PRODUCTION PART APPROVAL PROCESS (PPAP)

Production Part Approval Process (PPAP) First Edition Issued February 1993 Second Edition, Ist Printing, February 1995; 2nd Printing, July 1995 Tbird Edition, September 1999; 2nd Printing, August 2000 Fourth Edition, March 2006 Copyright Q1993,01995,01997,01999,O2000,02006 DaimlerChrysler Corporation, Ford Motor Company, General Motors Corporation

Production Part Approval Process (PPAP) First Edition Issued February 1993 Second Edition, Ist Printing, February 1995; 2nd Printing, July 1995 Third Edition, September 1999; 2nd Printing, August 2000 Fourth Edition, March 2006 Copyright 01993,01995,01997,01999,02000,02006 DaimlerChrysler Corporation, Ford Motor Company, General Motors Corporation Effective June 1,2006, PPAP Fourth Edition replaces PPAP Third Edition unless otberwise specified by your customer.

F u r t h e r copies are obtainable from A I A G at +I-248-358-3003 o r AdareCarwin (UK) in E u r o p e +44-1-708-861333

FOREWORD T 0 THE FOURTH EDITION

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Effective June 1,2006, PPAP Fourth Edition replaces PPAP Third Edition, unless othenvise specified by your customer.

Production Part Approval Process (PPAP) is updated to the 4'h edition to incorporate the customer focused process approach associated with ISOITS 16949:2002 and other changes listed below to update requirements. PPAP's purpose continues to be to provide the evidence that all customer engineering design record and specification requirements are properly understood by the organization and that the manufacturing process has the potential to produce product consistently meeting these requirements during an actual production mn at the quoted production rate. PPAP 4th Edition includes the following changes: Alignment of PPAP to the ISOiTS 16949:2002 process approach, including: Aligning the order of the PPAP requirements with the automotive product development and nianufacturing pmcess Inclusion of an exarnple process flow for PPAP
Relocation of Customer Specific Instmctions to appropriate websites, (e.g. OEM and IAOB, www.iaob.org) to provide current requirements Update of Tmck OEM requirements and moved to Appendix H Revised PSW (Part Submission Warrant) to: Provide a more logical flow for the pan I design deseription fields Make the supplier address fields applicable to international locations Include IMDS materials reporting to indicate reporting status Updated specific PPAP requirements, including: Materials reporting and polymeric identification requirements in the design record Process capability index usage (Cpk and Ppk) The definition and approval of catalog parts and the definition of black box parts Modified customer notification and submission requirements to align with OEM requirements (e.g., 1.3.3 from PPAP 3rd removed) Clarified and commonized Appendices C, D, and E to match the PPAP reporting requirements
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Revised Tire Appendix to allow OEM specification of applicability and to eliminate duplications with allowances already provided in the PPAP requirements Note: The Tire Appendix is not applicable 10 organizations supplying tires to Ford Motor Company. Reorganized and updated Appendix F to stress the importance of the Bulk Materials Checklist Note: Ford Motor Company requires all organizations supplying bulk material to Ford Motor Company to comply with PPAP. Revised Glossary to be consistent with the updates in the text

PPAP refers to the following reference manuals: Advanced Product Quality Planning & Control Plan, Potential Failure Modes and Effects Analysis, Measurement System Analysis, and Statistical Process Control. These manuals are authored by DaimlerChrysler Corporation, Ford Motor Company, and General Motors Corporation and are available through the Automotive Industry Action Group (AIAG) at www.aiag.org.

The Supplier Quality Requirements Task Force gratefully acknowledges the contributions of the many individual. and their respective companies that participated in the revision process.

TARLE OF CONTENTS
INTRODUCTIO

SECTtON I G E N E R A I.I Submission o/PPA SECTlON 2 P P A P PROCESS REQUIREMENTS ................................................................................................. 3 ...................................................................................................................... 2.1 SigniJcant Production Run 3
2.2

PPAP Reqirirrmrn

4 2.2.1 Design Record ...................... ............................................................................................................................. 2.2.2 Authorized Engineering Change document 2.2.3 Customer Engineering Approval 2 2.5 Process Flow Diagram(s) 22.7 Control Pla 2.2.8 Measurement System Analysis Studie 2.2.9 Dimensional Rrrult 2.2.10 Records of Material / Performance Tcst Results 2.2.1 1 Iniiial Process Studie 2.2.12 Qualified Laboratoiy Documeniation 2.2.13 Appearance Approval Report (AAR) 2.2.14 Sample Production Pa 2.2.15 Master Sample 2.2.16 Checking Aids 2.2.17 Customer-Specitic Requirements 2.2.18 Pait Submission Warrant (PSW

. .

SECTION 3 - CUSTOMER NOTIFICATlON A N D SUBMISSION REQUIREMENTS .................... . .............13 3.1 Customer Noti/jcation ................................................................................................................................ I3 3.2 Submission to Customer............................................................................................................................
15

SECTlON 4 - SUBMlSSlON T 0 CIISTOMER- LEVELS OF EVIDENCE ......................................................... 17 . . 4.1 Submission Levels .......................... . . . ................................. 17 SECTION 5 PARTSUBMISSION STATUS .................................................................................................... -..I9 5.1 General .............................................................................................................................................. 19

5.2 Customer PPAPSfahr

5.2.1 5.2.2 Approved lnterim Approval

19
19 19

5.2.3

Rejected ............................................................................................................................................. 19

SECTION 6 -RECORD RETENTION ......................................................................................................... 21 APPENDICIES APPENDIX A - COMPLETION OF THE PART SUBMISSION WARRANT ( P S & ) ' 2 APPENDIX 6 - COMPLETlON OF THE APPEARANCE APPROVAL REPORT ................................................... . . . ........26 APPENDIX C - PRODUCTION PART APPROVAL, DIMENSIONAL RESULT 9 I APPENDIX D PRODUCTION PART APPROVAI., MATERIAL TESTRESU APPENDIX E - PROUUCTION PART APPROVAL, PERFORMANCE TESTRESULTS 3 APPENDIX F B U L KMATERIAL - SPECIFIC REQUIREMENTS 5 APPENDIX G - TIRES - SPEClFlC REQUIREMENTS 5 APPENDIX H - TRUCK INDUSTRY - SPECIFIC REQUIREMENTS 7 GLOSSARY ............................................................................................................. ............................................... 65

INTRODUCTION

pur~ose
Production Part Approval Process (PPAP) defines generic requirements for production part approval, including production and hulk materials (see Glossary). The purpose of PPAP is io determine if all customer engineering design record and specification requirements are properly uriderstood by the organization and that the manufacturing process has the potential to produce product consistently meetirig these requiremenis duriiig an actual production mn at the quoted production rate

PPAP sliall apply to intcrnal and external organization sites (see Glossary) supplying production parts, service parts, production materials, or bulk materials. For hulk materials, PPAP is not required unless specified hy the authorized customer representative. An organization supplying standard catalog production or service parts shall comply with PPAP unless fomally waived hy the authorized customer representative.
NOTE 1: See customer-specific requirements for additional information. All questions about PPAP should be addressed to the authorized customer representative. NOTE 2: A customer can fomally waive PPAP requirements for an organization. Such waivers can only be issued by an authorized customer representative. NOTE 3: An organization or supplier requesting a waiver of a PPAP requireiuent should contacl the authorized customer representative. The organization or supplier should obtain documentation of waivers from the authorized ciistomer representative. NOTE 4: Catalog parts (e.g., bolts) are identified andor ordered by functional specifications or by recognized industry standards.

A~~roach
The word "shall" indicates mandatoty requirements. The word "should" indicates a recommendation Paragraphs marked "NOTE" are for guidance in understanding or clarifying the associated requirement. The word "should" appearing in a NOTE is for guidance only. For the purposes of PPAP, Ihe terms and definitions given in ISOITS 16949 and the PPAP Glossary ~PP~Y.

SECTION I - GENERAL
1.1 Submission of PPAP
The organization shall ohtaiii approval (See 5.2.1) from the authorired customer representative for: 1. a new part or product (e.g., a specific part, material, or color not previously supplied to the specific customer). 2. correction of a discrepancy on a previously suhmitted part

3. product modified hy aii engineering change to design records, specifications, or materials

4. any situation required hy Section 3. NOTE: If there is any question conceming the need for production part approval, contact the authorired customer representative.

SECTION 2 - PPAP PROCESS REQUIREMENTS

2.1 Sianificant Production Run
For production Darts, product for PPAP shall he taken from a significant production run. This significant production ruti shall be from one hour to eight hours of production, and with the specific production quantity to total s minimum of 300 ranserutiue parts, unless othenvise s p e c i M hy the authorized customer representative. This significant production run shall be conducted at the production site, at the production rate (See Glossary) using the production tooling, production gaging, production process, production materials, and production Operators. Parts from each unique production process, e.g., duplicate assembly line andlor work cell, each position of a multiple cavity die, mold, tool or Pattern, shall he measured and representative parts tested. For bulk materials: No specific numher of "parts" is required. The submitted sample shail he taken in a manner as to assure that it represents "steady-state" operation of the process. NOTE: For bulk material, production histories of current products may often be used to estimate the initial process capability or performance of new and similar products. In cases where no production history of a similar bulk material product or technology exists, a containment plan niay be put into effect until sufficient production has demonstrated capability or performance, unless othenvise specified by the customer.

2.2 PPAP Reauirements

The organization shall meet all specified PPAP requirements listed below (2.2.1 through 2.2.18). The organization shall also meet all customer-specific PPAP requirements. Production parts shall meet all customer engineering design record and specification requirements (including safety and regulatory requirements).

Bulk Material PPAP requirements are defined by a completed Bulk Material Requirements Checklist (see Appendix F).

If any part specifications cannot be met, the organization shall document their problem-solving efforts and shall contact the authorized customer representative for concurrence in determination of appropriate corrective action.
NOTE: ltems or records from 2.2.1 through 2.2.18 may not necessarily apply to every customer part number from every organization. For example, some parts do not have appearance requirements, others do not have color requirements, and plastic parts may have polymeric part marking requirements. In order to detemine with certainty which items must be included, consult the design record, e.g., part print, the relevant Engineering documents or speeifications, and your authorized customer representative.

