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APQP/PPAP

WORKBOOK V4.0
Copyright 2006 March Quality Services

Part Name
Part Number
Engineering Change Level
Engineering Change Level Date

NAME
NUMBER
ECL
ECL DATE

Supplier Name
Supplier Code
Street Address
City
State
Zip
Phone Number

SUPPLIER
CODE
ADDRESS
CITY
STATE
ZIP
555-555-5555

Customer Name
Division
Application

#NAME?
DIVISION
APPLICATION

File Name

FILE.XLS

Viking Supplier PPAP Checklist


NUMBER

Revision Level:

ECL

NAME
SUPPLIER

Date on Print:

ECL DATE

Part Number:
Part Name:
Supplier Name:

Date Received:

Note: PPAP to be per AIAG Standard (4th Edition). This checklist is a


list of crucial items that must be completed and is not a comprehensive
list of everything that must be completed.
Pass

ITEM NAME
1) Design Record

Fail

N/A

Pass

ITEM NAME

Fail

10) Material, Performance Test Results


All testing must be conducted by a Certified laboratory.
A Material specification must match print.
Must be clear and legible

Is it the correct revision level?

Must have correct properties (ex. chemical composition,


mechanical).

Is it ballooned?

Coating spec must match print spec.

Are all relevant specifications (material, performance, etc.)


ballooned?

Must meet coating test requirements.


Heat treat must match print specs.
Does heat treat cert show correct hardness

5) Process Flow Diagram


Correct part number/drawing number/revision level.

Part specific testing must be completed based on part


requirements (ex. Proof load, tensile, torque, ultimate, PV
Testing, etc.).

11) Initial Process Studies

All movements/operations included.

Correct part number/drawing number/revision level.

6) Process FMEA
Correct part number/drawing number/revision level

Conduct study on each customer identified


significant/critical characteristic.

Must include all potential failure modes for each operation.

If no characteristics are identified on the print, it needs to be


discussed with Viking which Characteristic is to be used for
Capability Studies.

All severities higher than 8 must have recommended action


taken.

CPK value must be 1.67 or higher on initial PPAP


submission.

RPN's over 150 must be addressed with recommended


actions.

12) Qualified Laboratory Documentation


Has qualified laboratory documentation been included for
labs used for any tests? (Must be a clear Copy)

Must match Flow Diagram sequence.


If no recommended actions are needed, they must be marked
N/A or None.

A Lab Scope Certification with scope of accreditation must be


provided for each facility. (Must be a clear and Legible Copy)
Heat Treated Parts must have CQI-9 Self Assessment
Plated Parts must have CQI-11 Self Assessment

7) Control Plan
Correct part number/drawing number/revision level.
All processes must be included and each process must
include the appropriate controls being used.

14) Product Samples


The 6 pieces used for Layout must be numbered and
Included with the PPAP Package.

18) Warrant

Reaction plan must be completed.

Correct part number/drawing number/revision level.

Must match Flow Diagram sequence and PFMEA.

Has IMDS info been submitted? If so, include IMDS # and


Version on PSW.

8) Measurement System Analysis Studies


Required for all gages shown on Control Plan.
Number of distinct categories (NDC) must be 5 or greater.

For attribute Gage R&R's sample size must be at least 30.


% gage R&R must be 10 or below.

9) Dimensional Results
Correct part number/drawing number/revision level.
Show 6 piece layout data results (not a range), or 1 per cavity
(whichever is greater).
Numbered per ballooned print.
All dimensions within tolerances.

Under submission results, if all design record requirements


are met check yes. If no, provide details in the comments
section.
In the declaration is the production rate noted?

Misc.
The original completed Excel PPAP Forms per the Viking
Format must be emailed. Supporting documents can be
scanned and emailed also. A hard copy and layout samples
are to be shipped to Viking.
For any outside processing (ex. Plating, coating, heat
treatment, etc.) a PPAP must be requested from outside
processor and Submitted.
The completed PPAP package must be reviewed in its entirety
by another Quality Engineer, Project Engineer or Manager
before submitting to Viking.

