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Seite 1
PPAP
13.01.2007 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Dipl.-Ing. Ralf Glner
Production Part Approval Process 4th Edition
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 2 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
to show you the basic content and the rules of the
Production Part Approval Process
and to explain the purpose and the background
but this lecture will not save you from learninghow to practically use this system
Its the goal of this lecture to
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 3 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Notes to This Lecture
this lecture was created fortraining purposes only;
it is not an extensive description, but a
help for getting started
view of contents, basic idea and goals
The content of this lecture shall not be used as a reference for daily work
Please make sure that you are working only with original latest level documents
Creating this lecture, the valid standards of Dec 2006 were used
This lecture does not refer to customer specific requirements, nor to special PPAP
rules/requirements for bulk materials, tires, nor truck industry!
Standards mentioned in this lecture can be obtained from the institutions listed in
section 6. Internet Links
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 4 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Process Requirements
3. Customer Notification and Submission Requirements
4. Submission to Customer - Levels of Evidence
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary6. Internet Links
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 5 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
1. Introduction
it is the purpose of advanced quality management
to prevent that unreliable designs or processes
are used in serial production
therefore it is necessary to have one
extensive, strict approval process for new
or changed designs orprocesses
inevitably this process causes some
administration work
but its worth while because it reduces the
production of muda!
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 6 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
PROJECT TIME
EXPENSES
Saving by taking advantage of the Rule Of The 10:
The cost of the remedy of a defect increases
tenfold with every step, the project advances!
Early identification of a defect
...saves the
major part of
the cost!
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 7 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Savings by avoiding the 7+1 muda
unnecessarymovement
overproduction
waitingtime
stock
unnecessarytransport
mudain the processerrors
Design ignoringthe customers
expectations
muda
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 8 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Too high stocks...
take space
raise assets employed
require additional searching
require additional administration
require additional transport
are a risk, because parts might exceed expiration date or become
unsaleable
are a risk, because parts might be damaged
complicate the overview
are often a consequence of a weak process
cover weak process
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 9 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Requirement for low stocks...
lower
stocks
are controlled and capable processes
and Total Productive Maintenance
since all kind of process problems will cause delivery stops,
if the stocks are low!
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 10 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Advantages of controlled & capable production processes
satisfied customers
by good quality and avoided muda
no scrap, no rework
constant flow of material
low stocks possible
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 11 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
According to QS-9000...
such an extensive and strict process is an obligatory requirement
(cp. QS-9000, main section I)
the name of this process is
Production Part Approval Process
its explanation is one QS-9000 reference manual
QS-9000 PPAP
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 12 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Process Requirements
3. Customer Notification and Submission Requirements
4. Submission to Customer - Levels of Evidence
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 13 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
2. Content of the QS-9000 PPAPIntroduction
Section 1 General
Section 2 PPAP Process RequirementsSection 3 Customer Notification and Submission Requirements
Section 4 Submission Levels
Section 5 Part Submission Status
Section 6 Record Retention
Manufacturer Specific Requirements
Will not be discussed here!
are to be found in internet
OEM Homepages or
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 14 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Appendicies
Appendix A Completion of the Part Submission Warrant
Appendix B Completion of the Appearance Approval Report
Appendix C PPAP, Dimensional Results
Appendix D PPAP, Material Test Results
Appendix E PPAP, Performance Test Results
Appendix F Bulk Material - Specific Requirements
Appendix G Tires - Specific Requirements
Appendix H Truck Industry - Specific Requirements
Glossary
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 15 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Process Requirements
3. Customer Notification and Submission Requirements
4. Submission to Customer - Levels of Evidence
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 16 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
PPAP is, so to speak, the goal of APQP...