2.2.1 Design Record

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., CADICAM math data, the organization shall produce a hard copy (e.g., pictorial, geometric dimensioning & tolerancing [GD&T] sheets, drawing) to identify measurements taken.
NOTE 1: For any saleable product, part or component, there will only be one design record, regardless of who has design-responsibility. The design record may reference other documents making tbem part of the design record. NOTE 2: A Single design record ean represent multiple part or assembly configurations, e.g., a sub-frame assembly with various hole configurations for different applications. NOTE 3: For parts identified as black box (See Glossary), the design record specifies the interface and perfomance requirements. NOTE 4: For parts identified as catalog parts, the design record may consist only of a functional specification or a reference to a recognized industiy Standard. NOTE 5: For bulk materials, the design record may include identification of raw materials, fomulations, processing steps and Parameters, and final product specifications or acceptance criteria. If dimensional results do not apply, then CADICAM requirements are also not applicable.

2.2.1.1 Reporting of Part Material Composition

The organization shall provide evidence that the MateriallSubstance Composition reporting that is required by the customer has been completed for the part and that the reported data complies with all customer-specific requirements.
NOTE: This materials reporting may be entered into tbe lMDS (International Materials Data System) or other customer-specified systedmethod. lMDS is available through http:l/www.mdsystem.comlindex.jsp.

2.2.1.2 Marking of Polymeric Parts

Where applicable, the organization shall identify polymeric parts with the ISO symbols such as specified in ISO 11469, "Plastics - Generic Identification and marking of plastic products" andlor ISO 1629, "Rubber and lattices - Nomenclature." The following weight criteria shall determine if the marking requirement is applicable:

Plastic parts weighing at least IOOg (using ISO 1146911043-1) Elastomeric parts weighing at least 200g (using ISO 1146911629)

NOTE: Nomenclature and abbreviation references to support the use of 1SO 11469 are contained in 1SO 1043-1 for basic polymers and in ISO 1043-2 for fillers and reinforcements.

2.2.2 Authorized Engineering Change documents

The organization shall have any authorized engineering change documents for those changes not yet recorded in the design record but incorporated in the product, part or tooling.

2.2.3 Customer Engineering Approval

Where specified by the customer, the organization shall have evidence of custorner engineering approvai.
NOTE: For bulk materials, this requirement is satisfied by a signed 'Engineering Approval' line item an the Bulk Material Requirements Checklist (see Appendix F) andlor inclusion an a customer maintained list of approved materials.

2.2.4 Design Failure Mode and Effects Analysis (Design FMEA)

if the organization is product design-responsible
The product design-responsible organization shall develop a Design FMEA in accordance with, and cornpliant to, customer-specified requirements (e.g., Potential Failure Mode and Effects Analysis reference manual).
NOTE 1: A single Design FMEA may be applied to a family of similar parts or materials. NOTE 2: For bulk materials, see Appendix F.

2.2.5 Process Flow Diagram(s)

The organization shall have a process flow diagram in an organization-specified 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). Fot bulk materials, an equivalent to a Process Flow Diagram is a Process Flow Description.
NOTE: Process flow diagrams for 'farnilies' of similar parts are acceptable if the new pans have been reviewed for commonality by the organization.

2.2.6 Process Failure Mode and Effects Analysis (Process FMEA)

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).
NOTE 1: A single Process FMEA may be applied to a process manufacturing a family of similar parts or materials if reviewed for commonality by the organization. NOTE 2: For bulk materials, ser Appendix F.

2.2.7 Control Plan

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).
NOTE 1: Control Plans for "families" of parts are acceptable if the new parts have been reviewed for cornmonality by the organization. NOTE 2: Control Plan approval may be required by certain customers.

2.2.8 M e a s u r e m e n t System Analysis Studies

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).
NOTE 1: Gage R&R acceptability criteria are defined in the Measurement Systems Analysis reference

manual.
NOTE 2: For bulk materials, Measurement System Analysis niay not apply. Customer agreement should be obtained on actual requirements.

2.2.9 Dimensional Results

The organization shall provide evidence that dimensional verifications required by the design record and the Control Plan have been completed and results indicate compliance with specified requirements. The organization shall have dimensional results for each unique manufacturing process, e.g., cells or production lines and all cavities, molds, pattems or dies (see 2.2.18). The 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 indicate the date of the design record, change level, and any authorized engineering change document not yet incorporated in the design record to which the part was made. The organization shall record the change level, drawing date, organization name and part number on all auxiliary documents (e.g., supplementary layout results sheets, sketches, tracings, cross sections, CMM inspection point results, geometric dimensioning and tolerancing sheets, or other auxiliary drawings used in conjunction with the part drawing). Copies of these auxiliary materials shall accompany the dimensional results according to the RetentiodSubmission Requirements Table. A tracing shall be included when an optical comparator is necessary for inspection. The organization shall identii'y one of the parts measured as the master sample (See 2.2.15).
NOTE 1: The Dimensional Results form in Appendix C, a pictorial, geometric dimensioning & tolerancing

[GD&T] sheets, or a checked print where the results are legibly written on a part drawing including crosssections, tracings, or sketches as applicable may be utilized for this purpose. NOTE 2: Dimensional resolts typically do not apply to bulk materials.

2.2.10 Records of M a t e r i a l 1 P e r f o r m a n c e Test Results

The organization shall have records of material andior performance test results for tests specified on the design record or Control Plan.
2.2.10.1

Material Test Results

The organization shall perform tests for all parts and product materials when chemical, physical, or metallurgical requirements are specified by the design record or Control Plan. Material test results shall indicate and include: the design record change level of the parts tested; any authorized engineering change documents that have not yet been incorporated in the design record; the number, date, and change level of the specifications to which the part was tested; the date on which the testing took place; the quantity tested;

the actual results; the material supplier's name and, when required by the customer, the customer-assigned supplierlvendor code. NOTE: Material test results may be presented in any convenient fomat. An example is shown in Appendix D. For products with customer-developed material specifications and a customer-approved supplier list, the organization shall procure materials andlor sewices (e.g., painting, plating, heat-treating, welding) from suppliers on that list.

2.2.10.2 Performance Test Results

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: the design record change level of the parts tested; any authorized engineering change documents that have not yet been incorporated in the design record; the number, date, and chatige level of the specifications to which the part was tested; the date on which the testing took place; the quantity tested; the actual results. NOTE: Performance test results may be presented in any convenient formal. An example is shown in Appendix E.

2.2.11 Initial Proeess Studies 2 . 2 1 1 General

The level of initial process capabiliiy or perfonnance shall be determined to be acceptable prior to submission for all Special Characteristics desigriated by the customer or organization. The organization shall obtain customer concurrence on the indes for estimating initial process capability prior to submission. The organization shall perform measurement System analysis to understarid how measurement error affects the study measurements. (see 2.2.8)
NOTE 1: Where no special characteristics have been identified, the customer reserves the right to require

demonstration of initial process capability on other characteristics.

NOTE 2: The purpose of this requirement is to detennine if the production process is likely to produce

product that will meet the customer's requirements. The initial process study is focused an variables not attribute data. Assembly errors, test failures, surface defects are examples of attribute data, which is important to understand, but is not covered in this initial study. To understand the perfonnance of characteristics monitored by attribute data will require more data collected over time. Unless approved by the authorized customer representative, attribute data are not acceptable for PPAP submissions.
NOTE 3: Cpt and Ppk are described below. Other methods more appropriate for certain processes or products may be substituted wiih prior approval from an authorized customer representative. NOTE 4: Initial process studies are short-term and will not predict the effects of time and variation in people, materials, methods, equipment, measurement Systems, and environment. Even for these short-tenn studies, it is important to collect and analyze the data in the order produced using control charts. NOTE 5: For those characteristics that can be studied using X-bar and R charts, a short-term study should be based on a minimum of 25 subgroups containing at least 100 readings from consecutive parts of the

significant production mn (see 2.1). The initial process study data requirements may he replaced hy longerterm historical data from the same or similar processes, with customer concurrence. For certain processes, alternative analylical tools such as individual and moving range charts may be appropriate and permitted with prior approval from an authorized customer representative.

2.2.11.2

Q u a l i t y Indices

Initial process studies shall be summarized with capability or performance indices, if applicable. NOTE 1: The initial process study results are dependent on the purpose of the study, method of data acquisition, sampling, amount of data, demonstration of statistical control, etc. See the Statistical Process Control reference manual for additional information in understanding the hasic principles of statistical stability and process measures (indices). For guidance on items listed helow, contact the authorized customer representative. Cpk - The capability index for a stable process. The estimate of sigma is hased on within subgroup variation (R-barld2 or S-barlc4). Cpk is an indicator of process capability hased on process variation within does not include the effect of process variahility hetween the subgroups. each subgroup of a set of data. Cpk Cpk is an indicator of how good a process could he if all process variation between subgroups was to he eliminated. Therefore, use of Cpk alone may be an incomplete indicator of process performance. For more information, see the Statistical Process Control reference manual. PPk - The performance index. The estimate of sigma is based on rornl vnnafion (all of individual sample data using the standard deviation [root mean square equation], "s"). Ppkis an indicator of process Ppk is not limited to the performance based on process variation throughout the full sei of data. Unlike Cpk, variation within subgroups. However, Ppk cannot isolate within suhgroup variation from between suhgroup and Ppk can be compared to analyze the sources of variation. When calculated from the same data set, Cpk process variation. For more information, see the Statistical Process Control reference manual. lnitial Process Studies. The purpose of the initial process study is to understand the process variation, not just to achieve a specific index value. When historical data are availahle or enough initial data exist to plot a control chart (at least 100 individual samples), Cpkcan he calculated when the process is stahle. Otherwise, for processes with known and predictable special causes and output meeting specifications, Ppk should he used. When not enough data are availahle (< 100 samples) or there are unknown sources of variation, contact the authorized customer representative to develop a suitable plan. NOTE 2: For Initial Process Studies involving more than one process stream, additional appropriate statistical methods or approaches may he required. NOTE 3: For hulk material, the organization should obtain customer agreement regarding the appropriate techniques for initial process studies, if requircd, in order to determine an effective estimate of capability.

