Ppap - Aiag Manual

 

PROD PA PAERST   APRO  AP P P RDOUCTI VA L PR PORNOCE OC S (PPAP)

Production Part Producti Part App Approva roval Proce Process (PP (PPA P) First Fi rst Edi Editi tion on I ssued ssued February, 1993 1993 Second Sec ond Edition, Editi on, 1st 1st P Pri rinting, nting, Februa February, ry, 1995 1995,, 2nd Printing, Pri nting, J uly, 1995 1995  Thir  Th ird d Edit Editio ion n, September, 1999 Copyri opyright ©1993, © 1995, ©1997, © 1999 DaimlerChrysler Corporation, Ford Motor Company, General Motors Corporation

 

Production Part Producti Part App Approva roval Proce Process (PP (PPA P) First Fi rst Edi Editi tion on I ssued ssued February, 1993 1993 Second Sec ond Edition, Editi on, 1st 1st P Pri rinting, nting, Februa February, ry, 1995 1995,, 2nd Printing, Pri nting, J uly, 1995 1995  Thir  Th ird d Edit Editio ion n, September, 1999 Copyri opyright ©1993, © 1995, ©1997, © 1999 DaimlerChrysler Corporation, Ford Motor Company, General Motors Corporation  The  Th e Second Edit Editio ion n, 2nd Pr Prin inttin ing g, J uly, 1995 edit itio ion n is obsole lette February 1, 2000 unless unl ess otherwi otherwise se specif cif ied by your custome customer

Furthe urther copiesare obtainable obtainablefr from omAIAG at 01-248-358-3003or Car arw win Continuou Continuous (UK) (UK ) in in Europe Europe44-1-708-861333

 

FOREW FO REWORD ORD TO THE T THI HIRD RD ED EDIITI TION ON  ThePr  The Produc oducti tion onPartApproval Pr Proce ocess(PPAP) Thi  Third rd Edi Editi tion on was issu issuedto incorporate incorporateanumber of revisions revisi ons whiich include wh include: • •

Use of “audi “auditable” table” langu langua age and a forma ormat cons consiistent with with QS-9000 to support third party auditing; A reord rde ering ring of the the PPAP requirements aligned with the typical process flow;

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Revision of “Prelim “Preli minary Proce Process ss Capa Capabil biliity Requirement nts”, s”, no now called “Initi “Initia al Process Studies Studies”, ”, to provide provi defor the useof eit eithe her Cpk Cpk or Ppk, Ppk, depending on theamount and typeof data avail vailable, consisten consistentt with our Statistical Pr Proce ocess Control Control ref  reference erence manual;

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Cl Cla ari riffication of whe when cus custom tomer notif notifiication and/or nd/or subm submissi ssion is requi quired; red;

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The The prio iorr IASG QS-90 QS-9000Sanctione tioned Interpretations tions sp  spe ecif ic to PPAP;

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A Truc Truck OEM-Sp OEM- Spe ecific if ic In I nstru ruc ctions ions;

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Requirem Requirements nts for bul bulk materia rial, including a Bulk Ma Materia rial-Specif -Specifiic Appe ppendi ndix;

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Tire I ndustry-Sp ry-Specific cifi c A ppendix;

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An enhanc nce ed gl glos oss sary of terms rms.

 The actual c  The ch hanges of tth he previou ious PPAP text are mini nim mal, and evoluti volutiona onary. Whil Whi le the the ad addi diti tions ons have increas ncreased ed the the size of the documen ent, t, they provide greater clarif clarif icati cation of PPAP requi  requirem remen ents ts and allow application of PPAP requi  requirem rements to a broader broader community unity of users. Current training training modul odules san sancti ctione oned by Daim DaimlerChrysl erChrysler er,, Ford and General Motors have been revise vised to incorporate ncorporate these changes. A cknowledgments ents are due due to the the DaimlerChrysl DaimlerChrysler er,, F Ford ord and and GM Supplier Suppli er Qual Quality Req Requi uirem remen ents tsTask Task F Force orce (Ha (Hank Gryn, Gryn, Da Dan Reid Reid and and Steve Wa Walsh sh), ), Michael Schons Schons ffrom rom Dai DaimlerC rChrysler, hrysler, Ca Carol Mye yers rs and and Rudy Pompe Pom perr from f rom Gene General M otors, Paul Norkevici N orkevicius us from Ford, Ford, Pa Patrici tri cia a Me Messen ssenge gerr from f rom the the Chem hemica call Man anufacture ufacturers rs A ssoci ssociat atiion, Jose J oseph Muscedere from the the A I AG Truck Truck and and Heavy Equipm Equipmen entt Group, and and SteveButcher from f rom theRubber ubber Man Manufacture ufacturers rs Associati Association. on.  The PPAP Thi  The  Third rd Editi Edi tion on obsol obsolet etes estheSecond Second Editi Edition on eff ffect ectiiveFebruary 1, 2000unlessotherwise rwi sespeci ciff ied by your custome customer.

September, 1999

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FOREWORD FOREW ORD TO THE SECOND EDITION  This document is the second editio  This ition n of tth he Chry Chrys sler ler, Ford and General Mot Motors Pro Production ion Part Ap App proval Pr Proces ocess (PPA (PPAP) P) procedure procedure. I t represe represents a refinement of the origi origina nal PPAP PPA P procedure procedure bas based ed on input from from representatives at each of these compani nies. es. I n particul rti cular, ar, it it iincl nclude udes recommendati ations ons by by the companies’ es’ Europe uropean aff aff iliates tes tha that wil will facil cilitate implem implementation tion of PPAP PPAP and QS-9000 in Europe.  The second edit  The itio ion n of PPAP PPAP,, Fe February 1995, do does not rre evise ise the production ion parts approval p prrocess. A change summary has been provided provided as Appendix ppendix E. E. Document control control requireme requirements mandate that the February, 1993, editi edition on of PPAP PPA P is obsol obsolet ete e eff ffective ective Septem September 1, 1995. While this procedure is intended to cover all situations normally occurring during the part approval process, there may be questions stions that arise arise duri during ng im implem plemen entati tation. on. Thes These questions stions should be directed directed to your customer’s part approval activi activity. I f you you are uncertain certain how how to contact the parts approval activi activity, the buyer in your customer’s Purchasing activi activity can assi assist st you. A s an an aid to suppli suppliers ers in im i mplem plemen enti ting ng PPAP PPAP, all all of the forms required by the proced procedure ure are avai vailable on disket di skette te and perm permit entry entry of all necessary data. Diske Di skette ttes s are avai vailable from AI AG at (248) 358-3003. Pl ease note the custom Plea customer-specif cif ic iinfor nform mation in in A ppendices B, C, C, and D. These appendices clarif clarify each customer’s indivi ndividual rrequ equiremen ents. ts.  The PPAP  The PPAP document rre epresents th the effort fforts s of of the the Chry Chrys sle lerr, For Ford and Ge General Moto Motors su subcommit itttee members, B. B. R Ra ay Dau Daugherty and Robert Panczyk (C (Chrysler), hrysler), Ste Stephe phen Walsh Walsh (Ford), (Ford), and Tim Ti mothy othy O’B O’ Brien ri en and an d Denn Denniis Whitm Whitman (G (Gen enera eral Motors). The subcommitte ttee e grate tefful ullly acknowl acknowled edge ges the contributions contributions of  many empl employees oyees in in their respective ctive compa compani nies es,, wi without thout whose assista ssistance nce and continui continuing ng support support the procedure could could not be effectively ectively iimp mplemen ented. ted.

Februar Febr uary y, 1995

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FOREW FO REWORD ORD TO THE FI FIRS RST T EDIT EDITIION  This Pr  This Pro ocedure was develop loped by the Quality lity and PartApp Approval s sttaff ffs s at Chr Chrysler ler, Ford, and General MoMotors, working working under under the au auspices spices of the A utomoti otive ve Di Divi visi sion on of the American erican Societ Society y ffor or Quality Quali ty Control (ASQC) (A SQC) and the theA utom utomotive Indust Industry ry Action Action Group Group (AI (A I AG).  The ASQC/  The ASQC/AI AIAG AG Task Fo Force chart rte er is is to standardize ize the reference manuals, ls, pr procedures, re reportin ing g fo forrmats, and technical chnical nomenclature nclature used by Chry Chrysl sler, er, For Ford d, and Gen eneral eral Motors M otors in in their respecti ctive ve supplier uppli er quality system systems. Accordi Accordingly, ngly, this this Proce Procedure dure shoul should d be used by su suppli ppliers ers in the subm submission of producti production on parts for for approval to any any of these companies. es. I n the past, Chrysl Chrysler er,, Ford Ford,, and General Motors each had their own procedures for revi revie ewi wing ng supplier ppli er submissions of producti production parts parts for custom customer approval (i (ini niti tial al samples ples). Di Diff ffere erences betw between thes these three three processe proce sses resulted ted in in addi additi tiona onal demands on suppli supplier er resource resources. s. To im i mprove upon thi this s situa situati tion, on, Chrysl Chrysler er,, Ford, and and General Motors M otors agreed to develop, and, through A I AG, distri distribute bute this this Procedure. Procedure. The work group responsibl sponsible e for the Pr Proced ocedure was led led by Rad Smith of Ford’s Ford’s Corporate Quality Quali ty Off Off ice. While this Procedure is intended to cover all situations normally occurring during the sample submission process, thep re wialpprova l be que stions stions that that ari arise se duri thi this s process. process. hesetoque stions stionsthe should houl d be beapprova di directed rected to your customer’s artwil l activi activ ities. ties. If y you ouduring areng uncertai uncertain n as toThow contact parts l activi activ ity, the buye buyer in i n your customer’s Purchasi Purchasing ng offi off ice can can help. Pl ease note the custom Plea customer-specif cif ic infor inform mation in in Appe Appendices B, C, and D. These These appendices clari clariffy each customer’s indivi ndividual rrequ equiremen ents. ts.  The Task Fo  The Force gratefu fully lly acknowled ledges: tth he le lea adership and commit itm ment of Vice Vice Pre Presid ide ents Tho Thomas T. Stalllkamp at Sta at Chrysler, Chrysler, Norm Norma an F. Ehle Ehlers at Ford, and J. J. I gn gna asio L opez de A rriortua rri ortua of Gene General Motors; otors; the as assi sista stance of of the AI AG in the development, production, production, and distribution stribution of the Procedure; rocedure; and the guidance guidan ce of of theTask Task Force Force principa princi pals Russ Jacob J acobs (C (Chrysl hrysler), er), S Ste teve Walsh (Ford) and Dan Reid (Gene (General Motors), Rad adlley Smith Smith and the the assistance ssistance of the A SQC A utomotive otive Reading ding Team. T Thi his s team, led by  Trip  Tr ipp p Mart Martin in (P (Pe eterson Sprin ing g), reviewed the Man Manual for for technic ica al c co ontent and accuracy and made valu lu-able contributi contributions ons to the form and content. Si Since the the Manu Manual was developed veloped to meet specif specif ic needs of the au autom tomoti otive ve indu industry, the A SQC SQC volunta voluntary standards process def defiined by by ASQ ASQC C poli polici cies es and procedure procedures was not used in in its its developm velopment.

