PAPP Checklists and Forms

8/18/2019 PAPP Checklists and Forms

1/27

Supplier PPAP Checklist Page 1 PPAP-ABG.xls

P S W

A A R

S A M P L E P A R T S

C O N T R O L P L A N

D I M E N S I O N A L R

E S U L S T S

I N I T I A L P R O C E S

S S T U D Y

D E S I G N R E C O R D S

P R O C E S S F L O W

D I A G R A M S

P R O C E S S F M E A

LEVEL 1

LEVEL 2

LEVEL 3

LEVEL 4

LEVEL 5

PSW PART SUBMISSION WARRTo clearly state to the Customer the reason for your submission.

Take special note of the folloing!

- "ecor# part re$ision le$el to the right of the part% &'g re$ision ( Part re$isions may be #ifferent)

- Supplier *ust mark +yes, or +no, to meeting all 'g. "euirements ( sign the PS.

- Part eight to be expresse# in kilograms to four significant #ecimal places &/.////).

"emin#er- Part eight is #etermine# by an a$erage of ten ran#omly selecte# parts.

- 0#entify hether the part #oes or #oes not contain "eportable"estricte# Substances

- Suppliers are encourage# to mark plastic parts ith the appropriate 0S2 symbols to #esignatetype of polymer ( filler use# in the part. 0#entify on the PS &34es3 or 35o3)

- The specific *ol#sCa$itiesPro#. Process6 pertaining to the PPAP shall be 0'6# on the PS.

- "ecor# the Pro#uction "ate at hich the PPAP samples ere pro#uce# on the PS.

- All checking ai#es use# in the e$ery#ay processing of a part shall be i#entifie# on the PS.

AAR APPEARANCE APPROVAL REP

For Appeara!e I"e#$ ONLY

Submitte# ith PPAP an# sample parts for the customer to sign7 $erifying parts are $erifying that the parts

meet all aesthetic criteria.

- *ust ha$e Spectrophotometer #ata rea#ings. &'l87 'a87 'b87 '987 C09 :AB)

SAMPLE PARTS SAMPLES FROM PPAP

Submitte# for Appearance an# ;unctional e$aluation. Six samples are reuire# ith each PPAP submission

- A fe of the parts use# for #imensional $erification shall be submitte#. These shall be labele#

ith part%7ca$ity7 re$ision7tool%7 etc. ( ith a sample number that correspon#s to the 'imensional

- Sample parts sent in shall be from a significant 3pro#uction3 run as outline# in the A0AG PPAP

*anual.

PPAPLEVEL M

A T E R I A L

% P E R F

O R M A N C E &

T E S T R E S U L T S

M E A S U R E M E N T

S Y S T E M

A N A L Y S I S S T U D I E S

L A B O R A T O R Y S C O P E A N D

A C C R E D I T A T I O N

"eport. Suppliers shall submit samples that represent each uniue ca$ity7 mol#7 line7 etc.

SUPPLIER PPAP C'EC(LIST


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Supplier PPAP Checklist Page < PPAP-ABG.xls

CONTROL PLAN PROCESS)PRODUCT CONTROL PLAN

To ai# in the manufacture of uality pro#ucts accor#ing to customer reuirements. A structure# approach for the

#esign7 selection7 an# implementation of $alue-a##e# control metho#s for the total system. 0t pro$i#es a ritten

summary #escription of the systems use# in minimi=ing process an# pro#uct $ariation.

- All Special Characteristics &e.g.7 critical7 key7 significant7 etc.) must be 0'6#a##resse# on the CP

- The CP is a li$ing #ocument that shoul# be utili=e#up#ate# for the life of the pro#uct.

- A54 C>A5G9S *A'9 T2 T>9 P"2'?CT C25T"2: P:A5 *?ST >A@9 3"0TT953

C?ST2*9" APP"2@A:.

- The Control Plan *?ST be signe##ate# by the Supplier an# the Customer.

- 0n some cases ABG ill allo ;amily Group P;'6s7 ;*9A6s an# Control Plan - hen this is agree#upon7 the supplier shall ha$e a reference attachment for all part numbers an# in#i$i#ual part

#ifferences of the parts in the ;amily Grouping.

