Production Part Approval Process Va Fourth EditionFOREWORD TO THE FOURTH EDITION Effective June |, 2006, PPAP Fourth Edition replaces PPAP Third Edition, unless otherwise specified by your customer. Production Part Approval Process (PPAP) is updated to the 4 edition to incorporate the customer focused process approach associated with ISO/TS 16949:2002 and other changes listed helow to update requirements. PPAP's purpose continues to be to provide the evidence that all customer engineering design record ard ris ate properly understocd by the organization and that the manufacturing process has the potential to produce product consistenily meeting these requirements during an actual production run at the quoted production rate PPAP 4th Edition includes the following changes: Alignment of PPAP to the ISO/TS 16949:2002 process approach, including: + Aligning the order of the PPAP requirements with the automotive produet development and manufacturing process + Inclusion oF an example process flow for PPAP ‘© Relocation of Customer Specific Instructions to appropriate websites, (e.g. OFM and [AOB, ‘[Link]) to provide current requirements © Update of Truck OEM requirements and moved to Appendix H ‘© Revised PSW (Part Submission Warrant) to: + Provide a more logical flow forthe part / design description fields 4+ Make the supplier address fields applicable to international locations 4+ Include IMDS materials reporting to indicate reporting status + Updated specific PPAP requirements. including + Materials eporting and pelymerie idcetification requirements in the design record + Provess capability index usaze (Cpk a! Pp) + Thedefinition and approval of catalog parts ard the definition of black box paris, ‘* Modified customer notification and submission requirements to align with OEM requirements 3.3 from PPAP 3rd removed) + Clerified and commonized Appendices C, D, and E to match the PAP reporting requirements ‘© Revised Tire Appendix to allow OEM specification of applicability and to eliminate duplications with allowances already provided in the PPA requirements Note: The Tite Appendis is aot applicable to organizations supplying ties to Ford Motor Company © Reorganized and updated Appendix F to stress the importance of the Bulk Materials Checklist Note: Ford Motor Company requires all organizations supplying bulk material (Ford Motor Compay 40 comply with PRAP. © Revised Glossary to be consistent with the updates in the text PPAP refers to the following reference manuals: Advanced Product Quality Planning & Control Plan, Potential Failure Modes and Effects Analysis, Measurement System Analysis, and Statistical Process Control, These manuals are authored by [daimlerChrysler Corporation, Ford Motor Company, and General Motors Corporation and are available through the Automotive Industry Action Group (AIAG) at [Link] ‘The Supplier Quality Requirements Task Force gratefully acknowledges the contributions of the many Individusls and their respective companies that participated in the revision process,‘sueao| aes srouek ui pu eau sroues u 2a fou unous so1oeN 2 TUBSax¢ 29 SEM UI UNCYS SHAY SON. ye" suoveayreds eg oven Ld ae va wes ey. besia dvad "uo" | % apooon sumeoy0005 MS ‘woneunioni * weieeo | aH |= woot Lf eed fe LS fe LLL oe — | NOLLYZINVYOYO: quousandoy YaWOLSND 4aWOLSND ajdwex3 ueyomol4 Ss9901d dddTABLE OF CONTENTS INTRODUCTION, Purpose a . ARPBEABIEDV sen vesnn rin Approwdd so. Sissi si SECTION | GENERAL... wi LL Submission of PPP... : SECTION 2 ~ PPAP PROCESS REQUIREMENTS. 2 Significant Production Ren. PPAP Requirements Design Revord Authorized Engineering Change documents Customer Engineering Approval Design Failure Mode and Etfecs Analysis (Design FMEA) Process Flow Dingram(s) - Process Failure Made and Fests Analysis (Process FMEA) Cont PAR. ees “4 Measurement System Analysis Dimensional Results - ae Records of Materia / Performance Test RES nweecnnernnnnentnnnon Initial Progess Studies oo an Qualified Laboratory Documentation . Appeamnce Approval Report (ASR) Sample Production Pans Master Sample. (Checking Aids. Case studies specific Requirements Par Submission Warrant (PNW), - . SECTION 3 ~ CUSTOMER NOTIFICATION AND SUBMISSION REQUIREMENTS... BU Customer Nouptewsion 3.2. Submission to Customer SECTION 4 SUBMISSION TO CUSTOMER - LEVELS OF EVIDENCE 41 Submission Levels SECTIONS - PART SUBMISSION STATUS. “ SI General 5.2. Customer PPAP Status S21 Approved Intesim Approval iti 17 7 19 19 19 19 19523 Rejecied SECTION 6~ RECORD RETENTION APPENDICIES APPENDIX A ~ COMPLETION OF THE PART SUBMISSION WARRANT (PSW).. 22 APPENDIX B COMPLETICN OF THE APPEARANCE APPROVAL REPORT - 26 APPENDIX C~ PRODUCTICN PART APPROVAL, DIMENSIONAL RESULTS. ee APPENDIX D ~ PRODUCTION PART ABPROVAL, MATERIAL TEST RESULTS... SL APPENDIX E - PRODUCTION PART APPROVAL, PERFORMANCE TEST RESULTS. . 33 APPENDIX F— BLL € MATERIAL ~ SPECIFIC REQUIREMENTS oc = i 35 APPENDIX G — TIRES - SPECIFIC REQUIREMENIS ce APPENDIX H— TRUCK INDUSTRY - SPECIFIC REQUIREMENT: GLOSSARYINTRODUCTION Purpose Production Part Approval Process (PPAP) defines generic requirements for production part approval, including production and bulk materials (sce C ). The purpose of PPAP is to determine if all customer engineering design recont and specification requirements are properly understood by the organization and that the manufacturing process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted proxluction rate. Applicability PPAP shall apply to internal and external organization sites (see Glossary) supplying preduetion parts, servive parts, production materials, or bulk materials. For bulk materials, PPAP is nol required unless specified by the authorized customer representative, An organization supplying Standard catalog production or service parts shall comply with PPAP unless fomnally waived by the authorized customer representative NOTE 1: See customer-specifie requirements for additional information, AHL questions about PRA should he addressed tothe authorized customer epresentative NOTE 2:4 customercan formally waive PPAP requirements for aa organization. Such waivers can only be isu by an authorzed customer representative. NOTE 3: An organization or supplier raquesting a waiver of a PPAP requirament should contact the authorized customer representative. The erganizaton or supplier should obtain documentation of waivers from the authorized customer representative NOTE 4: Catalog rarts (¢., bolls) are identified and/or ordered by functional specifications or by recognized industry standard foach Phe word “shal” indicates mandatory requirements. The word “should” indicates a recommendation. Paragraphs marked * dance in understanding or clarifying the assovisted requirement. The word “should” appearing in a NOTE is for guidance only For the purposes of PPAP, the terms and definitions given in ISO/TS 16949 and the PPAP Glossary apply.SECTION 1 —- GENERAL 411 Submission of PPAP ‘The organization shall obtain approval (see 5.2.1) fiom the authorized customer representative for L.8 mew part or product (eg.. a specific part, material, or color not previously supplied to the specific customer). 