Correction of a discrepancy on a previously Submission is required to correct any submitted part. A "discrepancy" can be related to: e The product performance against the customer requirements 0 Dimensional or capability issues 0 Supplier issues o Approval of a part replacing an interim approval Testing, including material, performance, or engineering validation issues 3.
Engineering change to design records, Submission is required on any engineering specifications, or materials for production change to the production productlpart design record.
Additionally, for Bulk Materials: 4. Process technology new to the organization, not previously used for this product. Level 2 Wai-sant with product samples and limited supporting data submitted to the customer. Level 3 Warrant with product samples and complete suppoi-ting 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. See RetentiodSubmission Requirements Table 4. The organization shall use level 3 as the default level for all subinissions unless othenvise specified by the authorized customer representative.
I: The authorized customer representative may identify a submission level, different from the default level, that is to be used with each organization, or organization and customer part number combiliation.
Different customer locations may assign different submission levels to the same organization manufacturing location. NOTE 2: All of the f o r m referenced in this document may be replaced by computer-generated facsimiles. Acceptability of these facsimiles is to be confirmed with the authorized customer representative prior to the first submission. Upon approval of the submission, the organization shall assure that future production continues to meet all customer requirements.
NOTE: For those organizations that have been classified as "self certifying" PPAP submission level 1 by a specific customer, submission of the required organization-approved documentation will be considered as customer approval unless the organization is advised otherwise. The organization is therefore authorized to ship production quantities of the product, subject to releases from the customer scheduling activity.
Interim Approval will only be granted when the organization has: 0 clearly defined the non-compliances preventing approval; and, c prepared an action plan agreed upon by the customer. PPAP re-submission is required to obtain a status of "approved.
Note 2: Parts with a status of "Interim Approval" are not to be considered "Approved. No additional shipments are authorized unless an extension of the interim approval is granted. For bulk materials, the organization shall use the "Bulk Material Interim Approval" form, or its equivalent see Appendix F.
The submission shall be approved before production quantities may be shipped. Part Name and 2a. Customer Part Number: Engineering released finished end item part name and number. Org, Part Number: Part number defined by the organization, if any. Shown on Drawing Number: The design record that specifies the customer part number being submitted. Safety andlor Government Regulation: "Yes" if so indicated by the design record, otherwise "No.
Weight: Enter the actual weight in kilograms to four decimal places unless otherwise specified by the customer. Checking Aid Number, Change Level and Date: If requested by the customer, enter the checking aid number, its change level and date. Street Address, Region, Postal Code, Country: Show the complete address of the location where the product was manufactured. For "Region," enter state, county, province, etc. Customer NameIDivision: Show the corporate name and division or operations group.
Application: Enter the model year, vehicle name, engine, transmission, etc. If submitted via other customer format, enter the date customer confirmation was received. Check the appropriate box es. For bulk materials, in addition to checking the appropriate box, check "Other" and write "Bulk Material" in the space provided. Check the appropriate boxes for dimensional, material tests, performance tests, appearance evaluation, and statistical data.
Check the appropriate box. If "no," enter the explanation in "comments" below. Enter the number of pieces manufactured during the significant production run. Enter the time in hours taken for the significant production run. Attach additional information as appropriate.
Part Name Cust. Part Number Shown on Drawing No. Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location. I further affirm that these samples were produced at the production rate of 24 ours 1 also certify that documented evidence of such compliance is on file and available for review.
FAX No. Weight kg I Checking Aid No. Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer.
I also certify that documented evidence of such compliance is on file and available for review. Drawing Number: Use the number of the drawing on which the part is shown if different from the part number. Part Name: Use the finished part name on the part drawing. Organization Name: Organization responsible for submission include supplier if applicable.
Manufacturing Location: Location where part was manufactured or assembled. SupplierNendor Code: Customer-assigned code for organization location where the part was manufactured or assembled. Reason for Submission: Check box es explaining the reason for this submission.
Color Suffix: Use alphanumeric or numeric color identification. Tristimulus Data: List numerical colorimeter data of submission part as compared to the customer-authorized master.
Master Number: Enter alphanumeric master identification not used by Ford. Master Date: Enter the date on which the master was approved. Material Type: Identify first surface finish and substrate e. Material Source: Identify first surface and substrate suppliers. Example: RedspotIDow. Color Shipping Suffix: Color part number suffix or color number.
Part Disposition: To be determined by customer approved or rejected. Comments: General comments by the organization or customer optional. Organization Signature, Phone No. Organizations are responsible for applying PAP to their suppliers of ingredients which have organization-designated special characteristics.