2.2.11.3

Acceptance Criteria for Initial Studv

The organization shall use the following as acceptance criteria for evaluating initial process study results for processes that appear stable

Index > 1.67 1.33 5 Index 5 1.67 Index < 1.33

The process currently meets the acceptance criteria The process may be acceptable. Contact the authorized customer representative for a review of the study results. The process does not currently meet the acceptance criteria. Contact the authorized customer representative for a review of the siudy results.
one

NOTE 1: Meeting the initial process study capability acceptance criteria is requirements !hat leads to an approved PPAP suhniission. NOTE2:See2.2.11.1 and2.2.11.2.

of a number of custonier

2.2.11.4

Unstable Processes

Depending on the nature of the instability, an unstable process may not meet customer requirements. The organization shall identiS, evaluate and, wherever possible, eliminate special causes o f variation prior to PPAP submission. The organization shall notify the authorized customer representative of any unstable action plan to the customer prior to any submission. processes that exist and shall submit a ~orrective NOTE: For hulk materials, for processes with known and predictable special causes and output meeting specitications,corrective action plaiis may not be required by ihe customer.

2.2.11.5 Processes With One-Sided Specifications or Non-Normal Distributions

The organization shall determine with the aiithorized customer representative alternative acceptance criteria for processes with one-sided specifications or non-nomal distributions. NOTE: The above mcntioncd ncceptance criteria (2.2.11.3) assurne normality and a two-sided specitication (target in the center). When this is not tme, using this analysis rnay result in unreliahle infomation. These alternate acceptance criteria could require a different type of index or some method of transformation of the data. The focus should be on understanding the reasons for tlie non-nonnality (e.g., is it stable ovcr time?) and managing variation. Refer to the Statistical Process Control reference manual for further guidancc.

2.2.11.6

Actions To Be Taken When Acceptance Criteria Are Not Satisfied

The organization shall contact the authorized customer representative if the acceptance criteria (2.2.1 1.3) cannot be attained by the required PPAP submission date. The organization shall submit to the authorized customer representative for approval a corrective action plan and a modified ControI PJan normally providing for 100% inspection. Variation reduction efforls shall continuc until the acceptance criteria are met, or until customer approval is received. NOTE 1: 100% inspectioii rnetliodologies are subject to review and concurrence by tlie custorncr. NOTE 2: For bulk materials, 100% inspection means an evaluation of a samplc(s) of product from a wliich is reprcsentative of the entire production nin. continuous process or honiogeneous bat~li

2.2.12 Qualified Laboratory Documentation

Inspection and testing for PPAP shall he performed by a 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 for the type o f measurements or tests conducted. When an externallcommercial 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 identified.

2.2.13 Appearance Approval Report (AAR)

A separate Appearance Approval Report (AAR) shall be completed for each part or series of parts if the productlpart has appearance requirements on the design record. Upon satisfactory completion o f all required criteria, the organization shall record the required information on the AAR. The completed AAR and representative production productsiparts 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 o f final submission based upon the submission level requested. See customer-specific requirements for any additional requirements.
NOTE 1: AAR typically applies only for parts with color, grain, or surface appearance requirements. NOTE 2: Certain customers may not require entries in all AAR fields. See Appendix B or customer-

specifics for detailed instructions on completing the AAR.

2.2.14 Sample Production Parts

The organization shall provide sample product as specified by the customer

2.2.15 Master Sample

The organization shall retain a master sample for the same period as the production pan 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 sample. The organization shall retain a master sample for each position of a multiple cavity die, mold, tool or Pattern, or production process unless othenvise specified by the customer.
NOTE 1: When part size, sheer volume of parts, etc. makes Storage of a master sample difficult, the sample retention requirements may be niodified or waived in writing by the authorized customer represrntative. The purpose of the master sample is to assist in defining the production standard, especially where data is ambiguous or in insufficient detail to fully replicate the part to its original approved state. NOTE 2: Many bulk material properties are by their nature time dependent, and if a master sample is required, it may consist of the manufacturing record, tesi results, and certificate of analysis of key ingredients, for the approved submission sample. (see Appendix F).

2.2.16 C h e c k i n g Aids

Ifrequested by the customer, the organization shall submit with the PPAP submission any pari-specific assembly or component checking aid. The organization shall ceriify that all aspects of the checking aid agree witli pari dimensional requirements. The organization shall document all released engineering design changes that have been incorporated in the checking aid at the time of submission. The organization shall provide for preventive maintenance of any checking aids for the life of the part (see Glossary - "Active Pari"). Measurement system anaiysis studies, e.g., gage R & R, accuracy, bias, linearity, stability studies, shall be conducted in compliance with customer requirements. (See 2.2.8 and the Mcasuremcnt Systems Analysis reference manual).
NOTE 1: Checking aids can include fixtures. variable and attribute gages, models, templates, mylars specific io the product being submitted. NOTE 2: Checking aids, etc. typically do not apply to Bulk Materials. If ehecking aids are used for bulk materials, the organization should eontact the aiithorized customer representative regarding this requireinent.

2.2.17 Customer-Specific R e q u i r e m e n t s
The organization shall have records of compliance to all applicable customer-specific requirements. For bulk materials, applicable customer-specific requirements shall be documented on the Bulk Material Requirements Checklist.

iB
7

2.2.18 P a r t Submission Warrant (PSW)

Upon completion of all PPAP requirements. the organization shall complete the Pari Submission Warrant (PSW). A separate PSW shall be completed for each customer part number unless othenvise agreed to by the authorized customer representative. If production Parts will be produced from more than one cavity, mold, tool, die, pattem, or production process, e.g., line or cell, the organization shall complete a dimensional evaluation (see 2.2.9) on one pari from each. The specific cavities, molds, line, etc., shall then be identified in the "Mold~Cavity/Production Process" line on a PSW, or in a PSW attachment. The organization shall verify that all of the measurement and test results show conformance with custonier requirements and that all required documentation is available and, For Level 2, 3, and 4, is included in the submission as appropriate. A responsible official of the organization shall approve the PSW and provide contact information.
NOTE 1: One Warrant per customer part number can be used to summarize many ehanges providing that

the changes are adequately documented, and the submission is in compliance with customer program timing requirements. NOTE 2: PSWs may be subtnitted electronically in compliance with custorner requirements.

2.2.18.1 Part Weight (Mass)

The organization shall record on ihe PSW the Part weight of the part as shipped, measured and expressed in kilograms to four decimal places (0.0000) unless otherwise specified by the customer. The weight shall not include shipping protectors, assembly aides, or packaging materials. To determine part weight, the organization shall individually weigh ten randomly selected parts, calculate and report the average weight. At least one Part shall be measured frorn each caviiy, tool, line or process to be used in product realization.
NOTE: This weight is used for vehicle weight analysis only and does not affect the approval process. Where there is no production or Service requirement for at least ten parts, the organization should use the required number for calculation of the average part weight. For bulk materials, the part weight field is not applicable.

SECTION 3 - CUSTOMER NOTlFlCATlON AND SUBMISSION REQUIREMENTS

3.1 Customer Notification
The organization shall notify the authorized customer representative of any planned changes to the design, process, or site. Examples are indicated in the table below (See Table 3.1).
NOTE: Organizations are responsible to notify the authorized customer representative of all changes to the part design andior the manufachiring process.

Upon notification and approval of the proposed change by the authorized customer representative, and after change implementation, PPAP submission is required unless othenvise specified.

Table 3.1
Examoles of chanees reauirine notification 1. Use of other construction or niaterial than was used in the previously approved Part or product Clarifications For example, other construction as documented on a deviation (permit) or included as a note on the design record and not covered by an engineering change as described in Table 3.2, #3. This requirement only applies to tools, which due to their unique form or function, can be expected to influence the integrity of the final product. It is not meant to describe standard tools (new or re~aired), such as standard measurine devices.

2. Production from new or modified tools (except perishable tools), dies, molds Patterns, etc. including additional or replacement tooling

- .I rearrangement of existing tooling or

transferred to a different plant site or from an additional plant site. equivalent niaterials, or services (e.g.. heattreatin , latin .

.modification of a tool or machine or to increase the capacity, performance, or change its existing function. This is not meant to be confused with normal maintenance, repair or replacement of parts, etc., for which no change in performance is to be expected and post repair verification methods have been established. Rearrangenient is defined as activity that changes the sequence of productlprocess flow from that documented in the process flow diagram (including the addition of a new process). Minor adjustments of production equipment may be required to meet safety requirements such as, installation of nrotective Covers. elimination of potential ESD risks, etc. Production Drocess tooline - and Ior equipment . . transferred between buildings or facilities at one or more sites. The oreanization is resoonsible for aonroval of supplier provided material and services.

..

For product that has been produced afier tooling has been inactive for twelve rnonths or rnore: Notification is required when the part has had no change in active purchase order and the existing tooling has been inactive for volurne production for twelve rnonths or more. The only exception is when the part has low volume, e.g., service or specialty vehicles. However a custorner rnay specify certain PPAP requirernents for service Parts. 7. Product and process changes related to Any changes, including changes at the suppliers to components of the production product the organization and their suppliers, that affect manufactured intemally or rnanufactured by custorner requirernents, e.g., fit, form, function, suppliers. prrfornuncc, Jurahility. 8. Change in testlinspection rnethod - new kor chanar in iest rcerhod. thc oraanization should technique (no effect on acceptance criteria) have evidrnce that the new rnethid has measurement capability equivalent to the old method. Additionally, for bulk rnaterials: These changes would norrnally be expected to have an effect on the performance of the product. 9. New source of raw material from new or existing supplier.
10. Change in product appearance attributes

6. Product produced afier the tooling has been inactive for volurne production for twelve months or more.

3.2 Submission to Customer

'

The organization shall submit lur PPAP approval prior to the first production shipment in the following situations unless the authorized customer representative has waived this requirement (see Table 3.2).
NOTE: in the situations described below, prior notification to, or cornmunication with, the authorized customer representative is assurned.

The organization shall review and update, as necessary, all applicable items in the PPAP file to reflect the production process, regardless of whether or not the customer requests a formal submission. The PPAP file shall contain the name of the authorized customer representative granting the waiver and the date.

Table 3.2
Requirement I . A new ~ a ror t oroduct (i.e. a soecific . ~ a r.t , material, or color not previously supplied to the customer)

2. Correction of a discrepancy on a previously siibmitted part.

3. Engineering change to design records, specifications, or rnaterials for production producdpart numbers(s). Additionally, for Bulk Materials:
4. Process technology new to the organization. n o t r e v i o u s l y used for this product.