2. conection of a discrepancy on a previously submitted part, 3. product modified by an engincering change to design records, specifications, or materials. 4, any situation required by Section NOTE: Ifthere is any quesion concerning the need for production part approval, contact the authorized customer representa SECTION 2 —- PPAP PROCESS REQUIREMENTS 24 Significant ion For production parts, product for PPAP shall be taken from a significant production run. This Significant production run shall be from one hour to eight hours of production. and with the specific production quantity to total a minimum of 300 consecutive paris, unless otherwise specific’ by the authorized customer representative. This significant production run shall be conducted at the production site, at the production rate (see Glossary) using the produetion tooling, production gaging, production process, production materials, and production operators. Parts from each unique production process, ex.. duplicate assembly line andor work cell, each position of 2 multiple cavity die, mold, tool or pattern, shall be measured and representative parts tested, For bulk materials: No specific aumber of “parts” is requited. The submitted sample shall be taken ina ‘manner as to assure that it represents “steady-state” operation of the process. NOTE: For balk material, production histories of eurrent products may often be used to estimate the intial process capability or performance of new and similar produe's. In cases where s10 production histox similar bulk material product or technology exists, a containment plan may be put into effect until sun production has demorsirated capability or performance, unless otherwise specified by the custome ofa it 2.2__PPAP Requirements The organization shall meet all specified PPAP requirements listed below (2.2.1 through 2.2.18), ‘The ‘organization shall also meet all customer-specific PPAP requirements, Production parts shall meet all customer engineering design record and spe (including safety and regulatory requirements). jon requirements, Bulk Material PPAP requirements are defined by a completed Bulk Material Requirements Checklist (see Appendix F).If any part specifications 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, NOTE: tems or records from 2.21 through 2.2.18 may not necessarily apply to every customer pari number from every organization, For example, some parts do not have appearance requirements, others do trot have color requirernents, and plastie parts may have polymeric part marking requirements. In ordsr to Getommune with certainty which items must be included, consult the design record, e.p.. pirt print, the relevant Engineering documents or specifications, and your authorized customer representative. 22 Design Record “The organization shall heve the design record forthe saleable pracuctpar, including design records for components or details of the saleable productpart. Where the design record is in electronic format, eg. CAD/CAM math data, the organization shall produce 4 baud copy (¢-g.. pictorial, geometric dimensioning & tolerancing [GD&T] sheets, drawing) to ideniily measurements taken, NOTE 1: For ary saleable product, part or component, there will only be one design recor, regardless of tho has desig-respamsiblity. The design record may reference otter documents making them part of the design record. NOTE 2: A single design record can represent multiple part or assembly configurations, ¢ a sub-frame assembly with various hole configurations for dilfevent applications. NOTE 3: Fer parts identified as black box (Gee Glossary), the design record specifies the interface and performance requicements NOTE 4: For pans ientied ay catalog parts, the design reeord may consist only of a functional specification ora reference 10a tecognized industry Sandard NOTE + For balk materials, the design record may include identification of raw materials, formulations processing steps and parameters, and final product specifications or acceptance criteria, 1F dimensional Fesults do not apply, then CAD/CAM requirements are also not applicable [Link] Reporting of Part Material Composition The organization shall provide evidence that the Material/Substance Composition reporting that is requited by the customer has been completed for the part and that the reposted data complies with all customer specific requirements NOTE: This mateviels reporting may be entered into the IMDS (nterational Materials Dats System) or (her customer specified systemn'mcihod. IMDS is avsilable through hip: / www madsystem com inex ip [Link] Marking of Polymeric Parts Where applicable, the organization shall identify polymeric pacts with the ISO symbols such as specified in ISO 11469, “Plastics — Generic Identification and marking of plastic products” and/or ISO 1629, “Rubber and lattices - Nomenclature.” The following weight criteria shall determine if the marking requirement is applicable: # Plastic pants weighing at least 10g (using ISO 11469/1043-1) ‘© Elastomeric parts weighing at least 200g (using ISO 1 1469/1629) NOTE: Nomenclature and abbreviation references to suppor the use of ISO 11469 are contained in ISU 1043-1 for basic polymers and in ISO 1043-2 for filers ard reinforeements,2.2.2. Authorized Engineering Change documents The organization shall have any authorized engineering change documents for those changes not yet recorded in the design record but incorporated in the product, part or tooling, 2.2.3 Customer Engineering Approval Where specified by the customer, the organization shall have evidence of customer engineering approval. NOTE: For bukk materials, this requirement is satisfied by & signed “Engineering Approval” line item on the Bulk Material Requirements Checklist see Appendix F) and/or inclusion on a eustomer maintained list of approved materials, 2.2.4 Design Failure Mode and Effects Analysis (Design FMEA) if the organization is product design-responsible The product design-responsible organization shall develop a Design FMEA in accordance with, and compliant to, customer-specified requirements (e.g., Potential Failure Mode and Effeets Analysis reference manual). NOTE 1; A single Design FMEA may be applied to a family of similar pars or materials NOTE 2: For bulk materials, see Appendix F. 22.5 Process Flow Diagram(s) Reyusrek by POX S705 & Repair ‘The organization shall have a process flow diagram in an organization-specitied format that clearly describes the production process steps and sequence, as appropriate, and meets the specified customer needs, requirements and expectations (¢.g., Advanced Product Quality Planning and Control Plan reference manual), For bulk: materials, on equivalent to a Process Flow Diagram is a Process Flow Description. NOTE: Process Alow diagrams for “families” of similar parts are acceptable iF the new parts have been reviewed for commonality by the organization. 