PPAP Checklist Generic

1 of 9 Supplier PPAP Submission Checklist file:///tt/file_convert/54493b82b1af9f56248b4bb8/document.xls

Submission Date:

Supplier: XXXXXX QE:

Part No: Part Name:

Sample part submission required Sample part submission not requiredPPAP AND CONTROL PLAN SUBMISSION LEVELS

Prototype Pre-production Production

APPROVE REJECT N/A The following sections are numbered per AIAG PPAP 4th Edition

1 Design Records of Saleable Producta Drawing must have an authorized XXXXXX approval signature or stamp.b Detailed top level drawing must have detailed part drawing for all components.c All specifications must be referenced on drawing.d A sequentially numbered drawing which correlates to the numbered dimensional/material/test report.

e

f

g Other requirements:

2 Engineering Change Documents, if anya

3 Customer Engineering approval, if required

a

b DVPR (Design Validation Product & Reliability) approval by XXXXXX Engineer.

4 Design FMEA, if applicable

a

b Other requirements:

5 Process Flow Diagrams(PFD)a Must be representative of the actual process flow including any offline operations.(Including rework ,re-test etc.)b Must have correct part number and current revision level.

c Must follow numbering scheme of Control Plan and Process FMEA.(PFD ,Control Plan ,PFMEA -Process sequence # must match )d Other requirements:

6 Process FMEAa Must be in the current AIAG or XXXXXX approved format.b Must follow numbering scheme of Process Flow Chart and Control Plan.

c Must have correct part number and current revision level.

d Other requirements:

7 Control Plan

a Must be in the current AIAG or XXXXXX approved format.

b Must address Prototype, Pre-Production (If applicable) and Production stages

c Must identify frequency of inspections, method of inspection, and responsibility.

d Must identify reaction plan for non-conformances.

e Must have correct part number and current revision level.

f Must follow numbering scheme of Process Flow Diagram and process FMEA.


Supplier PPAP Submission Checklist(PPAP/ISIR/ISR)

Supplier Rep:

Rev Level & Date:

All notes, specifications and material references must be numbered. The numbers must correlate to documents contained within the dimensional, material or test certification sections.

Notes that apply globally to a drawing should also be numbered and conformance indicated. (i.e. “all unspecified radii is +/- .2mm).

Must provide all engineering change documents not yet recorded in the design record but incorporated in the product, part or tooling.

Use of written Deviation/Waiver detailing all prototype processes & non-conforming dimensional/functional requirements.

DFMEA (Design Failure Mode & Effect Analysis) approval by XXXXXX Product Engineer is required for all products which the supplier is design responsible.

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APPROVE REJECT N/A

8 Measurement System Analysis Studies

a

b Must be conducted as required in the current AIAG standard “Measurement Systems Analysis”.

c

d Gage error over 30% is not allowed. Actions must be taken and documented to reduce gage error.

e Gage Study must be current within one (1) calendar year

f Other requirements:

9 Dimensional Results

a

b All dimensions on drawing are required including radii, angles and GD&T.

c All notes must be sequentially ballooned/numbered (see item #1) including material and test specifications.

d

e Samples must be identified as Sample #1 to Sample #5, which correlate to the dimensional report.

f

g Supplier must identify and retain one of the parts measured from each cavity as the master sample.

h Other requirements:

i Typically required on engineering changes.

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k

l Samples must be identified as Sample #1 to Sample #5, which correlate to the dimensional report.

m Supplier must identify and retain one of the parts measured from each cavity as the master sample.

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10 Material / Performance Test Results

a

b Material Certifications are required for all raw materials used.

c Actual test specifications must be attached to the test reports.

d Must be current within one (1) calendar year.

e MSDS sheets are required if applicable.

f Must have raw material lab data for all components.

g Other Requirements:

Supplier must have applicable MSA studies such as Gage R&R for all equipment used for new or modified gages, measurement, and test equipment.

Less than 10% gage error is preferred. Gage error between 10% - 30% may be acceptable if accompanied by a XXXXXX approved action plan or sign off by XXXXXX supplier quality representative.

ndc (number of discriminate units) should be equal to or greater than 5, and should be equal to or greater than 10 of used for variable SPC

5 Piece Full Layout (per cavity or production stream if applicable)

Typically required on new parts, major changes to existing parts, movement of production equipment, or annual re-submission.

Must be reported on the current AIAG Production Part Approval, Dimensional Results (Form # CFG – 1003, current revision) or XXXXXX approved format.