Februar Febr uary, y, 1993

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TABLE OF CONTE CONTEN NTS Introduction..................................... uction............................................................................................. .............................................................................................. ......................................  1 Secti ction on I I .1 G ene neral. ral............... ............................ ............................ ............................ ............................ ............................. ............................. ............................ ............................. ............................. ............................ .................... ...... 2 I .2 PPAP Pro Pr ocess cess R equireme uirement ntss ........................... ............ ............................. ............................ ............................ ............................ ............................. ............................. ............................ ................. ... 2 I.2. .2.1 1 I.2. .2.2 2

Signif Signif ican icant Prod Produc uction tion Run ..................... ................................ ..................... .................... ..................... ..................... ..................... ..................... ..................... ..................... ............ .. 2 PP PPA A P Re Requ quire irem ment nts s ..................... ............................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .............. .... 2 I .2.2.1 .2.2.1 Design Design Re Reccords rds ..................... ............................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... .................... ......... 3 I .2.2.2 .2.2.2 E ngin gi neeri ng Cha Chan nge D ocum cuments ........................... ............. ............................ ............................ ............................ ............................. ............................ ............. 3 I .2.2.3 .2.2.3 Enginee Engineeri ng App Approv roval ....................... ................................. .................... ..................... ..................... ..................... ..................... .................... ..................... ................... ........ 3 I .2.2.4 .2.2.4 Desig Design n Fa Failure ilure Mod Mode and E ffe ffect ctss Analy Analysis sis (D esign F MEA) ME A) ............................ .............. ............................. ............................ ............. 4 I .2.2.5 .2.2.5 Proce Process Flo Flow w Di agra gram ms ............. ........................ ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .............. .... 4 I .2.2.6 .2.2.6 Proce Process Fa Failure ilure Mod Mode And E ffe ffect ctss Ana Analys lysis is (Pro (Pr ocess cess F MEA) ME A) ................... ..... ............................ ............................ .................... ...... 4 I .2.2.7 .2.2.7 Di mensiona sional Re Resu sult ltss ........................... ............. ............................. ............................. ............................ ............................ ............................ ............................. .................. ... 4 I .2.2.8 Reco Records of Mate Materi al/ l/Pe Perform rforma anc nce e Test Resul Results ts ..... ......... ......... .......... ......... ......... .......... .......... ......... ......... .......... .......... ......... ......... .......... ......... ...... 5 I .2 .2.2 .2.8 .8.1 .1 Material Test Re Reco cord rds s .................... ............................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ............. .. 5 I .2 .2.2 .2.8 .8.2 .2 Performanc nce eTest Record Records ..................... ............................... .................... ..................... ..................... ..................... ..................... .................... ................ ...... 5 I .2.2.9 .2.2.9 I nitial itial Proc Process St Stu udies ies ..................... ............................... ..................... ..................... ..................... ..................... .................... ..................... ..................... .................... .......... 6 I .2 .2.2 .2.9 .9.1 .1 Gen General .................... ............................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... .............. .... 6 I .2 .2.2 .2.9 .9.2 .2 Qua Quali lity ty I ndices................ ices........................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... .................. ....... 6 I .2 .2.2 .2.9 .9.3 .3 A cc cce epta ptance nce Crite Criteria ria .......... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ................ ..... 7 I .2 .2.2 .2.9 .9.4 .4 Unsta Unstable Proce Processes .................... .............................. ..................... ..................... .................... ..................... ..................... ..................... ..................... ................. ....... 7 I .2 .2.2 .2.9 .9.5 .5 Proce Processes With One One-Side -Sided Spe Specifica cif ication tions s or Non-Norm Non-Norma al Dist Distribu ribution tions s ......... .................... .................. ....... 7 I .2 .2.2 .2.9 .9.6 .6 Stra Strategy Whe When Accepta ptance nce Criteria Criteria Are Not Satisfi Satisfie ed........... ..................... ..................... ..................... .................... .............. .... 8 I .2.2.10 .2.2.10 Mea Measu sure rem ment S Sys ysttemAnaly Analysis sis Stu Studies............. ies ........................... ............................. ............................. ............................ ............................ ................... ..... 8 I .2.2.11 .2.2.11 Qu Qua alifi lifie ed Lab Laborat rato ory Docu Documenta tattion........................... ion............ ............................. ............................ ............................ ............................ ..................... ....... 8 I .2.2.12 .2.2.12 Cont Control rol Plan................ Plan.......................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... .................... ......... 8 I .2.2.13 .2.2.13 Pa Part rt Sub Submission Warra rr ant (P (PSW SW)) ...................................... ....................... ............................. ............................ ............................ ............................. .................. ... 9 I .2 .2.2 .2.1 .13.1 3.1 Part Part Weight ight (Mass (Mass) .................... .............................. .................... ..................... ..................... ..................... ..................... .................... ..................... .................. ....... 9 I .2.2.14 .2.2.14 Ap App pearance ranceAp App prov roval Re Rep port ............................ .............. ............................. ............................. ............................ ............................ ............................ .................. .... 9 I .2.2.15 .2.2.15 Bulk Mat Materi al Re Req quire ir ements Chec Checklist............................ klist.............. ............................ ............................ ............................ ............................ ................. ... 10

II .2.2.16 .2.2 .2.2.17 .2.2.16 .17 I .2.2.18 .2.2.18 I .2.2.19 .2.2.19

Sam Sa pele Produ Prod ction ion Pa Parts rts............... ............................. ............................ ............................ ............................ ............................ ............................ ....................... ......... 1 Mast Mam ste r Sam Sa mpulect ............................ .............. ............................ ............................. ............................. ............................ ............................ ............................ ........................ .......... 10 0 Chec Checkin kingg Aids Aids .................... .............................. .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ............. 10 Custo Customer-Spe r-Specific Re Req quire ir ements ........................... ............. ............................ ............................. ............................. ............................ ......................... ........... 10

I .3 Cust Custo omer Notif Notif ica icatio tion n and Subm Submission R equireme uirement ntss ............................ .............. ............................. ............................. ............................ ............................ ................ 11 I.3. .3.1 1 I.3. .3.2 2 I.3. .3.3 3

Custo Custom mer Notifica Notif ication tion .................... .............................. ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... .................... ......... 11 Subm Submiss ission ion to Custo Custom mer .................... .............................. .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ................. ....... 12 Situations tions Where Custo Custom mer Notif Notifica ication tion I s Not Required ired ........... ..................... .................... ..................... ..................... ..................... ................ ..... 13

I .4 Sub Subm mission To To Custo Customer - L evels Of E vide videnc nce... e................. ............................ ............................ ............................. ............................. ............................ ........................ .......... 15 I.4. .4.1 1

Subm Submiss ission ion L evels .................... .............................. ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .............. .... 15

I .5 Pa Parr t Subm Submission Stat Status.................. us... ............................. ............................ ............................ ............................ ............................ ............................. ............................. ............................ ................... ..... 17 I.5. .5.1 1

Gene General ral .................... .............................. .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ..................... ............. .. 17

I.5. .5.2 2 Custo Custom mer PP PPA A P Statu tus s .......... .................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... .................... ......... 17 I .5 .5.2 .2.1 .1 Full A pprova roval ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 17 I .5 .5.2 .2.2 .2 I nterimA pproval ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... 17 I .5 .5.2 .2.3 .3 Reje Reject cte ed ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 17 vi

 

Ta Table ble of Conten ontents ts (Continu (Continued) ed)

I .6 R ecord cord R etention ntion ............................ .............. ............................ ............................ ............................. ............................. ............................ ............................ ............................. ............................. ................. ... 17

Section IIII I I .1 Da D aim imle lerC rC hrysler hrysler Corpo Corporat ration-Sp ion-Spe ecific cifi c I nstruct nstructions ions ............................ .............. ............................ ............................ ............................. ............................. .................. .... 19 I I .2 Fo Ford-Sp rd-Spe ecifi c I nstruct nstructions...... ions.................... ............................ ............................. ............................. ............................ ............................ ............................ ............................ .......................... ............ 24 I I .3 Gene General ral Moto Motors-Specifi rs-Specifi c I nstruct nstructions ions ........................... ............. ............................ ............................ ............................. ............................. ............................ ............................ .............. 33 I I .4 Truck OE M-Sp M-S pecifi c I nstruct nstructions............. ions........................... ............................ ............................. ............................. ............................ ............................ ............................ ..................... ....... 46

Appendices A ppe ppendix A : Comple Completion tion of the thePa Part rt Submission Warra rrant nt............. ........................... ............................. ............................. ............................ ............................ ................. ... 52 Part Part Sub Subm mission Warra rrant nt............ ........................... ............................. ............................ ............................ ............................ ............................. ............................. ................... ..... 53 - Indexed Form............... Form.......................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ................... ......... 53 - Bl Bla ank Form................... Form.............................. ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... .................. ........ 54 A ppe ppendix B: Com Comple pletion tion of the theA ppe ppeara ranc nce eA ppro pprova val Report... Report................. ............................ ............................ ............................ ............................ ...................... ........ 56 A ppe ppeara ranc nce eA pprova roval Rep Report ort ............................. ........................................... ............................ ............................ ............................ ............................. ......................... .......... 57 - Indexed Form............... Form.......................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ................... ......... 57 - Bl Bla ank Form................... Form.............................. ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... .................. ........ 58 A ppendix C: Dim Dimensional Re Repo port rt.......... .................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ............ 61 A ppendix D: Material rial Test Repo Report rt ........... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... .................... ......... 63 A ppendix E: Performanc nce eTest Rep Report .................... .............................. .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... .............. .... 65 A ppendix F: Bulk Materia riall - Spe Specific cif ic Requ Require irem ments nts .................... .............................. ..................... ..................... ..................... ..................... .................... .................... ............. ... 67 A ppendix G: Ti Tire re Ind I ndustry - Spe Specific cif ic Re Requ quire irem ments .................... .............................. ..................... ..................... ..................... ..................... .................... ..................... .............. ... 85 Glossa Gloss ary.......... ry .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... .................... ..................... ............. 87

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Introduction

INTRODUCTION PURPOSE Pr Produ oducti ction on PartApproval Pr Proce ocess(PPAP) def (PPAP) defiines gene generi ric c requi requirements for produc producti tion onpart approva vall, includi ncluding ng productiion and bulk product bulk mat aterial erials s (See Gl Glossa ossary). ry). Thepurposeof PPAP PPAP i is s to det determ ermine if all customer e enginee ngineeri ring ng design record and specif ci f icati cation on requirem requir em en ts are properly roperl y understood byd the supplier andlthat theprocess potential to produce product consisten consi sten tly tl y me eting these requirem requirements uring urisuppli ng aner actua producti production on runha ats the the quoted production roducti on rate.

APPLICABILITY  PPAP shall apply to iinte PPAP sha nternal and external supplier pli er sites (See Glossa Gl ossary) of bulk mat aterial erials, s, production materi terials, als, productiion or service product ervice parts. For bulk bulk material aterials, s,PPAP PPAP i  is s not req required uired unl unles ess requested by yo your ur customer. A suppl pliier of standard catalogue prod production uction or servi rvice ce parts parts s sha hall comply with withPPAP PPAP unl  unle ess for form mally ally waived by the customer. Tooli Tool ing shall be maintai aintained ned for standard catalogue item items as long as the items areof offfered or stated as being avail vailab able. NOTE 1:  1:  Seethe customer-specif ic instru instructions ctions in Section Section II II for add ddiitional informa information. A ll questions about PP about  PPAP shoul  should d be addressed to the customer product approval activ activiity ((See See Glossa Glossary ry). ). NOTE 2:  A customer canformally waive waivePPAP PPAP  requirem requirementsfor asuppli supplier er. Waivers for appli pplicableitems wil will be documented by tthe he customer.

APPROACH  Theword “shall” in  The ind dica icates mandatory require irements. The word “should” ld” ind indica icates amandatory require irement with ith some fle flexibil xibiliity allowe all owed iin n complia pli ance methodology. Paragraphs marked “NOTE Paragraphs “NOTE” ” are for guida guidance in understanding or clari clariffying ying the associ ociate ated requirem quirement. The word “should” appearing in a NOTE NOTE is  is for guidance only.  The  Th e Glos Glossary contain ins s in info forrmation ion that should be used fo forr purpo rposes of complia lian nce toPPAP PPAP requi  requireme rements.

