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Welcome to A Program on

Production Part Approval Process

 Production Part Approval Process
   Contents
 Introduction

 Forward (Changes in fourth edition as compared to third edition)

 Purpose

 ISO/TS requirements

 Example process flow chart for PPAP

 Comparison of PPAP with traditional approach

 Significant production run

 Requirements for part approval

 Situations when PPAP validation, customer notification &

submission required.
 PPAP submission levels.            

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 Production Part Approval Process
FOREWORD

PPAP fourth edition includes the following changes.

· Effective from June 1, 2006, unless otherwise specified by the
customer.
· Aligning the order of PPAP requirements with the Automotive
Product Development and Manufacturing Process
· Inclusion of an example process flow for PPAP
· Update of Truck OEM requirements
· Revision of PSW to include logical flow for part / design description,
Suppliers address applicable to International Locations, inclusion of
IMDS materials to indicate reporting status.
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 Production Part Approval Process

· Updation of PPAP requirements including Materials reporting and

polymeric identification requirements in design record.
· More clarity on Ppk and Cpk indices usage.
· Modified Customer Notification and Submission requirement.
· Refinement of Appendices (recommended reporting formats).

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 Production Part Approval Process
Purpose

· To ensure that all customer Engg. Requirements are understood,

and to demonstrate the capability of supplier to meet the
requirements, initially & during actual production run at quoted
production rate.

· To validate that the products made from production tools and

processes meet the Engg. Requirements

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 Production Part Approval Process

ISO/TS 16949:2009-QMS Requirements

7.3.6.3 Product approval process

The organization shall conform to a product and manufacturing
process approval procedure recognized by the customer .

NOTE Product approval should be subsequent to the verification of

the manufacturing process.

This product and manufacturing process approval procedure shall

also be applied to suppliers.

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 Production Part Approval Process
· If an Organization decides to comply with PPAP Manual, all
requirements in PPAP manual must be complied.
· All changes affecting production process environment are to be
validated properly and records shall be maintained
· PPAP Policies & Procedures must be in Place, whether customer
requires it or not.
· PPAP documentation must be available for all active parts or
Corrective action plan for PPAP going forward (intended).
· For Bulk Materials, PPAP is not required unless requested by
customer
· PPAP records shall be maintained till the part is active + 1 calendar
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 Production Part Approval Process
CUSTOMER CUSTOMER
PPAP Process Flowchart Example
Customer P.O./ Record of
Customer – Approved PSW
Spec.
Requirements
ORGANISATION

Customer Part Project Owner Completion of Submission (or

Design & Team PPAP Required Resubmission)
Receipt and
Requirements. Items of PPAP
Approval of
Warrant
Submitted PSW

Customer
Process design Gather Completion of
Requirements Information PSW Validated
Process
Supplier (PSO/Run at
Customer Initiated rate)
Specifications Changes
PPAP Table 4.1 Approved PSW
Records
Customer
Initiated
Customer Changes to
Logistics Part, Speci.,
Requirements Notes: 1. Activities shown will not always be present. etc.
2. Records shown may be in various media and in storage locations

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 Production Part Approval Process
Comparison of PPAP with Traditional approach

Traditional sample submission PPAP

Sample Taken from a small lot Sample taken from a significant
production run
Additional processes other than in No process other than PFD is
PFD followed. allowed without informing to
customer or notified after
production.

Non productionised tooling are Notified to customer.

used.
Submission of - Submission of –
-Samples, dimensional report, 18 documents /items along with
material test report, any samples as applicable, which
qualification record (spl. Processes). provides the evidence of controls
exercised on production/process
environment.

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 Production Part Approval Process

Comparison of PPAP with Traditional approach

Traditional sample submission PPAP

Customer approval for bulk production Customer approval based on sample &
based on evaluation of sample & evaluation of documents & items
documents submitted. which provides confidence to customer
that supplier has understood his
requirements & demonstrated his
capability to meet the same in bulk
production.

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 Production Part Approval Process
REQUIREMENTS FOR PART APPROVAL

1. Design Records of Saleable Product

- for proprietary components / details
- for all other components / details
2. Engineering Change Documents, if any
3. Customer Engineering Approval, if required
4. Design FMEA
5. Process Flow Diagrams
6. Process FMEA
7. Control Plan
8. Measurement System Analysis Studies
9. Dimensional Results
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 Production Part Approval Process
REQUIREMENTS FOR PART APPROVAL

10. Records of Material / Performance Test results

11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW)

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 Production Part Approval Process

1. DESIGN RECORDS

· Part drawings, specifications, CAD data or any documents referenced

· If it is electronic format, hard copy to identify measurements taken
· For any saleable product, part or component, there will be one design
record, regardless of who has design-responsibility.
· A single design record can represent multiple part or assembly
configurations.
· For ‘black box’ parts, the design record specifies the interface and
performance requirements.
· For ‘catalog parts’, the design record may give functional spec. or
reference to a recognized industry standard.

