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Chrysler Customer-Specific Requirements for Use with PPAP, 4th Edition. 2 . The supplier submits a copy of the signed/approved electronic copy (PDF) of the. AIAG – Production Part Approval Process (PPAP) 4th Edition - Download as PDF File .pdf), Text File .txt) or read online. PPAP. Is the submission to PPAP 4th edition requirements? 6. Is there clear and proper detail provided on “Reason for Submission”? 7. Was proper submission level.


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PPAP 4th Edition includes the following changes: e Alignment of PPA to the ISOITS process approach, including: * Aligning the order of the PPAP. 𝗣𝗗𝗙 | On Mar 1, , Ajit Hajare and others published AIAG - Production Part Approval process PPAP 4th Edition. Production Part Approval Process 4th Edition. PPAP. Dipl.-Ing. Ralf Please make sure that you are working only with original latest level.

Checking Aid Number: Enter the number of pieces manufactured during the significant production run. During manufacture of the bullc material. Check the submission items if a level 4 is requested. Submission is required to correct any discrepancies on a previously submitted part. The purpose of the master sample is to assist in defining the production standard.

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" 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. The organization is therefore authorized to ship production quantities of the product, subject to releases from the customer scheduling activity.

Interim Approval will only be granted when the organization has: PPAP re-submission is required to obtain a status of "approved. The organization is responsible for implementing containment actions to ensure that only acceptable material is being shipped to the customer.

Note 2: Parts with a status of "Interim Approval" are not to be considered "Approved. No additional shipments are authorized unless an extension of the interim approval is granted. For bulk materials, the organization shall use the "Bulk Material Interim Approval" form, or its equivalent see Appendix F.

The submission shall be approved before production quantities may be shipped. Part Name and 2a. Customer Part Number: Engineering released finished end item part name and number. Org, Part Number: Part number defined by the organization, if any. Shown on Drawing Number: 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.

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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.

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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.

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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.

Modified customer notification and submission requirements to align with OEM requirements e g , 1. Revised Glossary to be consistent with the updates in the text PPAP refers to the following reference manuals: The Supplier Quality Requirements Task Force gratefully acknowledges the contributions of the many individuals and their respective companies that participated in the revision process.

Specifications I! Activities shown will not always be present. Records shown may be in various media and in various storage locations. The word "shall" indicates mandatory requirements. All questions about PPAP should be addressed to the authorized customer representative.

Such waivers can only be issued by an authorized customer representative. NOTE I: See customer-specific requirements for additional information. NOTE 4: Catalog parts e.

For the purposes of PPAP. The word "should" indicates a recommendation. NOTE 2: A customer can formally waive PPAP requirements for an organization. For bulk materials. The word ccshould"appearing in a NOTE is for guidance only. Paragraphs marked "NOTE" are for guidance in understanding or clarifying the associated requirement.

NOTE 3: An organization or supplier requesting a waiver of a PPAP requirement should contact the authorized customer representative. PPAP shall apply to internal and external organization sites see Glossary supplying production parts.

In cases where no production history of a similar bulk material product or technology exists. This significant production run shall 6e conducted at the production site. The organization shall obtain approval see 5. The organization shall also meet all customer-specific PPAP requirements. No specific number of "parts" is required. The organization shall meet all specified PPAP requirements listed below 2. This significant production run shall be from one hour to eight hours of production.

Parts from each unique production process. The submitted sample shall be taken in a manner as to assure that it represents "steady-state" operation of the process. For bulk material.

Production parts shall meet all customer engineering design record and specification requirements including safety and regulatory requirements.

For parts identified as black box see Glossary. A single design record can represent multiple part or assembly configurations NOTE 1: For any saleable product. For example. Nomenclature and abbreviation references to support the use of I S 0 are contained in I S 0 for basic polymers and in I S 0 for fillers and reinforcements. For parts identified as catalog parts.

Where the design record is in electronic format. Items or records from 2. In order to determine with certainty which items intlst be included. The design record may reference other documents making them part of the design record. NOTE 5: Plastic parts weighing at least 1OOg using I S 0 If any part specifications cannot be met.

If dimensional results do not apply. Control Plan approval may be required by certain customers. Potential Failure Mode and Effects Analysis reference manual. Control Plans for "families" of parts are acceptable if the new parts have been reviewed for coinmonality by the organization. Process flow diagrams for 'families' of similar parts are acceptable if the new parts have been reviewed for commonality by the organization. A single Process FMEA may be applied to a process manufacturing a family of siinilar parts or materials if reviewed for commonality by the organization.

