PPAP Checklist

XtraLight Z3 / XL1846180397Z / 23 May 2023 /

Hannah Erlin Complete

Score 79.87% Flagged items 30 Actions 9

Manufacturer  

JIT Manufacturing, Inc.

Fergus Falls, MN 56537, USA

Address
(46.2835212, -96.0777887)

Customer  

Grandfame Motors Company

San Francisco, CA 94103, USA

Address
(37.7726402, -122.4099154)

Part Name & Number  

XtraLight Z3 / XL1846180397Z

Quality Manager Hannah Erlin

Conducted on 23.05.2023 12:00 PST

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1.Flaggeditems&Actions

Flagged items & Actions 30 flagged, 9 actions  

Flagged items 30 flagged, 9 actions

PPAP Checklist / 1. Design Records

Is the form of dimension throughout the PPAP identical in all

No
documentation?

Inconsistent drawings, one is for a headlight and the other is for a speaker.

Photo 1 Photo 2

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:19 PST | Created by S
afetyCulture Staff

Attach correct drawing.

PPAP Checklist / 1. Design Records

Are tolerances compatible with accepted manufacturing

No
standards?

Manufacturing tolerances below industry standard.

PPAP Checklist / 4. Design FMEA

Is a statement attached that DFMEA is available to be

No
presented to the customer upon request?

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:19 PST | Created by S
afetyCulture Staff

Attach DFMEA statement.

PPAP Checklist / 4. Design FMEA

Does FMEA consider all major “lessons learned” (such as high

warranty, campaigns, etc.) as input to failure mode No
identification?

Our lessons learned database is incomplete due to missing reports.

PPAP Checklist / 4. Design FMEA

Have the causes been described in terms of something that

No
can be fixed or controlled?

PPAP Checklist / 4. Design FMEA

Does FMEA address all high-risk Failure Modes, as identified No

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by the FMEA team, with executable Action Plans?

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:20 PST | Created by S
afetyCulture Staff

Resolve high-risk failures.

PPAP Checklist / 4. Design FMEA

Have appropriate countermeasures been planned or taken for

No
high-risk numbers?

Not yet, no time.

PPAP Checklist / 5. Process Flow Diagram Assessment

Are inspection/quality assurance steps, data recording,

attribute checks and/or functional testing included for each No
process step?

PPAP Checklist / 5. Process Flow Diagram Assessment

Is the process flow chart controlled, updated and reviewed for

No
completeness?

Need to update.

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:22 PST | Created by S
afetyCulture Staff

Update process flow chart.

PPAP Checklist / 6. Process FMEA

Is a statement attached that PFMEA is available to be

No
presented to the customer upon request?

PPAP Checklist / 6. Process FMEA

Are adequate controls in place for all characteristics? No

PPAP Checklist / 6. Process FMEA

Are special controls/actions in place for all Special

No
Characteristics?

None for some special characteristics.

PPAP Checklist / 6. Process FMEA

Is Process FMEA integrated and consistent with the Process

Flow Diagram, Process Control Plan and other PPAP No
documents?

PPAP Checklist / 6. Process FMEA

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Are the top RPNs addressed with recommended actions and
No
the actions are implemented?

PPAP Checklist / 6. Process FMEA

Is there evidence that the failure modes with action are

No
carried over to the Process Control Plan?

PPAP Checklist / 7. Control Plan

Are Special Characteristics and other major, significant,

No
features of special interest, etc. process variables identified?

PPAP Checklist / 7. Control Plan

Is there evidence of feedback from customer problems or

No
rejections?

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:25 PST | Created by S
afetyCulture Staff

Get customer feedback.

PPAP Checklist / 8. Measurement System Analysis

Have results been reviewed and approved by the customer? No

PPAP Checklist / 9. Dimensional Results

Is there evidence that all specification and other

No
requirements were documented?

PPAP Checklist / 9. Dimensional Results

Do all requirements, including drawing notes have a response

No
(pass/fail statement is unacceptable)?

PPAP Checklist / 9. Dimensional Results

Do results meet all Design Record Requirements? No

PPAP Checklist / 9. Dimensional Results

Is all reporting against customer specification? No

PPAP Checklist / 10. Records of Material / Performance Test Results

Are all testing results less than one (1) year old? No

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:29 PST | Created by S
afetyCulture Staff

Perform materials testing.

