PRODU'CTION PAR'T (PPAP)

Produd~(!In
First

ra!J't Approv!l! 1Precess (pr AP)

Eoditi~IiI~$Sru.lJeliIIF,cb['uar'.Y

~.9'J

See0nd E~dhion!.ht rm'int~ng, F,eblI'u~ry 1995; 2~d fr~n.twng,Ju~y 1995 Th iird Edliti,oO" September ~.9~19;:2 n~.Pf'i~nting:, A ugm.~ .2100

fQ'lmrth Edi~woOO1J, Mareh 2100'6 C(i)pym'ig;h~ ©l993,. ©l9'!)5" ©HI97,. ©199'9, ©2000~ ©2106 .Dn~m~el~Chrysrner::~lll·llllot:a.thD<m~. ord Mot!~.r Com.,any, GencFa~ Moton COr'plor'9Jti.o.1iJJ f F

-I _

----

-----_

--

-----_

-- --__ _ __

PI1''Ol)iuctiJl)IliIP:8!rt APi,fOll:!lJ1 Pn'cest> (PP AP) First Editilon Issued FeillI'l!tary 1993 SelCond E'~it[olm"b;t P'!I'ii!l!iijng~ February 1995; :2 nd P,riililiting1 July 1995

Tib~m 1IE4:1ition~ ,epitemlller 1999'; 2nd r,li.int~ng, August ]JOOO S Fourth Editiiol!!!, anb 2006 M

Da!im~eFChrys~er

Co"yri:g;bt ©l~'~n~©l~lH~5~ 1997, ©1999'"©200n~ ©100{i, © Corporntil!!iml, Ford Mo:toF 'Com;pa,li1Jy~ GeliJier:ililMoron OllciJoration

EUecti.ve June I ~2:006~PPAr Fourtb E,dliti.Od replacts .PPA.P Third Edi.fi'o,n gn~ess, ofhen;v:ise specifie-d by you!r cgston~er.

FUllllner eopi,es are o,b'taina.1!illenun MAG at "*" 1-148-3j,8~310!3 ir f

AdareCa,[wio (UK), in EU.f\ope +44-l-'71S-861333

F'O'REWORD TO THE FOUR'TU EDITION

Efiedive
yO'Uf CU stomer

june 1, lOU6, PPAP[fourlh .

P~!I!rt ~pl,rov;l!1

Edit]cin replacesPPAr

Third Edihon, unless otherwise specified by

.PnilliIl!lIdion

focusedprecess

rrocJCss (ll'PAP) is~pdJa1ed to t~e 4~ GdIl'tO:iil to incerporate the eustomer <li(ppmllcl:ia:ssodated. wl,th Isorrs 16949':2002 aad other cFI<lnge-slisted belowto um:u:lame

requirements. PP AP',s purpose contiuues to be to provide the evidence that aU customer e~ineeri[Jg design record and specificatiea requirements are pmpedy understood by the orgamruiZ<llt:ionaad thet the maJl:'JJufadmiIDIJJg process bas the potential to produce pmduet C{)iDS~stentLy eetin.g these requirements dmi.ng an aetna] m
produdio-n run at the queted production rate, FPAP 4th Edition includes the following chaages:

.,AJignmen:t
• • AUgning

ofPrAP

~,Q

U'l.e ISO(fS 16949:2002 process approod:l.~nc.lud[l1:g:

requi:rremerllswil" the aJlj~o.motfuVie :tOOuc~ de'!n~l(lpm~t ~
o\l!Jlcil

the order of fiaePPAP

ITII!I!Jlufactmil"lg process

Inclusion of ami.eXflmpl.eprocess flew EO:; PAP "

.. ..
..

Relocation of Cusiomer Specific .hlstnctions

to: appropriate websites, (e .. . OEM and JAcOB. g

www.iaob.erg) to pliolv~udecurrent requ][emIDleTl!ls

U,piiate ef Truek OEMl1eqllliremeOl~$ and moved to Appe~dix H

Revised

.. •
.'

P S W (P~!:iI: SI!]Jblnissic;m W<I:lTIlnt)to: ProviJe a more lo'gical (low fO!r tnepart 1 dcs:igll!de~[i!pt:iQIlI fields 1'I.lakethe $I!l,,p;iieraddress i'ic]ds applicabic to intem8!tiO:mi,aJ1loca:liQl1!s mllclll!lrl.c ]M DS milte:ria~rse~rlirlg to im:li.caitc ['cpomt.ilng StaJl!i'S r
tffiJJf::

Updated specific PPAr requirements, 1ndud]n£;: '. Milt!.\ria]s re:portimi.gflnd pO~ymeri!cid!entifi.Mti.on.O€qu~rem~n:~ tn .. PFl)C!CSS t::!llPahulilj' adex usage (Cpk and Ppk) i .. The ddiFJ!it'iol1! and approva] of cstelog p.arrtsaJtl!~the defilllllN of

dleSiignrecord box parts

black

..'

Mod~fiejd customer molific<iitiouand ~ubm]ss~()n re'r~]remen~to align wi~h OEM lfeqjU~n:mm:i[lts

(e.g., L 3.3 from PPAP 3:rd! removed)

.!
..

C1arifiea and commonised Append]oes

C~ 0, alnd E to rH.atl>C~the:PIP'APl1epon1:ingrequirements
dll,ilipl"~cat~QllS

Revised T~re Appendb::. to aUow OEM specification of app]:icab~~itya!ldt@, Ljj~i~ate e with <I11~)':l;·<Inceslllready provided in tJm:e PP AP reqairemeats

N~lte: The Tire Appendix is not aw]icaMe to' orgarrizatiolls, supp:.~yi.ng 1.0Ford Motor Ccmpany, t]re!l Reorgan ized aad I!l!pda'tedAiPpendix. F to stressthe importance of 'I:h.eBulk Matena]s Checklist N~h~'; Fo:!!d Mo~or Oo:mpan)' [~ql!J.iOO;S o:;g3nizalti.oms .sIJPj::i~yrur.l!g 3~1. 'bu~k material to. Ford Motor Com.piIlny to,
oo!1i1]l11y w]th "PAP.

..

Revised Glossary to be consistent with tllte: updates in.tlle text

PP AP refers t'O tbe .fo.llo"",lmgreference manuals: Advanoed r:r<!Ili1lU;:t Ql!I!aliltyrlanD~gg & Contli~~ PI:!!)", Pob!nlialFlili~ll!IfiC Moilil!es and Efrc.cts Analiysis.Measuf\e:meilllt SyS:~e'mJ AillaEys1s~ and Statisttta[ PN!l:eSS Cont[lot These manuals are authored by ])a~mlilerClirurys],eil: OOrpOfUL@liiII. Ford M@t@r O:um,arnzy. a'[!;dGeneral Moton OorporaJtio]l and :area\fai~able~hrougb the Autereotive Industry Action Gf01ilP I(AIA:G)
at www.aiag.org, The Supp~~er Q~al~ty Reqairements Task Forcegrate1mHyacuo'wledg.e":s, tfue contrihutions of the many indiv]dl1als and t~eir respective eampenies t:ilatpartiliclparred in the revisioupreeess.

II

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=_~_p_._. AP Process Flowchart. Exampille p

CUSTOMER
ReCord ~r .ApfJfOVedl PSW

CUSTOMER.
C~~~orn.er
~1l(i1\~6il. O~d'or J

Custornar"Sj)ad~~ Re(jlJlreme!ill~

1--+-.., OR.GANIIZA.TIOINJ

C'LIstmrler

PMjadQw.Mr

CDMJlI'Ci~j(Jn lI.f

Part 'D~S"'i'I
A,ie,q!.!ifeffiel1ts

So.
Team

--~

Req,1..J!red
l'li!lms

PPAP

Submis~

(Or Re$'!,I~rWiesiml}

R~c~p~

.~Il(l

9fPPAP WarraFlit

Appr·J;Wlllof Stlll~ll'OdPSW

I
CUSIOmBf

Vaiidare,d' Ga.Iti!lr Inrorm~lio.n

Pi~~e$ IOe~ig n RIlql!ireme;n~s.

COlil1lpll(f~lon of

f-

PSW'

[PSO r Run at Ra:L6]1

Pr(lCl!;!~~.

C~tomer S;p>eeifica~lons

PPAIt' iBitll~ 4:1 Re()ord~

,AppFQ'o'e(l

i"'~

P5W

SLipplier ~t]i~kJn~d C~a.11ges C~e~omer U'li!i!O!~¢! ChM'lleS

10 ~QrI,

f)F,)ecif!ca!ig!l~, elc. Customtl'r

IbggiSjK;~

Requil'el'l,lmbs

Notes:.

.2.. Fi.eaords slhOWfl may be In various rnedlaand

1. .AClI\,r~ti~ee!l1low!'lwl~ 00 ~1\!V.ey$ p~~:nt be

In vanmls storag.e i.ocallolils .

T'A]3'.L.E OF ,CONTENTS
rNTROO'UCIION.Purpose. , A'ppJtcabiIUy, .-.-..-..---.-- ----.. .. --."-- ---.-""" - - -"-""" , ,..•.,.,., .." ,., ,.., - " -.,." " " ,..""". ----, ,."l .1

~ --.--.. .- -----.-.-..---"----------~-------------.--..----------- --.---.. ------.------.. .. -.. , ,.,_.. . .., .. -_ ,.,., ..---.---.---..----.-.--.. "---.-.--,-,--..-..--.-..--.-, -----,-------,.., -.-.---

,..,"~_ . ._ , ._._._.. 1 ._ .

ApprO{1r::R .,.,

,.,.,

" ,.,., .. ,.,.,.,.,

,

,
,,

-.., ,

-. -.. -,. ,.,.,

,..,.,.,.,.,

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".

._,_,..,..__1
_ ,-3

SECT~ON 1. _ GENERAL i.l

Sub.miss'!cm ,of PPAP ..",.".,., ,.,.,., ,

,.,.,., ,

,., , ,.,.,

,.,., ,.

,.,

,., ,3

SECTlliON 2 _.P'PAP PROCESS RlEQUlRE·MENTS

2.1' 2.2' Sigt~ifir:{1ntProducti()r~RUJ'L ' PPA f' R'e:qUJirements , , , , ,
,"" ,•••••••••••••••• ,., ••• ,

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,.,
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_ _3

,.,

,., ,., ,

,.,.,.,.,.,.,.,.,

,.,.,

,.,_ _.__ ..

2_2,~. Design Recerd , ," , ------ ----- --- , --.. -..--..-.---.. -- ,.. ---.-------.-----.---., , ".,_""_ """ "_. _ 4. - -. . __ .. _ ,.. 2.2.2 A~Ul;(nri.:.edEn_gillleerlinJil Change documents , ,.....•••.....•...... __ , , ,' ," , ,, " , ,' , ,.. 5 22_3 Customer EIiIg;i:ru~erring pprov,al A ---.----_., ..---.., ---.., ----_----- ,..--.._----..---.., ----- , , .. .._. ".,""_" "' " S. ,
2,2.4 DeSlgi! failure' Mwe and E;fl:'eds Alla.lysls (DcslWl FMEA)." ", " " "" "" ,.. .__ ,,
••

", ,,, "

" .

.;. .5

:2 2._5 Pr~=s Ho'!'!'Dna,grnrn(s) , , ,,..--- - ----. ,..-.w, . -.--•.,'••--.. ,---.-••-.- ----•.'"',-.-----, ,-.. , . " 2.2:.6 P,riijj~ f,ai~ure MOOi;and Effec[S AII'!ia:~ys;u~<P.mces~VMEA). .. . " """ ..__ .,"" . , ::2.. 2.7 Co:tlIl'I'Q! Plall ...... ...... .", __ ", .... ,......, .. , 2.2 . .8 Mea;siI1t,em>eli~ SysMml A"a!ys;u~ Srudies _.,. ••" ,___",. "" "".. ." . ... ..,__"•••,.• . ,... , "
n ••••• '" , ...... ,n •••• " , •••• ,' •••• ," ...... ," ••• ," ••• ," .... ,' " ..... , ,••••• , ••••• "

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:5
6,

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.. .. "_

2_2_ [lil!nensiDlila~ ~lIU.!ll •.u, 9'

••••• ,' ••••• ,' ••••. ,' •••••• '" ,

,' •••••• ,

--

-. ,.••• --

---

---.,

•••• , ••••.

2.2.1<1 .Rlecotds (!if ~~a'eriall ¥lerfom:ttllJ'lceTest Res.t1lts ., "_•••"".,.•••__ ""

2_2. i 1 [nhial Process Stud~.{'$•••", •••••,' •••,' ,,., -,, ,, ,•••••,' 2.2, ~.2 Qualified LabotalO<y DQCUOlientaJtio[l ..

• __ ._•••,,.••••,' ••••••,' , """., ,'

....."', ••••••,••••., ,.... ,••••,•• 6 , ___.. ...•_7' " ,' ,' •••,' ,.•••,•. ~0

," - ,' ,..--" ..-.--_,.,---.-,••,' ••••,.. .. ,---"."---., •••.,' •

"." •••••,.,,.•--"., , -- ,.""""""---""' -"••" .-••,•••••••,'

2_2..~, 3
2.2.l4

}\:ppelll'allre

Approval Report {AAR) ".,' "., ,' ,' ,,'"

,' ,' ,

, ,"

,, ," ,'"

, ,

, ,,

, --,' ..---

".. ,' ..,," " "

.
,,'.,. ,,....,," ,

_I 0
,..

