Ppap Templates 6b6727
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PPAP Submission Date Initiated: Part Name Part Number Purchase Order # Engineering Change Level Engineering Change Level Date Supplier Name Street Address City State Zip Phone Number Supplier
PPAP Submission Level Guide Quick reference Level 4
- Will be defined by ACTIA during the PPAP request
Level 4a
- Predetermined by ACTIA
Level 4b
- Predetermined by ACTIA
1
Part Submission Warrant (PSW)
Level 5
Level 4b
Level 4a
Level 4
Level 3
Level 2
PPAP Requirements AIAG PPAP Fourth Edition
Level 1
Element Order
The additional comments below are only an ACTIA summary of AIAG manual. Refer to AIAG Manual current edition for complete information.
X X X * X X X
Required Documents
Additional Comments
ACTIA PSW only
Upon completion of all PPAP requirements, the organization shall complete the Part submission warrant (PSW). If production parts will be produced from more than one cavity, mold, tool die, pattern, or Production process e.g., line or cell, the organization shall complete a dimensional evaluation on one part from each . These specifics cavities, molds, line, etc..., shall then be identified in the "Mold/Cavity/Production Process" line on a PSW, or in a PSW attachment. A responsible official of the organization shall approve the PSW and provide information.
2
Design Records & Bubbled part print(s).
X X * X X X
ACTIA design record bubbled
The organization shall have the design record for the saleable product/part, including design records for components or details of the saleable product / part. Where the design record is in electronic format, e.g., CAD/CAM math data, the organization shall produce a hard copy (e.g., pictorial, geometric dimensioning & tolerancing (GD&T) sheets, drawing) to identify measurements taken.
3
Authorized Engineering Change Documentation
X X * X X X
Various engineering documentation
The organization shall have any authorized engineering change documents form those changes not yet recorded in the design record but incorporated in the product, part or tooling.
4
Customer Engineering Approvals
X *
X X
Customer engineering approval proof
Where specified by the customer, the organization shall have evidence of customer engineering approval.
5
Design FMEA,
X *
X
Can be ACTIA DFMEA Format or an AIAG compliant DFMEA.
The product design-responsible organization shall develop a Design FMEA in accordance with and compliant to, customer specified requirements.(e.g., potential Failure Mode and Effects Analysis reference manual)
6
Process Flow Diagrams
X *
X X
Any standard flowchart format.
The organization shall have a process flow diagram in an organizationspecified format that clearly describes the production process steps and sequence, as appropriate, and meets the specified customer needs, requirements and expectations (e.g., Advanced Product Quality Planning and Control Plan reference manual). For bulk materials, an equivalent to a process Flow Diagram is a Process Flow Description.
7
Process FMEA
X *
X
Can be ACTIA PFMEA Format or an AIAG compliant PFMEA.
The organization shall develop a process FMEA in accordance with and compliant to, customer-specified requirements, (e.g., Potential Failure Mode and Effects Analysis reference manual)
8
Control Plan
X *
X X
Can be ACTIA format or AIAG compliant format.
The organization shall have a control plan that defines all methods used for process control and complies with customer-specified requirements (e.g., Advanced Product Quality Planning and Control Plan reference manual).
9
Measurement System Analysis Studies
Not required by ACTIA
The organization shall have applicable Measurement System analysis studies, e.g., gage R&R, bias, linearity, stability, for all new or modified gages, measurement, and test equipment.( see the Measurement Systems Analysis reference manual)
X *
X
10
11-1
11-2
12
13
Dimensional Results
Material Test Results and Performance test result and related design notes
Performance Test Results
Initial Process Study (k) Capability Studies
Qualified Laboratory Documentation
14
Appearance Approval Report
15
Sample Product Parts
X X * X X X
The organization shall provide evidence that dimensional verifications required by the design record and the Control Plan have been completed and result indicate compliance with specified requirements. The organization Can use ACTIA Format or shall have dimensional results for each unique manufacturing process, e.g., an AIAG compliantformat cells or production lines and all cavities, molds, patterns or dies. The for dimention report organization shall record , with the actual results : all dimensions (except reference dimensions), characteristics, and specifications as noted on the design record and Control Plan. The organization shall identify the parts measured.
X X * X X X
Industry Standard reports or test result formats designated by ACTIA.
Material test results shall indicate and include : 1) The design record change level of the parts tested; 2) Any authorized engineering change documents that not yet been incorporated in the design record; 3) The number, date, and change level of the specification to which the part was tested; 4) the date on which the testing took place; 5) the quantity tested; 6) the actual results; 7) The material supplier's name and, when required by the customer, the customer-assigned supplier/vendor code.
Industry Standard reports or test result formats designated by ACTIA .