If drawing does not specify SC's, supplier is required to choose significant characteristics to measure based upon their expertise of the product and provide data.

5 Piece Partial Layout (per cavity or production stream if applicable)

All dimensions, specifications or notes affected by the engineering change must be addressed on dimensional report.

Must be reported on the AIAG Production Part Approval, Dimensional Results (Form # CFG – 1003) or XXXXXX approved format.

Other requirements:

Must be reported on the AIAG Production Part Approval, Material Test Results (Form # CFG – 1004, current revision) or XXXXXX approved format.

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APPROVE REJECT N/A

11 Initial Process Study

a 300 piece Sample Run required unless authorized by XXXXXX quality representative.

b If a SC is affected, a 300 Piece run is required for capability reporting purposes.

c

d The process must be in statistical control before capability can be demonstrated.

e


12 Qualified Laboratory Documentation

a

b

c Actual specification must be attached to the test report.

d Test report must be numbered which correlates to the number on the ballooned drawing (see item#1).

e


13 Appearance Approval Report, if applicablea Required on components where texture or color is specified.

b Must be documented on the current AIAG Appearance Approval Report (Form # CFG – 1002, current revision).

c Other requirements:

14 Sample Product

a

15 Master Sample

a Supplier must retain a master sample identified as such with the customer approval date on the sample.

b Each cavity must have a master sample.

16 Checking Aids

a

Process capability for normal distribution processes must be from 100 samples (20 subgroups of 5 parts) randomly selected out of a 300 piece run unless otherwise authorized by the XXXXXX quality representative

For bilateral normal distributions, after statistical control is established, then a minimum Ppk of 1.67 must be achieved for new processes. Existing processes must be in control and a minimum Cpk of 1.33.

If applicable Supplier shall have a laboratory scope and documentation showing that laboratories used are accredited by A2LA, SSC, or equivalent.

In the event of special notes on a drawing (i.e. “Must comply with FMVSS302”) a report from a certified lab (preferably a 3rd party) must be presented indicating conformance to that particular specification.

When a commercial laboratory is used, test results must be submitted on the laboratory letterhead or normal laboratory report format.

Supplier shall provide sample product as requested by the customer and as defined by the submission request.

The supplier must certify that all aspects of the checking aid agree with part dimensional requirements (e.g. CCM report).

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APPROVE REJECT N/A

17 Records of Compliance with Customer-Specific Requirements

a Supplier Onsite Process Approval required.

b Run at Rate required.

c

d Sample barcode label to XXXXXX specifications (reference Supplier Manual).

r Special Handling labels marked ____________ on outside of each container shipped for PPAP parts.

f Sub-component approvals (warrants etc).

g


18 Part Submission Warrant (PSW)

a Must be AIAG standard (Form # CFG – 1001, current revision), or XXXXXX approved.

b Must include part weight in Kg to 4 decimal places.

c Must include IMDS number

d Must include purchase order number

e Must include customer information.

f Must include correct part number and/or XXXXXX part number.

g Must have detailed explanation in declaration section, if anything is reported to be out of specification.

h

i Must have production rate (blank completed in "Declaration" section of PSW

j Other requirements:

These requirements have been reviewed by XXXXXX quality representative for product approval.

Submission is:

Other Notes:

XXXXXX Quality Representative Date

Submit package to the attention of:

Must be submitted with all 18 sections addressedin an electronic (preferred) tabbed file (.pdf or other approved format) or in a tabbed, soft-sided three-ring binder

Early production containment is required for 90 days after Start of Production, unless otherwise approved by XXXXXX quality representative

Must signify cavity numbers and percent regrind (if virgin material blend is not used) in the “EXPLANATION/COMMENTS” section.

If any requirements cannot be met by the supplier, it is the supplier's responsibility to complete and submit a request for a written deviation or waiver with the package, detailing the deviation request and number of parts effected and/or length of time needed.

XXXXXX Purchasing RepresentativeXXXXXX Mfg.

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Approved Interim Approval until: Rejected

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document.xls Page 5 of 9 Production

Location ChangeSubmission Date:

Supplier: Supplier Rep: Hi-Stat QE:

Part No: Part Name:

APPROVE REJECT N/A APPROVE

1 Design Records of Saleable Product

a Drawing must have an authorized Hi-Stat approval signature or stamp.

b Detailed top level drawing must have detailed part drawing for all components.

c All specifications must be referenced on drawing.

d A sequentially numbered drawing which correlates to the numbered dimensional/material/test report.

e

f


2 Engineering Change Documents, if any

a

3 Customer Engineering approval, if required

a

b DVPR (Design Validation Product & Reliability) approval by Hi-Stat Engineer.

