2.2.5 Process Flow Diagram Process flow diagram in organization-specified format that clearly describes the production process steps and sequence, as appropriate and meets the specified customer needs, requirements and expectation. 2.2.6 Process FMEA Organization shall develop a process FMEA in accordance with, and compliant to FMEA manual, (Reference, Potential Failure Mode and Bffects Analysis). 2.2.7 Control Plan The organization shall have a Control Plan that defines all methods used for process control and complies with customer-specified requirements (Reference Advanced Product Quality Planning and Control Plan Manual). 2.2.8 Measurement System Analysis Studies Organization shall carry gage R & R and Attribute gage study for all equipment used for measurement or performance test. Dimensional Results Organization shall provide the evidence that dimensional verifications required by the design record (Layout inspection) and Control Plan has been completed and results indicate compliance with specified requirements. Organization shall identify one of the parts measured as the master sample. 2.2.10 Record of Material / Performance test result Organization shall have records of material / performance! functional test specified on design records or Control Pian. 2.10.1 Jn Material test result, wherever chemical, physical or metallurgical requirements specified by design reord or control plan to be verified from in-house laboratory or outside-decredited laboratories. Material test report shall indicate Design record change level of parts tested ‘Authorized engineering change documents Number, date and change level of he specification Date on which the testing took place Quantity tested Actual results © Material supplier's name 22.1022 In Performance test result, whatever specified by design record or control plan to be verified form jnhouse laboratory or outside-aecredited Inboratories. Performance test report shell indicate «Design record change level of parts tested, number, date, change level of specification Any authorized engineering change documents that have not yet been incorporated in the design record. + Date on which the testing took place © Quantity tested © Actual results 1 LInitial Process Studies 2.2. 2.2.11.1 General ‘The level of initial process capability or performance to be evaluated for special characteristics only. Organization shall obtain customer concurrence on the index for estimating initial process capability prior to submission. Organization shall use calibrated measuring instrument with permi ‘measurement. ‘ble measurement error affects the study 2.2.11.2 Quality Indices auSimple oq Nobo Mast oe Grae Dunpte a eat - Bu. / Not ok. Pee ereeeeHeeetyOOO0OCODOOOCODGOOOO0D0O0GGSSEEEOOO Cpk - Capability Index for a stable process Ppk - Performance index Short-term studies 2.2.1.3 Acceptance Criteria for Initial Study For initial study, index Results Interpretation Tndex >1.67 Process currently meets the acceptance criteria _ Se ian Index 1.33 to | Process is currently acceptable, contact the authorized customer representative 1.67 Tndex <1.33 Process does not currently meet the acceptance criteria, contact the authorized customer representative i 7 2.2.11.4 Unstable process ‘An unstable process does not meet customer requirements. Organizer shall identify the nature of instability, evaluate and wherever possible eliminate special causes of variation prior to PPAP submission. 2.2.1.5 Process with one-sided specification or Non Normal Distribution Organization shall establish an alternative acceptance criterion or different type of index or some method of transformation data for special characteristics which are not bilateral equidistant tolerance or non normal distribution. 2.2.11.6 Action to be taken when acceptance criteria are not satisfied Organization shall submit corrective action plan and a modified control plan providing 100% inspection. Continue variation reduction efforts till acceptance criteria met. 2.2.12 Qualified laboratory Requirements Inspection & testing for PPAP shall be performed by a qualified laboratory as defined by c requirements Organization shall have laboratory scope, policy and related docuitientation. 2.2.13 Appearance Approval Report (AAR) ‘Appearance approval report to be completed for each part or series of parts for which submission required for parts with color, grain or surface appearance requirements, 2.2.14 Sample Production Parts: Organization shall provide sample product as requested by the customer and as defined by the submission request. 2.2.15 Master Sample: Organization shall retain a master sample for the same period as the production part approval records, or until a new master sample is produced for the same customer part number for customer approval or where a ‘master sample is required by design record, control plan or inspection criteria, as a reference or standard. ‘Master sample shall be identified with approval date on the sample. Organization shall retain a master sample for each position of a multiple cavity die, mold, tool or pattem or production process unless otherwise specified by customer. 