year old at the time of initial submission. Previously approved test data
shall be updated (less than one year old) if part performance, material, reliability, durability or validation is affected
by an engineering change. The updated test data shall be included in the PPAP submission for the engineering
change.
A GM-E364 form is required where the note Engineering Approval required or the stamp Engineering source
approval for functional performance is checked yes and found on the drawing or design record (see I.2.2.3)

II.3.2.6

Control Plans (see I.2.2.12)

GM requires suppliers to document and submit (depending on submission level) their Pre-Launch Control Plan. For
information on the Pre-Launch Control Plan, see section 3.7 of the Chrysler, Ford, General Motors Advanced Product
Quality Planning and Control Plan reference manual. General Motors General Procedure GP-12 Early Production
Containment proceduralizes the Pre-Launch Control Plan. All parts requiring production part approval (PPAP) shall
also comply with GP-12 Early Production Containment.
Whenever a supplier is required to submit a Production Control Plan, they shall also submit a Pre-Launch Control
Plan, as defined by GP-12.

II.3.2.7

Initial Process Study (see I.2.2.9)

The minimum required acceptance criteria for the PPAP initial study shall be a Cpk or Ppk of 1.67.

II.3.3

Customer Notification of Supplier-Initiated Changes

NOTE: The following does not include initial submissions, engineering changes, or changes
described in Table I.3.3.:

35

GM

1.
2.
3.
4.

5.

The supplier shall review the proposed change with the procuring division prior to implementation to obtain
concurrence per the divisions local practice.
Sufficient information shall be provided to explain the detailed reason for the submission. Attachments are
encouraged.
Level 1 submission should be checked.
GM will review the warrant and determine if the warrant is acceptable. If the warrant is acceptable the supplier
shall receive the standard supplier notification authorizing shipment. If additional information or a higher submission
is required, the supplier shall be notified by the procuring division.
For submissions other than Initial Submission and Engineering Change(s) sufficient information shall be
provided to explain the detailed reason for the submission. Additional attachments are encouraged.

II.3.4
1.
2.

Situations Where Customer Notification is not Required

For item 1, table I.3.3, the supplier shall notify GM per II.3.3 Customer Notification of Supplier Initiated Changes.
Resubmission is not required for a design record update that reflects a change that was previously approved per a
dated marked print with an EWO number and engineering signature per section I.2.2.2 and/or I.2.2.3.

II.3.5 Submission Levels (see I.4.1)

1.

Suppliers are not required to maintain full documentation from their subcontractors if they have decision criteria
and a process in place to establish the level of evidence required from their subcontractors, and the appropriate
level of evidence on file at their location. Upon a Procuring Divisions request for Production Part Approval
Documentation, suppliers must comply within a reasonable period of time.

2.

ATTENTION SUPPLIERS TO GENERAL MOTORS EUROPE: Level 2 shall be the default level for all
submissions to General Motors Europe, unless specifically advised otherwise by the responsible part approval
activity.

II.3.6 Part Submission Status

A. Full Approval (see I.5.2.1)
1.
2.
3.

Part meets all requirements as outlined on the GM approved drawing and in accordance with PPAP.
Drawing must be fully released or is a marked drawing accompanied by an EWO, product engineers signature
and date.
Multiple cavity tools can achieve full approval on individual cavities provided the cavity being submitted meets all
the requirements outlined in the PPAP manual. Each submission for a multiple cavity tool must specify the cavity
and/or cavities that are being submitted for full approval.

B. Interim Approval (I.5.2.2)

1.
2.
3.
4.

If a part is not a full approval, the Interim Approval will authorize the shipment to the customer. The status
Interim Approval indicates the customers decision to use the part without Full Approval.
All Interim Approvals require a corrective action plan. The Interim Recovery Worksheet (GM 1411), which has
been developed for this purpose, is to be completed with the supplier.
If an extension is required, the GM 1411 must be re-issued and the interim date changed.
All Interim Approvals require the part number to be classified A, B, C, D, or E as follows:

36

Section II - GM Specific Instructions

Class A: Parts are produced using 100% production tooling and meet design record specifications. However, not
all production approval requirements have been met.
Examples:
1. A capability study has been performed on less than 300 pieces and in the judgment of the SQE, satisfactory
stability and capability has not been achieved. The supplier shall implement temporary containment
actions until capability is achieved.
2. Documentation improvements required. Examples include DFMEA, PFMEA, Process Flow Diagram
and Process Control Plan.
3. Part only lacks formal PPAP processing for statusing. Parts and data have been reviewed by the SQE and
there is no indication of non-conformances.
4. Testing has not yet been completed and in the judgment of the appropriate engineer, usage of the parts
does not pose a significant risk to customer dissatisfaction e.g. Long term material tests, long term functional
test, environmental exposure etc. (Engineering signature is required).
5. Part and drawing do not match and a part change is not desired or anticipated. The interim worksheet
must specify the differences between the part and the specification. The interim worksheet must document
a commitment and date for the specification to be changed. (Engineers signature required.)
Class B: Parts are produced using 100% production tooling and require rework to meet design record specifications
as explained on the GM 1411 form.
Examples:
1. Parts have been produced not following the documented production process on the process flow diagram.
Examples include trimming, sanding, buffing, etc. The process flow diagram includes any temporary
operations except inspection. Added inspection alone should not be considered rework, but instead
documented in the GP-12 plan and/or the process flow diagram and process control plan.
Class C: Parts are not produced using 100% production tooling and/or production processes, but meet design
record specifications as explained on the GM 1411 form.
Examples:
1. Parts have been produced using additional, substitute or temporary tooling.
2. Parts have not been manufactured completely at the production site/environment.
NOTE: If low volume tools are intended to meet current production needs submit for full production
approval.
Class D: Parts do not meet design record specifications as explained on the GM 1411 form.
Examples:
1. Dimensional, material validation/functional testing or appearance characteristics that do not met design
record requirements but will not impact vehicle assembly or customer satisfaction. Product engineer
signature is required.
Class E: Parts do not meet design record specifications as explained on the GM 1411 form. Vehicles with Class
E parts require retrofit to make them saleable.
Examples:
1. Dimensional, material validation/functional testing or appearance characteristics that do not meet design
record requirements and will impact vehicle assembly or customer satisfaction. Product engineer signature
is required.
2.

Incomplete testing with high probability of failure and/or failed performance/functional material testing.
Parts require retrofit for saleable status. Product engineer signature required.
37

GM

3.
C.

Incomplete FMVSS testing.

Rejected (see I.5.2.3)

The part or associated documentation does not meet specified requirements. A resubmission shall be required. Shipment
of parts is not permitted.
D.

Reciprocity of part submission status within GM

1.

2.
3.

II.3.7

Production approval status from one GM Division applies to all GM. Suppliers do not need to reevaluate the
part or resubmit documentation, solely because the part will be used by another GM location. A copy of the
warrant and the document signifying approval must be supplied to the new using division. The new using
division reserves the right to review the PPAP information upon request.
Parts may be requested for a production trial run (PTR).
Interim approval granted by one division does not automatically guarantee authorization to ship to other GM
locations.

Packaging and Labels

Each sample submission to General Motors shall be packaged separately and identified with the General Motors
Sample Submission for Production Approval label, GM Form 1387. The information required on the label shall be
added by the supplier prior to shipment. When several submissions are to be shipped in one larger container, a Sample
Submission for Production Approval label, with only the To and From portion completed, shall be attached to the
container at the upper right hand corner, visible from two sides. Each sample submission inside the larger container
shall be packaged and labeled as specified. Parts and paperwork shall be packaged together.

38

Section II - GM Specific Instructions

INTERIM RECOVERY
WORKSHEET
(GM 1411)

39

GM

COMPLETION OF THE INTERIM RECOVERY WORKSHEET

Detailed Instructions for completion of Interim Recovery Worksheet (GM 1411)
Items 13 to 17, and item 19 are for customer PPAP group use only. For all other items, supplier must provide appropriate information in order to obtain interim approval.
1.
2.
3.

Supplier Name:
Supplier Code:
Resubmission date:

4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Interim Expire Date:

Application:
Part Name:
Part Number:
EWO#:
ECL:
ECL date:
Submission Level:
KG Wt:
Sample Number:
Inspector/SQE:
Additional Sample:
PKG#:
Interim #:
Interim Class:

19.
20.

Status:
Brief Reasons:

21.

Issues /Action Plan(s):

22.

GP-12:

23.

Supplier:

24.

Customer Approvals:

Name assigned to manufacturing location

Supplier assigned DUNS number of the manufacturing location.
New promise date or PPAP submission date. The suppliers commitment date to have the Corrective Action Plan item(s)
completed and resubmitted to the PPAP group. Part Readiness tracks the re-submission date for follow-up when required. The
re-submission date must be prior to the interim expiration date.
The expiration date is the last acceptable date of shipment of the part under this Interim Approval status report.
List programs where the part number is used.
Engineering released finished end item name.
GM 8 Digit Part Number submitted for PPAP.
Engineering Work Order number, of the associated PPAP submission that authorizes print changes.
Engineering Change Level of the associated PPAP submission.
Date of engineering change level submitted.
Submission Level 1 - 5. Enter submission level determined by the procuring division.
Enter the actual weight in kilograms to three decimal places.
The number of samples received under that part # for a given Duns location.
Customer use only. Inspector/SQE initials.
Additional sample parts required, specified by the metrology/PPAP lab.
Package number assigned to the submission. Generated by GQTS.
Interim number assigned by the procuring division to track interim submissions.
Type interim class or circle the appropriate interim class, A B C D E.
Class A - Parts are produced using 100% production tooling and meet design record specifications. However not all production
approval requirements have been met.
Examples:
1.
A capability study has not been completed: A capability study of less than 300 pieces and in the judgment of the SQE,
satisfactory stability and capability has been achieved.
2.
Documentation improvements required. Examples include DFMEA, PFMEA, Process Flow Diagram, and Process
Control Plan.
3.
Part only lacks formal PPAP processing for statusing. Parts and data have been reviewed by the SQE and there is no
indication of non-conformances.
4.
Testing has not yet been completed and in the judgment of the appropriate engineer, usage of the parts does not pose a
significant risk to customer dissatisfaction e.g. Long term material performance tests, long term functional test,
environmental exposure etc. ( Engineer signature required).
5.
Part and drawing do not match and a part change is not desired or anticipated. The interim worksheet must specify the
differences between the part and the specification. The interim worksheet must document a commitment and date for
the specification to be changed. (Engineers signature required.)
Class B - Parts are produced using 100% production tooling and require rework to meet design record specifications.
Examples:
1.
Parts have been produced not following the documented production process on the Process Flow Diagram. Examples
include trimming, sanding, buffing, etc. Process Flow Diagram includes any temporary operations except inspection.
Added inspection alone should not be considered rework but, instead, documented in the GP-12 plan and/or the Process
Flow Diagram and the Process Control Plan.
Class C - Parts are produced using non-production tooling and/or process but, meet design record specifications.
Examples:
1.
Parts have been produced using additional, substitute, or temporary tooling.
2.
Parts have not been manufactured completely at the production site/environment.
3.
Note: If low volume tools are intended to meet current production needs submit for a full PPAP approval.
Class D - Parts do not meet design record specifications.
Example:
1.
Dimensional, Material validation/functional testing or appearance characteristics that do not meet design record
requirements but will not impact vehicle assembly or customer satisfaction. (Product engineer and/or Assembly plant
signature is required)
Class E - Parts do not meet design record specifications. Vehicles with class E parts require retrofit to make them saleable.
Examples:
1.
Dimensional, material or appearance characteristics that do not meet design record requirements and will impact
vehicle assembly and/or customer requirements. (Product Engineer and/or Assembly plant signature is required.)
2.
Incomplete testing with a high probability of failure and/or a failed performance/functional material testing. Part
requires retrofit for saleable status. (Product Engineer and/or Assembly Plant signature is required.)
3.
Incomplete FMVSS testing.
Enter appropriate letter (A= Approved, I= Interim required, N= Not Made).
Provide a brief reason for requesting an interim approval. Where applicable specify if tooling modifications or other
modifications were made.
List all issues applicable, and use additional sheets if necessary. For non-grained parts, submit on Less Finish part number. For
color /Gloss issues submit on color part number. Provide a corrective action plan with date of completion, when requesting for
approval
Describe how Early Production Containment will be used to document countermeasures offsetting interim issues listed on the
GM1411 (interim recovery worksheet). If GP-12 is not used to document countermeasures an explanation is required.
Required supplier authorized signature from responsible supplier official to ensure compliance to the information provided for
Interim approval, legibly print or type name, title and include phone and fax number.
Obtain appropriate signatures from customer for areas of concern. Suppliers must have SQEs approval for all interim classes
and release engineers approval for interim D and E. Requirements are subjected to change and may vary for each procuring
division. ask SQE for details.