4 Design FMEA, if applicable

a

b Other requirements:

5 Process Flow Diagrams

a Must be representative of the actual process flow including any offline operations.

b Must have correct part number and revision level.

c Must follow numbering scheme of Control Plan and Process FMEA.


6 Process FMEA

a Must be in the AIAG or other approved format.

b Must follow numbering scheme of Process Flow Chart and Control Plan.

c Must have correct part number and current revision level.


Supplier Submission Requirements Checklist(PPAP/ISIR/ISR)

Rev Level & Date:

All notes, specifications and material references must be numbered. The numbers must correlate to documents contained within the dimensional, material or test certification sections.

Notes that apply globally to a drawing should also be numbered and conformance indicated. (i.e. “all unspecified radii is +/- .2mm).

Must provide all engineering change documents not yet recorded in the design record but incorporated in the product, part or tooling.

Use of Deviation/Waiver detailing all prototype processes & non-conforming dimensional/functional requirements.

DFMEA (Design Failure Mode & Effect Analysis) approval by Hi-Stat Release Engineer is required for all products which the supplier is design responsible.

= Sample Submission Required = Sample Submission NOT Required

= Prototype

= Pre-Production

= Production

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Part No: Part Name:


Rev Level & Date:

7 Dimensional Results

5 Piece Full Layout (per cavity or production stream if applicable)

a

b All dimensions on drawing are required including radii, angles and GD&T.

c

d

e Samples must be identified as Sample #1 to Sample #5, which correlate to the dimensional report.

f

g Supplier must identify one of the parts measured from each cavity as the master sample.


5 Piece Partial Layout (per cavity or production stream if applicable)

i Typically required on engineering changes.

j

k Must be reported on the AIAG Production Part Approval, Dimensional Results (Form # CFG – 1003).

l Samples must be identified as Sample #1 to Sample #5, which correlate to the dimensional report.m Supplier must identify one of the parts measured from each cavity as the master sample.

n

8 Material / Performance Test Results

a Must be reported on the AIAG Production Part Approval, Material Test Results (Form # CFG – 1004).

b Material Certifications are required for all raw materials used.

c Actual test specifications must be attached to the test reports.

d Must be current within one (1) calendar year.

e MSDS sheets are required if applicable.

f Must be on OEM approved supplier list, if applicable.

g Must have raw material lab data for all components.

h Other Requirements:

9 Initial Process Study

a 300 piece Sample Run required unless authorized by an Hi-Stat Q.E. representative.

b If a KPC is affected, a 300 Piece run is required for capability reporting purposes.

Typically required on new parts, major changes to existing parts, movement of production equipment, or annual re-submission.

All notes must be sequentially ballooned/numbered (see item #1) including material and test specifications.

Must be reported on the AIAG Production Part Approval, Dimensional Results (Form # CFG – 1003, current revision).

If drawing does not specify KPC's, supplier is required to choose critical characteristics to measure based upon their expertise of the product and provide data.

All dimensions, specifications or notes affected by the engineering change must be addressed on dimensional report.

Other requirements:

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Part No: Part Name:


Rev Level & Date:

c

d The process must be in statistical control before capability can be demonstrated.

e


10 Measurement System Analysis Studies

a

b Must be conducted as required in the AIAG standard “Measurement Systems Analysis”.

c

d Gage error over 30% is not allowed. Actions must be taken and documented to reduce gage error.

e Gage Study must be current within one (1) calendar year.


11 Qualified Laboratory Documentation

a

b

c Actual specification must be attached to the test report.

d Test report must be numbered which correlates to the number on the ballooned drawing (see item#1).

e


12 Control Plan

a Must be in the AIAG or other approved format.

b Must address Prototype, Pre-Production and Production stages.

c Must identify frequency of inspections, method of inspection, and responsibility.

d Must identify reaction plan for non-conformances.

e Must have correct part number and revision level.

f Must follow numbering scheme of Process Flow Chart and process FMEA.

