PPAP 4th Edition Roll-out

& ISO/TS 16949 Status

Conference

Hank Gryn, DaimlerChrysler

Russ Hopkins, Ford Motor Company
Joe Bransky, General Motors

IATF and SQRTF Representatives

1
 Status of TS 16949
ISO/TS 16949
Launched 1999
Current Edition
2nd Edition. – March 2002*
(based on and including ISO
*corrected version 12/15/03
9001:2000)

No. of certificates issued 19,791

No. of contracted CB’s 54

No. of Auditors 2,000+

Automotive Oversight 5 Global Offices

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IATF local oversight offices

COUNTRY FRANCE GERMANY ITALY UK USA

Oversight IATF
VDA-QMC ANFIA SMMT IAOB
Office France

# of CB’s 3 19 3 6 23

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 What has TS delivered?
‹ Almost 20,000 Organizations Certified to TS 16949
‹ Rules revised and 2nd Edition issued May 2004
‹ 54 Certification Bodies recognized
‹ 5 Oversight Offices staffed with 31 witness auditors
– IATF Administrative Office opened in Beijing
‹ Over 2000 qualified and licensed CB auditors
– Re-qualification revised and launched in the 4th quarter
2005
‹ QS 9000 expires 12/14/06
– July 2004: 20400
– January 2006: 9900

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 So what does this all mean?
‹ The global automotive standard: TS 16949:2002 is
in place
– Likely beyond 2010
‹ The certification scheme: Rules 2nd Ed. is in place
‹ The infrastructure: IATF Oversight is in place
including
– Oversight witness audit process
– Database
‹ OEM direction: Requirements/deadlines in place
‹ QS-9000 expires
– QS-9000 expires at midnight December 14, 2006.
– Suppliers need to transition from QS to TS in the next 9
months! Copyright 2006, DaimlerChrysler, Ford, General Motors,
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 So what does this all mean?

‹ Status of Core Tools Manuals:

– FMEA released as FMEA 3rd - July 2001
• FMEA 3rd is currently under review but no date for
revised version established
– MSA released as MSA 3rd - March 2002
• 2nd Printing - May 2003
– SPC released as SPC 2nd - July 2005
– APQP – no review under way
– PPAP released as PPAP 4th - March 1, 2006

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 ISO 9001:2000 Model of a Process-Based
Quality Management System

Continual improvement of The quality

management system

Management
responsibility

Customers Customers

Measurement,
Resource
analysis and Satisfaction
Management
improvement

Input Output
Product
Requirements realization Product

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 Defining Processes

INPUT OUTPUT
Customer who Customer who
has a need has a need met

Step Step Step Step

1 2 3 “N”

Input Output

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 Critical Elements of the
Process Approach
‰ Process owner exists
‰ Process is defined
‰ Process is documented, as appropriate
‰ Linkages of process established
‰ Process monitored, analyzed and improved
‰ Records maintained

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 The Automotive Required
Method for Identifying
Processes

There isn’t one!

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 PPAP Process Model –

CUSTOMER CUSTOMER

Customer
Purchase Order /
Customer-Specific
An Example Record of
Approved
PSW
Requirements
ORGANIZATION

Completion of Submission (or

Customer Project Owner Receipt and
PPAP Resubmission)
Part Design & Approval of
Required of PPAP
Requirements Team Submitted PSW
Items Warrant

Customer Validated
Process Design Completion Process
Gather
Requirements of [PSO / Run at
Information
PSW Rate]

Supplier Initiated
Changes
Customer Approved
PPAP Table 4.1
Specifications PSW
Records Customer Initiated
Changes
to Part ,
Specifications, etc.

Customer
Logistics
Requirements

: Copyright 2006, DaimlerChrysler, Ford, General Motors,

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Reserved March 2006
 PPAP’s Purpose
PPAP’s purpose continues to be to
provide the evidence that all customer
engineering design record and
specification requirements are properly
understood by the organization and that
the process has the potential to produce
product consistently meeting these
requirements during an actual production
run at the quoted production rate.

