UNDERTAKEN AT

IMPERIAL AUTO INDUSTRIES

LIMITED
FARIDABAD(HARYANA)



KUREKSHETRA UNIVERSITY

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 Acknowledgement

The successful realization of the project is an out growth of the consolidated

effort of the people from desperate fronts. So it·s only with their support and
guidance, I could meet my goal.

It is a proud privilege to acknowledge with deep sense of gratitude to Mr.

Pawan Saharan (Development Head).
I like to thank Mr. Manoj Batra (Manager- HR) who has given me the
opportunity to do my summer training at Imperial Auto Industries Ltd.

I am especially grateful to my guide Mr. L.M. Sharma (Plant Head) &

Ravinder Wadhwa ( Engineer- HR) for providing me valuable inputs so as
to complete my training successfully.

I would also like to extend my thanks to all the Development & production
Staff members who have been very helpful through out my training in
supplying with all the necessary information.

Lastly I would like to thank Ms. Imperial Auto Industries Ltd, for
accepting me as a summer trainee in such an esteemed organization.

AMIT MALIK
ROLL NO. 3407333
S.D.I.T.M

.UUnivity
c
 

 Preface

The following is a report of six weeks Summer Training at Imperial Auto

Industries Ltd. done in partial fulfillment of my B.E course from
S.D.I.T.M, K.U University.

The summer training was completed at Imperial Auto Industries Ltd. under
the guidance of Mr. Pawan saharan (Development Head). This training is a
part of my four years course. During the stipulated time period my aim was
to gain as much as knowledge and information possible and to be well
familiar with the working conditions of the Organization. In this report also
are the details of the project work allotted to me.

The training was to study the different processes used in the production of
the final product. I also went to understand ERP software running in the
company.


 

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 IMPERIAL AUTO INDUSTRIES LIMITED

DATE OF
INCORPORATION THMAY
  
  
REGD. OFFICE  
AAUSALAZAR
 HRUcLAC
DLHI
  
MAIN FACTORY & ccSITRAILAYDS
OFFICE SHD
ARIDAAD 
  
PLANT II cLTSCTR 
ARIDAAD 
  
  
PLANT III SCTR C
ARIDAAD 
  
PLANT IV cLT SCTR 
ARIDAAD 
  
PLANT V  M thu R 
ARIDAAD 
  
BRAKE IDLInuti 
HOSE A 
PLANT ARIDAAD





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 PRODUCT PORTFOLIO
   

HIGH PRESSURE FUEL INJECTION LINES

   

ULI CTICLUSTRcIcSTSRMULTI
CYLIDRIS

   

RAILAYDISLISHAVYTA
TC.

   

HYDRAULIC HIGH PRESSURE COMPONENTS

   

HYDRAULICHIHcRSSURHS
ASSMLY

   

SAAMLSSTUASSYSRHIHcRSSUR
MAILDSADHYDRAULICAccLICATIS

   

NYLON TUBES   

   

ULSYSTMS  

   

RA
STRcIcSLURICATIcIcS

   

CLUTCHVACCUMLURICATIcIcS

c


 BRAKE LINE & CLUTCH COMPONENTS

HYDRAULICRA
HSS

AIRRA
HSS

CCTILIS

RA
TUS

cRSTARIHSS

CLUTCHTUS

AIRLIS

FUEL LINE COMPONENTS

ULLIS

ULRTURLIS

VRLLISMAILDS!ScILLcIcS)

LLTHRLLSL"ILHSSITHcVCCA


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 TUBULAR COMPONENTS   

       

 "HAUSTcIcSCMcTS  

       

 ILATR#AIRDLIVRYcIcS 

       

 STRUCTURALAUTMTIVARICATDTUS
       

 ULTA
C
S    

       

 cIcS#HSSRTA
SARMURDVHICLS
 TC
       

 CMcTSRAIRSTARTISYSTMS
       

RUBBER PRODUCTS    

       

 HSSITHUTDITTIS  

       

 RADIATRDHSS   

       

 ULHSSAScRIVMTRY
 MULTILAYRDHSS
MRCSM


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 MAIN BUSINESS GROUPS
     
     

MANUFACTURER OF

AUTMTIVSTLTUI
RA
TUS  
ULTUS   
ULI CTITUS 
RADIATRTUS  
ULILTcIcS  
VRLLIS  
ARICATDTUASSY. 
CRSSMMRS  
    
L"ILHSS  
ULHSASSY.  
RADIATRHSS  
RA
HSASSY. 
HYD.HIHcRSSURHSASSY.
VACCUMHSASSY. 
AUTMTIVULSYSTM









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 CUSTOMERS

ÿ TATAMTRS
ÿ MARUTIUDYLTD.
ÿ MAHIDRA#MAHIDRA
ÿ SARA MAZDALTD.
ÿ A A VHICLS
ÿ A A AUT
ÿ HRHDA
ÿ HYUDAI
ÿ CIDIA
ÿ cU ATRACTRSLTD.
ÿ ICHRMTRS
ÿ cIAIVHICLS
ÿ L#T HDR
ÿ CUMMISIDIA
ÿ
IRLS
AR
ÿ SCRTSIDIA
ÿ ASH
LYLAD
ÿ TA
ÿ HIDUSTAMTRS
ÿ CUMMISUSA
ÿ HDRRAC
ÿ RALMTRSUSA
ÿ TRIUMcHMTRCYCLS

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 PROCEDURE

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Rejection from Customer

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) t-%t $ ti MRV!M ti RtunVu%h)i)) .Th t
) t-%t$ ti h t*) %'ithin y!th'i
+%i nn'*iin
).