2.2.16 Checking Aid: Organization shall certify that aspects of the checking aids agree with part dimensional requirements. Tashy LTrspeeb on gunn 2.2.17 Customer-Specifie Requirement: Organization shall have the records of compliance to all applicable customer specific requirements. 2DOOSOSSSSESSESSSEBRSESBSESESRES 2.2.18 Part Submission Warrant (PSW) Separate PSW shall be completed for each customer part number If production parts will be produced from more than one cavity, mould, tool, die, pattern or production process (e.g. line or cell) organization shall complete dimensional evaluation on one part from each with identified “Mold/ Cavity/ Production Process”, 2.2.18.1 Part Weight Organization shall record part weight upto 4 decimal places (in kg) unless otherwise specified by customer. PPAP 18 CHECK POINT 1 Design Records 2 Authorized Engineering Change Document 3 Customer Engineering Approval 4 Design FMEA (for design responsible) 5 Process Flow Diagram 6 Process FMEA 7 Control Plan 8 Measurement System Analysis Studies 9 Dimensional Results 10 Record of Material / Performance test result 11 Initial Process Studies 12 Qualified laboratory Requirements 13 Appearance Approval Report (AAR) 14 Sample Production Parts: 15 Master Sample: 16 Checking Aid: 17 Customer-Specific Requirement: 18 Part Submission Warrant (PSW) SECTION 3: CUSTOMER NOTIFICATION AND SUBMISSION REQUIREM! 3. ustomer Notific: mn The organization shall notify the authorized customer representative of any planned changes to the design, process, or site. Examples are indicated as follows ‘Note: organizations are responsible to notify the authorized customer representative of all changes to the part design and / or the manufacturing process. Upon notification and approval of the proposed change by the authorized customer representative, and after change implementation, PPAP submission is required unless otherwise specified. Examples of changes requiring notification Clarification 1. Use of other construction or material than was used in the previously approved art 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 2, Production from new or modified tools (except perishable tools), dies, moulds pattem, etc. including additional or replacement tooling ‘The 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 upgrade or rearrangement of existing tooling or equipment Upgrade 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 23ee0eeeece oO oO oceeo°0 ooo0eeco Qo established. Rearrangement is defined as activity that changes the sequence of the product /process flow from that, documented in the process flow diagram (including the addition of a new process). Minor adjustment of production equipment may be required to meet safety requirements such as, installation of protective covers, elimination of potential environment and safety risks, etc, 4 Production from tooling and equipment transferred to a different plant site or from an additional plant site Production process tooling and / or equipment transferred between buildings or facilities at one or more sites, 5. Change of supplier for paris , non equivalent materials, or service (e.g, heat treating, plating) The organization is responsible for approval of supplier provided material and services. 6, Product produced after the tooling has been inactive for volume production for twelve month 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 change in active purchase order and the existing tooling has been inactive for volume production for twelve months or mote, The only exception is when the part has low volume, e.g. service or specialty vehicles. However a customer may specify certain PAP requirements for service parts 7. Product and process changes related to components of the production produet manufactured internally or manufactured by suppliers. ‘Any changes, including changes at the suppliers to the organization and their suppliers, that affect customer requirements, e.g, fit, form, function, performance , durability. 8. Changes in test / inspection method new technique ( no effect on acceptance criteria) For change in test method, the organization should have evidence that the new method has measurement capability equivalent to the old method. ‘Additionally, for bulk material 9. New source of raw material from new or existing supplier. 