2.2.6 Process Failure Mode and Effects Analysis (Process FMEA) ‘The orgenization shall develop a Process FMEA in accordance with, and compliant to, eustomer-specified requirements, (¢.g., Potential Failure Mode and Effects Analysis reference manual), NOTE 1: A single Process FMEA may be applied to 4 provess manufacturing family of similar parts or materials iF reviewed for commonality by the organization. NOTE 2: For bulk materials, see Appendix F 2.2.7 Control Plan The orgsnization shall have a Control Plan that detines all methods used for proc With customer-specified requirements (¢.z., Advanced Product Quali reference manual) NOTE 1: Conteol Plans for “families commonality by the organization 5s control and complies and Control Plan of parts are acceptable if the res parts have heen reviewed for NOTE 2: Control Plan approval may be required by certain customers2.2.8 Measurement System Analysis Studies ‘The crganizstion shall have applicable Measurement System Analysis studies, eg. gage RAR, bids. lincarity, stability, for all new or modified gages, measurement, and test equipment. (see the Measurement Systems Analysis reference manual) NOTE 1: Gage R&R acceptability criteria are defi rman NOTE 2: For bulk materials, Measurement System Analysis may not apply. Customer agreement should be obtained on actual requirements, od in the Measurement Systems Analysis reference 2.2.9 Dimensional Results ‘The crganization shall provide evidence that dimensional verifications required by the desizn record and the Control Plan have een completed and results indicate compliance with specified requirements. ‘The organization shall have dimensional results Tor etch unique manufacturing process, eg. cells or produetion lines and all cavities, molds, patterns or dies (see 22.18). The organization shall record, with the actual results: all dimensions (except reference dimensions), characteristies, and specifications as noted on the design record and Control Plan. ‘The organization shall indicate the date of the design record, change level, and any authorized engineering change decument nat 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 results sheets, sketches, tracings, eross sections, CMM. inspection point results, geometric dimensioning and tolerancing sheets, or othe: auxiliary drawings used in conjunction with the part drawing). Copies of these auxiliary materials shall accompany the dimensional results according 1 the Retention’Submission Requirements Table, A tacing shall be included when an optical comparator is necessary for inspection. The organization shall ider ‘one of the parts measured as the master sample (see 2.2.15), NOTE 1: The Dimensional Results form in Appendix C, a pictorial, geometric dimensioning & tolerancing [GDA] shoots or a checked print where the results are legibly writien on a part drawing including cress: sections, tracings, or sketches as applicable may be utilized for this purpose. NOTE 2: Dimensional results typically do not apply 10 bulk materials 2.2.10 Records of Material / Performance Test Results ‘The organization shall have records of material and/or performence test results for tests specified on the design record or Contol Plan, [Link] Material Test Results ‘The organization shall perform tests for all parts and product materials when chemical, physical, or rmetallurgical requirements are specified by the design record or Control Plan, Material test results shall indicate and include: 4 the design record change level of the parts tested, © any authorized engineering change documents that have not yet been incorporated in the design rezond: + the number, date, and change level ofthe specifi + the date on which the testing took place; + the quantity tested: tions to which the part was tested:© the actual results; ‘© the material supplier's 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, For products with customer- 1.67 The process currently meets the acceptance criteria 1.33.< Index < 1,67 ‘The process may he acceptable. Contact the authorized customer representative fora review of the study results. Index < 1.33 The process does noi currently meet the acceptance criteria Contact the authorized customer representative for a review of the study results, NOTE 1: Mecting the initial process study capability acveptance criteria one of a number of customer ‘equiements that leads ton approved PPAP stibmission NOTE 2: See 2.211 Vand 2211.2 22, A 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 10 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 speciel causes and output meeting specifications, comective action plans may nos bo required by the customer 22.115 Processes With One-Sided Specifications or Non-Normal Distributions ‘The organization shall determine with the authorized customer representative alternative acceptance etiteria for processes with one-sided specilications or non-noemal distributions. NOTE: ‘The above mentioned acceptance criteria ([Link]) assume aormality and a vwo-sided specification (target in the center). When this is not tte, using this analysis may result in unreliable information. These alternate acceplance criteria could require a different type of index or some method of sransformation of the data, The focus should be on understanding the reasons lor the non-normal (2.8.18, |t stable over time?) and managing variation, Refer to the Statistical Process Control reference manusl for further guidance. [Link] Actions To Be Taken When Acceptance Criteria Are Not Satisfied ‘The organization shall contact the authorized customer representative if the acceptance criteria ([Link]) cannot be aitained 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 util the acceptance criteria arc met, or until customer approval is received. NOTE NOTE 2: For bulk materials, 100% inspection means an evaluation of a sample(s) of product from uous process er homogeneous batch which is representative of the entire production run + 10% inspection methodologies ars subject to review and concurrence by the customer,2.2.12 Qualified Laboratory Documentation Inspection and testing for PPAP shal) be performed by a qualified laboratory as defined by customer requirements (e.g, an accredited laboratery), The qualified laboraiory (internal or external to the organization) shall have a laboratery scope and documentation showing that the laboratary is qualified for the type of measurements or tests conducted, When an extemal’commercis! 