APQP makes sure
that all requirements are recognized before the Product
Development is started
that those special characteristics of the product are specified
which influence these requirements that it is verified again and again that the planed design can safely
meet these requirements, if the special characteristics are within
tolerance
that only those production processes are specified, which are
controlled and capable according to SPC regarding these
characteristics
A test production and PPAP are used to validate that all processes are under control and capable
the produced parts fulfil all requirements
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 17 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Purpose and Applicability
It is the purpose of PPAP to
define generic requirements for production part approval
determine if all customer engineering design record and specificationrequirements are properly understood by the organization
determine that the manufacturing process has the potential to produce
the product consistently meeting these requirements during an actual
production run at the quoted production rate
Applicability ( PPAP, Introduction)
PPAP shall apply to internal and external organization sites supplyingproduction or service parts, production materials or bulk materials.
For bulk material PPAP is not required unless specified by the customer
a supplier of standard catalogue production or service parts shall
comply with PPAP unless formally waived by the customer
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 18 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Submission of PPAP
The organization shall obtain full approval from the
authorized customer product approval activity for:
1. a new part or product
2. correction of a discrepancy on a previously submitted part3. product modified by an engineering change to
design records
specifications
materials
4. any situations required by section 3
Note: If there is any question concerning the need for PPAP,contact the authorized customer representative.
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 19 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Process Requirements
3. Customer Notification and Submission Requirements
4. Submission to Customer - Levels of Evidence
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 20 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
(2.) 2. PPAP Process Requirements
2.1 Significant Production Run
2.2 PPAP Requirements
2.2.1
2.2.2
2.2.18
Requirements describing the detailsof documentation to be attached
Will be discussed
in chapter 4 of this presentation!
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 21 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
(2.)2.1 Significant Production Run
Products 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 aminimum of 300 consecutive parts, unless otherwise specified by
the authorized customer representative
This significant production run shall be conducted at the
production, at the production rate, using the production tooling,
production gaging, production process, production materials, and
production operators.
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
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 22 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
(2.)2.2 PPAP Requirements
the supplier shall meet all specified requirements
as listed in this handbook
and all customer-specific requirements
Production parts shall meet all customer engineering design
record and specification requirements including safety and regulatory requirements
If any part specification cannot be met, the organization shall
document their problem-solving efforts and shall contact the
authorized customer representative for concurrence in
determination of appropriate corrective action.
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 23 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
View over the documentations to be created(see chapter 4 of this presentation for details)
Warrant
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 24 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Content of the documentation to be created
1. Design Record
2. Authorized Engineering Change
Documents
3. Customer Engineering Approval
4. Design-FMEA
5. Process Flow Diagram(s)
6. Process-FMEA
7. Control Plan
8. Measurement System Analysis
Studies
9. Dimensional Results
10. Records of Material/
Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory
Documentation
13. Appearance Approval Report
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer-Specific
Requirements
18. Part Submission Warrant
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 25 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Paperwork or EDP?
all forms mentioned in this document
may be replaced by identical computer
generated forms
these documents have to be approved
by the customer product approval
activity before first submission
at Adare Carwin a floppy with all formscan be obtained
PPAP?
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 26 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Process Requirements
3. Customer Notification and Submission Requirements
4. Submission to Customer - Levels of Evidence
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 27 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
2.3. Customer Notification and SubmissionRequirements( PPAP, Section 3)
1. Customer Notification
The organization shall notify the authorized customer representative of anyplanned changes to the design, process or site.
Examples are indicated in Table 3.1 Notification of all changes to desing nad process is the the organizations resonsibility.
Upon notification and approval of the proposed change by the authorizedcustomer representative, and after change implementation, PPAP submissionis required unless otherwise specified
2. Submission to Customer
The organization shall submit for PPAP approval prior to the first productionshipment in the following situations (see Table I.3.2) unless the authorizedcustomer representative has waived this requirement.
The organization shall review and update 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 authorized customer representative
granting the waiver and the date.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 28 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Table 3.1: Customer Notification Required1. use of other construction or material than was used in the previously
approved part or product
2. production from new or modified tools (except perishable tools), dies, molds,
patterns, etc., including additional or replacement tooling
3. production following refurbishment or rearrangement of existing tooling or
equipment
4. production from tooling and equipment transferred to a different plant
location or from a additional plant location.