The organization shall perform tests for all part(s) or product material(s) when performance or functional requirements are specified by the design record or Control Plan. Performance test results shall indicate and include : 1) The design record change level of the parts tested; 2) Any authorized engineering change documents that not yet been incorporated in the design record; 3) The number, date, and change level of the specification to which the part was tested; 4) the date on which the testing took place; 5) the quantity tested; 6) the actual results;
X X * X X X
X *
X
Process Capability Study using any statistical package or ACTIA Capability Form.
The level of initial process capability or performance shall be determined to be acceptable prior to submission for all Special Characteristics designated by the customer or organization. The organization shall obtain customer concurrence on the index for estimating initial process capability prior to submission. - Where no special characteristics have been identified, the customer reserve the right to require demonstration of initial process capability on other characteristics. Index > 1.67 : the process currently meets the acceptance criteria. 1.33=< Index =< 1.67 : the process may be acceptable. the authorized customer representative for review of the study results. Index <1.33 : Process does not currently meet the acceptance criteria. the authorized customer representative for a review of study results.
X X * X X X
Inspection and testing for PPAP shall be performed by qualified laboratory as defined by customer requirements (e.g. an accredited laboratory). the qualified laboratory (internal or external to the organization) shall have a laboratory scope and documentation showing that the laboratory is qualified Lab Scope and outside lab for the type of measurements or tests conducted. proof of accreditation. When an external/Commercial laboratory is used, the organization shall submit the test results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that performed the tests, the date(s) of the tests, and the standards used to run the tests shall be
X X X * X X X
A separate Appearance Approval Report (AAR) shall be completed for each part or series of part if the product/part has appearance requirements on the design record. Upon satisfactory completion of all required criteria, the organization shall record the required information on the AAR. The completed AAR and representative production product/part shall be submitted to the location specified by the customer to receive disposition. AARs (complete with part disposition and authorized customer representative signature) shall then accompany the PSW at the time of final submission based upon the submission level requested.
X X * X X X
ACTIA format or AIAG format
Upon ACTIA requirements The organization shall provide sample product as specified by the customer.
16
Master Samples
* X X X
The organization shall retain a master sample for the same period as the production part approval records, or a) until a new master sample is produced for the same customer part number for customer approval, or b) where a master sample is required by the design record, Control Plan or inspection criteria, as a reference or standard. The master sample shall be identified as such, and shall show the customer approval date on the Uppon Actia requirements sample. The organization shall retain a master sample for each position of a multiple cavity die, mold tool or pattern, or production process unless otherwise specified by the customer. When part size , sheet volume of parts, etc. makes storage of a master sample difficult, the sample retention requirements may be modified or waived in writing by authorized customer representative.
17
Checking aids
* X X X
Part specific assembly or checking aids
If requested by customer, the organization shall submit with the PPAP submission any pert specific assembly or component checking aid.
18
Customer specific requirements
To submit for PCA suppliers only
The organization shall have records of compliance to all applicable customerspecific requirements. For bulk materials, applicable customer-specific requirements shall be documented on the Bulk Material Requirement Checklist.
* X X
PPAP SAMPLE PARTS - LABEL Send identified sample(s). Each sample used for PPAP must be clearly identified with their identification number corresponding with data. Please complete, print in color and attach this page on the outside of each package in plain view of a fork lift/material handler/operator. Put the Packing slip pocket near the label. In the event parts are “Loose” shipped, a label should be placed on each part. This would apply to parts laying on pallets also. Label on a Painted Part must be wire tied or attached in a way painted surface is protected from label adhesion.
PPAP SAMPLE PARTS INSPECTION VERIFICATION REQUIRED Purchase Order#:
0
Part Number:
0
Revision Level:
0
Supplier Name:
0
Page 7 of 26
Potential Failure Modes and Effects Analysis Design FMEA FMEA Number Prepared By FMEA Date (Orig.) FMEA Date
Part # Part Name Rev # Process Responsibility
Item Number
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Item/ Function
Requirements
Potential Potential Effects Failure Mode of Failure
S E V
C l a s s
Current Product Controls Potential Cause(s)/ Failure Mechanisms
O C C
Prevention
Detection
Action Results D E T
R P N
Responsibility Recommended and Action(s) Completion Date
Actions Taken
S E V
O C C
Page 8 of 26
Potential Failure Modes and Effects Analysis Design FMEA FMEA Number Prepared By FMEA Date (Orig.) FMEA Date
Part # Part Name Rev # Process Responsibility
Item Number
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Item/ Function
Requirements
Potential Potential Effects Failure Mode of Failure
S E V
C l a s s
Current Product Controls Potential Cause(s)/ Failure Mechanisms
O C C
Prevention
Detection
Action Results D E T
R P N
Responsibility Recommended and Action(s) Completion Date
Actions Taken
S E V
O C C
Page 9 of 26
esults D E T
R P N
Page 10 of 26
esults D E T
R P N
Process flow Part # Part Name Rev # Process Process No.