Accounts Department
Th i n A%%unt D) t$nt 'h v iu %%untin
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n
in
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niz tinun.
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Feedback
$ th %ut$ nt ny th  i %iv *ut  th * %(
*utth)u%ti*t in.CCR!Cut$C$) int)/Th%$) int
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niz tin () n '(in
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 AUDIT SYSTEM
     
PROCESS AUDIT   VISUAL
( FREQ. - WEEKLY, MONTHLY ) DIMSIAL
   DSTRUCTIVTST
   
   
PRODUCT AUDIT LAYOUT  AccARAC
( FREQ. - DAILY, WEEKLY,
MONTHLY ) DIMSIAL
   SURACTRATMT
   cRRMAC
   
   
PRODUCT LAYOUT AUDIT  ULLDIMSIAL
( FREQ. - YEARLY )   ITMTUCTI
   cRRMAC
   MATRIAL
   
   
PRODUCT TESTING & EVALUTION DIMSIAL
   SURACTRATMT
   cRRMAC
   MCHAICALcRcRTIS
   CLALISS


c


 KEY QUALITY FUNCTIONS

 

PRODUCT QUALITY PLANNING 

 
PRE PRODUCTION  ASIILITYSTUDY#CMMITMT
QUALITY PLANNING  cRCSSSLDIARAM
AILURMD#CTAALYSIS
 cRCSS
 cRCSSCTRLcLA
 cRCSSCAcAILITYAALYSIS
UACALIRATIADUA
 R#RSTUDY
 TL#I"TURCTRL
 SUccLIRSLCTI#AccRVAL
 
 
PRODUCTION PROCESS  cARTLVLCTRLcLA
VALIDATION cRDUCTIcARTSAccRVAL
 cRCSS!ccAc)
 cRDUCTI0UALIICATI






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 INSPECTION SYSTEM

    

INCOMING INSPECTION  IITIALSAMcLVALUATI

    RULARSUccLYIScCTI
    SUccLIR0UALITYIScCTI
    
    
INPROCESS INSPECTION IITIALSTUcAccRVAL
  STAAccRVAL
  LITSTI
  LIR CTIAALYSIS
  
SPC CRITICALcRCSSCTRL
  CHARTI
  cRCSSCAcAILITYSTUDY
  
  
FINAL INSPECTION  ITMTUCTIAL
 DIMSIAL
    VISUAL
    cAC
I






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TYPES OF PIPES USED IN THE INDUSTRY

) unyTu*
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 !TS)

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hcuci)

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Di $tci)u$$t$$

Hu (Hci)HS#L
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INTRODUCTION

In th $ nu %tuin
 inuty MRc !M ti  R&ui$nt c nnin
)
*% $ th un $nt %n%)t)u%tin $ n
$nt n%nt in
th $i . At thi t
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 $ n
$nt th t utiiz ) t it $ n
$nt n ) t
v)$nt '  in th $ int $. An thi %n%)t !MRc) un
$  invnty $ n
$nt  $ ti  t ) nt n )nn
) nnin
 n iti*utin ) nnin
 'hi%h in tun *% $ MRcII
!M nu %tuin
Ru%c nnin
).Thiin%) tin n%i  %%untin

hu$ n u% $ n
$nt un%tin iti*utin $ n
$nt un%tin
n$ n
$nt %%untin
un%tin.It% $t
* y%v   
nt)i$ int y*uin nvntu y% $t*% ERP.

What is ERP?
u
 
     u  

 
    

   
 

  
  
       

 
 
 

   
 

  

     
 ERP ) %(
  int
 t !%vin
 
*uinun%tin)t' ) %(
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i
in y Rc ) %(
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t t th $ nu %tuin

inuty n%nit$ inyun%tin) nnin
 n$ n
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$nt )u%tin $ n
$nt %%untin

n in n%i   i t%. H'v in %nt y   )t tin nt ny t
th$ nu %tuin
inuty*ut tivty)inutyh *%$

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)i* nth+) nini$)$nt tin nuh *n)
in

n 
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th$ -*uin)% n

niz tin u%h  %ut$  ui$nt n $ nu %tuin
. It
u%%)n u)n %h %i%u$%i*Rcyt$ in¶t $u%h *tt
th nth
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      hn  ' hu in i 
nt %ut$%+ $)th t ' ut$ ti% ytth
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h &u tinMu$* i ntth$ nu %tuin
) ntinChnn i.Thu
 in$ tin int
 tin tu%(  %h 'ith C n CRc
vn¶)i$ yt 
t n Rct(inth y.

REASONS FOR THE GROWTH OF ERP MARKET
Th i n u*t th t th $ (t  nt)i Ru% c nnin
 !Rc)
yt$iin
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'th t
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 . Tn *i$)v*uin)$ n%
ÿ Cy%ti$u%tin
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iity

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. Th

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uti$ t 'inn in thi  % 'i * th %ut$ 'h 'i
t *tt
)u%t n*ttvi% t  *)i%.

ADVANTAGES OF ERP

Int in
 nRcyt$h $ ny v nt
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i%t v nt
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'i %ut$  ti %tin n  n. Th 'in
  $  th
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ÿ uinInt
 tin
ÿ +i*iity
ÿ ttAn yi nc nnin
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Y. Business Integration
Thit n$t v nt
iinth)$tinint
 tin.Th n
'hy Rc ) %(
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u) tin th t i )i* $n
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th %$$uni% tin n int
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int*uinun%tin.Inth%  
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ti$in
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it h  *%$ n *t % in th hit t n' )u%t n *uin

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% ii% tin. In th %   Rc ) %(
 th  t    t *uin
un%tini  ut$ ti% yu) t tthti$ t n %tin%%u.
thi nn i *t
 )*uint i in  ti$ n% yut
v iu ty)  $ n
$nt %iin in  ti$y $ nn *  n th t
in$ tin.