Any customer-specific requirements shall be documented on the Bulk Materials Requirements Checklist. Primary Responsibility - Customer: Identify by name or function the individual who will review and approve the element. Primary Responsibility - Organization: Identify by name or function the individual who will assemble and assure the completeness of the element to be reviewed.
Approved by: Enter the initials of the authorized customer representative who has reviewed and accepted the element. Plan agreed to by: Identify the individuals and their functions who made and agreed upon the project plan. Use of these suggestions will arsive at the same end point of a completed Design FMEA, but with greater applicability to bulk materials.
The Design Matrix detennines the complex interactions of fomula ingredients, ingredient characteristics, product characteristics, process constraints, and conditions for customer use.
Along the vertical axis, list the design iteins as Potential Causes CategoryICharacteristics : Formula Ingsedients o Ingredient Characteristics Product Characteristics Process Constraints Conditions for Use customer process constraints For each design item, enter the current robust threshold range levels and units.
Correlate the potential causes to the potential failure modes using a number, letter, or symbol representing the impact or strength of the relationship. Ask what would happen if a potential cause item is allowed to go under or over its robust minilnuin or maximum, respectively. After completion of the ranlcings in the Design Matrix, review the categorylcharacteristics for a preliminary assessment of Special Characteristics.
Designate any Special Characteristics in colu1m 1. List Effects of Failure Consumer Effects - General teims identifying the loss experienced by the ultimate user of the product e.
The following figure provides a guideline for severity rankings. If your situation only uses a small portion of the scale then develop your own scale to improve the differentiation. If yous situation is greater than two tiers back from the final consumer, then the guideline figure should be adjusted to reflect the effects that will be felt by your customer's customer.
Mechanisms are generally described as over or under a certain threshold. These thresholds define the boundaries of the product approval and subsequent requirements for change notification. The following step provides an alternate method for assigning Occurrence ratings. Rank Occurrence - the ranking scale in the Potential Failure ode and Effects Analysis manual difficult to relate to bulk materials and generally results in very low numbers with little differentiation the ultimate risk.
The following matrix is recommended as a replacement. It evaluates the frequency occurrence based upon observed evidence the formulator has in the design. Similar Experience: Based upon similar products or processes and the potential failure model. Assumption: Based upon a clear understanding of the chemical impact of the material and the potential failure mode. Frequency ranking clarifications: High is defined as - Repeated failures Moderate is defined as - Occasional failures Low is defined as - Relatively few failures F.
Variation of supplier specifications. Design controls identified by a number should be available so that the relevant content of that control cs be understood. The next step provides an alternate method for assigning Detection rankings. Rank Detection - the ranking scale in the Potential Failure Mode and Effects Analysis manual difficult to relate to bulk materials and generally results in very low numbers with little differentiation the ultimate risk.
The following matrix may be used. It evaluates the Detection as the ability of tl. AssuinptiodExperience: Infonnationldata based upon similar products or processes. May cause serious disruption to subsequent processing of the product or result in the product failing to meet its sales specifications.
Will result in a customer complaint and product return. Moderate: Failure causes some customer dissatisfactioii and may result in a customer complaint or limitation on shelf life. The customer may need to make modifications or adjustments to their process to accommodate the material. The problem is liltely to be detected as part of an incoming inspection or prior to use 4.
The problem will be detected during processing 5. The problem will be detected in subsequent processing steps 6. Low: Failure causing only a slight customer annoyance. Customer will notice only a slight deterioration or inconvenience with the product or processing of the product. Minor: Reasonable to expect that the minor nature of this failure would not cause any real effect on the product or its processing by the customer.
Customer will probably not even notice the failure. Additional process steps are developed to deal with the failures. I High: Similar processes have experienced repeated failures. The process is not in statistical control. Low: Similar processes have experienced isolated failures. I 2 Remote: Failure is unlikely. No failures ever associated with almost identical processes. The process is in statistical control.
Absolute Certainty of Non-Detection: Controls will not or cannot detect the existence of the defect. Low: Controls may detect the existence of the defect, but detection may not occur until packaging is underway. Moderate: Controls likely to detect the existence of the failure, but not until lot acceptance testing has been completed.
Tests with a higher degree of variability will have the higher ranking. In-Process testing is used to monitor the manufacturing process. Important raw materials are controlled via organization specifications. UVA intended. These are not necessarily intended to be Special Characteristics.
During the design phase, the Examples of manufacturing product characteristics can be process parameters control controls for final product characteristics are: temperature, attributes. This does not imply pressure, mix rate, test protocol. During manufacture of the bullc material, process parameters are the control characteristics. Control Characteristic Mfg. Prototype when required - A listing of tests, evaluations and their associated specificationsltolerances used to assess an experimental or developmental formulation.