Attach Part Submission Warrant with Customer approvals in order to have interim processed and send to processing group. Interim Approvals can
be obtained in person, fax, mail or via E-mail.

40

Section II - GM Specific Instructions

Supplier

GM

INTERIM RECOVERY WORKSHEET (GM 1411)

1

PART NAME:

SUPPLIER CODE:

PART #:

RESUBMISSION DATE:

INTERIM EXPIRE DATE:

EWO#:

APPLICATION:

ECL:

SUBMISSION LEVEL:
SAMPLE #:

Customer

SUPPLIER NAME:

13

11

18 INTERIM CLASS
19 STATUS:

10

DATE:

12

KG Wt:

INSP/SQE:

14

ADD. SAMPLE:

15

PKG:

(Type interim class or circle for manual entry):

16

Interim#

17

Type or fill in appropriate status (A=Approved, I = Interim, N = Not made).

DIM:

APP:

LAB:

PROCESS:

ENG:

20 BRIEF REASONS (116 characters max.):

ACTION PLANS (provide with date of completion)

(List DIM, APP, LAB, Process, tooling, capacity,o r start-up issues)

Supplier

21 ISSUES:

22 WHERE APPLICABLE, ARE INTERIM ISSUES ADDRESSED ON THE GP-12 PLAN? (e.g. rework, temporary operations)
(Please explain below):

23

SUPPLIER (Authorized signature):

PHONE:

NAME & TITLE: (Print)

FAX:

PART SUBMISSION WARRANT MUST BE INCLUDED WITH CUSTOMER APPROVALS IN ORDER TO PROCESS YOUR REQUEST AND SEND TO THE PROCURING DIVISION.

Customer

24 CUSTOMER APPROVALS:

SIGNATURE

NAME (Print)

SUPPLIER QUALITY ENGINEER:

PRODUCT ENGINEER (DRE):
LAB/MATERIAL ENGINEER:
APPEARANCE/PAINT ENGINEER:
OTHER (Buyer, Assembly Plant, etc.):

41

PHONE

DATE

GM

Supplier

GM

INTERIM RECOVERY WORKSHEET (GM 1411)

SUPPLIER NAME:

PART NAME:

SUPPLIER CODE:

PART #:

RESUBMISSION DATE:
INTERIM EXPIRE DATE:

EWO#:

APPLICATION:

ECL:

SUBMISSION LEVEL:

Customer

SAMPLE #:

KG Wt:
INSP/SQE:

ADD. SAMPLE:

PKG:

INTERIM CLASS (Type interim class or circle for manual entry):

STATUS:

DATE:

Interim#

Type or fill in appropriate status (A=Approved, I = Interim, N = Not made).

DIM:

APP:

LAB:

PROCESS:

ENG:

BRIEF REASONS (116 characters max.):

ACTION PLANS (provide with date of completion)

Supplier

ISSUES: (List DIM, APP, LAB, Process, tooling, capacity,o r start-up issues)

WHERE APPLICABLE, ARE INTERIM ISSUES ADDRESSED ON THE GP-12 PLAN? (e.g. rework, temporary operations)
(Please explain below):

SUPPLIER (Authorized signature):

PHONE:

NAME & TITLE: (Print)

FAX:

PART SUBMISSION WARRANT MUST BE INCLUDED WITH CUSTOMER APPROVALS IN ORDER TO PROCESS YOUR REQUEST AND SEND TO THE PROCURING DIVISION.

Customer

CUSTOMER APPROVALS:

SIGNATURE

NAME (Print)

SUPPLIER QUALITY ENGINEER:

PRODUCT ENGINEER (DRE):
LAB/MATERIAL ENGINEER:
APPEARANCE/PAINT ENGINEER:
OTHER (Buyer, Assembly Plant, etc.):

42

PHONE

DATE

Section II - GM Specific Instructions

43

GM

COMPLETION OF THE ENGINEERING SOURCE APPROVAL FOR FUNCTIONAL PERFORMANCE

1.

Part number

GM 8 Digit Part Number submitted for PPAP.

2.

Supplier Name

Name assigned to manufacturing location.

3.

Part name

Engineering released finished end item name.

4.

Duns Code

Supplier assigned duns number of the manufacturing location.

5.

Application

List of programs where the part number is used.

6.

ECL

Engineering change level of the associated PPAP submission.

7.

EWO

Engineering work order number of the associated PPAP

submission authorizing print changes.

8.

Drawing Number

Drawing number on which part number appears.

9.

Revision Date

Date of revision drawing that is being submitted.

10. Part meets engineering requirements

Indicate if the part meets all engineering requirements. If not

refer to section IV on this form.

11. Comments

Provides area to make comments if desired.

12. Parts not meeting engineering requirements

Parts that do not meet the requirements shall not use the GME364. The supplier shall clearly document the non
conformances on the GM 1411 and follow the interim approval
process. The Supplier shall obtain engineering signatures on the
GM 1411 form.

13. GM Product Engineer

Print product engineer or design release engineers name.

14. Phone Number

Product/design release engineer phone number.

15. Signature

Product/design release engineer signature.

16. Date

The date the product/design release engineer signs the GME364.

17. Code

Product/design release engineer code.

44

Section II - GM Specific Instructions

Engineering Source Approval for Functional Performance

I.

Part Number (s):

Supplier:

Part Name:

Duns Code:

Application:

ECL:

Drawing Number:

EWO:

Revision Date:

II. The Part Meets All Engineering Performance Requirements. (e.g., Sub System
Tech. Spec., Comp. Tech. Spec., Solar, Validation)
Yes 10
III. Comments:

11

IV. Part not meeting all engineering requirements specified above (section III).
Must be submitted on the GM1411 interim worksheet (the GM-E364 form
does not apply). 12
V. GM Product Engineer:
15

13
(Print)

Date:

Phone Number:
16

(Signature)

17
(Code)

Supplier GM Engineer (DRE) Supplier SQE/Part Approval Activity

45

14

GM

Engineering Source Approval for Functional Performance

I.

Part Number (s):

Supplier:

Part Name:

Duns Code:

Application:

ECL:

Drawing Number:

Revision Date:

EWO:

II. The Part Meets All Engineering Performance Requirements. (e.g., Sub System
Tech. Spec., Comp. Tech. Spec., Solar, Validation)
Yes
III. Comments:

IV. Part not meeting all engineering requirements specified above (section III).
Must be submitted on the GM1411 interim worksheet (the GM-E364 form
does not apply).
V. GM Product Engineer:

(Print)

Phone Number:

Date:
(Signature)

(Code)

Supplier GM Engineer (DRE) Supplier SQE/Part Approval Activity

46

Section II - Truck OEM Specific Instructions

II.4 Truck OEM-Specific Instructions

This truck specific section was developed to define those PPAP requirements, which are unique to subscribing North
American Heavy Truck OEMs. When completing PPAPs for the subscribing truck OEMs, this section will be applicable.
This section of PPAP was developed by Automotive Industry Action Group (AIAG) in conjunction with the Truck and
Heavy Equipment Group (THEG).

PPAP PROCESS REQUIREMENTS

II.4.1

Significant Production Run (see I.2.1)

The purpose of the production trial run is to ensure the effectiveness of the manufacturing process by running production
products off of production tools, materials, equipment, cycle times, and environments while using production operators,
gages, and other production methods. It is imperative that adequate quantities of parts be manufactured during this run
to sufficiently sample, test, and thoroughly try out the production process (at rate) prior to full production. Since parts
from the production trial run must be used to inspect and test for the initial sample submission, it is mandatory that
production processes and environments be used for this trial run. It is also mandatory to insure that sufficient quantities
of parts are run for preliminary process capability studies and for validation testing.
Since production trial runs in the truck industry are typically small, it is recommended that a maximum number of
production parts be run during the trial run to insure production has ample time to prove out the process, while yielding
sufficient quantities of parts to perform process capability studies. It is recognized that sample sizes as small as 30
pieces may be utilized for preliminary process capability studies. Sample sizes must be discussed and agreed to early
in the APQP process.
If projected volumes are so low that 30 samples are not attainable prior to production, interim PPAP approval may be
granted. A dimensional report with 100% inspection on special characteristics is required during the interim period.
Once the 30 production samples are produced, measured and the quality index calculated and accepted, then the interim
approval is changed to full approval.

II.4.2

Dimensional and Test Results Clarification (see I.2.2.7 and I.2.2.8)

Checked prints are not accepted within the truck industry. The supplier shall submit, as part of the PPAP package, a
copy of the drawing with each dimension, test, and or specification identified with a unique number. These unique
numbers shall be entered onto the dimensional or test results sheet as applicable, and actual results entered onto the
appropriate sheets. The supplier shall also identify print zone for each numbered characteristic as applicable.

II.4.3

Initial Process Studies - General (see I.2.2.9)

Due to the fact that small production trial runs are common in the truck industry, the supplier shall use the guidelines
described in II.4.1 above to maximize the number of parts run during the production trial run in order to have as many
parts as possible available to inspect for capability studies. Truck manufacturers require a minimum of 30 production
pieces be studied for preliminary process capability.

47

When the customer specifies special characteristics and the estimated annual usage is less than 500 pieces, the supplier
shall document in their control plan that they will either:

perform 100% inspection and record the results

OR

conduct an initial process capability study with a minimum of 30 production pieces and maintain SPC control
charts of the characteristics during production.

For special characteristics that can be studied using variable data, the supplier shall utilize one of the following techniques
to study the stability of the process:

X-Bar and R Charts, n=5, plot minimum 6 subgroups

OR

Individual X - Moving Range, plot minimum 30 data points

When performing the initial short term study, data shall be plotted from consecutive parts taken from the production
trial run. These studies could be augmented or replaced by long term results from the same or similar process run on
the same equipment with prior customer concurrence.

II.4.4

Acceptance Criteria for Initial Study (see I.2.2.9.3)

For initial process capability studies using 30 to 300 parts, the supplier shall use the following as acceptance criteria for
evaluating initial process study results for processes that appear stable:
For attribute features contact customer for appropriate sample size and statistical method.

II.4.5

Where the Customer has a long term

Minimum Capability Requirement of:

The Short Term (30 Piece Capability Study)

Minimum Acceptance Criteria is:

1.00
1.33
1.67

1.33
1.79
2.24

Measurement System Analysis Studies (see I.2.2.10)

The supplier shall have Measurement System Analysis studies, e.g. gage R&R, bias, linearity, stability studies, for all
gages and equipment used to measure special product characteristics or special process parameters. Measurement
System Analysis studies for gage families is not acceptable.

48

Section II - Truck OEM Specific Instructions

II.4.6

Special Characteristic Requirements

SAFETY AND/OR GOVERNMENT RELATED PART OR CHARACTERISTICS

TERM

CUSTOMER
Freightliner

SYMBOL

Key Characteristics

Mack Trucks, Inc.

Key Control Characteristics (KCC)

Navistar

Key Control Characteristics (KCC)

PACCAR

QA Codes (1,2,3 or 4) inside symbol in title

block

KCC

Kenworth

or Peterbilt

or Volvo Trucks N.A.

QA Codes (1 or 2) inside symbol in title block

Western Star

[1] or [2]

Refer to Western Star Part Drawings

IMPORTANT PERFORMANCE, FIT OR APPEARANCE CHARACTERISTICS

CUSTOMER
Freightliner

TERM

SYMBOL

Key Characteristics

Mack Trucks

Key Control Characteristics (KCC)

Navistar

Key Control Characteristics (KCC)

KCC
PACCAR

Volvo Trucks N.A.

Western Star

Critical Characteristic (C) or Signif icant

Characteristic (S)

Consequence Class

[1] [2] or [3]

Refer to Western Star Part Drawings

49

II.4.7 Part Submission Warrant

Suppliers to subscribing truck OEMs shall use the PSW form below instead of the PSW form in Appendix A. (see next

page for North American Truck Industry PSW Form). The North American Truck Industry PSW form is the same
as the automotive PSW except for the declaration statement, which is worded more properly for the truck industry.
Instructions for completing the form are the same as described on page 52.