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) ofthe tests, and the standards used {0 run the tests shall be identified, 2.2.13 Appearance Approval Report (AAR) AA separate Appearance Approval Report (AAR) shall be completed for each part or series of parts if the ‘product/part has appearance requirements on the design record Upoa satisfactory completion of all required criteria, the organization shall record the required information on the AAR, ‘The completed AAR and representative production produets/parts shall be bmitied to the location specified by the customer 10 reveive disposition, 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. See customer-spcific requirements for any additional requirements NOTE 1; AAR typically applies only for parts with color, gain, or surface appearance 1 NOTE 2: Certain castomers may not require entries in all NAR fields. See Appendix Bi or customer- specifics for detailed instrucions on completing the AAR. 2.2.14 Sample Production Parts “The organization shall provide sample product #s specified by the customer. 2.2.15 Master Sample ‘The organization shall retain a master sample for the sante period as the production part approval recards, for 4) until a new master sample is produced for the same customer part numnber for customer approval, or bb) where a master sample is required by the design record, Control Plan or inspection eriteria, as a reference or standard, The master sample shall be identified as such, and shall show the customer approval date on the sample. The organization shall retain a master sample for each position of a multiple cavity die, mold, too! oF pattem, or production process unless otherwise specified by the customer. NOTE 1: When part size, sheer volume of pars, etc, makes storage of a master sarmple difficuk, the sample retention requirements may be modified or waived in writing by the authorized customer representative. ‘The purpose of the mester sampke isto assist in defining the production standard, espevally where dsta is ambiguous or in insufficient deal to fally replicate the par to its original approved state. NOTE 2: Many bulk material properties are by their nature te dependent, and if & master sample is required, it may consist of the manufacturing recond, test results, and ceniicate of analysis of key ingredion, forthe approved submission sample (see Appendix F),2.2.16 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 becn 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 (sce Glossary ~ “Active Part”) Measurement system analysis studies, eg, uage R & R accuracy, bias, linearity, stability studies, shall be conducted in compliance with customer requirements, (see 2.2.8 and the Measurement Systems Analysis reference manual), NOTE 1: Checking aids can include fixtures, variable and attribute pages. models. templates, my specific wo the product being submitted NOTE 2: Checking aids, ee. typically do not apply to Bulk Materia. If checking aids are used for bulk materials, the organization should contact the authorized customer representative regaiding this requirement 2.2.17 Customer-Specific Requirements The organization shall have records of compliance to all applicable cusiomer-specitic requirements. For bulk materials, applicable customer-specific requirements shall be documented on the Bulk Material Requirements Checklist 2.2.18 Part Submission Warrant (PSW) Upon completion of all PPA requirements, the organization shall complete the Part Submission Warrant (PSW). A separate PSW shall be completed for cach customer part number unless otlnerwise agreed to by the authorized customer representative, If production parts will be produced from more than one cavity, mold, tool, die, pattern, oF production Process, ¢.£., line or cell, the organization shall complete a dimensional evaluation (see 2.2.9) ot one part from each. The specific cavities, molds. line, ete., shall then be identified in the “*Mold/Cavity/Produetion Process” line on a PSW, or in a PSW attachment The organization shall verify thot all of the measurement and test resulis show conformance with customer requirements and thai all requited documentation is available and, for Level 2, 3. and 4, 1s inclided in the submission as sppropriate A responsible official of the organization shall approve the PSW and provide contact information, NOTE 1: One warrant per customer part number ean be used to summarize many changes providing that the changes are adequately documented, and the submission is in compkance with customer program timing requirement. NOTE 2: PSWs may be submited electronically in compliance with customer requirements2218.1 Part Weight (Mass) ‘The organization shall revocd on the PSW the part weight ofthe part es shipped, measured and expressed in kilograms to four decimal places (0.0000) unless otherwise specified by the custorner, The weight shall hot 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 prosess Where there is no production or service requirernent for atleast ten pars, the organization should use the required number for calculation ofthe average part weight, For bulk materials, the part weight field is not applicableSECTION 3 - CUSTOMER NOTIFICATION AND SUBMISSION REQUIREMENTS 3.1 Customer Notification The organization shall notify the authorized customer representative of any planned changes to the design, process, or site. Examples are indicated in the table below (see Table 3.1). NOTE: Organizations are responsible to notify the authorized customer representative of all changes to the part design andior the manufacturing process. Upon notification and approval of the proposed change by the authorized customer represeniaiive, and after change implementation, PPAP submission is required unless otherwise specified Table 3.4 Examples of changes requiring, Clarifications: notificat 1. Use of other construction or material For example, other construction as documented on than was used inthe previously approved | a devistion (permit) or included as a note on the part or product design record and not cavered by an engineering charge as described in Table 3.2. 