&ample· .PrOOlI!c,tioo Parts, -.-- ----..---- --------".,---- ---- ----- ----- ----- ---- ---.. -----"-" .. " .---"-- -- --..,

In

2.2:_15 IVtas.ter Sample

,,' ,,'"

_." __ _'10

2..2.16 C:h~cking Ai!.h! ," -..- ----..--- ------- , --- ---- -----..,..--- --- ,..---- ---.,-.---..,., ,' --- ---.., ,' 2.,2_·~ lli~t.omf'r"S:~eifL<: I.EHluirrem.elilts,., '1 , ,' ,' ,,' ".....• , ,, , --•.--.. , ,' "..
::t:;L.18 P\lin StlbmnSf;.LOIi. W~t (PSW) -.------- -------..-----, ------.-----.------- ----" . .. ---.---- ----.-,., ..---,, ,'...,' "----

," ," ,' ,' , 11 __ .., ". l:~

, ,'.._." , ~1

SECTION 3 - CUSTOIvlliRNOHFlCATION AND SUBM]SS.[QN R6QUUtEMENTS 3..1 ,Customer JVofijicatian -.----- ----------.. .. -- -",..•......, ..".,

,_._

---

,..,.,
,.,.,

_._13 -. i 3
,.,.,., -,..--l5

3_ 2 Submission to Customer.,.,.,., -..-----.-..--------.--.. .-"-.---..- -.-.-.-.-"-.----.. --.". ,-..,"..,.,- ,..,., -- -.-SECTION 4 _ SUBII.lISSION TO CUSTOMER ~LEVElS OF EVl[)ENC'E 4 1 Suhmissioll.U!-leI's"., .,.,.,., ,., ,., ~ ,

.---------------._~_.11 __ " " ,.il

---,-.- -.... --------.. --- ,-.. -------..-- --.... .".-.... "- ,".--".... --- ---

SECT[,ON' 5 - PART SUB:M]SSION STA111S

5.1 G'enera:l., , , _ ___ ..-.... .. ..

" ,.,.,." ,
, ,.,

, ,.,

"

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,
,

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,.,.1.9
"_ ,.,.. 9 1

,.,..,., ,."

5.2 Customer P.P'AP'Sta.tus .__._.._._ ,_.._._'" , .

5_2..~ 5.2.2 Approved _ " ," [ntf}rim Approval _ ,' , ,' ,"

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,

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I

[, ~

5.2,,3

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_.~ 9

SECT~ON 6 - RECORD RETENTiON. -_.- .---.. _ - .. - ------_--.. .-.-.-.. .-., ---.. -.-, - -_ --_.. - - - --.. -_._ APPENDICIES
Al?iP'.EN1DIXA. - eOMPLET"[ON
AP:r.ml')~x

._____-.-,.,.., , ,- .

,.,., ,., ".21

Of THE PART SUBMISSION W A:R.RAN"F (PS\¥)

APPROVAL [{EPO!!.!

,.,
,.,.,.,.,.,.,.,.,., ,.,.,., ,., "

22:

BDF-

COMPLEf[ON OF nilE Ap.PEARAN[:E PART ApPROVAL.,

2:6

APPEJo-LDD: C - PRODUC:110N
Ap'PfNI:iLX PRiQDUCTIO'N

DIMENSIONAL

RESULTs

,. ,.,

""

"

,., .. _,

_._ _._._.29 _.33

PART APPROVAl .• NiATERIAl 'f"ESJ REsUL'fS

~ SPECliF]cRE(KJ]REME:NiI'S

••••••_•••••••••• ,_ ,•• ••

••_ ,,_ ••••• _,.,_ •• ._ ••_••_._._. .-.J I -

ArrENPIX Ar.PIiNDIX

E - PRODucnONr An APPRO\( .L, PEltFORMA.NCI A

BULK

1'&U Rf.~ULlS_ --_-.- --.--.-.-.-_-.-.-.-.---._

,

-.--...•-

N1A. TERIAl

••_-_ -••-.-••_••••••_-_._ •-_••__ ••-,. ,- _ -__ •__ •••_••••••-••••••,••••• ,., •••,.,. "••• .35

A.PPIl.N"DIX G - 'fiRES - SPE[,~f']CREQU.IRB.M:lENTS, ••••••,.,. ,.,. " AN'E}.fDIX

,••••,.•.., •••••••••••••••••• ,. ,.,., •••,••••••.,•••••••• ,. ,.•,.•..,. "•••••• 55 , ,

,., " , ,. ,

H - TRUCK

]:NIDUS'fRY - SP,EClfICREQ'UIREMBNTS

.. ,., ....•......•.

57

GLOSSARY __. .. .. . ..

."_._. "_"_._ .__ .. ..•...._

,.. ., ,

"._

"" ,.. .'6S ,

'INTRODIUCTION
'PUl'p,ose
Proodudiofll Part Applr0"f3~P!FOCess (PFAP) defines generic req'lliI~rem.emtsor prooucti.Oifl part approval, f jncludw[l,g prodJuchon end b"ulJl::mate:iials (see G]OSS::Ir;y),. Th,e purpose of PP APi s to determine if aU customer ,engineering destgn record and specification require:m.enl;S,[iFe properly understoed by tine organizatian end thaJt l1e m~!:l~facrnliin_gpreeess has the potential to' p:rod'u.ceprodlllc:~ consistently meeting these requirements durrung anacnaal pnxlucti1i:m fUl!JJ at ~he quowed p:rrod."ijctiO'!'I ate, r

PPAP sl:liaU.apply ,

10 lnternaland

ex~:erna]~rganizlilHon sires (see

Glossary) s11llpplyi:l]gproo~dion parts.

not required unless

service paets prodaction materia~s. or bldk materials, specified by m.eauthorlzcd CUS!tOMe:r representative.

For bl1dk mate:rial:s,PP AP'us

An OifgaJilWlzaUonllpplyh'JJg ~millD,da:mcOl!!talQg s p:[lJduot~mil ©il" service pam shall com.ply with pr Ar unless fonnally waived by the authorized cu,s,wcm:'le!r representative ..
NOTEl: Seeeustoraer-speeifie ~egjuireme[Jjtsfor addutioll.<ll m:fo.ml@lti.o.mt. questions AI] sh.O!iJ be addressed! ~othe <l'luimrized custerner re~[e5eIl!t:U]V,e. l.d 1I0Cm.1.I'PAP'

NOTE 2: A cussomer can ]'OITnal]ywaive r'p AP requ iremeets for an o.rgllnizatiol1. Such waivers can only be issued by 11[1 llutho.r,uzed customet .re<presentative. NOm.3: Alii organuzatioill or s'U~pLi.e.,req)Ue-stinga lWai.wr of a .PI"Al'requireme.nt s:tlOllJl.d eentaet t~.e aud'lo.r:ized, customer representative. Th.e erganization or sl.I!P'P]iersheald obtain docum.e'ntationl. of waivers fromthe auth{)irJze(:jcustomer representative. NOIJ'E4:: CilJtal.og pans. I(e.g.. bolts) are ]die[JItified .uiLdlfoxo1"«red by eJilcti.onal specifiestiens or by
recognized industry stendards.

App,rolalch
l'~:e word "shal I."ind icaees mandatory requiremenrs, faragrapbs
Tihle ",'oro "shoutd" .<'lpp.iy.

The word "should" indk:;!,oosa reeomrn e1.'l.datton.

marked "NOrrE" ere for ,g:uid,.;ilnc-e uaderstendieg orcLa]"i~ing the assacieted requirement. in <I[,peaTiQg ina NOTE isfm guidance om~y. AI', the Wem:Jisand.definitiens given in ]Sorr-s ] 6949an:d~he PPAr Glossary

for the pl!:ll:poSJes frr o

t .. Submission Q·f PP'AIP. 1

The' oFg:.mization s~aH ob~ifi approval (sec 5.2.1) frollll~he <1l!.l1tnO'riudcustQmer representative 1. a new part. Oil: pmd~cl (e.g., a speeific part. material, specific eustnmer), 2" corteetien of a discrepancy on
11 pf\i;:,'vi!Qusly
(If

for;

color no~ previously supplied to the

sl1omitl:ed parrt

3., product modified by an leingi:neering change to design records" spedfic<1Itions, or matenals.

4.. <I.]]!Y Utlkm. required sin.. by Section 3. NOTE: If these is!l1[J1Y question oom:em:ing the need fm ]l1'oooction ]Ji3rtOllpprQval,contact the, a.lltnoril:ed custcmer ~:resefitative_

SECTION 2 - PPAP [P'ROCIES,S RE.QUIRENlIENT·S

2.1, Si:glml iifl.C8nt Produ ction IRun
For P[iOdllll.t,ti!lIIIl. D'aJrtS. produ(;~t Af' shal I be taken fm--Oml ill si,~i.ficant production ro[[J, Thi s s1giIllmCMt productien run shaU be from one hour to 'e~gfit hours of production,ilnd w]tb~he specific prodnctien quailliltily to, I~Qtal.a mjii.IJ~mumof 300 Clo:nse¢utJ:v~ pruts., unless otherwise specified by the aill.lth.OIri:zl~dcustorner representajive. This significant production run shan be- eondacted at the production slte"att~e pn:x:h..i,ctioro rate (see Glessary] using the pro cluction tooling. prnduetion gaging.product]on process, producnon materials, and. production operotors" Paets frpm each unique PH;lduction process, e.g., duplicate assembly ]jme and/or woek cell, eachpositi.OIil of'a ffiJl.thJp]e cav]~y die" mo~d.j~o~ or palilleml,. :shaJlI be meul\ued and

forrr

representative penstesied,
:F1 or

bulk~~ateri.ds: N00specific E!!Lnnber of '~~a:rts" required, The s.ubm]t"l:ed sample slmU be taken in a is manner as to <ISSl1[1ethat it represents ~'steadJy~:Mate"opemtion of tililepr@oess.
NOTrE:; for bulk ma1lerill[,prodll.!ot:tOIii bJistories of eurrent produets .r.mty oien 00 ussd to estimate rue, il1i~ial. p.rocess,capa,bi.ljt:y or perfenaaace of new and sjmil.ar pFmJJuds. ill eases where ne p.roduotio.lll b~s;l"O:ryof a :s~mUa:r ulk material product or technology exists, a cO[JItammelll p]l}[1 may be put i:nto eWecll!![JItil sufficient b production has diemons,tlra'ted capalj)i]ity Or perfcrmance.ualess otherwise specified by U'lf cusmmer,

.2,,2 PPAP Reguiiremeli1ts

The organizaeian shan meet all specified PPA.....P requirements Ustoo below f2..2.1 lJlllir,ough 2.2..l 8).. The ,org_~zatio.n shaU also meet all c~stom,e['-spoc:ific PP'APrequ.wements .. Production
parts shaU meet aU customer eogineering d!esig~ reo~mjandspec]fic~tion (j11!c~udi.l]g safely 1.lndregu.bro[)' reqeiremeets), Appendix F). Iequi:renleJ1ts

BlLl!~k Ma.~eria:~ PPAP requ]rem.e~ts are defrne..dby:a comple~ed.BIJi~kMlI.lIEH:ia] Requirezeents Checklist (see

.-0.',1,·

_..

I. - . ,_. ~

I•

If!!Jtly pan specifications cannot be met. the organization 'shaU docull:tent their prcblenr-solving
and shall eentaet the authoriaed eusterserrepresentstive

eerrecti ve action.

for eoneusrence

]]:1

efforts determinarion of <lI1PP'IOpriat(e

,,-;

NO'.,·E: Hems Ot racorda from 2_2_1 tihn,lliigh .::t2_I Sma.;!" :IDIot neeessanly IlPP~Y to every C'llstomerpilrt number fr[)m e'olery o:~gal1l.Zii!lioriLFor ¢.1'1.amp]c. $Qm.~ parts do not have appeafaJlC>e req~.i[lemel.1ts. olll.ers diD !!lot have: color ['~qJiI1irumenl<l, andplastic parus may harvcpQl)m1eric part marking requirements If! erder jo d.eteFn:rlii.li1~ with oel!tainty whucb i.1:c:msmustbe lnelnded, ,consult the de;s~.gl"lrewnl. e.g., part print, the relevant Ellg,uneerillg doeumeus or sped.l'i.CfI~io[ls, and your lil!ithQnzed customer ~.ep[esenbtive-

2;,.2.1 ne:dg;n. Reeord

The Drganlzartion shall havethe design reeord fOir the sal!ealb~e plrOO~ctJpa:rt. including desrugn records for cornpo~~llts or detallsof'the salesble pm d~ctlpart Wbere the des,igj[irecord is ~n eleetronie format; e.g., CADiCAM math da!lttl. the organWZl3!tiQ!1hall pr,oducea hard. copy I~e,g.>pictorial, geometric dimensioning s &. ®oleNI~dn,g[GD&T] sheets, drnwiug)i 10 ]de:nti~ measurements mkeFl. NOTE I: F or ,a!]}, ¥lI.]eable prndill.C!l, pari: Or compoH1,(:":ii~, ~b~re w~U oirlJy be one des]gn iiecoJ:'di,regaro]ess of who has d!e5ign.,;respOi~t.d,bi lhe: de.sj.g~ recom may [efe:reJ:!c~other docu.mertiLs IDLlaki[lg~lilelM pall efthe I~ly_ des,ignreO(llrd. NOTI[-2: A singl(t dcs.ugn record can represent multiple part or a£$¢.mbly COT!figru[!'It~.olli~. ,e-g,.,a sub-frame assembly ""'.itilVlrrIouoSh.ole co[lfigufa[(ions fur different 8:PP ]~catlo:ns_ NOTE: 3: For parts ideruified as black box. (SieC GI(J~ary).tlJe diesilgflreCO!!"O :spedfi.e.s the interface and p~rro.lli:tmnce reqIJioom.emrlS_ N(n][ 4: For parts lci:e:ntificiiJIasceralegpasts, d1e desig~. [ecow may i:OI"l~i5l Illy ofa f~liI.ctiQnal o speciFlca:titm. Or 3 [ef~re1!!Ice~o recognized rn.duslry standard. a
NOTE 5; Por bulk ro<i!~e(ials" t]i[e: design [l:::cQ"OOImay iaclude id.e!lt~ ficationofrawmateria:Ls,. fO:m:u,J~tiens, a proceSS1rl:l,gteps and ~flrnJ:liii;te[$, andfiaa! pirodluc[ spoci fica:~.iiQrns acceptance criteria. If dimelmsiO!lll.] s 10.11

t"';
.)

resalts dQrrl.ot,apply. then CADleAMrequ~rem.e:l1.ts are also not app'HcaiJ.~e"

