(APQP). AND CONTROL PLAN. Reference Manual. Second Edition. Issued June Additional copies can be ordered from AIAG at caite.info Organizations The fourth quarter is the stage where the importance of. Aiag Apqp Manual 4th caite.info - Free Download. APQP and Control Plan Second Edition includes: • incorporation of the customer focused process approach. AIAG Production Part Approval process PPAP 4th Edition. AIAG PPAP Manual 4th Edition Forms (Including Control Plan) - Download as PDF File .pdf), Text File.
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Download as PDF, TXT or read online from Scribd. Flag for cesar_PNA. Re: Here are the Various AIAG PPAP Manual 4th Edition Forms Muchas gracias!. PPAP 4th Edition includes the following changes: e Alignment of PPA to the the text PPAP refers to the following reference manuals: Advanced Product uality. Adobe PDF with Assessment File (English) . The APQP manual provides guidelines for creating a product quality plan that supports the .. , the TSRULES 4th edition, and the Core Tools manuals: APQP, PPAP, FMEA, MSA, & SPC.
What is being done to ensure defective product is contained, date when the action was implemented and Exit Criteria necessary to end need for continuing the action or its individual elements. In-Process testing is used to monitor the manufacturing process. Ask what would happen if a potential cause item is allowed to go under or over its robust minilnuin or maximum, respectively. Skip to main content. For those organizations that have been classified as "self certifying" PPAP submission level 1 by a specific customer, submission of the required organization-approved documentation will be considered as customer approval unless the organization is advised otherwise. IfJrther clarijcation is necessary, please contact your customer representative. UVA intended.
The design record that specifies the customer part number being submitted. Show the change level and date of the design record. List all authorized engineering changes not yet incorporated in the design record but which are incorporated in the part.
Safety andlor Government Regulation: Purchase Order Number: Enter the actual weight in kilograms to four decimal places unless otherwise specified by the customer. If requested by the customer, enter the checking aid number, its change level and date. Show the name and code assigned to the manufacturing site on the purchase orderlcontract. Show the complete address of the location where the product was manufactured. For "Region," enter state, county, province, etc.
Customer NameIDivision: Show the corporate name and division or operations group. Enter the buyer's name and code. Enter the model year, vehicle name, engine, transmission, etc. Substances of Concern: If submitted via IMDS include: If submitted via other customer format, enter the date customer confirmation was received.
Polymeric Parts Identification: Enter "Yes," "No," or "nla". Check the appropriate box es. For bulk materials, in addition to checking the appropriate box, check "Other" and write "Bulk Material" in the space provided. Identify the submission level requested by the customer. Check the appropriate boxes for dimensional, material tests, performance tests, appearance evaluation, and statistical data. Check the appropriate box. If "no," enter the explanation in "comments" below.
For instruction, see 2. Enter the number of pieces manufactured during the significant production run. Enter the time in hours taken for the significant production run. Provide any explanatory comments on the Submission Results or any deviations from the Declaration.
Attach additional information as appropriate. A responsible organization official, after verifying that the results show conformance to all customer requirements and that all required documentation is available, shall approve the declaration and provide Title, Phone Number, Fax Number, and E-mail address. Part Name Cust. Part Number Shown on Drawing No. Are polymeric parts identified with appropriate I S 0 marking codes?
Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location. I further affirm that these samples were produced at the production rate of 24 ours 1 also certify that documented evidence of such compliance is on file and available for review. FAX No. Weight kg I Checking Aid No. I Are polymeric parts identified with appropriate I S 0 marking codes?
Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer. I also certify that documented evidence of such compliance is on file and available for review.
Is each Customer Tool properly tagged and numbered? Engineering released customer part number. Drawing Number: Use the number of the drawing on which the part is shown if different from the part number. Part Name: Use the finished part name on the part drawing. Enter the code for specific buyer of part. Engineering change level and EIC date for this submission. Organization Name: Organization responsible for submission include supplier if applicable. Manufacturing Location: Location where part was manufactured or assembled.
SupplierNendor Code: Customer-assigned code for organization location where the part was manufactured or assembled. Reason for Submission: Check box es explaining the reason for this submission. List all first surface tools, graining source s , grain type s , and grain and gloss masters used to check part. Pre-Texture Evaluation: To be completed by authorized customer representative not used by GM. Color Suffix: Use alphanumeric or numeric color identification.
Tristimulus Data: List numerical colorimeter data of submission part as compared to the customer-authorized master. Master Number: Enter alphanumeric master identification not used by Ford. Master Date: Enter the date on which the master was approved. Material Type: Identify first surface finish and substrate e. Material Source: Identify first surface and substrate suppliers.