3 Production from new oF modified ols | This Fequirement only applies to tools, which due (except perishable tools}, dies. molds to their unique form or function, can be expected pratiers, ete including additional or tw influence the integrity of the final product. Its replacement tooling not meant to describe standard tools (new or repaired), such as standard measuring devices, drivers (manual or power), ete 3. Production following upgrade or Upgrade means the reconstiuction andor rearrangement of existing tooling or modification of a tool or machine or to merease the equipment capacity. performance, or change its existing finetion. This is not meant to be confused with normal maintenance, repair or replacement of parts, etc. for which no change in performance is to be expected and post repair verification methods hove been established. Rearrangement is defined as activity that changes the sequence of product/process flow from that documented in the process flow diagram Cneluding the addition of a new process) Minor adjustmenis of production equiorment may he required io meet safety requirements such as installation of protective covers, elimination of potential ESD risks. ete. 4, Production from woling and equipment | Production provess tooling and “or equipment | transferred to a different plant site or trom | transferred between buildings or facilities tone or an additional plant site more sites. 5. Change of supplier for paris, non- ‘The organization is responsible for approval of ‘equivalent materials, or services (e.g..heat- | supplier provided material and services, treating. plaiing). B6. Product produced alter the tooling bas been inactive for volume production for ‘wwelve months or more 7, Product and process changes related 10 components ofthe production product ‘manufactured internally oF manufactured by | suppliers. For product that has been produced after tooling has been inactive for twelve months of 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. The anly exception is ‘when the part has low volume, e.g., service or specialty vehicles. However @ customer may specify certain PPAP requirements for service pans. | ‘Any changes. inchuding changes at the suppliers to the organization and their suppliers, hat affect ceastomer requirements, git, form, fiction, performance, durability. 8. Change in testinspection method ~ new technique (no effeet on acceptance eriterie) For change in test method. the organization should hhaye evidence that the new method has measurement capability equivalent to the old method, ‘Additional ior balk materials 9, New sourve of raw material from new or caisting supplier. LO, Change in product appearance attributes ‘These changes would normally be expected to have an effect on the performance of the product.3.2_Submission to Customer ‘The organization shall submit for PPAP approval prior to the first production shipment in the fallowing situations unless the autaorized customer representative las waived this requirement (see Table 3.2). NOTE: In the situations described below, prior notification to, or communication wilh, the authorized ceustomer representative is assumed. The organization shall review and update, as necessary, all applicable items in the PPAP file to reflect the production process, regardless of whether or not the eustomer requests a formal submission. The PPAP file shall contain the name of the authorized customer representative granting the waiver and the date, Table 3.2 EE Requirement 1. A new part or product (i.e. a specific pan, material, or eolor not previously supplied to the customer) 2. Conection ofa discrepancy on a previously submitted part 3. Engineering chonge «© design records, ications, or materials for production part numbers(s) “Additionally, for Bulk Materials: 4, Process technology new’ to the organization, not previously used for this product. Clarifications Submission is required fora new product (initial reiease) or a previously approved product that has a new or revised productipart number (¢.2. suffix) assigned to it. A new part/product or material added to a family may uuse appropriate PPAP documentation irom a previously spproved part within the same product family. Submission is required fo comect any discrepancies ona previously submitted par. A “discrepancy” ean be related to: + The product pertormance against the customer requirements ional or capability issues + Approval of « part replacing an interim approval # Testing, inetuding materi performance, or engineering validation issues | Submission is required on any engineering change to the production product/pant design record, specifications ar materialsSECTION 4-— SUBMISSION TO CUSTOMER - LEVELS OF EVIDENCE 4.1 Submission Levels ‘The organization shall submit the items andor records spe odin the level identified below in Table 4.1: Table 4.1 Level | | Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to the customer. Level 2 Warrant with product samples and limited supporting date submitted to the customer. Level 3 Warrant with product samples and complete supporting data submitted 10 the customer. Level 4 Warrant and other requirements as defined by the customer. Level § Warrant with procuct samples and complete supporting data reviewed at the organization's manufacturing location. See Retention’Submission Requirements Table 4.2 for exact retention/submission requirements for each submission level. ‘The organization shall use level 3 as the default level for all submissions unless otherwise specified by the authorized customer representative ‘The minimum submission requirement for bulk materials is the PSW and the Bulk Materials Checklist ick “Other” in the Reason for Submission Section on the PSW form and specify “Bulk Meterial.” This indicates that the "Bulk Material Requirements Checklist" was used to specify the PPAP requirements fer the bulk material and shall be included in the submission packet. NOTE 1: The authorized customer represemative may identify @ submission level, different from the default level, that $ to be wed with each organization, or organization and customer part number combination Different customer locations may assign different submission levels to the same organization manufacturing locatian NOTE 2: All of the forms referenced in this document may he replaced by