10
20
30
40
50
60
0 0 0
Control plan Number Prepared By Control plan Date (Orig.) Control plan Date Operation
Transport
Inspect
Store
Idle
Page 12 of 26
Potential Failure Modes and Effects Analysis Process FMEA Part # Part Name Rev # Process Responsibility
FMEA Number Prepared By FMEA Date (Orig.) FMEA Date
Process Number
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Process/Step Function
Requirements
Potential Potential Effects Failure Mode of Failure
C S l E a V s s
Current Process Controls Potential Cause(s)/ Failure Mechanisms
O C C
Prevention
Detection
Action Results D R E P T N
Responsibility Recommended and Action(s) Completion Date
Actions Taken
S O D E C E V C T
R P N
Page 13 of 26
Potential Failure Modes and Effects Analysis Process FMEA Part # Part Name Rev # Process Responsibility
FMEA Number Prepared By FMEA Date (Orig.) FMEA Date
Process Number
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Process/Step Function
Requirements
Potential Potential Effects Failure Mode of Failure
C S l E a V s s
Current Process Controls Potential Cause(s)/ Failure Mechanisms
O C C
Prevention
Detection
Action Results D R E P T N
Responsibility Recommended and Action(s) Completion Date
Actions Taken
S O D E C E V C T
R P N
Control Plan Prototype
Pre-Launch
Control Plan Number Part Number 0 Core Team
Production
Key / Phone Latest Change (Rev) Level 0
Date (Orig.)
Part Description
Current Release Level
Current Release Date
Plant Location 0 Supplier Name
Quality Department Approval
METHODS
CHARACTERISTICS
NO.
PRODUCT
PROCESS
PRODUCT / SPECIAL PROCESS / CHAR. SPECIFICATION / CLASS TOLERANCE
SAMPLE EVALUATION/ MEASUREMENT TECHNIQUE
FREQ
MACHINE DEVICES / PROCESS JIG / TOOLS FOR NAME / MANUFACTURING OPERATION DESCRIPTION
SIZE
PART / PROCESS NUMBER
0
CONTROL METHOD
REACTION PLAN
Page 14 of 26
DIMENSIONAL RESULT Part name Part number: Revision #
0 0 0
Tooling num Cavity # Sample size :
Cavity number:
Check by:
Gauge Type
Specification
Low. tol.
Upp. tol.
# Insp out Pts of Sample 2 Sample 3 tol
Actual measurements Sample 1
Result
Bubble #
Total # of measurements taken = 0 Total # of measurements within in spec = 0 % of measurements meeting spec = #DIV/0!
comment
Specification
Low. tol.
Upp. tol.
# Insp out Pts of Sample 2 Sample 3 tol
Actual measurements Sample 1
Result
Bubble #
Gauge Type
comment
Part Submission Warrant 0 Part Name Safety and/or Government Regulation
Part Number 0 Yes
No
0
Engineering Drawing Change Level
Dated
Additional Engineering Changes
Dated
Shown on Drawing no. Checking Aid No.
Weight (kg)
Engineering Change Level
ORGANIZATION MANUFACTURING INFORMATION 0 Supplier Name 0 Street Address 0 0 0 State Zip City Note:
0
Purchase order No.
Dated
CUSTOMER SUBMITTAL INFORMATION Customer Name / Division Buyer Name/Code Application
Does this part contain any restricted or reportable substances
Yes
No
N/A
Are plastic parts identified with appropriate ISO marking codes
Yes
No
N/A
REASON FOR SUBMISSION Initial Submission Engineering Change(s) Tooling: Transfer, Replacement, Refurbishment, or additional Correction of Discrepancy Tooling Inactive > than 1 year
Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part processing Parts Produced at Additional Location Other - please specify
REQUESTED SUBMISSION LEVEL (Check one) Level 1
-
Warrant, only (and for designated items, an Appearance Approval Report) submitted to customer.
Level 2
-
Warrant with product samples and limited ing data submitted to customer.
Level 3
-
Warrant with product samples and complete ing data submitted to customer.
Level 4
-
Warrant and other requirements as defined by customer. Include Level (4a) and (4b) predefined in ACTIA procedure.
(Check) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Level 5 - Warrant with product samples and complete ing data reviewed at supplier's manufacturing location. SUBMISSION RESULTS The results for dimensional measurements material and functional tests appearance criteria statistical process package These results meet all drawing and specification requirements: Yes No (If "No" - Explanation Required) Mold / Cavity / Production Process: DECLARATION I hereby affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable Production Part Approval Process Manual 4th Edition Requirements. I further warrant these samples were produced at the production rate of / 8 hours. I have noted any deviations from this declaration below. EXPLANATION/COMMENTS: Print Name
Title
Phone No.