- The inspection freuency *?ST be #efine# in uantifiable terms. & i.e.- hat is a 3:ot3)

DIMENSIONAL RESULTS FIRST ARTICLE DIMENSIONAL LAYOUT RES

This recor# is use# to $erify the parts meet all of the #imensional reuirements calle# out on the 'raing an# Control P

- 0f pro#uction parts ill be pro#uce# from more than one ca$ity7 mol#7 tool7 #ie7 pattern7 or

pro#uction process7 the supplier shall complete a #imensional e$aluation on a minimum of one

part from each uniue process$ariation &0nclu#ing color7 if applicable7 for certain process6)

The specific ca$ities7 mol#s7 line7 etc. shall then be i#entifie# on the PS ( on the 'imensional

"esults "eport.

- All #imensions7 characteristics an# specifications note# on the 'raing an# Control Plan shoul#

- All recor#s shall be submitte# on the ABG 'imensional "esults ;orm.

MATERIAL% PERFORMANCE TEST RESULTS LAB & FUNCTIONAL RES

This recor# is use# to $erify that the parts meet all of the *aterial an#or performance

reuirementsspecifications calle# out on the 'raing an# Control Plan.

- All #imensions7 characteristics7 an# specifications note# on the 'raing an# control plan shoul#

- *aterial Testing "esults7 Performance Testing "esults7 an# other engineering reuirements on the

#esign recor# shall be less than one year ol# at the time of the initial submission. This #ata shall

be up#ate# for engineering changes that affect the original #ata. The supplier shall also maintain

an# up#ate all testing #ata for each lot of material. hen PPAP is reueste# for an engineering

change7 the supplier shall submit the testing #ata that correspon#s to the material for the change.

INITIAL PROCESS STUDY CAPABILITY *Cp()Pp(, STU

The purpose of this recor# is to #etermine if the pro#uction process ill pro#uce pro#uct that meets

the Customer6s reuirements.

-

T-e ra. /a"a */a"a po0"$, ere #eri$e# from or the PPAP ill not be consi#ere# for appro$al. Also inclu#e a copy

of the histogram &Graphs).- Supplier *?ST submit 0nitial Process Stu#y for all Special Characteristics &e.g.7 critical7 key7

T-e re$"$ significant7 etc.) that are calle# out on the 'raing or Control Plan. Stu#ies must be submitte# that*CP(% PP(% CP% e"!+, are representati$e of each uniue pro#uction process7 e.g. #uplicate assembly line an#or ork

cell7 each position of a multiple ca$ity #ie7 mol#7 tool7 or pattern7 etc.- The acceptance criteria for Capability Stu#ies is as follos!

8 S>2"T T9"* ST?'4- *?ST meet or to 1.DE Cpk

8 :25G T9"* ST?'4- *?ST meet or to 1.FF Cpk- 0f CP falls beteen 1.FF an# 1.DE &Short Term Stu#y)7 a correcti$e action plan an# interim re$ise#

Control Plan &normally pro$i#ing for 1//H inspection) must be #e$elope# by the supplier an#

appro$e# by the customer prior to appro$al. 5e stu#ies *?ST be performe# after correcti$e

action is implemente# an# must be inclu#e# in a re$ise# PPAP submission.- A:: 0nitial Process Stu#ies must be accompanie# by *easurement System Analysis Stu#ies.-

be liste# in a con$enientorgani=e# format ith the a!"a re$"$ recor#e#.

be liste# in a con$enientorgani=e# format ith the a!"a re$"$ recor#e#.

Suppliers must submit ith their Cpk results a" ea$" 3 /a"a re$"$ that the Cpk results

0nitial process stu#ies must be performe# for A:: engineering changes that coul# ha$e an


3/27

Supplier PPAP Checklist Page F PPAP-ABG.xls

effect on the Special Characteristics &e.g.7 critical7 key7 significant7 etc.) that are calle# out on the

'raing or Control Plan. 0f it is unclear please contact ABG 9ngineering.

MEASUREMENT SYSTEM ANALYSIS STUDIES GAGE R&R% BIAS% LINEARITY% & STAB

The purpose of this recor# is to $erify that the Gage or measurement system is capable of accurately

assessing the uality of the parts.

- *easurement System Analysis Stu#ies must be submitte# ith A:: 0nitial Process Stu#ies.-

De00"0o$6 Pea$e reere!e "-e Mea$re#e" S7$"e#$ Aa7$0$ #aa+A!!ep"a!e Cr0"er0a6

an#


4/27

Supplier PPAP Checklist Page M PPAP-ABG.xls

upon7 the supplier shall ha$e a reference attachment for all part numbers an# in#i$i#ual part


PROCESS FMEA PROCESS = POTENTIAL FAILURE MODE AND EFFECTS ANAL

To assure that all potential failure mo#es an# the effects they ha$e on a process ha$e been consi#ere#

an# eliminate#a##resse#. Please note the folloing!

