F1021 PPAP Checksheet Instructions-Update

8/12/2019 F1021 PPAP Checksheet Instructions-Update

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Global Supply Management

2! Process (lo& "iagram /P("!+ The Process 'low 9iagram must ollow the process rom receipto raw material and receiving inspection- through any warehousing and shipping steps. It shouldalso include any ?9oc! Audits? and 'inal Inspections. The P'9 shall comprehend all potentialpaths that a part can ta!e in the process- including inspection- containment- rewor!- and scrap.

The P'9 must include material shipped to sub;contractors and the returning o the material bac!to the Supplier3s plant. The Nexteer ormat available on the Nexteer Supplier eb Site$Appendix (>


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number is not acceptable in the control method column unless a brie description o theprocedure or a copy o the procedure is included. I wor! instructions are reerred to in the,ontrol Plan- they should be included in the PPAP pac!age. The ,ontrol Plan must include theprint revision number and letter and be comprehensive $i.e. it must include all part dimensionalcharacteristics and notes provided on the blueprint. These characteristics must be listed on the

,ontrol Plan with the process characteristics that lin! to them in a cause and eect relationship%.The ,ontrol Plan must be part- or part amily- speciic. Sub;Supplier ,ontrol Plans should beavailable or Nexteer review $i requested%. Anything required to ma!e a deect;ree part needsto be addressed in the ,ontrol Plan. Sample si8es must be deined in number o parts. Samplerequencies must be deined as a speciic quantity o parts- or as a speciic time interval./eneral terms such as2 5Per :ox6- 5#ach Bot6- #ach Production Run6- 5#ach load6- etc- are notacceptable. 3mportant* There must be a one;to;one match o the 4peration numbers betweenP'9- '1#A and the ,ontrol Plan to allow or cross;reerencing o the documents.

7! Measurement System Analysis /Gage #8#! ' All gages in the Control Plan must ha-e aGage #8# stu$y complete$9 'or the PPAP Submission7 only /age RFR3s or Special,haracteristics are to be submitted.

:ariable Gage #8#;s+ 1ust be done and included in the PPAP submission even i the

gage is a hand tool- such as micrometers or calipers. This also includes ,11. Gariablegage studies are to be o the ormat2 > operators- > trials- using () parts. The () parts needto be representative o the process. All variable gage RFR studies should have a minimumo = distinct categories. The preerred method or calculating the gage RFR is by using the

AN4GA method./ages not meeting the acceptance criteria per the AIA/ 1SA manual shallhave a containment plan $such as ())E inspection- gage improvement- or other means%./age study records shall be maintained. The preferred tool for reporting this data is Minitab

Attribute Gage #8#+ At a minimum a @appa Study must be completed with a =)x>x>

method. The A"#&S"# can provide an electronic template or this attribute study- which willstreamline the gage study method and eliminate conusion and inconsistencies with

Nexteer3s expectations. 3mportant2 I a ,11 is used to complete the initial processcapability study on a eature that is chec!ed with an attribute gage in the ,ontrol Plan- then avariable gage study must be completed on the ,11 and an attribute study on the attributegage.

The latest version o the 1SA 1anual2 www.aiag.org


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conormance to those speciications in the PPAP pac!age7 spea! to your Nexteer A"#&S"# ordetails.

=b! Test #esults /Performance0 "urability! ' Includeany perormance or durability tests asprescribed in the design record7 including drawings and unctional and validation speciications.

The required level o detail $i.e. summaries vs. charts vs. raw data% shall be as directed byNexteer Product #ngineering and&or Nexteer A"#&S"#.

! 3nitial Process Capability Stu$ies /Cp>)Pp>!+ I the Nexteer Product #ngineer or A"#&S"#has not identiied @P,3s or special characteristics $",I3s% to measure- the Supplier should selectnot less than one dimension to demonstrate process capability. (*= piece capability studies arerequired at time o PPAP or all @P,3s and ",I3s and other characteristics directed by Nexteer.The (*= piece data points should come rom the >)) piece PPAP production run- in time;ordered subgroups o > to = pieces. The sampling plan is to be documented and pre;approvedby Nexteer. Hnless otherwise directed by the Nexteer A"#&S"#- each cavity o a multiple cavitymold- or multiple tool process- must have its own capability study

4n the initial process studies or special characteristics $i.e.- ",I3s- @P,3s- etc% the Supplierneeds to demonstrate that the process is stable and in control through the use o a control chart.Normality and capability must also be demonstrated. The preerred statistical sotware pac!ageis 1initab and the above can be shown using the 5,apability Six Pac!- within 1initab.6

The acceptance criteria or the process indices is per the AIA/ PPAP requirements.