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 Applicability
PPAP shall apply to internal and
external organization sites (see
Glossary) of bulk materials,
production materials, production or
service parts.

For bulk materials, PPAP is not

required unless specified by the
authorized customer
representative.*
*Ford Motor requires PPAP of Bulk
Material Suppliers.

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 Effective Date

The PPAP Fourth Edition replaces

the Third Edition effective

June 1, 2006

unless otherwise specified by your

customer.

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 Changes in the 4th Edition
The Fourth Edition of PPAP includes the following
changes:
• Identified issues in the application of PPAP
• Removal of QS-9000 references
• Necessary edits including typographical or
grammatical corrections
• Removal of vehicle OEM Customer Specifics
• Some rearrangement of clauses to improve flow

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 Overview

‹ Alignment of PPAP to the ISO/TS 16949:2002

process approach, including:
– Aligning the order of the PPAP requirements with
the automotive product development and
manufacturing process
– Inclusion of an example process flow for PPAP
‹ Relocation of Customer Specific Instructions to
appropriate websites, (e.g. OEM and IAOB,
www.iaob.org) to provide current requirements
‹ Update of Truck OEM requirements and moved to
Appendix H

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 Overview

‹ Revised PSW (Part Submission Warrant) to:

– Provide a more logical flow for the part / design
description fields
– Make the supplier address fields applicable to
international locations
– Include IMDS materials reporting to indicate
reporting status

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 Overview

‹ Updated specific PPAP requirements, including:

– Materials reporting and polymeric identification
requirements in the design record
– Process capability index usage (Cpk and Ppk)
– The definition and approval of catalog parts and
the definition of black box parts
‹ Modified customer notification and submission
requirements to align with OEM requirements
(e.g., I.3.3 from PPAP 3rd removed)

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 Overview

‹ Clarified and commonized Appendices C, D, and

E to match the PPAP reporting requirements
‹ Revised Tire Appendix to allow OEM specification
of applicability and to eliminate duplications with
allowances already provided in the PPAP
requirements
Note: The Tire Appendix is not applicable to organizations
supplying tires to Ford Motor Company.

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 Overview

‹ Reorganized and updated Appendix F to stress

the importance of the Bulk Materials Checklist
Note: Ford Motor Company requires all organizations
supplying bulk material to Ford Motor Company to comply
with PPAP.
‹ Revised Glossary to be consistent with the
updates in the text

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 TABLE OF CONTENTS
‹ INTRODUCTION
‹ SECTION 1 – GENERAL
‹ SECTION 2 – PPAP PROCESS REQUIREMENTS
‹ SECTION 3 – CUSTOMER NOTIFICATION AND SUBMISSION
REQUIREMENTS
‹ SECTION 4 – SUBMISSION TO CUSTOMER - LEVELS OF EVIDENCE
‹ SECTION 5 – PART SUBMISSION STATUS
‹ SECTION 6 – RECORD RETENTION
‹ Appendix A – Completion of the Part Submission Warrant (PSW)

‹ Appendix B – Completion of the Appearance Approval Report

‹ Appendix C – Production Part Approval, Dimensional Results
‹ Appendix D – Production Part Approval, Material Test Results
‹ Appendix E – Production Part Approval, Performance Test Results