PPAP Checklist / 11. Initial Process Studies

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Is there a program to update the studies on a routine basis? No

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:31 PST | Created by S
afetyCulture Staff

Schedule continuous improvement studies.

PPAP Checklist / 12. Qualified Laboratory Documentation

Is a complete, signed and dated lab scope available? No

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:31 PST | Created by S
afetyCulture Staff

Capture digital signature.

PPAP Checklist / 12. Qualified Laboratory Documentation

Does the lab scope (as defined on the certification or

addendum to the certification) list all tests performed by the No
lab?

PPAP Checklist / 12. Qualified Laboratory Documentation

Are all Special Characteristics from the drawing (and drawing

No
notes) included?

PPAP Checklist / 15. Master Sample

Is the master sample approved by the customer and identified

No
as a master sample?

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:49 PST | Created by S
afetyCulture Staff

Gain customer approval.

PPAP Checklist / 16. Checking Aids

Are all Checking Aids numbered, calibrated, included in the

No
Control Plan and provided for preventive maintenance plans?

PPAP Checklist / 18. Part Submission Warrant

Is a completed bulk material checklist and warrant in place

for all bulk material used in production parts? (See page 36 of No
AIAG PPAP 4th edition Manual)

Other actions 0 actions

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2.PPAPChecklist-79.87%

PPAP Checklist 30 flagged, 9 actions, 79.87%  

2.1.1.DesignRecords-80%

 
1. Design Records 2 flagged, 1 action, 80%

Is a copy of the drawing included to support the part or

Yes
assembly (both manufacturer and customer drawings)?

Is a list of specification supporting the production of this part

Yes
provided?

Is change level verification assured or available that the

Yes
supplier has the latest revisions of specification?

Is the form of dimension throughout the PPAP identical in all

No
documentation?

Inconsistent drawings, one is for a headlight and the other is for a speaker.

Photo 1 Photo 2

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:19 PST | Created by S
afetyCulture Staff

Attach correct drawing.

Is the form of reporting dimensions throughout the PPAP

Yes
according to customer drawing?

Have dimensions that affect fit, function and durability been

Yes
identified?

Are reference dimensions identified to minimize inspection

Yes
layout time?

Are sufficient control points and datum surfaces identified to

Yes
design functional gages?

Are tolerances compatible with accepted manufacturing

No
standards?

Manufacturing tolerances below industry standard.

Are there any requirements specified that can be evaluated

Yes
using known inspection techniques?
2.2.2.AuthorizedEngineeringChangeDocuments-100%

 
2. Authorized Engineering Change 100%
Documents

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 Are authorized engineering changes applicable? No
2.3.3.CustomerEngineeringApproval-100%

 
3. Customer Engineering Approval 100%

Is customer engineering approval required? No

2.4.4.DesignFMEA-66.67%

 
4. Design FMEA 5 flagged, 2 actions, 66.67%

Does the FMEA drive Design Improvements as primary

Yes
objective?

Is a statement attached that DFMEA is available to be

No
presented to the customer upon request?

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:19 PST | Created by S
afetyCulture Staff

Attach DFMEA statement.

Does FMEA consider all major “lessons learned” (such as high

warranty, campaigns, etc.) as input to failure mode No
identification?

Our lessons learned database is incomplete due to missing reports.

Has all dimensional tolerances and material properties been

Yes
considered?

Have customer reliability and warranty data been utilized in

Yes
preparing FMEA?

Have the causes been described in terms of something that

No
can be fixed or controlled?

Were attribute characteristics included? Yes

Does FMEA identify appropriate Special Characteristics

candidates as input to the Special Characteristics selection Yes
process?

Are New Product Introductions and design changes included

Yes
in identifying Special Characteristics?

Does Analysis/Development/Validation (A/D/V) and/or Design

Verification Plan and Report (DVP&R) consider the failure Yes
modes from the Design FMEA?

Does FMEA address all high-risk Failure Modes, as identified

No
by the FMEA team, with executable Action Plans?

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:20 PST | Created by S
afetyCulture Staff

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 Resolve high-risk failures.

Have appropriate countermeasures been planned or taken for

No
high-risk numbers?