Clarifications Submission is reauired for a new oroduct (initial release) or a previously approved product that has a new or revised productipari nuniber (e.g., suff~x) assigned to it. A new partlproduct or material added to a family may use appropriate PPAP documentation from a previously approved pari within the Same product family. Submission is reauired to correct anv discrepancies on a previously submitted part. A "discrepancy" can be related to: The product performance against the customer requirements Dimensional or capability issues Supplier issues Approval of a part replacing an interim approval Testing, including material, performance, or engineering validation issues Submission is required on any engineering change to the production producdpart design record, specifications or materials.

SECTION 4 - SUBMISSION T 0 CUSTOMER LEVELS OF EVIDENCE

4.1 Submission Levels
The organization shall submit the items andior records specified in the level identified below in Table 4.1:

Table 4.1
Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to the customer. Level 2 Warrant with product samples and limited supporting data submitted to the customer. Warrant with product samples and complete supporting data submitted to the customer. Warrant and other requirements as defined by the customer. Warrant with product samples and complete supporting data reviewed at the organization's manufacturing location. See RetentioniSubmission Requirements Table 4.2 for exact retention/submission requirements for each submission level. The organization shall use level3 as the default level for all submissions unless othenvise specified by the authorized customer representative. The minimum submission requirement for bulk materials is the PSW and the Bulk Materials Checklist. For Bulk Material PPAP submissions, check "Other" in the Reason for Submission Section on the PSW form and speciS. "Bulk Material." This indicates that the "Bulk Material Requirements Checklist" was used to specify the PPAP requirements for the bulk material and shall be included in the submission packet.
NOTE 1: The authorized customer representative may identify a submission level, different from the default level, that is to be used wilh each organizatiori, or organization and customer part number combination. Different cuslonier locations may assign different submission levels to the same organization manufacturing location. NOTE 2: All of the forms referenced in lhis document may be replaced by computer-generated facsimiles. Acceptability of lhese facsimiles is lo be confirnied with the authorized customer representative prior to the first submission.

Level 3

Level 4 Level 5
I

RetentionlSubmission Requirements Table 4.2

(Normative)

Submission Level
Rrquiremwi
1. Design Record
- for proprietary componentsldetails - for all other componentsldetails Engineering Change Doeuments, if any Customer Engineering approval, if required Design FMEA Process Flow Diagrams Process FMEA Control Plan Measurement System Analysis Studies Dimensional Results Material, Performance Test Results Initial Process Studies Qualified Laboratory Documentarion Appearance Approval Report (AAR), if applicable Sample Produci Master Sample Checking Aids Records of Compliance With Custorner-Specific Requirements Part Siibmission Warrant (PSW) Bulk Material Checklist (See 4.1 above)

2. 3. 4. 5. 6. 7.

S = The organization shall submit to the customer and retain a copy of records or documentation items at appropriate localions. R
= =

The organization shall retain at appropriate locations and make available to the customer upon request The organization shall retain at appropriate locations and submit to the customer upon request

fr

SEC'TION 5 - PART SUBMISSION STATUS

5.1 General
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 I )

by a specific customer, submission of the required organization-approved documentation will be considered as customer approval unless the organization is advised othenvise.

5.2 Customer PPAP Status

5.2.1

Approved

Approved indicates that the part or material, including all sub-components, meets all customer requirements. The organization is therefore authorized to ship production quantities of the product, subject to releases from the customer scheduling activity.

5.2.2

Interim Approval

Interim Approval permits shipment of material for production requirements on a limited time or piece quantity basis. Interim Approval will only be granted when the organization has: clearly defined the non-compliances preventing approval; and, prepared an action plan agreed upon by the customer. PPAP re-submission is required to obtain a status of "approved." Note 1: The organization is responsible for implementing containment actions to ensure that only acceptable material is being shipped to the customer. Note 2 : Parts with a status of "lnterim Approval" arc not to be considered "Approved." Material covered by an interim approval that fails to meet the agreed-upon action plan, either by the expiration date or the shipment of the authorized quantity, will be rejected. 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).

5.2.3

Rejected

Rejected means that the PPAP submission does not nieet customer requirements, based on the production lot from which it was taken andlor accompanying documentation. In such cases, the submission andlor process, as appropriate, shall be corrected to meet customer requirements. The submission shall be approved before production quantities may be shipped.

B'

SECTION 6 - RECORD RE'TEN'TION

PPAP records (see 2 . 2 ) , regardless of submission level, shall he maintained for the length of time that the pari is active (see Glossary) plus one calendar year.
The organization shall ensure that the appropriate PPAP records from a superseded part PPAP file are included, or referenced in the new pari PPAP file.
NOTE: An example of an appropriate documenVrecord that should be carried fonvard from the old file to the new part file would be a material certification from a raw material supplier for a new part that represents only a dimensional change from the old part number. This should be identified by conducting a PPAP "gap aiialysis" between the old and new part numbers.

Appendix A - Completion of the Part Submission Warrant (PSW)

PART INFORMATION 1. 2b.
3.

Part Name and Za. Cuslomer P a r t Number: Engineering released finished end item part name and number. Org, Part Number: Part number defined by the organization, ifany. S h o v n on Drawing Number: The design record that speeifies the customer part number being submihed. Engineering Change Level & Date: Show the changc level and datc of the design rccord. Additional Engineering Chsnges & Date: List all authorired engineering changes not yet ineorporated in the design record but which are incorparaled in the part. Safeiy sndlor Gavernmont Regulation: "Yes'?if so indicated by the design record, othcrwise "No." Purchere Order Number: Enter this number as found on the contractlpurchase order. Weight: Enlcr the actual weight in kilograms to four decimal places unless othenvise specified by the customer. Cheeking Aid Nurnher, Change Level and Date: If requesled by the customer, enter the ehecking aid numbei. its change level and date. Organization Name & SupplierNendor Code: Show l h e name and code assigned to ihe manufaeturine site a n the purehase orderlconlracl. Street Address, Region, Postal Code, Country: Show the complete addresn ofthe lacatian where the product was manufactured. For "Region," enter slaie, counly, province, etc. Customer NamdDivision: Show the corporaie name and diuieian ar opcrations group. BuyerIBuyer Code: Enter the buyer's name and rode.

4. 5. 6. 7.
8.

9.110.

ORGANIZATION MANUFACTURING INFORMATION 11. 12.

CUSTOMER SUBMITTAL INFORMATION 13. 14.

15. Applieation: Enter the model year, vehicle name. engine. tranemission, ete. MATERIALS REPORTING Substanees o l c o n e e r n : Enicr "Yei.""Na," ar "nla". 16. IMDSIOther C u ~ t o m e Formst: r Cirele either "IMUS" or "Other Customer Format" as appropriate. if submined via IMDS include: Modulc ID #, Version #, and Creatian Uatc If submitred via othcr customer fomat, enter the date customer confirmation was received.
17.

Polymcrir Parts Identilieation: Enter "Yes," "No," or "nla".

REASON FOR SUBMISSION 18. Check the appropriatc box(es). For bulk materials, in addition io checking thc appropriate box, check "Other" and write "Buik Material" in the space provided. SUBMISSION LEVEL 19. SUBMISSION LEVEL: Identify the submission level requested by the customer. SUBMISSION RESULTS 20. Check the appropriate boxes for dimensional, material tests, perfonance lests, appearanCD evaluation, and slalistical data. 21. Check the appropriate box. If no," enter the cxplanation in "commentn" below. 22.
MoldslCavitiesIProduetion Proeesses: For inslruction, see 22.18.

DECLARATION Enter the numbcr of pieccs manufactured during the significant produetian run. 23. 24. 25. 26 27 Enter the timc (in hours) takcn for the significant produciion nin. EXPLANATIONICOMMENTS: Provide any erplanatory commentr on the Submission Resulls or any deviations froin the Declaration. Attach additional infomalion as sppropriatc. CUSTOMER TOOL TAGGINGINUMBERING: Are cuslomer-owned tools identified in accord with lSO/TS 16949 and any customer-spccilic requiremcnts, anewer "Yee" or "No." May not be applicable 10 OEM intemal supplicrs. OKti.4YII \l'IO\ \I'TIi<IHILFI) >Lti>.4TI HE: ,\ rc,p.>ii,thlt .dr?*r>.,>t..v..%tN.~.%i. .)iirr \;r.i\.,~, t11.i th. rc.u.t, \ h d ~ i i r < r r m n i r I,> i i i .u$t.imci rcqu remciiia anJ thu J I I r;quirc.l .I< ;unieiiiatiuii I, r\aillhlc, ,hall >ppr.>rc thc .leilarai.. n .<iiil Pr.>\ .%Ic Title, Phone Numher, Fax Number, and E-mail address.

..

FOR CUSTOMER USE ONLY

Leavr blank.

DAIMLERCHRYSLFR
Pan Name

Part Submission Warrant

(3

-1

Shown on Orawing Na

Englneer~ng Change Level

-(4)
@ NO

Cust Part Number

__

Org Pan Number Dated

2b

I
Weight (kg) Dated

Additional Engineering Changes Sa'ety andlor Government Regulation O Y e Cheeking Aid Na Purchase Order No

( 9 )Checking Aid Engnsering Change Level

ORGANILATION M NUFACTURING INFORMATION Supplier Name a SupplierNendoi Code

8
-

CUSTOMER SUBMITTAL INFORMATION

Cuslamsi Name,Div,zion

Strssl Addresr

BuyerlBuyer Code Countrq AppI~al~n

City

Region

Poslsl Cede

MATERIALS REPORTING Hai customer-required Substances of Concern inlormation been reported?

0 l6

Yes

q NO q

nla

I
q

Submitted by IMOS or other cuilomer lormal

I
@
OYes

Are polymeric parts identified wilh appropriate 1SO marking codes? REASON FORSUBMISSION (Check at least one) Initial Submission Engineering Change($) [7 Tooling: Transfer, Replacement. Reiurbishment. or additional q Correction 01 Discrepancy q Tooling Inactive > thao 1 year

[7 NO

, , l a

q Change to Optianal Construction or Material q Supplieror Malerial Source Change

O C h a n g e in Part Processing q Parts Produced at Additional Location

REQUESTED SUBMISSION LEVEL (Check one) q Lwel 1 - Warrant only land lor designated appearance items, an Appearance Approval Repart) submilted to customer.

q 01her - please specily

q Level 2 - Warrant with product samples and limited supponing data submitted to customer.
Level 3

- Warrant with product sampiei and compete supporting data submitted to customer. - Warrant wilh pioduct samples and mmplele supporting data reviewed at arganization's manulacturing location.