. Flexibility
Th %n v nt
  Rc ) %(
 i thi +i*iity. Dint
 n
u
%un%i %%untin
t n  nn% n*%vinn
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 $uti)% tin 
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* iz tin n yt$ unii% tin thi +i*iity i nti 
n n % n  y th t it h  $ - v nt
 nt i$)y  v)$nt
n$ intn n%*ut int$$ n
$nt.

3. Better Analysis and Planning Capabilities
Yt nth v nt
ith*ttth) nnin
un%tin.yn *in
th
%$)hniv n unii $ n
$nt   t *uin n it  t  it
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+i*iity nin ti$thiin
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i$nin n i * t
iv th %iin $ ( th in$ tin thy
' nt.thun *in
th$t$ (*tt nin$%iin.


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4. Use of Latest Technology
Th uth v nt
 i th utiiz tin  th  tt v)$nt in
In$ tin T%hn
y!IT). Th Rc vn' vy&ui%(t iz
th t in  t
' n t ut in th t
'th. thy h  t $* % th
 ttv)$ntinthiIn$ tinT%hn
y.Ththy
&ui%(y  )t thi yt$ t t ( v nt
  th  tt t%hn
i
i( )n yt$ %intv t%hn
y IntntInt nt CALS
!C$)utAiA%&uiitin nL
iti%Su))t)%tni%%$$%
t%. It i thi &ui%(  )t tin t th  tt %h n
 in In$ tin
T%hn
yth t$ (th+i*  )t tint%h n
inutu*uin
nvin$nt )i*. It i thi +i*iity th t $ ( th in%) tin 
th ttt%hn
y)i*uin
yt$%ut$iz tin$ intn n% n
+) nin)h .
Ah *nt t *vRcin%u$ nythun%tinth t'i*
n% y  utu yt$. H'v unt (in
 $ t %$) ny
tu%tu n*uin)% tn *thuuth$ -
 tuith
 ttt (%$) nith t'iuth$.Itin% y
t t ( nt th t % u y )%in
 'ith th i$)$nt tin  Rc
$y nyt$%ntu%tin))  tinthy  
i i(y t ut in tunin
 th *v $ntin v nt
 n
i v nt
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BUSINESS MODULES IN AN ERP PACKAGE

Introduction
h ti *uin2Itint-ut*uiin
$ %hiny$ny.uini
))ntny))'hvunt iy%$t
th*% uthy% n
$u%h $ '(in
 t
th th n thy %u '( n *ut  ))
'h'(nthi'n nt)nu.uinthn% n*in 
th %tiviti  iniviu  
u) th t  invv in v)in

)u%in
 n iti*utin
 th
 n vi% n t  tiy th
))¶n.
uin u u% t )u%
 n vi%. Th
u%   n  * n % )it . Th th u% *%$
)u%tiv 'hn %$*in in   tin  ' y  $ % tiv 
inu
)u). Thi i th un%tin  th uth u%nt)nuhi) 
$ n
$nt. nt)nu  $ n
 %$*in th u% i(  n
 * n % )it  in int ' y t )u%
  vi%. It i th
un%tin  th $ n
$nt t ) n th %tiv n i%int u  th
u% v i *tthnt)i.Thnt)iu%) nnin
!Rc)
yt$ h) th $ n
$nt in $ (in
 th ) nnin
 )% $
)u%tiv ni%int.
ARc) %(
%nt in$ ny$u.Thnu$* n tu
th$uv i'iththRc) %(
.Inth'in
''i$
 th $t %$$n $u v i * in $t  ) %(
. Thy 
in n% M nu %tuin
 n cu%tin c nnin
 S  n Diti*utin
c ntM intn n%0u ityM n
$ntM ti M n
$nt nn.
Thii*yn$ n %$)hnivit.S$) %(
'ih v u*t

c
 

 thi n $ 'i h v $ $u n  tu.  t i
in$ tin yu 'i h v t %nut th )u%t it tu  th )%ii%
Rcyt$.
C$)utizyt$+itthint*uin$uvn
*thRc .ut'h t$ (Rcint n% ) *)u%in

 $ ti% ut i th int
 tin n ut$ tin  th v iu *uin
un%tin.R thth nun%tinin
ini tin% tin
tthnthi
'n ) t$nt th int $u in n Rc yt$  int
 t.
Thy n n %iv  t  % ) t$nt  * i. Anth  tu
th t i$)v )u%tivity n u% )n n  %tin ti$ i th
ut$ tin  th v iu )%u n t (. Mt  th t ( 'hi%h
'n $ nu y inth )Rc   n' ut$ t. At ( 'hi%h
invvth%in tint'th) t$nt'ut ( yin 
nnRcnvin$nt.H'v'ithth)%u ut$ tin n$u
int
 tinth $t ('i*%$)t'ithin$inut nth tt-ut
*y n %tin initi t *y  in
 )n !'hi%h ti

  t  th
)%in$ nyint$u).