Not yet, no time.

Were customer plant problems used as an aid in developing

Yes
the FMEA?

Have customer product problems and/or rejections been

Yes
included with countermeasures?

Does submission include action list from Design Review? Yes

2.5.5.ProcessFlowDiagramAssessment-86.67%

 
5. Process Flow Diagram Assessment 2 flagged, 1 action, 86.67%

Is the Process Flow Chart in place and identifies all

manufacturing operations, handling techniques, inspection
Yes
steps, alternate/back-up processes, and sub-contract
suppliers?

Photo 3 Photo 4

Does the process layout reflect planning so that a logical flow

Yes
of material can occur during manufacturing of the product?

Does the flow chart illustrate the sequence of production? Yes

Has the pull system/optimization been considered for this

Yes
process?

Are steps in the process where product is stored and/or

Yes
staged clearly identified?

Does the flow chart describe how the product will move, i.e.
Yes
roller conveyor, slide containers, tubs, etc?

Are the sequences identified (operation or sequence number)

Yes
so as to follow through to other PPAP documents?

Are inspection/quality assurance steps, data recording,

attribute checks and/or functional testing included for each No
process step?

Does the flow chart indicating the material flow and control
Yes
for handling rework and scrap?

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 Does the material flow consider potential quality problems
Yes
due to handling and subcontracted operations?

Does the flow chart include all assembly and packaging

Yes
operations?

Does the flow chart illustrate shipment to the customer and

Yes
steps to consumption?

Is the process flow chart controlled, updated and reviewed for

No
completeness?

Need to update.

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:22 PST | Created by S
afetyCulture Staff

Update process flow chart.

Does the flow chart identify in detail all in-house alternate or

back-up processes and sub-contract alternate or back-up Yes
sources of supply for products or services provided?

Have alternate or back-up processes or sub-contract suppliers

Yes
been validated?
2.6.6.ProcessFMEA-60%

 
6. Process FMEA 6 flagged, 60%

Does FMEA drive Process Improvements as the primary

Yes
objective, with emphasis on Error/Mistake Proofing solutions?

Photo 5

Is a statement attached that PFMEA is available to be

No
presented to the customer upon request?

Did the right people participate as part of the FMEA team

throughout the analysis, and are adequately trained in the Yes
procedure?

Is the correct part number, engineering change, and other

Yes
information documented?

Is there evidence that all print, specification, purchase order,

Yes
attribute, etc. characteristics are included?

Are adequate controls in place for all characteristics? No

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 Are special controls/actions in place for all Special
No
Characteristics?

None for some special characteristics.

Are there measurable quality improvement projects in place

Yes
for Special Characteristics?

Is Process FMEA integrated and consistent with the Process

Flow Diagram, Process Control Plan and other PPAP No
documents?

Is there evidence of Statistical Process Control for all Special

Characteristics or controls as identified and approved in the Yes
Control Plan?

Are quality performance indicators provided as evidence that

sufficient methods are in-place to monitor and control all Yes
characteristics?

Are the top RPNs addressed with recommended actions and

No
the actions are implemented?

Have capability studies been performed to validate the

Yes
control of the characteristics?

Is FMEA completed during the “window of opportunity” where

it could most efficiently impact the design of the product or Yes
process?

Is there evidence that the failure modes with action are

No
carried over to the Process Control Plan?
2.7.7.ControlPlan-88.24%

 
7. Control Plan 2 flagged, 1 action, 88.24%

Are Control Plans and input criteria reviewed with

Yes
manufacturing personnel?

Are all sections filled out including evidence of

Yes
cross-functional team involvement?

Are detailed and complete Process Control Plans in place to

purchase, manufacture, inspect, test, assemble, package, and Yes
ship product for each operation performed?

Does the Control Plan provide detail methods of correcting

out of control processes, handling nonconforming products,
Yes
and corrective action program on all quality problems
including attribute variables?

Are Special Characteristics and other major, significant,

No
features of special interest, etc. process variables identified?

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 Are there Process Control Plans in place for all customer part
Yes
numbers?

Are Engineering Test and Performance requirements

Yes
identified?

Is there a documented program for establishing sample sizes

Yes
and test frequencies?