Part Submission Warrant

North American Truck Industry

Part Name

Part Number

Safety and/or
Government Regulation

Additional Engineering Changes

Shown on Drawing No.

Yes

No

Engineering Drawing Change Level

Dated

Dated

Purchase Order No.

Checking Aid No.

kg

Dated

SUBMISSION INFORMATION

11

Weight

10

Engineering Change Level

SUPPLIER MANUFACTURING INFORMATION

Dimensional

13

Materials/Functional

Appearance

Supplier Name & Supplier Code

Customer Name/Division

12
Street Address

Buyer/Buyer Code
Application

14

15

16

City/State/Postal Code

Note:

Does this part contain any restricted or reportable substances.

Yes

No

Are plastic parts identified with appropriate ISO marking codes

Yes

No

REASON FOR SUBMISSION 17

Initial Submission
Engineering Change(s)
Tooling: Transfer, Replacement, Refurbishment, or additional
Correction of Discrepancy
Tooling Inactive > than 1 year
REQUESTED SUBMISSION LEVEL (Check one)

Change to Optional Construction or Material

Sub-Supplier or Material Source Change
Change in Part Processing
Parts Produced at Additional Location
Other please specify

18

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.

(Circle)

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

Level 5 Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
TS
SUBMISSION RESULTS

19

The results for

dimensional measurements
material and functional tests
appearance criteria
statistical process package
These results meet all drawing and specification requirements:
Yes
NO
(If NO Explanation Required)
Mold / Cavity / Production Process
20
DECLARATION
I hereby affirm that the samples represented by this certification are representative of our parts, have been made to the applicable customer
drawings and specifications, and are made from the 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.

21

EXPLANATION/COMMENTS:
Print Name
Supplier Authorized Signature

Title

FAX No.

Phone No.

22

Date
FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition:

Approved

Part Functional Approval:

Rejected

Customer Name
J u l y
1999

Approved
Waived

Interim Approval
Customer Signature

TAG-1001
50

Date

Section II - Truck OEM Specific Requirements

Part Submission Warrant

North American Truck Industry

Part Name
Safety and/or
Government Regulation

Part Number
Yes

No

Engineering Drawing Change Level

Dated

Additional Engineering Changes

Dated

Shown on Drawing No.

Purchase Order No.

Checking Aid No.

Engineering Change Level

SUPPLIER MANUFACTURING INFORMATION

kg

Weight
Dated

SUBMISSION INFORMATION
Dimensional

Materials/Functional

Appearance

Supplier Name & Supplier Code

Customer Name/Division
Street Address

Buyer/Buyer Code
Application

City/State/Postal Code

Note:

Does this part contain any restricted or reportable substances.

Yes

No

Are plastic parts identified with appropriate ISO marking codes

Yes

No

REASON FOR SUBMISSION

Initial Submission
Engineering Change(s)
Tooling: Transfer, Replacement, Refurbishment, or additional
Correction of Discrepancy
Tooling Inactive > than 1 year

Change to Optional Construction or Material

Sub-Supplier or Material Source Change
Change in Part Processing
Parts Produced at Additional Location
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.

(Circle)

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

Level 5 Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTS
The results for
dimensional measurements
material and functional tests
appearance criteria
statistical process package
These results meet all drawing and specification requirements:
Yes
NO
(If NO Explanation Required)
Mold / Cavity / Production Process
DECLARATION
I hereby affirm that the samples represented by this certification are representative of our parts, have been made to the applicable customer
drawings and specifications, and are made from the 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.
EXPLANATION/COMMENTS:
Print Name

Title

Phone No.

FAX No.

Supplier Authorized Signature

Date
FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition:

Approved

Part Functional Approval:

Rejected

Customer Name
July
1999

Approved
Waived

Interim Approval
Customer Signature

TAG-1001
51

Date

Appendix A
Completion of the Part Submission Warrant
PART INFORMATION
1.
Part Name and 2. Customer part number: Engineering released finished end item part name and number.
3.

Safety/Regulated Item: Yes if so indicated on part drawing, otherwise No.

4.

Engineering Change Level & Approval Date: Show change level and date for submission.

5.

Additional Engineering Changes: List all authorized engineering changes not yet incorporated on the
drawing but which are incorporated in the part.

6.

Shown on Drawing Number: The design record that specifies the customer part number being submitted.

7.

Purchase Order Number: Enter this number as found on the purchase order.

8.

Part Weight: Enter the actual weight in kilograms to four decimal places.

9.

Checking Aid No. Enter the checking aid number, if one is used for dimensional inspection, and,

10.

Its Engineering Change Level and Approval Date.

SUPPLIER MANUFACTURING INFORMATION

11. Supplier Name & Supplier Code: Show the code assigned to the manufacturing location on the purchase
order.
12.

Supplier Manufacturing Address: Show the complete address of the location where the product was
manufactured.

SUBMISSION INFORMATION
13. Submission type: Check box(es) to indicate type of submission.
14.

Customer Name: Show the corporate name and division or operations group.

15.

Buyer Name: and Buyer Code: Enter the buyers name and code.

16.

Application: Enter the model year, vehicle name, or engine, transmission, etc.

REASON FOR SUBMISSION

17. Check the appropriate box. Add explanatory details in the other section.
REQUESTED SUBMISSION LEVEL
18. Identify the submission level requested by your customer.
SUBMISSION RESULTS
19. Check the appropriate boxes for dimensional, material tests, performance tests, appearance evaluation, and
statistical data.
20. Check the appropriate box. If no, enter explanation in comments below.
DECLARATION
21. Comments: Provide any explanatory details on the submission results; additional information may be attached
as appropriate.
22. The responsible supplier official, after verifying that the results show conformance to all customer requirements
and that all required documentation is available shall approve the declaration and provide Title, Phone Number,
and Fax Number.
FOR CUSTOMER USE ONLY
Leave blank.
52

Appendices

D
aimlerChryslerFord
DaimlerChrysler
Part Name

Part Submission Warrant

General Motors

Safety and/or
Government Regulation

Shown on Drawing No.

Yes

Additional Engineering Changes

Checking Aid No.

Part Number
No

Engineering Drawing Change Level

Dated

Dated

Purchase Order No.

Engineering Change Level

SUPPLIER MANUFACTURING INFORMATION

7
10

Dated

SUBMISSION INFORMATION

11

Weight (kg)

Dimensional

13

Materials/Functional

Appearance

Supplier Name & Supplier Code

Customer Name/Division

12
Street Address

Buyer/Buyer Code
Application

City

State

Note:

14

15

16

Zip

Does this part contain any restricted or reportable substances

Yes

No

Are plastic parts identified with appropriate ISO marking codes

Yes

No

REASON FOR SUBMISSION 17

Initial Submission
Engineering Change(s)
Tooling: Transfer, Replacement, Refurbishment, or additional
Correction of Discrepancy
Tooling Inactive > than 1 year
REQUESTED SUBMISSION LEVEL (Check one)

Change to Optional Construction or Material

Sub-Supplier or Material Source Change
Change in Part Processing
Parts Produced at Additional Location
Other please specify

18

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.
Level 5 Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTS

19

The results for

dimensional measurements
material and functional tests
appearance criteria
statistical process package
These results meet all drawing and specification requirements:
Yes
NO
(If NO Explanation Required)
20
Mold / Cavity / Production Process
DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable
Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were
produced at the production rate of
/ 8 hours. I have noted any deviations from this declaration below.

21

EXPLANATION/COMMENTS:
Print Name
Supplier Authorized Signature

Title

Phone No.

FAX No.

22

Date
FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition:

Approved

Part Functional Approval:

Rejected

Customer Name
J u l y
1999

CFG-1001

Approved
Waived

Other
Customer Signature
The original copy of this document shall remain at the suppliers location
while the part is active (see Glossary).

53

Date
Optional: customer tracking
number: #

D
aimlerChrysler Ford
DaimlerChrysler

Part Submission Warrant

General Motors

Part Name
Safety and/or
Government Regulation

Part Number
Yes

No

Engineering Drawing Change Level

Dated

Additional Engineering Changes

Dated

Shown on Drawing No.

Purchase Order No.

Checking Aid No.

Weight (kg)

Engineering Change Level

SUPPLIER MANUFACTURING INFORMATION

Dated

SUBMISSION INFORMATION
Dimensional

Materials/Functional

Appearance

Supplier Name & Supplier Code

Customer Name/Division
Street Address

Buyer/Buyer Code
Application

City

State

Note:

Zip

Does this part contain any restricted or reportable substances.

Yes

No

Are plastic parts identified with appropriate ISO marking codes

Yes

No

REASON FOR SUBMISSION

Initial Submission
Engineering Change(s)
Tooling: Transfer, Replacement, Refurbishment, or additional
Correction of Discrepancy
Tooling Inactive > than 1 year

Change to Optional Construction or Material

Sub-Supplier or Material Source Change
Change in Part Processing
Parts Produced at Additional Location
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.
Level 5 Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTS
The results for
dimensional measurements
material and functional tests
appearance criteria
statistical process package
These results meet all drawing and specification requirements:
Yes
NO
(If NO Explanation Required)
Mold / Cavity / Production Process
DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable
Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were
produced at the production rate of
/ 8 hours. I have noted any deviations from this declaration below.
EXPLANATION/COMMENTS:
Print Name

Title

Phone No.

FAX No.

Supplier Authorized Signature

Date
FOR CUSTOMER USE ONLY (IF APPLICABLE)

Part Warrant Disposition:

Approved

Part Functional Approval:

Rejected

Other
Customer Name
J u l y
1999

CFG-1001

Approved
Waived

Customer Signature
The original copy of this document shall remain at the suppliers location
while the part is active (see Glossary).

54

Date
Optional: customer tracking
number: #

Appendices

55

Appendix B

Completion of the Appearance Approval Report

Note: DaimlerChrysler Appearance Approval Requirements (See II.1.4)
1.

Customer part number: Engineering released customer part number.

2.

Drawing Number: Use the number of the drawing on which the part is shown if different from the
part number.

3.

Application: Enter the model year(s) and vehicle or other program on which the part is used.

4.

Part Name: Use the finished part name on the part drawing.

5.

Buyer Code: Enter the code for specific buyer of part.

6/7. E/C Level & Date: Engineering change level and E/C date for this submission.
8.

Supplier Name: Supplier responsible for submission (include subcontractor if applicable).

9.

Manufacturing Location: Location where part was manufactured or assembled.

10. Supplier Code: Customer-assigned code for supplier location where the part was manufactured or
assembled.
11. Reason for Submission: Check box(es) explaining the reason for this submission.
12. Supplier Sourcing & Texture Information: List all first surface tools, graining source(s), grain
type(s), and grain and gloss masters used to check part.
13. Pre-Texture Evaluation: To be completed by customer representative (not used by GM).
14. Color Suffix: Use alphanumeric or numeric color identification.
15. Tristimulus Data: List numerical (colorimeter) data of submission part as compared to the customerauthorized master.
16. Master Number: Enter alphanumeric master identification (not used by Ford).
17. Master Date: Enter the date on which the master was approved.
18. Material Type: Identify first surface finish and substrate (i. e.: paint/ABS).
19. Material Source: Identify first surface and substrate suppliers. Example: Redspot/Dow.
20. Color Evaluation, Hue, Value, Chroma, Metallic Brilliance & Gloss: Visual assessment by customer.
21. Color Shipping Suffix: Color part number suffix or color number.
22. Part Disposition: To be determined by customer (approved or rejected).
23. Comments: General comments by the supplier or customer (optional).
24.

Supplier Signature, Phone No. & Date: Supplier certification that the document information is
accurate and meets all requirements specified.

25. Customer Representative Signature & Date: Customer approval signature.

THE AREAS INSIDE THE BOLD LINES ARE FOR CUSTOMER USE ONLY.

56

PART
NAME

SUPPLIER
NAME

57

25

23

Sept. 1999 CFG-1002

SUPPLIER
SIGNATURE

COMMENTS

Db*

DE*

CMC

TRISTIMULUS DATA

COLOR
SUFFIX

Da*

5
9

BUYER
CODE
MANUFACTURING
LOCATION

17

18

19

DATE

RED
YEL
BLU

LIGHT

DARK

VALUE

25

CLEAN

CHROMA
GRAY

20

CUSTOMER
REPRESENTATIVE SIGNATURE

GRN

HUE

COLOR EVALUATION

MATERIAL MATERIAL
SOURCE
TYPE

PHONE NO.