- 0f there are no recommen#e# actions you must state +none, in the recommen#e# actions column.

- 'o not use +2perator 9rror, as a potential failure. The failure is roote# to a process or system.

- A P;*9A shoul# be create# by a team hich has representation from e$ery area of the process.

- All Special Characteristics &e.g.7 critical7 key7 significant) must be 0'6#a##resse# on the P;*9A.

- Any issue7 customer or internal7 ill reuire re$iea#Iustment of ".P.5. numbers.

- The P;*9A is a li$ing #ocument that shoul# be utili=e#up#ate# for the life of the pro#uct.

- 0n some cases ABG ill allo ;amily Group P;'6s7 ;*9A6s an# Control Plan - hen this is agree#

upon7 the supplier shall ha$e a reference attachment for all part numbers an# in#i$i#ual part


DESIGN FMEA DESIGN = POTENTIAL FAILURE MODE AND EFFECTS ANAL

ONLY app0!a:e .-e "-e $pp0er -a$ /e$0; re$po$0:00"7+

A tool use# hen #esigning a component7 system7 process7 etc. to assure7 to the extent possible7

that all potential failure mo#es &'esign relate#) an# their associate# causesmechanisms ha$e been

consi#ere# an# a##resse#.

- "etain at supplier facility. *ust be a$ailable for customer re$ie at any time.


5/27

Part Name Part Number

Safety and/or

Government Regulation Engineering Drawing Change Level Dated

Additional Engineering Changes Dated

Shown on Drawing No! Pur"hase #rder No! $eight %&g'

Che"&ing Aid No! Engineering Change Level Dated

SUPPLIER MANUFACTURING INFORMATION SUBMISSION INFORMATION

Su((lier Name ) Su((lier Code

ustomer ame v s on

Street Address *uyer *uyer Co e

A((li"ation

City State +i(

52T9! 'oes this part contain any restricte# or reportable substances.

Are plastic parts i#entifie# ith appropriate 0S2 marking co#es.

REASON FOR SUBMISSION

Change in Part Pro"essing

REQUESTED SUBMISSION LEVEL (Check One)

SUBMISSION RESULTS

,he results for

,hese results meet all drawing and s(e"ifi"ation re-uirements. %f 0N#0 E1(lanation Re-uired'

2old / Cavity / Produ"tion Pro"ess

DECLARATION

hereby affirm that the sam(les re(resented by this warrant are re(resentative of our (arts3 have been made to the a((li"able

Produ"tion Part A((roval Pro"ess 2anual 4rd Edition Re-uirements! further warrant these sam(les were

(rodu"ed at the (rodu"tion rate of / 5 hours! have noted any deviations from this de"laration below!

E1(lanation/Comments.

Print Name ,itle Phone No! 6A7 No!

Su((lier Authori8ed Signature Date

6#R C9S,#2ER 9SE #NL: %6 APPLCA*LE'

Part $arrant Dis(osition. Part 6un"t ona A((rova .

Customer Name Customer Signature Date

,ooling. ,ransfer3 Re(la"ement3 Refurbishment3 or additional

PART SUBMISSION WARRANT

:es No

:es No

:es No

Dimensional 2aterials/6un"tional A((earan"e

:es No

nitial Submission

Engineering Change %s'

Corre"tion of Dis"re(an"y

,ooling na"tive ; < year

Change in Part Pro"essing

Change to #(tional Constru"tion or 2aterial

SubSu((lier or 2aterial Sour"e Change

Parts Produ"ed at Additional Lo"ation

#ther (lease s(e"ify

Level 4 $arrant with (rodu"t sam(les and "om(lete su((orting data submitted to "ustomer!

Level < $arrant only %and for designated a((earan"e items3 an A((earan"e A((roval Re(ort' submitted to "ustomer!

Level = $arrant with (rodu"t sam(les and limited su((orting data submitted to "ustomer!

Level > $arrant and other re-uirements as defined by "ustomer!