Visual assessment by customer. Color Shipping Suffix: Color part number suffix or color number. Part Disposition: To be determined by customer approved or rejected. General comments by the organization or customer optional. Organization Signature, Phone No. Organization certification that the document information is accurate and meets all requirements specified.
Authorized Customer Representative approval signature. Organizations are responsible for applying PAP to their suppliers of ingredients which have organization-designated special characteristics. Examples of bulk material include, but are not limited to: Any customer-specific requirements shall be documented on the Bulk Materials Requirements Checklist. Use the Bulk Materials Requirements Checklist as follows: For each item listed in the checklist either enter a target date for completion of the element or enter "NR" for Not Required.
Primary Responsibility - Customer: Identify by name or function the individual who will review and approve the element. Primary Responsibility - Organization: Identify by name or function the individual who will assemble and assure the completeness of the element to be reviewed.
Identify any qualifying information or references to attached documents that provide specific information regarding the element. Approved by: Enter the initials of the authorized customer representative who has reviewed and accepted the element. Plan agreed to by: Identify the individuals and their functions who made and agreed upon the project plan.
Use of these suggestions will arsive at the same end point of a completed Design FMEA, but with greater applicability to bulk materials. The Design Matrix detennines the complex interactions of fomula ingredients, ingredient characteristics, product characteristics, process constraints, and conditions for customer use.
Construct the Design Matrix referring to the example which will follow: Formula Ingsedients o Ingredient Characteristics Product Characteristics Process Constraints Conditions for Use customer process constraints For each design item, enter the current robust threshold range levels and units. Correlate the potential causes to the potential failure modes using a number, letter, or symbol representing the impact or strength of the relationship. Ask what would happen if a potential cause item is allowed to go under or over its robust minilnuin or maximum, respectively.
After completion of the ranlcings in the Design Matrix, review the categorylcharacteristics for a preliminary assessment of Special Characteristics. Designate any Special Characteristics in colu1m 1.
List Effects of Failure Consumer Effects - General teims identifying the loss experienced by the ultimate user of the product e. The following figure provides a guideline for severity rankings. If your situation only uses a small portion of the scale then develop your own scale to improve the differentiation.
If yous situation is greater than two tiers back from the final consumer, then the guideline figure should be adjusted to reflect the effects that will be felt by your customer's customer. Mechanisms are generally described as over or under a certain threshold. These thresholds define the boundaries of the product approval and subsequent requirements for change notification. The following step provides an alternate method for assigning Occurrence ratings.
Rank Occurrence - the ranking scale in the Potential Failure ode and Effects Analysis manual difficult to relate to bulk materials and generally results in very low numbers with little differentiation the ultimate risk.
The following matrix is recommended as a replacement. It evaluates the frequency occurrence based upon observed evidence the formulator has in the design. Obtained from appropriate experimentation on the specific final product and the potential failure mode. Similar Experience: Based upon similar products or processes and the potential failure model. Based upon a clear understanding of the chemical impact of the material and the potential failure mode. Frequency ranking clarifications: High is defined as - Repeated failures Moderate is defined as - Occasional failures Low is defined as - Relatively few failures F.
Supplementing the Failure Mode Effects and Analysis manual, bulk material desig controls may also include: Variation of supplier specifications. Design controls identified by a number should be available so that the relevant content of that control cs be understood. The next step provides an alternate method for assigning Detection rankings.
Rank Detection - the ranking scale in the Potential Failure Mode and Effects Analysis manual difficult to relate to bulk materials and generally results in very low numbers with little differentiation the ultimate risk. The following matrix may be used. It evaluates the Detection as the ability of tl.
Syininetric design space analyzed with appropriate statistical tools. Screening Experiments: Screening design or ladder evaluation strategically set to develop DOE. Infonnationldata based upon similar products or processes. Potential failure mode may result in a field failure 9 ' or constitute a safety hazard or noncompliance with a government regulation High degree of customer dissatisfaction due to the nature of the failure. May cause serious disruption to subsequent processing of the product or result in the product failing to meet its sales specifications.
Will result in a customer complaint and product return. Failure causes some customer dissatisfactioii and may result in a customer complaint or limitation on shelf life. The customer may need to make modifications or adjustments to their process to accommodate the material. The problem is liltely to be detected as part of an incoming inspection or prior to use 4. The problem will be detected during processing 5. The problem will be detected in subsequent processing steps 6. Failure causing only a slight customer annoyance.