This may be the only control plan that is product specific. Pre-launch - Documentation of the productlprocess control characteristics, process controls affecting Special Characteristics, associated tests, and measurement systems employed during product scale up and prior to noi-mal production. Additional items may be included at the Organization's discretion.
Bulk materials often require further processing after sampling in order to make a measurement. Measurements are often destructive in nature and this prevents retesting the same sample. Measurement variability is often imch larger for properties important in the process industries e. Standardized test methods e. MSA studies are not required where standardized tests are used, however it is still important for thc organization to understand the measurement component of variation in the test methods used.
Customer agreement on the actual requirements for MSA for either non-standard test methods or "new-to supplier" test methods should be obtained during the planning phase. Any MSA studies should be applied to each test method associated with Special Characteristics, and no to each individual product measured by the test method. Therefore, the MSA studies should be conductec as broadly as possible across all products which use a particular test method.
If the resulting variability i unacceptable, then either the studies should be conducted on a narrower class of products or action shoulc be taken to improve the test method. The manufacture of bulk materials consists of industries which span a variety of production processe: from high volume products to specialty products produced in small quantities no more than once or twic per year.
Often the production process is completed or already in place before sufficient samples can b tested. By the time the product is made again, personnel andlor equipment may have changed. Alsc these processes have numerous input variables, many control variables, and a variety of produt variations. The effects and relationships between all thes variables and controls are also not usually known without error.
Multiple processes are usual1 interconnected, sometimes with feedback loops. There are also timing considerations and delays i reaction time. Further, measurements of component variables are generally less precise tha measurements of component parts, such that in many cases correlated variables must be used.
The requirements for master sample or equivalent shall be agreed by the customer and organization. Physical Sample: Some bulk materials are stable and unchanging over an extended period of time e. In this case, a physical sample will serve as a Master Sample. Analytical Sample Record: Other bulk materials change with time, but can be precisely quantified by appropriate analytical techniques.
In this case the analytical record e. This record provides an "audit trail" to the information which may be stored in various documents and or electronic systems. The following is the basic information suggested to accomplish this task: The quantity of product produced. The critical equipment required to manufacture the bulk material. AB CD Control temperature of mix.
Not to exceed O F. If a customer agrees that PPAP is not required, no warrant needs to be prepared. The information required by the Submission Warrant which does not apply to bulk material e.
For those organizations that have been classified as "self certifying" by a specific customer, subniission of a warrant signed only by the organization shall be evidence of PPAP approval, unless the organization is advised otherwise. For all other organizations, evidence of PPA approval shall be a warrant signed by both the authorized customer representative and organization or other customer approval documents.
Most products will achieve approval prior to initial use. In cases where approval callnot be obtained, a "Bulk Material Interim Approval" may be granted. A form is shown on the facing page; other forins may be used. Why won't this happen again? This connection defines the interaction of specific customer plant processing steps with Special Characteristics and final product attributes of the bulk material. This interaction is especially significant when bulk materials undergo chemical or physical transfoimation s.
For bulk materials, conducting the steps outlined in this "Customer Plant Connection" is highly recommended. This may not be applicable to all bulk materials i. It is recognized by the organization that it is their responsibility to deliver the product to the customer with the characteristics of the bulk material per organization and customer agreement.
During the transformation from bulk product to final product, both bulk product characteristics and final product attributes may be impacted by customer process controls. Since the product is frequently two products bulk and finished , there is a shared responsibility for the final product attribute. For example, percent solids and viscosity of a bulk coating which impacts the final coating's film build attribute, may be affected by the customer's mix room percent solvent reduction.
The percent reduction process parameter may therefore be controlled to aid in control of film build. The process steps at customer plants may be matrixed versus the Special Characteristics determined jointly by the organization and the customer.
The Special Characteristics may then be determined, and be included in a Control Plan for the customer process. These special control characteristic items inay be monitored and continuously improved. Assemble cross-functional teains of customer personnel for each customer process area.
Include appropriate organization representatives on each team. Select Champions for each team - these are the customer process owners i. Define critical customer handling, application steps and process parameters in each area. Also review the desired final product attributes for items needing control. From 4, develop a list of Special Characteristics and Attributes.
Construct a Customer Process Matrix, using 3 as the top, and 5 as the side of a matrix. Prepare a Control Plan for each affected customer process area. Monitor and record all Special Characteristics by appropriate means control charts, checklists, etc. Ensure stability of Special Characteristics and continuously improve where possible. Performance testing, based upon design requirements used by each OEM to select tire construction technical approval , 1-educesthe need to repeat all tests during confisrnation tests are specified by each OEM.