The organization shall record the change level. The organization shall identify one of the parts measured as the master sample see 2. A tracing shall be included when an optical comparator is necessary for inspection. Dimensional results typically do not apply to bulk materials.

Customer agreement should be obtained on actual requirements. The Dimensional Results form in Appendix C. The organization shall have applicable Measurement System Analysis studies. The organization shall have dimensional results for each unique manufacturing process. Material test results shall indicate and include: CMM inspection point results.

The organization shall indicate the date of the design record. Measurement System Analysis may not apply. The organization shall record. Even for these short-term studies. The organization shall obtain customer concurrence on the index for estimating initial process capability prior to submission. Material test results may be presented in any convenient format. The purpose of this requirement is to determine if the production process is likely to produce product that will meet the customer's requirements.

An example is shown in Appendix D. For those characteristics that can be studied using X-bar and R charts. The initial process study is focused on variables not attribute data. An example is shown in Appendix E. For products with customer-developed material specifications and a customer-approved supplier list. Other methods more appropriate for certain processes or products may be substituted with prior approval from an authorized customer representative.

Where no special characteristics have been identified. Assembly errors. The organization shall perform measurement system analysis to understand how measurement error affects the study measurements.

Initial process studies are short-term and will not predict the effects of time and variation in people. To understand the performance of characteristics monitored by attribute data will require more data collected over time.

Performance test results shall indicate and include: Unless approved by the authorized customer representative. C'k and Ppk are described below. Performance test results may be presented in any convenient format. The performance index. Pplccannot isolate within subgroup variation froin between subgroup variation. For more information. Cplccan be calculated when the process is stable. The purpose of the initial process study is to understand the process variation.

Cplcand Ppkcan be compared to analyze the sources of process variation. Initial Process Studies. For guidance on items listed below. CpIcis an indicator of process capability based on process variation within each subgroup of a set of data. For Initial Process Studies involving more than one process stream. The initial process study results are dependent on the purpose of the study.

See the Statistical Process Control reference manual for additional information in understanding the basic principles of statistical stability and process measures indices. Ppkis not limited to the variation within subgroups. When historical data are available or enough initial data exist to plot a control chart at least individual samples.

For certain processes. The estimate of sigma is based on total variation all of individual sample data using the standard deviation [root mean square equation]. Unlike Cpk. The capability index for a stable process. The initial process study data requirements inay be replaced by longerterm historical data from the same or similar processes.

Cplcis an indicator of how good a process could be if all process variation between subgroups was to be eliminated. Pplcis an indicator of process performance based on process variation throughout the full set of data. When calculated from the same data set. When this is not true. Meeting the initial process study capability acceptance criteria is one of a number of customer requirements that leads to an approved PPAP submission.

The above mentioned acceptance criteria 2. The organization shall identify. Variation reduction efforts shall continue until the acceptance criteria are met.

These alternate acceptance criteria could require a different type of index or some method of transformation of the data.

Contact the authorized customer representative for a review of the study results. Refer to the Statistical Process Control reference manual for further guidance. 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.

For bulk materials.. See 2. The focus should be on understanding the reasons for the non-normality e. Control Plan or inspection criteria. AARs complete with part disposition and authorized customer representative signature shall then accompany the PSW at the time of final submission based upon the submission level requested. The name of the laboratory that performed the tests.

The master sample shall be identified as such. When an externallcoinmercial laboratory is used. Many bulk material properties are by their nature time dependent. The purpose of the master sample is to assist in defining the production standard.

See customer-specific requirements for any additional requirements. The organization shall retain a master sample for each position of a multiple cavity die. Certain customers may not require entries in all AAR fields. The completed AAR. Upon satisfactory completion of all required criteria.

A separate Appearance Approval Report AAR shall be completed for each part or series of parts if the productipart has appearance requirements on the design record. AAR typically applies only for parts with color. NOTE When part size.

The organization shall document all released engineering design changes that have been incorporated in the checking aid at the time of submission. Checking aids. One warrant per customer part number can be used to summarize many changes providing that the changes are adequately documented..

If checking aids are used for bulk materials. Measurement system analysis studies. Checking aids can include fixtures. If production parts will be produced from more than one cavity. 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. The organization shall provide for preventive maintenance of any checking aids for the life of the part see Glossary.

A separate PSW shall be completed for each customer part number unless otherwise agreed to by the authorized customer representative.

A responsible official of the organization shall approve the PSW and provide contact information. The specific cavities. 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.

At least one part shall be measured from each cavity. The weight shall not include shipping protectors. To determine part weight. Use of other construction or material than was used in the previously approved part The organization shall notify the authorized customer representative of any planned changes to the design..