1

 

SEC ECTI TION ON I I. 1

GENERAL  The  Th e supplier lier shall obtain fu full ll approval (S (Se ee I.5. I.5.2.1) fr fro om the customer product approval activit ivity y fo forr: 1. a new part or product (i.e., (i.e., a specif cif ic part, mate teri rial, al, or col color or not previ viously ously supplied to the specif cific cust custom omer). 2. correcti correction on of a discrepancy on aprevi viously ously submitte tted d part. 3. product modif ied by an engineeri ring ng change to design records, records, specif cif ica cati tions, ons, or mat aterial erials. s. 4. any s siituations requ requiire red d by Section II.3. .3. NOTE: If there is is anyquesti tion onconcerning concerningthe needfor for pr productio oduction npartapproval, contactthe responsibl ponsible e customer product approval acti activi vity. ty.

I.2 I.2 I.2.1

PPAP PRO ROCES CESS S REQ REQU UIREMEN IREMENTS TS Significant Pro Production ion Run

Forprod production parts, product forPPAP for PPAPsha shall betaken from asignif signif ica cant nt p production roduction run. This production run shall be from one one hour to eight hours of producti production, and with the s spe pecif cif ic production quantity quantity to total a mini minim mum of 300 consecutive parts, unl unles ess otherwise rwi se specif cif ied by the authorized ori zed customer quality representative.  This run shall be manufa  This fac ctured at the production ion site ite usin ing g the tooling ling, gagin ing g, process, materials ials,, and operators fr fro om the production production envi nvironme ronment. Parts from from eachuni unique queproducti production on process, e.g. duplicate dupli cateassembly lliineand/or work work cell cell,, each posi positi tion on of a multi ultipl ple e cavity vity die, die, mol old d, tool tool or pattern, shall be measured and representative parts tested. For bulk materials:  als:  No specif cific number of “parts” “parts” is i s required uired. If a sa sample iis s require uired to besubmitted tted, it i t shall beta taken ken in a manner as to assure that it represe represents “steady-state” “steady-state” operation operation of the process. NOTE: For bulk bul k material, terial, production production histori histories of current current products may of often ten be used to estim stimate the initi nitial al process capabili process bil ity or performa performanceof new and and simil similar products. I n ca case ses where no producti ction on history of a s siimilar bulk material rial product or techn technol ology ogy exi xists, sts, a conta contaiinment plan may be put into into e eff ffec ectt until suff suffiicien cient production has demonstrated capabi billity or perform performance.

I.2.2

PPAP Requirements

 The supplier  The lier shall meet all specified ified require irements, e.g. design ign record, specific ifica ation ions, and fo forr bulk material, ial, the Bu Bulk lk Material Requirements Checkl Checkliist (see (see II.2.2.15 .2.2.15 and andA ppendix F). A ny results results tha thatt areoutside s spe pecif cif ica cati tion on a are re causefor thesupplier suppli er not to submit theparts, documentation tion and/or records. Every eff effort ort shall shall bemadeto correct correct theprocess so that all design record requir requirem ements are met. I f the suppl ppliier iis s unable ble to meet any of these requirem quirements, the customer shall be contacted for determination termination of appropriate ropri ate corrective corrective action. ction.

2

 

Section I

I nspecti ection on and testing for forPPAP PPAP sha  shall be performe rformed by a qualifiedlabora boratory tory (See (SeeQS-90 QS-9000,Third hirdEdition Edition,, cl. cl. 4.10 4.10.6). .6). Commerci ercial/ al/iindependent test laboratories laboratories used shall be accredited facil aciliities ties (see (seeQS-90 QS-9000, Third Third Edition Edition,, cl. 4.10.7, and 4.11.2.b.1). 4.11.2.b.1). When a commercial ercial labora laboratory iis s used, the supplier suppli er shall submit the test results on the laboratory letterhead, or the normal laboratory report for form mat. The name of the laboratory that perf rformed ormed the tests, and thedate (s) of the tests, and the standards used to run run the tests shall be indicate indi cated. Blanket statements of conformance conformance are unacceptabl ble efor any test results results..  The supplier shall have the applic  The lica able ite items and records (S (Se ee QS-9000, Third Third E Edition dition,, cl. 4.16), listed below, for each part, or family of parts, regardl rdles ess of the part submission lle eve vell. These records (I (I.2.2.1 .2.2.1 – 15 and 19 19 if if any) shall be in a PPAP part ffiile, or referenced in such file and be readily dil y ava vaiilable. The items b below elow (I (I.2.2.16 .2.2.16 - 18) sh shall all be readily dil y availab vail able for customer use in PPAP PPAP..  The supplie  The lierr shall ob obtain prior ior approval (s (see QS-9000, Thi Third rd Edition, dition, cl. cl . 4.16) 4.16) ffrom rom the customer product approval activity for exceptions or deviations to PPAP PPAP requi  requireme rements. NOTE 1:  The supplier uppli er may, upon special arrangement, have tests perf rformed ormedby thecustomer’s laboratori laboratories es. NOTE 2:  2:  A ll I.2. .2.2 2 items or records may not necessaril ri ly apply to every customer part number from every suppliier. For example, some parts do not have appearance requi suppl requirem rements, and others do not have color col or requirem requir ements. In order to determi rmine ne wi with th certai rtainty nty whi which ch item items must beinclude ncluded, consul consultt the design record, e.g. part print, pri nt, the rele relevant E Engi nginee neering ri ng documents or specif cif icatio cations, ns, and your customer responsibl sponsible e part approval proval acti activity vity.

I.2.2.1 DesignRecords  The supplier shall have all design  The ign records fo forr the sale lea able product, inc includ luding ing design ign records fo forr components or details of the saleable p product. roduct. Where the design record record,, e.g. CAD/ CA D/CA CAM M math data, part drawings wings,, specif cif ica cati tions, ons, is in electronic electroni c format, format, e.g. math data, the suppli supplier er shall produce a hard copy (e.g. pictori pictorial, al, geometric tri c dimensioni sioning ng & tol tolera erancing ncing [G [GD& D&T T] sheets, drawing) wing) to identif identify measurements taken. NOTE 1:  1:  For any saleabl ble e product, part or component, there wil will only only be one design record, regardles rdless of who has design-r gn-res esponsibi ponsibillity. The design record may refere reference other documents making aking them part of the design sign record. NOTE 2:  2:  For bulk bulk mat aterial erials, s, the desi sign gn records may include include identif ntifiica cati tion on of raw materials, terials, form formulations, ulations, processing proce ssing steps and paramet eters ers,, and ffiinal product product specif cif icati cations or acceptance criteria. criteria. I f dimensional res results ults do not apply, then CAD/ CA D/CA CA M requirements are also not applicab ppli cable.

I.2.2.2 Any authorizedEngineeringChangedocuments  The supplie  The lierr s sh hall ha have any authoriz ize ed engin ine eerin ing g change documents not y ye et rre ecorded in the design ign record but incorporated in the product, part or tooling.

I.2.2.3 EngineeringAppro Approval, when require uired Where speci ciff ied by the desi sign gn record, the supplier suppli er shall have evi vide dence of customer engineeri engineering ng approval. NOTE:  For bulk NOTE:  bulk material terials, s, this requirement iis ss satisf atisfiied by by a signed ‘Engineeri ring ngA pprova vall’ li line itemon the Bulk Material rial Re R equ quiirements Checklist Checkli st(Appe (A ppendixF) F ) and/or inclusion inclusionona custo custom mer maintainedli listof appro prove ved materi terials. als.

3

 

I.2.2.4 Design Fai Faillure Modeand Eff ffe ectsAnalysis (Design FMEA), if thesuppli pplie er is is design responsible. ble.  See Potential Failure Failure Mod Mode and E Eff ffe ectsAnalysis is ref  reference erence manual.  The supplier shall ha  The have a Design ign FMEA d de evelop loped in accordance with ith, and complian liant to, QS-9000Third hird E Edition dition requi req uirem rements for parts or materi teria als for which they they are desi sign-resp gn-responsibl onsible e. For bul bulk k materials, terials, a Desi Design M Ma atrix trix (See Appendix F), F), when requi uired red by the Bul Bulk k Mat M aterial erial Requirements Checklist Checkli st (se (see e I.2.2.15), I.2.2.15), shall be prepared prior prior to developing the the De Design sign FMEA FM EA.. NOTE:  For bulk materi NOTE:  terials, als, Design FME FM EA ranki rankings ngs(Se (Severity, Occurrence, Detecti ction) on) as discussed inA ppendix F, may be utilized to provide proper differentiation of risk factors.

I.2.2.5 Pr Proce ocessfl flo ow diagrams  Thesupplier shall haveaprocess flow  The flow dia iag graminsupplier-s -sp pecified ified fo form rmat that clearly describe ibes theproduction ion process steps and sequence, as appropri ppropriate ateand meets the specif cifiedcusto custome mer needs, requi requireme rements andexpectati expectations ons (see (seeAdvanced Advanced Pr Prod oduct Quali Quality ty PlanningandControl P Plan lan ref  reference erence manual). nual).  For bulk material terials, s, an equiva quivallent to a Pr Proce ocess ss Fl Flow ow Diagram is a Process Flow Description. NOTE:  Pr NOTE:  Process ocess flow diagrams for ‘f ‘ families’ of sim similar parts are acceptable if the new parts have been revie viewed for commonality. ty.

I.2.2.6 Pr Proce ocess Fail Failure Mode and Eff ffe ects Analysis (Process FMEA).  FMEA). See Potential Failure Failure M Mod ode and Effects Effects Analysis ref  reference erence manual.  The supplie  The lierr shall have a Pro Process FMEA develop loped in accordance with ith, and compliant with ith QS-9000Thir hird d Edition Edition requireme requi rements. NOTE:  A single NOTE:  single Design or Process FMEA may be applied ppli edto a process manufactu nufacturi ring ng afamily of simi simillar p parts arts or materi terials. als. For bulk bulk materials, terials, see A ppendi ndix x F for for a severity, verity, occurren occurrence, and detection ction ranking ki ng system to provide proper differentiation of risk factors.

I.2.2.7 Di Dime mensional results ults  The supplie  The lierr shall provide ide evide idence that dimension ional verific ifica ation ions require ired by the design ign record and the Con Control Plan have been compl plete eted and resul ults ts iindi ndicate catecompli complian ance with with specif cif iedrequir requirem ements. Thesuppli supplier er shall have dimensional results res ults ffor or each each unique manufacturing process, process, e.g. cells cell s or production production li lines and all cavi viti ties es, mol molds, ds, patterns tterns or di die es (see I .2.2.13). .2.2.13).  Thesupplier  The lier shall ind indica icatethedateof thedesign ign record, changelevel, and any authorize ized engine ineering ing changedocument not yet incorpor incorporate ated iin n the desi sign gn record to which whi ch the part was made.  The  Th e supplie lierr shall id ide entify one of the parts rts measured as the master sample (S (Se ee I.2. I.2.2.17).  The supplie  The lierr shall rre ecord the change level, drawin ing g date, supplier lier name and part number on all auxiliary documents (e.g. supplem supplementary la layout results sheets, sketches, tracings, tracings, cross sections, ections, CM CMM M inspection ction point result results, s, geometric tri c dimensioning nsioning and tolerance she sheets, ets, or other auxi xilliary drawings wings u use sed in in conjuncti conjunction on wi with th thepart drawing). Copi Copies es of  theseauxil auxiliiary materi terials als shall accompany thedi dim mensional result results s according ccordi ng to the Retention/S ntion/Subm ubmissio ssion n Requir Requirem ements  Ta  Table le.. A tr tracing ing shall be in inc clu lud ded when an optica ical comparator is necessary fo forr ins inspection ion.