V iuint$uRcin*uin 
Y. Finance
Thi%tin)vi nvvi'thin n%i utinin$t
th Rc ) %(
. In t y¶ *uin nt)i yu n t (n' th t
yuin n%i %iin * nt y¶ t ntnu$*$%
%  $nth
  vn  '(
. An yu n t (n' th t thi
 $ 3t y¶¶  t  )nt vy 
$nt  yu 
niz tin¶
%tiviti 'hth yu nt)i tt%h %  $  un th

c
 


*.Thiinti *% uth$ti%int' yt
tyunt)i
t'hyu' ntitt$'it(n'+ %ty'hitit y.
Thin n%$uh v'in
u*yt$
ÿ !   

 
ÿ á 

  

ÿ 
  
ÿ 2

ÿ u

  

. Production
M nu %tu $ut )n &ui%(y n %tivy t %ut$
$ n. hi
iity i i *
iity 'ithut n %tiv nt)i
$ nu %tuin
yt$utin)'ithut)u).Thvyh t n
nt)i$ nu %tuin
yt$%ntnitint
 t) nnin
*uin
)% n+%utin% ) *iiti.T itin C L)MRc%n%)t
h v n
 h  th i$)t n%  %tiv ) nnin
 *uin )%
unt nin
 nti$y+%utin.St t
i% y%tiv) nnin
ut
ini$)vinvntytunin% )u%tivity ni$)vtunn
t. T %ti% y %tiv *uin )% )vi i$)v %ut$
 ti %tinu%ti$t$ (t ni$)v$ (th .S$th
$ -u*yt$th$ nu %tuin
$u 
ÿ 
  
   
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c
 

 ÿ u   !
  

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ÿ 2  

3. Human Resources
Hu$ nu%$ n
$nti nnti  %t nyu%%u
*uin. Th %$)titiv nvin$nt  th n+t $inniu$ 'ith it
%n$i% n t%hn
i%  %h n
 'i %t th HR ) t$nt in
th  $ ' y it 'i  th th    yu nt)i. In ht HR
$ n
 $ut %ntinu y vi' n )ti$iz thi *uin )%.
ThHR$u$tRcyt$h v ti%h tu n'i
int
 t $y'iththth$u n thuinv u * iin
i$)vin
 )u%tivity. Thy  %$) ny'i utin  HR
) t$nt n $ ( it )i*  th ) t$nt t %% )%ii%
$)y t .V iuu*yt$unthi 
ÿ     

ÿ — 
    

ÿ  

 
ÿ 2  

ÿ   ! 



c
 

4. Plant Maintenance
c ntM intn n%)viyu'itht%hni%  n*uin)t n
v iu )nt tin )tin %%in
 t th %iti  u  + $)

niz tin  unit % tin +%utin )i  th t (  yt$
$ nu %tu.Thiin$ tinh)yutu%thu tin n%t
) nt 'nti$   ut   $
 n t %
niz )i* ' (
)int'ithinyut%hni% yt$in
ti$.It $th* i
inin
 n)ti$u$$ intn n%t t
yinthn4Tt cu%tiv
M intn n%5!TcM)i()ti$iz$ intn n%.Th$ -u*yt$
c ntM intn n%$u 
ÿ 

  
 
ÿ u


" 
ÿ   

" 
ÿ  

   
 
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ÿ  

  
 
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V. Materials Management
ThM ti M n
$nt$u)ti$iz )u%h in
)%
'ith '('ivn )%in
 un%tin n * ut$ t u))i
v u tin ' )%u$nt n ' huin
 %t 'ith %%u t
invnty n ' hu $ n
$nt n int
 t invi% vii% tin.
Th$ in$uM ti M n
$nt 
ÿ #
 


ÿ 
 
ÿ r  u

 
ÿ á 
  


c
 

 ÿ á  r
   
 á 
 

A. Quality Management
Th IS  i n  ht  t n  in th un%tin 
0u ityM n
$nt nth$nt 0u ityM n
$ntyt$.
Th un%tin in th 0u ity M n
$nt $u u))t th nti 
$nt  u%h  yt$. Th th int
 t $u in th yt$
%$)$nt thi un%tin ity. Th t n  &ui th t 0u ity
M n
$nt yt$ )nt t  )% 'ithin n 
niz tin. Th
t ()iiti %%in
tth&u ity)hit)u%tint)u%tin
) nnin
 n )u%tin v)$nt t )%u$nt n   n
iti*utin  '  int th nti u
 )h . In th   
)u%tin &u ity u n% i n n
 vi' in t$  in)%tin
nthi$in tin%t n.Int th)u%tin)%it
*%$th %u ttntin. Th0u ityM n
$nt $u ui
th'in
un%tin
ÿ l
 
   
ÿ l
 
á 
 
ÿ l
 

 

7. Sales and Distribution

ith t y¶ *uin nvin$nt %h  %tiz *y
'in

%$)titin hin(in
 %y% ti$ n th %% tin
 ) % 
t%hn
i%  innv tin %$) ni  in% in
y *in
 % t
t $in*uin)%.In 'in'hi%hitinn
nu
h
t i$)y h v th *t )u%t. th %$) ni  %uin
 n %

c
 

 %$)tn%i n%) tnhi)vth'hu))y%h in. H
in% i%in%yin  niti*utini (y %ttnuth t
%$) nit in %$)titiv
 ni$)v*th)it$ 
in n
%ut$vi%.Inh)in
*uint3* tth$nivy¶th 
niti*utin$u$ nyRcvn %$)hnivt
 *t* %$)nnt  *th  n 
iti% $ n
$nt.
M ny  th yt$  ti
hty int
 t 'ith th Diti*utin
R&ui$nt c nnin
 !DRc) n
in  th 3 -utinti$¶ ivi.
Thi int
 tin n * th $ ))in
 n u))y  in
it  $uti
it 
niz tin n th initin   tinhi) in  %$) ny¶
intn  u))y %h in. Dv)in
 )%i 
iti% ) nnin
  -utin
ti$ ivi thi yt$ % n 
n t )nih$nt  *y
uin
in' hu&ui$nt.Th'in
 th  t
t n %tin
.S &uiu%h in&uii n&ut tin
.S 
.utin
$ntu%h %nt %t n%huin

$nt
.DivyShi)$nt
.Invi%in
iin

.AtS R)t







c
 

 A S  n Diti*utin $u 'i %nt in th 'in

u*yt$
ÿ 
!
  