2..2,1.1 Reporting ofPnt Material Com,osiUon The '@Fga:ni~ti on shall provide customer-specific req_uirem.ents. evideaee t!l1at tl1J.e MaJte[lal!lSubstaElce Compos]ti:@iJl('ieportin.g
fOJ

tMrt ~s

required by the eustomer. has been completed

the part and that. the reported data complies withall

NOTE: n-.is m8!l.~rials rC.poQrti!ll[g may beentered ~.mJtotne ]MDS (Irrl.t:e:ma.tionaiMflterial.s D.a!ta.Sys!.mn) Qr ,other cllstoltle-;r·spec:ifh:;d s-y.s~-mfm.e:th.od" [MDB is a.vailabk: ili[ou,ghr bup:Jlwww.rmJlsys1em.comflndex.jsp.,

2.2,.1.2 Mu£:kiiug:of Polymerh: Pans

'Wllef,e a:ppUc.a:b]e. fhe orgtl£Jib:atiliOf:lshai]j idet'litl fy polymeric parts wffith ~he~:SO symbols such as specified [[]I ~SO ] l469, "Plastics - Gern!el)".ic[dentiFijcat[o:n and marking of plastic prodaces" a:nd/o]"~:sO US.29. "Rubber and ]aIttice:s, - Nemeaclamte." The f-ol owing w-ei,g_ht ,niteria shall determine if the m.<lrkmg ~ n~quiIeme!n:t~sapp]icalble: • '. P~asticparts 'l,"'eig~~p-: at least ~'O'Og (l]sirn_g [SO I 14691l 043-[) Blastomeric parts we.igb.]]1Ig at ~eMl200g (using ISOI.~.469/Hi29)
Me

NOrrIE; Nom.eo.d<!tu.fe ad .aJb!b;r>e\~iat]Q[lrefe{~r.uoes~o slq)rpOirt the use of ~:sO l l 469 l043-1 fOT basic: polynl.e-ifSilind .in ISO l 043 ~2 fUI fiUer$ ariel ",eill!force.m.enm.

contained

~[1

180-

.)
4

•••••

.~g'l

., ••

• _.-

• __

••

2.2 ..2 Auth!!ll.rized .Engi.neeriilil.g Change docameats

The organization shall have my aUlth~lfi2ed engi:lleetil:'J:gchange documents for these changes not yet recorded in design reeord butincerpnrated in the product" part OF toolilng_

me

2.:1.3 CllJ:s~omerE,ngiDeering Ap'p'f€ly.ai

Where specified by the c1l8t()m~1,.Ule organizancn shall haveevidence ofcustomer ,eng1nee!flngapprovat
NOTE; For buM:;m_~t~dilJS, thisrequirement is satisfied by a signed ·Etlgl.nee~ifl.,g Approvaf lineitem 0[1 the BuG;:Ma~eria] Requ~remen;ts Checklist (we Appendix F) andlorindusi(}n. on a cuOOm.ev mailJitai:lllied list of approved m.a~·ef~lIk

2,.204 Design Fa.U:ureMede and [[J'fects Analysis (IDesig;n Fl\:1:EA)

if the o:rga:nr~za.tiolil.ispr~d1!ld:de:!dgn.-l'IesponsiiMe
The product design-responsible OI:ganizatiQFI shall develop <I. Design FMEA U"I aecerdance with, and c(lmp]iant to" customer-specified requirements (e.g., Potelil.tial Flliibtre M@dJt and Effeds: Analysis reference manual),
NOTE 1: A sin.g~e Design fMEA m.fl:y be sppliedto a fam ily of s.umilar parts 0., materials. NOTE 2; For b:u~kmaserials, see Appendix F.

2.2. Sf'roce:ss

F~ow [):iiagra,mf s)

Theorgani.zat~.cm shall have a proeess flow diagram in an organization-specified format tnat dearly describes the production process step-s and. sequence, as appropriate, and meets the specified customer needs, requirements and expectations [e.g., Advanced Preduct Q~lJa~U'Y rbnning and Cont[iol. Plan reference manual}. f()'f bu]k materi~!s, 3[1 equiv~lent to a Process Flow Diagramis a Precess Flow

Description,
NO'FIi:,~ Precess flow diagrnlIhsfor 'famulies·' of similar partsate ,acceptable if title newpens reviewedfor commona.~~Llyythe organization, b bave been

2 ..2.6Pr~ce:5,S

.Jii'jdlufe Mode and Effects A.na,1ysis (proCless Fl'v[EA),

The; o~ga[luzat;ion shall develop a Process fMEA in accordance With> and comp~]~nt to, customer-speeifled requiremenrs, (e "g.,r0,tenUal F,ailuiileMade ll!liId Effects Analysis reference manual],
.NOTE I: A si:ngle Process f'MEA .rnay beflppl.ied to 11 process manufacturing material'> if reviewed for commonfll~1iYby the orgllni.zJtion. NOTE 2.~ FDr bulk roateria~s.
~GlC

a ftil][i]y of simil<tr parts or

Appendix F.

2 1." Contrel Plan

e,

The organ]za!tion sha]] ]:mve ill Comrol Plan that defines an methods used for process COln.t!1Q] andccmplies with eustomer-specifiedrequirements (e.g., Advau,cedProdllH::t 'Q'I!l!antyPlanl!l!ing and Con.trol. Plan reference manual),
NOTE 1.; Controi .P]am fOIr "families" of parts areacceptable oomm(JI1ls1uty by tl\ieo:rganlzaliol1.
]f

the ne-w parts have been reyi.ewed for

NOTE

:z;

Control P~an!approval may be required by certain customers,

2.2:.1 ~lle9SUreMlent s.yst:em Ana'ys~s $bl.dii,es

The mganimtiofl shaU have applicable Measuremeet System Analysis smdies, e.g_.gage R&R, bias. ]i:o.earity >stabi.Hty, f~j:f all new or modified gages.~ m.eas,ureme]]Jt. and testi eq1iilipment (see the Mell!suremefllt 8ysh~mls AnalYSis reference manual),
NOTE I; Ga:ge~R&R ac()eptab]~i.zyCJfikriaal)c defined
mi8J1ilJJat

~11 the

Me~suli'cment

Sys'tcrn.s AlJa~ys~s.[,eference

NOTIE 2~ For bulk mate~,al:s, Measll!["tlmmt System A:na]ysis may not apply. Customer agtt:E;:me[IJt~hould
be 'i)btarurnoo onilctl!,ll reql1irements.

1:.•2.'9 DimnensionalResults
1

The orgam::l;flltion shallpravide evidencethat dlmeusienal verifieaticns requked by t!lic de:si.~ record <lind the Control Plan have been oom.p~~tedand resu lts ind]ca.te 'CO~1ip1i:uJJoe with specified requiremeets, The organi:lalionsh<liU. have dimensional r,esu~~ fo!!"~ch uniqae marr-llf:act!lMllimg process. e.g ..,. cells C!f production Iines and all cavities molds, patterns Or dies [see 22:, 18)" l'h,e ,or_ga!lizati,cm. shall record. with the actual resalts: aU. dimeesieas (except reference di meesioas ),. charaeeerisries, ruld spedfl.cati.ons as noted on the designteeord and (;olltro:~Plan. The orga[ilJiza:t]on shall indicate tile dfllte oft!he designrecQrdi. change leve~.ao.dany ~uthorized engineeringebenge doclilmellil not yetinoo]"po.rared III the des~gn recordto :which the part was made" The organization sha Ilrecol.rrl tJw:e, chenge level, d:rnwing date, o.rg<ll.li.zation name <lrnd pari! number on all auxiliary documents (e .. ., s~pp~.e:ment:<liryltlyout resultkssheets. skeroli:les,. tracings cross sectieas, CMM g inspection point [egu~ts, :geol11etric dimens iO[[l.i.ng and to leF.a:ndng shee1s,. or o~he, auxiliary drawings used in conjnnction with. the pert drall~ing). Copies 'of these auxil.iary materials siiI:aU aocompany the dimensional results acoonlhl1l.gto jhe Retenti@:ru'Subm]ssion~equirell1le:nt5 Table, A trodllig s:l]aU be included when an optical .compamtor is necessary for inspectioJi)J.

The. ()irga.f'l,~.zation shallldentii'y one ofthe

p~it1Smeasured

as the master sample (see 2.2 ..15). .

NO(fE 1: The Dimensio[}a~Results rmm~11Appendix C, ...piclOiJ.al,geQmetui; JimcmJsio])mg &tole.rn:J];cing [GDlt T] 'Sheets, or a checked p.illlt wbere theresults arelegib liy wrinen On a part drai\?i'i:ng illdudin.,g crossseclions.mu;:]ng~.
Of

sketches as appl icsble mJY be utilized for this puspese,

tYp'ic:illl~y

NOTEl: D ~me[l1sklll!fl1esults r

do na~ 3!pply to bulk rrtcSJtenals_

.:1.2.11 Rec~n·,dsof Materia.I/',ertonna

ace Test Re:s1iI1ts test [esultsfof rests ~pe()~fied 'on the

Th.e 'Organization shall have reeasds of m.a:tetiai and/or perfoFmanoe d'es~gn n,lOOifd or CQ[!.t[iQl Plen ..
2.2.1 m!.l Mate!f'illJ~ 'fest [{esu[1s

The organization shallperform tests fm: an parts and productmatueFi.;ds\';belilichem:ic~l, metaU~rgical[1equ;ln,~.m.e[l1l:s<lin:sped'fied by the des]gn n;::card (If Conool Plan. Material test results shall [nd]calleal1dim::~ude; • • .' .. ..

phys iCaJl, or

Ute design reaoro c~Mge levelef the palm. tested; .any all1tbon2ioo ,e:ngmee:ni[lg change doc~mei!illts t~tbave not yet: been irloorpora:red ~~ t~e design Feooro~ tD.enumlbeI., dawe~a[ld change level ()if~be s!pedfic~tions to which the part. was tested; the date on which the testing took place; the qU(lolti:lytested;

"

• "".

__,_

~ I•• -

_, _•• ~,I.

_ ••••••••

'--'--

•
•

the actual results;

the material supplier'S name and. when requil1ed by thecustomer, the eustomer-assigned
is S:~0WIil
~fl'l

suppUertvendOi code.
NOTE:

Appendix D,.

Mal:e:r:ia:~teS~fe;5111t8 may be ~re5e:mttoo tn Ii.FlY c'On'ile:!Iient f~Jilna!t. An example

for products W~U'l eustomer-developed material speeificetionsand iii custcmer-epproved s:olPpHerUsc, tlle o,g~u],i;z;a6on shall promre materials andilor services [e.g., p<ai]]tillg,. plaiting, fuea:t-treating,wdding) IToOm suppUewson that list
2:.2:.10.2,

Pierfof.aan!ce

1',estt:1!te:Sll~ts
8]]

The ofga!'ljz~tiQ~ s~aUped@~ tests tor

requirements
P,e"nOJi'J:llailliL~"e

pan(s) or product materia~(s)when performance

Oir

functional

are specified by the design reeord Or Control .P~aD.

test results sl:tall iadicateand include;

the de:siglllrecord cbangelevel of thepartstested; any authodzed eng~lileer:in.g ehsnge documents tlru.:lU lillJaveI1O:~ y!e~ti een ]rJJoorpQrated ]u the b designrecord;

'. •

• •
•

the aumber, diate,and dta.l.lge ]evd of~he specifications to which the part was tested; the date on which the testi ngtaok place;
the CJ!uantity ~iested;

the actual resaks,

i:ll

NOTE: Perfbrmsnee test resahs .may be presented Appendix E_

aillYCOI'IIVetllen~ fl!)m:Lt!l!t.

A]! eltample is shown in

The level. of hl~[ialprecess capeoility or perfcrmance shallbe determined

jo

be acceptsble prioa to

suhmission for all Special Characteristics designated by the customeree org.anjzaltiQ:!1_ The organiza!ltion shall obtain customer ceacurrenee on thejndex for estimaiing initial process capability prior tn submission,

The organ iz;atiOI[l shall perform mea.su:reme']1fl system a]llial.ys]s to u.!){k:rsttlJ_tld how measurement affects the study measurements, (see 2.2.8)

error

NOTE J1.; Where]1.o s~ecja]ch<l!(acte.r~stir;!i bave been ideJiuified>UiIe customer reserves the rightto require demoasnatiorr of initialprecess capabi lit}' Q!JI ottier e:~t.eristics_ NOTIE 2; The parpase of this ~eqjuil'emen.t isto d.ere.rm_ine II lie production processis .like1yto p:!'Imliuce
product that will meet the cusiomer's (@i;[l,lir~rn..:m:ts- TheiDjtial process studiy is tocused on variables not <liUr~bute data. As~rnbTy errors, testrail[1~, $urface defec!:S are exmples of O1Jtil:ribule ata, whichis d i.mpo:rt.m:u w und.e.rstand, bl,lt~8ID:1t ClOve['ecli In tht~ injt~al sfudy _ To uJ1den!alil;clthe Fffu.rmanceof cbaeaeteeisties moaitered by <liuriblIoo dab wiU~l)!Ii~ more data cellectsd Q¥'er time. U nless applo<wd! by tlite authorized customer :repre:sentati.'II'e.,Ilmll)ll1~edam Me aot a.c.Ci!'ip'lJa1ille WAf' submissioaa For ,
"

NO"lE 3: Cpk and Ppfr .are deserlbed below, Other methodsmere appropri8!~e fo., cenala proeesses or products may be substitared with ~riO'.iappmval.£rom H1Jiurlioxroedi custosner .repre-seotativ,e. NO"F.E 41:Initialprecess studies are sFI.mHernn .ulldwin [lot predict ile, effects of time :oo;d! variation ~1Ji peoiIi!e:, mseerials, me1llilods. eqlll,ipmenl, measuremeat systems e 'and enVIDll1ment, Even forr these short-teem saidies, it ts irn.p!Ylitant to cnllectand analyze the dlllta [rnthe o:rne,r produced! using control charts, NOTE 5~ for those ch!l![8:cteds~ics tl1ff~ carl be .srud!~.ed Ilsing X~bar8!ll:dIR charts •. a shert-tsrm stuJy should be based On.a ffil:nimtlm of 25 subgroups oonta,ining at least l OOrnad:ingslrom eonsecutivcpans of rhe

,_~.---

.- •..-_._ .•• _ , .~I'. ....