Production process tooling and lor equipment transferred between buildings or facilities at one or more sites. It is not meant to describe standard tools new or repaired. Production from tooling and equipment transferred to a different plant site or from an additional plant site. Rearrangement is defined as activity that changes the sequence of productlprocess flow from that documented in the process flow diagram including the addition of a new process.

Change of supplier for pasts. Upgrade means the recoiistruction andlor modification of a tool or machine or to illcrease the capacity. Examples are indicated in the table below see Table 3. Production from new or modified tools except perishable tools. The organization is responsible for approval of supplier provided material and services. This requirement only applies to tools.

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Upon notification and approval of the proposed change by the authorized customer representative. Change in product appearance attributes. These changes would normally be expected to have an effect on the performance of the product.. For product that has been produced after tooling has been inactive for twelve months or more: Notification is required when the part has had no change in active purchase order and the existing tooling has been inactive for volume production for twelve months or more.

Change in testlinspection method. For change in test method. The only exception is when the part has low volume. Product produced after the tooling has been inactive for volume production for twelve months or more.

However a customer may specify certain PPAP requirements for service parts. New source of raw material from new or existing supplier. Any changes. Product and process changes related to the organization and their suppliers.

Correction of a discrepancy on a previously submitted part. A "discrepancy" can be related to: Process technology new to the organization. The organization shall submit for PPAP approval prior to the first production shipment in the following situations unless the authorized customer representative has waived this requirement see Table 3.

The organization shall review and update. Engineering change to design records. A new part or product i. Submission is required to correct any discrepancies on a previously submitted part. In the situations described below. The PPAP file shall contain the name of the authorized customer representative granting the waiver and the date. The organization shall use level 3 as the default level for all subinissions unless othenvise specified by the authorized customer representative.

For Bulk Material missions. Level 3 Warrant with product samples and complete suppoi-ting data submitted to the customer. Level 4 Warrant and other requirements as defined by the customer. Level 5 Warrant with product samples and complete supporting data reviewed at the organization's manufacturing location.

Acceptability of these facsimiles is to be confirmed with the authorized customer representative prior to the first submission. The authorized customer representative may identify a submission level.

Level 1 Warrant only and for designated appearance items. Different customer locations may assign different submission levels to the same organization manufacturing location. Level 2 Wai-sant with product samples and limited supporting data submitted to the customer. All of the f o r m referenced in this document may be replaced by computer-generated facsimiles. Table 4. The organization shall retain at appropriate locations and submit to the customer upon request.

No additional shipments are authorized unless an extension of the interim approval is granted. Upon approval of the submission. Note 2: Parts with a status of "Interim Approval" are not to be considered "Approved. The organization is therefore authorized to ship production quantities of the product. In such cases. The submission shall be approved before production quantities may be shipped. PPAP re-submission is required to obtain a status of "approved.

Interim Approval will only be granted when the organization has: The organization is responsible for implementing containment actions to ensure that only 0 c acceptable material is being shipped to the customer.

For those organizations that have been classified as "self certifying" PPAP submission level 1 by a specific customer. The organization shall ensure that the appropriate included. If submitted via IMDS include: Module ID. Check the appropriate box es. List all authorized engineering changes not yet incorporated in the design record but which are incorporated in the part.

Safety andlor Government Regulation: Enter the actual weight in kilograms to four decimal places unless otherwise specified by the customer.

Check the appropriate box. For "Region. Shown on Drawing Number: The design record that specifies the customer part number being submitted. Fax Number. Customer Part Number: Engineering released finished end item part name and number. Provide any explanatory comments on the Submission Results or any deviations from the Declaration.

If submitted via other customer format. Part Number: Part number defined by the organization. Check the appropriate boxes for dimensional. Enter the buyer's name and code. Identify the submission level requested by the customer.

Part Name and 2a. Show the corporate name and division or operations group. For instruction. Enter the model year. Change Level and Date: If requested by the customer. Show the name and code assigned to the manufacturing site on the purchase orderlcontract. If "no. Enter "Yes. Street Address. Show the complete address of the location where the product was manufactured. Enter the time in hours taken for the significant production run. Phone Number. Show the change level and date of the design record.

Attach additional information as appropriate. Checking Aid Number. Postal Code. Polymeric Parts Identification: A responsible organization official. Are polymeric parts identified with appropriate I S 0 marking codes? 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.