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c
 

INTRODUCTION
Th)u)thi)%it%$$uni% tu))i¶%$$nAv n%
cu%t 0u ity c nnin
 !Ac0c) n Cnt c n
uiin v)
-inty *y Chy  n n  Mt. Th )t )vi

uiini
nt)u% )u%t&u ity) n'hi%h'iu))tth
v)$nt )u%tvi%th t'i tiyth%ut$.Tht$
4)u%t5'i*uthu
hutthi)t ni$ nt ith)u%t
vi%.Tht$4u))i5'i *uthu
hutthi)t n
i $ nt t ))y t u))i n u*%nt %t. S$  th +)%t
*nitinuin
th
uiin 
. A u%tin in th %$)+ity  )u%t &u ity ) nnin
  th
%ut$ nu))i.
. A $ n  u))i t  iy %$$uni% t )u%t &u ity ) nnin

&ui$nttu*%nt %t.

FUNDAMENTALS OF ADVANCED PRODUCT QUALITY
PLANNING
Av n% cu%t0u ityc nnin
 i tu%tu $th inin
 n
t *ihin
 th t) n% y t u th t  )u%t  tii th
%ut$. Th
   v n% )u%t &u ity ) nnin
 i t  %iit t
%$$uni% tin'ithvyninvvt uth t &uit) 
%$)tnti$.%tiv v n%)u%t&u ity) nnin
)nn
 %$) ny¶ t) $ n
$nt %$$it$nt t th t &ui in
%hivin
 %ut$  ti %tin. S$  th *nit  v n% )u%t
&u ity) nnin
 


c
 

.Ti%tu%t tiyth%ut$.
.T)$t yintii% tin&ui%h n
.
.T vi t%h n
.
.T)vi &u ity)u%tnti$ tth't%t.

Th'() %ti%t n n yti% t%hni&u%i* inthi
)t itin 
i% &un%t$ (it yt'. %h v n%
)u%t&u ity) niuni&u.Th %tu ti$in
 n&un%+%utin
i )nnt n %ut$ n n +)%t tin n th ) %ti% 
$ tt.

Organize the Team

Th u))i¶ it t) in v n% )u%t &u ity ) nnin
 i t
i
n )ni*iity t  % un%tin  t $. %tiv )u%t &u ity
) nnin
&uithinvv$nt$th n-utth&u ity) t$nt.
Th initi  t $ hu in%u )nt tiv $ n
inin

$ nu %tuin
 $ ti  %nt )u%h in
 &u ity   i vi%
u*%nt %t n%ut$  )))i t.

STEPS IN ADVANCED PRODUCT QUALITY
PLANNING

Y. PLAN AND DEFINE PROGRAM

Thi%tin%i*h'tt$in%ut$n n+)%t tin
int) n nin &u ity)
 $. A'( $ut*n'ith

c
 

th %ut$ in $in )viin
 *tt )u%t n vi% th n th
%$)titin. Th  y t
  th )u%t &u ity ) nnin
 )% i
i
n t u th t %ut$ n n +)%t tin  % y
unt.
Thin)ut nut)ut ))i% *tth)% $ yv y %%in

t th )u%t )% n %ut$ n n +)%t tin. S$
%$$n tini%uinthi%tin  '
Inputs
ÿ Vi%th%ut$
Y. M (tR %h
. Hiti%   nty n0u ityIn$ tin
3. T $+)in%
ÿ uinc nM (tin
St t
y
ÿ cu%tc%n%h$ (D t
ÿ cu%tc%Au$)tin
ÿ cu%tRi *iityStui
ÿ Cut$In)ut

Outputs
ÿ Di
n 
ÿ Ri *iity n0u ity 
ÿ ci$in yiM ti 
ÿ ci$in yc%'Ch t
ÿ ci$in yLitin
S)%i cu%t nc%Ch  %titi%
ÿ cu%tAu n%c n
ÿ M n
$ntSu))t

c
 

. PRODUCT DESIGN AND DEVELOPMENT
Thi %tin i%u th $nt  th ) nnin
 )% uin

'hi%h i
n  tu n %h  %titi%  v) int  n  in 
$. Th cu%t 0u ity c nnin
 T $ hu %ni  i
n
 %tinth) nnin
)%vnithi
ni'n*yth%ut$
 h . Th t) in%u )tty) *ui t viy th t th )u%t 
vi%$tth*-%tivthVi%thCut$.A i*i
n
$ut)$it $tin
)u%tin vu$ n%hu n*%nitnt
'ith *iity t $t n
inin
 &ui$nt n
 'ith &u ity
i *iity invt$nt %t 'i
ht unit %t n ti$in
 *-%tiv.
Athu
h  i*iity tui n %nt ) n  )i$ iy *  n
n
inin
 'in
 n)%ii% tin &ui$nt v u * in$ tin
% n*iv$th n yti% t%i*inthi%tintuth
in n )iitiz th %h  %titi% th t $ y n )%i  )u%t n
)%%nt.

