Course Material for PPAP Rev. No.

Q Nathan & Nathan Consultants Pvt. Ltd.,

COURSE MATERIAL

ON

PRODUCTION PART APPROVAL PROCESS

(PPAP) – FOURTH EDITION

No.36, Muktha Building, 8th Main 18th Cross, Malleswaram, Bangalore 560 055
Ph: 080-23463193 Fax: 080-3311622
Email: [email protected]

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Course Material for PPAP Rev. No.0

CONTENT

No. Description

01. INTRODUCTION

02. FOREWORD

03. PURPOSE

3.1 ISO/TS 16949:2009 REQUIREMENTS

3.2 EXAMPLE PROCESS FLOW CHART FOR PPAP

04. COMPARISON OF PPAP WITH TRADITIONAL APPROACH

05. SIGNIFICANT PRODUCTION RUN

06. REQUIREMENTS FOR PART APPROVAL

07. SITUATIONS WHEN PPAP VALIDAITON, CUSTOMER

NOTIFICATION & SUBMISSION REQUIRED

08. PPAP SUBMISSION LEVELS

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Course Material for PPAP Rev. No.0

1.0 INTRODUCTION

This course material is designed to provide comprehensive knowledge to the

participants on understanding the requirements of PPAP Manual &

Implementation Guideline.

This course material is prepared for all production material, bulk material, and

part suppliers to OEM customers or who requires ISO / TS 16949:2009 or

PPAP.

This course material is prepared in line with PPAP Manual IV edition.

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Course Material for PPAP Rev. No.0

2.0 FOREWORD

PPAP fourth edition replaces PPAP third edition and includes the following
changes:

• Aligning the order of PPAP requirements with the Automotive Product

Development and Manufacturing Process

• Inclusion of an example process flow for PPAP

• Update of Truck OEM requirements

• Revision of PSW to include logical flow for part/ design description,

Suppliers address applicable to International Locations, inclusion of
IMDS materials to indicate reporting status

• Updation of PPAP requirements including Materials reporting and

polymeric identification requirements in design record

• More clarity on Ppk and Cpk indices usage

• Modified Customer Notification and Submission requirement

• Refinement of Appendices (recommended reporting formats)

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Course Material for PPAP Rev. No.0

3.0 PURPOSE

• To ensure that all customer Engg. Requirements are understood, and to

demonstrate the capability of supplier to meet the requirements, initially
& during actual production run at quoted production rate.

• To validate that the products made from production tools and processes
meet the Engg. Requirements

3.1 ISO/TS 16949:2009 REQUIREMENTS

• Comply with a Part Approval Process as recognized by the Customer

• If an Organisation decides to comply with PPAP Manual, all
requirements in PPAP manual must be complied
• All subcontractors (Suppliers) must be covered under Part Approval
Process.
• If required by customer (e.g. GM) PPAP manual must be used with
subcontractors (Suppliers).
• All changes affecting production process environment are to be validated
properly and records shall be maintained
• PPAP documentation must be available for all active parts or Corrective
action plan for PPAP going forward
• For Bulk Materials, PPAP is not required unless requested by customer
• PPAP records shall be maintained till the part is active + 1Year

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 Course Material for PPAP Rev. No.0

SECTION 3.2

PPAP PROCESS FLOW CHART EXAMPLE

CUSTOMER CUSTOMER
ORGANISATION

Purchase Order /
Customer Specific Record of
Requirements Approved PSW

Project Owner Completion of Submission,

& Team PPAP Required Resubmission
Items of PPAP
warrant

Customer
Part Design Receipt &
Approval of
Requirement Submitted PSW
Gather Completion of
Information PSW

Customer Process
Design
Requirements
Validated Process
(PSO / Run at
Rate)

Customer
Specifications

Approved PSW Supplier

PPAP Initiated
Table 4.1 Changes
Records Customer
Initiated Changes
Customer to Part
Logistics Specification etc.,
Requirements

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Course Material for PPAP Rev. No.0

4.0 COMPARISON OF PPAP WITH TRADITIONAL

APPROACH

TRADITIONAL SAMPLE PPAP

SUBMISSION
- Sample taken from a small lot Sample taken from a significant
production run
- additional processes other than in No process other than PFD is
process flow diagram followed allowed without informing to
customer or notified after production
- Non productionised tooling where Notified to customer
used
- submission of Submission of
- samples - samples
- dimensional report - 18 other documents / items as
- material test report applicable, which provides the
- any qualification record (for evidence of controls exercised on
spl. Processes) production / process environment
- customer approval for bulk based Customer approval based on sample
on evaluation of sample & & evaluation of documents & items
documents submitted which provides confidence to
customer that supplier has
understood his requirements &
demonstrated his capability to meet
the same in bulk production

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Course Material for PPAP Rev. No.0