Customer will notice only a slight deterioration or inconvenience with the product or processing of the product. Reasonable to expect that the minor nature of this failure would not cause any real effect on the product or its processing by the customer.
Customer will probably not even notice the failure. Failure is almost inevitable. Additional process steps are developed to deal with the failures. I High: Similar processes have experienced repeated failures. The process is not in statistical control.
Similar processes have experienced occasional failures, but not in major proportions. Similar processes have experienced isolated failures. I 2 Remote: Failure is unlikely. No failures ever associated with almost identical processes. The process is in statistical control. Absolute Certainty of Non-Detection: Controls will not or cannot detect the existence of the defect.
Organization controls probably will not detect the existence of the defect, but the defect 9 may be detected by the customer. Controls may detect the existence of the defect, but detection may not occur until packaging is underway. Controls likely to detect the existence of the failure, but not until lot acceptance testing has been completed. Tests with a higher degree of variability will have the higher ranking.
Controls have a good chance of detecting the existence of the defect before the manufacturing process has been completed. In-Process testing is used to monitor the manufacturing process. Very HigWEarly: Important raw materials are controlled via organization specifications. UVA intended. These are not necessarily intended to be Special Characteristics.
During the design phase, the Examples of manufacturing product characteristics can be process parameters control controls for final product characteristics are: This does not imply pressure, mix rate, test protocol. During manufacture of the bullc material, process parameters are the control characteristics.
During transformation from bulk Examples of customer product to final product, both bullc transformation process parameters product characteristics and final control characteristics are: Control Characteristic Mfg. Prototype when required - A listing of tests, evaluations and their associated specificationsltolerances used to assess an experimental or developmental formulation.
This may be the only control plan that is product specific. Pre-launch - Documentation of the productlprocess control characteristics, process controls affecting Special Characteristics, associated tests, and measurement systems employed during product scale up and prior to noi-mal production.
Additional items may be included at the Organization's discretion. Bulk materials often require further processing after sampling in order to make a measurement. Measurements are often destructive in nature and this prevents retesting the same sample. Measurement variability is often imch larger for properties important in the process industries e. Standardized test methods e. MSA studies are not required where standardized tests are used, however it is still important for thc organization to understand the measurement component of variation in the test methods used.
Customer agreement on the actual requirements for MSA for either non-standard test methods or "new-to supplier" test methods should be obtained during the planning phase. Any MSA studies should be applied to each test method associated with Special Characteristics, and no to each individual product measured by the test method. Therefore, the MSA studies should be conductec as broadly as possible across all products which use a particular test method. If the resulting variability i unacceptable, then either the studies should be conducted on a narrower class of products or action shoulc be taken to improve the test method.
The manufacture of bulk materials consists of industries which span a variety of production processe: Often the production process is completed or already in place before sufficient samples can b tested.
By the time the product is made again, personnel andlor equipment may have changed. Alsc these processes have numerous input variables, many control variables, and a variety of produt variations. The effects and relationships between all thes variables and controls are also not usually known without error. Multiple processes are usual1 interconnected, sometimes with feedback loops.
There are also timing considerations and delays i reaction time. Further, measurements of component variables are generally less precise tha measurements of component parts, such that in many cases correlated variables must be used. The requirements for master sample or equivalent shall be agreed by the customer and organization. Physical Sample: Some bulk materials are stable and unchanging over an extended period of time e. In this case, a physical sample will serve as a Master Sample.
Analytical Sample Record: Other bulk materials change with time, but can be precisely quantified by appropriate analytical techniques. In this case the analytical record e. When bulk materials can not be distinctly identified or change over time, a manufacturing sample record should be generated. This record provides an "audit trail" to the information which may be stored in various documents and or electronic systems.
The following is the basic information suggested to accomplish this task: The quantity of product produced. The critical equipment required to manufacture the bulk material. Plant 1 MFG.
Product Code: AB CD Control temperature of mix. Not to exceed O F.
Filmformer Resin LotIBatch: AB Material Code: A Part Submission Warrant shall be prepared and submitted for approval when required by the customer. If a customer agrees that PPAP is not required, no warrant needs to be prepared. The information required by the Submission Warrant which does not apply to bulk material e. For those organizations that have been classified as "self certifying" by a specific customer, subniission of a warrant signed only by the organization shall be evidence of PPAP approval, unless the organization is advised otherwise.
For all other organizations, evidence of PPA approval shall be a warrant signed by both the authorized customer representative and organization or other customer approval documents.