4

 

Section I

NOTE 1:  A ll dimensions (except ref reference rence dimensions), characteristics, ristics, and s spe pecif cifica cati tions ons as noted on th the e design record and Control Pl Plan an should be listed in aconvenien nient fo forma rmat with with theactual res results ults recorded. The Dim Di mensional Results fform orm in Appe A ppendix C, or a checked print rint where the res results ults are legibly writte written n on a p part art drawing wing iincludi ncluding ng cross-secti ctions, ons, tracings, or sketches as applica ppli cable ble may be utili util ized for this purpose purpose.. NOTE 2:  Dim Di mensi siona onal results results typi typicall cally y do not not apply to bulk material terials. s.

I.2.2.8 Records of material / performancetest results ults  The supplier shall have records of materia  The iall and/or /or perfo forrmance te test results lts fo forr tests specifie ified d on the design ign record or Control Plan.

I.2.2.8.1 Material Test Results  The supplier shall perfo  The forrm tests fo forr all part(s rt(s) and product material(s ial(s) when chemica ical, physica ical, or metallur llurgica ical requir req uirem ements are specif cif ied by the design rec record ord or Control Plan Pl an. A ll tests required b by y the design re record and related ated spe specif cif icati cations should should be liste li sted in in a convenient forma format along along with with the quanti ntity ty tested and the actual results of each test. A lso iindi ndicate cate any authori orized zed enginee ngineeri ring ng change documents that have not yet been incor incorpor porate ated iin n the desi sign gn record.  The  Th e material ial test report (Se (See App Appendix D) shall in ind dica icate the: • desi sign gn record changelevel of the parts tested, and thenumber, date, and changelevel of thespecif cifications to which whi ch the part was tested; • date on whi which the the te testing took took pla place; ce; • material terial subcontractor’s nameand, when requi quired red by your customer, their their suppli supplier er codenumber ffor or the material terial ffrom rom thecustomer-approved subcontractor li l ist. For products products with with customer-developed material ri al specif ications cations and a customer-approved subcontractor lliist, the suppl pliier shall procure materi terials als and/or service services s (e (e.g. painting, plating, plating, he heat at--treating) ting) ffrom rom subcontra subcontractors on that list.

I.2.2.8.2 Perfor forma manceTest Results  Thesupplier shall perfo  The form rmtests fo forr all part(s) or product material( ial(s s) when perfo form rmanceor fu fun nction ional require irements arespeci ciffied by thedesign record or Control Control Pl Plan an.  The  Th e test report shall in ind dic ica ate: • the desi sign gn record change level of the parts tested, the number, date, and change level of the specif cif icatio cations ns to which which the part w was as tested; • any authori authorized zed engi ngine neering ering change documents that have not yet been incor incorporate porated in in the design record; • the date on which the te testing sting took place. NOTE:  Results for NOTE:  for all te tests sts required by by the design record or relate related specif cif ica cati tions ons should ould be listed in in an understandable ffor orm mat and include incl udethe quanti ntity ty tested. The Perf Performa ormanceTest Results fform orm iin n A ppendix ndix E may be used for thi this s purpose.

5

 

I.2.2.9 Initial nitial Pr Proc ocessStudies I.2.2.9.1

Genera rall

 Thelevel of init  The initia iall process capability ility or perfo form rmanceshall bedetermine ined to beacceptableprior ior to submiss ission ion fo forr all Special Special C Cha haracteri racteristi stics cs desi signa gnated by thecustomer or suppli pplier.  The supplie  The lierr shall perfo form rmmeasurement system analys lysis to understand how measurement err rro or is affecting ing the study measurements. (See (See I.2. .2.2.10 2.10 andM and Measurement SystemsAnaly nalysis sisref reference erence manual ) NOTE 1:  1:  The purpose of this requirement iis s to determine if the product productiion process is lliikely to produce product that wil will meet the customer’s requir requirem ements. The initi nitial al process study is ffocused ocused on vari riab ables not attribute attri butes data. A ssembly error errors, s, test fail ailures, ures, surface surfacedefects are examples ples of “count” ti tim me data, whi which ch iis s important to unde understand rstand, but is is not covered covered in this ini i niti tial al study. To unde understand rstand the perf performa ormance nce of  characteri cteristi stics cs monitored onitored by attribute attribute data will wil l require require more data collecte coll ected over ti tim me. NOTE 2:  Theindex for for estimating processcapabi billity or performa performance wil will beagreedupon by thecustomer and supplier. Cpk and Ppk are descri scribe bed below. Other methods more appropriate ropri atefor certain certain processes or products may be substi tituted tuted with with prior prior custom customer approval. NOTE 3:  3:  I niti nitial al process studies studies are short-term short-term and wil willl not p pred rediict the effec effects ts of ti tim me and vari ria ation tion in people, peopl e, material aterials, s, methods, equipme equipment, measurement systems, andenviro vi ronme nment. Even Even for tthese heseshor shortt-term term studies, it it iis s iim mportant to coll collect and analyze nalyze the data in the order produced using using control charts. NOTE 4:  For those thosecharacteristi cteristics cs that canbestudied using X X--bar and R charts, a short term study should be based on a minim mini mum of 25 subgroups containi containing ng at lea l east 100 readings dings ffrom rom consecuti cutive ve parts of of the signifiicant pro signif produ duction ction run (SeeI .2.1).  .2.1).  The Thein init itia iall datarequire irements may bereplac laced by lon longer-te -termresults lts from thesame or sim similar processes, with wi th customer concurrence. For certain processes, al alterna ternative tive analytical yti cal tools tool s such as iindiv ndiviidual and movi oving ng range charts may be appropri ppropriate ate and permi rmitted tted with with pri prior or customer approval.

I.2.2.9.2 Quali Quality ty Indices Initi nitial al process studies should be summarize arized wi with th capabili bil ity or performa performance indices, iiff appli plicable. NOTE 1:  1:  The ini niti tial al proces process study resul ults ts are dependent on the purpose of the study, data normality (assumption is i s normality and two side sided specif cif icati cations), ons), method of data acquisiti cquisition, on, sampli pling, amount of  data, demonstration tion of stati tistical stical control, control, etc. It is is assumed that anyone tryi trying ng to a apply pply the princi principles ples lliisted be bellow has reviewed the capabi billity section section iin n the Statistical Proce Process Control reference reference manual and understands basi sic c princi principl ples es of stability from from an average and range chart perspective. For guida guidance on items li listed below, contact thecustomer responsible ponsibl e part approval activi activity. ty. See SeeStatisti Statistical cal Proce ProcessControl ref reference erencemanual nual,, Chapter 2, Section Section 5, D: S Sugge uggested Use of Pr Process ocess Measures. Cpk- The The capabi billity index for a stable process. The The estima timate of sigm si gma is based on wi withi thin n subgroup varia riation ((RR-ba bar/d2 or S-ba S- bar/c4). Ppk- The perfor forma mance index. The esti tim mate of sigm sigma is based on total variat riatiion (all of indivi ndividua dual sample ple data using tthe he standard deviatio deviation n [[root root mean square equation], ation], “s”) “s”).. Short-term studies. T Short-te The he purposeof theiniti nitial al process study study is is to understand theprocess vari riat atiion, not jjust ust to achi achie eve a specif cif ic iinde ndex value. When historica storicall data is ava vaiilable or enough ini initi tial al data exist xist to plot a control chart (at llea east 100 indiv ndiviidual samples ples), Cpk can be calc calcul ulate ated when the process is stable. For 6

 

Section I

chronicall chroni cally y unstable processes with with outputmeeting specif cificatio cations ns and apredictabl predictable e pattern, P Ppk pk should be used. When not enough data is avail vailable ( 1.67

Th The e process currently meets customer require irements. Aft After approval, begin production and follow Control Plan.

1.33 ≥ (I  (Inde ndex Value) ≥ 1.67

Th The e process is currently acceptable, b bu ut may require ire some improvement. Contact your customer and revie view results of the study stu dy. This wil will re require changes to the Control Plan Pl an, if if not improved pri prior or to start of volum volume production. production.

In Ind dex Value than 1 year REQUESTED SUBMISSION LEVEL (Check one)

S u b - S u p p l i e r o r M a t e ri a l S o u r ce C h a n g e Change in Par t Process iin ng P a r t s P ro d u ce d a t A d d i t i o n a l L o ca t i o n Other – please specify

18

Level 1 – Warrant only (and for designated appearance items, an Appearance Approval Approval Report) submitted to customer. Level 2 – Warrant with product samples and limited supporting data submitted to customer. Level 3 – Warrant with product samples and complete supporting data submitted to customer. Level 4 – Warrant and other requirements requirements as defined defined by customer.

1

(Circle)

2 3 4 5 6 7 8 9 10 11 1 12 2 13 14 15 16 17 18 19

Level 5 – Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. TS SUBMISSION RESULTS The results for

19

dimensional measurements

material and functional tests

These results meet all drawing and specification requirements:

Yes

appearance criteria NO

statistical process package

(If “NO” – Explanation Required)

20

Mold / Cavity / Production Process DECLARATION

I hereby affirm that the samples represented represented by this certification are representative of our parts, have been made to the applicable customer drawings and specifications, and are made from the specified materials on regular production tooling with no operations other than the regular production process. process. I also certify that documented evidence evidence of such compliance is on file and available available for review.

21

EXPLANATION/COMMENTS: Print Na me

Tit l e

Ph o n e N o .

FAX No.

22

S up pli er A ut h or iz ed S ig nat ur e

Da t e FOR CUSTOMER USE ONLY (IF APPLICABLE)

P a r t W a r r an t Di s p o s i t i o n:

Approved

Part Functional Approval:

R e j e c te d

Waived

Interim Approval C u s t o me r N a m e J u l y 1999

Approved

C u s t o m e r S i g n a t u re

Da t e

TAG-1001 50

 

Section II - Truck OE OEM M Specif cific ic Re Requir ire ements

North Ame Ame ric ric a n T Truck ruck Indus try

Part Submission Warrant

Part Name Safety and/or G ov er nm ent R egul at i on

Part Number Yes

No

Engineering Drawing Change Level

Da t e d

A ddi t i on al E ng i ne er i n g C h an ges Shown on Drawing No. Checking Aid No. SUPPLIER MANUFACTURI NG INFORMATION

Da t e d Purchase Order No.

Weight

Engineering Change Level

kg

Da t e d

SUBMISSION INFORMATION Di m e n s io n a l

M a te r ia l s /F u n c ti o n a l

Supplier Name & Supplier Code

Customer Name/Division Name/Division

Ap p e a r a n c e

Street Address

Buyer/Buyer Code Application

City/State/Postal City/State/Pos tal Code

Note:: Note

Doe Does s thi this s pa part rt contai contain n any any res restricte tricted d or reportab reportable le substa substances nces..

Y es

No

Are plastic parts identified with appropriate ISO marking codes

Y es

No

REASON FOR SUBMISSION Initial Submission

Change to Optional Construction or Material

E ngi neer i n g C han ge( s ) Tooling: T Trransfer, Re Replacement, Re Refurbishment, o orr ad additional Correction of Discrepancy Tooling Inactive > than 1 year

Sub-Suppli er or Material Source Change Change iin n Pa Part Pr Processing Parts Produced at Additional Location Other – please specify

REQUESTED SUBMISSION LEVEL (Check one) Level 1 – Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer. Level 2 – Warrant with product samples and limited supporting data submitted to customer. Level 3 – Warrant with product samples and complete supporting data submitted to customer. Level 4 – Warrant and other requirements as defined by customer.