Notes:
Supplier Signoff:
Signature

Date

Signature

Date

Secondary Supplier Approval:

N/A

PROCESS FLOW DIAGRAM


NUMBER

DATE:
ECL:
PREPARED BY:

OPERATION
DESCRIPTION

ITEM #

STORE

MOVE

INSPECT

STEP

FABRICATION

NAME

PRODUCT AND
PROCESS
CHARACTERISTICS

Page 3 of 15

ECL

ITEM #

PART NUMBER:
PART DESCRIPTION:

CONTROL
METHODS

Print #

NUMBER

Item:

Rev.

ECL

NAME

Model Year(s)/Vehicle(s)

POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS
(PROCESS FMEA)
Process Responsibility

APPLICATION

FMEA Number:

SUPPLIER

Prepared by:

Key Date

Date (Orig.)

Core Team:
Process
Function/
Requirements

FILE.XLS

Date (Rev.)
Potential
Failure
Mode

Potential
Effect(s)
of Failure

S
e
v

C
l
a
s
s

Potential
Causes(s)/
Mechanism(s)
of Failure

O
c
c
u
r

Current
Process
Controls
Prevention

Page 4 of 15

Current
Process
Controls
Detection

D
e
t
e
c

R.
P.
N.

Recommended
Action(s)

Responsibility
& Target
Completion
Date

Action Results
Actions
Taken

S
e
v

O
c
c

D
e
t

R.
P.
N.

CONTROL PLAN
Prototype
Control Plan Number

Pre-Launch

Production
Key Contact/Phone

Date (Orig.)

FILE.XLS

555-555-5555

Part Number/Latest Change Level

NUMBER

Date (Rev.)

1/1/1996

1/1/1996

Core Team

Customer Engineering Approval/Date (If Req'd.)

Supplier/Plant Approval/Date

Customer Quality Approval/Date (If Req'd.)

Other Approval/Date (If Req'd.)

Other Approval/Date (If Req'd.)

ECL

Part Name/Description

NAME
Supplier/Plant

SUPPLIER
PART/
PROCESS NAME/
PROCES
OPERATION
S
DESCRIPTION
NUMBER

Supplier Code

CODE
MACHINE,
DEVICE
JIG, TOOLS
FOR MFG.

CHARACTERISTICS
NO.

PRODUCT

PROCESS

METHODS
SPECIA
L
PRODUCT/PROCESS EVALUATION/
SAMPLE
CHAR.
SPECIFICATION/ MEASUREMENT
CLASS
SIZE
FREQ.
TOLERANCE
TECHNIQUE

Page 5 of 15

CONTROL
METHOD

REACTION
PLAN

Page 6 of 15 Pages

Production Part Approval


Dimensional Test Results
ORGANIZATION:
SUPPLIER / VENDOR CODE:

SUPPLIER
CODE

NUMBER
NAME

PART NUMBER:
PART NAME:

INSPECTION FACILITY:

ECL

DESIGN RECORD CHANGE LEVEL:


ENGINEERING CHANGE DOCUMENTS:

ITEM

DIMENSION / SPECIFICATION

SPECIFICATION /
LIMITS

TEST
DATE

ORGANIZATION MEASUREMENT RESULTS


(DATA)

#1

#2

#3

#4

#5

OK

#6

Blanket statements of conformance are unacceptable for any test results.


SIGNATURE

March CFG-1003
2006

TITLE

DATE

NOT
OK

Page 7 of 15 Pages

Production Part Approval


Dimensional Test Results
ORGANIZATION:
SUPPLIER / VENDOR CODE:

SUPPLIER
CODE

PART NUMBER:
PART NAME:

INSPECTION FACILITY:

NUMBER
NAME

DESIGN RECORD CHANGE LEVEL:

ECL

ENGINEERING CHANGE DOCUMENTS:

ITEM

DIMENSION / SPECIFICATION

March CFG-1003
2006

SPECIFICATION /
LIMITS

TEST
DATE

ORGANIZATION MEASUREMENT RESULTS


(DATA)

OK

NOT
OK

Page of Pages

Production Part Approval


Material Test Results
ORGANIZATION:
SUPPLIER / VENDOR CODE:

SUPPLIER
CODE

NUMBER
NAME

PART NUMBER:
PART NAME:

MATERIAL SUPPLIER:

DESIGN RECORD CHANGE LEVEL:

*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE:

ENGINEERING CHANGE DOCUMENTS:


NAME of LABORATORY:

*If source approval is req'd, include the Supplier (Source) & Customer assigned code.