MASTER MASTER
DATE
NUMBER

16

HIGH

LOW

GLOSS

APPROVED TO
TEXTURE

CORRECT
AND PROCEED
CORRECT AND
RESUBMIT

PRE-TEXTURE
EVALUATION

21

HIGH

LOW

DATE

22
PART
DISPOSITION

CUSTOMER
REPRESENTATIVE
SIGNATURE AND DATE

10

COLOR
METALLIC SHIPPING
BRILLIANCE SUFFIX

13

OTHER

SUPPLIER
CODE

6/7 DATE

APPLICATION
(VEHICLES)

RE-SUBMISSION
ENGINEERING CHANGE

E/C LEVEL

12

APPEARANCE EVALUATION

SPECIAL SAMPLE
FIRST PRODUCTION SHIPMENT

DRAWING
NUMBER

APPEARANCE APPROVAL REPORT

SUPPLIER SOURCING AND TEXTURE INFORMATION

PART SUBMISSION WARRANT

PRE TEXTURE

15

11

14

DL*

REASON FOR
SUBMISSION

PART
NUMBER

Appendices

58

DL*

Da*

Db*

DE*

CMC

DATE

MATERIAL MATERIAL
SOURCE
TYPE

PHONE NO.

MASTER MASTER
DATE
NUMBER
RED
YEL
BLU

LIGHT

DARK

GRAY

CLEAN

CHROMA

CUSTOMER
REPRESENTATIVE SIGNATURE

GRN

HUE

COLOR EVALUATION

HIGH

LOW

GLOSS

APPROVED TO
TEXTURE

CORRECT
AND PROCEED
CORRECT AND
RESUBMIT

PRE-TEXTURE
EVALUATION

HIGH

LOW

DATE

PART
DISPOSITION

CUSTOMER
REPRESENTATIVE
SIGNATURE AND DATE

COLOR
METALLIC SHIPPING
BRILLIANCE SUFFIX

OTHER

SUPPLIER
CODE

DATE

APPLICATION
(VEHICLES)

RE-SUBMISSION
ENGINEERING CHANGE

E/C LEVEL

VALUE

APPEARANCE EVALUATION

SPECIAL SAMPLE
FIRST PRODUCTION SHIPMENT

SUPPLIER SOURCING AND TEXTURE INFORMATION

PART SUBMISSION WARRANT

PRE TEXTURE

TRISTIMULUS DATA

Sept. 1999 CFG-1002

SUPPLIER
SIGNATURE

COMMENTS

COLOR
SUFFIX

REASON FOR
SUBMISSION

MANUFACTURING
LOCATION

BUYER
CODE

PART
NAME

SUPPLIER
NAME

DRAWING
NUMBER

PART
NUMBER

APPEARANCE APPROVAL REPORT

Appendices

59

60

Appendices

Appendix C
DaimlerChrysler

Production
Part
Production Part
Approval
Approval
DimensionalDimensional
Results
Results

SUPPLIER

PART NUMBER

NAME OF INSPECTION FACILITY

PART NAME

ITEM

May
1995

DIMENSION/SPECIFICATION

CFG-1003

Page

of

SUPPLIER MEASUREMENT RESULTS

SIGNATURE

61

TITLE

Pages

OK

DATE

NOT
OK

62

Appendices

Appendix D
DaimlerChrysler

Production Part
Approval
Approval
Production
Part
Material TestMaterial
Results Test Results

SUPPLIER

PART NUMBER

NAME OF LABORATORY

PART NAME

TYPE OF
TEST

May
1995

MATERIAL SPEC. NO./DATE/SPECIFICATION

CFG-1004

Page

of

SUPPLIER TEST RESULTS

SIGNATURE

63

Pages

OK

TITLE

DATE

NOT
OK

64

Appendices

Appendix E
Daimler Chrysler

Production Part Approval

Performance Test Results

SUPPLIER

PART NUMBER

NAME OF LABORATORY

PART NAME

REF.
NO.

May
1995

REQUIREMENTS

CFG-1005

TEST QTY.
FREQ. TESTED

SIGNATURE

65

Page

of

OK

SUPPLIER TEST RESULTS AND TEST CONDITIONS

TITLE

DATE

Page

NOT
OK

66

Appendices

Appendix F
Bulk Material - Specific Requirements
F.1 Introduction
A supplier of bulk materials shall comply with the requirements in this Appendix or use guidance herein for clarification
of PPAP. This document is a minimum requirement and may be supplemented at the discretion of the supplier and/or
the customer.

F.2 Applicability
OEM PPAP approval of a bulk material eliminates the need to complete PPAP for that material at other levels in the
supply chain.
Suppliers are responsible for applying PPAP to their subcontractors of ingredients which have supplier-designated
special characteristics.
Examples of bulk material include, but are not limited to: adhesives and sealants (solders, elastomers); chemicals
(rinses, polishes, additives, treatments, colors/pigments, solvents); coatings (top coats, undercoats, primers, phosphates,
surface treatments); engine coolants (antifreeze); fabrics; film and film laminates; ferrous and non-ferrous metals
(bulk steel, aluminum, coils, ingots); foundry (sand/silica, alloying materials, other minerals/ores); fuels and fuel
components; glass and glass components; lubricants (oils, greases, etc.); monomers, pre-polymers and polymers (rubbers,
plastics, resins and their precursors); and performance fluids (transmission, power steering, brake, refrigerant).

F.3 Customer Plant Connection

F.3.1 Customers Responsibilities
The customer plant connection is a shared responsibility between the bulk material supplier and the customer. This
connection defines the interaction of specific customer plant processing steps with Special Characteristics and final
product attributes of the bulk material. This interaction is especially significant when bulk materials undergo chemical
or physical transformation(s). Three key components of the Customer Plant Connection are the development of a
Customer Process Matrix (SEE FOLLOWING EXAMPLE), determination of Special Characteristics from the Customer
Process Matrix, and the preparation of a Control Plan which systematically directs corrective actions. For bulk materials,
conducting the steps outlined in this Customer Plant Connection is highly recommended.
NOTE: It is not the intent of PPAP to compromise proprietary information.

F.3.2 Customer Plant Connection - Clarification

The following is applicable to materials that are transformed from bulk (e.g. wet can of paint) to final product (e.g.
cured paint film). This may not be applicable to all bulk materials (i.e. washer fluid, engine oil, etc.). It is recognized
by the supplier that it is their responsibility to deliver the product to the customer with the characteristics of the bulk
material per supplier and customer agreement.
The impact of the transformation of bulk materials by the customer plant on final product attributes may be accounted
for in the customers application process. During the transformation from bulk product to final product, both bulk
product characteristics and final product attributes may be impacted by customer process controls.
67

PPAP does not require a Process FMEA or Control Plan for the customer process. Since the product is frequently two
products (bulk and finished), there is a shared responsibility for the final product attribute. For example, percent solids
and viscosity of a bulk coating which impacts the final coatings film build attribute, may be affected by the customers
mix room percent solvent reduction. The percent reduction process parameter may therefore be controlled to aid in
control of film build. The process steps at customer plants may be matrixed versus the Special Characteristics (determined
jointly by supplier and customer). Where high impact is evident, those process steps may be analyzed by the Process
FMEA methodology.
The Special Characteristics may then be determined, and be included in a Control Plan for the customer process. These
special control characteristic items may be monitored and continuously improved.
F.3.3 Customer Plant Connection - Guidelines
The following is a recommended set of guidelines for the customer plant when implementing process controls for bulk
materials.
1.
2.
3.
4.

5.
6.
7.
8.
9.
10.
11.

Assemble cross-functional teams of customer personnel for each customer process area. Include appropriate
supplier representatives on each team.
Select Champions for each team - these are the customer process owners (i.e. chief process engineer, area
supervisor, etc.).
Define critical customer handling, application steps and process parameters in each area.
Review the suppliers Design Matrix and Design FMEA items for application functions which have been
designated as Special Characteristics. Also review the desired final product attributes for items needing
control.
From #4, develop a list of Special Characteristics and Attributes.
Construct a Customer Process Matrix, using #3 as the top, and #5 as the side of a matrix.
Perform a Customer Process FMEA, focusing on the high impact customer process areas which impact the
Special Characteristics. (Do the PFMEA per Appendix F).
Determine Special Characteristics from the Customer Process Matrix and PFMEA (e.g. paint fluid flow,
gun distance, etc.).
Prepare a Control Plan for each affected customer process area. The plan (utilize DaimlerChrysler, Ford,
GM APQP guidelines) might contain at a minimum all process steps containing Special Characteristics.
Monitor and record all Special Characteristics by appropriate means (control charts, checklists, etc.).
Ensure stability of Special Characteristics and continuously improve where possible.

Customer Process Matrix Example

Special Char.
& Attributes

Dirt Check
Film Build
Sags
Popping
Peel
Hiding
Adhesion

paint %
reduction

1
3
2
2
3
1
1

paint
fluid
flow

1
3
3
3
2
3
1

Customer Handling, Application Steps and Process Parameters

gun fan
gun
gun
gun
gun
booth booth
air
atomair
cap
distwash temp
hum-

ance
2
2
2
3
3
1
1

2
2
2
2
2
1
1

3
2
1
1
2
1
1

Impact Ratings: 3= High, 2= Medium, 1= Low

68

1
3
3
2
2
3
1

box
3
1
1
1
1
1
1

bake
temp

idity
1
1
1
3
1
1
1

3
1
1
1
2
1
1

1
1
2
3
2
1
3

Appendices

F.4 Part Submission Warrant (CFG-1001) [see I.2.2.13]

A Part Submission Warrant shall be prepared and submitted for approval when required by the customer. If a customer
agrees that PPAP is not required, no warrant needs to be prepared. The information required by the Submission Warrant
which does not apply to bulk material (i.e. part weight, dimensional measurement) does not need to be provided.
For those suppliers that have been classified as self certifying by a specific customer, submission of a warrant signed
only by the supplier shall be evidence of PPAP approval, unless the supplier is advised otherwise. For all other suppliers,
evidence of PPAP approval shall be a warrant signed by both the customer and supplier or other customer approval
documents.

F.5 Design Matrix

F.5.1 Introduction
Bulk material suppliers generally deal with the chemistry and functionality of the product being designed. Use of these
suggestions will arrive at the same end point of a completed Design FMEA, but with greater applicability to bulk
materials. For bulk materials, a Design Matrix, when required, shall be prepared prior to developing the Design FMEA.
The Design Matrix determines the complex interactions of formula ingredients, ingredient characteristics, product
characteristics, process constraints, and conditions for customer use. High impact items can then be effectively analyzed
in the Design FMEA.

F.5.2 Design Matrix Elaboration

This matrix correlates customer expectations with the product design items.
Construct the Design Matrix referring to the example which will follow:
1. Along the horizontal axis, list the Functions (Desired Attributes/Potential Failure Modes).
2. Along the vertical axis, list the design items as Potential Causes (Category/Characteristics) :
Formula Ingredients
Ingredient Characteristics
Product Characteristics
Process Constraints
Conditions for Use (customer process constraints)
3. For each design item, enter the current robust threshold range levels and units.
4. Correlate the potential causes to the potential failure modes using a number, letter, or symbol representing the
impact or strength of the relationship. Ask what would happen if a potential cause item is allowed to go under or
over its robust minimum or maximum, respectively.
5. After completion of the rankings in the Design Matrix, review the category/characteristics for a preliminary
assessment of Special Characteristics. Designate any Special Characteristics in column 1.
6. The high negative impact potential causes are transferred to the Design FMEA for analysis.

69

70

Prelim. Special Characteristics

Final Bake Temp.

over
under

over

under
1
3
250
275

70
110

UNITS

minutes

megaohms

#4 Ford Cup

%N.V. @ 110C

% Molar Comp.

Poise (#1 @ 50)

Formula Wgt.

Formula Wgt.