‹ Appendix F – Bulk Material - Specific Requirements

‹ Appendix G – Tires - Specific Requirements
‹ Appendix H – Truck Industry - Specific Requirements
‹ GLOSSARY Copyright 2006, DaimlerChrysler, Ford, General Motors,
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 2.2 PPAP Requirements
The organization shall also meet all customer-specific instructions
‹ 2.2.1 Design Record
‹ 2.2.2 Authorized Engineering Change documents
‹ 2.2.3 Customer Engineering Approval
‹ 2.2.4 Design Failure Mode and Effects Analysis (Design FMEA)
‹ 2.2.5 Process Flow Diagram(s)
‹ 2.2.6 Process Failure Mode and Effects Analysis (Process FMEA)
‹ 2.2.7 Control Plan
‹ 2.2.8 Measurement System Analysis Studies
‹ 2.2.9 Dimensional Results
‹ 2.2.10 Records of Material / Performance Test Results
‹ 2.2.11 Initial Process Studies
‹ 2.2.12 Qualified Laboratory Documentation
‹ 2.2.13 Appearance Approval Report (AAR)
‹ 2.2.14 Sample Production Parts
‹ 2.2.15 Master Sample
‹ 2.2.16 Checking Aids
‹ 2.2.17 Customer-Specific Requirements
‹ 2.2.18 Part Submission Warrant (PSW)
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 Part Name
1 Cust. Part Number
2a

Shown on Drawing No.

3 Org. Part Number
2b
4 Dated
Engineering Change Level

Additional Engineering Changes

5 Dated
7 8

PSW
Safety and/or Government Regulation Yes No Purchase Order No. Weight (kg)
6
Checking Aid No.
9 10 Dated
Checking Aid Engineering Change Level

ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION

11 13

Revised and
Supplier Name & Supplier/Vendor Code Customer Name/Division
12 14
Street Address Buyer/Buyer Code
15
City Region Postal Code Country Application

Reorganized
MATERIALS REPORTING
Has customer-required Substances of Concern information been reported?.
16 Yes n/a
No

Submitted by IMDS or other customer format:

Are polymeric parts identified with appropriate ISO marking codes? 17 Yes No n/a
REASON FOR SUBMISSION (Check at least one)
Initial Submission
18 Change to Optional Construction or Material
Engineering Change(s) Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts Produced at Additional Location
Tooling Inactive > than 1 year Other – please specify
REQUESTED SUBMISSION LEVEL (Check one) 19
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 organization's manufacturing location.

SUBMISSION RESULTS 20
The results for dimensional measurements material and functional tests appearance criteria statistical process package
These results meet all design record requirements: Yes NO (If “NO” – Explanation Required) 21
Mold / Cavity / Production Process 22
DECLARATION
I affirm that the samples represented by this warrent are representative of our parts, which were made by a process that meets all Production Part
Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the production rate of 23 / 24 hours.
I also certify that documented evidence of such compliance is on file and available for review. I have noted any deviations from this declaration below.
EXPLANATION/COMMENTS:
25
Is each Customer Tool properly tagged and numbered? Yes No 26
27
Organization Authorized Signature Date

Print Name Phone No. FAX No.

Title E-mail

FOR CUSTOMER USE ONLY (IF APPLICABLE)

PPAP Warrant Disposition: Approved Rejected Other

Customer Signature Date

Print Name Customer Tracking Number (optional)
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March
Ford, General Motors,
CFG-1001
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2006
March 2006
 Appendix A – Completion of the
Part Submission Warrant (PSW)
‹ PART INFORMATION
1. Part Name and 2a. Customer Part Number: Engineering released
finished end item part name and number.
2b. Org, Part Number: Part number defined by the organization, if any.
3. Shown on Drawing Number: The design record that specifies the
customer part number being submitted.
4. Engineering Change Level & Date: Show the change level and date
of the design record.
5. Additional Engineering Changes & Date: List all authorized
engineering changes not yet incorporated in the design record but which
are incorporated in the part.
6. Safety and/or Government Regulation: “Yes” if so indicated by the
design record, otherwise “No.”
7. Purchase Order Number: Enter this number as found on the
contract/purchase order.
8. Weight: Enter the actual weight in kilograms to four decimal places
unless otherwise specified by the customer.
9./10. Checking Aid Number, Change Level and Date: If requested by the
customer, enter the checking aid number, its change level and date.
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 Appendix A – Completion of the
Part Submission Warrant (PSW)
‹ ORGANIZATION MANUFACTURING INFORMATION
11. Organization Name & Supplier/Vendor Code: Show the
name and code assigned to the manufacturing site on the
purchase order/contract.
12. Street Address, Region, Postal Code, Country: Show
the complete address of the location where the product was
manufactured. For “Region,” enter state, county, province,
etc.
‹ CUSTOMER SUBMITTAL INFORMATION
13. Customer Name/Division: Show the corporate name
and division or operations group.
14. Buyer/Buyer Code: Enter the buyer’s name and code.
15. Application: Enter the model year, vehicle name,
engine, transmission, etc.