MATERIAL SPEC. NO. / REV / DATE

SPECIFICATION /
LIMITS

ECL

TEST
DATE

QTY.
TESTED

SUPPLIER TEST RESULTS (DATA)

OK

Blanket statements of conformance are unacceptable for any test results.


SIGNATURE

March CFG-1004
2006

TITLE

DATE

NOT
OK

Page of Pages

Production Part Approval


Material Test Results
ORGANIZATION:
SUPPLIER / VENDOR CODE:

SUPPLIER
CODE

PART NUMBER:
PART NAME:

NUMBER
NAME

MATERIAL SUPPLIER:

DESIGN RECORD CHANGE LEVEL:

*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE:

ENGINEERING CHANGE DOCUMENTS:


NAME of LABORATORY:

*If source approval is req'd, include the Supplier (Source) & Customer assigned code.

MATERIAL SPEC. NO. / REV / DATE

March CFG-1004
2006

SPECIFICATION /
LIMITS

ECL

TEST
DATE

QTY.
TESTED

SUPPLIER TEST RESULTS (DATA)

OK

NOT
OK

Page 10 of 15 Pages

Production Part Approval


Performance Test Results
ORGANIZATION:
SUPPLIER / VENDOR CODE:

SUPPLIER
CODE

NUMBER
NAME

PART NUMBER:
PART NAME:

NAME of LABORATORY:

DESIGN RECORD CHANGE LEVEL:

*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE:

ENGINEERING CHANGE DOCUMENTS:

ECL

*If source approval is req'd, include the Supplier (Source) & Customer assigned code.

TEST SPECIFICATION / REV / DATE

SPECIFICATION /
LIMITS

TEST
DATE

QTY.
TESTED

SUPPLIER TEST RESULTS (DATA)/


TEST CONDITIONS

OK

Blanket statements of conformance are unacceptable for any test results.


SIGNATURE

March CFG-1005
2006

TITLE

DATE

NOT
OK

Page 11 of 15 Pages

Production Part Approval


Performance Test Results
ORGANIZATION:
SUPPLIER / VENDOR CODE:

SUPPLIER
CODE

PART NUMBER:
PART NAME:

NUMBER
NAME

NAME of LABORATORY:

DESIGN RECORD CHANGE LEVEL:

*CUSTOMER SPECIFIED SUPPLIER / VENDOR CODE:

ENGINEERING CHANGE DOCUMENTS:

ECL

*If source approval is req'd, include the Supplier (Source) & Customer assigned code.

TEST SPECIFICATION / REV / DATE

March CFG-1005
2006

SPECIFICATION /
LIMITS

TEST
DATE

QTY.
TESTED

SUPPLIER TEST RESULTS (DATA)/


TEST CONDITIONS

OK

NOT
OK

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET


VARIABLE DATA RESULTS
Part Number

Gage Name

Appraiser A

Gage Number

Appraiser B

Gage Type

Appraiser C

NUMBER
Part Name

NAME
Characteristic

Specification

Lower Upper
Characteristic Classification

Trials

Parts

APPRAISER/
TRIAL #
1

2.

3.

4.

AVE

5.

6. B

7.

8.

9.

AVE

10.

11. C

12.

13.

14.

AVE

15.

Date Performed

PART
1

1. A

Appraisers

AVERAGE
6

10

xa=
ra=

xb=
rb=

x c=
rc=
X=

16. PART

Rp=

AVERAGE
17.

(ra + rb + rc) / (# OF APPRAISERS) =

18.

xDIFF = (Max x - Min x) =

19.