Total Solids

Total Solids

Binder Solids

Binder Solids

Binder Solids

2
3

3
2

1
2

1
1
2

2
1

3
2
1
1

1
1

3
2

No Telegraphing
1
1

1
1

1
1

1
1
1

2
1

2
1
1
1

1
1

1
1

No Pinholing
1
1

3
2

1
1

1
1
1

1
1

1
1
1
1

1
1

2
1

No Mudcracking
1
1

2
1

1
1

2
1
0

1
1

1
1
1
1

1
1

2
1

Dirt / Seed Free

0
1

1
1

2
3

1
1
0

1
1

1
1
1
3

1
1

1
1

Crater Free
0
1

1
1

2
3

1
1
2

2
1

2
1
1
2

1
1

2
1

Good Color Match

3
3

2
3

2
2

1
1
0

2
3

0
1
0
1

1
1

0
1

Good Accelerated Durability

3
2

1
1

1
2

1
1
0

1
1

1
1
1
1

1
1

1
1

Good Florida Durability

3
2

1
1

1
2

1
1
0

1
1

1
1
2
2

1
1

1
1

Good Chip Resistance

3
3

1
1

1
1

1
1
0

1
1

1
1
2
3

1
1

1
1

Good Crack Resistance

2
3

1
1

1
2

1
1
0

1
1

1
1
2
3

1
1

1
1

Good Delamination Resistance

2
2

1
1

1
1

1
1
0

1
1

1
1
2
2

1
1

1
1

Good Repair Adhesion

3
3

1
1

1
1

1
1
0

1
1

1
1
2
2

1
1

1
1

Good FMVSS (Windshield Adh)

2
3

1
1

1
2

1
1
0

1
1

1
1
2
3

1
1

1
1

Good Sag Resistance

1
1

3
2

1
1

2
2
1

3
2

1
1
1
1

1
1

1
3

Workable Visc/Atomization
0
0

0
0

1
1

2
2
3

3
3

2
3
1
1

1
1

2
2

Good Shelf Stability

0
0

0
0

3
3

2
3
1

2
1

2
2
1
1

3
1

1
1

Good Circulation Stability

0
0

0
0

2
1

2
2
1

3
3

2
1
1
1

3
1

1
2

Stable Rheology
0
0

0
0

3
3

2
2
1

2
1

2
3
1
1

2
1

2
2

Ne Edge Pull
1
1

2
1

1
1

2
2
1

3
1

1
1
1
1

1
1

2
3

1
1

1
1

1
1

1
1
0

1
1

1
1
0
0

1
1

0
0

Good Hiding Latitude

PROCESSABILITY

PERFORMANCE

APPEARANCE

NEGATIVE IMPACT ON CUSTOMER EXPECTATIONS: HIGH=3; MED=2; LOW=1; NONE=0; UNKNOWN=?

SP

Conditions for Use

Flash Time before Clear

under
over

0.15

Process Constraints
Batch Mixing Temp

0.01

over

Resistivity

61%

57%

over
under

30 sec
40 sec

over
under

% NV Solids

SP

under

30%
40%
1%
10%

2%
4%

5%
15%

Viscosity

Product Characteristics

Crosslinker-Imino (-NH) %

over
under
over

under

under
under

Alcohol Solvent

Ingredient Characteristics
Resign A-Viscosity

under
over

1.00%
2.00%

under
over

2.5%

30%
0.50%

under
over

over

35%
20%

over
under

25%

over
under

40%
50%

under

Solvent D

Color Dispersion-B

Rheology Control Additive

Formula Ingredients

FAILURE

SP

SP

SP

Crosslinker

Resin B

Resin A

CATEGORY /
CHARACTERISTICS

ROBUST THRESHOLD RANGE

Project #: 00001

1
1

1
1

2
3

2
1
2

2
1

1
2
2
3

2
3

2
2

Good Overspray Compatibility

FUNCTION - DESIRED ATTRIBUTES (POTENTIAL FAILURE MODES)

3
3

1
1

1
1

1
1
1

1
1

1
1
2
1

1
1

2
1

Good Repair Processability

POTENTIAL CAUSES

ENVIRONMENTAL

Product Code/Description: xxR-yyyyy Basecoat Paint

Good Gloss / Image / Peel

DESIGN MATRIX GENERIC PAINT EXAMPLE

Low/Acceptable VOC
1
2

1
2

1
1

3
1
1

1
1

1
1
0
1

1
2

1
3

Low/Acceptable Odor
1
3

1
1

0
1

1
1
1

0
0

0
0
0
1

1
2

1
2

1
1

0
0

1
1

1
1
1

1
1

1
1
0
1

1
3

1
3

HAPS Compliant

Appendices

F.6 Special Characteristics

F.6.1 Introduction
If product characteristics/attributes can have normal variation resulting in movement outside their design-intended
robust range which results in significant impact, they are designated special, and must be controlled by special
controls.
Special Characteristics - Clarification Table
#
1

Difference
Special Characteristics
and/or Key Product and
Key Control
Characteristics

Symbols for customeridentified Special

Characteristics

Clarification

Example

For Bulk Materials, a frequent occurrence

is a transformation from bulk material to
final product.

Illustrations of the flow of materials

through final product follow (e.g. % solids
Resin A, % UVA intended). These are not
necessarily intended to be Special
Characteristics.

The differences between bulk product

characteristics (features of the supplied
product) and the final attributes (features
of the transformed product) should be
understood.

Examples of product characteristics are:

viscosity, % NV Solids, % Resin A.
Examples of final product attributes are:
appearance, film build, FMVSS safety,
durability.

During the design phase, the product

characteristics can be controls for final
product attributes. (This does not imply
that they are control characteristics).
During manufacture of the bulk material,
process parameters are the control
characteristics.

Examples of manufacturing process

parameters (control characteristics) are:
temperature, pressure, mix rate, test
protocol.

During transformation from bulk product

to final product, both bulk product
characteristics and final product attributes
can be controlled by customer process
control characteristics.

Examples of customer transformation

process parameters (control
characteristics) are: fluid flow,
temperature/humidity, air pressure.

The suppliers may designate their own

internal symbols to designate Special
Characteristics in their working documents.

The supplier may choose to use S

(Safety), or sp (special), or K (Key),
etc.

For customer-designated/identified Special

Characteristics, the customer-specific
symbols will be used for required customer
documentation and required shipping
labels.

The customer designated shield, delta,

diamond, etc. will be used when required
per customer identification.

71

F.6.2 Special Characteristics - Elaboration

For clarif ication purposes, the following f igure is intended to demonstrate the flow of potential special
characteristics through the supply chain.
Illustration of the flow of materials through final product:
Item A (Paint)

Item B (Paint)

Item C (Sealant)

Subcontractor (Tier II)

Bulk Product Characteristic
(Raw Material)

Subcontractor (Tier II)

Bulk Product Characteristic
(Raw Material)

Subcontractor (Tier II)

Bulk Product Characteristic
(Raw Material)

% Solids Resin A

Purity Assay of UVA

Polymer Viscosity

Subcontractor (Tier II)

Mfg. Control Characteristic

Subcontractor (Tier II)

Mfg. Control Characteristic

Subcontractor (Tier II)

Mfg. Control Characteristic

Resin Synthesis Temperature

Final Reaction Hold Time

End-Blocker Feed Rate

Supplier (Tier I)
Bulk Product Characteristic

Supplier (Tier I)
Bulk Product Characteristic

Supplier (Tier I)
Bulk Product Characteristic

Paint Viscosity

% UVA intended

% Polymer in Sealant

Supplier (Tier I)
Mfg. Control Characteristic

Supplier (Tier I)
Mfg. Control Characteristic

Supplier (Tier I)
Mfg. Control Characteristic

Tank Mix Rate

Scale Calibration

Polymer Feed Rate

Customer Transformation
Control Characteristic

Customer Transformation
Control Characteristic

Customer Transformation
Control Characteristic

% Solvent Reduction

Fluid Flow (for film build)

Extruder Bead Size

Final Product Attibute

Final Product Attibute

Final Product Attibute

Film Build; Free of Sags

Excellent Durability

Leak Free Sealant

F.7 Design FMEA (see I.2.2.4)

F.7.1 Effects of Failure and Severity Rankings
The following two steps provide an alternative method for identifying the Potential Effects of Failure and assigning a
Severity Ranking.
List Effects of Failure
Consumer Effects - General terms identifying the loss experienced by the ultimate user of the product (e.g. the
car buyer).
Customer Effects - General terms identifying the loss experienced by the intermediate user of your product
(e.g. the vehicle manufacturer).
Assign a Severity Ranking to each Effect
See the Severity Definition and Evaluation Criteria in the Potential Failure Mode and Effects Analysis
reference manual.
72

Appendices

The goal for each of the items that multiply to arrive at the Risk Priority Number is to differentiate between the
items in that category. The following figure provides a guideline for severity rankings. If your situation only
uses a small portion of the scale then develop your own scale to improve the differentiation. If your situation
is greater than two tiers back from the final consumer, then the guideline figure should be adjusted to reflect
the effects that will be felt by your customers customer.
Effects of Failure and Severity Rankings:
Stakeholder

Effects of Failure

Severity

Consumer
(e.g. vehicle buyer)

Owner Safety Problem

Major Owner Dissatisfaction (Loss of Owner Loyalty)
Moderate Owner Dissatisfaction (Inconvenience)
Minor Owner Dissatisfaction (Annoyance)

10
8
6
4

Customer
(e.g. vehicle
manufacturer)

Plant Safety Problem

Possible Recall
Line Stoppage
Warranty Costs
Scrap
Regulatory Penalty
Moderate Rework (e.g. < 20% or moderate repair)
Plant Dissatisfaction
Minor Rework (e.g. < 10% or simple repair)

10
9
8
7
7
7
5
4
3

F.7.2 Potential Cause(s)/Mechanisms of Failure and Design Matrix

From the Design Matrix (if used), list the high negative impact characteristics as the Potential Causes/Mechanisms of
Failure which are associated with Potential Failure Modes.
Mechanisms are generally described as over or under a certain threshold. These thresholds define the boundaries of the
product approval and subsequent requirements for change notification.
F.7.3 Likelihood of Occurrence Rankings
The following step provides an alternate method for assigning Occurrence ratings.
Rank Occurrence - the ranking scale in the Potential Failure Mode and Effects Analysis manual is difficult to
relate to bulk materials and generally results in very low numbers with little differentiation in the ultimate risk.
The following matrix is recommended as a replacement. It evaluates the frequency of occurrence based upon
observed evidence the formulator has in the design.

73

Occurrence Matrix:
Formulation Occurrence
Ranking

FREQUENCY

Type of Evidence

LOW

MODERATE

HIGH

Actual Experience

Similar Experience

Assumption

No Background
Actual Experience:
Similar Experience:
Assumption:

10
Obtained from appropriate experimentation on the specific final product
and the potential failure mode.
Based upon similar products or processes and the potential failure mode.
Based upon a clear understanding of the chemical impact of the material
and the potential failure mode.

Frequency ranking clarifications:

High is defined as Repeated failures

Moderate is defined as Occasional failures
Low is defined as Relatively few failures

F.7.4 Current Design Controls

Design Control: Supplementing the Failure Mode Effects and Analysis manual, bulk material design controls may
also include:

Designed Experiments (DOEs) - List experiment #s

Customer validation tests and trial runs - e.g. gravelometer panels, fender sprayouts (list customer reference #s).
Test protocols - list Test Methods, Standard Operating Procedures, etc.
Variation of subcontractor specifications.
Formulating practice robust ranges.

Design controls identified by a number should be available so that the relevant content of that control can be understood.
F.7.5 Likelihood of Detection Rankings
The next step provides an alternate method for assigning Detection rankings.
Rank Detection - the ranking scale in the Potential Failure Mode and Effects Analysis manual is difficult to
relate to bulk materials and generally results in very low numbers with little differentiation in the ultimate risk.
The following matrix may be used. It evaluates the Detection as the ability of the current Design Control to
actually detect a cause of failure and/or failure mode based upon the assessed R&Rs percent of specification
range and the quality of evidence.

74

Appendices

Detection Matrix:
Detection by Design
Control

Testing Method R&R

Quality of Evidence

< 30%

30% - 100%

> 100%

DOE (Response Surface

Analysis)

Screening Experiments

Assumption/Experience

No Evidence
DOE (Response Surface Analysis):
Screening Experiments:
Assumption/Experience:

10
Symmetric design space analyzed with appropriate statistical tools.
Screening design or ladder evaluation strategically set to develop DOE.
Information/data based upon similar products or processes.