Are gage methods compatible and are they traceable to

Yes
national standards?

Does the Control Plan provide detail on: machine make &
Yes
model, machine type, machine number/identification, etc.?

Is all manufacturing equipment identified i.e. press type,

Yes
paint booth type, etc.?

Is Receiving Inspection, Process Inspection, and Final

Yes
Inspection included in Control Plan?

Photo 6

Have all known customer concerns been identified to

facilitate the selection of Special Required/Design/Process Yes
Characteristics?

Is there evidence of feedback from customer problems or

No
rejections?

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:25 PST | Created by S
afetyCulture Staff

Get customer feedback.

Are appropriate reaction plans included in the Control Plan? Yes

Are Control Plans completed and readily available for

Yes
alternate or backup process?

Are Process Control Plans completed/updated for new product

Yes
or design changes?
2.8.8.MeasurementSystemAnalysis-80%

 
8. Measurement System Analysis 1 flagged, 80%

Are MSAs for all (including attribute, process controls, etc.)

Yes
gages listed on the control plan provided?

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 Do all MSAs refer to the correct part number and/or gage
Yes
family

Did the supplier submit an acceptable MSA as above and

Yes
documented in the AIAG MSA Manual?

Have correlation concerns been addressed? Yes

Have results been reviewed and approved by the customer? No

2.9.9.DimensionalResults-60%

 
9. Dimensional Results 4 flagged, 60%

Are the dimensions references on a ballooned customer

Yes
drawing or documented within a characteristics library?

Is there evidence that all specification and other

No
requirements were documented?

Are the correct numbers of parts laid out? Yes

Do all requirements, including drawing notes have a response

No
(pass/fail statement is unacceptable)?

Are all Special Characteristics highlighted? Yes

Do results meet all Design Record Requirements? No

Is any nonconformance highlighted in the report? No

Is layout result legible and understandable? Yes

Are the inspection sheets approved and signed? Yes

Is all reporting against customer specification? No

2.10.10.RecordsofMaterial/PerformanceTestResults-90%

 
10. Records of Material / Performance Test 1 flagged, 1 action, 90%
Results

Are material and performance test results provided for

chemical, physicals or metallurgical to the customer Yes
specification and compliance confirmed?

Photo 7 Photo 8 Photo 9

Does the submission include correct part and engineering Yes

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 change level, specification numbers, date and change level,
authorized engineering change documents not yet
incorporated into the design, test date, quantity tested, the
actual results, the material supplier’s name and, when
required by the customer, the customer-assigned vendor
code, special requirements for approved steel, heat
treatment, plating, etc., other relevant information
specifically required by the customer?

Is any nonconformance highlighted in the report? No

Is product testing to be done in-house? No

Are all testing results less than one (1) year old? No

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:29 PST | Created by S
afetyCulture Staff

Perform materials testing.

Is all testing summarized with actual criteria and data

Yes
(pass/fail statement is unacceptable)?

Is test loading sufficient to provide all conditions, i.e.

Yes
production validation and end use?

Have parts manufactured at minimum and maximum

Yes
specification been tested?

Can additional samples be tested when a reaction plan

Yes
requires it?

Is the specified test sampling size and/or frequency feasible? Yes

2.11.11.InitialProcessStudies-93.33%

 
11. Initial Process Studies 1 flagged, 1 action, 93.33%

Is there preventive maintenance, gage and fixture calibration,

tooling verification needed to maintain an acceptable level of Yes
capability?

Were results utilized in determining preventative

Yes
maintenance schedules?

Was a study performed on the packaging of products for

shipment, assembly operations, and final product Yes
conformance?

Photo 10 Photo 11 Photo 12 Photo 13

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 Is the method utilized to perform studies and calculate
capability level documented along with evidence that results Yes
are within customer requirements?

Is the measurement method/device noted? Yes

Were correlation studies required and performed? Yes

Are results for standard deviation and the distribution noted? Yes

Is variable data reporting preferred for process capability

Yes
reporting?

Is the attribute data indicating zero (O) defects found? Yes

Does the data indicate that the process is under control? Yes

Is the sample size according to the agreed upon criteria and

Yes
documented within the submission?

Are capability studies performed on new product and/or

Yes
design changes and when process changes are implemented?