6i.gr.li.fiC1lil[~prcductian run (see 2.1)1. The mltifli! process sru~y ~ait.l requir-em.en.ts nlay be replaced by 1(I!l]g,eif~ liGI][1nistQrica1 data fr:!i:mttli1e: same: or simibr processe-s; with eustnmez oonc11I:rre:noe" For eertain processes, aherm.8!tive ,'!!lillytic,d toob ~!l¢tJ as ~llidJi'l,fidua[ movmg ruge charts .may be approl?ri.8!~eal:'ldpe:mlil!:e~ and with pni:Q:[ ppF(l¥:!'I~,oom a~ tlll!I1il.orlZW cI]Mom~rreprl'l~llIl:ati¥e. a f

2.1.l1.2

Qu;aUty liIlIdtces NOTE 1: Th.eunitiill procees smdlyresl1I]ts are d.f5Pf;fld!em o[l~epurpose of theswdJy, method of ,d1ata 8icquisi~ioml.sa.fi'lp!.l1i11g., m;Qi1!l]1~. dara, d!emQJilsbillitiOJiiJ Qf sblitisti.cal ocmwol, ete, See the Statiisti'c8.~ P:r.oeess a of Contm~refcfC1!lce manual for a.ddi.tioJ1al ~f1ftlrmat:iQI1 h:J!ulld~rs~!1clilllg the basic prilJJc~ph:I\ of'statistical stabiliry amid process measuees (indices), For glll.daJrlce On ~re~ listed below., contact the a~~horized
eusiomer fe]l'rest11tatcive.

Init~!JJ 1process sffidi es shall be su~m$riJ~e-d w~U\JicaJpabihtyOw perfasmaace iadices, if a.iPplicable,

C~ ~ The eapi8bUi.ty iUldic% .for a stab.le pr~ceS$. The e$tiWl!itfl o( si,IDtrlais b~~ (I[I~iliithin subgroup var,ialioi.i (R;[w"Jdl O:f S-:bru'/04). Cp.l:is all'lindh:;atQ:rof pFOceS!!i,eapabi lity based 011PI~S vari ..tion wi!hill!l each Sl1bgooup of a set ofda:I:EI.Cpii; oes motinc]l1rn:e the effect. of proeess vaii.:!'Ibility ~MWIli tbe suibgrolap5. d c~ 1.6an indtcfltor of how geoda process cOIJ~dbe if all process variation between subgroups was 1'(11' be e.~umiu[l<lted, Therefore, use of Cp&: :~o[le may !be <In.inoompl,e,te'u[I[iic8IllOD: of prooess per:[or:ma:n.ro. Po:! more a

,uuformatioll. see the Sta:tis,tical.Pr,o eess COmItro~ reference marlllal. Ppi. .~ Tile ~H!Ii"![oftman0e ~m!l!cx.The estimate of sigma us based Omi.,vtalmri'atiol'l f {all of imtdividua] &arnple: data uslog me stam:lap[i ,d!evia~io:n.[root. mesn square eqUfI.tiOIlJ]. "s"), : F~i& .8!I'I~midicak:lir ofpmccs$ performance based on process variatio.l'lllhrou.gJlout mefuU W~ of d.a:~, U~]~ki~CpW. PIM ]S, not ~im:ited to the varlaHoll wi[h:in :subgroll~s,. Howeve:!",. PpJ, ,Mnnot isolate wit:h:ill subgroup va:ria~iQIli f{o:m behvee'&!. sulbgm~p 'l!'a:,.~aHoil:l.When ()8ikll~8Itedi fr.oM tll.e same data set" Cp ,and! PjN;. can ~ compared! t08!nal)'2iel the s![)l[[fCes of process variatioIl. For 1:l1C1re:nfoEma.th:m. see tile St:at.lstic81~ Pmesss 'C'O.lltlrll!l~eferellCemlHl!1l£lL i r Initi8i~ Pmcess Studies. The pu~ose of tie ilThi~:iil~ process, study is ti:lllmd.erstand(h.e process V8Iriall01l. not just to achievea specific indexvalue, Will/en.h.isrorica~ data are ava:i]ab~e .or ellough i.<J.i;tua~ exist to plot data a ~mltro~.chart (alt least 100 i:n[ii.vidmd S<lrllp.les.),. Cp.tcan be calculered when lilleproce5s, is staOle. O~iJ:Je"'\l'·is-e.far p:mcesses, with !rn:OI\;\1D p[iedicu~b.le' special causes and @utput~lleeti[lg specifieasiens, and Ppl should be, 1!lse[j. When [lot enough dliita axe aVll]l",Me (.;:;:100 samples) Of ~hen are unknown sources of variatioJll, coataet t:h.eautho.iized eustnmer rf-:p'Jj'esm.tatillveto dieveLop a sllIilubre plan, NOTE 2; for ]nitial Process Stm:lles lnvelving .:statis{ucal methods or a,pl\Mches ~lii1I!Yerequired, b
IUQf'e

......
•

tha:n. one process stream, additional. approp'liflte

NOTE J.: .For bulk nn:at~na~j the org.arl1Ji:zaJtiortl. shoiLlld ebtain C'U5l'O:m~raJgfttment reg.8!itI:ung the appropriate ltx:hnlCjues .rovill~ti;8i!.prOOf:SSsmdies.,if required, in erderte de~~m1ilte;:um.. ~ffective ,eg6m~~e of c8!pab~ IhJi.

2.2.11.3

AClCeprtllllce C.rUe~Fia'oli ini:tiaJl Study

tlliu:atappear staMe.

The organ~zaltOitiL s~aH usethe folLowmg.as eeeeptanee eriteria for rev,aluattinginiti;al. process smdJy results
fm processes

,mfJrt?tetu#tm

Iadex>

~.67

The process currently meers the aoceptance criteria. The process mary be: aco~p[al~l.e. Contact Ulieauthorized customer r1l(pl1e'.sentatruv e. areview of the study results, for
r

Index < ].33

does Hot curreatly meet Ulie acceiPt1il!];cecrliwn<'l. Contact the al!Jthorized.customer representetive far a review of 'fheprocess the ,studiy results. cnteria ws o,~e of a number of easterner

NOTE 1. Meclillg~ih.e' imirNa~pmcess study ,capability acceptance requaements tllat leads to (l]1,appoovedrPAF' s,]!~misslolli.
NOlJ'iE 2,: See 2.2. ~L] and 2,2.11.2.

2.2.11 ..1 r

1]J ~stable

Precesses

Oe;pending 'on the nature of the i,msrn:bl]i.ry. <'Inuru;mMe process maynot meet eustomerrequirements, Tbe OFgallJ.iza~ioIl. shall ].deIlH~. eva1uaitl;': nd. whereverpossible, eliminate special eauses of variation priertn a f'rA p ,sllllmi.ssion_ n.e orgi!lniZ<lJtiQl1shaU notify the UJtrn.~YI".izedc~tome:r representative of aJoy !mSmb~e processes th<ll~,existand shall submit <1. eorrective actionplan to the customer p.riJlilI" a.lilIy flO :sui:rmJiuiolil.
NO"{'E:: Fer bulk Dale rials, for processeswith knewn ad predieteble spec ial causes and ollllpu~meeting speci ficatioas, correctiveaetion p~<tn_smaYIm$.lt be r¢quir,e;d by the customer.

2.:2:.11.5
w~th 'lheautl1mlzedcustom.errepresen'tui.veal.temative criteria for precesses with one-sided speciflcat~ons GiI liD,o~!1orwaldistributions,
,

The, ,oi.rg<l[1[j,zalion shan d!etemfline,

,[J,ccep:l:anoe

nle above memi.o.n.ed acceptance criteria r(2..2.11.3) assume ]lo'l'tlli'.ll.ity and a two-sided speejfleetion (target ia the cell[erl,Whel1th~:sus not true, using th.is am..~ysis may result in unreliable im) formatioa, These aUerl1la:wacceptance eraeria 'OOll,ld require a differe:nt~'pe OF index 0:, some method of lnu'I&forttt'l!8!lio]l of the data. 'I11C f'OclJssholilld be on nd.en:irUmd:ing thereasons forthen.on-Itor:ll!l,dity (e.,g.,is i~s:~aMeOVel" time?) and l'llJ.a:ooging vMia!tJ:ollJ. Refer to tn.e :Sbtffisti~) ProccS:!l Contll"o~ reference m<lllilliil] fOF furtherguidaaee,

NOn?:

1.2:.U.6

Acti.OD;S, To Be Taken Wbrefl . .AJe~~,hln(je Cr.~h~ri3J. Ar"e No,1\ ati.sfied S

The orgenizatien shall contact the authorieed custom.er represeotative if the .acceptam,c.ecriteria: r(2.2.1].3.) cannot be attained by the requized PP AP submission date. T1The rganiza!Jt:ioril 8h~n sulbmlt to time o suihorized customer representative for app.r'(lv.ala oorwectruve;actiol1l pla:n aada moomed Contro~ Plan . normally providing feu lOO%i:nspootioJ!ili. VarlattoJiDJeduc,no.lmJ ,eft:o:ru shall 'oo~tIDue until d'le aecepeanee r cnw.ria are met, or u.ntil eustomer ap;prOrvai is .receivedI
1: I •....... ,
I

NOTE ~: 1OO%ills,pe1::liioll me,thodologies,8Ire Silillbject reviewa:rn.d eoneerrenee w

by the (;1LI.s~o:m.e:I" ..

NOTE 2, For bulk materials, lOO%im.pe-c'l:io[lmea]!8 <111 revaluation of a saJmple(s)of p&Od!.l~t from!'! coatinuous pr-ocess orn.omogellJel[lus batch whiclt is [epreselJltati ve ~f tlile entire r[{) jjJl,.u~luQI'I nm,

2.2,.11 QU3UfledLaboraro:ry

DlenlW:enbtiln
,

Inspection <lind~estingtoFrpAP shall beperformed by a qualified laboratory as defined by customer reqrulremL~ts (e.g .• an secrediied ~aJoorntory)" The quaUfied laboratory (i.ntem<li] OF external. to the organi~lti()in) shall have a ~.abo'J<I1to.ry scope and d~OIlrne:l1ltat:ion shJ)w]~g mat the laboratory is qualified for the type of measurements or tests eondueted,

laboratory is used, the OrgaWz,atiOro silThaU submit the test results On the laboratory letterhead Qir the ~ormal. 1a bomJt:ory reporn format The name of the lal!)O~atory thasperfermed the tests, the date (s) of l$u.e tests" and the standards used to run the-tests shan beidentified,
1

When an exremel/commereial

1.1..13 App earaaee Approv:alltep!illrt . A separate

p:r-Qd!ucfuipart has appeaeance

(AA.R)'

Appearance AppirovarnRepo:rt (AJ\R) shall be completed for eaeh part Or series ofpans if the Feql1l!~rell1eQ~S Oi[! the design. recolrd.

Upon satlsfaclo.ryoompleti!QF1 of all reqjuiIl":d ,c:riteTia,~he orga~zation sham record tilwe reqjuiired ][1UfolJInationo]JJ the MR.. The completed Al\R aadrepresentative produetion pl10diucts/parts shan be subm]~e>d roU"elocalio!1 specifi ed by t~e Cl1stOfJJl!e',~o receive dispcsition, A1\.Rs (compl~te w ith part disposition and 1l.1I.lItfiorizedcustomer representstive ,s,i.gna:turej shaH~\hen accomp<l!ny the PSW atthe time offiilillialsebmissiee based open the submission levelrequested, See eustomer-specifie requ1remerUs for any additional requirements,
NOTE 1; AAR typi.cally <l:PIP]ies lJily fur pads with color, gacaillL. 0:1' s~daoe appearance requirements" o NOTE 2: Ce:mrio customers may not require entries
]0 <I]~ MR

fields.

See' Appe'ntdix B or customer-

speelflcs for detailed instructicns on oo;mpk~ti'lll;g AAR.. the

2.2.J4

Samp~ef't:'~d.uet~l!nlJParts: by the customer.

t)

The o.rganizal ion shall provide sall];ple pr<nducl as. specified

2.2.ISMJ aster Sattlp~e

The organizatioa shall retain a master sample f@rthe same period as the prcductioa p<illtt approval records, or <I) until a new master sample is prQdlLlJoodforr same custemee pad number for eustomer a.pp11(;~V<I]. the or b) where a master sampl.e is req "ired b~ the des~gt1 eeeerd, Control Plan (lrif.lspecti.oro Q1.ite:da, as a referenceor standard. The ~aste]" s~mpl.e shall be identified acSsl1.ch, end shaH show the customer appreval date en the sample. The o.rganizat]oIl.shall retain a master ~O'IJlfl~e each posim:ioll. of <'I mull.hiple f.or cav~ty die, mold, tool O'f pattern, or preductien [l!I1Qces~sl!JJ1]~es$' otherwise specified by the GllJIsto:nlle:u • .NOTE~.:: When pal'lt size, sheer vo.lume of pam. etc. mll~es sm.ra,ge of a master sample dUlicu]t,. the sample retention requirements Imly be modifled or waived i:nt w.r.itiQg by the authorized eustomer representative. The ptlli:Jl'DS!e me master sa.mp~eis to assislin d.efilJlmg the pmdiwctio:n standard, especlally of where data iS8im:bigum~s or~f.IJ]os.uffi.cie;nJt:<i.etd] to eny replicate tbe part t(litsQrig;i.mlili ap'piI'uv,e('lstate, NOTE ] ~ Ma!!lyD1ttl~ material properties lillie by their ffilige time depfHlIdent" a!Jjd!if a master SiliI1iLpleis mquircod, .it may consist of the manlllfarau.r.ing record, te-st res~l!S, oerl:~fic!li~eofililJi<llys]s, of key ill~d:i~[lts. [QF d1.eapproveOi s.ulb<misslo:n sample, (see Appe:ndm F),

aoo

HI

••••

I-

,.,_ -

_......-

2.1. Ui Cheicklng Aillis,

If requested by the customer, the organization S~ThaU s'Ulli)fnitwith the PI' AP suhmissien any part-specific
assembly or component

cllliecikimgai.d.