NOTE: The above R&R limits are suggested unless otherwise agreed upon by the customer and the supplier.
R&R calculations can initially be based using design matrix thresholds.

F.8 Process FMEA (see I.2.2.6)

Process FMEA Ranking Tables
SEVERITY RANKINGS
Severity of Effect

Ranking

Very High: Potential failure mode may result in a field failure (9), or constitute a safety hazard or
noncompliance with a government regulation (10).

9 - 10

High: High degree of customer dissatisfaction due to the nature of the failure. May cause serious
disruption to subsequent processing of the product or result in the product failing to meet its sales
specifications. Will result in a customer complaint and product return. Failure is likely to be detected
during the customers final product testing.

7-8

Moderate: Failure causes some customer dissatisfaction and may result in a customer complaint or
limitation on shelf life. The customer may need to make modifications or adjustments to their process to
accommodate the material. The problem is likely to be detected as part of an incoming inspection or
prior to use (4). The problem will be detected during processing (5). The problem will be detected in
subsequent processing steps (6).

4-6

Low: Failure causing only a slight customer annoyance. Customer will notice only a slight deterioration
or inconvenience with the product or processing of the product.

2-3

Minor: Reasonable to expect that the minor nature of this failure would not cause any real effect on the
product or its processing by the customer. Customer will probably not even notice the failure.

75

OCCURRENCE RANKINGS
Frequency of Failure

Ranking

Very High: Failure is almost inevitable. Additional process steps are developed to deal with the failures.

9 - 10

High: Similar processes have experienced repeated failures. The process is not in statistical control.

7-8

Moderate: Similar processes have experienced occasional failures, but not in major proportions. Process
is in statistical control.

4-6

Low: Similar processes have experienced isolated failures.

Very Low: Almost identical processes have experienced only isolated failures.

Remote: Failure is unlikely. No failures ever associated with almost identical processes. The process is in
statistical control.

DETECTION RANKINGS
Likelihood and Location in the Process the Defect is Detected

Ranking

Absolute Certainty of Non-Detection: Controls will not or cannot detect the existence of the defect.

10

Very Low: Supplier controls probably will not detect the existence of the defect, but the defect may be
detected by the customer.

Low: Controls may detect the existence of the defect, but detection may not occur until packaging is
underway.

7-8

Moderate: Controls likely to detect the existence of the failure, but not until lot acceptance testing has
been completed. Tests with a higher degree of variability will have the higher ranking.

5-6

High: Controls have a good chance of detecting the existence of the defect before the manufacturing
process has been completed. In-Process testing is used to monitor the manufacturing process.

3-4

Very High/Early: Controls will almost certainly detect the existence of the defect before the product
moves onto the next step in its manufacturing process. Important raw materials are controlled via
supplier specifications.

1 -2

F.9 Control Plan (see I.2.2.12)

F.9.1 Introduction
The Bulk Material Control Plan serves as a mechanism to:
Highlight Special Product/ Process Characteristics and their controls
Link together sources of control methods, instructions and specification / tolerance limits and reference them
in one document
Additionally, this control plan is not intended to recreate specification and/or tolerance limits that exist in other control
sources such as batch tickets, work instructions and testing protocols.
F.9.2 Control Plan - Elaboration
Refer to the control plan format found in the Advanced Product Quality Planning and Control Plan reference
manual.
Prototype (when required) - A listing of tests, evaluations and their associated specifications/tolerances used
to assess an experimental or developmental formulation. This may be the only control plan that is product
specific.
Pre-launch - Documentation of the product/process control characteristics, process controls affecting Special
Characteristics, associated tests, and measurement systems employed during product scale up and prior to
76

Appendices

normal production.
Production - Documentation of the product/process control characteristics, process controls affecting Special
Characteristics, associated tests, and measurement systems employed during normal production. Additional
items may be included at the Suppliers discretion.
Pre-launch and production control plans may be applied to a family of products or specific processes.

F.10 Initial Process Studies For Special Characteristics (see I.2.2.9)

The manufacture of bulk materials consists of industries which span a variety of production processes, from high
volume products to specialty products produced in small quantities no more than once or twice per year. Often the
production process is completed or already in place before sufficient samples can be tested. By the time the product is
made again, personnel and/or equipment may have changed. Also, these processes have numerous input variables,
many control variables, and a variety of product variations. There are non-linearities - meaning for example that
doubling the change in a particular input does not necessarily double the change in the output. The effects and relationships
between all these variables and controls are also not usually known without error. Multiple processes are usually
interconnected, sometimes with feedback loops. There are also timing considerations and delays in reaction time.
Further, measurement of component variables are generally less precise than measurements of component parts, such
that in many cases correlated variables must be used.

F.11 Measurement System Analysis (MSA) Studies (see I.2.2.10)

Bulk materials often require further processing after sampling in order to make a measurement.
Measurements are often destructive in nature and this prevents retesting the same sample.
Measurement variability is often much larger for properties important in the process industries (e.g. viscosity and
purity) than it is for properties measured in mechanical industries (e.g. dimensions). Measurement may account for
50% or more of the total observed variation.
Standardized test methods (e.g. ASTM, AMS, ISO) are often followed. The supplier need not reverify bias, linearity,
stability, and Gage R&R.
MSA studies are not required where standardized tests are used, however it is still important for the supplier to understand
the measurement component of variation in the test methods used.
Customer agreement on the actual requirements for MSA for either non-standard test methods or new-to-supplier
test methods should be obtained during the planning phase.
Any MSA studies should be applied to each test method associated with Special Characteristics, and not to each
individual product measured by the test method. Therefore, the MSA studies should be conducted as broadly as
possible across all products which use a particular test method. If the resulting variability is unacceptable, then either
the studies should be conducted on a narrower class of products or action should be taken to improve the test method.

77

Bulk Materials Requirements Checklist

Project:
Primary Responsibility
Customer
Supplier

Required /
Target Date
Product Design and Development Verification
Design Matrix
Design FMEA
Special Product Characteristics
Design Records
Prototype Control Plan
Appearance Approval Report
Master Sample
Test Results
Dimensional Results
Checking Aids
Engineering Approval
Process Design and Development Verification
Process Flow Diagrams
Process FMEA
Special Process Characteristics
Pre-launch Control Plan
Production Control Plan
Measurement System Studies
Interim Approval
Product and Process Validation
Initial Process Studies
Part Submission Warrant (CFG-1001)
Elements to be completed as needed
Customer Plant Connection
Change Documentation
Subcontractor Considerations

Plan agreed to by: Name

Company/Title/Date

78

Comments /
Conditions

Approved
by / date

Appendices

F.12 Bulk Materials Requirements Checklist (see I.2.2.15)

Use the Bulk Materials Requirements Checklist as follows:
Required/Target Date: For each item listed in the checklist either enter a target date for completion of the
element or enter NR for Not Required.
Primary Responsibility - Customer: Identify by name or function the individual who will review and approve
the element.
Primary Responsibility - Supplier: Identify by name or function the individual who will assemble and assure
the completeness of the element to be reviewed.
Comments / Conditions: Identify any qualifying information or references to attached documents that provide
specific information regarding the element. For example, this may include specific formats to be used for the
Design Matrix or acceptable tolerances for Measurement System Analysis (MSA) studies.
Approved by: Enter the initials of the Customer representative who has reviewed and accepted the element.
Plan agreed to by: Identify the individuals who made and agreed upon the project plan.

F.13 Master Sample (see I.2.2.17)

F.13.1 Introduction
The requirements for master sample or equivalent should be agreed by the customer and supplier.
Physical Sample: Some bulk materials are stable and unchanging over an extended period of time (e.g. they do
not significantly change physical or chemical composition, if properly stored, for decades). In this case, a physical
sample will serve as a Master Sample.
Analytical Sample Record: Other bulk materials change with time, but can be precisely quantified by appropriate
analytical techniques. In this case the analytical record (e.g. Ultra-Violet or Infra-Red spectra fingerprint,
Atomic Absorption or Gas Chromatographic-Mass Spectrometric analysis) is an appropriate Master Sample.
Manufacturing Sample Record: When bulk materials can not be distinctly identified or change over time, a
manufacturing sample record should be generated. The record should include the information required to
manufacture a normal production size run (lot or batch), according to the final Production Control Plan
supporting the PSW. This record provides an audit trail to the information which may be stored in various
documents and or electronic systems. The following is the basic information suggested to accomplish this task:

The quantity of product produced.

The important performance results.
The raw materials utilized (including manufacturer, Lot # and important properties records).
The critical equipment required to manufacture the bulk material.
Analytical sample records, as described above, on the material as produced.
Batch ticket used to manufacture the bulk material.

79

F.13.2 Paint Manufacturing Master Sample Record - Examples

The following figures show examples of paint manufacturing master records:

Paint Mfg Master Sample Record - Batch/Lot Mfg. Record

MFG. LOCATION: Plant #1

Batch
Number 1X97

MFG. DATE: 12/5/97

Product Code: xxR-yyyyy Basecoat

Product Name: White Basecoat

Formula
Date: 1/18/97

Lbs/Gals Reqd.: 1000 Gals.

Equip. ID.: Mixer #2

TESTING INFORMATION
Name

Test Method

Specifications

Wt/Gallon

TM001

10.50 - 10.70

% Non Volatile

TM004

57 - 61%

Viscosity

TM003

30 - 40 Secs

Ingredients

Amt.

Amt. Loaded Lot/Tank #

Date/Time

Add in order, with mixing

Resin A

1000 Lbs.

999 Lbs.

AB345

12/5/97 9.35 AM

Resin B

500 Lbs.

501 Lbs.

CD678

12/5/97 10.00 AM

Control temperature of mix. Not to exceed 105 F. Temperature recorded =

Crosslinker

100 Lbs.

100 Lbs.

FILLING INSTRUCTIONS
Containers

250 Gal Tote

Filtering

25 Micron Bag

Labeling

Per contract

80

AC250

Initials
12/5/97 10.25 AM

Operator
Initials

Appendices

Paint Mfg Master Sample Record - Product Test Results

Product Code: xxR-yyyyy
Manufacturing location: Plant #1
Date

12/5/97

Batch #

Gallons

Wt/Gallon
TM001
10.50 - 10.70

% non Volatile
TM004
57 - 61%

Viscosity
TM003
30 - 40 Secs

1000

10.59

59.6

34

Batch Size

1X97

Product Name: White Basecoat

Initials

Remarks

Ok

Paint Mfg Master Sample Record - Certificate of Analysis Ingredients

Certificate of Analysis
Material Name: Filmformer Resin

Lot/Batch #: AB345

Material Code: Resin A

Specification Requirements
Property

Min.

Max.

Lot/Batch

57%

61%

58.8%

7.3

7.2

Result
% Non Volatile
(TM004)
pH
(TM005)
Certification Signature:
Date:

81

F.14 Interim Approval (see I.5.2.2)

Most products will achieve full approval prior to initial use. In cases where full approval cannot be obtained, a Bulk
Material Interim Approval may be granted. A form is shown on page 83; other forms may be used.

COMPLETION OF THE BULK MATERIAL INTERIM APPROVAL FORM

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

21.
22.
23.
24.
25.
26.
27.
28.