U Level 4 - Warrant and othei requirements as delined by customer.

[7
Level 5 SUBMISSION RESULTS The results far q dimensional measuremeots Mold ICavity IPmductioo Pracess DECLARATION odu I anilm that the samples represented by this warrenl are representativeol our parts. which were made by a process that meets a Approval Process Manual 4th Edition Requiremenls. I further anirm that these samples were pioduced al the production rals of I also eertily that dacumented evidenceaf such compliance is on lile and availabie lor reuiew. I have nated any deviations lrom this declaration below EXPLANATIONICOMMENE:

[?

material and lunctiooal tests

appearance criteria [? smtistical process package

These rssults meet all design remrd roquiremenb:

q er

NO (I1 "Nm-Explanation Required)

(gq yeS q N ,
Phone No. E-mail

1 s each Customar Tool prapsriy tagged and numbered? Organilatian Authorized Signature

@
Date FAX No.-

Print Name Titie

I
I

FOR CUSTOMER USE ONLY (IF APPLICABLE) PPAP Warrant Disposition:[? Appraved

q Rejecled

i ]Olher
Date Cuitomer Tracking Number (optional)

1 Customer Signature
Pllnt Name
s
March

CFG-1001

DAIMLERCHRUSLER
Part Name Shown on Drawng No Engineering Change Level Additionai Engineering Changes Safety andlor Government Regulation U y e s Checking Ald No No

Part Submission Warrant

Cuit Part Number Org Part Number Dated Dated Purchase Order No Weighl (kg) Dated

Check~ng Aid Engneering Change Level

ORGANIZATION MANUFACTURING INFORMATION

CUSTOMER SUBMlTTAL INFORMATiON

Clly

Region

Portal Code

Country

~pplic~ti~~ Yes ~o
nia

MATERIALS REPORTING Ha3 customer-required Subslances o i Concern intormaiion been reported? Submined by IMOS or other cuslomer lormal:

Are polymeric parts idenlified with apprapriale ISO marking Codes? REASON FOR SUBMISSION (Check at least One) Initial Submiseon Engineering Change($) Tooling. Translsr. Replacement, Refurbishmenl, or additional Correcilon o l Discrepancy Tooling inactive > than 1 year

Uyes

NO

"ia

q Change l o Oplional Construction or Material

Supplieror Material Source Change U C h a n g e in Part Plocessing Part3 Produced at Additional Location q Other - plsaie specify below

REQUESTE0 SUBMISSION LEVEL (Check one) Levei 1 - Warranl only (end for designated appearance ilams. an Appearance Appraval Repad) iubmined lo cuslomer.

n Levei 3 - Warrant with product samples and complete supporting dala submlted to cuslamer
Level 4
-

Levei 2 - Warranl with product sampies and iimited supporting dala submined ta cusiamer. Warrant and other requirements as defined by cuslomer.

Level 5 W a r r a n t with product samples and complete supporting data reviewed al orgaoization's manulacturing location. SUBMISSION RESULTS dimensional measurements The results foi These resulls meet all design record requirements: Mold / Cavity I Produdion Process OECLARATION I affirm that the samples represented by this warrent are represenlalive of our parts which were made by a process lhat meeh all Praduction Part Approval ProCes5 Manual 4th Edition Requlremenls. I lurther anirm lhal lhese samples were produced at the production rate of 1-hovrs. I also certify lhat documented evidence of such compliance is an file and available lor review. I heve noted any devialions lrom lhis dRlaraliOn below EXPLANATIONICOMMENTS: 1 s each Customei Tool properly lagged and numbered? Organizalion Aufhorized Signature Prtnt Name Title E-mail FOR CUSTOMER USE ONLY (IF APPLICABLE) PPAP Warrant Disposition Cuslomer Slgnature Print Name
March

material and lunclional lesls

q appearance criteria q statistical process package

q Yes

NO (11 '"NO" - Explanation Required)

qyes
Phone No.

N~

nla
Date FAX No.

Approved

Rejecled

qOther
Date Customer Tracking Number (optional)

CFG-1001

Appendix B - Completion of the Appearance Approval Report

1. 2. Customer part number: Engineering released customer part number, Drawing Number: Use the number of the drawing on which the part is shown if different from the part number. Application: Enter the model year(s) and vehicle or other program on which the Part is used. Part Name: Use the finished part name on the part drawing. Buyer Code: Enter the code for specific buyer of part. EIC Level & Date: Engineering change level and EIC date for this submission. 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. Organization Sourcing & Texture Information: List all first surface tools, graining source(s), grain type(s), and grain and gloss masters used to check part. Pre-Texture Evaluation: To be completed by authorized customer representative (not used by GM). 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: IdentiS. first surface finish and substrate (e.g., paint1ABS). Material Source: IdentiS. first surface and substrate suppliers. Example: RedspotlDow Color Evaluation, Hue, Value, Chroma, Gloss and Metallic Brilliance: Visual assessment by customer. Color Shipping Suffix: Color Part number suffix or color number. Part Disposition: Tobe determined by customer (approved or rejected) Comments: General comments by the organization or customer (optional) Organization Signature, Phone No. & Date: Organization certification that the document information is accurate and meets all requirements specified. Authorized Customer Representative Signature & Date: Authorized Customer Representative approval signature.

3.
4.

5. 6.17.

X.
9.
10.

I I.
12.

13.
14.

15. 16. 17. 18. 19. 20. 21. 22. 23.

24.

25.

THE AREAS INSIDE THE BOLD LINES ARE FOR CUSTOMER USE ONLY.

NAME

W
C h

!CODE

ORGANlZATlON

IMANUFACTURING /n\

I
~SUPPLIERI VENDOR

ORGANIZATION SIGNATURE March

PHONE NO

DATE

AUTHORIZED CUSTOMER REPRESENTATIVE SIGNATURE

DATE

2006

CFG-1002

31W

38fllVNblS 3AIlVlN3S38d38 83WOlSfl3 03Zl8OHlllV

3 1 ~ a

'ON 3NOHd

38lllVNOIS NOIlWINVD80

NOIlISOdSla LMVd

X l M l S MO1 H3IH DNlddlHS 3NVll1188

I 1

MO1

I1

HolH NW131hVX9

Y 1 \ ( 0 11H011

fl18

I 1

NB5

I 1 1% I(

031

SSOlD

VWO8H3

3fllVA

3llH

338llOS 3 d N 31Va 838WflN 3 ~ 3 1 . 3 0 1.90 1.W 1 . 1 0 XlddflS 1 ~ 1 8 3 11 ~~ 1~ 8 3 81 ~ 3 ~ 1 8 ~ 3 ~ 1 ~ ~V V IO ~ ~ ~f l l f l ~ i l ~ 1 8 80103 1

I I I

80103

3lllV13W

ONV 1 3 3 8 8 0 3

NOllVtllVA3 33NmV3ddV
30NVH3 ON1833NION3 83HlO 30031 NOISSlWQnS-38 lN3WdlHS N0113llaO8d l S 8 l d 3ldWVS lV133dS 38fliX3138d I N W H V M NOISSIWBflS 1 8 V d NOISSIWBflS 8 0 3 NOSEI8
~NVN

NOI~V~OTI

Appendix C - Production Part Approval, Dimensional Results

Production Part Approval Dimensional Test Results
DAIMLERCHRYSLER
ORGANIZATION: SUPPLIERNENDOR CODE: INSPECTION FACILITY: PART NUMBER: PART NAME. DESIGN RECORD CHANGE LEVEL: ENGINEERING CHANGE OOCUMENTS:

I Blanket Statements of canfarmance are unacceptable for any lest r e ~ u l l I~ .

March SIGNATURE

TlTLE

DAiE

zoo6

CFG-1003

Appendix D - Production Part Approval, Material Test Results

Production Part Approval Material Test Results

DESIGN RECORD CHANGE LEVEL: CUSTOMER SPEClFlED SUPPLIERNENDOR CODE:

I ~ i a n k eStatements t of conformance are unacceptable for any lest results.

March SIGNATURE

2006

CFG-1004

TlTLE

DATE

Appendix E - Production Part Approval, Performance Test Results

Production Part Approval Performance Test Results
DAIMLERCHRYSLER

I Blanket Statements of conformance are unacceptablefor any test reSulb.

March

2006

CFG-1005

SIGNATURE

TlTLE

DATE

Appendix F - Bulk Material Specific Requirements

F.1 lntroduction
An organization supplying bulk materials shall comply with the requirements in this Appendix or use guidance herein for clarification of PPAP. The requirements in this Appendix are minimums and may be supplemented at the discretion of the organization andlor the customer.

Organizations are responsible for applying PPAP to their suppliers of ingredients which have organization-designated special characteristics. Where OEM PPAP approval of a bulk material exists, evidence of tliat approval is sufficient as the PPAP submission at other levels in the supply chain. Examples of bulk material include, but are not limited to: adhesives and sealants (solders, elastomers); chemicals (rinses, polishes, additives, treatments, colorslpigments. solvents); coatings (top coats, undercoats, primers, phosphates, surface treatments); engine coolants (antifreeze); fabrics; film and film laminates; ferrous and non-ferrous metals (bulk steel, aluniinuni, coils, ingots); foundry (sandlsilica, alloying materials, other mineralslores); fuels and fuel components; glass and glass components; lubricants (oils, greases, etc.); monomers, pre-polymers and polymers (mbbers, plastics, resins and their precursors); and performance fluids (transmission, power steering, brake, refrigerant).