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 Production Part Approval Process

1. DESIGN RECORDS

for bulk materials

· Raw material identification

· Formulations
· Processing steps & parameters
· Final product specifications & acceptance criteria

· Reporting of Part Material Composition

· Demonstrate compliance to material / part composition reporting. This

material reporting may be entered into the IMDS (International Material
Data System) or other Customer specified system / method
(www.mdsystem.com)
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 Production Part Approval Process

1. DESIGN RECORD

Marking of Polymeric Parts

Identify Polymeric parts with ISO symbols such as specified in ISO

11469, “ PLASTICS – GENERAL INTRODUCTION AND MARKING OF
PLASTIC PRODUCTS”.

Refer ISO 11469 / 1043 –1 for weighment of Plastic Parts, ISO

1043-2 for fillers and reinforcements and ISO 11469 / 1629 for
weighment of Elastomeric Parts.

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 Production Part Approval Process

2. ANY AUTHORISED ENGG. CHANGE DOCUMENT

· Authorized change documents provided by customer incorporated in

the part not incorporated in the drawing

3. CUSTOMER ENGINEERING APPROVAL

· As required by design record

· For bulk materials, signature of customer on bulk material approval
check list or inclusion of supplier’s name in customer list of approved
materials
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 Production Part Approval Process
4. DESIGN FMEA

• Applicable to design responsible suppliers

• for bulk materials, Design Matrix & Design FMEA are prepared as
required by bulk material requirements checklist
• for bulk materials, Design FMEA ratings for SEV, OCC, DET specified in
PPAP manual can be used

Single Design may be applied to a family or similar parts or materials.

5. PROCESS FLOW DIAGRAM

As per APQP manual

For bulk materials process flow description satisfies the requirement
Family concept is acceptable.
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 Production Part Approval Process
6. PROCESS FMEA
• Compliance to customer requirements (use current version of FMEA
Manual)
• Process FMEA for family of parts
• For bulk materials, Process FMEA rating for SEV, OCC, DET specified in
PPAP manual can be used

7. CONTROL PLAN
• As per APQP manual &ISO/TS requirement and Customer specific
requirement.
• Family Control Plans are acceptable if the new parts have been reviewed
for commonality by the Organization.
• Control Plan approval may be required by some Customers.

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 Production Part Approval Process
8. MEASUREMENT SYSTEMS ANALYSIS STUDIES

• Compliance to MSA studies as per current version of the reference Manual or as

required by Customer.

9. DIMENSIONAL RESULTS
• Compliance to control plan & Design Record and all characteristics (except ref.
Dimensions)
• Dimensional results for each production lines, each cavities, molds, patterns, dies
• Indicate design record, change level, authorized engg. Change document ref. On
all reports
• Identify master sample which is measured
• Tracing is required when optical comparator is required
• Appendix C can be used.
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 Production Part Approval Process

10. RECORDS OF MATERIAL / PERFORMANCE TEST RESULTS

• Compliance to design record / control plan

• Record of qty. tested on each tests
• Engg. Change level or authorized engg. Change
• Date of testing
• Material supplier’s name and their code (from customer approved List)

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 Production Part Approval Process

11. INITIAL PROCESS STUDIES

• Prior to submission, acceptable level of initial process capability or

performance shall be determined with customer.
• MSA prior to initial process studies.
• For special Characteristics of variable data.
• Where there are no special characteristics identified, the Customer
reserves the right to require demonstration of initial process capability
on other characteristics.
• Cpk or Ppk can be as per customer agreement.
• Control charts are preferred, if X bar – R charts used, Min. 25 sub groups,
min 100 nos. from significant production run.

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 Production Part Approval Process

11. INITIAL PROCESS STUDIES

QUALITY INDICES

a. Use Cpk or Ppk

b. Where historical Cpk data is available for similar parts of
same process, Cpk can be captured.
c. For chronically unstable processes (within specification) use
Ppk.
d. For bulk material, customer agreement on usage of
techniques.
e. Index value  1.67, Else CA plan is reqd.
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 Production Part Approval Process
11. INITIAL PROCESS STUDIES

QUALITY INDICES

f. For Unstable processes, notify customer & submit CA plan.

g. Modify Control Plan, normally providing for 100% inspection.
100% inspection methodologies are subject to review and concurrence
by the Customer.
h. One sided specification or non normal data
E.g. R/O, concentricity, twist, effort, surface finish, uniformity,
etc., - Alternate method of calculation & acceptance criteria with
customer agreement.

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 Production Part Approval Process
11. INITIAL PROCESS STUDIES
QUALITY INDICES
i. For bulk materials, if Ppk/Cpk is not achieved 100% inspection a sample
(s) from a continuous process or homogeneous batch, which represents
online production run.
12. QUALIFIED LABORATORY DOCUMENTATION

• If in house laboratory is only used for testing / calibration, add

laboratory scope
• If outside laboratory is used for testing / calibration, add NABL
certificate or equivalent of that laboratory
• Add scope of accreditation of that lab
• Qualified outside laboratory must be as defined by the customer.
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 Production Part Approval Process
13. APPEARANCE APPROVAL REPORT (AAR)

• Separate report for each part or series of parts, if part has the appearance
requirements on design record.
• Record of AAR with complete information.
• AAR applies only for parts with color, grain, or surface appearance
requirements.
• Certain customers may not require entries in all AAR fields. Refer
Appendix B or customer specifics.