Most products will achieve approval prior to initial use. In cases where approval callnot be obtained, a "Bulk Material Interim Approval" may be granted. A form is shown on the facing page; other forins may be used. Name assigned to Organization's manufacturing location. The Organization's designated name for the product-as identified in the Customer's Engineering Release Documents. Code DUNS number or equivalent assigned to the manufacturing location as shown on the Customer's purchase order.
Customer's Part Number. Customer Use Only. Customer Use Only Customer Representative. Submission Level that Organization is required to subinit to as defined by the Customer. Date that the Interim Approval expires. Date organization will resubmit for production approval. Customer's Engineering Release authorizing the use of the product in the Customer's facility.
Indicate reason for Interim Request. For each item marked as "17'in 15, provide explanatory details regarding problem issues and filrnish a date for problem resolution. What is being done to ensure defective product is contained, date when the action was implemented and Exit Criteria necessary to end need for continuing the action or its individual elements.
Update on progress of problem resolution, generally the midpoint from issuance to expiration of the interim period. Date material is due to Customer's site. Why won't this happen again? Responsible and Authorized Organization official to ensure compliance to the above mentioned actions and dates. Product Engineer's signature, printed name, phone number, and date. Material Engineer's signature, printed name, phone number, and date.
Quality Engineer's signature, printed name, phone number, and date. Special Product Characteristics: Control Plans: Special Process Characteristics: Test Results: Process Studies: Dimensional Results: Master Sample: Measurement Systems Studies: Appearance Approval Report: Engineering Approval: Process Flow Diagram: This connection defines the interaction of specific customer plant processing steps with Special Characteristics and final product attributes of the bulk material.
This interaction is especially significant when bulk materials undergo chemical or physical transfoimation s. For bulk materials, conducting the steps outlined in this "Customer Plant Connection" is highly recommended.
It is not the intent of PPAP to compromise proprietary information. This may not be applicable to all bulk materials i. It is recognized by the organization that it is their responsibility to deliver the product to the customer with the characteristics of the bulk material per organization and customer agreement.
During the transformation from bulk product to final product, both bulk product characteristics and final product attributes may be impacted by customer process controls. Since the product is frequently two products bulk and finished , there is a shared responsibility for the final product attribute.
For example, percent solids and viscosity of a bulk coating which impacts the final coating's film build attribute, may be affected by the customer's mix room percent solvent reduction.
The percent reduction process parameter may therefore be controlled to aid in control of film build. The process steps at customer plants may be matrixed versus the Special Characteristics determined jointly by the organization and the customer.
The Special Characteristics may then be determined, and be included in a Control Plan for the customer process. These special control characteristic items inay be monitored and continuously improved.
Assemble cross-functional teains of customer personnel for each customer process area. Include appropriate organization representatives on each team. Select Champions for each team - these are the customer process owners i. Define critical customer handling, application steps and process parameters in each area.
Also review the desired final product attributes for items needing control. From 4, develop a list of Special Characteristics and Attributes.
Construct a Customer Process Matrix, using 3 as the top, and 5 as the side of a matrix. Prepare a Control Plan for each affected customer process area.
Monitor and record all Special Characteristics by appropriate means control charts, checklists, etc. Ensure stability of Special Characteristics and continuously improve where possible.
Performance testing, based upon design requirements used by each OEM to select tire construction technical approval , 1-educesthe need to repeat all tests during confisrnation tests are specified by each OEM. The above definition applies to all uses of "significant production run" within PPAP.
Most designs are basic to the organization's process. All additional molds shall be certified by the organization's internal certification criteria and documentation. For tires, tooling is defined as the tire mold. This definition of tooling applies to all uses of "tooling" within PPAP. Testing is applicable only to finished tires and not to raw materials.
Tire industry practice does not require chemical, physical, or metallurgical testing. Material test results are not required for PPAP. Tire uniformity force variation and balance are designated Special Characteristics. Master samples are not retained. Checking Aids see 2. AP Submission Warrant see 2. Part Weight Mass Reference 2. The average is reported on the PSW to four 4 decimals xx.
An organization supplying to subscribing truck OEMs shall comply with the requirements in this Appendix or use guidance herein for clarification of. The following additional requirements are added: The Customer has the right to request a at any time to re-qualify a production component. Feature Base Process or Past Number Generated components are qualified using the highest content configuration to qualify the master part number.
All other configurations may be approved with the submission of a PSW linking the new part number with the master past number. For bulk material and standard catalog pasts, the organization shall formally qualify their product to their design record and submit a PSW when requested by the customer.
It is important that adequate quantities of parts be manufactured during this run to confirm the quality and capability of production process at rate prior to full production.