F.3 Bulk Materials Reauirements Checklist lsee 2.2)

,I$'

For bulk material, the PPAP elements required are defined by the Bulk Materials Requirements Checklist. Any customer-specific requirements shall be documented on the Bulk Materials Requirements Checklist. Use the Bulk Materials Requirements Checklist as follows: Required I Target Date: For each item listed in the checklist either enter a taget date for conipletion of the element or enter "NR" for Not Required. Priinary Responsibility - Customer: IdentiS. by name or function the individual who will review and approve thr element. Primary Responsibility - Organization: ldenti@ by name or function the individual who will assemble and assure the completeness of the element to be reviewed. Comments I Conditions: ldenti@ any quali@ing information or references to attached documents that provide specific information regarding the element. For example, this may include specific formats to be used for the Design Matrix or acceptable tolerantes for Measurement System Analysis (MSA) studies. Approved by: Enter the initials of the authorized customer representative who has reviewed and accepted the element. Plan agreed to by: IdentiS. the individuals (and their functions) who made and agreed upon the project plan.

Bulk Materials Requirements Checklist

1 Product Design and Developrnent Verification

v1

Project:

Required I Target Date

1 Primaw Respnribility
1
customer Oreanization

CommenW Conditions

~~~~d b~ 1 daie

1
1

1 Process Design and Development Verification

-

1
I

Interim Apgroval Product and Process Validation bnitial Process Studies ~ u b m i s s i o Warrant n
I

I
- 2 4
I

Elements to be completed as needed Customer Plant Connection C u o s tm Chan e Documentation Supplier Considerations Plan A reed to b : Name I Function

Company / Title I Date

'

F.4 Desian Matrix

F.4.1 Introduction
Organizations supplying bulk material generally deal with the chemistry and functionality of the product being designed. Use of these suggestions will arrive at the Same end point of a completed Design FMEA, but with greater applicability to bulk materials. For bulk materials, a Design Matrix. when required, shall be prepared prior to developing the Design FMEA. The Design Matrix determines the complex interactions of formula ingredients, ingredient characteristics, product characteristics, process constraints, and conditions for customer use. High impact items can then be effectively analyzed in the Design FMEA.

F.4.2 Design Matrix - Elaboration

This matrix correlates customer expectations with the product design items Construct the Design Matrix referring to the example which will follow:
I. Along the horizontal axis, list the Functions (Desired AttributeslPotential Failure Modes)

2. Along the vertical axis, list the design items as Potential Causes (CategorylCharacteristics) :
Formula Ingredients Ingredient Characteristics Product Characteristics Process Constraints Conditions for Use (customer process constraints)
3. For each design item, enter the current robust threshold range IeveIs and units.

4. 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 minimum or maximum, respectively. 5. After completion of the rankings in the Design Matrix, review the category/characteristics for a preliminary assessment of Special Characteristics. Designate any Special Characteristics in column 1.

6. The high negative impact potential causes are transfemd to the Design FMEA for analysis.

F.5.1 Effects of Failure and Severity Rankings

The following two steps provide an alternative method for identifying the Potential Effects of Failure and assigning a Severity Ranking. List Effects of Failure Consumer Effects - General terms identifying the Ioss experienced hy the ultimate User of the product (e.g., the vehicle buyer). Customer Effects - General temis identifiing the loss experienced by the intermediate User of your product (e.g., the vehicle manufacturer). Assign a Severity Ranking to each Effect See the Severity Definition and Evaluation Criteria in the Potential Failure Mode and Effects Analysis reference manual. The goal for each of the items that multiply to arrive at the Risk Priority Number is to differentiate between the items in that category. 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 your situation is greater than two tiers hack from the final consumer, then the guideline figure should be adjusted to reflect the effects that will be felt by your customer's customer.

Effects of Failure and Severity Ranking Table

Moderate Owner Dissatisfaction (Inconvenience) Customer (e.g., vehiele manufacuirer) Minor Owner Dissatisfaction (Annoyance) Plant Safety Problem

6
4

10

4 3

F.5.2 Potential Cause(s)/Mechanisms of Failure and Design Matrix

From the Design Matrix (if used), list the high negative impact characteristics as the Potential Causes/Mechanisms of Failure which are associated with Potential Failure Modes. 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.

F.5.3 Likelihood of Occurrence Rankings

The following step provides an alternate method for assigning Occurrence ratings Rank Occurrence - the ranking scale in the Potential Failure Mode and Effects Analysis manual is difficult to relate to bulk materials and generally results in very low numbers with little differentiation in the ultimate risk. The following matrix is recommended as a replacement. lt evaluates the frequency of occurrence based upon observed evidence the formulator has in the design. Formulation Occurrence Ranking

Occurrence Matrix FREOUENCY

Tvoe of Evidence
Actual Experience Similar Experience Assumption No Background Actual Experience: Similar Experience: Assumption:
1

MODERATE

HIGH.
7 8 9 10

2
3

4 5 6

Obtained from appropriate experimentation on the specific final product and the potential failure mode. Based upon similar products or processes and the potential failure model. 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.5.4 Current Design Controls

Design Control: Supplementing the Failure Mode Effects and Analysis manual, b u k material design controls may also include: Designed Experiments (DOE's) - List experiment #'s Customer validation tests and trial runs - e.g., gravelometer panels, fender sprayouts (list customer reference #'s). Test protocols - list Test Methods, Standard Operating Procedures, etc. Variation of supplier specifications. Formulating practice robust ranges.

Design controls identified by a number should be available so that the relevant content of that control can be understood.

F.5.5 Likelihood of Detection Rankings

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 is difficult to relate to bulk materials and generally results in very low numbers with little differentiation in the ultimate risk. The following matrix may be used. It evaluates the Detection as the ability of the current Design Control to actually detect a cause of failure andlor failure mode based upon the assessed

Testing Method R&R's percent o f specification range (see the Measurement System Analysis reference manual) and the quality of evidence.

Detection Matrix:
m o n by ~ e s c & R

30% - 100%
DOE (Response Surface Analysis) Screening Experiments AssumptiodExperience No Evidence

>100%
7

I
-

,4

DOE (Response Surface Analysis): Symmetric design space analyzed with appropriate statistical tools. Screening Experiments: Screening design or ladder evaluation strategically set to develop DOE. AssumptiodExperience: Informationidata based upon similar products or processes. Note: The ahove R&R limits are suggested unless othenvise agreed upon hy the customer and organization. R&R calculations can initially be hased using design matrix thresholds.

F.6 Process FMEA (see 2.2.61

Process FMEA Ranking Tables

Severity Rankings
rscverity of Effect

Ranking

1 hazard or noncoinpliance wirh a govemment regulation (10).

1

1 Very High: Potential failure mode may result in a field failure (9), or constitute a safety
7-8

1 High: High degree of customer dissatisfaction due to the nature of the failure. May cause 1
serious disruption to subsequent processing of the product or result in the product failing to meet its sales specitications. Will result in a customer complaint and product retum. Failure is likely to be deteeted during the custoriier's final product testing. Moderate: Failure causes some customer dissatisfaction and may result in a customer complaint or liiiiitation on shelf life. The customer may need to make modifieations or adjustments to their process to accommodate the material. The problem is likely to be detected as pari 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).

4-6

Low: Failure causing only a slight customer annoyance. Customer will notice only a slight aeterioration or inconvenience with the product or processing of the product.

2-3

Minor: Reasonable to expect that the minor nature of this failure would not cause any real by the customer. Customer will prohably not even effect on the product or its ~rocessing notice the failure.

Occurrence Rankings

- Frequency of Failure
Very High: Failure is almost inevitable. Additional process steps are devcloped to deal with the failures. High: Similar processes havc experienced repeated failures. The process is not in statistical control. Moderate: Similar processrs have experienced occasional failures, but not in major proponions. Process is in statistical control. Low: Similar processes have experienced isolated failures. Very Low: Almost identical processes have experieneed only isolated failures. Remote: Failiire is unlikely. No failures ever associated with almost identical proeesses. The process is in statistical control.

Ranking
9 - 10
7-8
4-6

3
2
1

Detection Rankings
Likelihood and Location In the Process the Defect 1s Detected
Absolute Certaintv ofNon-Detection: Controls will not or cannot deteet the existente of the defect. Very Low: Organization controls probably will not detecr the existence of the defect, biit the defect may be detected by the customer. Low: Controls may detect the existenee of the defect, but detection may not occur until packaging is undenvay.

Ranking

10

Moderate: Controls likely to deteet the existente of the failure, but not until lot acceptance testing has been completed. Tests with a higher degree of variability will have the higher ranking.
High: Controls have a guod chance ofdetecting the existence of the defect bzfore thr maniifacturing proeess has been completed. In-Proeess testing is used to monitor the manufacturing process. Veiy HighlEarly: Controls will almost certainly detect the existence of the defect before the product moves onto rtie next s t e in ~ its manufacturine. ~rocess.Im~ortant raw materials are controlled via -. organization specifications.

11

11

F.7 Special Characteristics

F.7.1 Introduction
If product characteristics/attributes can have normal variation resulting in movement outside their designintended robust range which results in significant irnpact, they are designated special, and must be controlled by special controls.

r I

Special Characteristics Clarification Table

CIarification
For Bulk Materials, a frequent occurrcnce is a transformation from bulk matcrial to final product.

Examplcl