computer-generated facsimiles. Acceptability of these facsimiles is to be confirmed with the authorized customer representative prior to the firs! submussion,Retention/Submission Requirements Table 4.2 (Nonmative) INOTE Table 42 lists submissicn aud reweton reauiroments, Mandatory and applicable reine: for « PBAB record are defied in the PPAP mama and by the customer] ‘Submission Level Reyirement Level) Lewl2 Levwl3 Level Level S 1 Design Record 4 s for propristay components dots + val eter omponeutsdesals 2 Enginvering Change Documents if ary 3 Customer Engincering approval, if requir 4 Design FMEA 5. Process Flow Diagrams 6. Process FMEA. RRR RRR REE 7. Control Plan Measarement Srstem Analysis Studies Dimensional Resuls 10, Mera, Pentormanee Test Ress UL, nit Process Sutes 12, Quslfod Laboratory Documentation 13, Appourance Approval Report (AAR), ifapplicabie 14 Sample Prod 15, Maso Saraple 16, Checking ats 17. Recs of Compliance With CustomerSpevific Reauirements 1S. Pan Submission Warrant (PSW) uk Materia! Checklist 600-41 above) 8 8 s s aneee nme 'S = The ergization shall sipmit wo the cxstomer and ein x copy of records ur documentation ems a propre locations. R= The cegonication hall resan at sppropriaie leeations and make available to the customer upon request © = Thecezoniction shall ren at appropriate locations and subi to the customer upon requesSECTION 5 — PART SUBMISSION STATUS 5.1_General Upon approval of the submission, the organization shall assure that future production continues to meet all customer requirements, NOTE: For those organizations that have been classified as “self certifying” (PRAP submission level 1) by aspesifie eustomer, submission ofthe required organization-pproved documentation will b as customer approval unless the organization is advised otherwise 5.2_Customer PPAP Status 5.2.1 Approved Approved indicates that the part or material, including all sub-components, mects all customer requirements. The organization is therefore authorized to ship production quanties of the preduct subject to releases from the customer scheduling activity 5.2.2 Interim Approval Interim Approval permits shipment of material for production requiremenis on a limited time or piece quantity basis. Interim Approval will only be granted when the organization has: ‘© cleatly defined the non-compliances preventing approval; and, © prepared an action plan agreed upon by the customer, PPAP re-submission is required to obtain a status of “approved.” [Nee 1s ‘The organization is responsible for implementing coatainment aetions to ensure chat only acceptable mater s being shippet to the customer Note 2: Pacts with a sian f “Inter Approval” are not be eonsidered “Approved” Material covered by an interim approval that fails to meet the agreed-upon aetion plan, either by the ‘expiration date or the shipment of the authorized quantity, will be rejected. 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) 5.2.4 Rejected Rejected means that the PPAP submission does not meet customer requirements, based on the production lot from which it was taken andior accompanying documentation, In such eases, the submission and/or process, ay appropriate, shall be corrected meet customer requirements. The submission shell be approved before production quantities may be shipped.SECTION 6 —- RECORD RETENTION PPAP records (see 2.2), regardless of submission fevel, shall be maintained for the length of time that the part is active (see Glossary) plus one calendar year. ‘The organization shall ensure that the appropriate PPAP records from a superseded part PPAP file are included, or referenced in the new part PPAP fle. NOTE: An example of an appropriate decument/record thal should be carried forward from the old file to the now part fle would he a msterisl certifiestion from a raw materal supplier for a new pact that represents only a diniensional change ftom the old part number. This should ke identified by conducting a PPAP “gap analysis" between the old and new part numbers.Appendix A — Completion of the Part Submission Warrant (PSW) FAILINORMATION Part Name ar 2s. Catomer Part Number, Hnpicoing lowed frisbee en part name and aber 2h Ong, Part Number: Pat our defied by the crest, any. 4 Shown an Denuing Nembers The design ne th spi the ean pit ter hing abi 4. ingoring Change Level & Date: Show thestang evel arc de ofthe deson cod, 5 Adeicanat Eaginceriog Charge Date Lis ll atheriedenginseringchanes not yt incopert in the eng eel Ha ‘bic ate insepnta hep 6 Salty anor Goserament Regulation: “Yes orice ty the dest ee tens “Ne. z iihase Order Neeser: Ere hic umber as Santon the coma pura cr Weim Ear ne acu meant loge fie dina places utes terse pid hy tne usta, 810 Checking Aid Number, Change Level ard Dave: frequent’ by he same, ens the checking id mor. chine em ORGANIZATION MANUFACTURING INFORWATION 1 Onpanbaiton Nam & Soppllar/VonderCode: Show he name and ale signed the manaficuring st eth urchins 2. Street Adres Region, Pestl Code, Conary, Sow theeomplete ales ofthe satn whore te pot was manaitcd Fer Resin ener sae eve, provane ec CUSTOMER SUBMITTAL INFORMATION 3. Cestomer NameDivsion: Sho the cerperaic tune une dio or peatns pop 14 eyeettayer Code Earths bayer mae and ede, 15 Applicaton: Laut he model ya, yb nae, eine, tansrisson MATERIALS REPORTING 6 Subntanceso Concer: Enier"Yes"” "Ni" ar-wa IMDS/Other Cetemer Ferma Cie eher“TUDS" “Otho Core Fame” appriprit, Ishi va IMDS fla Module 1D 4, Version cand Creation ite. IF aibrate va oher ister fort exterthe abe stemer confirmation Ws Pelymerle Parts defieaton: Emer“Ves*No" or REASON F 1 1X Chester tones. Forbuk mira addtoewnchecknesheapopriat,csck “Dien wie “Bulk Miers” nthe spose pow SUBMISSION LEVEL, 1, SUBMISSION LEVEL. Llei the unison eel route by theese SUBMISSION RESULTS 20 Chesksheaprpre Hoes ime ler es perisins e, ppeaanc ato ntti dat 21 Gheskieapprapes bn. If," ete esplaton emote, 22 MilvCavteePraduction Process For srion ee22.18 DECLARATION 3 Enorhenarber of ics manicure dre be sipifiat pseon in M oh eine) a he see predtn n 2S _EXFLANATION/COMMENTS: Hovde sy espanatory eommentson he Subeisicn Results any deans fmm he Deviation Aish adetonal lorax appa, 2 CUSTOMER TOOL TAGGING/NUMIERING: Ave timer owe Loh eed in con ith SCS 1699 sd any ‘xoraropencregarents aver "Yes" x "Se Mey tbe spelt OEM sera appar ORGANIZATION AUTHORIZED SIGNATURE: \ reporsileoruanizatn ofl fe veri tha the sls ste onferance al ester reuters thal egsieddocumesion save allapprovedcars pide Tals hans Saher Fax Nome, Eeabdre HOR CUSTOMER LSE ONLYPawecuvn oe EM Part Submission Warrant a None cont Pan Nene — 23) To e ‘Shown on Orang No ) (fg, Part Number (2B) nsowing Gargetet __) ___oaag ‘Aston Enpnsonag Cangas 5 pate @ Satyantor covering nequaten [Irey(G LIne Pastas On Wo wie) rg wae (2) hig iia gens — ing OnCANDATEN MANUFACTURE oan CUSTOMER SUBMITTAL FORMATION o ‘a [aE oR aaa @ “_ ® = a MATERIALS REPORTNG ) Hscosanerrogured Stans of Cerca neni banger TL] ves CIno CI ‘Submit by IMDS or oar oastomer format ‘Jes ohm sare ntid wh aopoprats SO marke codes? 