Process capability for normal distribution processes must be from 100 samples (20 subgroups of 5 parts) randomly selected out of a 300 piece run unless otherwise authorized in writing by the Hi-Stat Q.E. Precision machining: Studies must be 30 sequential individual values. For processes with little tool wear or adjustment, adjusted sampling rate (e.g. every other piece or every third piece) may be used. Each sample measurement for diameters must indicate the largest and smallest diameter of the measured section. Each sample measurement for lenghts must indicate the longest and shortest length of the measured section. Control limits are to be 75% of the total tolerance or less.

For bilateral normal distributions, after statistical control is established, then a minimum Ppk of 1.67 must be achieved for new processes. Existing processes must be in control and a minimum Cpk of 1.33.

Supplier must have applicable MSA studies such as Gage R&R for all equipment used for new or modified gages, measurement, and test equipment.

Less than 10% gage error is preferred. Gage error between 10% - 30% may be acceptable if accompanied by a Hi-Stat approved action plan or sign off by Hi-Stat plant supplier quality/corporate supplier development.

Supplier shall have a laboratory scope and documentation showing that laboratories used are accredited by A2LA, SSC, or equivalent.

In the event of special notes on a drawing (i.e. “Must comply with FMVSS302”) a report from a certified lab (preferably a 3rd party) must be presented indicating conformance to that particular specification.

When a commercial laboratory is used, test results must be submitted on the laboratory letterhead or normal laboratory report format.

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Part No: Part Name:


Rev Level & Date:


13 Part Submission Warrant (PSW)

a Must be AIAG standard (Form # CFG – 1001).

b Must include weight, purchase order #, customer information.

c Must include correct part number and/or Hi-Stat part number.

d Must have detailed explanation in declaration section, if anything is reported to be out of specification.

e

f Must be signed and dated by an authorized supplier representative.


14 Appearance Approval Report, if applicable

a Required on components where texture or color is specified.

b Must be documented on the AIAG Appearance Approval Report (Form # CFG – 1002).


15 Bulk Material Requirements Checklist, if applicable

a Required on bulk material PPAP submissions only

b Bulk Materials Requirements Checklist or as agreed to by customer


16 Sample Product

a

17 Master Sample

a

b Each cavity must have a master sample.

18 Checking Aids

a

19 Records of Compliance with Customer-Specific Requirements

a SOPA (Supplier Onsite Process Approval) required.b Run at Rate required.

c

d

Must signify cavity numbers and percent regrind (if virgin material blend is not used) in the “EXPLANATION/COMMENTS” section.

Supplier shall provide sample product as requested by the customer and as defined by the submission request.

Supplier must retain a master sample identified as such with the customer approval date on the sample.

The supplier must certify that all aspects of the checking aid agree with part dimensional requirements (e.g. CCM report).

Manufacturing Floor Plan must show processing sequence, method and equipment used at each station.Manufacturing Floor Plan must illustrate number of operators required per station including inspection & repair/rework stations.

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Part No: Part Name:


Rev Level & Date:

e

f Must be submitted in a tabbed, soft-sided three-ring binder.

g Completed, signed checklist submitted with the package.

h

i Process Mapping (reference Supplier Manual).j Supplier contact list.

k Sample barcode label to Hi-Stat specifications (reference Supplier Manual).

l

m Digital picture of each component with accompanying terminology for identification.

n Bright pink labels marked ____________ on outside of each container shipped - (prototype).

o Yellow labels marked ___________ on outside of each container shipped - (pre-production).

p Green labels marked ___________ on outside of each container shipped - (production).

q Sub-component approvals (warrants, MATSPC, etc).

r Early production containment is required for 45 days after Start of Production.

s Other requirements:

These requirements have been reviewed by Hi-Stat quality representative for product approval.

Submission is:

Other Notes:

Hi-Stat Quality Representative Date

Submit package to the attention of:

Manufacturing Floor Plan must illustrate entire manufacturing process from receiving of raw materials through shipping operations.

Packaging design form (carton and pallet size, cartons per pallet, parts per carton, expendable vs. returnable).

Customs Documentation (see Hi-Stat Supplier Manual, Section XI, Miscellaneous, Paragraph D, Customs Documentation) if applicable.

If any requirements cannot be met by the supplier, it is the supplier's responsibility to complete and submit a request for Deviation/Waiver with the package, detailing the deviation request and number of parts effected and/or length of time needed.

Bob DoeringAPQP Engineer

Hi-Stat Mfg. - A Division of Stoneridge345 South Mill Street

Lexington, Ohio 44904

Approved Interim Approval until: Rejected