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
6. product produced after tooling has been inactive for volume production for
twelve months or more
7. product and process changes that impact fit, form, function, performance,
and/or durability of the salable product
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 29 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Table 3.2: Submission to Customer
1. a new part or product (i.e.: a specific part, material, or color notpreviously supplied to this specific customer)
2. correction of a discrepancy on a previously submitted part
3. engineering changes to design records, specifications, or
materials for production product/part number(s)
4. bulk material only: process technology new to the supplier, not
previously used for this product
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 30 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Process Requirements
3. Customer Notification and Submission Requirements
4. Submission to Customer - Levels of Evidence
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 31 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
2.4. Submission Levels
Note:
The content of the documentation to be generated
is always the same!
The supplier has to retain everything (e.g.. as a copy)!
the Submission Level just indicates what has to be submitted to
the customer!
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 32 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
There are five Submission Levels:
1. warrant only (and if applicable an Appearance Approval Report)
2. warrant with product samples and limited supporting data
3. warrant with product samples and complete supporting data
4. warrant with other requirements as defined by the customer
5. warrant with product samples and complete supporting data available
for review at the organizations manufacturing location
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 33 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
The customer decides about the submission level
I want
I need
I wish
...looking at:
the status of the supplier
(Ford Q1, ...)
his experience with earlier
approval processes
the know-how of the supplier
concerning this product the importance of the part
so the submission level might
be different for every product
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 34 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
S = submit
retain a copy at an
appropriate
location, (including
manufacturing)
R = retain at
appropriate locations(including manufacturing)
has to be made
readily available to
the customer
representative upon
request
* = retain atappropriate locations submit upon
request
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 35 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
LEVEL 3 IS THE STANDARD LEVEL"
IT SHALL BE USED FOR ALL SUBMISSIONS UNLESS
SPECIFIED OTHERWISE BY THE RESPONSIPLE CUSTOMER
PRODUCT APPROVAL ACTIVITY
Level 1 = just warrant
and (if applicable) Appearance Approval Report
Level 2 = standard minus process description
and background information
Level 3 = standard
Level 4 = warrant, other requirements as defined by the customer
Level 5 = the complete list,
and everything will be checked at the suppliers site!
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 36 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Requirements
3. Customer Notification and Submission Requirements
4. Submission Levels
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 37 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
After everything is ready, it will be
submitted to the customer!
namely at the responsible product approval activity
the customer will inspect everything and notify the
organization of the result using the Part Submission Status
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 38 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Part Submission Status
Upon approval of the submission, the organization shall assure
that future production continues to meet all customer requirements
For those organizations that have been classified as self-certifying
by a specific customer (PPAP Submission Level 1), submission of
the required organization-approved documentation will be
considered as customer approval unless the organization is
advised otherwise.
ORGANIZATIONS MAY NEVER
SHIP PRODUCTION QUANTITIES
BEFORE CUSTOMER APPROVAL!
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 39 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Part Submission Status:
A B CApproved Interim Approval Rejected
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 40 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Part Submission Status A = Approved
indicates that the part or material meets all customer specifications
and requirements
the organization therefore is authorized to ship production quantitiesof the product subject to releases from the customer scheduling
activity
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 41 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Part Submission Status B = 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 organization has:
clearly defined the non-compliances preventing approval; and,
prepared an interim approval action plan agreed upon by the customer
The organization is responsible for implementing containment
actions to ensure that only acceptable material is beeing shipped to
the customer.
PPAP re-submission is required to obtain a status of Approved
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 extention of the interim approval
is granted.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 42 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Part Submission Status C = Rejected
Means that the PPAP submission does not meet the customer
requirements, based on the production lot from which it was taken,
and/or accompanying documentation
In such cases, the submission and/or process (as appropriate)
shall be corrected to meet the customer requirements.
The submission shall be approved before production quantities
may be shipped.