The organizadaa s~aH certrnfy ~ataU ,aspects of ~e checking aid agree:w~th pact. d:imensi(jna~. requirements" Tbe Qrganlza:ti!Q]Il shan dOClllnrJie:nt all released eilgiueering design changesthat have been incorporated in the: c:hed:ing a]d a:t the time ef s~bmi:ssio:n. The organization :shaU provide for prev,~m.ti ve

tnaintenacce

of any cbeckrn,ga~ds t@r the] ife of the PaJrt'(Sie:e G~QssaQ' _,"Active Part").

Measurenl1e'Jlt system enalysis stu.di,e:s,'e"g., ~~ge R & R, accuracy, bias lin.earity. s:tiMlily studies, shan be conducted in co.mp:.li<lIDi.ce witii customer requirements. {see 2.2.. am]theMc9£urnm~nJt 8 SysteMs AUaJlysis reference ~a:Duan,
NOTE 1: Cfu.eeik:ingaids
'C8!r1

if.ldllde fixtures, variable8!I1JCI a!1riol!Jlte ga&~$, models, te:m~ lates, my lam

specific totlle p.roduct beilng suilmiined. male-rials. vhe organization

NOTE 2! C!!J.~king al~,. etc" typicaJUy diG!~ot aJpply~o SIIDI! M:a:~8!ls. ~f eheeking ai.ds are ~sed [QI,i bulk should cantaet tilefll]Worized customer {Cpn::';$ElllJtative regard ~Ilg this requieemene,

2:.2.17 Custom~er-Spedfiiceequ.h:'eme1illts
The, oirg:an~zation shall have records of compl iaace to ~~~a.ppUca;b]e castcmer-specific requirements. For bu~k materials, epplicable custoIne:i~specdi,c requirements shall be docurnemed en the Bulk Material
Requirements Checklist,

'.

2.2.18 (P'SW).

Part SuD,missiio11llWar.rant

,(PSW), the '[r,~anizal~o:n shall cotnp le1te the P:art Suhrn~ss~on Warrant

UpOIi1l'CQmiP~etion of allP'P.AP requirements,

A seperate P SW shaU be oomp.leood fOI each customer pan nsmber unless otbe["\\'lse agreed to by the
autherieed

cnstomerrepreseutati ve,
partes win be produced. from more than one cavity, mold, mol, die, pattem, orprodnction

I.f prcduction

process. e.g., line or cell, the organization shai]1 complete a dimensionalevaluauon

fronseach,
The

(see 2.2.9) on one part

Tin: specific cavities. melds, line. etc., sbaH ~hen be, identified in the ~'Mo]difC<llv.i.tyfProdnct;i(m

Process" lime ana PS W. or in a P:SW ~Ua.chme.lJ.t mgabza[~On shall verify thatall of the meesuremeetand lest resu]is show cenformanee wiill. customer requirements and tbat all Ieqruired docUmID1lentatillo:n ava~J<lJbl.e <'I!nd,fur Level 2" 1, and 4, us is included in the submission as approprri.uie. A respensible ·oiffidal of tJh.e organiza:tion shal I approve the PSW and provide eontaet ~rrformati(m,"
NO'I'm I ~ One watrant per custa.rner pMl [JJumlbercan be used to summarize marry ch<l!nge5 providing that ili.e changes are a.d.equ8ite:~y docume'ntet1, and rue !ruomi:ss,i.o[lis in eemptiance w:~th eustomer program tim1ng, requh~,em.e:lilils. NOTE 2: PS \,Vs may be sub:m.itted ele(1;mlll.caUy in co.flllP]ial1ce with custnmer requirements .

•
• I_ •• • __ ~I ." _.. • ., •• .~ I .,_ ~~. I •• ,_ --

11

..------~----------------------------~~----------------~----

.2.2.UU Part W!e~mu (Mass) The organization shall reccrd.en theP;SW.e part w~l~t of fhepart as shipped, ffiea:5l!]red<rnrnelq,uessed ]]].krulogmms ~o fom dec:i IJI;1I1 p!la.ces.(O.!OOOO) ualess othernr~se specified by ~.e c~soomer. Th.e weigilwtsl:i.<'!U ~ot iru;:lil!1de,bipp~!}g pro~ocrorn> ~sSlemb!y aides, 01' packagjngm.arerialss Too:ere'[mine part we~ght, the organizadan shan. ]nd~vJdu<linyw,eigiJ[ te]iJJ. mnd!o.~y selected parts. ca101ai~ate and report tile average weig~t:. At least eae part shall be measured from eamcavHy, tool,~ine or process tobe used inprodnet realization ..
NOTE-; Thisweigffil~ Is used to.r ve~ide weigbtma]ysis only :andl does. not affiectthe appllQval proce~. \VbeiL'e.I~e ]$ ll10 ~rodlJctiJomt0:; service requj~em.mt fO\i at ~eilSt tea patts,.the QI~tiOH l :sllOuh~U!se.~.e I!e>rJlllli:redIlurn'her for ci1.I[culation onib.e average part 'W'eightfo:r bL!U..~teria]s. the pi3!(I: we:igbtfie;ld ~s I:'!@t app]ica.b1e. ~

12

SIE'CTI'ONI3 ~ 'CUS:TOME!R, NOTI'F'ICATI'ON AND, SU'BMISSIO'NR!E,QUIR'EMEINTS

,3.1
lC:lIIS~ORU~!JNolfii~i,~OFII
jc

The orgam~zation shall fiotlf)r the authO.l;'l2iOO. customer rep.resenlltalive of any p.lall1!ned ehangea
design, pmoe":ss, or site. Examples <Ireindicated in the ta'Me below (see T.a];)]e 3d )_

the

NOT!!!::: Orga;ni2atiolls are responsible to not~zy the auilio:r:izedlCusto:m,eoi .re!p:I'esemt:l:~ivef ilI[ldha]lges 10 o

the p.a!A~esigni1lnMGr the M!l!lJIufi.!diJri agproeess,

Upon notification and approvalof the proposed change bythe 1I.llJ!thQr]zedcustomer representative, after change iln:plemenmti!orn" PI"AP' :submission J;S required unless otherwise specified
Ta'blle 3.1 ,Exa.• ples of changes req uii!iiiD:g notifieatjon l . Use of other construction or material rhau was used in the previously approved
~L'md or

and

product

2. Pteduction from new or modified roo Is

(except peri shableteols), replacement tooling d]es, molds

P o'.r example, olih.e'i oom1tmct'ion <IS documented on a dev~aUolilJ(permit) or included as a note on the designreeord aadnet eovesed by an enginee .• ing ,chiao e as descrioed in Table 3.2. #3. This, requirement onlyapplies to tools, which due

to theiliruniqae form
teinflaence

0.1"

function, can be expected

p~:tte:ms, etc, wnduding additional or

tffillie~~egrity oflJfue tina] p.mdJuct Itis i not mea.fJ!tto describe smnd~rd tools (new or repaired), such as staodard meesuring devices,
dri vers manual or ower, etc, U pgwad.e means the reconseuctiocand/cr modification ofa toQI. or maehine 'ijr tn increase the

, 3. Prodm:'tiQ:n following lIpgrad.e Or r,~mn.gemenl of existl~,g tool ing Or'

equipsneut.

cap~tity. performance, Or c~a:nge its existing fll!nctioll. This is nor meantto be confused with noemal maintenance, re:pa~ror replacement of parts. etc., for wllM:cb DO ch~ge lR performance is

and post repair verification methods have been estabBshed. Rearr~~_,gementi$ defined as adivity that. changes the sequenceofprod,~C'rJprroCle;ss flow from that documented in the process now diagram. (iillildw:ru~iIi!lS tile :ad!diti.onof a, uewprneess),
Minaradjlllsil:rn;e:OItsofproductio.n installation 'ij,fPI(ltl;lctive M:eillWUa~ ES]) risks. etc.
'C>Q'II,eTS,

~ij'be' expected

equiprnentmay

be required to mee:~sdety roquke:M!emts such as,

eUminati.on of

4. frodll![ctionfiQm tooling equipme~t transferred to til different p laatsite Or from , an additional ·la:nJJt S]te,
I I

a~d.

P'l1@du.cti,@1[I process b:d~I].g: and /<riJli equipnlent transferred between buiMings or fadHt(aes an Orne OJ
more s]tes. 'fbe@Fgani.zatimil is, responsib]efm: approval of ;suprp]ier provided materialand services"

____

,. _., _

• ~ .• I

I ••

._

,. - -

_ ••

~ I~.

I I ••••

_.

,_

•••

, .. I..

I I••

_ •• , -

_ ••••••

6. Product pro(k~lced a:fl:er i~bel@oU~g ~as

been inactive for volume p[QductiQn for

twelve months m more,

I FOfpIOd!U.ot ~lIathas been produoedafte:r tooling has been inactive for-twelve mOI]t115 or more: N olificalioFi is reqll!J]red w!lU;enfhe part has had no dumge in active purchase Older and the ex iS1]~g ~ooU[i[g~as oeeftlmacU 'lie for volume pmduclliolill

II

fortwelve months or more. The (Un]y exeeption is

wne:nt;hepmt has Lo,wvO]IINIm.e,e.g .• service
OF

spocialty vehicles; However a eustomer may

specify certain P.PAP :reqruin:-me:nf;S.fur service
D~!:its. '1" 'Product and proce-ss chal!rrgesrelal.ted to oompollclIDiLS of fheprodactionpreduct mannfaetutedictemally or m.am.lif~ct~red by

suppliers.

Any cnafi!es, jncludl~q, changes a,i the suppliers to the orgamru~zatinIlad~eir supplieT~.tfuJal,dlbc:t customer req ulrements.e.g, ,flt,fiomll. function, perfonnance, dJu:rnib!i~~i;y.

8. Charnge in test/iaspectina method - new

~edmiq~e
fl1Q

For ,cba;nge mwst nlielthod. tk orgsnization snou]d

~!ilVe

eillect on aeceptanee criteria)

eV~de'D()etl!at the new method has

measuremeot capab]1ity equivalertt to the old method. These changes w@~~dnOffilaJWly be expected to 9.. 'New source of raw material from new ~r e%]sting s.upp~ier_
have
an

effect on the perfoemance of the

pirodulc-t

3.2, SIlIbmis:si 0 HI ~o Customer

The orgaaization shall :submit forpr At appmvalpruol to the, first prodnetion sblpmefi[ in the foUowing situafionsunless the !3!utho.ii~ed customer representative has waived this requirement [see Table 3.2). NOrriE:
customer h1 tile sirrua,t]oll!s described, below, prior notifica:tiolil to, representative isassumed .. Of

C\!;I(mmurncatiQJ] willi. the authorized

The organlZli1tionshaU review and update,. asuecessary, all applicable items ~n the PlP'AP'fi~e to reftecttae productionproeess, regardless of whether OI not the customer requests a formal s1!lbmiss]on. The I:tpAP me shan contain the name of illIe .allliwm:tzed customer representative grl!l:llItingthe waiverand the date.

1. A new part or product (i.e. a specifle p~rt:, material, or (;ol,oF mlmtpreviously suppliedto the

SUbtIDSS,tOn isrequ]red
(in]~ial.release

'{OF

a new product prcdiuct/pa'rt

lor

13!.

previously appn)lved
or revised

euseamer)

pr@du}CJ~ '!halt ha.s anew

number (e.g., suffix) assigned to it. A ]J]evv

part/product OF materialadded to a f<llniTy nUly use' appropJ"1 alePr AP d©c·'Ii.lime:iltaUofi from a
l

:2. Correction of a discrepancy on a previously

subm iUed part

previously approved P<I:rI: within the S<lnle prod~c1 fam.iJy. Submission. is required to correct any

discrepencies on a previously 8~bhu:ed part, A "discrepancy" can be IeI.... to: ted .. The product perfm:mance .aga~figl tile
customer requ irements

..
•

Dimensional
Supplierissues
A,ppr.ova:~ of

Or c;)lpaMli~y

issues

.1
•

a part replacing an ]]]ter.~m

a.pprova~
TeSling,ind.uding

matetial, performance, ore:ngineering validatiou tssues

3.. EngiDEleting clN!fIIgeto design records, speeificatiens, or material s for production

Submission

is .required on aJiliY engineering:

desiga

PWdllcti])~d filunibe1fS(s). AdditionaUy ~for Bulk Materiais:

4" Process technology
110~prev.~o!1lls~y used

change to the prodaction producUpart rooord. specifica!Uons. or materials.

new I/Othe org<lnh~;at]o:n,

for tl1sproduct

]5

S,E,'CTIONI 4 ,_ .sUBM~IS,SI'ON TO 'CU,STOME,[R O,F E,VIIDENCE

I..

LE,VEtS

The organization shall submJ~tthe .itemS<l]lJ(l/or records

specified in the Jevelidentitied

below in 1'aMe 4. ]:

'fable 4.1
Level l Level :2
Level 3 Warrant on]y (and for desi,gl1iatedappearance i~eJJls.a:n Apperu:anC-e Approy,al

~epon) submitted tothe eusiomer. Warrant with product samples

customer"
0iI[l;(J

limieed supporting data, submjtted

tn

the

Waerantwith product. samples <lindc'{)mpl!e:llie slJ:p]lo<rhng data subm~twed.o the t

customer, Level 4 WaJf['a.utand other [lequi.l'eme'l1ltsas defi ned by the customer. Warmllt with prednet samples and. cQlu,1ete Sl)]Ip'portjng dati reviewed organizatio[lJ's manufacturing ]OC-atlOXil •
;;Iii:

the

See ReoontiowSubml!5Si.o.n R,equiremen~s Table 4.2 for exact retenti@ws~bmissioIThrequ]reme,nts for each submiss ion leve 1The organization shall use level :3 as the defuu~t~evel.foll all submissions unless othen-vise specified by the

authorized customer representative, The minlmom subrnission requirerneat for bulkmaterisls is the PSW and the Bulk Materials Checklist,
For Bu]kMaJtec]:3!] rp'ld' submi.sslons, check "OtheT"'in the-Reason fOirSubmission Section on the PSW form and ~pecify "Bulk MaJtedaL" This indieates thatthe "Bulk Material R:equkemellts Checklist" was used to specify the PF.AI' reqllUJire:menls fOil the bulk material and shall. beincksded ][11 the submission packet NOTE 1; Th.eautil,orued customer rerreselltaJti ve may id)entil)<~ subrnissien ~Je¥et,dlfferenl fr.om the
deKau.b level, that is to ibe ~sed with each orgaIDI:izalion"or Q:rgoo]Zl'I!f.h~r1 and CI1M.OMcr parl:r1Lllm.oor eembiaaticn, Differe.flt cU!5hn]1~ locations may8!ss~.gu!I. dlff(l[eil~ submission levels to d\Il.'~; ame organization. s manl1fu.crurmg ]ocatio;mL.