17 One Oo wm REASON FORSUBMISSION (Cheek at least one) 5) ET ital Submision a Dlotange optional Consrutin or Matra Gi Enanesnng Cnangete) [DSinniar ar uaters: Siem Chanoe Ey seeing: Tarstor Mepecenent, Ratuushmort. of sears! [leranee m pan Pears El conection of crepancy ret renuces at Air! Lecton El Teng race > min year ooner= seace spac faeces mismo ca eaics) (O CU Fo ea od cage as tt een pong rananIRCR (C] Lovel 2 — Werrant with product sampies ard liited supporing dare submited to customer 1 leet 3 Wore oh pat rere on snaina on wri a Elle 4 vorataane esianens wareetraoacens Esai Were poe omer meinen uo sis evi ae anita, summesion nesuite 2) Tie esas ol anessusl nesurerens 2 mace ww unsere i CI promi cena] etal oie pate ‘These msuts meet al dsien record reauitements: [Yes 8 ‘NO. iNO"— Expimaton Requted) 21) (tv ody i wane in oi pr i nda roche nan bir {SErcaay oat secretes excenoolvue carpi wate sascaascierion far rlcton tale kes as aia eae fran TONtConn oo, Ise ioneTo mobos antainiaed? Cee Le) i inns Sip ED tite it Ne one Ho at Te ema FOR COSTER USE ONLY WF APPLOAEE PPP warart Oxpesion[ Amped Tl AWanad Clover Pant Warne case raceng Number optna, ——— CFG-1001damuecievsie a El Part Submission Warrant Pat None Cunt Pat Numba ‘Shown on awe Na, On. Fatnunber fenahowing charge ew) at sara Cognoning Change —_—____— iva Saley andor Govranot Regulate (Tee [] No Putchase Order Na Win a) —__ Crecang Ai No. — CChotirg Ae Enginoring Change Level ae ORGAMZATION MANUFACTURING WEORNATION CUSTOMER SUMITIAL FORMATION See Signin = ar Pouce cen fepienon MATERIALS REPORTING ‘Hos cuslomer-eauied Subearcesct Corcem intomatonteen wocnes? Cl Yes Linn L ola Subs by IMDS or one eusamet ara ‘reper parte enti wih aan ISD making ees? Dyes One 0 we REASON FORSUBMISSION (Check at least one) 5 tna Suomston (C] orange wo Oman coratvetin or Mato! 7 Exanoering Cnangeish Subp Matera! Source Chanre [Ey Thotna: Tense Flacoment otabishmant or aeina Glnange in Pat Proceteng [Ey carectont Chereparcy ete Pedieed ot Absitora eon 1 ete toeties Bh bree othe — please pect blew REQUESTED SUBMISSION LEVEL (cnack ore) — CT Lave 1 nara ony ro desta appearance ts as Appearance Anorval enor aurea Ow (17 Lew! 2 — naar wan proeuer saps ane comple upping da sate cure (Gy level a — arama che roqtemont as deine ty stem 5) Lew 5 navart win podict sampine a cami signoring dla avenge at rganiaton's nautacunng locaton [SUBMISSION RESULTS The asus ee [_ divonsnalmsaciromerts | mitral ang tnctona tests appearance cles] atta toes package “Thee rece ata dai recat sequnmarte [_]¥ee | NO. (HNO Explanation Raqurad DECLARATION "Pati athesanples presen by ths ware ae epeserat2 of ou pars hich were mae by ocmis tha meas a radu Pa ‘sora roves nua Een Maquramar. ute stm wa hess sampee were roascaa fe poaictow ect ras | Seo con ter ounces evgoren af uch carparen sn fr ana aoe revi ve rot any deve re EXPLANATONCOMMENTS: each Gusomer Teo pooetviansdardnamterd? Elven Cine Cl wa [Crganetion Auttonzes Sgratine ate Print Name Pane ee pg el FER GORTOUER USE OMY (F APPOSHELE PAP Warrant Disoostion. ] Avoraved []Relected ther ‘Custer Sgranwe ggg Print Name customer Tacing Mtoe opera) CFG-1001Appendix B - Completion of the Appearance Approval Report L. Customer part number: Engineering released customer part nuber, 2. _Draying Number: Use the number of the drawing on which the part is shown if different from the part rumber. 3. Application; Enter the model year(s) and vehicle or other program on which the paris used. 4. Part Name: Use the finished part name on the part érawing, 5. Buyer Code: Enter the code for specific buyer of part 6./7. BIC Level & Date: Engineesing change level and E:C date for this submission, § Organization Name: Organization responsible lor submission (inelude supplier if applicable) 9. Manufacturing Location: Location where part was manufactured or assembled. 10. Supplier/Vendor Code: Customer-assigned code for organization location where the part was rmanufaccured or assembled. 11. Reason for Submission: Cheek box(es) explaining the reason for this submission. 12, Organization Sourcing & Texture Information: List al first surface tools, 21 rain type(s), and grain and gloss masters used to check part. 3. Pre-Texture Evaluation: To be completed by authorized customer representative (not used by GM). 14, Color Suffix: Use alphanumerie or numeric color identi 1S. ‘Tristimatus Data: List numerical (colorimeter) data of submission part as compared to the crustomer-authorized! master 16. Master Number: Enteralphanumerie master identification (not used by For. 17. Master Date: Enter the date on which the master was approved. 18 Material Type: Identify first surface finish and substrate (eg., pain ABS). 19, Material Source: Identify firs! surface and substrate suppliers. Example: 20, Color Evaluation, Hue, Value, Chroma, Gloss and Metalic Bril 21. Color Shipping Suffix: Color part number suffix or color number. 22, Part Disposition: To be determined by customer (approved or rejected) 23, Comments: General comments by the organization oF customer (optional) ining source(s), edspouDow. Visual assessment by 24, Organization Signature, Phone No. & Date: Organization cerbfication thatthe document information is accurate and meets all requirements specitied 25, Authorized Customer Representative Signature & Date: Authorized Customer Representative approval signature: SIDE THE BOLD LINES ARE FOR CUSTOMER USE.2001-949 ove ud awa] —_-ouanond @__vouivanvond ta SINSAWOD| ae bac oom heen emer oe [rors [area fa) Lay. Lon. Gl D—bes a raTaOTOH svosotaa’ auras es ERE anwanassuase LS @ NOLLVIROINI SYNLX3L ONY SNIDHNOS NOLLWZINYDYO- coerced NOLLWN TVA FJONVYV3ddv ae Sa Ae BST Sn eee = Sa oe a @ sooranrsanains © _ornssuinne ©) noussne a a ata aiivieal ie @ tv oe a © __ wuvona| 2) exsmnoud © ee 1YOdsY WAOUddV SONVUVAddv [ia2001-949 fin SHINES] atv ‘on ano] NoUVEIYOXO| ROSSA] wan [pom [sofas [ree ne [ee [oe fSoenos | Saat | Siva |eaannw pro) 20 [90 ea [a fraans| ave Ss0Te | eHaar | ann a prmauwfmesivn saisw fuaisyal viva sriMmMUsK /¥oTCo| NOILWN TWAS HO1OD [naa oonnoa3] = Lot 1934409 ‘dase Lon 19309 TT GN SITES TROT WTWAS