Supplier Authorized Signature
FAX No. Date
FOR ACTIA USE ONLY (IF APPLICABLE) Part Warrant Disposition: Rejection/Other Comments:
Customer Name
APPROVED
REJECTED
OTHER
Customer Signature
Date
Production Part Approval Material Test Results and Related Design Record Notes PART NUMBER: PART NAME:
0
DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE DOCUMENTS date:
0
0 1/0/1900
NAME of LABORATORY: Bubble #
MATERIAL SPEC. NO. / REV / DATE
SPECIFICATION / LIMITS
TEST DATE
QTY. TESTED
SUPPLIER TEST RESULTS (DATA)
OK
NOT OK
Blanket statements of conformance are unacceptable for any test results. SIGNATURE
TITLE
DATE
Production Part Approval Performance Test Results and Related Design Record Notes PART NUMBER: PART NAME: Bubble #
TEST SPECIFICATION / REV / DATE
0
DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE DOCUMENTS DATE:
0 SPECIFICATION / LIMITS
TEST DATE
0 1/0/1900
QTY. TESTED SUPPLIER TEST RESULTS (DATA) / TEST CONDITIONS
SIGNATURE
TITLE
OK
DATE
NOT OK
INITIAL SAMPLES CAPABILITY REPORT Part Name : Part number : Drawing number : Tool number : Cavity number : Check by : Inspection date :
0 0 0
Revision #
Gauge type
Comments :
0
0
k
Average
Maxi.
Mini
Range
0.00
0.00
0.000
Out of spec. 0
0
0
0
0
0 0.000
0
0.000
0
0.000
0
0.000
0
0.000
0
0.000
Histogram
0.000
1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0
Cat. nbr. 10
Std. deviation
0.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Ok Out
Sample size 30
0.000
Data
Upp. dim.
0.000
N°
Low. dim.
QTY
Nominal. Low. Upp. dim. tol. tol.
Inch
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
ACTIA Corporation APPEARANCE APPROVAL REPORT Part number 0
Revision level
0
ECN change 0 level date
Supplier name
0
PPAP ELEMENTS 1
COLOR
N/A
2
BRILLANCE
N/A
3
GLOSS
N/A
4
GRAIN
N/A
5
TRANSPARENCY
N/A
6
SINK MARK
N/A
7
WELDING LINES
N/A
8
INJECTION GATE
N/A
9
KNIT LINE MARK
N/A
10
EJECTOR MARKS
N/A
11
PAINT
N/A
12
MARKING AND DECORATION (Silk-screen printing, Pad printing)
N/A
14
Approved Sample Matched
N/A
ACCEPTED
0
APPLICABLE
Part Name
COMMENTS
ACTIA Special requirement Bill Of Material review (Applicable for PCA only) Supplier
0
Part name
0
Part #
0
Revision level
0
Bubble Number on BOM
Is component present?
Is component orientation correct?
Bubble Number on BOM
Is component present?
Is component orientation correct?
Document Number:
SUPPLIER DEVIATION REQUEST ACTIA SUPPLIER TO COMPLETE Supplier Name: 0 Date:
Part Number: 0 P.O.#
P.O Qty
Qty Produced
Part Name: 0 Name: EMAIL:
Scheduled Delivery Date
Type of deviation: Limited Qty Limited Time
Quantity: From:
PO's affected: PO's affected:
To:
Permanent
Reason: (Please include a physical sample or picture depicting the deviation to be approved.)
How does this deviation affect the scheduled delivery date of the product?
Date approval needed to meet scheduled delivery date? Submit this deviation request to ACTIA Purchasing ACTIA PURCHASING TO COMPLETE Add the document number and forward to ACTIA Engineering and Quality.
Date product needed to meet order dates? Quantity needed to meet order dates?
ACTIA ENGINEERING AND QUALITY TO COMPLETE
Approved by: Engineering: Quality:
No ACTIA customer approval required - No customer specification or drawing requirements.
Submitted:
ACTIA customer approval/PPAP submission required.
Yes
Date:
By:
Date:
**
No
Add reason below:
Approved by: Engineering: Quality:
** Please provide the customer approval for this deviation.
Name:
Name:
Date:
ACTIA ENGINEERING TO COMPLETE REJECTED APPROVED* Limited Qty
Limited Time Permanent
Reason: By: Quantity: From: ECN #:
Date:
To:
PO's affected: PO's affected:
Comments:
Return this completed document to ACTIA Purchasing. * This approval is granted upon the understanding that it is advisory in nature and in no manner changes the Sellers original responsibility for insuring that all characteristics, designated in the applicable engineering specifications and/or inherent in the samples as originally tested and approved, are maintained.