1

(Circle)

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Level 5 – Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. SUBMISSION RESULTS The results for

dimensional measurements

material and functional tests

These results meet all drawing and specification requirements:

Yes Yes

appearance criteria NO

statistical process package

(If “NO” – Explanation Required)

Mold / Cavity / Production Process DECLARATION I hereby affirm that the samples represented by this certification are representative of our parts, have been made to the applicable customer drawings and specifications, and are made from the specified materials on regular production tooling with no operations other than the regular production process. I also certify that documented evidence evidence of such compliance compliance is on file and available available for review. EXPLANATION/COMMENTS: Print Name

Tit l e

FAX No.

P ho ne N o.

S up p l i e r A u t h or i z ed S i gn a t u r e

D a te FOR CUSTOMER USE ONLY (IF APPLICABLE)

P a r t W a rr a n t D i s p o s i t i o n :

Approved

Part Functional Approval:

Re j e c te d

Waived

Interim Approval Customer Name July 1999

Approved

Customer Signature

D at e

TAG-1001 51

 

 Ap  A ppend ndii x A Compl ple eti tion on of the Par artt SubmissionWarr arrant PART INFORMATION 1. Partt Name and 2. Customer part Par part number:  Engi ngine neeri ering ng relea released ffiinishe nished end item itempart name and numbe ber. r. 3.

Safety/ ty/R Regulated IItem tem:  “Ye “Yes” if so indicated ndicated on part drawi wing, ng, otherwi rwise se “No”. “No”.

4.

Engineering ChangeLevel & Approva Approval Date Date:  Show change level and datefor submission. ssion.

5.

Additiona dditional Engineering Chang Changes:  L ist al all authorized thorized engine gineering ring ch chan anges not yet incorporate incorporated on the the drawing drawi ng but which which are incorpor incorporate ated iin n the part.

6.

Shown on Draw Drawing Number:  The design record that speci ciff ies the customer part numbe berr bei being ng submitted.

7.

Purchas Pur chaseOrder Numb Number: Enter  Enter thi this s number as found on the purchase order.

8.

ParttWeight:  Enter the actua Par actual wei weight in ki killogram ograms to four deci decim mal plac places es.

9.

CheckingAid No.  Enter the checki checking ng ai aid d numbe ber, r, if if one is use used d for di dim mensional sional iinspe nspection, ction, and,

10. It Its s Engineering Chang ChangeL evel and Appr  Appro oval Date.

SUPPLI UPPLIER ER MANUFACTURING ACTURI NG INFO INFORMATION RMATION 11. Supplier Name& Suppli lie er Code: Show the code assi ssigne gned to the manufacturi acturing ng llocati ocation on on the purchase order. 12. Supplier Manufacturing ufacturingAddress:  Show the compl plete ete address of the locati location on where the product was manufactured. nufactured.

SUBMISSION INFORMATION 13. Submissi Submission on type:  Check bo box(es) x(es) to indicate indicate type of submission. 14. Customer Name: Show the corporate corporate name and divisi divi sion on or operations operations group. 15. Buyer Name: and Buyer Buyer Code: Code: Enter the buyer’s name and code. 16. Application: Ente  Enterr the model odel year, vehicl vehicle e name, or engine, trans transmissi mission, on, etc.

REAS RE ASON ON FOR SUBMIS UBMISSION 17 17.. Check Check theapp ppropriate ropriate bo box. x. A dd explanat xplanatory ory deta taiils in the “other” section. section. REQUESTED SUBMISS SUBMISSION LEVEL LE VEL 18 18.. Identify ntify the subm submiss ssiion level re requ que ested b by y your custom customer. SUBMIS UBMISSION RES RE SULTS 19. Check theappropriat propriate e boxes for for dim dimensional, materi rial al tests, tests, performa rformancetests, tests, appe peara aranceevaluation, tion, and 20 20..

statistical data. Check Check the app ppropriate ropriate bo box. x. I f “no”, ente enter explanati tion on in “comm “comments” be bellow.

DECLARATION 21. Comments: P  Provi rovide de any expl xplan anatory details on thesubmission ssion results; additi additiona onal infor nform mation may be attached as appropriate ropri ate. 22. Theresp respons onsible supp supplieroff offici cia al, afterverifyi verifying ngthatthe resul sultssh show owconforman ormance toall customerre requ quiirem rements andthat all all required requireddocumentation tation is is availab vail able shall approve the de decl claratio aration n and provide rovideTitl tle, e,PhoneNumber, and Fax Numbe Number.

FOR CUSTOMER USE ONLY    L eave blank. blank. 52

 

Appendices

D Chrysler Daaimler imlerChrys imlerChrys ler Ford Part Name

G enera l Motors

Part Submission Warrant

1

Safety and/or Government Regulation

Yes

A dd i t i o na l E n gi n ee r i ng C h ang es Shown on Drawing No. Checking Aid No.

3

No

6

9

11

Engineering Drawing Change Level

4

D at e d

5

SUPPLIER MANUFACTURING INFORMATION

D at e d Purchase Order No. Engineering Change Level

7

Weight (kg)

10

SUBMISSION INFORMATION D i m e n s i o n al

8

D at e d

13

M a te r ia l s /F u n c ti o n a l

Supplier Name & Supplier Code

12

2

Part Number

Customer Name/Divisio Name/Division n

14

Ap p e a r a n c e

Street Address

16

Application City

State

No Note: te:  

15

Buyer/Buyer Code

Zip

Do Does es tthis his par partt co conta ntain in a any ny rest restric ricted ted or rrepo eporta rtable ble substa substance nces s

Yes

No

Are plastic parts identified with appropriate ISO marking codes

Yes

No

REASON FOR SUBMISSION I nitial Submission

17

Change to Optional Construction or Material

Engineering Change(s) Tooling: T Trransfer, Re Replacement, R Re efurbishment, o orr a ad ddi t i ona l

Sub-Supplier or Material Source Change Change iin n Pa Part Pr Processing

Correction of Discrepancy Tooling Inactive > than 1 year

Parts Produced at Additional Location Other – please specify

REQUESTED SUBMISSION LEVEL (Check one)

18

Level 1 – Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer. Level 2 – Warrant with product samples and limited supporting data submitted to customer. Level 3 – Warrant with product samples and complete supporting data submitted to customer. Level 4 – Warrant and other requirements as defined by customer. Level 5 – Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. SUBMISSION RESULTS The results for

19

dimensional measurements

material and functional tests

These results meet all drawing and specification requirements:

Yes

appearance criteria NO

statistical process package

(If “NO” – Explanation Required)

20

Mold / Cavity / Production Process

DECLARATION I hereby affirm that the samples represented by this warrent are representative of our parts, have been made to the applicable Production Part Approval Process Manual Manual 3rd Edition Requirements. I further warrant these samples were produced at the production rate of / 8 hours. I have noted any deviations from this declaration below. EXPLANATION/COMMENTS: P r i nt N am e

Title

21

Phone No.

FAX No.

22

Supplier Aut hori zed Signat ure

D a te FOR CUSTOMER USE ONLY (IF APPLICABLE)

Pa r t W a r r a n t D i s p o s i t i o n :

Approved

Part Functional Approval:

R e j e c te d

Approved Waived

Other C us t om er N am e   J u l y 1999

Cust omer Signature

Da te

The original copy of this document shall remain at the suppliers location while the part is active (see Glossary).

CFG-1001

Optional: customer tracking number: #

53

 

D Chrysler Ford Daaimler imlerChrysler

G enera l Motors

Part Submission Warrant

Part Name Safety and/or Government Regulation

Part Number Yes

No

Engineering Drawing Change Level

D a t ed

Additional Engineering Changes Shown on Drawing No. Checking Aid No. SUPPLIER MANUFACTURING INFORMATION

Supplier Name & Supplier Code

D a t ed Purchase Order No.

Weight (kg)

Engineering Change Level

D a t ed

SUBMISSION INFORMATION Di m e n s io n a l

M a t e r i a l s / F u n c t i o na l

Customer Name/Divis Name/Division ion

A p pe a r a n c e

Street Address

Buyer/Buyer Code Application

City

State

N o t e:

Zip

Does this part contai n any restricted or reportable subst ances.

Ye s

No

Are plastic parts identified wit h appropriate ISO marking codes

Ye s

No

REASON FOR SUBMISSION I nitial Submission

Change to Optional Construction or Material

Engineering Change(s)

Sub-Supplier or Material Source Change

Tooling: T Trransfer, R Re eplacement, R Re efurbishment, o orr a ad ddi t i onal

Change iin n Pa Part P Prrocessing

Correction of Discrepancy Tooling Inactive > than 1 year

Parts Produced at Additional Location Other – please specify

REQUESTED SUBMISSION LEVEL (Check one) Level 1 – Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer. Level 2 – Warrant with product samples and limited supporting data submitted to customer. Level 3 – Warrant with product samples and complete supporting data submitted to customer. Level 4 – Warrant and other requirements as defined by customer. Level 5 – Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. SUBMISSION RESULTS The results for

dimensional measurements

material and functional tests

These results meet all drawing and specification requirements:

Yes

appearance criteria NO

statistical process package

(If “NO” – Explanation Required)

Mold / Cavity / Production Process DECLARATION I hereby affirm that the samples represented by this warrent are representative of our parts, have been made to t he applicable ProductionatPart Proce Edition IRequirements. Requireme nts. warrant samples were produced the Approval productionProcess rate ss of Manual 3rd / 8 hours. have noted anyI further deviations fromthese this declaration below. EXPLANATION/COMMENTS: P r i nt N am e

Tit l e

P hone N o.

FAX No.

S u p pl i e r A ut ho r i z e d S i g na t u r e

Da t e FOR CUSTOMER USE ONLY (IF APPLICABLE)

P a r t W a r r a n t D i s p o s i ti o n :

Approved

Part Functional Approval:

R ej ect ed

Waived

Other C us t om er N am e   J u l y 1999

CFG-1001

Approved

C us t om er S i gna t ur e The original copy of this document shall remain at the suppliers location while the part is active (see Glossary).

D at e Optional: customer tracking number: #

54

 

Appendices

55

 

 A  Ap ppendi ndi x B

Comple pleti tion on of theAppearance aranceApproval Report Note:  Daim DaimlerChrysler erChrysl er AppearanceA pproval val Req Requi uirem rements (S (See eeI I .1.4) 1.

Customer part part number:  Engine ngineeri ering ng released customer part number.

2.

Dr Dra awing Number:  Use the number of the drawi wing ng on which the part part is is shown shown if di diff ffere erent from from the part number.

3.

Application:  Enter themodel year(s) an and d vehi vehicle cle or other program programon which which the part is is used.

4. 5.

Part Name:  Use the f ini Part nishe shed part name on thepart drawing. wing. Buyer Code:  Enter the code for specif specifiic buyer buyer of part.

6/7. E/C Level & Date:  Engineering ring chan ange ge level and E/C date for this this s subm ubmission. 8.

Supplie Suppli er Name:  Supplier Suppli er respons responsiible for su subm bmission (incl (include udesubcontractor contractor if appl pliicable).

9.

Manufacturing turing Loc Location:  L ocation ocation where part was manufactured or assembl bled. ed.