Inputs
ÿ Di
n 
ÿ Ri *iity n0u ity 
ÿ ci$in yiM ti 
ÿ ci$in yc%'Ch t
ÿ ci$in yLitin
S)%i cu%t nc%Ch  %titi%
ÿ cu%tAu n%c n
ÿ M n
$ntSu))t


c
 

Outputs
ÿ Di
n iuM n%tAn yi!DMA)
ÿ Di
nM nu %tu *iity nA$*y
ÿ Di
nVii% tin
ÿ Di
nRvi'
ÿ ctty)uiCntc n
ÿ n
inin
D 'in
!in%uin
$ th t )
ÿ n
inin
S)%ii% tin

3. PROCESS DESIGN AND DEVELOPMENT
Thi %tin i%u th $ -  tu  v)in
 
$ nu %tuin
 yt$ n it  t %nt ) n t %hiv &u ity
)u%t. Th t ( t * %%$)ih t thi t)  th )u%t &u ity
) nnin
)%)nu)nthu%%u%$)tinth)it

%nt in inth itt'%tin.Thi n+tt) ii
ntnuth
%$)hniv v)$nt  n %tiv $ nu %tuin
 yt$. Th
$ nu %tuin
 yt$ $ut u th t %ut$ &ui$nt n n
+)%t tin $t.

Inputs
ÿ Di
n iuM n%tAn yi!DMA)
ÿ Di
nM nu %tu *iity nA$*y
ÿ Di
nVii% tin
ÿ Di
nRvi'
ÿ ctty)uiCntc n
c
 

 ÿ n
inin
D 'in
!in%uin
$ th t )
ÿ n
inin
S)%ii% tin
ÿ M ti S)%ii% tin
ÿ D 'in
 nS)%ii% tinCh n

ÿ '&ui)$ntTin
 n %iitiR&ui$nt
ÿ S)%i cu%t nc%Ch  %titi%
ÿ 
Ttin
&ui)$ntR&ui$nt
ÿ T $ i*iityC$$it$nt nM n
$ntSu))t

Outputs
ÿ c %(
in
St n 
ÿ cu%tc%0u itySyt$Rvi'
ÿ c%'Ch t
ÿ c nL yut
ÿ Ch  %titi%M ti+
ÿ c% iuM n%tAn yi!cMA)
ÿ cL un%hCntc n
ÿ c%Intu%tin

4. PRODUCT AND PROCESS VALIDATION
Thi %tin i%u th $ -  tu  v i tin
 th
$ nu %tuin
 )% thu
h n v u tin   )u%tin ti  un.
Duin
  )u%tin ti  un th cu%t 0u ity c nnin
 T $ hu
v i tth tth%nt) n n)%'%h t *in
' n
th )u%t $t %ut$ &ui$nt. Aitin  %n%n hu *
intiiinvti
tin nutin)it
u )u%tinun.

c
 


Inputs
ÿ c %(
in
St n 
ÿ cu%tc%0u itySyt$Rvi'
ÿ c%'Ch t
ÿ c nL yut
ÿ Ch  %titi%M ti+
ÿ c% iuM n%tAn yi!cMA)
ÿ cL un%hCntc n
ÿ c%Intu%tin
ÿ M u$ntSyt$An yic n
ÿ ci$in yc%C ) *iityStuyc n
ÿ c %(
in
S)%ii% tin
ÿ M n
$ntSu))t

Outputs
ÿ cu%tinTi Run
ÿ M u$ntSyt$v u tin
ÿ ci$in yc%C ) *iityStuy
ÿ cu%tinc tA))v 
ÿ cu%tinV i tinTtin

ÿ c %(
in
v u tin
ÿ cu%tinCntc n
ÿ 0u ityc nnin
Si
n nM n
$ntSu))t

c


V. FEEDBACK, ASSESSMENT AND CORRECTIVE
ACTION
0u ity) nnin
ntn'ith)%v i tin nint  tin.
It i th %$)nnt $ nu %tuin
 t
 'h ut)ut % n * v u t
'hn )%i  n%$$n% uv i tin )nt.Thii th
ti$tv u tth%tivnth)u%t&u ity) nnin
t.Th
)u%tin%nt) nith* iv u tin
)u%tvi% tthi
t
.V i * n tti*ut t $ut*v u t.Itith*i
tin 
u))i t $t %ut$ &ui$nt n  %h  %titi%. S)%i 
%h  %titi%$ut$tthini%)%ii*yth%ut$.

Inputs
ÿ cu%tinTi Run
ÿ M u$ntSyt$v u tin
ÿ ci$in yc%C ) *iityStuy
ÿ cu%tinc tA))v 
ÿ cu%tinV i tinTtin