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 43 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Process Requirements
3. Customer Notification and Submission Requirements
4. Submission to Customer - Levels of Evidence
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 44 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Record Retention and Sampling
PPAP records, regardless of submission level,
shall be maintained for the length of the time
the part is active (in production or service)
plus one calendar year
the supplier shall ensure that the appropriate PPAP records from asuperseded part PPAP file are included, or referenced in the new
part PPAP file
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 45 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Requirements
3. Customer Notification and Submission Requirements
4. Submission Levels
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 46 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
3. Summary of the Process
before delivering new or changed parts or changing the production
processes the supplier has to document that he has successfully
finalized all activities of to ensure
that the product will meet all requirements
that the processes are under control and capable
These activities are mostly described in QS 9000APQP the documentation consist of the Part Submission Certificate and
the required attachments
according to his Submission Level the supplier has to submit
everything or just parts of it to the customer
the customer checks the documentation and sets the Part
Submission Status depending on that the supplier can start delivery or not
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 47 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Task:
Assume you have received a PPAP
Submission Level 3 from your supplier.
Supplier has design responsibility.
How to make sure whether or not the supplier
worked carefully?
but without leaving your desk!
Time frame:
Preparation 15 min.
Teamwork: How to judge about PPAP?
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 48 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Requirements
3. Customer Notification and Submission Requirements
4. Submission Levels
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
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4. The Documentation and its Preparation
Warrant
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 50 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Only English report forms
have to be filled out and
submitted to the
customer!
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Content of the documentation to be created
1. Design Record
2. Authorized Engineering Change
Documents3. Customer Engineering Approval
4. Design-FMEA
5. Process Flow Diagram(s)
6. Process-FMEA
7. Control Plan
8. Measurement System AnalysisStudies
9. Dimensional Results
10. Records of Material/
Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory
Documentation
13. Appearance Approval Report
14. Sample Production Parts
15. Master Sample
16. Checking Aids17. Customer-Specific
Requirements
18. Part Submission Warrant
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 52 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.1 Design Records
all design records for the saleable product e.g.
CAD/CAM Data
part drawings
specifications
including component drawings
For parts identified as black box the design record specifies the
interface and performance requirements
The organization shall provide evidence that the
Material/Substance Composition reporting has been completed
and that reported data complies with all requirements
Reporting and requirements as prescribed by the customer
Reporting may be entered into International Materials Data System(IMDS), www.mdsystem.com/index.jsp
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4.1 Design Records /
Where applicable, the Organization shall identify polymeric parts
with the ISO symbols
for plastics: 100g, see ISO 11469 / 1043-1
for elastomers: 100g, see ISO 11469 /1629
4.2 Authorized Engineering Change Documents
all authorized engineering change documents, which are not yet recorded in the design record
but incorporated in the product, part or tooling
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 54 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.3 Customer Engineering Approval
where specified by the customer, the
organization shall have evidence ofcustomer engineering approval
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4.4 Design-FMEA
If the supplier is design responsible a Design-FMEA
is required
according to the customer-specific requirements
e.g. QS-9000 FMEA
(Potential Failure Mode and Effect Analysis)
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 56 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.5 Process Flow Diagrams
see QS-9000 APQP
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4.6 Process-FMEA
according to the customer-specific requirements
e.g. QS-9000 FMEA
(Potential Failure Mode and Effect Analysis)
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 58 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.7 Control Plan
The Organization shall have control plan that
defines all controls used for process
control and complies with the customer-
specified requirements,
e.g. QS-9000 APQP
control plans for families of similar
parts are acceptable if the new parts
have been reviewed for commonality
Note: Certain customers require control plan approval e.g.
customer signature on the control plan, prior to submission.
QM-Plan
according to
QS-9000
APQP
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13.01.2007 Seite 59 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.8 Measurement
System Analysis
Studies
the organization shall have applicable Measurement System
Analysis Studies (e.g. Gage R & R) for all new or modified
gages, measurement, and test equipment
See QS-9000 MSA (Measurement System Analysis
reference manual.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 60 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.9 Dimensional Results
The organization shall provide evidence that
dimensional verifications required by die design record
and the Control Plan have been completed and
results indicate compliance with specified
requirements.