* UCLR =

R x D4 =

R=
xDIFF=
UCLR=

* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.
Notes:

GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET


VARIABLE DATA RESULTS
Part Number

Gage Name

Appraiser A

Gage Number

Appraiser B

Characteristic

Gage Type

Appraiser C

Characteristic Classification

Trials

NUMBER
Part Name

NAME

Parts

Appraisers

Measurement Unit Analysis

Date Performed

% Tolerance (Tol)

Repeatability - Equipment Variation (EV)


EV

R x K1

Trials

K1

% EV

0.8865

0.5907

100 (EV/Tol)

Reproducibility - Appraiser Variation (AV)


AV

{(xDIFF x K2)2 - (EV2/nr)}1/2

% AV

n = parts

Appraisers

K2

0.7087

0.5236

r = trials

Repeatability & Reproducibility (GRR)


GRR

K3

0.7087

0.5236

0.4464

0.4032

0.3745

0.3534

0.3378

{(EV2 + AV2)}1/2

RP x K3

Tolerance (Tol)
Tol

% GRR
Parts

Part Variation (PV)


PV

Upper - Lower / 6

0.3247

( Upper - Lower ) / 6

10

0.3145

% PV

ndc

100 (AV/Tol)

100 (GRR/Tol)

100 (PV/Tol)

1.41(PV/GRR)

=
=

For information on the theory and constants used in the form see MSA Reference Manual, Third edition.

Part Submission Warrant


NAME

Part Name

NUMBER

Cust. Part Number

Shown on Drawing Number

Orig. Part Number

ECL

Engineering Change Level

Dated

Additional Engineering Changes

ECL DATE

Dated

Safety and/or Government Regulation

Yes

Checking Aid Number

Purchase Order No.

No

Weight (kg)

Checking Aid Eng. Change Level

ORGANIZATION MANUFACTURING INFORMATION

SUPPLIER

Dated

CUSTOMER SUBMITTAL INFORMATION

CODE

###

Organization Name & Supplier/Vendor Code

DIVISION

Customer Name/Division

ADDRESS
Street Address

Buyer/Buyer Code

CITY
City

STATE

ZIP

Region

Postal Code

APPLICATION
Country

Application

MATERIALS REPORTING
Has customer-required Substances of Concern information been reported?

Yes

No

n/a

Yes

No

n/a

Submitted by IMDS or other customer format:

Are polymeric parts identified with appropriate ISO marking codes?


REASON FOR SUBMISSION (Check at least one)
Initial submission

Change to Optional Construction or Material

Engineering Change(s)

Sub-Supplier or Material Source Change

Tooling: Transfer, Replacement, Refurbishment, or additional

Change in Part Processing

Correction of Discrepancy

Parts produced at Additional Location

Tooling Inactive > than 1 year

Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)


Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at organization's manufacturing location.
SUBMISSION RESULTS
The results for

dimensional measurements
material and functional tests
appearance criteriastatistical process package
(If "NO" - Explanation Required)
Yes
NO

These results meet all design record requirements:


Mold / Cavity / Production Process
DECLARATION

I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all
Production Part Approval Process Manual 4th Edition Requirements. I further affirm that these samples were produced at the production
rate of ____/____ hours. I also certify that documented evidence of such compliance is on file and available for your review. I have noted
any deviation from this declaration below.
EXPLANATION/COMMENTS:

Is each Customer Tool properly tagged and numbered?

Yes

No

n/a

Organization Authorized Signature

Date

Print Name

Phone No.

Title

555-555-5555

Fax No.

E-mail
FOR CUSTOMER USE ONLY (IF APPLICABLE)

PPAP Warrant Disposition:

Approved

Rejected

Other

Customer Signature
Print Name

March
2006

CFG-1001

Date
Customer Tracking Number (optional)

CUSTOMER LIST
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

ACTIVE # IN DOCUMENT
GM
Ford Motor Company
DaimlerChrysler
Viking Products

D/P FMEA LISTS


4

SEVERITY SCALE
10 Hazardous - w/o warning
9 Hazardous - w/ warning
8 Very High
7 High
6 Moderate
5 Low
4 Very Low
3 Minor
2 Very Minor
1 None
OCCURENCE SCALE
10 >100 Per 1,000
9 50 Per 1,000
8 20 per 1,000
7 10 Per 1,000
6 5 Per 1,000
5 2 Per 1,000
4 1 Per 1,000
3 0.5 per 1,000
2 0.1 Per 1,000
1 <0.01 Per 1,000
DETECTION SCALE
10 Absolute Impossible
9 Very Remote
8 Remote
7 Very Low
6 Low
5 Moderate
4 Moderately High
3 High
2 Almost Certain
1 Certain