5.0 SIGNIFICANT PRODUCTION RUN

• This is carried out as per APQP timing plan

Any one or more of the following as appropriate shall satisfy the intent
• Min. of 1 hr to 1 shift production with specific production quantity to a
total of min.300 consecutive parts
• Quantity specified by customer quality representative
• Produced from production site using tooling, gauging, process , material,
operators from the production environment
• Parts from unique tools, lines, cavity, mould, pattern are measured and
representative Parts tested

• for bulk material any one or more of the following as appropriate can
be applied

• No specific quantity is required

• If sample submission required, then it is taken from a “Steady

State” operation

• Production histories of similar products may be judged (using

Cp/Cpk)

• Containment plan, till adequate production has demonstrated

capability or performance

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Course Material for PPAP Rev. No.0

6.0 REQUIREMENTS FOR PART APPROVAL

1. 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
5. Process Flow Diagrams
6. Process FMEA
7. Control Plan
8. Measurement System Analysis Studies
9. Dimensional Results
10. Material / Performance Test Results
11. Initial Process Study
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR), if applicable
14. Sample Product
15. Master Sample
16. Checking Aids
17. Records of Compliance with Customer Specific requirements
18. Part Submission Warrant (PSW)

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Course Material for PPAP Rev. No.0

6.1 DESIGN RECORDS

• Part drawings, specifications, CAD data or any documents referenced

• If it is electronic format, hard copy to identify measurements taken

• for bulk materials

• Raw material identification

• Formulations

• Processing steps & parameters

• Final product specifications & acceptance criteria

• Reporting of Part Material Composition

• Demonstrate compliance to material / part composition reporting. This

material reporting may be entered into the IMDS (International Material
Data System) or other Customer specified system / method
(www.mdsystem.com)

Marking of Polymeric Parts

Identify Polymeric parts with ISO symbols such as specified in ISO 11469,
“PLASTICS – GENERAL INTRODUCTION AND MARKING OF PLASTIC
PRODUCTS”.

Refer ISO 11469 / 1043 –1 for weighment of Plastic Parts, ISO 1043-2 for
fillers and reinforcements and ISO 11469 / 1629 for weighment of Elastomeric
Parts.

6.2 ANY AUTHORISED ENGG. CHANGE DOCUMENT

• Authorized change documents provided by customer incorporated in the

part not incorporated in the drawing

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Course Material for PPAP Rev. No.0

6.3 ENGINEERING APPROVAL

• As required by design record

• For bulk materials, signature of customer on bulk material approval

check list or inclusion of supplier’s name in customer list of approved
materials

6.4 DESIGN FMEA

• Applicable to design responsible suppliers

• for bulk materials, Design Matrix & Design FMEA are prepared as
required by bulk material requirements checklist

• for bulk materials, Design FMEA ratings for SEV, OCC, DET specified
in PPAP manual can be used

Single Design may be applied to a family or similar parts or materials.

6.5 PROCESS FLOW DIAGRAM

• As per APQP manual

• For bulk materials process flow description satisfies the requirement

6.6 PROCESS FMEA

• Compliance to FMEA III edition requirements

• Process FMEA for family of parts

• For bulk materials, Process FMEA rating for SEV, OCC, DET
specified in PPAP manual can be used

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Course Material for PPAP Rev. No.0

6.7 CONTROL PLAN

ƒ As per APQP manual &ISO/TS requirement and Customer specific
requirement.
ƒ Family Control Plans are acceptable if the new parts have been reviewed
for commonality by the Organisation.
ƒ Control Plan approval may be required by some Customers.

6.8 MEASUREMENT SYSTEMS ANALYSIS STUDIES

• Compliance to MSA studies as per current version of the reference

Manual or as required by Customer.

6.9 DIMENSIONAL RESULTS

• Compliance to control plan & Design Record and all characteristics

(except ref. Dimensions)
• Dimensional results for each production lines, each cavities, molds,
patterns, dies
• Indicate design record, change level, authorized engg. Change document
ref. On all reports
• Identify master sample which is measured
• Tracing is required when optical comparator is required

6.10 MATERIAL / PERFORMANCE TEST RESULTS

• Compliance to design record/ control plan

• Record of qty. tested on each tests
• Engg. Change level or authorized engg. Change
• Date of testing
• Material sub contractor’s name and their code (from customer approved
List)

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Course Material for PPAP Rev. No.0

6.11 INITIAL PROCESS STUDIES

• Prior to submission, acceptable level of initial process capability or

performance shall be determined with customer
• MSA prior to initial process studies
• For special Characteristics of variable data. Where there is no special
characteristic identified, the Customer reserves the right to require
demonstration of initial process capability on other characteristics.
• Cpk or Ppk can be as per customer agreement
• Control charts are preferred, if X bar – R charts used, Min. 25 sub groups,
min 100 nos. from significant production run.