Level ? $arrant with (rodu"t sam(les and "om(lete su((orting data reviewed at su((lier@s manufa"turing lo"ation!

dimensional measurements material and fun"tional tests a((earan"e "riteria statisti"al (ro"ess (a"&age

A((roved

Ree"ted

A((roved

$aived

A * E

C D


6/27

Customer A!!e$$ B$0e$$ Grop 'ate

ABG P5 "e$ision 0nspector

Supplier P5 "e$. 'ate 9ngineer

Tool % 0nspection Purpose I0"0a S:#

A Calipers ' 'rop Gage G >eight Gage *icro@u 5 "a#ius Gage

B C** 9 ;eeler Gage > *icrometer : Protractor P "ing Gage

C Comparator ; Gage Block N *icroscope * Pin Gage J *icro @u - C**

:oc. G a g e 'imensional Sample Sample Sample Sample Sample Sample Sample Samp

5ominal O Tol. - Tol. 1 < F M D E Q

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7/27

Customer A!!e$$ B$0e$$ Grop 'ate

ABG P5 "e$ision 0nspector

Supplier P5 "e$. 'ate 9ngineer

Tool % 0nspection Purpose I0"0a S:#

A Calipers ' 'rop Gage G >eight Gage *icro@u 5 "a#ius Gage

B C** 9 ;eeler Gage > *icrometer : Protractor P "ing Gage

C Comparator ; Gage Block N *icroscope * Pin Gage J *icro @u - C**

:oc. G a g e 'imensional Sample Sample Sample Sample Sample Sample Sample Samp

5ominal O Tol. - Tol. 1 < F M D E Q

'im.%

FM

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FD

FE

FQ

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Co##e"$6


8/27

Customer: Material Used:

Part Number: Date Sampled:

Part Description: Date Inspected:

Tool Number: Measurement Method:

Revision: No of Samples Measured:

Inspected By: U0" o Mea$re6

Cavity # 1 2 3 1 2 3

!a"e Used

Description

olerance Upper $imit%s&

olerance $o'er $imit%s&

Sample # 1234!"#$

1%1112131411!1"1#1$2%21

22232422!2"2#2$3%31323334

3

&'(R&)( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((+TD %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((

Cp %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((

Ppu %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((Ppl %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((Pp, %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((


9/27

-IN %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((-&. %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((

*ecommended $imits +ased on Sample Data %from Sheet 1&

3 si/ma limits: -IN %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((0Pp 1*%% -&. %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((

si"ma limits,: MIN ()(((( ()(((( ()(((( ()(((( ()(((( ()(((( ()(((( ()((((

%-p. / 1)33& M0 ()(((( ()(((( ()(((( ()(((( ()(((( ()(((( ()(((( ()((((

si/ma limits: -IN %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((

0Pp 1*!" -&. %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((

! si/ma limits: -IN %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((

0Pp 2*%% -&. %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()(((( %*%%%% ()((((

-inimum limits re5uired 6or lon/ term capability per &B) procedures*

isto"ram +in *an"es ased on the aove data:

Min %*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((

1 %*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((

2 %*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((3 %*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((

%*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((

4 %*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((

5 %*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((

6 %*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((

7 %*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((

Ma8 %*%% ()(( %*%% ()(( %*%% ()(( %*%% ()((


10/27

ProIect %! 2ri

Part %! Customer! ACCESS BUSINESS GROUP "e$

Part "e$. :e$el! Customer ContactPhone! "

Part 5ame! BP "e$ 'ate BP

Process!

Company! Customer Appro$al Sign'ate!

ContactPhone!Core Team! Supplier Appro$al Sign'ate!

S"ep

O p e r a

" 0 o

M o 8 e

S " o r e

I $ p e !

"

Opera"0o De$!r0p"0o Pro/!" a/ Pro!e$$ C-ara!"er0$"0!$6 Co"ro Me"-o/$6

PRE=PRODUCTIONPROTOTYPE PRODUCTION PROCES


11/27

ProIect %!

Part %! Customer! ACCESS BUSINESS GROUP

Part "e$. :e$el! Customer ContactPhone!

Part 5ame!

Process!

Company!

ContactPhone!

Core Team!

Process ;unction "euirements

Potential;ailure*o#e

Potential 9ffect&s)of ;ailure

Se$

SC

Potential Cause&s) *echanism&s) of ;ailure

2cc

Current Process ControlsPre$ention

Current Process Controls'etection

'e

PROCESS POTENTIAL FAILURE MODE AND EFFECTS

*PFMEA,


12/27

ProIect %! Customer! ACCESS BUSINESS

Part %! Customer ContactPhone!

Part "e$. :e$el!

Part 5ame!

Process!

Company!

ContactPhone! Customer Appro$al Sign'ate!

Core Team!

Supplier Appro$al Sign'ate!