Is there evidence of capability results feedback to

Yes
management and production personnel?

Is a mechanism in place to feedback the product testing

Yes
results to the capability study?

Is there a program to update the studies on a routine basis? No

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:31 PST | Created by S
afetyCulture Staff

Schedule continuous improvement studies.

2.12.12.QualifiedLaboratoryDocumentation-70%

 
12. Qualified Laboratory Documentation 3 flagged, 1 action, 70%

Is a complete, signed and dated lab scope available? No

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:31 PST | Created by S
afetyCulture Staff

Capture digital signature.

Does the lab scope (as defined on the certification or

addendum to the certification) list all tests performed by the No
lab?

Are qualified independent laboratory checks defined? Yes

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 Is the quantity tested identified? Yes

Are all Special Characteristics from the drawing (and drawing

No
notes) included?

Has testing specification been identified on all tests? Yes

Are results reported on the letterhead? Yes

Are performance test results and material test (chemical,

Yes
metallurgical, etc.) results included?

Is any nonconformance highlighted in the report? Yes

Has customer approval been obtained for the test? Yes

2.13.13.AppearanceApprovalReport-100%

 
13. Appearance Approval Report 100%

Are appearance items identified on the engineering drawing? Yes

Is the standard AAR form filled out completely? Yes

Is a formal, approved, controlled waiver submitted? Yes

Is formal approval in place from the proper organization

Yes
(engineering, marketing, met lab)?

Was submission according to customer specification? Yes

2.14.14.SampleProductionParts-100%

 
14. Sample Production Parts 100%

Are the formal requirements for samples documented? Yes

Photo 14 Photo 15 Photo 16 Photo 17 Photo 18

Is there a formal, approved, controlled waiver for samples

Yes
attached?

Are the samples shipped before PPAP Submission with

Yes
documentation of the parts included?

Were the samples measured from taken from the Production

Yes
Trail Run or a production run?

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Photo 19 Photo 20 Photo 21

2.15.15.MasterSample-80%

 
15. Master Sample 1 flagged, 1 action, 80%

Is there evidence of a master sample according to the

Yes
standard?

Photo 22

Is there a formal, approved, controlled waiver in place for

master sample or documentation to consume master sample Yes
in production?

Are master samples controlled for life of PPAP records or until

Yes
a new sample is approved and disposition of old sample?

Is the master sample approved by the customer and identified

No
as a master sample?

To Do | Assignee SafetyCulture Staff | Priority Low | Due 30.05.2023 12:49 PST | Created by S
afetyCulture Staff

Gain customer approval.

Are master samples available for multiple dies, cavities,

Yes
molds, impressions, etc.?
2.16.16.CheckingAids-75%

 
16. Checking Aids 1 flagged, 75%

Is submission according to customer specific requirements? Yes

Were prints copies and duplication gages submitted? Yes

Are all Checking Aids numbered, calibrated, included in the

No
Control Plan and provided for preventive maintenance plans?

Do all Checking Aids have acceptable Measurement Systems

Yes
Analysis studies?
2.17.17.CustomerSpecificRequirements-100%

 
17. Customer Specific Requirements 100%

Is a list of “Specific Requirements” along with compliance Yes

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 documentation provided or a waiver that none exist?

Does reporting take place for those requirements listed and

all others identified by PPAP approver representative plus Yes
other process partners (met lab, engineering, logistics, etc.)?
2.18.18.PartSubmissionWarrant-80%

 
18. Part Submission Warrant 1 flagged, 80%

Is the warrant compliant to the AIAG PPAP standard? Yes

Is proper detail provided for “Reason for Submission”? Yes

Are all fields completed as per PPAP instructions? Yes

Is a completed bulk material checklist and warrant in place

for all bulk material used in production parts? (See page 36 of No
AIAG PPAP 4th edition Manual)

Submission Level 3

Are all 16 elements provided along with full explanation of

Yes
any that are not provided in full?
2.19.Completion

 
Completion  

Additional Comments  

Attach missing documents, align PPAP documentation like FMEAs and special characteristics,
gather digital signatures for customer approval, and provide more photo evidence of the PPAP.

Quality Manager Name & Signature  

Hannah Erlin
23.05.2023 12:50 PST

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3.Mediasummary

Media summary

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