Most designs are basic to the organization's process. All additional molds shall be certified by the organization's internal certification criteria and documentation. NOTE 4: For tires, tooling is defined as the tire mold. This definition of tooling applies to all uses of "tooling" within PPAP. Testing is applicable only to finished tires and not to raw materials.
Tire industry practice does not require chemical, physical, or metallurgical testing. Material test results are not required for PPAP. Tire uniformity force variation and balance are designated Special Characteristics. Master samples are not retained. Checking Aids see 2. AP Submission Warrant see 2. Part Weight Mass Reference 2. The average is reported on the PSW to four 4 decimals xx. An organization supplying to subscribing truck OEMs shall comply with the requirements in this Appendix or use guidance herein for clarification of.
The following additional requirements are added: The Customer has the right to request a at any time to re-qualify a production component.
Feature Base Process or Past Number Generated components are qualified using the highest content configuration to qualify the master part number.
All other configurations may be approved with the submission of a PSW linking the new part number with the master past number. For bulk material and standard catalog pasts, the organization shall formally qualify their product to their design record and submit a PSW when requested by the customer.
It is important that adequate quantities of parts be manufactured during this run to confirm the quality and capability of production process at rate prior to full production. It is recognized that in low volume applications, sample sizes as small as 30 pieces may be utilized for preliminary process capability studies. When perforning the Significant Production Run, all aspects of variability within the production process should be considered and tested where practicable, e. If projected volumes are so low that 30 samples are not attainable prior to production, interim PAP approval lnay be granted.
Once the 30 consecutive production samples are produced, measured, and the quality index calculated and accepted, then the interim approval is changed to approved. These unique numbers shall be entered onto the dimensional or test results sheet as applicable, and actual results entered onto the appropriate sheets. The organization shall also identify the print zone for each numbered characteristic as applicable.
These studies could be augmented or replaced by long-term results from the same or similar process run on the same equipment with prior customer concurrence. Master Sample see 2.
Part Submission Warrant see 2. OKg, To determine part weight, the organization shall individually weigh ten randomly selected parts, and calculate and report the average weight. At least one part shall be measured from each cavity, tool, line, or process used in product realization. Customer Notification see 3.
The customer may subsequently elect to require a submission for PPAP approval. Organizations supplying to subscribing truck OEMs are required to complete the Product Process Change notification form to advise of forthcoming process or proprietary product changes. Past Name: Engineering released finished end itein part name. Customer Part Nuinber s : Engineering released finished end itein part number. Who normally works with the customer? There is no standard for who interfaces with the customer for PPAPs.
Your organization can decide. Ideally you don't want too many people contacting them though Thanks again. The customer's approval of the warrant would be the waiver of the other PPAP requirements. If not Ford, find out your customer requirements and contact the appropriate contact. Sales may be able to handle it. But whichever way you go make sure you get a customer signature and date or it could come back to haunt you later.
Many years ago I was out in the plant with a GM engineer and he was reviewing how our parts fit the car. He wanted to make a minor change on our part and told me what to do, and we made the change. Later a GM QC guy came in and said we didn't comply with the print because of the change.
I told him the GM engineer told us to make the change, and he asked to see the marked and signed print showing the change. Medical has no PPAP process as such in ISO but some of the large American medical companies are using the term now, so I guess it is better to be proactive and implement first before they tell you what you must do. I am extraordinarily patient provided I get my own way in the end. Good idea. Inspection Plan - What exa ctly is the difference dear sir we need version-4 control plan excel format.
The forms are in post 1 or just click here. There is no actual requirement but if they are radically different they might cause eyebrows to raise. Is it only PPAP for this companies? Best regards No, these forms can be used by all automotive supplier companies and customers. The "big" three: Ford, Chrysler and GM originally designed these forms. Best regards These are the "originals" a lot of companies put there own logo instead.
Please let me know, 'cause one customer is asking for such form and is something new for us. Thanks a lot for any help. I have att ac hed my modified version cre ated in Excel but saved as so it should work.
Hi Murray, Do you have a completed form as an example so that I can understand the formulas! I have attacehd a completed GRR so you can see how it works, any queries just shout. Life and death is in the power of the tongue. They are not required to be PPAPed They may only run as needed I also need to know about Factory as sist parts. We get factory assist but they may only run 3 times Thank you. The time now is PM. All times are GMT We are m aking such material available in our efforts to advance understanding of environmental , pol itical, human rights, econom ic, dem ocracy, scientific, and social j ustice i ssues, etc.
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