10. Supplier Code C ode:  Customerer-ass assigned code for supplier suppli er locati location on where the part was manufactured or assembl bled. ed. 11. Reason for Submission:  Check box(es) explaini xplaining ng the the reason for this this submission. 12. Supplier Sourci urcing ng & Texture Information: Information:  L ist all ffiirst su surf rfa ace tools, graini graining ng source source(s), (s), grain type(s),, an type(s) and d grain grain and gloss masters asters used to check part. 13. Pr Pre e-Te -Texture Evaluation:  To be complete pleted by by customer rep represe resentative (not used by GM). GM ). 14. Color Suffix:  Use alphanum alphanumeric or num numeric color color identi identificati cation. 15. Tristimu TristimulusData:  L ist num numeri erical cal (col (colori orim meter) data of submission ssion part part as compared to thecustomerauthorized authori zed master. 16. Master Numbe Number:  Enter alphanumeric master ide identif ntificati cation (not use used by by Ford). Ford). 17. Master Date:  Enter the date on which which the master was approved. 18. MaterialType Type:  I dentify ntify ffiirst su surf rfa ace f inish and su subs bstra trate te (i (i.. e.: e.: paint/AB nt/ABS). 19. Material Source:  I dentify ntif y ffiirst surf urface acean and d substrate strate suppl suppliiers. Exampl ple: e: Redspot Redspot/D /Dow ow. 20. ColorEva Evaluation,Hue,Value,Chrom Chroma,Metallic llic Bril Brilli lian ance& Gloss: Visual assessment by customer. 21. Color ShippingSuffix: ffix:  Color olor part number suff suff ix or color color num number. 22. Par Partt Disp Dispositi tion: on:  To be determined by customer (approved or rejected). rejected). 23. Comments: General comments by thesupplier suppli er or customer (optional) (opti onal).. 24. Supplier Signature, Phone No. & Date: Suppli Supplier er certif rti f ication that the the document iinfor nform mat atiion is accurateand meets all all requirem requirements specif ied. 25. Customer Repre presentative ntativeSi Signa gnature ture& Date: Customer approval approval signa signature.

 THE AREAS AREAS INSIDE THE BOLD BOL D LINES LI NESARE FOR CUSTOME CUSTOMER R USE USE ONLY.

56

 

APPEARANC APPEARAN CE APPROVAL REPORT REPORT 1

DRAWING NUMBER

PART NAME

4

BUYER CODE

5

SUPPLIER NAME

8

MANUFACTURING MANUFACTUR ING LOC ATION

9

PART NUMBER

REASON REASON FOR SUBMISSION

PARTS UB MISS ION WARRANT P RE T TEXT EXTUR E

11

APP LICATION (VEHI VEHICLES CLES )

2 E/C LEVEL

3

6/7 D ATE SUPPLIER CODE

S P ECIAL ECIAL SAMPLE FIRST P RODUC TION SHIP MENT

RE-SUBMISSION ENGINEERING ENGINEERI NG CHAN CHANG GE

10

OTHER

APPEARANCE EV EVALUA ALUATION TION CUS TOMER

S UP P LI LIER ER S OU RC ING AND AND TEXT TEXTUR E IN INFOR FORMA MAT TION

P RE-TEXTUR E EVALUATION

12

13

RE P RE S ENTATIVE S IG NA NAT TUR E AND D ATE

CORRECT AND PROC EED CORRECTAND RESUBMIT AP P ROVED TO TO TEXTURE

 5  7 

14

15

16

17

COLOR SUFFIX

TR IS TIMU LU S D ATA

MAS TER NUMBER

MASTER D ATE

18 18

19

COLOR COL OR EV EVALUA ALUATION TION

MATER IAL MATERIAL TYP E S O U RC E

HU G H

21

20 VALU E

C H R O MA

G LO S S

COLOR METALLIC SHIPPING SUFFIX B RILLIANCE

22 PART DISP OS ITION

D L*

Da *

COMMENTS

Db *

D E*

C MC

RED

YE L

G RN

B LU

LIG H T

D AR K

G R AY

C LE AN

H IG H

LO W

H IG H

LO W

23

SUPPLIER S IG NATUR E

P HO NE NO .

25

D ATE

CUS TOMER REP RES ENTATIV IVE E S IG NATUR E

D ATE

25

 

A   p   p  e n  d  i     c  e  s

MAY 1995 CF CFG-100 G-1002

 

APPEARANC APPEARAN CE APPROVAL REPORT REPORT PART NUMBER

DRAWING NUMBER

PART NAME

BUYER CODE

APP LICATION (VEHI VEHICLES CLES ) E/C LEVEL

D ATE SUPPLIER CODE

MANUFACTURING MANUFACTUR ING LOC ATION

SUPPLIER NAME REASON REASON FOR SUBMISSION

PARTS UB MISS ION WARRANT P RE T TEXT EXTUR E

S P ECIAL ECIAL SAMPLE FIRST P RODUC TION SHIP MENT

RE-SUBMISSION ENGINEERING ENGINEERI NG CHAN CHANG GE

OTHER

APPEARANCE EV EVALUA ALUATION TION S UP P LI LIER ER S OU RC ING AND AND TEXT TEXTUR E IN INFOR FORMA MAT TION

CUS TOMER RE P RE S ENTATIVE S IG NA NAT TUR E AND D ATE

P RE-TEXTUR E EVALUATION CORRECT AND PROC EED CORRECTAND RESUBMIT AP P ROVED TO TO TEXTURE

 8   5 

COLOR COL OR EV EVALUA ALUATION TION COLOR SUFFIX

TR IS TIMU LU S D ATA D L*

Da *

Db *

D E*

MAS TER NUMBER

MASTER D ATE

MATER IAL MATERIAL TYP E S O U RC E

C MC

HU G H RED

YE L

G RN

VALU E B LU

LIG H T

D AR K

C H R O MA G R AY

C LE AN

G LO S S H IG H

LO W

COLOR METALLIC SHIPPING SUFFIX B RILLIANCE H IG H

PART DISP OS ITION

LO W

COMMENTS

SUPPLIER S IG NATUR E

P HO NE NO .

D ATE

CUS TOMER REP RES ENTATIV IVE E S IG NATUR E

D ATE

MAY 1995 CF CFG-100 G-1002

 

Appendices

59

 

60

 

Appendices

 A  Ap ppendi ndi x C  DaimlerChrysler

Production Part Production Part Approval — Approval— DimensionalDimen Results Dimensio sional nal Res Result ults s

Page

of

Pages

SUPPLIER

PART NUMBER

NAME OF INSPECTION FACILITY

PART NAME

ITEM

May 1995

DIMENSION/SPECIF ICATION

CFG-1003

SUPPLIER MEASUREMENT RESULTS

  SIGNATURE

61

 

TITLE

OK

DATE

NOT OK

62

 

Appendices

 A  Ap ppendi ndi x D Production Part Approval — Approval— Production Part

DaimlerChrysler

Material TestMaterial Results Test Results

SUPPLIER

PART NUMBER

NAME OF LABORATORY

PART NAME

TYPE OF TEST

May 1995

MATERIAL SPEC. NO./DATE/SPECIFICATION

CFG-1004

of

SUPPLIER TEST RESULTS

  SIGNATURE

63

 

Page

Pages

OK

TITLE

DATE

NOT OK

64

 

Appendices

 A  Ap ppendi ndi x E  Production Part Approval— Daimler Chrysler

Page

of

Page

Performance Test Results SUPPLIER

PARTNUMBER

NAME OF LABOR ATORY

PARTNAME

REF. NO.

R EQ U IR EMENTS

Ma y 1995

TES T QTY. FREQ. TESTED

S IG NATU R E

CFG-1005 65

 

OK

S U P P LIE R TES T R ES U LTS AND TE S T C O ND ITIO NS

TITLE

D ATE

NOT OK

66

 

Appendices

 A  Ap ppendi ndi x F 

B ulk Ma M ater i al - Speci Speciff i c Re R equir ui r ements nts F.1 Introdu Introduction A supplie pli er of bulk materia rials shall comply with wi th the the requirements in this this Appe Appendix ndix or useguida guidance nceherein ffor or cla clari riffica cati tion on of PPAP PPAP.. This his document is i s a mini nim mumrequir requirem ement and may be supplemented at the discreti discretion on of the suppli pplier and/or the custome customer.

F.2 Appli Applicab cabili lity ty OE OEM M PPAP PPAP approval of a bulk materi terial al el eliiminate tes s the need to complete ete PPAP PPAP for  for that material at other levels in the supply chain. Suppliers are responsible for applying PPAP PPAP to  to their subcontractors of ingredients which have supplier-designated speci cia al characteristics. ristics. Exampl ples es of bul bulk k materi rial al iincl nclude ude, but are not lim li mited to: adhesives and sealants (sol (solders, ders, elastomers); chemicals (r (riinses, pol poliishes, additi tives ves, treatments, col colors/ ors/pi pigm gments, solven solvents); coatings (top coats, undercoats, prim primers, phosphates, surface treatm atments); engine coolan coolants (anti (antifreeze); fabrics; brics; ffiilm and fi film laminates; ferr rrous ous and non-ferrous metals (bulk steel, aluminum, coils, ingots); foundry (sand/silica, alloying materials, other minerals/ores); fuels and fuel components; glass glassandglass glasscomponents; llubri ubricants cants(o (oiils, greases, etc.); tc.); monomers, prepre-pol polyme ymers andpol polyme ymers (rubbe (rubbers, plastics, res resiins and the theiir pre precursors); cursors); and perf performa ormance fl fluids uids ((tran transm smission, power steering, bra brake, ke, refri refrigeran rant). t).

F.3 Customer Pl Plant ant Connecti ction on F.3.1 Cus Customer’s Responsibi billiti tie es  The customer plan  The lant connection ion is a shared shared res  responsibi ponsibillity between the bulk bulk materi rial al suppli supplier er and the customer. This his connecti ction on def ines the interaction of specif cific customer plant processing steps with S Spe pecia cial Chara Characte cteri ristics stics and ffiinal product attri ttribute butes of thebulk mat aterial erial.. This inte i nteraction is i s especia cially signif signif ica cant nt when bu bullk materi terials als undergo chemica call or physical physical transfo transforma rmation(s) tion(s).. Three key components of the Customer Plan Plant Connecti Connection on are the develo velopm pment of a Custom Cust omer Process Ma Matrix (SEE (SEE FOL L OWING OWING EX EXA A MPLE) PL E),, dete determ rmiination of Special Cha Chara racte cterist ristiics from tthe heCust Custom omer Proces Pr ocess Matri Matrix, andsthe prep ara tion ti on aC ontrolerPl Plan which whic h system aticall atical ly dir directs corr corrective For bul bulk k materi rials, als, conducti conducting ng thx, e step outli outlined ned in thisof“Custom “C ustom Plant Plan ant Conne ction” ction” is is highl highly yects recom mective endedactions. . NOTE:   It is not the intent of PPAP NOTE: PPAP to compromise propriet proprietary ary inf informa ormation. tion.

F.3.2 Customer Pl Plan ant Connection - Cl Clarifi arification cation  The fo  The follo llow wing ing is applica licable to materia ials ls that are transfo form rmed fr fro om bulk (e.g. wet can of p pa aint int) to fin fina al pr product (e.g. cured cure d paint fil fi lm). This his may not be applica pli cable ble tto o all bul bulk k materi rials als (i (i.e. .e. w was asher fluid, fl uid, engine oil oil, etc.). etc.). It is re recogn cogniized by the supplier that it is their responsibility to deliver the product to the customer with the characteristics of the bulk materi terial al per suppli supplier and customer agreement.  The impact of the transfo  The form rmation ion of bulk materia ials ls by the customer plan lant on fina final product attribu ibutes may be accounted for in in the customer’s applica pli cati tion on process. During Duri ng the the transformation tion from from bulk product to ffiinal product product,, both bulk product characteri risti stics cs and fi f inal pro product duct attribute attributes may be im impacted by customer process controls. controls. 67

 

PPAP does not require a Process FME PPAP doe FM EA or Control Control Pl Pla an for thecustom customer proces process. s. Since Sincetheproduc productt is is freq frequently two products product s (bulk and ffiinished), there is a sharedres respons ponsibi billity for for thefinal productattri attribute bute. For example, percent s sol oliids

and vi viscosity scosity of a bulk coating whi which ch im impacts thef inal coati coating ngs s ffiilm b buil uild d at attri tribute bute, may be aff ffect ected ed by the customer s mix room room percent sol solvent vent reduction. duction. The percent reduction reduction process parameter may therefore therefore be control controllled to aid iin n control of f ilmbuild. The The process steps atcustomer plants maybe matrixedversus theSpecial Characteri ristic stics s (determined  join  jointtly by supplie lierr and customer). Whe Where high igh impact is evide ident, those process steps may be analyz lyzed by the Pr Pro ocess FMEA FM EA methodology thodology.  The  Th eSpecial ial Cha Characteris isttics ics may then be determin ine ed, and be in inc clu lud ded in aCon Control Plan fo forr thecustomer process. Th The ese special cial contr control ol characteristi cteristic c item items may be monitored onitored and continuously continuously im i mproved. F.3.3 Customer Pl Plan ant Con Connection - Guideli line nes  The fo  The follo llow wing ing is a recommended set of guide idelin line es fo forr the customer plan lant when implem lementing ing process controls fo forr bulk materi rials. als. 1. 2. 3. 4.