SUPPLIER NAME: Name assigned to Suppliers manufacturing location

PRODUCT NAME: Suppliers designated name for the productas identified in the Customers Engineering
Release Documents
SUPPLIER CODE: Code (D.U.N.S. # or equivalent) assigned to the manufacturing location as shown on the
Customers purchase order
ENG. SPEC.: Customers identified Specification through which the product is approved and released
MANUF. SITE: Physical address of the manufacturing location as shown on the Customers purchase order
PART #: Customers Part Number
ENG. CHANGE #: Formula Revision Level or number identifying the formula
FORMULA DATE: Engineering Release Date of the formula identified in item #7
RECEIVED DATE: Customer Use Only
RECEIVED BY: Customer Use Only (Customer Representative)
SUBMISSION LEVEL: Submission Level (1-5) that Supplier is required to submit to as defined by the Customer
EXPIRATION DATE: Date that the Interim Approval expires
TRACKING CODE: Customer Use Only
RE-SUBMISSION DATE: Date supplier will resubmit for production approval
STATUS: For each item, enter appropriate code (NR Not Required, A Approved, I Interim)
SPECIFIC QUANTITY OF MATERIAL AUTHORIZED: Utilized when Interim Approval specifies a specific
quantity of volume of product
PRODUCTION TRIAL AUTHORIZATION: Customers Engineering Release authorizing the use of the product
in the Customers facility
REASON(S) FOR INTERIM APPROVAL: Indicate reason for Interim Request
ISSUES TO BE RESOLVED, EXPECTED COMPLETION DATE: For each item marked as I in #15, provide
explanatory details regarding problem issues and furnish a date for problem resolution
ACTIONS TO BE ACCOMPLISHED DURING INTERIM PERIOD, EFFECTIVE DATE: What is being done
to ensure defective product is contained, date when the action was implemented and Exit Criteria necessary to
end need for continuing the action or its individual elements
PROGRESS REVIEW DATE: Update on progress of problem resolution, generally the midpoint from issuance
to expiration of the interim period
DATE MATERIAL DUE TO PLANT: Date material is due to Customers site
WHAT ACTIONS ARE TAKING PLACE TO ENSURE THAT FUTURE SUBMISSIONS WILL CONFORM
TO ALL PPAP REQUIREMENTS BY THE SAMPLE PROMISE DATE? Why wont this happen again?
SUPPLIER: Responsible and Authorized Supplier official to ensure compliance to the above mentioned actions
and dates
PRODUCT ENG.: Product Engineers signature, printed name, phone number and date
MATERIALS ENG.: Material Engineers signature, printed name, phone number and date
QUALITY ENG.: Quality Engineers signature, printed name, phone number and date
INTERIM APPROVAL NUMBER: Customer Use Only.

82

Appendices

BULK MATERIAL INTERIM APPROVAL FORM

SUPPLIER NAME:

PRODUCT NAME:

SUPPLIER CODE:

ENG. SPEC.:

MANUF. SITE:

PART #:

ENG. CHANGE #:

FORMULA DATE:

RECEIVED DATE:

RECEIVED BY:

10

SUBMISSION LEVEL:

11

EXPIRATION DATE:

12

TRACKING CODE:

13

RE-SUBMISSION DATE:

14

STATUS: (NR - Not Required, A - Approved, I - Interim)

15

Design Matrix:

DFMEA:

Special Product Characteristics:

Engineering Approval:

Control Plans:

PFMEA:

Special Process Characteristics:

Process Flow Diagram:

Test Results:

Process Studies:

Measurement Systems Studies:

Dimensional Results:

Master Sample:

Appearance Approval Report:

16

SPECIFIC QUANTITY OF MATERIAL AUTHORIZED (IF APPLICABLE):

PRODUCTION TRIAL AUTHORIZATION #:
REASON(S) FOR INTERIM APPROVAL:

ISSUES TO BE RESOLVED, EXPECTED COMPLETION DATE

(CLASSIFY AS ENGINEERING, DESIGN, PROCESS, OR OTHER):

17
18

19

ACTIONS TO BE ACCOMPLISHED DURING INTERIM PERIOD, EFFECTIVE DATE: 20

21
22
PROGRESS REVIEW DATE:
DATE MATERIAL DUE TO PLANT:
WHAT ACTIONS ARE TAKING PLACE TO ENSURE THAT FUTURE SUBMISSIONS WILL CONFORM
TO BULK MATERIAL PPAP REQUIREMENTS BY THE SAMPLE PROMISE DATE?
23

SUPPLIER (AUTHORIZED SIGNATURE)

24

PHONE:

(PRINT NAME)

DATE:

CUSTOMER APPROVALS (as needed):

PRODUCT ENG. (SIGNATURE)

PHONE

25

(PRINT NAME)
MATERIALS ENG. (SIGNATURE)

26

(PRINT NAME)
QUALITY ENG. (SIGNATURE)

27

(PRINT NAME)
INTERIM APPROVAL NUMBER:

28

83

DATE

BULK MATERIAL INTERIM APPROVAL FORM

SUPPLIER NAME:

PRODUCT NAME:

SUPPLIER CODE:

ENG. SPEC.:

MANUF. SITE:

PART #:

ENG. CHANGE #:

FORMULA DATE:

RECEIVED DATE:

RECEIVED BY:

SUBMISSION LEVEL:

EXPIRATION DATE:

TRACKING CODE:

RE-SUBMISSION DATE:

STATUS: (NR - Not Required, A - Approved, I - Interim)

Design Matrix:

DFMEA:

Special Product Characteristics:

Engineering Approval:

Control Plans:

PFMEA:

Special Process Characteristics:

Process Flow Diagram:

Test Results:

Process Studies:

Measurement Systems Studies:

Dimensional Results:

Master Sample:

Appearance Approval Report:

SPECIFIC QUANTITY OF MATERIAL AUTHORIZED (IF APPLICABLE):

PRODUCTION TRIAL AUTHORIZATION #:
REASON(S) FOR INTERIM APPROVAL:

ISSUES TO BE RESOLVED, EXPECTED COMPLETION DATE

(CLASSIFY AS ENGINEERING, DESIGN, PROCESS, OR OTHER):

ACTIONS TO BE ACCOMPLISHED DURING INTERIM PERIOD, EFFECTIVE DATE:

PROGRESS REVIEW DATE:

DATE MATERIAL DUE TO PLANT:
WHAT ACTIONS ARE TAKING PLACE TO ENSURE THAT FUTURE SUBMISSIONS WILL CONFORM
TO BULK MATERIAL PPAP REQUIREMENTS BY THE SAMPLE PROMISE DATE?

SUPPLIER (AUTHORIZED SIGNATURE)

PHONE:

(PRINT NAME)

DATE:

CUSTOMER APPROVALS (as needed):

PHONE

PRODUCT ENG. (SIGNATURE)

(PRINT NAME)
MATERIALS ENG. (SIGNATURE)
(PRINT NAME)
QUALITY ENG. (SIGNATURE)
(PRINT NAME)
INTERIM APPROVAL NUMBER:

84

DATE

Appendices

Appendix G
TIRE INDUSTRY - SPECIFIC REQUIREMENTS
G.1 INTRODUCTION AND APPLICABILITY
A supplier of tires shall comply with the requirements of PPAP and use this appendix as guidance for clarification of
requirements. These guidelines are based on existing approved practices between the tire supplier and the OEM.
Design tests used by each OEM to select tire construction (technical approval), reduces the need to repeat all tests
during PPAP. Specific PPAP confirmation tests are specified by each OEM.
G.2 GUIDELINES FOR PPAP PROCESS REQUIREMENTS (REFERENCE SECTION I.2)
Significant Production Run (I.2.1)
Unless otherwise specified by the OEM, the size of the production run for the PPAP parts is to be determined by the
supplier. Current industry practice requires a minimum of 30 tires. The typical development of a new tire design
involves multiple builds of a small quantity of tires. Most designs are basic to the suppliers process. For the tire
industry, PPAP is typically completed with an initial mold or molds, and well in advance of customer requirements for
large volume production. PPAP is not required for additional molds that are brought on line in the approved production
process; however, for additional molds, the suppliers internal certification criteria and documentation are utilized.
The PPAP for the tire industry typically is derived from 1 to 8 hours of tire curing from the approved production
process as specified in the suppliers control plan. Subsequent parts from duplicate assembly lines for volume production
are not required to be represented in the PPAP sample, nor are additional PPAP submissions required.
The above definition for Significant Production Run applies to subsequent sections of I.2.
Tire industry practice defines tooling as a tire mold. This definition of tooling applies to all sections of PPAP.
Part Weight (Mass) (Reference I.2.2.13.1)
The tire industry practice is to weigh a specified number of PPAP tires to two (2) significant decimals (xx.xx). The
average is reported on the PSW to four (4) decimals (xx.xxxx).
Appearance Approval Report (AAR) (Reference I.2.2.14)
Tires are not an appearance item for the OEMs, consequently the AAR requirement is not applicable.
Material Test Results (Reference I.2.2.8.1)
Testing is applicable only to finished tires and not to raw materials. Tire industry practice does not require chemical,
physical or metallurgical testing.
Process Flow Diagrams (Reference I.2.2.5)
Process flow diagrams may be generic for families of similar parts.
Process Failure Mode and Effects Analysis (Reference I.2.2.6)
Tire industry practice is to have a generic process FMEA for a family of similar parts.
Design Failure Mode and Effects Analysis (Reference I.2.2.4)
Tire industry practice is to have a generic design FMEA for a family of similar parts.
85

Control Plan (Reference I.2.2.12)

Industry practice is to have control plans for families of similar parts. Tire industry practice does not require customer
review and approval of control plans unless otherwise specified.
General (Reference I.2.2.9.1)
Tire industry practice is that customers and suppliers have designated uniformity and balance as Special Characteristics.
Measurement System Analysis Studies (Reference I.2.2.10)
In the tire industry, where the testing is destructive in nature, the measurement system analysis studies are limited to the
equipment measurement system, rather than product repeatability or reproducibility.
Master Sample (Reference I.2.2.17)
Tire industry practice does not require retention of master sample.
Checking Aids (Reference I.2.2.18)
Checking aids are not required for the tire industry.

G.3 SUBMISSION TO CUSTOMER - LEVELS OF EVIDENCE (REFERENCE I.4)

Retention/Submission Requirements (Reference Table I.4.1)
Records of items submitted (S) and retained (R) are maintained at appropriate locations designated by the supplier.

86

Glossary

GLOSSARY
For additional related definitions, Refer to the Statistical Process Control reference manual, Measurement Systems
Analysis reference manual, and QS-9000, Third Edition.
ACCREDITED LABORATORY is one that has been reviewed and approved by a nationally-recognized accreditation
body [e.g. American Association for Laboratory Accreditation (A2LA) or the Standards Council of Canada (SCC)] for
test laboratory accreditation to ISO/IEC Guide 25 or its replacement, or national equivalent.
ACTIVE PART is one currently being supplied to the customer for original equipment or service applications. The
part remains active until tooling scrap authorization is given by the appropriate customer activity. For parts with no
customer-owned tooling or situations where multiple parts are made from the same tool, written confirmation from the
customer Purchasing activity is required to deactivate a part.
NOTE: For bulk material, active part refers to the bulk material contracted, not the parts that are subsequently
produced from that material.
AGREEMENT - used only for bulk material PPAP herein and refers to a situation where the customer and supplier
understand the boundaries of an issue without requiring signatures or records documenting the specifics.
APPEARANCE ITEM is a product that is visible once the vehicle is completed. Certain customers will identify
appearance items on the engineering drawings. In these cases, special approval for appearance (color, grain, texture,
etc.) is required prior to production part submission.
APPROVED is used in PPAP to mean that the parts, materials and/or related documentation or records submitted to,
or reviewed by, the customer meet all customer requirements. After full or interim approval, the supplier is authorized
to ship product as directed by the customer. For bulk material PPAP only: 1) approval requires a signature or record
of a verbal approval; 2) Any record of verbal approval shall include the date, scope of the approval, the name of the
customer representative granting the approval, and the name of the supplier representative involved; 3) The term
customer agreement does not require signatures or records.
APPROVED DRAWING is an engineering drawing signed by the engineer and released through the customers system.
APPROVED MATERIALS are materials governed either by industry standard specifications (e.g. SAE, ASTM,
DIN, ISO) or by customer specifications.
APPROVED SOURCE LIST is a list of suppliers and sub-suppliers that have been found to be acceptable to the
customer. Utilizing product from an approved sub-supplier does not relieve the direct supplier of responsibility for the
quality of that product.
ATTRIBUTES DATA are qualitative data that can be counted for recording and analysis. Examples include the
presence or absence of a required label, the installation of all required fasteners. Attributes data are not acceptable for
production part submissions unless variables data cannot be obtained.
BULK MATERIAL is a substance (e.g. non-dimensional solid, liquid, gas) such as adhesives, sealants, chemicals,
coatings, fabrics, lubricants, etc. A bulk material may become production material if issued a customer production part
number (PRODUCTION MATERIAL).