10, Change in product appearance attributes ‘These changes would normally be expected to have an effect on the performance of the product Submission to Customer ‘The organization shall submit for PPAP approval prior to the first production shipment in the following situations unless the authorized customer representative has waived this requirement, Requirement Clarification 1. A new part or product Submission is required for a new product or a previously approved product that has a new or revised produet / art number assigned to it. A new part/ product or material added to a family may use appropriate PPAP documentation from a previously approved pet within the same product family. | 2. Comection of a discrepancy on a previously submitted part. Submission is required to correct any discrepancies on a previously submitted part. A discrepancy can be related to: * The product performance against the customer requirements, * Dimensional or capabilities issues * Supplier issues * Approval of a part replacing an interim approval | * Testing, including material, performance, or engineering validation issues3. Engineering change to design records, | Submission is required on any engineering change to the specifications, or materials for production | production product/ part design record, specifications or product / part numbers materials, ‘Additionally, for bulk materials Process technology new to the organization, not previously used for this | product, i Section 4—-Submission to Customer-Levels of evidence 4.1 Submission Levels: ‘The organization shall submit the items and / or records specified in the level identified eoeoo0000g00G Gooo0o0ageooge Level I ‘Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to the customer. | Leva Warrant with product samples and limited supporting data submitted to the i customer Level I ‘Warrant with product samples and complete supporting data submitted to the customer Level IV ‘Warrant and other requirements as defined by the customer Level V Warrant with product samples and complete supporting data reviewed at the organization's manufacturing location. = The organization shall do level 3 as the default level for all submissions unless otherwise specified by the authorized cus tomer representative. SN_| Requirernent Submission Level Level! [ievel2 [Level | Level 4 1 | Design Record R S s * = for pro prictary components! details R R R " R -forall other components details |RSS + JR 2 | Engineering Change Documems, if an R 8 s * R 3 | Customer Engineering Approval, iftequired [R R s ‘ R lo oe Design FMEA. R R Ss * [R Process flow Diagram R R $ x R Provess FMEA R R 8 IR Control ‘Plan R R 8 = R Measure ment System Analysis Studies R R s = R Dimensi onal results R 8 8 ° R Material, Performance Test Result R $ 8 * R Initial process studies R [Rs *__[R Qualifiect Laboratory Documentation R $ 8 . R ‘Appearance Approval Report (AAR 8 8 8 * R Sample Product R 8 8 = TR Master Sample R R R = TR Checking: Aids Te R RR |? R Records. of Compliance R R s 7 R with customer specific requirements | ¢ Part Subsmission Warrant (PSW) s s is g R | oy L__[Bulk Ma terial Cheokdist s__|s 8 8 Ree i S = The organi. zation shall submit to the customer and retain a copy of records or documentation items at ©) appropriate locations R= The organization shall retain at appropriate locations and make available to the customer upon request. * = "The organi. zation shall retain at appropriate locations and submit to the customer upon request. £8 25eoeseoo0oo0oocoeo eaoo000000 Section 5: PART SUBMISSION STATU: 5.1 General: Upon approval of the submission, the organization shell assure that future production continues to meet all customer requirements. 5.2 Customer PPAP status 5.2.1 Approved ‘Approved indicates that the part or material, including all sub components, meets all customer requirements. Organization is therefore to ship production quantities of the product, subject to releases from the customer scheduling activity. 5.2.2 Interim approval: Tntetim approval permits shipment of material for production requirements in a limited time or piece ‘quantity basis. Interim approval will only be granted when the organization has: Clearly defined the non-compliance preventing approval; and, Prepared an action plan agreed upon by the customer. 5.2.3 Rejected Rejected means that the PPAP submission does not meet customer requirements, based on the production lot from which it was taken and / or accompanying documentation. SECTION 6: ECORD RETENTION PPAP records, regardless of submission level, shall be maintained for the length of time that part is active plus one calendar year. 26| | CUSTOMER INPUTS CHECKLIST [CUSTOMER NAME & ADDRESS; ISTANDARD REF. : JAPPLICATION REQUIREMENT = eceodocoeoo0nag0e once [SAMPLE RECEIVED OR NOT: OEVELOPMENT TIME ;o oO JDELIVERY PATTERN : 8 ESTIMATED VOLUME PER ANNUM: 98 TARGET PRICE : Q |PACKING REQUIREMENT : oO 9 © |SPECIAL CHARACTERISTICS (if any) : QO ce 3 |CUSTOMER APPROVED RAW MATERIAL SUPPLIER : © INO. OF SAMPLES REQUIRED FOR PPAP = PPAP SUBMISSION LEVEL : © ® © |CUSTOMER SPECIFIC REQUIREMENTS (if any) : 8 eases |e z b | ‘al STISSOd ALIMAISWAs * STEISW3d LON 4 SUSBNNAN 140 angisvad LON sigisvas ‘NoIsIo3q Save AUTiBISvES SINaWSuINOT SILSRISIOVEVHO “ds | ON US | AIMIaISvad AlMWNO & ‘Suva ALMIBISVSS, Sinawauinoay ‘SUVISG NOWOSASNi | “ON US | AiNIGISWas TWOINHOSL ¢ ANaWaYINDSY JO 3ouNOS Aurigisvad |"daWOS 401m | 3zis | “iv | SiisdWRSIvW | ON US | AlMIeISvas TwesivN SVN. Ainisisvad SINSWSUINDTE suwisa "ON SS | Altiiaisvad NOISSaT ‘OSs0 Laval iva ~ ON Lyd} ABU ONL NWWUAWOLENO wawoisno| Taw ‘ON ALITalsv34] 4aSHS AGNIs ALmiaiswad 140 1 39¥e 900 COOCOC COD OSES SOOO 068-6 8-8-9