5. 6. 7. 8. 9. 10 10.. 11 11..

A ss sse emble cross-f cross-funct unctiional teams of custom customer personnel for e ea ach customer processarea. Includeappropriate suppliier representatives suppl tives on each team. Select Cha Cham mpions for for each eachte tea am- these these arethecustomer proces rocess s owners (i (i.e. .e. chief processengineer, a area rea supervisor, etc.). Defi Define critical critical custom customer hand handlling ng,, appli applica cation steps and proce process pa para ram meters in in e ea ach area. Re Review view the sup suppli plie er’s Design Ma Matrix and and Design Design FM FMEA EA items for ap appli plica cation funct functions ions which have been desi signa gnated ted as Special Characte Characteri ristics. stics. A lso revi revie ew the d de esired sired ffiinal produc productt attributes attributes ffor or iitem tems needing control. From #4, de develop alist of Spe Special cial Cha Chara racte cteristics andA ttribute ttributes. Construct a Customer Process Process Matrix, trix, using #3 as th the e top, and #5 as the side of a matrix. trix. Perf Perform orma Custom Customer Proce ProcessFMEA FM EA,, ffocus ocusing on on the the high im impa pact cu custo stom mer processarea reas which imp impa act th the e Specia cial Cha Chara racte cteristics. ristics. (Do (Do the the PF PFM MEA per A pp ppe end ndiix F) F).. Dete Determ rmine ine Spe Special C Cha hara racte cteristics from tthe he Custom Customer Proce Process ss Matrix an and d PFMEA PFM EA (e.g. pa paint int fflui luid d fl flow ow, gun distance, etc.) etc.).. Prepa Prepare a Control Pl Plan for ea each aff ffe ected c cus ustom tomer process are rea a. The plan (util (utiliize DaimlerChrysler DaimlerChrysler,, Ford Ford,, GM APQP APQP guidelines)  guidelines) might contain at a minimum all process steps containing Special Characteristics. Monitor and and re record cord all Special Charac Characte teri ristics stics b by y approp appropri ria ate means (con (control trol charts, checkli cklists, etc.). Ensurestabil biliity of Special Characteristics ristics and cont contiinu nuous ously ly im i mpro prove ve wh whe ere poss ossiible.

Customer ProcessMatrix atrix Exam Example Special Char.

paint %

paint

& Attri Attribu butes

reduction

fluid flow

Customer Handli andling, ng,Appli Application Steps and Pr Proce ocess Parameters gun gun fan gun booth booth gun gun atomair

air

cap

distance

wash box

temp

humidity

bake temp

Dirt Check

1

1

2

2

3

1

3

1

3

1

Film Build

3

3

2

2

2

3

1

1

1

1

Sags

2

3

2

2

1

3

1

1

1

2

Popping

2

3

3

2

1

2

1

3

1

3

Peel

3

2

3

2

2

2

1

1

2

2

Hiding

1

3

1

1

1

3

1

1

1

1

A dhesion

1

1

1

1

1

1

1

1

1

3

I mpact Ratings: Ratings: 3=Hi 3=High gh,, 2=Me 2=M edium, 1=Low 1=L ow

68

 

Appendices

F.4 Part SubmissionWar arr rant (C (CF FG-1001) [seeI.2.2.13]

A Part Subm Submission ssion Warrant shall beprepared and submitted for approval whenrequir required edby thecustomer. I f a customer agrees thatPPAP that PPAP i is s not requir required ed, no warran warrant needs to be prepared. The The inf information ormation rreq equired uired by theSubmissi Submission on Warr rrant ant which whi ch does not apply to bulk bulk material terial (i (i.e. part weight, dime dimensi nsional onal measurement) does not need to be provided. For thosesupplie pli ers that have been classif ied as “self ce certi rtiffyi ying” ng” by a spec speciif ic customer, submission of a warrant si signe gned only by thesupplier shall beevide videnceof PPAP PPAP a  approval, unless thesupplier is advi dvise sed otherwi erwise se. For all othersuppliers, evi viden dence of PPAP PPAP approva  approval shall be a warran rrant si signe gned by both the customer and suppli plier or other customer approval documents.

F.5 De Design Matri atrix x F.5.1 Introdu I ntroduction Bul ulk k materi terial al suppliers suppli ers generally rall y deal deal wi with th thechemistry andfunctionality unctionali ty of theproduct being designed signed.. Useof these suggestions wi willl arrive arrive at the same end poi point nt of a completed pleted Design FM FME EA , but wi with th gre greate ater applica cabi billity to bulk materials. For bulk materials, a Design Matrix, Matrix, when requir required ed, sha shalll be prep repa ared pri prior or to dev developi eloping ng theDesign F FM MEA .  The  Th e Desig ign n Mat Matrix determin ine es the complex iin nteractio ion ns of form formula ing ingredien ients, ingredien ient characterist istics ics, pr product characteri risti stics, cs, process constraints, traints, and conditions conditi ons for customer use. High impact item items can then beeff effectively ectively analyz analyzed ed in the Design FMEA.

F.5.2 Design Matrix atrix – Elaboration E laboration  This  Th is matrix corre rrelat lates customer expectation ions with ith the product design ign ite items. Construct theDesign Mat Matri rix x referring referring to the the example whi which will wil l ffol olllow: 1. A long the the horizont horizonta al axis, li l ist tthe heFunctions Functions (Desi (Desire red d Attribute Attributes/Po s/Pote tenti ntial Fai Failure Modes). 2. A long thevertica rtical axis, xis, lliist the design items as Potential C Ca ause uses (Category/Characteristics) ristics) : Formula Ingre Ingredients I ngredient ngredient Characteristics ristics Product Characteristics Process Constraints Conditions for Use (customer process constraints) 3. For each design item item, enter the current robust threshold range levels and u units. nits. 4. Cor Correlate relate the potential causes to the potential fail ailure ure modes us usiing a number, lett l etter er, or symbol rep repres rese enting the impact or strength of the relationship. ationship. A sk what would would happen if if a potential tial causeitemis allowed to go under or over iits ts robust mi mini nim mum or maxi axim mum, rres espectively. 5. A fter completion of the ra rankings nkings in the Desi Design Matrix, trix, re revi vie ew the cate category/chara racte cteristics ristics for a preliminary assessment of Speci Special al Characteri Characteristi stics. cs. Designa Designate any Special cial Characteri risti stics cs in colum column 1. 6. The high negative im impact potential causes a are re trans nsferred ferred to to the Design FM FMEA EA for ana analysis. lysis.

69

 

DESIGN MATRIX — GENERIC PAINT EXAMPLE P ro d u c t C o d e /D e s c rip t io n : x x R -y y y y y B a s e c o a t P a in t

POTENTIAL CAUSES

P ro je c t # : 0 0 00 1

FUNCTION - DESIRED ATTRIBUTES (P (POTENTIAL FAILURE MODES)

  s   c    i    t   s    i   r   e    t   c   a   r   a    h    C    l   a    i   c   p   e    S  .   m    i    l   e   r    P

   E    R    U    L    I    A

CATEGORY / CHARACTERISTICS

   F

   E    G    N    A    R    D    L    O    H    S    E    R

   S    T    I    N    U

   T    H    T    S    U    B    O    R

       E        C        N        A        R        A        E        P        P        A

   l    e    e    P    /    e    g    h    a    c    t    g    e    m    a    n    I    g    n    i    e    i    r    /    h    k    M    F    a    c    i    n    g    s    p    e    r    o    a    l    r    d    e    o    r    l    c    e    l    r    o    g    o    e    F    h    d    e    G    l    n   u    S    r    C    i    d    e    d    /    e    t    P    M    T    o    o    r    o    o    o    o    t    r    o    i    a    G    N    N    N    D    C    G

   )    e    h    c    d    n    A    a    t    d    s    l    i    e    s    n    e    i    c    e    h    n    R    o    i    s    a    d    t    n    s    e    s    i    o    h    n    i    i    s    t    d    W    e    a    A    (    R    n    i    r    S    i    S    k    m    d    a    R    e    l    i    p    a    V    r    i    c    l    a    p    c    a    e    e    M    c    o    l    h    r    A    F    C    C    D    R    F    d    d    d    d    d    d    d    o    o    o    o    o    o    o    o    o    o    o    o    o    o    G    G    G    G    G    G    G

  y    t    i    l    i    b    a   y    r    t   u    i    l    e    c    D    i    b    n        E    d    a    a    t        C    e    r    i   u    s    t        N    a    D    s    e    r        A        M        R        O        F        R        E        P

       Y        T        I        L        I        B        S        A        S        E        C        O        R        P

  y    t    i    l    i   y    b    n    i    i    l   y    t    t    o    t    i    a    i    i    t    l    i    p    b    a    a    b   z    e    i    e    m    s    c    m   y    a    s    t    d    n    o    t   u    o    i    C    e    t    a    c    i    S    i    t    l    t    t   y    o   y    b    n    s    r    i    A    a    o    a    /    a    i    s    c    t    L    r    P    t    g    e    l    l    p    r    l    S    a    o    i    i    n    g    e    o   u    r    s    l   u    l    f    R    V    i    s    P    e    a    p    g    e    e    c    i   v    e    i    h    e    d    a    l    h    r    S    C    R    S    b    g    H    O    R    e    a    d    l    d    d    d    d    d    d    k    o    r    o    o    b    E    o    o    o    o    o    o    o    a    t    e    o    o    o    G    W   G    G    S    N    G    G    G

       L        A        T        N        E        M        N        O        R        I        V        N        E

   r    C    o    O    d    V    O    t    e    l    e    l    n    a    b    b    i    a    a    l    p    t    t    p    m    e    p    e    c    c    o    c    c    C    A    A    /    /    S   w   w    P    o    o    A    L    L    H

Formula Ingredients R e s in A

u nd e r

B in d e r S o lid s

3

1

1

1

1

2

3

1

1

2

1

2

2

0

1

1

1

o ver

5 0%

“

3

1

1

1

1

1

0

2

2

1

2

1

1

1

2

1

1

2

2

1

0

1

1

1

1

1

R e s in B

u nd e r

2 5%

B in d e r S o lid s

1

1

3

1

1

1

1

1

2

3

1

1

2

2

1

1

1

1

1

1

0

1

2

1

1

1

o ver

3 5%

“

1

1

1

1

2

1

1

2

2

2

1

1

1

2

1

1

2

2

2

1

0

1

1

1

1

1

u nd e r

2 0%

B in d e r S o lid s

1

2

3

1

1

2

1

2

2

3

1

2

2

2

1

1

1

2

2

1

0

2

2

1

2

2

o ver

3 0%

“

1

2

1

1

1

1

1

2

2

2

1

3

1

2

1

1

1

3

1

1

0

1

1

1

3

1

0 . 50 %

To t a l S o lid s

1

1

2

3

2

1

1

1

1

1

1

C ro s s lin ke r

7   0 

SP

4 0%

1

0

2

1

1

1

1

1

1

R h e o lo g y C o n t ro l Ad d it ive

u nd e r

3

1

1

1

0

1

1

1

1

1

1

1

3

2

3

o ver

2. 5 %

“

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

2

2

2

1

1

1

1

1

1

C o lo r D is p e rs io n -B

u nd e r

1 . 00 %

To t a l S o lid s

1

1

1

1

2

1

3

2

1

2

1

1

2

2

1

1

1

1

1

1

3

1

1

1

1

1

o ver

2 . 00 %

“

2

1

1

1

1

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

S o lve n t D

u nd e r

5%

Fo rm u la Wg t .