anwwinasausay | gunweusue NOILWABOANI SENDXSL ONY ONOUNOS NOILWZINVDUO NOILWNTVAT SONVUV addy [| SONROONRSNENE [] aNaMeIis NCLoNGONdLSys SEADGI sad) —_NOISSINaNG| usHi0| noissmans- 3a] TNs WoIes [] __NvueViA NOISSHNBNS Lava wosnosy 3} 3000] ‘Noulvoy] Savn| woanan /wanuans| onruniovanwv sanaans| '3009] Sav] atva| rani 903| sane| vel STOAA TWaawnn| wsannn| Nouvonsay| nung} 7) LY¥OdSuy TWAONddY SONVUVAddY BaAppendix C — Production Part Approval, Dimensional Results Production Part Approval Dimensional Test Results RaEATON maT ER RECTION ASOT oesion eCoRO CHANGE LEV: ENGNEERNG cuANce DOCUMENTS rem _[Diension /seccricanon| UNITS are |resteo] RESULTS (DATA) Blanket staiements of sonfornane bi CFG-1003 ae Tor any test esults. DEEAppendix D — Production Part Approval, Material Test Results Production Part Approval Material Test Results dasurCumssn oa RGANIZATION PART NONEER fuse pr ref nde Ne Sper (ee) Catena asgne ae [NAVE STLABORATORY are [Link] | uMirs | eaTe [resieo| suruen resrmesuLrs DATA, Blanket siatemont of conformance are unacceptble for any teri reault wen eae Sane Te THEAppendix E - Production Part Approval, Performance Test Results Production Part Approval Performance Test Results acs. foRcANizATION: PART MOWER [sup iemveNnon cone Jpere Naw franc otcaonarony. JDESIN RECORD CHANCE LEVEL ‘CUSTOMER SPECIFEDSUPPLERNENDCR CODE Jencnceane cxANGE DOCUMENTS. a E SUPPLIER TEST RESULTS TOATAT JEST SPEGIFICATION, Lats ove {resrea EST CONDITIONS. [[Biarke statements of conformance ara unacceptable Tor any fest results_] Maen SaaS TE Tae ae CFG-1005Appendix F - Bulk Material - Specific Requirements E:1_ Introduction An organization supplying bulk materials shall comply with the requirements in this Appendix or use {guidance herein for clarification of PAP. The requirements in this Appendix are minimums and may be supplemented at the diseretion of the organization and/or the custom £.2 Applicability Organizations are responsible for applying PPAP tw their suppliers of ingredients which have organization-designated special characteristics. Where OEM PPAP approval of a bulk moterial exists, evidence of that approval is sufficient as the PPAP. submission at other levels in the supply chain. Examples of bulk material include, but are not limited to: adhesives and sealants (solders, elastomers): chemicals (rinses, polishes, additives, treatments, colors/pigments, solvents); coatings (top coats, undercoats, primers. phosphstes, surface treatments); engine coolants (antifreeze), fabries: film and film laminates; ferrous and non-ferrous metals (bulk steel, aluminum, coils, ingots); foundry (sanéisilica, alloying materials, other minerals/ores); fuels and fuel components; glass and glass components, lubricants (oils, cic.|; monomers, pre-polymiers and polymers (rubbers, plastics, resins ard their precursors}, and performance fluids (transmission. power steering. brake, refrigerant). Nk. rem is For bulk material, the PPAP elements required are defined by the Bulk Materals Requirements Checklist, Any customer-specific requirements shall be documented on the Bulk Materials Requirements Checklist. Use the Bulk Materials Requ rements Checklist as follows: + Required / Target Date: 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 funetion the individual who will review and approve the element. * Primary Responsibility - Organization: Identify by name or funetion the individual who will assemble and assure the completeness o* the element to be reviewed. + Comments / Conditions: Mdeatily any qualifying information or references to altlached documents that provide specific information regarding the element. For example. this may include specific formats 10 be used for the Design Matrix or acceptable tolerances. for ‘Measurement System Analysis (MSA) studies, + Approved by: Enter the initials of the awhorized customer representative who has reviewed nd accepted the element. ‘© Pian agreed to by: Iéemtify the individuals (and their funetions) who made and agreed upon the project planBulk Materials Requirements Checklist Project: Required ‘| Primary Responsibility | Comments’ | Approved ‘Target Date | Customer | Orsarivation | Conditions | fy ate Product Design and Development Verification Design Matrix Design FMEA Special Product Characteristics Design Records Prototype Control Plan ‘Appearance Approval Report Master Sample Test Results Dimensional Reais Checking Aids Engineering Approval Process Design and Development Ve ification Process Flow Diagrams Process FMEA Special Process Characteristics re-launch Control Plan Production Contwel Phun ‘Measurement System Analysis Interim Approval Product and Process Validation Inkial Process Studies Part Submission Warrant Elements to he completed as needed (Customer Plant Connection Customer-Speeifie Requirements (Change Documentation Supplier Considerations Plan Agreed ie by: Name /Tunetion Company Tile / Date 364 Design Matrix P.4.1 Introduction Organizations supplying bulk material generally deal with the chemistry and functionality of the product being designed, Use of these suggestions will arrive at the same end point of a completed Design FMEA, but with greater applicability to bulk materials. For bulk materials, a Design Matis, when required, shall be prepared prior to developing the Design FMEA. ‘The Design Matrix determines the complex interactions of formula ingredients, ingredient characteristics, product characteristies, process corstraints, and conchtions for customer use. High impact items can then be effectively analyzed in the Design FMEA FA.2 Design Matrix — Elaboration This matrix correlates customer expectations with the product design stems. Construct the Design Matrix referring to the example which will Follow 1. Along the horizontal axis, list the Functions (Desired Attributes/Potential Failure Modes) 2. Along the vertical axis, list the design items as Potential Causes (Category/Characteristics) Formula Ingredients Ingredient Characteristics Product Characteristics, Process Constraints Conditions for Use (customer process constraints) For each design item, enter the current robust threshold range levels and uniis, 4. 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 ifa potential cause item is allowed to go under or over its robust minimum or maximum, respectively. 5, Afier completion of the mnkings in the Design Matrix, review the category/charactcristies for 4 preliminary assessment of Special Characteristics. Designate any Special Characteristics in column 1, 6. The high negstive impact potential causes are transferred to the Design FMEA fer analysis. 7