Form 4.7.19
ACTIA PURCHASING FORWARD THIS COMPLETED DOCUMENT TO THE SUPPLIER Revision C
6-23-10
PPAP Submission Level Guide Quick reference Level 4
- Will be defined by ACTIA during the PPAP request
Level 4a
- Predetermined by ACTIA
Level 4b
- Predetermined by ACTIA
1
Part Submission Warrant (PSW)
Level 5
Level 4b
Level 4a
Level 4
Level 3
Level 2
PPAP Requirements AIAG PPAP Fourth Edition
Level 1
Element Order
The additional comments below are only an ACTIA summary of AIAG manual. Refer to AIAG Manual current edition for complete information.
X X X * X X X
Required Documents
Additional Comments
ACTIA PSW only
Upon completion of all PPAP requirements, the organization shall complete the Part submission warrant (PSW). If production parts will be produced from more than one cavity, mold, tool die, pattern, or Production process e.g., line or cell, the organization shall complete a dimensional evaluation on one part from each . These specifics cavities, molds, line, etc..., shall then be identified in the "Mold/Cavity/Production Process" line on a PSW, or in a PSW attachment. A responsible official of the organization shall approve the PSW and provide information.
2
Design Records & Bubbled part print(s).
X X * X X X
ACTIA design record bubbled
The organization shall have the design record for the saleable product/part, including design records for components or details of the saleable product / part. Where the design record is in electronic format, e.g., CAD/CAM math data, the organization shall produce a hard copy (e.g., pictorial, geometric dimensioning & tolerancing (GD&T) sheets, drawing) to identify measurements taken.
3
Authorized Engineering Change Documentation
X X * X X X
Various engineering documentation
The organization shall have any authorized engineering change documents form those changes not yet recorded in the design record but incorporated in the product, part or tooling.
4
Customer Engineering Approvals
X *
X X
Customer engineering approval proof
Where specified by the customer, the organization shall have evidence of customer engineering approval.
5
Design FMEA,
X *
X
Can be ACTIA DFMEA Format or an AIAG compliant DFMEA.
The product design-responsible organization shall develop a Design FMEA in accordance with and compliant to, customer specified requirements.(e.g., potential Failure Mode and Effects Analysis reference manual)
6
Process Flow Diagrams
X *
X X
Any standard flowchart format.
The organization shall have a process flow diagram in an organizationspecified format that clearly describes the production process steps and sequence, as appropriate, and meets the specified customer needs, requirements and expectations (e.g., Advanced Product Quality Planning and Control Plan reference manual). For bulk materials, an equivalent to a process Flow Diagram is a Process Flow Description.
7
Process FMEA
X *
X
Can be ACTIA PFMEA Format or an AIAG compliant PFMEA.
The organization shall develop a process FMEA in accordance with and compliant to, customer-specified requirements, (e.g., Potential Failure Mode and Effects Analysis reference manual)
8
Control Plan
X *
X X
Can be ACTIA format or AIAG compliant format.
The organization shall have a control plan that defines all methods used for process control and complies with customer-specified requirements (e.g., Advanced Product Quality Planning and Control Plan reference manual).
9
Measurement System Analysis Studies
Not required by ACTIA
The organization shall have applicable Measurement System analysis studies, e.g., gage R&R, bias, linearity, stability, for all new or modified gages, measurement, and test equipment.( see the Measurement Systems Analysis reference manual)
X *
X
10
11-1
11-2
12
13
Dimensional Results
Material Test Results and Performance test result and related design notes
Performance Test Results
Initial Process Study (k) Capability Studies
Qualified Laboratory Documentation
14
Appearance Approval Report
15
Sample Product Parts
X X * X X X
The organization shall provide evidence that dimensional verifications required by the design record and the Control Plan have been completed and result indicate compliance with specified requirements. The organization Can use ACTIA Format or shall have dimensional results for each unique manufacturing process, e.g., an AIAG compliantformat cells or production lines and all cavities, molds, patterns or dies. The for dimention report organization shall record , with the actual results : all dimensions (except reference dimensions), characteristics, and specifications as noted on the design record and Control Plan. The organization shall identify the parts measured.
X X * X X X
Industry Standard reports or test result formats designated by ACTIA.
Material test results shall indicate and include : 1) The design record change level of the parts tested; 2) Any authorized engineering change documents that not yet been incorporated in the design record; 3) The number, date, and change level of the specification to which the part was tested; 4) the date on which the testing took place; 5) the quantity tested; 6) the actual results; 7) The material supplier's name and, when required by the customer, the customer-assigned supplier/vendor code.
Industry Standard reports or test result formats designated by ACTIA .