QUALITY INDICES

• Use Cpk or Ppk

• Where historical Cpk data is available for similar parts of same process,
Cpk can be captured
• For chronically unstable processes (within specification) use Ppk
• For bulk material, customer agreement on usage of techniques
• Index value > 1.67, Else CA plan is reqd.
• For Unstable processes, notify customer & submit CA plan. Modify
Control Plan, normally providing for 100% inspection. 100% inspection
methodologies are subject to review and concurrence by the Customer.
• Use appropriate statistical tools for One sided specification or non normal
data
E.g. F/O, R/O, concentricity, twist, effort, surface finish, uniformity, etc.,

• Alternate method of calculation & acceptance criteria with customer

agreement

• For bulk materials, if Ppk/Cpk is not achieved 100% inspection of a

sample (s) from a continuous process or homogeneous batch, which
represents online production run.

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Course Material for PPAP Rev. No.0

6.12 QUALIFIED LABORATORY DOCUMENTATION

• If in-house laboratory is only used for testing / calibration, add laboratory

scope

• If outside laboratory is used for testing / calibration, add NABL

certificate or equivalent of that laboratory

• Add scope of accreditation of that lab

• Qualified outside laboratory must be as defined by the Customer.

6.13 APPEARANCE APPROVAL REPORT

• As required in Design Record

6.14 SAMPLE PRODUCTION PARTS

• As per customer request

6.15 MASTER SAMPLE

• Retain till new master sample is produced or as per design record

requirement for inspection criteria
• For each position of a multiple cavity, die, tool, mould or pattern, line.
• Retention period can be waived or modified by customer

6.16 CHECKING AIDS

• Inspection Fixtures, gages, models, templates, etc. specific to the part

• If more than one , prepare & refer the list in PSW including its change
level
• Submit if required by customer
• Certification of checking aid w.r.t part dimensions
• Demonstration of engg. Change in gauge change
• Appropriate MSA studies
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Course Material for PPAP Rev. No.0

6.17 CUSTOMER SPECIFIC REQUIREMENTS

• compliance records to all specific requirements of customer (Sec. II)

6.18 PART SUBMISSION WARRANT (CFG-1001)

• Separate PSW for each part no.

• Identify Mould / cavity / line no. in PSW
• Part weight shall be rounded off to four decimals derived out of 10
randomly selected parts
• 10 parts represent all moulds, cavities, lines as appropriate

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Course Material for PPAP Rev. No.0

7.1 SITUATIONS WHERE NOTIFICATION & SUBMISSION TO

CUSTOMER IS REQUIRED

The Organisation shall submit for PPAP approval prior to the first production
shipment in the following situations unless the Customer has waived this
requirement.

Sl. Requirements
No.
1. A new part or product
2. Correction of a discrepancy on a previously submitted part
3. Engg. Change to design records, specifications, or materials
4. For bulk materials, Process technology new to the supplier, not
previously used for this product

The Organisation shall review and update, as necessary, all applicable items in
the PPAP file to reflect the Production, regardless of whether or not the
Customer requests a formal submission. The PPAP file shall contain the name
of the authorized Customer representative granting the waiver and the date.

Specimen Format for Product / Process Change Notification that has to be

submitted to Customer for approval is specified in PPAP manual.

SITUATIONS WHEN PPAP VALIDAITON CUSTOMER NOTIFICATION

AND SUBMISSION IS REQUIRED

The Organisation shall notify the Customer of any planned changes to the
design, process or site. Upon notification and approval of the proposed change
by the Customer representative, and after change implementation, PPAP
submission is required, unless specified.

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 Course Material for PPAP Rev. No.0

8. PPAP SUBMISSION LEVELS

Sl.No. Requirements Submission Level

1 2 3 4 5
1. Design Records of Saleable Product R S S * R
for proprietary components / details R R R * R
for all other components / details R S S * R
2. Engineering Change Documents, if any R S S * R
3. Customer Engineering Approval, if rqd R R S * R
4. Design FMEA R R S * R
5. Process Flow Diagrams R R S * R
6. Process FMEA R R S * R
7. Control Plan R R S * R
8. Measurement System Analysis Studies R R S * R
9. Dimensional Results R S S * R
10. Material, Performance, Test Results R S S * R
11. Initial Process Study R R S * R
12. Qualified Laboratory Documentation R S S * R
13. Appearance Approval Report (AAR), if S S S * R
applicable
14. Sample Product R S S * R
15. Master Sample R R R * R
16. Checking Aids R R R * R
17. Records of Compliance with Customer R R S * R
Specific requirements
18. Part Submission Warrant (PSW) S S S S R
19. Bulk Material Requirements Checklist R R R * R
(for bulk material PPAP only)

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Course Material for PPAP Rev. No.0

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

• Level 3 as default level

• For Bulk materials, Level 1 as default level

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