NOTE 2; All of the fOIDh<l refeU(lneedin th iso;oclI:meI!.t may MrC:p.la.ct\ldi by eemputer-generared facsimiles, Acceptability ofilies.e fi'lc~imile'sis to be confirmed with the flillilhod.zedmls'tome'.r representative priorto the firs~5ubl]ilissiolfl.

17

Retenfh):n/Submission

Reqluirelm,enrtsTaltlile

4.2

(Normative)
(NOTE.- :rQ~J:e lists swmwiem and rettmUrm .r:equ.il"emeflt~_ 4."2 Mandamry mui applicable r~lj'uiroments .fo,~a PPA'P' rocord <Iredejimld in the PPA'P man~!21 (Jnd by tM CilSlo.mer 1 Suibmissmn .Levell

&g_uireme:nl
L

Level I
R ~ornpol1.eilWdetails R R R It

["ewell

Le'IIeJ 3 S
R

u"!!'e14
OJ:

.Lewd 5
It It R It R R R
R

Design Record

.fM~roprle~_ry'

s
R

2.
3_

4.
.:S_

- forliH ohr c6IDponen(&i\details El'lginee~ln,g Clm[lge DOOumeilt5., ihny ClIsLmliler E<J]gi"ee~ <"lpp.~(l".a:~, ir~e;ql,lired Design fMEA
PFoceS'~ FIIIl.w Di~ll!l'l1s
PI'OC"Css

S S
R

S S S S S S S S S S S S
8 51 R

'"
oj,

R
R

R
R

'" '" *
*
rtl

6. 1_ 8.

FMEA
Sysrrem Aru'dys.:is StlJuili,es

R
R R R R R Fe

R
It R

COlltro~ rial'! Measurt:iED1t Dimensional

,e

R R R R

9-

*
$,

n, n,
13, 1'1,

w.

Reslllts,

M~.tetia]. PC'Ir'O:flna[lCe T!i:5~Rcsl!llt.!l [nitiaI Process, Sl'Uldi,es

S S
R

Qual~[ied 1.8bora:tOl), DOO~I110l1taltiOll

Appe~rnnre if <lpphcnlillc Sample Procl~tcl M aster Sample Cht:cking Aids Approvll~ Repo~ (A.AR),

'" ~, '"
,~

R.
R: R

s
R
R

s
S
R R R

.~

rs.
Hi,
l7, ]8..

R
R

Reco.rds of Om'!p:tklac!: With Cus.tomer-Spec:~tic

Part Submission

R R
S

R S S 'S

'"
Il'

R
R R

'*

RequUemellts W"mllnlt (PSW)

S S

S S

BI:!lk I'.Ja-.enal Ctl~ckH~. (see'!.,I ,~OOV~)

S .. 1]1"; mgaruiz.::nton
~.Ocat'iO!lliL

R.

slmll[~ submit

to the Cl!Ismrne:r :mdret1l!U:! a oopy o:hroo:ms

or documelilltatiOJil ltems, <It apiP1',oprl<!:~e

18

SE,ICTIION5 - PART' SUBMISSIO,NI ST'AT'US

Upon. approval ofthe submission, the organization shall assure that future production continues to' meet
an. customer requiremerus,

NOTE; For those Q'rgaoi~liorrs that bave beenclassified as "self oelilify.iI}g"(F'lPAP submissio]1 h'lve] ])1 by ,!lj specific cus,to:mer, subm.iss.iQ.IiI oflherequirrecl orgaJitizartiou"O<lppr"Oved, doeumentation will be coms.lderecl! as C~~~Qmer !lIpproll'llIl u!ll~s the orgi3!l"liza:liQnis ..dvisedetherwise.

5,.1:.1

Approv1ed

Approved indicates t~;11,t the part Of m~,terial,.indlading all su.b-GQ<mpQl:lents, meets all custoreer requiremeats. The o,rgaJl] izationis therdore al!l!tlliD,Oll"ized ~o s~ip prod:llJcctionquantiti,e's of the pr..od!uc:l. :subj ectto releases from t~heCUS~O~1Jjile]" :scheduling Olic6vruty.

5.2.2,

lnter~m A.pproval

~ntefim Approval permits shipment of material for production requirements on a limited time or piece quantity basis. Interi In Applioval will. o]"l~ybe granted when the Q:r-gan iZl3!£ion has;
.' dearilly defined the, nen-compl iencespreventi ngappreeal;

•'

prepared an aetion plsn ::Jlgr1eed upon by the customer.

obtain a status of "approved ..~

<Ind• PPM

re-subruission is, requir,ed, to actionato ensure that only

No~e t ; The orga!:liz~lioJ1iisres-roJ:l$ibh;l fQr imple:me:mt~Ilg contaimnent acceptable material is being shippe-ci to the customer. M,lJeri,al covered

Note 2: Parts with a status of "Illiterim Aprrova~" are not to be'co!JJs]d~ecl·'Appmved."

plan, either by the authorized q l.!;i!!nllty, wil I be rejected. No additional shipmeets are authorized unless all extension ofdleinrerim approval is :grnl]~ed" by <In .inten[!l';lll]lprl)vul. that fails to meet ~\heagweed-!~]pon action
0

e.xpim:~~()i[I or lbeshipme[lJt d,are

r the

For bulk materials, the orga:[I1za.ti,oH equivalent (see Appendix. F).

shall 1!is>ethe "Bulk

Male:rij.a~.mnterim

Approv<lf'

fO'rm., or jts

5..2.3 R,cjected.
Rejected means that ~:fuJe prAP' :SU[II:[1Ilssion does ]JJot meet cllstn.e,I requirements, based On the: producti·on. lou fHn/.m which it was mken and/o[ a.ooomp{l!llY~ID1g docu~.entatitn:l:l"m such cases, tll.e submissieaand/os process, as approp.riale, shall be con:ected to 11111eei castnmer requ itements _ The submission sham be a.ppl1@,ved before production quantities mary be shipped.

1.9

I:
__ •••• ,11 • I •• • _, __ • ••.• __ ~ ~~ .,. ----. _ ••••• ---••• -.~ •• , ••• 1.'" .,--". _ •• _-

PPAP' records (see 2,2), re:gardh:ss ofsuib.m]ss~onleve~,> shall be ma]ntained for the length of rime tba~ the part: is active {see Glossary )p]IiS orne,calendar year,
The ()Ig<lrJJ~zil:tio[i[shall. ensure mat the ,appropriate PI' Arreooros ~mLdurded. referenced in the new pa:rtPf' AI' file, or
from a superseded part

PP AP'liile are

NOTE: An ,example of all!app:ropria~fldeeumenereeord tfuat sheuld be carried f~[1;O,Iard from the ,oldn~e to the new pan. .~le w'OHM be a material certi fiosrion from a. raw f1m.a:n:eiial sllrpplh:;r f'O'F ,SJ.IiiI,eWpalIil: that [l:lpr'~$erib.[)n!lya dimel1istOl1!8i~, ,change from jhe eldpart number, T~is5hould be i4ellil~fled by com:lfLlcting a
PPAP "gap analysis" lDe;~eenl~e old andnew pari: numbers.

21

Ap'p,endix A ~ Co'mpletion of the Part, Submis,g,ion

W,arrant (,PS,W)
PARJL[tIl1iFJ1H,MA 'Ilj'lON
~_M~

L
2b. 3. 4. 5. liS, i_ 8~ '9<J] 0..

hll't Name
Org, rart
SIUlWllij;g,

C:us!!Om~f Part N~_mber;

"lilt

Ellgrn~fing fiel~~dtill'llii&llw

end [tempart
p;lift fijJjnber

iiI~meillltt'l.num'bcr.

N1JIIDber:

number dcfITH~d~ytb"o:;'(frgall~tiion, lhl~. Dl'~~'i!lg N~mber= 1M dc:si~L'tCo:rd lbat s;p~cifill's.th~ C!lSIDIDe<r

tgvel·~ !i)!.~~e~SllO'T.\'thl;"chl!~e llil¥el ~

lJeim;g;5ubmittm :

hgJll.eeriJlg:'C!!~!li~'

d!lte oflile des~gn

l'ec.om
odwm.'~:;.e"i">i(!!. ~ ..

Add'lti(lIl:i!J Engin~Illr']Dl! C1il;'ln~ '& U!!i!~f~: Ll.!;tall aud!l;J!Jizgd ~nsill~exlng dUl_1)g.e£nM yet i.ilCOl'pOfllteflin [he dMtgn nloernH.DIll Vi·h11[;dbBre ~1l'IX!fpt!i<lite.d. in th~.1fI3rtSillJ~t'!1r' 1I0d/'tIt 'Gu\l\tlfmmtiit J'u~~hfiSt lVei::=ht: Q,ruKr ~lllm'bef: R.egjilill!i'1)ii~ ~yes,~U[.so ini'lltaiCd by lire dc5igll.rooord, Ell •. r ti1it;ii1iJ.i:'tl.~ a.sfMi!ld Oil !he OQni:ta.cllpwrcbill;~ oocLer.. e deocii1'lill places Ilm.liess OO'Ieii'wiise sP'\ciified. Dy the customer

HIII.er thee ~c~\l~1 '~\'Eli;gI'Lt ill, kiliognuIIll tofeur

Chm::~[jj.~ ,'\Id .~lurnfj>eJr, 'Qllang.e Le~·d Illlili D;a1e: mf ~ue:;te>d1 by dat~,

me cilimurner.

enter mce di~.ki!1Jg ~id! number, it:5 'l:\h8n~ kvd ,!lnd

OIIR!GANIZATIOcN II. ~2_

MA~!l!!M~UcBII]lGJ.t.u~-"GJ1i11.!ll!!ulONI
Dam~,~l1d toc!~

Organizg!il(l!! N8m~ &: S!lp[il~ie'.n;Ne:D.d!oi!l'C(I!!e: S.l!~~.c

order~lXlntract.

a5!i1igm~dlQItq~ nl~i:l!!flII;!lUrjog~iliootl'!.el!)~i\CI'L~e

Stn:ti ..oli.c:{llm;ls,. R~gAilfi.r,~Sl~~m Code·, 'Country:: fur ·~R.'egi:or.L,"eillU Sla~e, cOlIl'It),.llw"'ince. ete, 8'l!l1 B MIIlilrAl M>liFOiRMA,TIOI\II
CIl15llj);ljjtjf

So""" lite

eillmp~~I,e address o:rtIJ,e IDCl!Ill~D. wlWn= the prodlJc~.\¥3!,~Ii1'l~llu[~CWJoo.

.cUS:'li\OM:~R

D_ ]4_ 15.,
'l6,

~1~rn;eJlJ[)lvl~1QD: SI!iO'o'l' ~te !be

Mln!:.and

,division

0.1:

~ii'a!iMS,

!¥fIup,

BU~'f'rfBu~'>er ode: .lEr.t>!tr tbeMlY~'s, ruune.aM ro(fc. C A.,rpplic~~i(l!l: Enter the lllotrcl y~r, ~'cl1i~k name, C'ng;ill(1:, i{l!ns!llii:ssk!.D. ew,
S!lb~~lIi!l~e:l' 'C~miCull1;~m1.cr ,~f

MIAiOERl.!!.L.8If;1EJ'ORiI'I~M:G

"Y~~;~"Ne,"

~r ~.oh.~ ..

IMB&!t)thci: '('IJJ~tDI1ii:Il:, [<lonn~:!: Cir,d'l:: eilh~ ~[MDS" Or ''Otbcr Cu~tm1!lC=" Frn:mIl!"'SS apPfQllri:lt~. If51l!brn~!led~i~ 1]..1DS tQ"du~; MotMe Ij. Version ill. ;ttu:l C=ti.ooDale.lfsl.lb:f!!:lltled via! oit!et CIlSOOll\et fOrm;U:, clil1NtlJ.e&re eliiS!nmer eii:!D.flmlati.on was

received.
~,', 18,

.l"{llymeric

l'~jr!s [d~!ltill~~"ti~J!l= fntc~ ~y~~~"No, .. or ''I\/'I!~cOOck "Oth!;r~ and wrile ~Bu lk

II:it~ASON fOftS'~:EtiM ILSSli:ON Cltec.k. (~,e ~PJl~OiPri.a:t~ ~,,(es}. For bl!lrk !I1al~ri~h;.ill ad~ itLf;i!l ~"ch~cki:nig !Il~ app.ropri3!t~ Mj[Lerial" in t1~~~pilre provided. ILIE.VEIL ~,rlIcD,tify the SUD:rlli!;:;iIIm Ic~cl .re!llue~tJOO. by the customer, tests:.. a~ S'IJBl\US:SfO'i'I LEVEL:
i)(IX,

,SUBMLi$!S~iON 19c

SUJU!!IJ:SSjI>ClN IRESULTS lit Choclt. 11K: 2I3l'prDjJri~le

boxes ftiir di~s:i.onal,rnajei'i.::IJ,lesIs.pef.fGtm;]Jloe

evallla~no:l'I. ;jjjd st;]tiSliciJ.t diJ!~.

n.
22_

Cile"k Ih~ appTGpri~~e OaK,. ]J "ItO," ~Ier !he exp1.~!1:Il.~i.on '~omm~[jJs"l:oel!OlW, in

M;)I.ds.lC!i,¥iti\;~flodll(ltio:o f,fIOCiesses: f(!r iMUUction, see 2,,2.1 g,

Ji)!I!lCLAIRATfO'N

2324_ 25_
J)6,

Em:~~r!he

i1li:lt.dti-erCif

pieees l'IlMu:r~e~ll!'eddu:ring(be signifh:;a:ln product LOllI"Ii!Jl.