ÿ c %(
in
v u tin
ÿ cu%tinCntc n
ÿ 0u ityc nnin
Si
n nM n
$ntSu))t

Outputs
ÿ Ru%V i tin
ÿ Cut$S ti %tin
ÿ Divy nSvi%

c


A. CONTROL PLAN
Th )u)  thi Cnt c n $th
y i t i in th
$ nu %tu&u ity)u%t %%in
t%ut$&ui$nt.It
thi *y )viin
  tu%tu  )) %h  th i
n %tin n
i$)$nt tinv u %nt$ththtt yt$.Cnt
c n )vi  'ittn u$$ y %i)tin  th yt$ u in
$ini$izin
)% n)u%tv i tin.ThCntc nnt) %
th in$ tin %nt in in t i ) t intu%tin. Thi
$th
y i ))i% *t 'i n
 $ nu %tuin
)% n
t%hn
i. Th Cnt c n i n int
  ) t  n v  &u ntity
)% nit*utiiz ivin
%u$nt.
An i$)t nt )h   th )%  &u ity ) nnin
 i th
v)$nt Cntc n.ACntc ni 'ittn%i)tinth
yt$%ntin
) t n)%.Ain
Cntc n$ y ))y
t 
u) $iy)u%tth t )u%*yth $)% tth
 $u%.S(t%h n% y$ y* tt %htthCntc n
iut tin )u). In u))t   Cnt c n )% $nitin

intu%tinhu*in nu%ntinu y.
In %t th Cnt c n %i* th %tin th t  &ui t
 %h )h   th )% in%uin
 %ivin
 in)% ut
in
 n
)ii%&ui$ntt uth t )%ut)ut'i*in t t
%nt. Duin
 
u  )u%tin un th Cnt c n )vi th
)% $nitin
 n %nt $th th t 'i * u t %nt
%h  %titi%. Sin% )%  +)%t t * %ntinu y u) t n
i$)v th Cnt c n %t  t t
y th t i )niv t th
%h n
in
)%%nitin.

c
 

 ThCntc n i $ int in n uthu
hutth)u%t i
%y%. yinth)u%ti%y%it)i$ y)u)it%u$nt n
%$$uni% t th initi  ) n  )% %nt. Su*&unty it
ui
$ nu %tuin
 in h' t %nt th )% n nu )u%t &u ity.
Uti$ ty th Cnt c n $ in  ivin
 %u$nt %tin
 th
%unt $th  %nt n $ u$nt yt$ u. Th Cnt
c niu) t $ u$ntyt$ n%nt$th v u t
ni$)v.
  )% %nt n i$)v$nt t * %tiv  * i%
unt nin
th)% $ut**t in. A $utii%i)int $ i
t *ih t v) th Cnt c n *y utiizin
  th v i *
in$ tint
in *ttunt nin
th)%u%h 
ÿ c%'Di
 $
ÿ Syt$Di
nc% iuM n%tAn yi
ÿ S)%i Ch  %titi%
ÿ LnL n$Si$i c t
ÿ T $¶
n'
thc%
ÿ Di
nRvi'
ÿ )ti$iz tinMth

Th*nitv)in
 ni$)$ntin
 Cntc nin%u
.0u ity
ti$)v.
.Cut$
tuy tii.
. C$$uni% tin  ny %h n
 in )u%t )% n %nt $th

t*tt.



c
 

 









































c


INTRODUCTION
Purpose:
cu%tin c t A))v  c% !ccAc) in
ni%
&ui$nt  )u%tin ) t ))v  in%uin
 )u%tin n *u(
$ ti .Th)u)ccAcitt$ini %ut$n
inin

i
n% n)%ii% tin&ui$nt ))yunt*yth
u))i n th t )% h  th )tnti  t )u% )u%t %nitnty
$tin
 th &ui$nt uin
 n %tu  )u%tin un t th &ut
)u%tin t.

Applicability:
ccAc h  ))y t intn  n +tn  u))i it  *u(
$ ti  )u%tin $ ti  n )u%tin  vi% ) t.  *u(
$ ti  ccAc i nt &ui un &ut *y yu %ut$. A
u))it n % t 
u)u%tinvi%) th %$)y'ith
ccAcun$ y' iv*yth%ut$.Tin
h *$ int in
 t n  % t 
u it$  n
  th it$    t t 
*in
 v i *.

Y. GENERAL
Thu))ih *t in u ))v  $ th%ut$)u%t ))v 
%tivity
) An') t)u%t
*) C%tin i%) n%yn )viuyu*$itt) t
%) cu%t $ii *y n n
inin
 %h n
 t i
n %
)%ii% tin$ ti .

c


. PPAP PROCESS REQUIREMENTS
Significant Production Run
  )u%tin ) t )u%t  ccAc h  * t (n $ 
i
nii% nt )u%tin un. Thi )u%tin un h  * $ n hu t
i
hthu)u%tin n'ithth)%ii%&u ntityttt  $ini$u$
  %n%utiv ) t un th'i )%ii *y th uthiz
%ut$&u ity)nt tiv.
Thi un h  * $ nu %tu t th )u%tin it uin
 th
tin

u
in
 )% $ ti  n ) t $ th )u%tin
nvin$nt. c t $  %h uni&u )u%tin )% .
. u)i% t
$*yin n'(% %h)itin $uti)% vityi$
t) ttnh *$ u n)nt tiv) ttt.
*u($ ti n)%ii%n.4) t5i&ui.I  $)i
&ui t * u*$itt it h  * t (n in  $ nn  t u th t it
)nt4t yt t5) tinth)%.

PPAP Requirements
Th u))i h  $t  )%ii &ui$nt .
. i
n %
)%ii% tin n  *u( $ ti  th u( M ti  R&ui$nt
Ch%(it. Any ut th t  uti )%ii% tin  % u  th
u))inttu*$itth) t%u$nt tin n%.vyt
h  * $  t %%t th )%  th t  i
n % &ui$nt
 $t. I th u))i i un * t $t ny  th &ui$nt th
%ut$ h  * %nt %t  t$in tin  )))i t %%tiv
%tin.

c


 In)%tin n ttin
  ccAc h  * )$ *y  &u ii
 * ty. C$$%i in)nnt tt  * ti u h  *
%%it  %iiti. hn  %$$%i   * ty i u th u))i
h  u*$it th tt ut n th  * ty tth   th n$ 
 * ty )t $ t. Th n $  th  * ty th t )$ th
tt nth t!)thtt ntht n utunthtth 
* ini% t. Blanket statements of conformance are unacceptable for
any test results.
Th u))i h  h v th ))i% * it$ n % it *' 
 %h) t $iy) t
th) tu*$iinv.Th
%h *in PPAP) tin%inu%hi n* iy
v i *. Th it$ *' h  *  iy v i *  %ut$ u in
ccAc. Th u))i h  *t in )i ))v  $ th %ut$ )u%t
))v  %tivity+%)tinvi tintccAc&ui$nt.