The organization shall have dirnensional results for each unique
manufacturing process, e.g. cells or production limes and all
cavities, molds, patterns or dies
The organization shall record, with the actual results: all
dimensions (except reference dimensions), characteristics, and
specifications as noted an the design record and Control Plan.
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4.9 Dimensional Results /
The organization 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 organization shall record
the change level,
drawing date,
organization name and
part number
on all auxiliary documents (e.g. supplementary layout resultssheets, sketches, tracings, cross sections, CMM inspection point
results, geometric dimensioning and tolerancing sheets, or other
auxiliary drawings used in conjunction with the part drawing).
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 62 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.9 Dimensional Results /
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. The organization shall identify one of the parts measured as the
master sample
NOTE 1: The Dimensional Results form in Appendix C,
a pictorial, geometrie dimensioning & tolerancing [GD&T] sheets,
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.
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 64 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.10 Records of Material/Performance Test Results
The organization shall have records of test results for
material tests
performance tests
for tests specified
in the design record
in the control plan
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4.10.1 Material Test Results
The organization shall perform tests for all parts and product
materials when chemical, physical, or metallurgical requirements
are specified by the design record or control plan
Material test results shall indicate and include:
the design record change level of the parts tested;
any authorized engineering change documents that have not yetbeen incorporated in the design record;
the number, date, and change level of the specifications to which thepart was tested;
the date on which the testing took place;
the quantity tested;
the actual results; the material suppliers name and, when required by the customer, the
customer-assigned supplier/vendor code.
NOTE: Material test results may be presented in any convenient
format. An example is shown in Appendix D.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 66 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
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4.10.1 Material Test Results /
For products with customer-developed material specifications and
a customer-approved supplier list, the organization shall procure
materials and/or services (e.g., painting, plating, heat-treating,
welding) from suppliers on that list.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 68 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.10.2 Performance Test Results
The organization 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.
Performance test results shall indicate and include:
die design record change level of the parts tested;
any authorized engineering change documents that have not yetbeen incorporated in the design record;
the number, date, and change level of the specifications to which thepart was tested;
the date on which the testing took place;
the quantity tested;
the actual results.
NOTE:
Performance test results may be presented in any convenientformat.
An example is shown in Appendix E.
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PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 70 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.11 Initial Process Studies
4.11.1 General
4.11.2 Quality Indices
4.11.3 Acceptance Criteria for Initial Study
4.11.4 Unstable Processes
4.11.5 Processes With One-Sided Specifications
or Non-Normal Distributions
4.11.6 Actions To Be Taken When Acceptance Criteria Are Not Satisfied
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4.11.1 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 the organization (sc,cc)
the organization shall perform measurement analysis
to understand how measurement error is affecting
the study measurements
(see Measurement System Analysis reference manual)
for explanations about Cpk or Ppk see SPC (StatisticalProcess Control manual)
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 72 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Gau Normal Distribution
Standard Deviation sMean Value x
Turning
Point
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Definitions Process under Control / Capable Process
capablenot capable
notundercon
trol
under
control
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 74 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
The Capable Process
Cp = Process Capability Index
Shows proportion of the permissible
tolerance interval to the scatter
Scatter is measured in multiples of
the standard deviation s
If the scatter is with +/- 3 s within the
tolerance, then Cp=1
Cpk = Critical Process Capability
Index
Supplementary considers the mean
of the process not being equal to themiddle of the tolerance interval
Process
Capability
IndexExample Comment
No capability
High amount of
scrap
No capability
If centered pretty
exact, just about no
scrap
Very good capability
Statistically no scrap
No capability
Not centered
Scrap
Good capability
Process is centered
enough
Little scrap
Example 1 to 3Process adjusted
exactly to center
of tolerance
interval
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4.11.2 Quality Indices
Initial process studies shall be summarized with capability or
performance indices, if applicable.