Enk<r In~ me (in. IJtQLIl:'S) '~~n foc~ltc fi[gni Ili~-@t prnd~tl(m ~li EXPL.\.l"!iA T,IONlCOMl'rl.l!N'WS: f'll)\fiod~ !Ill}' ~x.plllJ!21t~ ~~mr.nc:m:t:!i Ih~ :Su.bml:!15l00 Qn! Re,5UHs Dr iIrI)' (lellr.o:t!oo~ from lihe Dee~~ratiO:IlI. i\ruJ;ch ~d'di~iorul~ infmmatocln as appFOprillf~ .. CUS'IO',M!~Hl T'OOl. 'I·ACG~I:'\lGiNID!fB~R!lND: An: ruSlomet-~,~oo~s i~elLtlliil)din. ~~~m w.ith mOlTS: 16949 ~m:1J any ~-U!;mmN-_~Fihe ~lIiremetit-r;. ~''Yes~ O~ ~~ May IK"I be f!Pp!i~bl~ 00 'OEM im.t=n:1. ~FJ1IHft'li~
OR(M.NmZA:nON AUl'IiiOiRlZEID S[GNAW!JRIE: A respoonsib!c .arS3!nml:i.t!l!1Jomcl~l, after ~·crir)'inliS.th~4Eh~ w..uUs she .... ' wnfb:lT.J]aru:e ~o all cus~omerl'e!!l.l!iN;mellts, ~.d!lhat an~oiFc:d daeumcntatiJOii~,avajJa,b.lie. IsMIl approve ili~ dl!'iC!a;~[Q1I alld [lr{I"'id~ rme, Plume N!!lIIbem:, .FJiM NlJ"mb~f., !I.ml E-m:a:n1 alldl'CS!5.

27

FOR nrSTO!ll'n:RJjLS~t:!JS

le~"eblmk.

22

III

Pari.Submliss~ol1ll Warr.a:nt
0IJIst. Part Nwrober __ ~"'-"----;,..,..,:--

t?. ,

Org. Part Nutmber .

@ ---'_""""

~ __ _

IVa

o o o
D

REA:SON fOiR .SUB:M.ISSI@NtlCllc.c.1!at ~ol'lr;!

Ini1;i~11 :Subrni~~on En9":inearin9 !Goli!lg; Ghallge(s}

on~l' @1 ~6
. . '. or a;dCliliMa!'

nanr;r.er, "'~~iMnl,
In:ro1i:ve.>!ban

RlIrurbishmffit.

o lIoolri1ig
o o o
l.e~el:2 Level::l

C@rFe!(;lio.nof Disc~anc'l'

1'1'88r lEV!::l ~Cn~.c~ one)

o CM!!JlIge !o O.pliOnai ~ter!i!lISO!!.!rce o in

D $WJwrler or
CNfigEI
IP,i!1J1.

CGnstrueliM

Dt'

IMaterial

Cbal'\ge

P_asing

I'tIEOJ~IES'IiEII), Sill EllMlSSm:t\I - Wai~~m ~

@
b'j' eustQmer_

D 0Uile.r
items. an tilppe-arancB Awrc.~al

Parts. PrQd~C!

at Ad!d!llooall.Oc:atiDri

- pla;as,e ~

t8\1!31 1 - W.artant 0tilIy' ~a.-.dlor d9sigmal'Eld appe:ar_

Il'taport) 8ulillmiftBd to rusll;l1l11ef,

p(OX!ucl SilLffipteS aQ!lI .In!te!;I SY:;<J)OIi1I~ aaJIi! .~bmllte!1 'to ~omef. supporting (data submitteo1i to customer. as; dellned

D D

- Warran; M'ih product aarnplas andcomplete

~e,"-ei 4 _, Warrant.ana olner i·eq,ul~l:S ~eveI ~,-Waffanl mlh ~rwuct

I TlIB

SY~IM.!$$IO,N r.BSull5lCr

~_!:is~l.:r$

@
few.'

~arnpie-s .~ncl complete ~UPPOrli~9 aaUl r·e,;\lcwe<!lIt ·organinli~'

FMf!urad.wl'ling [OCa1iM.

dimBrloonal,mEtaBupsrnsnt-\l. ra. ~,erne!'lts~

mateiiiaJ andl'fuIl~

~B'.s[!!;

appear.anca

mlsutalD

atalislicall

paQ~8

T:.I'!.ee resw~.s ~.e. I aJ~ d.e~n, ..$. Moll:! 'C~ f PFodIJeOOiI p~

05CLARATION

0 v.e~

(ggl
Q. _ ..• '.

NO

(if "N'O' - ~Ian~ion

FI~ulre;:,n

I ",ffi./m.'tl1.al~e sa ...m~J~presem'edl !:I'I'!hi~ _ rmentare re~1ive. .. {]i 001 parta..""'hi£h~1e ~'by ~p~~. ~.U.~.!I;S a~.· .~. _. Parl #!(p~1 ?roeess ~ 4lt1 EdJ)lon Requlrem~. ~~er ~JfWmth8.l1fuese,~rn;pI~ ""'-ere ~uoed'a~ !he ,PrWliIC1!OQ f~ Q~ ~ ~ours" ~atSo Ce!1liI1It'!alliloet!!ne!'l~ e\I1C!e1'lM a.{~lJch.~planoe !s. Qfi me and ,a!la\lsble f-or ~-e.w. na...-e· otedl.~_~y cIe~~t1oll!S. fl'OO! ~ c!ee!~J81kln below. i n EX~LANATIOMfOO.MME~ ----:;::;:_

Is each Cus!ome~ T,o~ property '~ed

Qir.ganiz.alioo .Autl'ioozed

aM nuinbere(!?

D '(>S8
----

D iN'~ @
Date -

Sfgn<!.1Ure .....;@::.~.;. '.._.

Print N@1ne ------------'lillf.e------:E·ma!~ --------------------FOR CUS:li(lMER PPAP W:mant mE;posi~ion:D AI!,Pr01o'8d

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

FAX No.- __

-_-_
_

IlISE ONLY ,(IF Al'PiU:GJ!tI3LE)

0 RB'j8~'ad

DOli!b!lr
O~le _

Ou~tQmer S<!gml.lure ,
Print N8im8

CFG-~IOCl1

.23

,_.

_. __

I••• ·--·-

.-.~.

IPal1·Sut)miission W,arra,ni
Pa~ Mame S!hewn
00

___ D,rawing, III". L.evlII -..,, ~ _

Cust PM Number
Org_ P~rl: N)Amiber _ {)~~dl _

~_

~ng"Jne-er1lli.g Cnange Additiooal Engln~ring

Chang:es

Oalad
_ _

_
Weight ~gl----.Datedl __

SafeLy 8n(!'/o.r Go ... mmaifrt R~u"'ii[]n e Check~ng .Aid No.

0 Yes 0
C~I~9 Aikl

No

PurchaseOmer Cnanga

No. laval

e~nMn..'1g

C~y MAliE'RIAILS

~bn

F(~PORTING

Has cus1DJ111ar-requlredSubslance~ 01' Q)nOOfli inlorma!ion been repOf1:ed'l

DYes D

Nc'

n!a

10 ~e$ D No 0

fll.a

o Inrl,ai o D o
o
Level

REASON FOR SU,BMISSION

I.Ched!: at lea~t

,one)

Subm;;ssion
Chan~etsl'

Enginsering

·~Oc.lin9; Tf.;3Mlar_ Rlspla'CSflEm, RelurblsJwnent, Corl,eablcn O'f EII~epl(lney lnactiv.e :.. Ihan 1 year lLeva. fcncck Oiil~} foaling

oor Mt111100al

D ChlIDfl8 im, F'al'1 P~s:sl'ng D Parts 'P(MUC>ec at .Ad!l;IitiOlMlI~n

o SUPf;1lier
Otber

D Change

io D,ptional CQn~truct!o!'l ~ M\i1:Elrial

C!'!'

Mat-erial Sooroa C~nge

o
de~n~led ~weara~oe
i!t:ms,

- please spe>Cil)' oolow

REQUES,TEIL! SUBMISSION

o o o o lLevei o
~vel

1 - Waflfant

onl~ {andl for

an App8\3:lanaa

AlPpf"O\'OII,li'bepC!l1) ~ubli1'lilted '1:0customer,

w-otel ~ - 'il!.l'arrant \'iitl; prOOuti ..~mplBs 4 - I#~rr&lt and O<ih91 ~r;ile'l1ll5

and limited supporting da~~ S'lJi)m!tte<l as da{ined by customer,

to (;US10Ii'iBf.
ttl custemer, ail O~i'lilatiM"S

lLevel.3 _ Warran' \'.119 Pfot;lO!1Jil:l S~lmpl'es,and cornp!e~~ su.pportingl data auemlned ~ _ WaJ.raF!1 ",.,LI'IP'I'Odlli:i samples and oomplata suppoIli1ng d~·ta ~·ted

rnanuiacturing criteria.

Iccsllol'1l.

SI!JIBMflSSIONR,es Tt,e- reSUlI"Sflor These raaults

U!.is dimMsiMa1 rnaasursrnsnts FeQ}!ftfeme.nts:

mast all, dssign recordl

0 Yes D ~o

II1i3lsrial

amiiunctlon~II'~

!Illp9a~e

8IatiIicai

~s

pad(age

0(11' "NO" _ E:o!IPlanationReq,u'lred)

Mold I CaNi!y/" PrwtlCllon, Process

I .~Ilirlfril fhal ilia samples rapreserned by bhis: warrell' are repIe!OentaM ot our parts wNch'l~rB matia by a prccaas tha; m~ aJ ProdUC[1OfI PM Approval Procaas Manual A,lh Edilil;jI'1Il'I~l,Jifernen~ I ful1rer affirm Ih~t 'lIlIelill samples ""'BfI~ produead 13.1: lhe ~uction n~te 01'__ - ' __ l'Iilurll. I also ceflifytha~ ~mented ~de~ ad$uctI compli~.l'lQ6 is. on r!le andii,~ailalikl fOr review_ I have nOle.;! ~JrlY ...latlon~, 'I'roon, '1I'IiS, cBclara.lioo m-alow. de
SXPlANAliIOWDOMMiENTS: .

DECLA.RA.iiON

DYes 0 NII;l 0
Qf'!Ilanlzlltlon
Prjnl' Name Tille _

nfa

AulhOr:ll:ed

Signa1nme _

0318 _____ ~ FA.X NQ,-~ ~

_ _

pilone N'o,

E·ma!l -------fOR CUSTOMER USE ONl V {IF AIPPlICA6LEl

PPAP WaITsnt

OiSPQslllon:

D Appr(>,,~

Rej~oted

DOlliar

Cusromer ,Signa;l!J'ra
Print Name

[)i!!B

CF,G-1001

2:5

_.-

-- - - -

_ .. - - - --------------------------------

Appendix B - Comlpletio,n of the AppearanceApproval

Rep,ort:

]. 2.
1.

O!~sti0meJr,art number: Engi~eeilin.g re]easoo customer part num ber; Uratl;¥igg Number: Use the nsmber of the, drow1ng on.\vhicllru the part is shown if different fr·om
the p.llt u!;mm,ber.

Appli.tat"ion: Enter the m.ood year(s) and vehicle ,Orotbe~prilgTam

'~)[I

which the part is woo.

4,
.. i 6.f7.
8.

rad

Name: Us.etlle finished p~n nam.e on tiThe: dim-wing . part

.1IEnteTflie code for specific huyer ofpaJrt~

mu.yerCollille:

EIC Level,&: Date: Eng][iI:eerlling change level and EtC dat~, f~;lir submissi.on thus Or.g;lIImzaU~!i] Name,: OfgMlW!Jt.i:OliJi resp@i.c$iib~.e sltbm:ission (include supplier ~fappliea.hleJ. f@;I"
.Manl!l!:f:ac1tl!l!ringLl)lclilltion~

9..

Location

wlli1,ere part. was miul!ufacruredl

'0', assembled.

10.
1]• ] 2,

Supplie:r:fVenlllor (;ode: Customer-assigned! code fOE organization location where the pi3irtwas manufactured or assembled. Rea~'On~or Subnllission: Check b GXI~e:s)exp~.a.ining the :reaJson for th~s submis.s:l[l'fi.
Or'gan:iizatlou SQiIlIFdng Termre l.iilJfl1l'rmaJtiolill~Ust aU first surfacetecls, gra~ni~g &
SOlif\Cle{s),

grain type(s}, and grain and gloss masters used to check pan,
1.3.PIm~l'iCXhjn·~ JEva~u3t~on:. 1'0 beeomplesed byau~ho]'.iz:ed customer represeetative '(not

~sedby

GM). 14. 15..

i6 _

C@h)r SllIffill!: Usealpharnaneric Tristi!mulus D.d;a:

l.]S~ numerical

'~Jillumeric:o@ior [

identification.
[0

(co:lorimete:n) data. of "'l1]bmiss~QIl artas compated p

the

I 7" l8. 19.

2J}

2I.
2~t

23.
24. 25.

customer-authorized master. MlIIsh~.1!" IUlmli)ell": E~ler alpm.lITIumeric masle:ride:OIt:ifk:aJtio:r1l (nQt~used by Ford). N [Vb:!lf'CF Dat~: Elder the date on whichthe master was approved .. Ma.te.ri.aJl'fYlile: Idenltify first surfaee fin ish and sulbstr.ate:(e.g .• painuASS}. Material SO~I!]iCie: ld.e:l]ttiifY first surface and sl!ibsb'a!te seppliers, Exsmple: RedspoUDow. OllIIQl' EVIli~u~rn.t)ln,Ml!le~ V,lJJllUle~'Cnr~m;3i. 'G~.o.s:s 3.nd.M.cUdlili:; Brri~liance: Visealassessment customer. 'Colm1'Shipi,in:g Suffh:: Color part number suffix or coler number" .Pan [)iis,.rJ\sirtton: 1'0 be deternlliined by cussomee (approved.oi[ rejected):. Co,mmen,ts: General comments by iliLeorgaruza.Uon or eustemer (Op'tiOillaJ]). OrgalliliDltiil@D Sigl!l;amre~ PhQine NOI. &Iil:mte: Org<lniz.alt~.o]Thcertification that the decumeut
infarmatien

by

is <loc.umte and meets all reqeiremenss

specified.