3

1

2

2

1

2

0

1

1

1

1

1

1

1

1

2

1

1

2

2

0

2

2

1

1

1

o ver Alc o h o l S o lve n t

1 5%

“

1

1

u nd e r

2%

Fo rm u la Wg t .

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

3

2

1

1

2

1

1

1

1

u nd e r

4%

“

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

2

1

1

1

2

1

2

1

3

1

0

3

2

1

1

2

3

2

2

3

3

u nd e r

3 0%

P o is e (# 1 @ 50 )

3

2

1

1

1

2

0

1

1

1

1

1

1

1

1

2

2

2

2

1

1

1

1

1

0

1

o ver

4 0%

“

2

1

1

1

1

1

1

1

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1

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1

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3

2

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3

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2

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0

1

un d e r o ver

1% 1 0%

% Mo la r C o m p . “

1 1

1 1

1 1

1 1

1 3

1 2

0 1

1 1

2 2

2 3

2 3

2 2

2 2

2 3

1 1

1 1

1 1

1 1

1 1

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2 1

0 1

0 1

0 1

u nd e r

30 s e c

# 4 Fo rd C u p

2

2

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1

1

2

2

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1

1

1

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3

3

2

3

2

3

1

2

1

1

0

1

o ver

40 s e c

“

1

1

1

1

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1

3

1

1

1

1

1

1

1

2

3

1

3

1

1

1

1

1

1

0

1

un d e r

5 7%

%N. V. @ 11 0ºC

1

1

1

2

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2 1

2

1

3

1

1

o ver

6 1%

“

1

1

1

1

1

1

1

1

1

1

1

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1

2

2

3

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1

1

1

1

1

un d e r

0. 0 1

m e g a o hm s

2

1

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0

0

2

0

0

0

0

0

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0

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3

1

1

1

1

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2

1

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1

o ve r

0. 15

“

1

1

1

0

0

3

0

0

0

0

0

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0

0

1

3

1

1

1

1

0

2

1

1

1

1

Ingredient Characteristics R e s ig n A-Vis c o s it y SP

C ro s s lin ke r-Im in o (-NH ) %

SP

Vis c o s it y

Product Characteristics

SP

% NV S o lid s R e s is t iv it y

Process Constraints B a t c h Mix in g Te m p

u nd e r

70 º

ºF

1

1

1

1

2

2

2

1

1

1

1

1

1

1

1

1

3

2

3

1

1

2

1

1

0

1

11 0º

“

2

1

1

1

3

3

2

2

2

1

2

1

1

2

1

1

3

1

3

1

1

3

1

1

1

1

u nd e r

1

m in ut e s

3

1

3

2

1

1

2

1

1

1

1

1

1

1

3

0

0

0

0

2

1

1

1

1

1

0

o ver

3

“

2

1

2

1

1

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1

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1

1

2

0

0

0

0

1

1

1

1

2

1

0

o ver

25 0º

ºF

2

1

1

1

0

0

3

3

3

3

2

2

3

2

1

0

0

0

0

1

1

1

3

1

1

1

u nd e r

27 5º

“

3

1

1

1

1

1

3

2

2

3

3

2

3

3

1

0

0

0

0

1

1

1

3

2

3

1

o ver

Conditions for Use Fla s h Tim e b e fo re C le a r SP

Fin a l B a ke Te m p .

NEGATIVE IMPACT ON CUSTOMER EXPECTATIONS: HI HIG G H= 3; MED= 2; LOW= LOW= 1; NONE= NONE= 0; UNKNOW UNKNOWN= N= ?

 

Appendices

F.6 Special Characteristics tics F.6.1 Introdu Introduction I f product product characteri racteristi stics/attri cs/attribute butes can have normal vari variatio ation n resulti sulting ng in movement outsi outside de their designdesign-iintended robust range which results in i n signif signif icant cant iim mpa pact, ct, they are designated s spe pecial, cial, and and must be control controllled by special controls. Special Charac Characte teristics ristics - C Cllarif rif ication Table Table # 1

Difference Special Characteristics and/or K ey Product and K ey Control Characteristics

Clarification

Example

For Bulk B ulk Materi rials, als, a ffreq requent occurrence is a transformation from bulk material to f inal product.

I llustrations of the fl flow ow of materials through f inal product foll through fol low (e.g. % solids Resin A, A, % UVA intended). These arenot necessari rily ly intended to be Special Special Characteristics.

 The diffe  The ifferences between bulk product characteristics (features of the supplied product) and the f inal attri attribute butes (f (fea eatures of the transfor sform med product) should be understood.

Examples of product characteristi racteristics cs are: viscosity, % NV Solids, % Resin “A”. Examples of ffiinal product attribute attributes are: appearance, fi f ilm buil build d, F FM MV SS safety, durability.

During thedesign phase, the product Duri characteri ristics stics can becontrols ffor or fi f inal product attri attribute butes. (T (Thi his s does not imply that they are control characteri cteristi stics). cs). During Duri ng manufactureof the bul ulk k materi terial, al, process parameters are the contro controll characteristics.

Examples of manufacturing nufacturing process parameters (control characteristi cteristics) cs) are: temperature, pressure, mi mix x rate, test protocol.

During transformation from bulk product to ffiinal prod product, uct, both bulk product characteri cteristi stics cs and f inal product attributes can becontr control ollled by customer process control characteri ristics. stics. 2

Symbols for customeridentifi ntif ied Special cial Characteristics

 The suppliers may desig  The ign nate their own internal symbols to designate Special Characteristi cteristics cs in in their worki working ng documents.

Examples of customer transformation process parameters (contr (control ol characteri ristics) stics) are: fl fluid uid flow, temperature/humidit dity, y, air pressure.  The supplier may choose to use “S”  The (Safety), or “sp” (spec ecial) ial),, or “K” “K ” (K (Ke ey), etc.

For customer-designated/iden d/identi tiff ied Special  The  The customer desig ign nated shie ield ld, delt lta a, Characteristi cteristics, cs, the customer-speci ciff ic di diam amond, etc. wi willl be used whenrequired symbols ols wi willl be used for requir required ed customer per customer ide identifi ntif ication. documentati tion on and required shipping shipping labels.

71

 

F.6.2 Special Characte Characteristics- Elaboration Elaboration For clarif cl arif i ca cati tion on purpose purposes, s, the fol olll owing fi f i gure i s inte intende nded to demonst onstrate rate the fl ow of poten potenti tia al specia ci al characteristi cteristics cs through thesupply chain. chain. Ill llus ustr tration ation of the flo flow of materials ials through final final prod product: ItemA (Paint)

Item B (Paint)

Item C (Sealant)

Subcon contra tractor (Ti (Tier er IIII ) Bulk Product Characteristic (Raw Ma Materia rial)

Subcontractor (Ti (Tier er II II ) Bulk Product Characteristic (Raw Ma Materia rial)

Subcontractor (Tier Subcon (Ti er II II ) Bulk Product Characteristic (R (Ra aw Ma M aterial)

% Soli lids dsResin “A”

Puriity Assay of U Pur UVA VA

Polymer Visco Viscosity

Subcon contra tractor (Ti (Tier er IIII )

Subcontractor (Ti (Tier er II II )

Subcon Sub contractor (Tier (Ti er II II )

Mfg. C Cont ontrol Cha Charac racte teristic ristic

Mfg. Contro Controll Cha Charac racte teristi ristic c

Mfg. Control Characteristic

Resin SynthesisTemperature ature

Final Reaction Hold Ti Tim me

End-Blocke nd-Blocker Feed Rate Rate

Supplier (Tier I) Bulk Product Characteristic

Supplier (Tier I) Bulk Product Characteristic

Supplier (Tier I) Bulk Product Characteristic

Paint Viscosity

% UVA iinte ntended

% Polymer iin n Sealant

Supplier (Tier I) Mfg. C Cont ontrol Cha Charac racte teristic ristic

Supplier (Tier I) Mfg. Contro Controll Cha Charac racte teristi ristic c

Supplier (Tier I) Mfg. Control Characteristic

Tank Mix Rat Rate

Scale Cali alibration bration

Polymer FeedRate

Customer Transformation Control Characteristic

Customer Transformation Control Characteristic

Customer Transformation Control Characteristic

% Solvent Reduction

Fluid Flui d Fl Flo ow (for film build)

Extruder Bead Size

Fina Final Produ Product ct Atti Attibu bute te

Fi Fina nal Product Product A Attibut ttibute

Fina Fi nal Product Product Attibu Attibute te

Film Fi lm Buil Build; d; Fre Freeof Sags

Excell lle entDurabili Durability ty

L eak Fr Fre ee Sealant

F.7 Design FMEA (seeI.2.2.4) F.7.1Effe ffects of Failure Failure and Severity Ranki Ranking ngs  The fo  The follo llow wing ing two steps provide ide an alt lte ernative ive method fo forr ide identify ifyin ing g the Potential ial Effe Effects of Failur ilure and assign igning ing a Severity Ranking. L ist Effe Effects of Fa Faililure ure • Consumer Eff Effect ects s-G Ge eneral terms iide dentifyi ntif ying ng the the loss experie ri enced by theultim ulti mate user of theproduct (e.g. the car buyer). r). • Custom ustomer E Eff ffec ects ts - Ge General terms identifyi ntif ying ng the loss experien rience ced d by the intermediat ate eu use ser of your product product (e.g. the vehicle cle manufacture nufacturer). r). A ssign a Severity rity Ra Ranking nking to each Eff ffe ect • See the Se Seve verity rity Def Def initi nition on and Evaluation Evaluation Crite Cri teria ria in tthe he Potential Failure Failure Mod Mode and E Effects ffectsAnalysis ref reference erence manual. nual. 72

 

Appendices

• Thegoal for each of theite tem ms that thatmul ulti tiply ply to arrive arriveat theRisk Ri sk Pri Priori ority ty Numb Numbe er is is to diff ffe erent rentiiatebetweenthe item tems in th that at ca cate tegory. The fol olllowing fi figureprovides a guideline guideli ne for seve veri rity ty ranki rankings ngs. If your situation only uses a small portion portion of thescale thendevel velop your own scale to im improvethediff differentiati ntiation. on. I f your situation is greater than two tiers back from from thefinal consumer, then theguideli guideline ne f igure should should beadjusted to refl reflect ect the eff ffects ects that wil willl be felt by your customer’s customer. Effe ffects of Failure Failure and Severity Ranking Rankings: Stakeholder Consumer (e.g. vehicle ehiclebuyer)

Effects of Failure

Severity

Owner Safety Problem

10

Major O Ow wner D Diissatisfaction (Los Loss of Owner Loyalty)

8

ModerateOwner Dissatisfaction (Inconvenience)

6

Minor Owner Dissatisfaction (Annoyance)

4

Customer

Plant Safety Problem

10

(e.g. vehi hicl cle e manufacturer)

PossibleRecall L ineStoppage

9 8

Warranty Costs

7

Scrap

7

Regulatory Penalty

7

ModerateRework (e.g.