It is recognized that in low volume applications, sample sizes as small as 30 pieces may be utilized for preliminary process capability studies. When perforning the Significant Production Run, all aspects of variability within the production process should be considered and tested where practicable, e.
If projected volumes are so low that 30 samples are not attainable prior to production, interim PAP approval lnay be granted. Once the 30 consecutive production samples are produced, measured, and the quality index calculated and accepted, then the interim approval is changed to approved. These unique numbers shall be entered onto the dimensional or test results sheet as applicable, and actual results entered onto the appropriate sheets.
The organization shall also identify the print zone for each numbered characteristic as applicable. These studies could be augmented or replaced by long-term results from the same or similar process run on the same equipment with prior customer concurrence. Master Sample see 2. Part Submission Warrant see 2. OKg, To determine part weight, the organization shall individually weigh ten randomly selected parts, and calculate and report the average weight.
At least one part shall be measured from each cavity, tool, line, or process used in product realization. Customer Notification see 3. The customer may subsequently elect to require a submission for PPAP approval. Organizations supplying to subscribing truck OEMs are required to complete the Product Process Change notification form to advise of forthcoming process or proprietary product changes.
Past Name: Engineering released finished end itein part name. Customer Part Nuinber s: Engineering released finished end itein part number. Part Revision Level: Tool Purchase Order Number: Show change level and date for submission. Additional Engineering Changes: Include all authorized engineering change documents and approval dates not yet incorporated on the drawing but which are incorporated in the past.
I tried to open the PSW and receive an error message "file error. If that does not work.
I had no problem opening the links and forms. Try to open it from there. Choose "Save Target. Thanks in advance Irene Irene. Thanks in advance Irene Stijloor Re: I have modified it to suit how we read stuff over here in NZ but as mentioned before the templates are great.
All the other information has been fantastic. I had a bit of a play last night and worked out the the lower tol is first and then the upper tol as the response said this morning. Auditing is FUN Re: May God bless you for doing so.
I have attached my modified version created in Excel but saved as so it should work. I would like to remind you that they were given from the goodness of Jeff Henry's heart. Please post an improved version if you have one zancky Re: MurrayB45 Re: Howard Atkins Re: The parts are always rejected when the dimensions are in tolerance.. Thought I'd share it with yous: D MurrayB45 Re: MacGray Re: Thanks for those documents. Very nice. Thanks 10th January I cannot find the thread in the forum but the question was: We're gripped.
Basically the same as an other PSW. Qual-Latte Re: Thank you very much. This is our first time requesting a waiver. Any help would be appreciated.
Thanks again! Stijloor Re: I wrote my first post today! My engineering group wants to revise the drawing and avoid PPAP if possible. Do you know if there's a standard customer waiver form?
I will be greatfull to you. It would be best to speak with a customer representative. What kind of drawing revision are they wanting to make? If it affects the part form. There is no standard waiver form unless your customer has one.
If you have persuasive sales people. Re-submission may be required unless waived by the customer. PPAP requirements are tough. Which department handles the issue is a matter of personal preference. Your organization can decide. Ideally you don't want too many people contacting them though. The customer's approval of the warrant would be the waiver of the other PPAP requirements.
But whichever way you go make sure you get a customer signature and date or it could come back to haunt you later.. He wanted to make a minor change on our part and told me what to do. Thanks again. Do the PPAP forms have to look exactly the forms in the manuals?: Many years ago I was out in the plant with a GM engineer and he was reviewing how our parts fit the car.
Sales may be able to handle it. I told him the GM engineer told us to make the change. Thank you both very much for your quick replies! Later a GM QC guy came in and said we didn't comply with the print because of the change.
Who normally works with the customer? There is no standard for who interfaces with the customer for PPAPs. If not Ford. Good idea. Control Plan vs. I work in Medical but am an ex Automotive person from England supplying Ford. Margaret Thatcher bobdoering Re: The forms are in post 1 or just click here.
What exactly is the difference dear sir we need version-4 control plan excel format. I am extraordinarily patient provided I get my own way in the end.
Nissan etc and have modified the form to suit our needs. Medical is pretty far behind in quality systems. Inspection Plan. I am sorry but your question got overlooked some how.
The "big" three: There is no actual requirement but if they are radically different they might cause eyebrows to raise. Is it only PPAP for this companies? Best regards These are the "originals" a lot of companies put there own logo instead. Best regards Stijloor Re: Best regards No.
I suggest for your own sake stick to the format and save the questions: Steav Re: Chrysler and GM originally designed these forms. Do you have a completed form as an example so that I can understand the formulas!