Part Process 5umber

Characteristic *etho#s

5o. Pro#uct Process SC Pro#uctProcess SpecTolerance 9$aluation *eas. Techniue

Process 5ame 2peration'escription

*achine7 Tools forCon$ersion

CONTROL PLANPRPROTOTYPE


13/27


14/27

PPAP GUIDELINES REFERENCE S'E

E>UIREMENT FOR NOTIFICATIO CLARIFICATION OR E?AMPLES

:

MINIMUM PPAPRE>UIRED

Pro#uction tools an#or euipmenttransferre# to a #ifferent plantlocation.

9x. 0f the tool an#or euipment is mo$e# fromone manufacturing site to anothermanufacturing site. ABG is still purchasing fromthe same supplier.


15/27

:<

:F

*aIor tool an#or euipment repairor refurbishment.

9x. Any maIor tool an#or euipment repair thatmay effect any critical #imensions.

9x. Any maIor tool an#or euipment repair thatmay effect the fit an# fuction of the pro#uct.

9x. Any maIor tool an#or euipment repair thatmay effect the reliability of the pro#uct.

9x. '29S 52T inclu#e normal pre$entati$emaintenance.

5e tooleuipment or ne pro#uctpre$iously not supplie# to ABG.

9x. Any ne pro#uction tool an#or euipment.0nclu#es replacement tooling.

9x. Any pro#uct that ABG is purchasing for the

first time.


16/27

:<

Change from an ABG appro$e#process to unappro$e# process.

9x. *o$ing a mol# from the ualifie# press toan unualifie# press7 e$en if the presses arethe same tonnage7 make7 an# mo#el.

:< - *inimal7 suppliers arereueste# to measure thecritical #imensions on F

pcs.

9x. Any process change that effects theprocess flo #iagram.

9x. Changing the ca$iation of appro$e#pro#uction tool.

9x. Pro#ucing pro#uct outsi#e the accepte#processsetup parameters.

9x. ?sing non-"2>S compliant material.

9x. Change in the assembly or pro#uctionprocess. Change in the ork cell.

9x. A##itonal euipment or remo$al ofeuipment in the pro#uctionassembly process.

9x. ?sing regrin# material for the first time.


17/27

:1

:F

Transferring the tool an#oreuipment from one location of the

facility to another location ithin thefacility.

9x. *o$ing the tool euipment from a clean

room to non-clean room.

A change in material or componentnot appro$e# by ABG.

9x. The use of substitute material orcomponents that #e$iate from ABGspecification.

9x. Any change in material or components isreuire# to be appro$e# by ABG.


18/27

:F A change in subcontractor ofmaterial7 components7 or ser$ices&paint).

9x. Any sub-supplier change is reuire# to beappro$e# by ABG. This inclu#es a change insub-supplier that is supplying the same materialor component. - :<

9x. 0nclu#es outsourcing assembly7 processing7etc.


19/27

:F?se of ra material7 components7 orchemicals that #o not meetspecifications.

9x. ?sing material7 components7 or chemicalsthat #o not conform to ABG6s specification.0nclu#es #imensional7 performance7 or anycharacteristics that affects form7 fit7 function7an#or reliability.

9x. 0nclu#es materials7 components7 orchemicals that are expire#.


20/27

*in. :1

*in. :<

A change in the appro$e#packaging.

9x. Any change in the package uantity7 si=e oreight.

9x. Any change to internal package cushioning

an#or protection i.e foam bags7 partitions7corner posts7 etc.

9x. Any change in the pallet si=e an#oruniti=ation of cases. *ust comply ith SupplierShipping "euirements Gui#e.

9x. Any change in the structure of the package7i.e. expen#able packaging to returnablepackaging7 corrugate# compression strength7etc.

9x. Any change in the pack metho#7 i.e. layerpack to bulk pack7 bulk bagge# to in#i$i#uallybagge#7 etc.

9x. Any packaging change that may affect theintegrity an# the appearance of the pro#uct7 i.e.9S' Bags &static protection)7 Class A surfaceprotection7 etc..

9x. All case labeling must a#here to theSupplier Shipping "euirements Gui#e

Contact ABG Procurementor ABG Packaging

9ngineer

Any change to the ABG #esignspecifications or prints.

A change in ABG appro$e#assembly testing inspectionmetho#.

9x. Any change in testing metho# or testingeuipment.

9x. A change upgra#e in testing softare.


21/27

T

4es

ENGINEERING C'ANGE NOTICERE>UIRED


22/27

5o

4es


23/27

4es


24/27

4es

4es


25/27

4es


26/27

4es


27/27

4es

4es

4es

Documents

PAPP Checklists and Forms