The organization shall perform tests for all part(s) or product material(s) when performance or functional requirements are specified by the design record or Control Plan. Performance test results shall indicate and include : 1) The design record change level of the parts tested; 2) Any authorized engineering change documents that not yet been incorporated in the design record; 3) The number, date, and change level of the specification to which the part was tested; 4) the date on which the testing took place; 5) the quantity tested; 6) the actual results;
X X * X X X
X *
X
Process Capability Study using any statistical package or ACTIA Capability Form.
The level of initial process capability or performance shall be determined to be acceptable prior to submission for all Special Characteristics designated by the customer or organization. The organization shall obtain customer concurrence on the index for estimating initial process capability prior to submission. - Where no special characteristics have been identified, the customer reserve the right to require demonstration of initial process capability on other characteristics. Index > 1.67 : the process currently meets the acceptance criteria. 1.33=< Index =< 1.67 : the process may be acceptable. the authorized customer representative for review of the study results. Index <1.33 : Process does not currently meet the acceptance criteria. the authorized customer representative for a review of study results.
X X * X X X
Inspection and testing for PPAP shall be performed by qualified laboratory as defined by customer requirements (e.g. an accredited laboratory). the qualified laboratory (internal or external to the organization) shall have a laboratory scope and documentation showing that the laboratory is qualified Lab Scope and outside lab for the type of measurements or tests conducted. proof of accreditation. When an external/Commercial laboratory is used, the organization shall submit the test results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that performed the tests, the date(s) of the tests, and the standards used to run the tests shall be
X X X * X X X
A separate Appearance Approval Report (AAR) shall be completed for each part or series of part if the product/part has appearance requirements on the design record. Upon satisfactory completion of all required criteria, the organization shall record the required information on the AAR. The completed AAR and representative production product/part shall be submitted to the location specified by the customer to receive disposition. AARs (complete with part disposition and authorized customer representative signature) shall then accompany the PSW at the time of final submission based upon the submission level requested.
X X * X X X
ACTIA format or AIAG format
Upon ACTIA requirements The organization shall provide sample product as specified by the customer.
16
Master Samples
* X X X
The organization shall retain a master sample for the same period as the production part approval records, or a) until a new master sample is produced for the same customer part number for customer approval, or b) where a master sample is required by the design record, Control Plan or inspection criteria, as a reference or standard. The master sample shall be identified as such, and shall show the customer approval date on the Uppon Actia requirements sample. The organization shall retain a master sample for each position of a multiple cavity die, mold tool or pattern, or production process unless otherwise specified by the customer. When part size , sheet volume of parts, etc. makes storage of a master sample difficult, the sample retention requirements may be modified or waived in writing by authorized customer representative.
17
Checking aids
* X X X
Part specific assembly or checking aids
If requested by customer, the organization shall submit with the PPAP submission any pert specific assembly or component checking aid.
18
Customer specific requirements
To submit for PCA suppliers only
The organization shall have records of compliance to all applicable customerspecific requirements. For bulk materials, applicable customer-specific requirements shall be documented on the Bulk Material Requirement Checklist.
* X X
PPAP SAMPLE PARTS - LABEL Send identified sample(s). Each sample used for PPAP must be clearly identified with their identification number corresponding with data. Please complete, print in color and attach this page on the outside of each package in plain view of a fork lift/material handler/operator. Put the Packing slip pocket near the label. In the event parts are “Loose” shipped, a label should be placed on each part. This would apply to parts laying on pallets also. Label on a Painted Part must be wire tied or attached in a way painted surface is protected from label adhesion.
PPAP SAMPLE PARTS INSPECTION VERIFICATION REQUIRED Purchase Order#:
0
Part Number:
0
Revision Level:
0
Supplier Name:
0
Page 7 of 26
Potential Failure Modes and Effects Analysis Design FMEA FMEA Number Prepared By FMEA Date (Orig.) FMEA Date
Part # Part Name Rev # Process Responsibility
Item Number
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Item/ Function
Requirements
Potential Potential Effects Failure Mode of Failure
S E V
C l a s s
Current Product Controls Potential Cause(s)/ Failure Mechanisms
O C C
Prevention
Detection
Action Results D E T
R P N
Responsibility Recommended and Action(s) Completion Date
Actions Taken
S E V
O C C
Page 8 of 26
Potential Failure Modes and Effects Analysis Design FMEA FMEA Number Prepared By FMEA Date (Orig.) FMEA Date
Part # Part Name Rev # Process Responsibility
Item Number
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Item/ Function
Requirements
Potential Potential Effects Failure Mode of Failure
S E V
C l a s s
Current Product Controls Potential Cause(s)/ Failure Mechanisms
O C C
Prevention
Detection
Action Results D E T
R P N
Responsibility Recommended and Action(s) Completion Date
Actions Taken
S E V
O C C
Page 9 of 26
esults D E T
R P N
Page 10 of 26
esults D E T
R P N
Process flow Part # Part Name Rev # Process Process No.