+! ?ualifie$ 6aboratory "ocumentation ' Itesting is perormed in a Suppliers internal lab- theymust provide a copy o their quality certiication. The Supplier should also providedocumentation o the appropriate laboratory scope. I an external lab is used- send a copy ooutside lab certiication and the scope o accreditation $must be IS4 ()*=&A*BA certiied orregional equivalent%. As a best practice- the Supplier should indicate speciically which labs wereused or the applicable part number $i.e. by test log or other indication o laboratory usage%.

Baboratories which were not used expressly or indirectly in the testing o the applicable partnumber should not be reerenced.

,! Appearance Appro-al #eport+ Any part that is color matched- needs graining- or otherappearance approval must have an appearance approval report attached to the PPAP. ,onsultthe 4#1 ,ustomer Speciic Requirements or speciic use o orms.

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.! Sample Pro$uct to Plant ' Send the sample product to the using plant as instructed by thePPAP purchase order or by the Nexteer A"#&S"#9 The Supplier will provide the shippinginormation $i.e. the carrier name- and shipment trac!ing number% to the Nexteer A"#&S"#- andto the person receiving the PPAP at the Nexteer Plant. As a best practice- this shipping

inormation may be included in this section in the PPAP submission. Samples need to beproperly identiied with the Nexteer /lobal Sample and PPAP Babel $'orm J>0K>%. The Babelmust be illed in and printed on bright orange paper by the supplier- and irmly aixed to All 'ourSides o the container or box. Paper dimension must be A0- K;(&*6x((6- or similar si8e. The labeltemplate may be obtained rom the Nexteer Supplier eb Site. It can be ound by navigating toNexteer.com and selecting Suppliers in the top right ribbon. 'rom there- select Processes romthe let banner- then Shipping and Babeling. ,lic! on the /lobal Sample and PPAP Babel. 4nceopen- select your preerred language rom the bottom tabs.

2! Master Sample 'Per AIA/ PPAP 1anual 0thedition2 5The organi8ation shall retain a mastersample or the same period as the production part approval records- or $A% until a new master

sample is produced or the same customer part number or customer approval- or $:% where amaster sample is required by the design record- ,ontrol Plan or inspection criteria- as areerence or standard. The master sample shall be identiied as such- and shall show thecustomer approval date on the sample. The organi8ation shall retain a master sample or eachposition o a multiple cavity die- mold- tool or pattern- or production process unless otherwisespeciied by the customer.6 Note that PPAP 0thedition includes some guidelines which detailconditions upon which this requirement can be waived. The waiving o this requirement shallultimately be determined by the Nexteer A"#&S"#- and can be indicated on the chec!sheet $as5N46 to being required%. NOTE2 The Nexteer A"#&S"# will direct the Supplier on the numbero 1aster Samples to be retained.

4! Checking (i@tures ) Ai$s ) Gages+ I needed to veriy- the Supplier will provide a list- ordrawing- and&or duplicate ixture & aids & gages to the Nexteer Plant with the PPAP parts.

5! Ne@teer Supplier #euirements ' These are PPAP submission requirements that are speciicto Nexteer Supplier components. hile several o these items are typically mandated- at leastunder certain conditions- the inal applicability o any o these requirements pertaining to acertain component PPAP submission shall be indicated on the PPAP Process ,hec!list by theNexteer A"#&S"#. $3mportant2 The latest revision o the Nexteer Supplier Requirementsshould be requested rom the A"#&S"# by the Supplier and then reerenced as the ormalrequirement documentation. Points below are identiied as helpul lessons learned rom pastPPAP experiences.%

5a! 3nterim #eco-ery Borksheet /(=.+!+ I or any reason the Supplier anticipates lessthan ull approval $or example2 print changes being made by engineering but not yet

released- etc.% a Nexteer Interim Recovery or!sheet must be illed out and included inthe pac!age. The Interim wor!sheet needs to include the Nexteer Product #ngineer-and Nexteer A"#&S"#- signatures prior to the PPAP submission to the Nexteer1anuacturing Plant. The A"#&S"# is responsible to obtain the signatures.

5b! SoC Confirmation 6etter; A copy o the Substance o ,oncern ,onirmation Approvalmust be included in the PPAP pac!age. Suppliers must submit into I19S. I anymaterials prohibited by the /A9SB Bist are contained in the product- the ProhibitedSubstance Reporting 'orm $*>))))))% approved by the ,hie ,hemist $or So, Team%

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must be included in the pac!age and the appropriate box be noted on the PartSubmission arrant.

