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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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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



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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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!



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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Savings by avoiding the 7+1 muda

unnecessarymovement

overproduction

waitingtime

stock

unnecessarytransport

mudain the processerrors

Design ignoringthe customers

expectations

muda



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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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!



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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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



Contents

1. Introduction






6. Record Retention



5. Summary


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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



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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Contents

1. Introduction






6. Record Retention



5. Summary



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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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



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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Contents

1. Introduction






6. Record Retention



5. Summary



(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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(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



(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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View over the documentations to be created(see chapter 4 of this presentation for details)

Warrant



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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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?



Contents

1. Introduction






6. Record Retention



5. Summary


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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.



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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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



Contents

1. Introduction






6. Record Retention



5. Summary


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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!



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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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



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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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!



Contents

1. Introduction


2. PPAP Requirements


4. Submission Levels


6. Record Retention



5. Summary


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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



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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Part Submission Status:

A B CApproved Interim Approval Rejected



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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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.



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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Contents

1. Introduction






6. Record Retention



5. Summary



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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Contents

1. Introduction






6. Record Retention



5. Summary




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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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?



Contents

1. Introduction






6. Record Retention



5. Summary


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Warrant



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



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



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)



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)



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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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.



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).



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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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.




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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.



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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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)



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



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.



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.



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



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.



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.



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




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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).



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



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)



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.



Contents

1. Introduction






6. Record Retention



5. Summary


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The Attempt to Run PPAP without APQP!



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.


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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