14. SAMPLE PRODUCTION PARTS

As per customer request.
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 Production Part Approval Process

15. MASTER SAMPLE

• Retain till new master sample is produced or as per design record

requirement for inspection criteria.
• For each position of a multiple cavity, die, tool, mould or pattern, line.
• Retention period can be waived or modified by customer
16. CHECKING AIDS

• Inspection Fixtures, gages, models, templates, etc. specific to the part

• If more than one , prepare & refer the list in PSW including its change
level.

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 Production Part Approval Process

16. CHECKING AIDS

• Submit if required by customer

• Certification of checking aid w.r.t part dimensions
• Demonstration of engg. Change in gauge change
• Appropriate MSA studies

17. CUSTOMER SPECIFIC REQUIREMENTS

Compliance records to all specific requirements of customer.

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 Production Part Approval Process

18. PART SUBMISSION WARRANT

• Separate PSW for each part no.

• Identify Mould / cavity / line no. in PSW
• Part weight shall be rounded off to four decimals derived out of 10
randomly selected parts
• 10 parts represent all moulds, cavities, lines as appropriate.

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 Production Part Approval Process
Part Submission Warrant

Separate PSW for each part no.

Identify Mould / cavity / line no. in PSW

Part weight shall be rounded off to four decimals derived out of 10

randomly selected parts
10 parts represent all moulds, cavities, lines as appropriate

Appendix A – PPAP Manual

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 Production Part Approval Process
Situations when PPAP Validation, Customer Notification and
Submission is Required
 The Organization shall submit for PPAP approval prior to the first production
shipment in the following situations unless the Customer has waived this
requirement.

 The Organization shall review and update, as necessary, all applicable items in
the PPAP file to reflect the Production, regardless of whether or not the
Customer requests a formal submission. The PPAP file shall contain the name of
the authorized Customer representative granting the waiver and the date.

 Specimen Format for Product / Process Change Notification that has to

submitted to Customer for approval is specified in PPAP manual.

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 Production Part Approval Process

Situations where Submission to Customer is Required

# Requirements
01 A new part or product (Ex: a specific part, material, or colour not
previously supplied to Customer)

02 Correction of a discrepancy on a previously submitted part

03 Engg. Change to design records, specifications, or materials

production product / part numbers(s)

04 For bulk materials, Process technology new to the supplier, not

previously used for this product

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 Production Part Approval Process
SITUATIONS WHEN PPAP VALIDAITON, CUSTOMER NOTIFICATION AND
SUBMISSION ARE REQUIRED

The Organization shall notify the Customer of any planned changes to the
design, process or site. Upon notification and approval of the proposed
change by the Customer representative, and after change implementation,
PPAP submission is required, unless specified.

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 Production Part Approval Process
Situations where Notification to Customer and Submission is Required
(Unless waived by the Customer)
# Requirements
01 Use of construction or material other than what was used in the
previously approved part or product (e.g. under deviation permit
cases)
02 Production from new or modified tools , dies, moulds patterns,etc.
03 Production following upgrade or rearrangement of existing tooling
or equipment
04 Production from Tooling and Equipment transferred to a different
plant site or from an additional plant site

05 Change of Supplier for parts, non-equivalent materials, or services

(Ex: Heat Treatment, Plating)

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 Production Part Approval Process

Situations where Notification to Customer and Submission is Required

(Unless waived by the Customer

# Requirements
06 Product produced after the tooling has been inactive for volume
production for 12 months or more
07 Product and Process related changes to components of the
production product manufactured internally or by Suppliers
08 Change in test / inspection method – new technique (no effect on
acceptance criteria)
09 For bulk materials, new source of raw material from new or existing
supplier
10 Change in Product appearance attributes

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 Production Part Approval Process

Submission to Customer – Levels of Evidence

Level 1 Warrant only (and for designated appearance items, an
AAR) submitted to the customer.

Level 2 Warrant with product samples and limited supporting data

submitted to the customer.

Level 3 Warrant with product samples and complete supporting

data submitted to the customer

Level 4 Warrant and other requirements as defined by the

customer.

Level 5 Warrant with product samples and complete supporting

data reviewed at the organization’s manufacturing
location.
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PPAP Submission Levels
Notations:
 S – The supplier shall submit to designated customer product approval activity
and retain a copy of records or documentation items at appropriate locations,
including manufacturing

 R – The supplier shall retain at appropriate locations, including manufacturing,

and make readily available to the customer representative upon request

 * - The supplier shall retain at appropriate locations, and submit to customer

upon request

 Level 3 as default level

 For Bulk materials, Level 1 as default level

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