NOTE* I19S Recipient or Nexteer Automotive is L =K)(. Any other recipient codesubmitted will be reDected. The speciic inormation or suppliers on how to ill out an

I19S request or Nexteer- as well as the prohibited substance reporting orm- can beound on the Nexteer Supplier eb Site.

See Also + Nexteer Supplier Requirements- Section (.0 or urther inormation.

5c! Supplier Characteristic Summary /SCS! (orm ' This is a summary o technology andquality strategy or the critical and notable product eatures and process controls o thecomponent. It must include a summary o certain process and capability inormationconcerning all @P,3s- ",I3s- and other characteristics as directed on the orm. Thiselectronic orm is to be initiated by the Supplier or initial program review- updatedthroughout process development phase- and ultimately submitted with the PPAPpac!age. Instructions are included in the comments or each column heading within theelectronic orm.

5$! Ne& Tool 3nformation* Photos0 "escription 8 "ra&ing+ 'or new tools and ixturesor which any payment is expected to be made by Nexteer- some minimal inormationshall be required to be included in this section o the PPAP submission in order to helpsubstantiate Supplier claims o tooling expense. This inormation should include + at aminimum + recent photo$s%- drawings- and brie written description. Inormation shoulddescribe applicability o this tool regarding any other usage by the Supplier beyond theexpress purpose o creating or ensuring quality o the submitted component.

5e! Supplier Packaging 3nformation /SP3! (orm 'Include the approved SPI orm$minimum requirement + sign;o should be completed at the preliminary stage o theSPI 'orm%. 'or urther inormation regarding this orm- Supplier should consult with theNexteer :uyer. Applicability o this section to a particular PPAP submission shall beprescribed on the chec!list by the A"#&S"#.

5f! Contact 6ist ' I requested by the A"#&S"# per the chec!list- the Supplier shall includea list o !ey Supplier contacts in the PPAP submission. This will increase the visibility o!ey contacts which may be required or Nexteer business purposes.

5g! (actory (loor 6ayout 'As requested by the A"#&S"# per the chec!list.

17h) Nexteer Problem Solver Access Confirmation Nexteer Problem Solver access isMANDATORY for all production component Suppliers to Nexteer. The NexteerAQE/SQE will indicate YES as a requirement for PPAP submission if there is anydoubt concerning the Suppliers access and/or usage capability for Nexteer ProblemSolver. In this case, the Supplier must include in the PPAP submission, evidence ofhaving registered and accessed the Problem Solver application. (Example: Screenshot

from Nexteer Problem Solver). I the Nexteer A"#&S"# has conidence o theSupplier3s access and usage o the Nexteer Problem Solver application- then he&shemay indicate 5N46 + not required + on the chec!list.

5i! Assessments+ Nexteer A"#&S"# should indicate whether special surveys-wor!sheets- or questionnaires are to be submitted with PPAP. These assessments shallpertain to the location o applicable processes- whether at Supplier or sub;tier Supplier.'or example- i the Tier;( Supplier purchases the heat treat process rom their Tier;*Supplier- then the heat treat system at the Tier;* Supplier shall be assessed using the

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,"I; wor!sheet- and shall be included in the Tier;( PPAP to the customer. Theseassessments can include2

,"I; $Oeat Treat System Assessment% ,"I;(( $Plating System Assessment% ,"I;(* $,oating System Assessment% ,"I;(= $elding System Assessment% ,"I;( $Soldering System Assessment%

'ord ;OTJ supplement $In which case- the word 5other6 would be circledand a note could be added at bottom o PPAP chec!list to indicate theassessment type%

Toyota eld Survey $In which case the word 5other6 would be circled anda note could be added at bottom o PPAP chec!list to indicate theassessment type%

5! Other Customer Specific #euirements ; In addition to the requirements noted above-the Supplier must meet all Nexteer Supplier Requirements noted in the NexteerSupplier eb Site- and&or :est Practices as noted by your Nexteer A"#&S"#.

Some examples o these include2

Babels2 Include an example o the :arcode Babel that will identiy the partsprepared or shipping to Nexteer.4rder the PPAP Pac!age in an electronic submission ormat- as requiredin the Nexteer Supplier Requirements. Reerence the Nexteer #lectronicPPAP Submission Instructions that is located in the Nexteer Supplier ebSite.I applicable- include approved PPAP warrants- or all sub;tier Suppliercomponents that have a Nexteer part number noted on the print.

7! Part Submission Barrant $reer to the latest AIA/ PPAP manual or the template% + A Part

Submission arrant 1HST be properly illed out. Any inormation that is not illed out musthave an explanation. #lectronic signatures are acceptable.

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Documents

F1021 PPAP Checksheet Instructions-Update