Illustrations of the flow of rnaterials through final product follow (e.g., % solids Resin A, % U V A intcnded). These are not necessarily intended in br Special Characteristics. Examples of product characteristics are: viscosity, I/o N V Solids, 96 Rcsin "A" Examples of final product attributes are: appcarancc, film build, FMVSS safety, durability. Examples of manufacmring process parameters (control characteristics) arc. temperaturc, pressure, mix rate, test protocol.

Special Characteristics

The differentes between bulk product characteristics (features of the supplicd product) and thc final attributes (featurcs of the transfonned product) should be undcrstood. During the design phase, the product characteristics can be controls for final product attributes. (This does not imply that lhey are control charaeteristics). During manufacture of the bulk material, process parameters are the control characteristics. During transfomation from bulk product to final product, both bulk product characteristics and final product attributes can be controlled by customer proccss control characteristics. Symbols for customer-identified Spccial Characteristics Organizations may designate their own internal symbols to designate Special Characteristics in their working documents. For customer-designatedl identified Special Characteristics, the customer-specific symbols will be used for required customer documentation and required shipping labels.

Examples of custonier transformation process parameters (control characteristics) are: fluid flow, temperaturelhumidity, air pressure. The organization may choose to use "S" (Safety), or "sp" (special), or " K (Key), etc. The customer designated shield, inverted delta, diamond, etc. will bc used when required per custorner identification.

F.7.2 Special Characteristics - Elaboration

For clarification purposes, the following figure is intended to dernonstrate the flow of potential special characteristics through the supply chain.

Illustration of the Flow of Materials through Final Product: Item A (Paint) Itern B (Paint) ltern C (Sealant)
Supplier (Tier 11) Bulk Product Characteristic (Raw Material)
% Solids Resin "A"

Bulk Product Characteristic

Bulk Product Characteristic (Raw Material)

Supplier (Tier 11) Mfg. Control Characteristic Resin Synthesis Temperature Organization (Tier I) Bulk Produit Characteristic Paint Vlscositv

Mfg. Control Characteristic

Mfg. Control Characteristic

Bulk Product Characteristic

Organization (Tier 1) Bulk Product Characteristic

% Polymer I n Sealant

Mfg. Control Characteristic l a n k Mix Rate Custorner Transformation Control Charaeteristic

% Solvent Reduction

Organization (Tier I) Mfg. Control Characteristic Scale Calibration

I I
I

Mfg. Control Characleristic

Custorner Transformation Control Characteristie Fluid Flow (for film build)

Control Characteristic

Final Product Attribute Excellenl Durahiliiv

Final Product Attribute

F.8 Control Plan (see 2.2.7)

F.8.1 Introduction
The Bulk Material Control Plan serves as a mechanism to: Highlight Special ProductlProcess Characteristics and their controls Link together sources of control methods, instnictions and specification/tolerance limits and reference thern in one document Additionally, this control plan is not intended to recreate specification andlor tolerante limits that exist in other control sources such as batch tickets, work instnictions and testing protocols.

F.8.2 Control Plan - Elaboration

Refer to the customer's specified control plan format (e.g., that found in the Advanced Product Qualify Planning and Control Plan reference manual).

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 producVprocess control characteristics, process controls affecting Special Characteristics, associated tests, and measurement systems employed during product scale up and prior to normal production. Production - Documentation of the producVprocess control characteristics, process controls affecting Special Characteristics, associated tests, and measurement systems employed during normal production. Additional items may be included at the Organization's discretion.

Pre-launch and production control plans may be applied to a family of products or specific processes

F.9 Measurement Svstem Analvsis (MSA) Studies Isee 2.2.8)

Bulk materials often require further processing after sampling in order to make a measurement Measurements are often destnictive in nature and this prevents retesting the same sample. Measurement variability is often much larger for properties important in the process industries (e.g., viscosity and purity) than it is for properties measured in mechanical industries (e.g., dimensions). Measurement may account for 50% or more of the total observed variation. Standardized test methods (e.g., ASTM, AMS, 1SO) are often followed. The organization need not reverify bias, linearity, stability, and Gage R&R. MSA studies are not required where standardized tests are used, however it is still important for the 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-tosupplier" test methods should be obtained during the planning phase. Any MSA studies should be applied to each test method associated with Special Characteristics, and not to each individual product measured by the test method. Therefore, the MSA studies should be conducted as broadly as possible across all products which use a particular test method. If the resulting variability is unacceptable, then either the studies should be conducted on a narrower class of products or action should be taken to improve the test method.

F.10 Initial Process Studies For S~ecial Characteristics Isee 2.2.11)

The manufacture of bulk materials consists of industries which span a variety of production processes, from high volume products to specialty products produced in small quantities no more than once or twice per year. Often the production process is completed or already in place before sufficient samples can be tested. By the time the product is made again, personnel andlor equipment may have changed. Also, these processes have nunierous input variables, many control variables, and a variety of product variations. There are non-linearities meaning for example that doubling the change in a particular input does not necessarily double the change in the output. The effects and relationships between all these variables and controls are also not usually known without error. Multiple processes are usually interconnected, sometimes with feedback loops. There are also timing considerations and delays in reaction time. Further, measurements of component variables are generally less precise than measurements of component parts, such that in many cases correlated variables must be used.
-

QI
1

1
1
!
G

F.11 Master Samnle (see 2.2.151

F . l l . l Introduction
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.g., they do not significantly change physical or chemical composition, if properly stored, for decades). 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 appmpriate analytical techniques. In this case the analytical record (e.g., Ultra-Violet or Infra-Red spectra "fingerprint," Atomic Absorption or Gas Chromatographic-Mass Spectrometric analysis) is an appropriate Master Sample. Manufacturing Sample Record: When bulk materials can not be distinctly identified or change over time, a manufacturing sample record should be generated. The record should include the infonnation required to manufacture a "nonnal production size" run (lot or batch), according to the final "Production Control Plan" supporting the PSW. 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 infonnation suggested to accomplish this task: The quantity of product produced. The important performance results. The raw materials utilized (including manufacturer, Lot # and important properties records). The critical equipment required to manufacture the bulk material. Analytical sample records, as described above, on the material as produced. Batch ticket used to manufacture the bulk material.

F.11.2 Paint Manufacturing Master Sample Record

- Examples

The following figures show examples o f paint manufacturing master records:

Paint Mfg Master Sample Record - BatchlLot Mfg. Record

MFG. LOCATION:

'Iant ' I

MFG. DATE: 12/5/97

Product Name: White Basecoat

Number

1x97

I
:

Product Code: x x R - y m LbslGals Req'd.: 1000 Gals.

Forrnula ~ ~ 1/18/97 t -~

Equip. ID.:

MixerX2

I
I

I
Test Method TM001 Specifications 10.50 - 10.70 57 - 61% 30 - 40 Secs

TESTlNG INFORMATION

Name
WVGallon % Non Volatile Viscosity

I
I
Operator Initials

1 lnaredients -

Amt.

Amt. Loaded

Add in order, with rnixing

Resin A Resin B

1000 Lbs

1 500 Lbs
qOOLbs

999 Lbs 501 Lbs.

I / I 1 I
L

Lomank # I Daterime

( AB345

CD678

12/5/97 9:35 AM

12/5/97 10:25 AM Initials

I
I

Control ternperature of mix. Not to exceed 105" F. Ternperature recorded =

Crosslinker

~ 7 0 0 L b s ~ 5 0 [12/5/9710:25AM!

1
I
I
I

- P - - - -

----- ------ ---------- -----

'r---FlLLlNG INSTRUCTIONS Containers 250 Ga1 Tote Filtering 25-Micron Bag Labeling Per Contract

------

T-----1

Master Sample Record - Product Test Results

Product Code: xxR-yyyy Manufacturing location: Plant # l WtIGallon Batch Size Batch # Date TM00 l Gallons 1215197 1197 1000 10.50 10.70 IG 9 Product Name:
% nonVolatile TM004 57 - 61%

White Basecoat Initials ~ernarks

Viscosily TM003 30 - 40 Secs

34

59.6

Paint Master Sample sis R e

Certificate of Analysis
Material Name: Filmfonner Resin Material Code: Resin A Specification Requirements Propeciy Min. Result LotIBatch #: AB345

lngredients

Max

LotiBatch

I
1

% Non Volatile

57% 7

61%
7.3

58.8% 7.2

(TM004) $MOOS) Certification Signature: Date:

F.12 Part Submission Warrant (CFG-10011 Isee 2.2.181

A Part Submission Warrant shall be prepared and submitted for approval when required by the customer. 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.g., part weight, dimensional measurement) does not need to he provided. For those organizations that have been classified as "self certifying" by a specific customer. submission of a warrant signed only by the organization shall be evidence of PPAP approval, unless the organization is advised othenvise. For all other organizations, evidence of PPAP approval shall be a warrant signed by both the authorized customer representative and organization or other customer approval documents.

F.13 Interim ARRroval (see 5.2.2)

Most products will achieve approval prior to initial use. In cases where approval cannot be obtained, a "Bulk Material Interim Approval" may be granted. A form is shown on the facing page; other forms may be used. COMPLETION OF THE BULK MATERIAL INTERIM APPROVAL FORM
1. 2.
3. 4. 5.
6.

ORGANlZATlON NAME: Name assipncd ta Orgaiiizalion's manufacturing localion. PRODLtCi NAME: Doe~menls. The Organization's designatcd name for the product-ss identified in the Customer's Engineering Release

SUPPLIERNENWR CODE: Code (DUNS number or equivalent) assigned to the manufachiring location as shown on the Customer'r purchase order.