NOTE 1: The initial process study results are dependent on the
purpose of the study, method of data acquisition, sampling,
amount of data, demonstration of statistical control. etc.
See the QS-9000 Statistical Process Control reference manual
for additional information in understanding the basic principles of
statistical stability and process measures (indices).
For guidance on items listed below, contact the authorizedcustomer representative.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 76 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Cpk and Ppk Cpk - The capability Index for a stable process.
The estimate of sigma is based on within subgroup variation .
Cpk is an indicator of process capability based on process variation withineach subgroup of a set of data.
Cpk does not include the effect of process variability between the subgroups.
Cpk is an indicator of how good a process could be if all process variationbetween subgroups was to be eliminated.
Therefore, use ofCpk alone may be an incomplete indicator of processperformance.
Ppk - The performance index. The estimate of sigma is based on total variation (all of individual sample data
using the standard deviation.
Ppk is an indicator of process performance based on process variationthroughout the full Set of data.
Unlike Cpk, Ppk is not limited to the variation within subgroups.
However, Ppk cannot isolate within subgroup variation from between subgroupvariation.
When calculated from the same data set, Cpk and Ppk can be compared toanalyze the sources of process variation. For more information, see QS-9000 Statistical Process Control.
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Purpose of Initial Process 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 are available or enough initial data exist to
plot a control chart (at least 100 individual sarnples), Cpk can be
calculated when the process is stable.
Otherwise, for processes with known and predictable special
causes and output meeting specifications, Ppk should be used.
When not enough data are available (< 100 samples) or there are
unknown sources of variation, contact the authorized customer
representative to develop a suitable plan.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 78 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Examination of the stability
(Process control)
examine capability
continue with 4.11.3
process seems instableprocess seems stable
Process may not meet
customer requirements
continue with 4.11.4
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4.11.3 Acceptance Criteria for Initial Study
Index > 1.67
the process currently
meets the
acceptance criteria
after approval, begin
production and
follow control plan
Index < 1.33
the process does not
currently meet the
acceptance criteria
contact the authorized
customer representative
for a review of the study
results
1.33 Index 1.67
the process may be
acceptable
contact the
authorized customer
representative for a
review of the study
results
Capability Index for stable process
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 80 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.11.4 Unstable Processes
Depending on the nature of the instability, an unstable process
may not meet customer requirements.
The organization shall identify, evaluate and, wherever possible,
eliminate special causes of variation prior to PPAP submission.
The organization shall notify the authorized customer
representative of any unstable processes that exist and shall
submit a corrective action plan to the customer prior to any
submission.
NOTE: For bulk materials, for processes with known and
predictable special causes and output meeting specifications,
corrective action plans may not be required by the customer.
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4.11.5 Processes With One-Sided Specifications
or Non-Normal Distributions
The organization shall determine with the authorized customer
representative alternative acceptance criteria for processes with
one-sided specifications or nonenormal distributions.
NOTE: The above mentioned acceptance criteria assume
normality and a two-sided specification (target in the center).
When this is not true, using this analysis may result in unreliable
information.
These 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.
Refer to the Statistical Process Control reference manual for
further guidance.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 82 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.11.6 Actions To Be Taken When
Acceptance Criteria Are Not Satisfied
The organization shall contact the authorized customer
representative if the acceptance criteria cannot be attained by the
required PPAP submission date. The organization shall submit to the authorized customer
representative for approval a corrective action plan and a modified
Control Plan normally providing for 100% inspection.
Variation reduction efforts shall continue until the acceptance
criteria are met, or until customer approval is received.
NOTE: 100% inspection methodologies are subject to review and
concurrence by the customer.
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4.12 Qualified Laboratory Documentation
Inspection and testing for PPAP shall be
performed by a qualified laboratory as defined
by customer requirements(e.g., an accredited laboratory).
The qualified laboratory (internal or external to the organization)
shall have a laboratory scope and documentation showing that the
laboratory is qualified for the type of measurements or tests
conducted.