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BULK MATERIAL REQUIREMENTS CHECKLIST defines the customer PPAP requirements for bulk material.
(See Appendix F).
CAD/CAM MATH DATA is a form of design record by which all dimensional information necessary to define a
product is conveyed electronically. When this design record is used, the supplier is responsible for obtaining a drawing
to convey results of dimensional inspection.
CALIBRATION is a set of operations which compare values taken from a piece of inspection, measuring and test
equipment or a gage to a known standard under specified conditions.
CAPABILITY is the total range of inherent variation in a stable process. (see Statistical Process Control reference
manual)
CHECKED PRINT is a released engineering drawing with actual measurement results recorded by the supplier
adjacent to each drawing dimension and other requirements.
CONFORMANCE means that the part or material meets the customers specifications and requirements.
CONTROL - see STATISTICAL CONTROL
CONTROL CHARTS - see Statistical Process Control reference manual.
CONTROL PLANS are written descriptions of the system for controlling production parts or bulk materials and
processes. They are written by suppliers to address the important characteristics and engineering requirements of the
product. Each part must have a Control Plan, but in many cases, family Control Plans can apply to a number of parts
produced using a common process. Refer to Advanced Product Quality Planning and Control Plan reference
manual and QS-9000 Section II for customer-specific requirements.
CRITICAL CHARACTERISTIC: Ford definition: Critical characteristics are those product requirements (dimensions,
performance tests) or process parameters that can affect compliance with government regulations or safe vehicle/
product function and which require specific supplier, assembly, shipping, or monitoring and inclusion on Control
Plans. Critical characteristics are identified with the inverted delta symbol.
CRITICAL CHARACTERISTIC: GM definition: See Key Product Characteristics.
CUSTOMER is the activity that has contracted to buy the product.
CUSTOMER PRODUCT APPROVAL ACTIVITY is the customer location assigned responsibility for supplier
PPAP approval.
NOTE: Some customers assign this responsibility geographically, while others use the procuring division.
DESIGN-INTENDED ROBUST RANGE are limits within which parameters may be allowed to vary while still
ensuring that a product complies with fitness for use requirements.
DESIGN RECORD is the part drawing, specifications, and/or electronic (CAD) data used to convey information
necessary to produce a product.
DOCUMENTATION is material (typically paper or electronic) defining the process to be followed, e.g. quality
manual, operator instructions, graphics, pictorials.

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Glossary

ENVIRONMENT is defined as all of the process conditions surrounding or affecting the manufacture and quality of
a part or product. Environment will vary for each site, but generally includes: housekeeping, lighting, noise, HVAC,
ESD controls, and safety hazards relating to housekeeping. See Production Environment.
FAILURE MODE AND EFFECTS ANALYSIS (FMEA) is systematized technique which identifies and ranks the
potential failure modes of a design or manufacturing process in order to prioritize improvement actions. Refer to
Potential Failure Modes and Effects Analysis reference manual.
FULL APPROVAL used in PPAP to indicate that the part or production material meets all customer specifications and
requirements. The supplier is therefore authorized to ship production quantities of the part or material subject to
releases from the customer scheduling activity.
GAGE REPEATABILITY AND REPRODUCIBILITY (Gage R&R) - Refer to the Measurement System Analysis
reference manual.
INITIAL PROCESS STUDY is a short-term study conducted to obtain early information on the performance of new
or revised processes relative to internal or customer requirements. In many cases, preliminary studies should be conducted
at several points in the evolution of new processes (e.g., at the equipment or tooling subcontractors plant, after installation
at the suppliers plant). These studies should be based on as many measurements as possible. When utilizing X-Bar
and R charts, at least twenty-five subgroups (minimum of four pieces per subgroup) are required to obtain sufficient
data for decision making. When this amount of data is not available, control charts should be started with whatever data
is available. (Refer to the Statistical Process Control reference manual.)
INITIAL SAMPLE is a term previously used for production part submissions.
INTERIM APPROVAL used in PPAP to permit shipment of products for a specified time period or quantity. Since
not all customers allow interim approvals, consult your responsible customer product approval activity.
KEY CONTROL CHARACTERISTICS (KCCs) are those process parameters for which variation must be controlled
around a target value to ensure that a significant characteristic is maintained at its target value. KCCs require ongoing
monitoring per an approved Control Plan and should be considered as candidates for process improvement.
KEY DESIGN CHARACTERISTICS (DaimlerChrysler Corporation) - Toleranced and measurable characteristics
of a part, system, and/or assembly which may have an adverse or degrading effect on the function, quality, or reliability
of that part or system if an out of tolerance condition occurs. A Shield symbol is used to designate a key design
characteristic on components, systems or assemblies that have a safety or regulatory designation. On all other components
or systems, the key design characteristics are designated by the Diamond symbol. Good judgment should be used when
designating key design characteristics, as some designs have more robustness than others or the manufacturing process
may not be susceptible to variation.
KEY PROCESS CHARACTERISTICS (DaimlerChrysler Corporation) - Key Process characteristics are measurable
elements of the process used to manufacture or assemble a component or system that have significant impact on the
function, quality and/or reliability of that component or system. With a process characteristic, an actual element of the
process is measured, as opposed to a Key Design Characteristic where the measurement is taken at the component or
assembly.
KEY PRODUCT CHARACTERISTIC (KPC) are those product features that affect subsequent operations, product
function, or customer satisfaction. KPCs are established by the customer engineer, quality representative, and supplier
personnel from a review of the Design and Process FMEAs and must be included by the supplier in the Control Plan.
Any KPCs included in customer-released engineering requirements are provided as a starting point and do not affect
the suppliers responsibility to review all aspects of the design, manufacturing process, and customer application and to
determine additional KPCs.

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LABORATORY is a test facility that may include chemical, metallurgical, dimensional, physical, electrical, reliability
testing or test validation.
LABORATORY SCOPE is quality record containing the following:
the specific tests, evaluations and calibrations a supplier laboratory has the ability and competency to perform
a list of the equipment which it uses to perform the above
a list of the methods and standards to which it performs the above.
MARKED PRINT is an engineering drawing modified, signed and dated by the customer engineer (the engineering
change number must be included).
MEASUREMENT SYSTEM ANALYSIS STUDIES - Refer to the Measurement System Analysis reference manual.
PART SUBMISSION WARRANT is an industry-standard document required for all newly-tooled or revised products
in which the supplier confirms that inspections and tests on production parts show conformance to customer requirements.
PERISHABLE TOOLS are drill bits, cutters, inserts, etc. used to produce a product and which are consumed in the
process.
PROCESS is a combination of people, equipment, methods, materials, and environment that produces output, a given
product or service. A process can involve any aspect of a business.
PROCESS FLOW DIAGRAM depicts the flow of materials through the process, including any rework or repair
operations.
PRODUCTION ENVIRONMENT is the manufacturing location within the production site which includes the
production tooling, gaging, process, materials, operators, environment, and process settings, e.g. feeds, speeds, cycle
times, pressures, temperatures, quoted line rate. Environment is defined as all of the process conditions surrounding or
affecting the manufacture and quality of a part or product. Environment will vary for each site, but generally includes:
housekeeping, lighting, noise, HVAC, ESD controls, and safety hazards relating to housekeeping.
PRODUCTION MATERIAL is material which has been issued a production part number by the customer and is
shipped directly to the customer.
PRODUCTION PART is manufactured at the production site using the production tooling, gaging, process, materials,
operators, environment, and process settings, e.g., feeds/speeds/cycle times/pressures/temperatures.
PRODUCTION PART APPROVAL SUBMISSION is based on specified quantities of production parts or production
materials taken from the significant production run made with production tooling, processes, and cycle times. These
parts or materials submitted for production part approval are to be verified by the supplier as meeting all specified
requirements from the design record.
QUALITY INDICES are defined herein as either Cpk or Ppk for purposes of PPAP. See the Statistical Process
Control reference manual.
QUALITY PLANNING is a structured process for defining the methods (i.e., measurements, tests) that will be used
in the production of a specific product or family of products (i.e., parts, materials). Quality planning embodies the
concepts of defect prevention and continuous improvement as contrasted with defect detection (see Advanced Product
Quality Planning and Control Plan reference manual).

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Glossary

QUALITY RECORD is documented evidence that the suppliers processes were executed according to the quality
system documentation, e.g. test results, internal audit results, calibration data, and which records the results. See QS9000, cl. 4.16.
REGULAR PRODUCTION TOOLING is the tooling with which the manufacturer intends to produce production
product.
REJECTED used in PPAP to mean that the production part submission and/or documents did not meet the customers
requirements. The supplier must correct the production process and a make a new submission. (Advise the customers
Purchasing activity of the date when corrected parts will be available.) Do not ship production parts until the customer
approves the corrected parts. The customer may withhold tooling payments until part approval is obtained.
REMOTE LOCATION is a location at which production processes do not occur, e..g. does not fit the definition given
for Site, but which support such sites.
REPEATABILITY AND REPRODUCIBILITY (R&R) Refer to Measurement System Analysis reference manual.
SAFETY CHARACTERISTICS (DaimlerChrysler Corporation Definition) are specifications which require special
manufacturing control to assure compliance with DaimlerChrysler Corporation or government vehicle safety
requirements.
SALEABLE PRODUCT - generally refers to the product specified on the contract between the supplier and customer.
SELF-CERTIFYING SUPPLIER - is a supplier that an authorized customer representative has designated as selfcertifying, which means that the supplier submits the PSW (e.g. Level 1 PPAP) to the customer, but the response from
the customer is not necessary. This designation is to be documented. The PSW submittal from a self-certifying
supplier results in a simultaneous approval status by the customer for that submittal, which may not be a full
approval.
SIGNIFICANT PRODUCTION RUN is manufacture of a lot consisting of a minimum of 300 consecutive pieces, or
other quantity as agreed to by the customer product approval activity, and from a minimum of one hour of production
from the production environment.
SITE is defined as a supplier or subcontractor location at which value-added processes occur. Site also includes
distributors of parts manufactured by other companies. External locations which only stage material for onward shipment,
indirect material suppliers or assembly plants are not included. Providers of bulk or raw materials should contact their
procuring division buyer to determine if their material is considered to be production material.
SPECIAL CHARACTERISTICS - see Critical Characteristic or Key Product Characteristic. Reference individual
Truck Supplier Quality requirements for their definition. For bulk materials, see Appendix F.
SPECIFICATIONS are engineering requirements for judging the acceptability of a part or bulk material characteristic.
For the production part approval process, every feature of the product as identified by engineering specifications must
be measured. Actual measurement and test results are required. Specifications should not be confused with control
limits which represent the voice of the process.
STABLE PROCESSES are processes that are in statistical control. Variation in the output of a stable process arises
only from common causes. A stable process is predictable. For initial process studies performed prior to production
part submission, tests for stability may not be as rigorous as those used for ongoing processes.

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SUBCONTRACTORS are defined as providers of production materials, or production or service parts, directly to a
supplier to DaimlerChrysler Corporation, Ford, General Motors or other customers requiring this document. Also
included are providers of heat treating, painting, plating or other finishing services.
SUPPLIERS are defined as providers of: a) production materials, b) production or service parts, or c) heat treating,
plating, painting or other finishing services, directly to DaimlerChrysler Corporation, Ford, or General Motors or other
customers requiring this document, e.g. Heavy Truck OEMs.
STATISTICAL CONTROL is the condition of a process from which all special causes of variation have been eliminated
and only common causes remain. Statistical control is evidenced on a control chart by the absence of points beyond the
control limits and by the absence of any non-random patterns or trends. (STATISTICAL CONTROL is a descriptive
term for a STABLE PROCESS.)
SUBMISSION LEVEL refers to the level of evidence required for production part submission (reference I.4.1 of this
document).
TOOL is defined as the portion of process machinery which is specific to a component or sub-assembly. Tools (or
tooling) are used in process machinery to transform raw material into a finished part or assembly.
TOOLING MAINTENANCE is the periodic sharpening, polishing, or other servicing of a tool. This maintenance
will not significantly affect the dimensions or other characteristics of the product produced by the tool. (contrasts with
TOOLING REFURBISHMENT)
TOOLING REFURBISHMENT is the major overhaul of a tool. Refurbishment can affect dimensions or other
characteristics of the product produced by the tool. Production part approval submission of product made with refurbished
tools is required before such product may be shipped to the customer.
VALIDATION is confirmation by examination and provision of objective evidence that the particular requirements for
specific intended use are fulfilled.
VARIABLES DATA are quantitative results where measurements are used for analysis. Examples include the diameter
of a bearing journal in millimeters, the closing effort of a door in newtons, the concentration of an electrolyte in
percent, and the torque of a fastener in newton-meters.
VERIFICATION is confirmation by examination and provision of objective evidence that specified requirements
have been fulfilled.
WARRANT - see Part Submission Warrant.

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