ENG. SPEC.: Customer's identitied Speeification ihrough which the product is approvcd and released. MANUF. SITE: Physical address of the manufachiring location as shown on the Curtomer's purchaie arder. PART Q: Cuslomer's Pan Number. ENG. CHANGE #: Formula Revision Level or number idenrifying the formula. FORMULA DATE: Engine~ring Release Date ofthe formula identified in ilem #7. RECEIVED D A T E Customer Use Only. RECEIVED BY: Customer Use Only (Custorner Repreeentative). SUBMISSION LEVEL: Submission Level (1-5) thal Organization is required to rubmit to as defined by the Cusiomer. EXPlRATlON DATE: Date that the Interim Approval expiren. TRACKMG CODE: Customrr Use Only. RE-SUBMISSLON DATE: Date oiganilation will resubmit for produilion appraval. STATUS: For each ilem, enter appropriaic code (NR - Not Requircd, A - Approved. I - Interim). SPECrFlC QUANTITY OF MATERIAL ALITHORIZED: Lltilized when Interim Approval rpecifies a rpeeific quantity of volume of product. PRODUCTION TRIAL AUTHORIZATION: faeility. Customer's Engineering Release authorizing the use of the prodilet in the Cuslorner's

7.
8.

9.
10.
I I.

12. 13. 14. 15. 16. 17. 18.

I'>.

REASON(S) FOR MTERIM APPROVAL: Indicate reason for lnterim Requesl. ISSUES T 0 BE RESOLVED, EXPECTED COMPLETION DATE: For rach itern marked as "I" in #l5, provide explanatory details regarding problern isrues and furninh a date far problern resolutian. ACTIONS T 0 BE ACCOMPLISHED UURMG MTERTM PERIOD, EFFECTIVE DATE What is being donc to ensure defcctivc product is contained, daic whcn the action was implemcnted and Exil Crircria necessary 10 end need for eonlinuing the aetion or iis individual elcmcnts. PROGRESS REVIEW DATE: Updaie on Progress of problem rcsolution, generally the midpoint from issuance to expiraiian of ihe interim period. DATE MATERIAL DUE T 0 PLANT: Ilale material is due tu Custornir's site. WHAT ACTTONS ARE TAKMG PLACE T 0 ENSURE THAT FUTURE SUBMISSIONS WILL CONFORM T 0 ALL PPAP REQUIREMENTS BY THE SAMPLE PROMISE DATE? Why won'l this happen again? ORGANIZATION: Rrspansihlc and Auihorized Orgvnization offiiial 10 enSure compliance to thc above mentioiicd actions aud daies. PRODUCT ENG.: Product Ingineer's signature, printrd name, phone number. and date. MArERlALS ENG.: Material Engineer's signature, printed name, phone "umher, and date. QUALITY ENG.: Quality Engineer's signaturc, printed name,phone number, and date.

20.

LI.

22. 23. 24.

25.

26.

27.

28. INTERIM APPROVAL NUMBER: Customer Use Only.

BULK M TERIAL INTERIM APPROVAL ORM

SUPPLIER NAME: SUPPLIER CODE: MANUF. SITE: ENG. CHANGE #: RECEIVED DATE: SUBMISSION LEVEL: TRACKING CODE: FORMULA DATE: RECEIVED BY: EXPIRATION DATE: RE-SUBMISSION DATE: 10 12 l4

PRODUCT NAME: ENG. SPEC.:

STATUS: (NR Not Required, A - Approved, I - Interim)

Design Matrix: Control Plans: Test Results: DFMEA:PFMEA:Special Product Character1stics:-Engineering Special Process Characteristics:-Process Results: A p p r ~ v a l : ~ Flow Diagram:

Process Studies:-Dimensional

Master Sample:

Appearance : ~ Approval Repoit: Measurement Systems S t u d i e ~

SPEClFlC QUANTITY OF MATERIAL AUTHORIZED (IF APPLICAB PRODUCTION TRIAL AUTHORIZATION #: REASON(S) FOR INTERIM APPROVAL: 18 V

ISSUES T 0 BE RESOLVED, EXPECTED COMPLETION DATE (CLASSIFY AS ENGINEERING, DESIGN, PROCESS. OR OTHER):

@
R20

ACTIONS T 0 BE ACCOMPLISHED DURING INTERIM PERIOD, EFFECTIVE D

ATE MATERIAL DUE T 0 PLANT PROGRESS REVIEW DATE: ENSURE THAT FUTURE SUBMl WHAT ACTIONS ARE TAKl CONFORM T 0 BULK MATERIAL PPAP REQUIREMENTS BY THE SAMPLE PROMISE DATE? ( ' 3

SUPPLIER (AUTHORIZED SIGNATURE) (PRINT NAME) CUSTOMER APPROVALS (as needed): PRODUCT ENG. (SIGNATURE) (PRINT NAME) MATERIALS ENG. (SIGNATURE) (PRINT NAME) QUALITY ENG. (SIGNATURE) INTERIM APPROVAL NUMBER: (24)
W

25

PHONE: DATE: PHONE

DATE

(26)
A

(27)

BULK MATERIAL INTERIM APPROVAL FORM

SUPPLIER NAME: SUPPLIER CODE: MANUF. SITE: ENG. CHANGE #: RECEIVED DATE: SUBMISSION LEVEL: TRACKING CODE: PRODUCT NAME: ENG. SPEC.: PART #: FORMULA DATE: RECEIVED BY: EXPlRATlON DATE: RE-SUBMISSION DATE:

STATUS: (NR Not Required, A Approved, I Interim)

Design Matrix: Control Plans: Test Results: DFMEA:PFMEA:Special Product Characteristics:-Engineering Special Process Characteristics:-Process Results: A p p r ~ v a l : ~ Flow Diagram:

Process Studies:-Dimensional

Master Sample:

Appearance : ~ Approval Repofl: Measurement Systems S t u d i e ~

SPEClFlC QUANTITY OF MATERIAL AUTHORIZED (IF APPLICABLE): PRODUCTION TRIAL AUTHORIZATION #: REASON(S) FOR INTERIM APPROVAL:

ISSUES T 0 BE RESOLVED, EXPECTED COMPLETION DATE (CLASSIFY AS ENGINEERING, DESIGN. PROCESS, OR OTHER):

ACTIONS T 0 BE ACCOMPLISHED DURING INTERIM PERIOD, EFFECTIVE DATE:-

PROGRESS REVIEW DATE: DATE MATERIAL DUE T 0 PLANT: WHAT ACTIONS ARE TAKING PLACE T 0 ENSURE THAT FUTURE SUBMISSIONS WILL CONFORM T 0 BULK MATERIAL PPAP REQUIREMENTS BY THE SAMPLE PROMISE DATE?

SUPPLIER (AUTHORIZED SIGNATURE) (PRINT NAME) CUSTOMER APPROVALS (as needed): PRODUCT ENG. (SIGNATURE)(PRINT NAME) MATERIALS ENG. (SIGNATURE) (PRINT NAME) QUALITY ENG. (SIGNATURE) (PRINT NAME) INTERIMAPPROVAL NUMBER

PHONE: DATE: PHONE

DATE

F.14 Customer Plant Connection

F.14.1 Customer's Responsibilities
The customer plant connection is a shared responsihility heiween the organization supplying hulk material and the customer. This connection defines the interaction of specific customer plant processing steps with Special Characteristics and final product attrihutes of the hulk material. This interaction is especially significant when hulk materials undergo chemical or physical transfom~ation(s). Three key components of the Customer Plant Connection are the development of a Customer Process Matrix (SEE FOLLOWING EXAMPLE), determination of Special Characteristics from the Customer Process Matrix, and the preparation of a Control Plan which systematically directs corrective actions. For hulk materials, conducting the steps outlined in this "Customer Plant Connection" is highly recommended.
NOTE: It is not the intent of PPAP to compromise proprieiary information.

F.14.2 Customer Plant Connection - Clarification

The following is applicahle to materials that are transformed from hulk (e.g., wet can of paint) to final product (e.g., cured paint film). This may not he applicahle to all hulk materials (i.e. washer fluid, engine oil, etc.). It is recognized hy the organization that it is their responsihility to deliver the product to the customer with the characteristics of the b u k material per organization and customer agreement. The impact of the transformation of hulk materials hy the customer plant on final product attrihutes may he accounted for in the customer's application process. During the transformation from hulk product to final product, hoth hulk product characteristics and final product attrihutes may he impacted hy customer process controls.

PPAP does not require a Process FMEA or Control Plan for the customer process. Since the product is frequently two products (hulk and finished), there is a shared responsihility for the final product attrihute. For example, percent solids and viscosity of a hulk coating which impacts the final coating's film huild attrihute, may he affected hy the customer's mix room percent solvent reduction. The percent reduction process Parameter may therefore he controlled to aid in control of film huild. The process steps at customer plants may he matrixed versus the Special Characteristics (determined jointly hy the organization and the customer). Where high impact is evident, those process steps may he analyzed hy the Process FMEA methodology.
The Special Characteristics may then he determined, and he included in a Control Plan for the customer process. These Special control characteristic items may he monitored and continuously improved.

F.14.3 Customer Plant Connection - Guidelines

The following is a recommended set of guidelines for the customer plant when implementing process controls for hulk materials.
1. Assemhle cross-functional teams of customer personnel for each customer process area. Include appropriate organization representatives on each team.

2. Select Champions for each team - these are the customer process owners (i.e., chief process engineer, area supervisor, etc.).
3. Define critical customer handling, application steps and process parameters in each area.

4. Review the organization's Design Matrix and Design FMEA items for application functions which have heen designated as Special Characteristics. Also review the desired final product attrihutes for items needing control. 5. From #4, develop a list of Special Characteristics and Attributes.

6 . Constmct a Customer Process Matrix, using #3 as the top, and #5 as the side of a matrix.
7. Perform a Customer Process FMEA, focusing on the high impact customer process areas which impact the Special Characteristics. (Do the PFMEA per Appendix F).

8. Determine Special Characteristics from the Customer Process Matrix and PFMEA (e.g., paint fluid flow, gun distance, etc.). 9. Prepare a Control Plan for each affected customer process area. The plan (utilize current DaimlerChrysler, Ford, GM APQP guidelines) might contain. at a minimum all process steps containing Special Characteristics.

10. Monitor and record all Special Characteristics by appropriate means (control charts, checklists, etc.). -

11. Ensure stability of Special Characteristics and continuously improve where possible

Custorner Process Matrix Exarnple

Impact Ratings: 3=high, 2=Medium, l=Low

Appendix G - Tires Specific Requirements

G.1 lntroduction anti A ~ ~ l i c a b i l i t y
An organization supplying tires shall comply with the requirements of PPAP This Appendix is to be used as guidance for clarification of requirements unless othenvise specified by the authorized OEM customer representative. Performance testing, based upon design requirements used by each OEM to select tire construction (technical approval), reduces the need to repeat all tests during PPAP. Specific PPAP confirmation tests are specified by each OEM.

G.2 Guidelines for PPAP Reauirements [Reference Section 2.1)

Significant Production Run (2.1)
Unless othenvise specified by the OEM, the size of the production run for the PPAP parts is a minimum of 30 tires.
NOTE 1: The above definition applies to all uses of "sigriificant productiori mri" within PPAP. NOTE 2: The typical development of a new tire design involves multiple builds of a small quantity of tires. Most designs are basic to the organization's process. For the tire industiy, PPAP is typically

completed with an initial niold or niolds, and well in advance of customcr requirements for large volume production. NOTE 3: The PPAP for the lire industry typically is derived from I to 8 hours of tire curing from the approved production process as specified in the organization's control plan.
PPAP is not required for additional molds that are brought on line in the approved production process. All additional molds shall be certified by the organization's intemal certification criteria and documentation.
NOTE 4: For tires, tooling is defined as the tire mold. This definition of tooling applies "tooling" within PPAP.
10

all uses of

Material Test Results (Reference 2.2.10.1)

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.

Special Characteristics (Reference 2.2.11.1)

Tire uniformity (force variation) and balance are designated Special Characteristics.

Appearance Approval Report (AAR) (Reference 2.2.13)

The AAR requirement is not applicable.

Master Sample (See 2.2.15 and 2.2.9)

Master samples are not retained

Process Flow Diagrams

See PPAP 2.2.5.