Warrant and other requirementsas defined by customer. FAX No. Warrant only and for designated appearance items. Part Number Shown on Drawing No. Warrant with product samples and complete supporting data submitted to customer. Part Name Cust. Level 5. Part Number Org. Warrant with product samples and limited supporting data submitted to customer.

Warrant with product samples and complete supporting data reviewed at organization's manufacturing location. Level 4. Level 3. I also certify that documented evidence of such compliance is on file and available for review. Level 2. Warrant and other requirements as defined by customer. I Are polymeric parts identified with appropriate I S 0 marking codes? Part Number Part Name Org. Phone No. Organization Signature. Customer part number: Engineering released customer part number.

Tristimulus Data: List numerical colorimeter data of submission part as compared to the customer-authorized master. Manufacturing Location: Location where part was manufactured or assembled. Material Type: Identify first surface finish and substrate e. Gloss and Metallic Brilliance: Visual assessment by customer. Material Source: Identify first surface and substrate suppliers. Color Evaluation. Master Number: Enter alphanumeric master identification not used by Ford.

Part Disposition: To be determined by customer approved or rejected. Authorized Customer Representative approval signature. SupplierNendor Code: Customer-assigned code for organization location where the part was manufactured or assembled. General comments by the organization or customer optional. Organization certification that the document information is accurate and meets all requirements specified. Enter the code for specific buyer of part. Organization Name: Organization responsible for submission include supplier if applicable.

Drawing Number: Use the number of the drawing on which the part is shown if different from the part number. Engineering change level and EIC date for this submission. Pre-Texture Evaluation: To be completed by authorized customer representative not used by GM.

Color Suffix: Use alphanumeric or numeric color identification. Master Date: Enter the date on which the master was approved. List all first surface tools.

Reason for Submission: Check box es explaining the reason for this submission. Part Name: Use the finished part name on the part drawing.

Color Shipping Suffix: Color part number suffix or color number. I Blanket statements of conformance are unacceptable for any test results. I March Identify by name or function the individual who will assemble and assure the completeness of the element to be reviewed. For bullc material. Any customer-specific requirements shall be documented on the Bulk Materials Requirements Checklist.

Primary Responsibility. Approved by: Enter the initials of the authorized customer representative who has reviewed and accepted the element. Organizations are responsible for applying organization-designated special characteristics. Identify any qualifying information or references to attached documents that provide specific information regarding the element.

Plan agreed to by: Identify the individuals and their functions who made and agreed upon the project plan. 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. An organization supplying bulk materials shall coinply with the requirements in this Appendix or use guidance herein for clarification of PPAB.

Identify by name or function the individual who will review and approve the element. PAP to their suppliers of ingredients which have approval of a bullc material exists. Examples of bulk material include. Construct the Design Matrix referring to the example which will follow: Along the horizontal axis. Ask what would happen if a potential cause item is allowed to go under or over its robust minilnuin or maximum.

Designate any Special Characteristics in colu1m 1. Correlate the potential causes to the potential failure modes using a number.

AIAG – Production Part Approval Process (PPAP) 4th Edition

After completion of the ranlcings in the Design Matrix. Along the vertical axis. The Design Matrix detennines the complex interactions of fomula ingredients. List Effects of Failure Consumer Effects. General terns identifying the loss experienced by the inteimediate user of your product e g. If your situation only uses a small portion of the scale then develop your own scale to improve the differentiation.

Mechanisms are generally described as over or under a certain threshold. If yous situation is greater than two tiers back from the final consumer. The following figure provides a guideline for severity rankings. These thresholds define the boundaries of the product approval and subsequent requirements for change notification. General teims identifying the loss experienced by the ultimate user of the product e. Variation of supplier specifications. It evaluates the frequency occurrence based upon observed evidence the formulator has in the design.

Test protocols. The following step provides an alternate method for assigning Occurrence ratings. It evaluates the Detection as the ability of tl. Rank Occurrence. List experiment 's Customer validation tests and trial runs. The following matrix may be used. The next step provides an alternate method for assigning Detection rankings. Standard Operating Procedures. Similar Experience: Based upon similar products or processes and the potential failure model.

The following matrix is recommended as a replacement. Supplementing the Failure Mode Effects and Analysis manual. Rank Detection.

(PDF) AIAG Production Part Approval process PPAP 4th Edition | G C - caite.info

Formulating practice robust ranges. Relatively few failures F. Design controls identified by a number should be available so that the relevant content of that control cs be understood.

Repeated failures Moderate is defined as. Based upon a clear understanding of the chemical impact of the material and the potential failure mode. Frequency ranking clarifications: High is defined as. Occasional failures Low is defined as.