Various Records in PPAP File

)Di
nR%
*)Any uthizn
inin
Ch n
%u$nt
%)n
inin
A))v 'hn&ui
)Di
n iuM n%tAn yiiu))iii
n
)ni*.
)c%'i
 $
)c% iuM n%tAn yi

)Di$nin Rut
h)R%$ ti )$ n%ttut
i)Initi )%tui
c


 )n 
 )0u ityIni%
 )A%%)t n%%iti initi tuy
)Unt *)%
)c%'ithnSiS)%ii% tinn$ 
Diti*utin
)St t
yhnA%%)t n%Citi AtS tii

-)M u$ntSyt$An yiStui
()0u iiL * tyD%u$nt tin
)Cntc n
$)c tSu*$iin  nt!cS)
n)A))  n%A))v R)t!AAR)
)u(M ti R&ui$ntCh%(it
))S $)cu%tinc t
&)M tS $)
)Ch%(in
Ai
)Cut$S)%ii%R&ui$nt


3.CUSTOMER NOTIFICATION AND SUBMISSION

REQUIREMENTS
Customer Notification
Thu))ih ntiyth)ni*%ut$)u%t ))v  %tivity
 nyi
n n)%%h n
.Th%ut$$ yu*&unty%tt
&ui u*$iinccAc ))v .


c


Submission to Customer
Th u))i h  u*$it  ccAc ))v  )i t th it )u%tin
hi)$ntinth'in
itu tinunth)ni*)u%t ))v 
%tivityh ' ivthi&ui$nt.
Th u))i h  vi' n u) t  n% y  ))i% * it$ in
thccAcit%tth)u%tin)%
'hthnt
th%ut$&ut $ u*$iin.ThccAcih %nt inth
n $th)ni*%ut$)u%t ))v  %tivity)n
 ntin

th' iv nth t.

4. SUBMISSION TO CUSTOMER- LEVELS OF
EVIDENCE
Submission Levels
Thu))ih u*$itthit$ n%)%ii*ythv 
&ut*yth%ut$
Lv  /   nt ny ! n  i
n t ))  n% it$ n
A))  n%A))v R)t)u*$itttth%ut$.
Lv  /   nt 'ith )u%t  $) n i$it u))tin
  t 
u*$itttth%ut$.
Lv  /   nt 'ith )u%t  $) n %$)t u))tin
  t 
u*$itttth%ut$.
Lv/  nt nth&ui$nt in*yth%ut$.
Lv  /   nt 'ith )u%t  $) n %$)t u))tin
  t 
v i *vi' tthu))i¶$ nu %tuin
% tin.


c


 Thu))ih  u v  th ut v  u*$iin
un )%ii th'i *y th )ni* %ut$ )u%t ))v 
%tivity.Au))i*u($ ti nyh uv th utv
  *u( $ ti  ccAc u*$iin un )%ii th'i *y th
)ni*%ut$)u%t ))v  %tivity.


V. PART SUBMISSION STATUS

General
Th u))i h  * ntii *y th %ut$  th i)itin  th
u*$iin.At)u%tin) t ))v u))ih  uth tutu
)u%tin%ntinut$t %ut$&ui$nt.

Customer PPAP Status
Full Approval ini% t th t th ) t  $ ti  $t  %ut$
)%ii% tin n&ui$nt.Thu))iith uthizthi)
)u%tin &u ntiti  th )u%t u*-%t t   $ th %ut$
%huin
 %tivity.

Interim Approval)$ithi)$nt$ ti )u%tin&ui$nt
n  i$it ti$  )i% &u ntity * i. Inti$ A))v  'i ny *

 nt'hnthu))ih 
ÿ % y in th t % u  th nn%n$iti )vntin

)u%tin ))v . n
ÿ c)  n inti$ ))v  %tin ) n
 u)n *y th
%ut$.Ru*$iint*t in4u ))v 5i&ui.


c


 M ti  %v *y n inti$ ))v  th t  i t $t th

u)n %tin ) n ith *y th +)i tin  t  th hi)$nt  th
uthiz&u ntity'i*-%t. itin hi)$nt  uthiz
un n+tninthinti$ ))v i
 nt.
 *u( $ ti  th u))i h  u th 4u( M ti  Inti$
A))v 5$it&uiv nt.
Rejected $ n th t th u*$iin th )u%tin t $ 'hi%h it
'  t (n n %%$) nyin
 %u$nt tin  nt $t %ut$
&ui$nt.C%t)u%t n %u$nt tinh *u*$itt n
))v*)u%tin&u ntiti$ y*hi)).


A. RECORD RETENTION
cu%tin ) t ))v  % 
  u*$iin v h  *
$ int in  th n
th  ti$ th t th ) t i %tiv )u n % n 
y .
Th u))i h  nu th t th )))i t ccAc % $ 
u)) tccAci in%un%inthn') tccAc
i.










c