10
20
30
40
50
60
0 0 0
Control plan Number Prepared By Control plan Date (Orig.) Control plan Date Operation
Transport
Inspect
Store
Idle
Page 12 of 26
Potential Failure Modes and Effects Analysis Process FMEA Part # Part Name Rev # Process Responsibility
FMEA Number Prepared By FMEA Date (Orig.) FMEA Date
Process Number
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Process/Step Function
Requirements
Potential Potential Effects Failure Mode of Failure
C S l E a V s s
Current Process Controls Potential Cause(s)/ Failure Mechanisms
O C C
Prevention
Detection
Action Results D R E P T N
Responsibility Recommended and Action(s) Completion Date
Actions Taken
S O D E C E V C T
R P N
Page 13 of 26
Potential Failure Modes and Effects Analysis Process FMEA Part # Part Name Rev # Process Responsibility
FMEA Number Prepared By FMEA Date (Orig.) FMEA Date
Process Number
Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"
Process/Step Function
Requirements
Potential Potential Effects Failure Mode of Failure
C S l E a V s s
Current Process Controls Potential Cause(s)/ Failure Mechanisms
O C C
Prevention
Detection
Action Results D R E P T N
Responsibility Recommended and Action(s) Completion Date
Actions Taken
S O D E C E V C T
R P N
Control Plan Prototype
Pre-Launch
Control Plan Number Part Number 0 Core Team
Production
Key / Phone Latest Change (Rev) Level 0
Date (Orig.)
Part Description
Current Release Level
Current Release Date
Plant Location 0 Supplier Name
Quality Department Approval
METHODS
CHARACTERISTICS
NO.
PRODUCT
PROCESS
PRODUCT / SPECIAL PROCESS / CHAR. SPECIFICATION / CLASS TOLERANCE
SAMPLE EVALUATION/ MEASUREMENT TECHNIQUE
FREQ
MACHINE DEVICES / PROCESS JIG / TOOLS FOR NAME / MANUFACTURING OPERATION DESCRIPTION
SIZE
PART / PROCESS NUMBER
0
CONTROL METHOD
REACTION PLAN
Page 14 of 26
DIMENSIONAL RESULT Part name Part number: Revision #
0 0 0
Tooling num Cavity # Sample size :
Cavity number:
Check by:
Gauge Type
Specification
Low. tol.
Upp. tol.
# Insp out Pts of Sample 2 Sample 3 tol
Actual measurements Sample 1
Result
Bubble #
Total # of measurements taken = 0 Total # of measurements within in spec = 0 % of measurements meeting spec = #DIV/0!
comment
Specification
Low. tol.
Upp. tol.
# Insp out Pts of Sample 2 Sample 3 tol
Actual measurements Sample 1
Result
Bubble #
Gauge Type
comment
Part Submission Warrant 0 Part Name Safety and/or Government Regulation
Part Number 0 Yes
No
0
Engineering Drawing Change Level
Dated
Additional Engineering Changes
Dated
Shown on Drawing no. Checking Aid No.
Weight (kg)
Engineering Change Level
ORGANIZATION MANUFACTURING INFORMATION 0 Supplier Name 0 Street Address 0 0 0 State Zip City Note:
0
Purchase order No.
Dated
CUSTOMER SUBMITTAL INFORMATION Customer Name / Division Buyer Name/Code Application
Does this part contain any restricted or reportable substances
Yes
No
N/A
Are plastic parts identified with appropriate ISO marking codes
Yes
No
N/A
REASON FOR SUBMISSION Initial Submission Engineering Change(s) Tooling: Transfer, Replacement, Refurbishment, or additional Correction of Discrepancy Tooling Inactive > than 1 year
Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part processing Parts Produced at Additional Location Other - please specify
REQUESTED SUBMISSION LEVEL (Check one) Level 1
-
Warrant, only (and for designated items, an Appearance Approval Report) submitted to customer.
Level 2
-
Warrant with product samples and limited ing data submitted to customer.
Level 3
-
Warrant with product samples and complete ing data submitted to customer.
Level 4
-
Warrant and other requirements as defined by customer. Include Level (4a) and (4b) predefined in ACTIA procedure.
(Check) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Level 5 - Warrant with product samples and complete ing data reviewed at supplier's manufacturing location. SUBMISSION RESULTS The results for dimensional measurements material and functional tests appearance criteria statistical process package These results meet all drawing and specification requirements: Yes No (If "No" - Explanation Required) Mold / Cavity / Production Process: DECLARATION I hereby affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable Production Part Approval Process Manual 4th Edition Requirements. I further warrant these samples were produced at the production rate of / 8 hours. I have noted any deviations from this declaration below. EXPLANATION/COMMENTS: Print Name
Title
Phone No.