When an external/commercial laboratory is used, the organization
shall submit the test results on the laboratory letterhead or the
normal laboratory report format. The name of the laboratory that
performed the tests, the date (s) of the tests, and the standards
used to run the tests shall be identified.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 84 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.13 Appearance Approval Report (AAR)
AAR = approval report for the appearance of
appearance items concerning requirements
on color, structure, or surface
For completion of AAR, see instruction in PPAP, appendix B
A separate AAR shall be completed for each part or series of partsfor 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 information on the AAR
since the Appearance Approval Report is a industry wide used form
not all customers will require entries in every position
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4.13 Appearance Approval Report (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
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 86 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
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4.16 Checking Aids
If requested by the customer, the organization
shall submit with the PPAP submission any
part-specific assembly or component checking aid. The organization shall certify that all aspects of the checking aid agree
with part dimensional requirements.
The organization shall document all released engineering design
changes that have been incorporated in the checking aid at the time of
submission.
The organization shall provide for preventive maintenance of any
checking aids for the life of the part. measurement system analysis studies, e.g. gage R&R, accuracy, bias,
linearity, stability studies, shall be conducted in compliance with the
customer requirements. See MSA (Measurement Systems
Analysis reference manual).
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 90 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.17 Customer-Specific Requirements
The organization shall have records of compliance to all applicable
customer-specific requirements.
For bulk materials, applicable customer-specific requi rements
shall be documented on the Bulk Material Requirements Checklist.
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4.18. Production Part Submission Warrant
Upon completion of all PPAP requirements,
the organization shall complete the
Part Submission Warrant (PSW).
A separate PSW shall be completed for each customer part number
unless otherwise agreed to by the authorized customer
representative.
If production parts will be produced from more than one cavity, mold,
tool, die, pattern, or production process. e.g., line or cell, the
organization shall complete a dimensional evaluation 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.
Warrant
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 92 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
4.18. Production Part Submission Warrant/
The organization shall verify that all of the
measurement and test results show conformance
with customer requirements and that all
required documentation is available and, for Level 2, 3, and 4,
is included in the submission as appropriate.
A responsible official of the organization shall approve the PSW and
provide contact information.
Warrant
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Part Submission Warrant
consists of:
Information about the part
Some formal information
Materials reporting
Reason of the submission
Requested submission level
Result of the submission
Declaration
For customer use (result)
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 94 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Detail of Part Submission Warrant
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Dimension Results / Part Weight (Mass)
The organization shall record on the PSW the part weight
of the part as shipped, measured and expressed in
kilograms to four 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 organization 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 organization should use the required
number for calculation of the average part weight.
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 96 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Contents
1. Introduction
2. Content of the QS-9000 PPAP1. General
2. PPAP Requirements
3. Customer Notification and Submission Requirements
4. Submission Levels
5. Part Submission Status
6. Record Retention
3. Summary of the Process
4. The Documentation and its Preparation
5. Summary
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The Attempt to Run PPAP without APQP!
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 98 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
Summary
The Production Part Approval Process is an
extensive strict approval process for new
or changed designs orprocesses.
It is very formalized, so it inevitably causes
some administration work,
but it doesnt demand anything that
makes no sense from an engineers point
of view!
Later changes of the product or the process
are expensive and take a lot of time.
The prerequisite to fulfill PPAP demands is a
carefully done quality planning according to
QS-9000APQP.
7/30/2019 Ppap_engl.pdf
50/50
PPAPDipl.-Ing. Ralf Glner
13.01.2007 Seite 99 PPAP_engl.PPT vom 2007 by R.Glner, D-85221 Dachau,+49-8131-53595, www.glaessner.de
6. Internet Links
http://www.din.de
http://www.iso.ch
http://www.cenorm.be
https://www.carwin.co.uk/qs/qs9000default.htm
http://www.aiag.org
http://www.iaob.org
http:// www.vda-qmc.de