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 Appendix A – Completion of the
Part Submission Warrant (PSW)
‹ MATERIALS REPORTING
16. Substances of Concern: Enter “Yes,” “No,” or “n/a”.
IMDS/Other Customer Format: Circle either “IMDS” or
“Other Customer Format” as appropriate.
If submitted via IMDS include: Module ID #, Version #,
and Creation Date.
If submitted via other customer format, enter the date
customer confirmation was received.
17. Polymeric Parts Identification: Enter “Yes,” “No,” or
“n/a”.

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 Appendix A – Completion of the
Part Submission Warrant (PSW)
‹ REASON FOR SUBMISSION
18. Check the appropriate box(es). For bulk materials, in
addition to checking the appropriate box, check “Other” and write
“Bulk Material” in the space provided.
‹ SUBMISSION LEVEL
19. SUBMISSION LEVEL: Identify the submission level
requested by the customer.
‹ SUBMISSION RESULTS
20. Check the appropriate boxes for dimensional, material tests,
performance tests, appearance evaluation, and statistical data.
21. Check the appropriate box. If “no,” enter the explanation in
“comments” below.
22. Molds/Cavities/Production Processes: For instruction, see
2.2.18.
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 Appendix A – Completion of the
Part Submission Warrant (PSW)
‹ DECLARATION
23. Enter the number of pieces manufactured during the
significant production run.
24. Enter the time (in hours) taken for the significant production
run.
25. EXPLANATION/COMMENTS: Provide any explanatory
comments on the Submission Results or any deviations from the
Declaration. Attach additional information as appropriate.
26 CUSTOMER TOOL TAGGING/NUMBERING: Are customer-
owned tools identified in accord with ISO/TS 16949 and any
customer-specific requirements, answer “Yes” or “No.” May not
be applicable to OEM internal suppliers.
27 ORGANIZATION AUTHORIZED SIGNATURE: A responsible
organization 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, Fax Number, and E-mail address.
‹ FOR CUSTOMER USE ONLY
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Glossary aligned, revised, and simplified

‹ Deletions:
Agreement
Critical Characteristic (both Ford and GM definition)
Customer Product Approval Activity
Documentation
Environment
Full Approval
Gage Repeatability & Reproducibility (Gage R&R)
Initial Sample
Interim Approval

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Glossary aligned, revised, and simplified
(continued)

‹ Deletions (continued)
Key Characteristics (All four)
MSA Studies
Rejected
Remote Location
Repeatability and Reproducibility
Safety Characteristics
Self Certifying Supplier
Subcontractor
Tooling Maintenance
Tooling Refurbishment

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Glossary aligned, revised, and simplified
(continued)

‹ Revised:
Approved
Attribute Data
Customer
Initial Process Study
Part Submission Warrant
Process
Process Flow Diagram
Quality Indices
Saleable Product

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Glossary aligned, revised, and simplified
(continued)

‹ Revised (continued):
Significant Production Run
Site
Special Characteristics
Specification
Stable Process
Suppliers
Statistical Control
Submission Level
Variables Data

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Glossary aligned, revised, and simplified
(continued)

‹ Added:
Authorized Customer Representative(s)
Black Box
Organization
Production Rate

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 Measure of quality

‹ Customer demand and their willingness to pay for

a product or service is the only measure of
quality.
Peter Drucker

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 Bottom Line

‹ Sustained improvement at the…

OEM manufacturing and assembly centers:
– Warranty reduction
– Elimination of supplier disruptions
– Significant improvement in delivered part quality
– Continual quality system improvement

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