Supplier Authorized Signature
FAX No. Date
FOR ACTIA USE ONLY (IF APPLICABLE) Part Warrant Disposition: Rejection/Other Comments:
Customer Name
APPROVED
REJECTED
OTHER
Customer Signature
Date
Production Part Approval Material Test Results and Related Design Record Notes PART NUMBER: PART NAME:
0
DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE DOCUMENTS date:
0
0 1/0/1900
NAME of LABORATORY: Bubble #
MATERIAL SPEC. NO. / REV / DATE
SPECIFICATION / LIMITS
TEST DATE
QTY. TESTED
SUPPLIER TEST RESULTS (DATA)
OK
NOT OK
Blanket statements of conformance are unacceptable for any test results. SIGNATURE
TITLE
DATE
Production Part Approval Performance Test Results and Related Design Record Notes PART NUMBER: PART NAME: Bubble #
TEST SPECIFICATION / REV / DATE
0
DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE DOCUMENTS DATE:
0 SPECIFICATION / LIMITS
TEST DATE
0 1/0/1900
QTY. TESTED SUPPLIER TEST RESULTS (DATA) / TEST CONDITIONS
SIGNATURE
TITLE
OK
DATE
NOT OK
INITIAL SAMPLES CAPABILITY REPORT Part Name : Part number : Drawing number : Tool number : Cavity number : Check by : Inspection date :
0 0 0
Revision #
Gauge type
Comments :
0
0
k
Average
Maxi.
Mini
Range
0.00
0.00
0.000
Out of spec. 0
0
0
0
0
0 0.000
0
0.000
0
0.000
0
0.000
0
0.000
0
0.000
Histogram
0.000
1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0
Cat. nbr. 10
Std. deviation
0.000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Ok Out
Sample size 30
0.000
Data
Upp. dim.
0.000
N°
Low. dim.
QTY
Nominal. Low. Upp. dim. tol. tol.
Inch
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%
ACTIA Corporation APPEARANCE APPROVAL REPORT Part number 0
Revision level
0
ECN change 0 level date
Supplier name
0
PPAP ELEMENTS 1
COLOR
N/A
2
BRILLANCE
N/A
3
GLOSS
N/A
4
GRAIN
N/A
5
TRANSPARENCY
N/A
6
SINK MARK
N/A
7
WELDING LINES
N/A
8
INJECTION GATE
N/A
9
KNIT LINE MARK
N/A
10
EJECTOR MARKS
N/A
11
PAINT
N/A
12
MARKING AND DECORATION (Silk-screen printing, Pad printing)
N/A
14
Approved Sample Matched
N/A
ACCEPTED
0
APPLICABLE
Part Name
COMMENTS
ACTIA Special requirement Bill Of Material review (Applicable for PCA only) Supplier
0
Part name
0
Part #
0
Revision level
0
Bubble Number on BOM
Is component present?
Is component orientation correct?
Bubble Number on BOM
Is component present?
Is component orientation correct?
Document Number:
SUPPLIER DEVIATION REQUEST ACTIA SUPPLIER TO COMPLETE Supplier Name: 0 Date:
Part Number: 0 P.O.#
P.O Qty
Qty Produced
Part Name: 0 Name: EMAIL:
Scheduled Delivery Date
Type of deviation: Limited Qty Limited Time
Quantity: From:
PO's affected: PO's affected:
To:
Permanent
Reason: (Please include a physical sample or picture depicting the deviation to be approved.)
How does this deviation affect the scheduled delivery date of the product?
Date approval needed to meet scheduled delivery date? Submit this deviation request to ACTIA Purchasing ACTIA PURCHASING TO COMPLETE Add the document number and forward to ACTIA Engineering and Quality.
Date product needed to meet order dates? Quantity needed to meet order dates?
ACTIA ENGINEERING AND QUALITY TO COMPLETE
Approved by: Engineering: Quality:
No ACTIA customer approval required - No customer specification or drawing requirements.
Submitted:
ACTIA customer approval/PPAP submission required.
Yes
Date:
By:
Date:
**
No
Add reason below:
Approved by: Engineering: Quality:
** Please provide the customer approval for this deviation.
Name:
Name:
Date:
ACTIA ENGINEERING TO COMPLETE REJECTED APPROVED* Limited Qty
Limited Time Permanent
Reason: By: Quantity: From: ECN #:
Date:
To:
PO's affected: PO's affected:
Comments:
Return this completed document to ACTIA Purchasing. * This approval is granted upon the understanding that it is advisory in nature and in no manner changes the Sellers original responsibility for insuring that all characteristics, designated in the applicable engineering specifications and/or inherent in the samples as originally tested and approved, are maintained.
Form 4.7.19
ACTIA PURCHASING FORWARD THIS COMPLETED DOCUMENT TO THE SUPPLIER Revision C
6-23-10
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