AIU(h!!B<r~ed(;u:s~ome1' .R.e,resf:ntatiJ'\re Si:~lDarntie& .o:aJ~e:Authorieed Custemer

Representadve a:pJ.'!ron~s]gll~tu;re. THE AREAS INSIDE THE, BOLm' LINES ARiE~FOR ellS-TOMER USE ONLY ..

26

. !PART

ilL

APP'EARANCE. APPROVAL

REPORT
iAlPP!JCA flO:t\I i{\J'EHI~C!LES)

NUMBeR
PART

NAME

o
o o

IMAN UFACTURIING ILOCAnOr!J

S P,I:CIAL. SAMPLE f'HUlT PRODlJC1I'tON

1("9'\

LJ
SIH IPME:!NT

RE-SUBlMISSIQ_t>! ENG~f'lJEEFUN:Q, CHAN:G'iE

AP PEARANIG IE.lEV A!I-IlJAlilON

1-----------------1--------------------:1

COi'l:IRECT AND PFliOCEEiO

20
VALl),!;:
LIGHT
I

(21)
MET.AJU..iC COU)R
I

~
\::::;;

CH ROMA~l.OOS
OOIIV
I

~ Rll,ILlIANCE SHJPP!N!G
bOW HlGHI LOW .

PART

DIIJ1K

CLE!'J>I

StiFF IX. I mspQS IliON

IOOMM~MTS
FI

~~~-4~2~.r.----------------------------------------------------------~--~~~~~
~

(~)
March

I'lHQNE NO.

'AUlT'HOR~ZJED CUSTOM5.R REPRIESEfNTATIVl1E SIGNATURIE

eces

CFG-1002

AP'PEARANCE APPROVAL
DRAWINIG

REPORT

!VENDOR. PAR.T SUBMISSION PRlE!!f~URIE WARP.;A,NT RE-SiLiBM ISEIDON

I::NGlfN CHANGE E.BRIING

ORGANIZATION SOURC~NGAND lEXTURE: INFORMATION

N 00

F-~--------------~--------~---r--------------~~~~------------~~
OORRECiAND RlE:SUElMIT

PBOCEED

F-~--------------------~------~-------------------------------------iETC~TOOUEDM

.APPROV"ED TO

eOlOIR EVAUu.AnON
METAl-LIe COLOR SUFF~X TRISTIMUI..US 01.· DATA MASTIER MA.,s,TER MAiERIAl DATE TYP~ COLOR

MATERIAL
SOURCE
Rim
YR

HUE.
I Mt4 BU!.I

VALUE
~!(lHT DARK

CHROMA
GRAY

GII.OSS
HIGH LOW·

)3RILUANCi I SHIPPING
HigH LOW

MRT
DISPOOiTION

D.:i.·1

D~· DE' eM!:: NUMBER

I CLIYINI

SUF'FIX

I~
,I

COMMENTS

O:RGANiiZA iliON

PHOrNiE NO.

DATIE:

AUTHORIZED

CUSTOME.R $IGrr..tATURE

DATE

I SIGNA

inURE

RE.PRESENTATIVE

Mardh
2006

CFG~1002

App,endix C ,~ Production Part. AIPP,roval"Di'm,ensional

Results
Producfi,o'FiI P'an. Approval
DijD1len:f:i'i!ona.~Te!st Res'lLIllts

0:1(

NOT OK

I .131aJrnkelstallemeifl:ts
M~Fl)h ~00i6

of ~o:nformaUl,oo are Il!looooeptablel,or any ~ecs;ll~e\Sulbo.

DATIE

~I
II

GIFG~1003

29

Prodl!llction P,ad AJ!lP:liov:a~

Mateda~ Test Resl!.I'l:ts

~1I1
ORGANI!lA no Nt PARII NUMaER; ""S""U""Ii'F'"",L"",IE",,:ru'iJ-::' '-::-::EN=D:-:-O-:-:::,:R=C_O_DiE~-:~_~

t#;.TE~I,I!!ILSUI"PL!~R;
'CUSTOMER SPECI FlED SUPPLlERIVENlDllfl GOlDE:

~,_P,A!Rlif>4.WE:: I)SSlGN RE.OORIJCI'IAMGE lEVEL: ENmNE,!"J~IN!3! CI-IA~e ,DOellM!: MrS: NGlir otr.:
I

OIK

_jL

____j

[II BI.u'!k)3l

sta:temeJJlls of

<combnma:nwa:1le

~,maooeiPtable

f()r

any~,e;s;l

t~e<s~u:s.1

,Marcil! 2000

S!IGNA11LIRE

31

AIP,pen diix. E - Produetl on Part AlPlPr,ova~, Performance Test Resu lts

f'l!lodllJlct!iion Part ..Appr,ovall lPedormance Test Resulits
O~GAt<!!!Z.o\TIONi: $iJ.P'P!.I~~F!: 'CllSTOMEif!: CODe:
·I.<ON RECORD CI-I,MiG~ LEVEL: NiAME M LA80RATOIR,(~

$Pf~IF;!=:O SUPPLIEWVEt>lOOR CQ!'.'!E:

reo;f'dI.IoolWe S~lOi!r I ~;;;;;;~~j~~'&BtUJswm~' the

:I~G!;N::cRIING

CtlANG~

··lr900r,ce8:!lIl_.~iB

-;

~~far ~~l'l'E!d:::;oodii·~e-nl~Qr9TF. ~ruPRilEKmrnE&Jrn~i'i':iijf"T-Tm~1 til SlJF'RIERTESirlRlESUITSlO~T.oIl;~ f NOT

DATE li1Esn;[) TEST COMOi'1ilONIS OK
'OQ(

OOCUMElN-rS:

TeST SP~CW!CI\iK1~ I !'lW I PATE

UMITS

I,

;1

'II

Blanket$latemenl:s of conformi\lnlce are ~!1Iacce'p~bl~ fQ, al1'jlteS!~ resullts,

Matdl!

I
!II

:2006

CfG-1005

SIGMA. TUJRE

:33

Appen d iix 'F ~,Bu II'kNIaterial .. Spe:cific Re'qu Irements

IP'.1
In~fiOdll.lc,tiOlril.
COtll]:dy with

An (jI]"ganiUli!ion supp~y]n,g~bulk ma,tedaJs shall

guidance

the requirements

ill.

this Appen.d~x

Or USe

heJ:eiiofo]" da:riJiclIti.on of .P.PA.P. The requ]rero:e-nt:s, [II this A,Ppencl~x.<Ire inimums m suplplieoemed at the discretion of the orgsnizaaon and/or tih,e custorner,

<l!nd maybe

Or!lani:zaJti'QFl!S <Ireres;pO'ns]b~e for <lpp]ying orgeaization-designated sp eda~ characteristics"

PP AP

to their :s:uppliers

of ingredients

which

have

Where OE~i~. r'Ar a~pmva'~ of a bulk ma1le:ri.al exists, ev~d~oe of t1h.a~ p appreval

is sufficient as the'PPAP

submission at other kvel~ in the surply

cll<I~[t

Examples (If bWilik ml~lterialinc~ude" but are not l~ID1IlIi.led. ti():ad.fuJesi.ves and sealants (solders, elastomers); chemicals (rii[1[ses,polisJu~s, aClditi'!1es.tre.a:tmt~ts.oo]orsJp]gM!e-nts. solvents); eaatings (tOip coats, undercoats, primers. p~~OspllaJJtes. surface treatments); engine ecolants (a:l1ti.ft~eze); fa.brwc8~mm end film
laminates; ferrous <lind non-ferrous metals (bUi]k steel, alnmieum, coils ingots); fuundry (s<lnd/si~ic:a• .alloyi o:g materials, other rui nerals/eres )~rneb; and fuel component:s; glass and glass components~ lubeicants (oiJs. greases, etc.); usonomers, pre-polymers and polymers (rlL.ltlbers. plastics, resins a[ld their precursers]; aad perfcrmanee fluids i(n.aIDIsmissim1!> :po'wersteeriag.brake, :refr~gi(;rn~t).

For bulk material, theP'()'AP

Cnedclist
Checklist

,el.em:ents required are defined by the BulJk: Materials AilY customer'-Ispedfiic roqui rements .':i,haU documented on the Bulk Materials be Checklist as follows:
item listed in the checklist either

Requirements Requ~rel:1[);e:n1J:s;

Use the Bl!JI!~k M<lIt;e:ri<li.~s Requiremerus ,. Required I Target

Dl1lt:e:. Foreach

enter a target

date for

I.
..

eempleuoa ofthe element or enter "MR" for Not Required,

Pr~mary Responsibi lity - Custemer: Ide:nu:tifyby name or function tfue .indi vidua I who will the in.dl~v]dual who will

review and approve the element,

Prirn~fY Re-S:P()lflS~bUity-Organization: Menti.fy by naeae orooncti.on asserebleand <lSS;U[,e the completeness of tile dement. to be reviewed,

..

•' ..

Comments I Cond itions: Idenl]fy any q:l;JJa~jfy.i[lgnformation ee reterences to attached i doeumeres that p:r1;lvide specificinfermation rega[diDg~fue element Fo·[ example, tbis may include spedfi.c formats to be used for the Deslgn Matrix or :acceptab~e toleraaces :£'0 1 Measurement System Analysis rMSA) studies . Approved by: .Ente;r ~:he initials of U'D.,e authorized eustomer representarive who has reviewed and accepted the element Plan agreed to by: h~,en;lify theindividuals (aad their functions) who made and. agreed upon
1

the project phm.

35

••

--_.

__

---

••• _

••

•••

,_

• __

LL

I~"

.,---

Reqnieed I
Target Date

Comments! CormtdJitions

Approyed by/date

De;s]gll Matrix

Protot.:rn_e Control. Plan

Master Samg]e

Checking Aids

Process FMEA Pre-laanch Coutrol Plan

lnterim Appmva I Produd and Proeess Vali.dat1i.on

lnitialProeess St(l!ldies PBlI:1Sl,Ib:lllil!i:ss]o[l Wa:rrant

Change Documemetian

Comparnll'VI Title / Date

36

.--

I •••

, ••••

I&r--·

f.4 D'e!siigFtlMaJl!rix
, O(gam~~t10ns slIipplyrnfig bulk [iJ:lIa~e-ria]ge~ernUyeillwilh the cbemlsrry <IndW!n.ctiofl('lmy of the produet d being designed. Usc of these suggestions willarri ve <ill! the same end point of a completed Des,i.gl"l MEA, F
but wid] greater applicabi Iity to bulk materials, Fo<rbu Ik materials, a Design Matrix, when req IIired, shall

F.4.1 lotrjJjIdudi.oB

be prepared prier to deve:[op.JIlg tle Design. .fMEA, The .Desi.!;,liiI M.ll;~[illx. determines the cmm_p]ex iateractions offomll[j,hl ingredients, ingred.ie]]Jl cb,ar<l,ot.e:ristics., p'wdJuu characteristies, process corrstrn]]]Jts. and conditions for customer lise, High impact items 'can then be effeeti ve~y analyzed in the Design
FMEA.

F.4,.2 Ues,~g;n.Matrix: - Elaheration

r~~s atrix m

earrelaseseustomer

expeeretions wlth U1ie roduct design hems, p

Construct the Design Ma:tdx!'Ieferring to the example which will follow:

L. Along me borizontal axis, list uhefunctioros (Desired Awl butes/Ptlrentlal Failure Modes). 2. Along the vertical axis, list the designitems .. • Fnrmulalngredierus llilgredien~ Cfu:<i:r<ictens(]cs as Poteatial Causes (CatcgoryfC~,a:l:"acreFist]cs)

'.
"

'.
3.

Producr Chamd:erist]cs Process COIlBtrai nts ComJill.o'IDIsfQr Use (customer process eoastraints)
tbeeurrent robustrhreshold range levels and units,

for leach designitem.enter

4, Ccrrelate the porential causes to [he potential failure modes using a number, leuer, or symbol representi ng theimpact m :strength of the relationship. As.k what would happen if a potential ceuse item isallowed to go under or over itsrobust min IIDu m or maximum ..respectively,

:s:.

After cempletien of the rankings in the Des]gn Matrix, review the eategcry/eharaeterisrics

for

a preliminary assessment of Special Characteristics,

column .~.

Designate any Special Characteristics in

D[E.SIGN MATRIX ,. G,ENERIC: IP,AI NT EX~MPILIE, L

CATEGOfty.f GH!MAlCTIEIR!IIS'I"IICS

'I 1

I 'I

1 ,

""~,
_

I
I

~~"'r,

~noj .. ,~~

I~' "

'I

I,

I~ ~
'I 'I

.1
2
I

::10'"
I I
~

:.!

'!

'

a
I

1
,

1 iii

D~ I

l'

11111 ,
1 1
1 :

I
I

II

II ~

'I

_.

L1
1 1

'I

I· I.
1
~I 1 1

~ ,I,
I1
: 'I ,

I
~~ 5t;ilwili

I
I

...

1)1~2112D
r

1~
~ F~!.J ~~ 1 I I I ~

'I
L I

l'
I

~,~

I
I

1
~

~
::I I

~"
:i! I I

~
~ I

I~ ~ , I
1 1 ~ ~ .~

ul"J...~r u .... r

I'

'I

~"I

'I'

I'

'I'

l'
I 1

~,

J'

,I

'illdU' ['".

~1

1lii:1g.liJh!."¥

i~~ ' I
I I'

Q g

(I ~

;;: ~

0,1 ~

I,

0
U

0
~

[i

!J U

I]

0:
~

(I

(!

;,.

'I

(I

ii! ~

I
I

1"
, 1 ,

I
1

Q,

I.)!

I~

, '11
~; I

11
, , I I

~ 1
~ I

11
I

!l

2
I

0
'I

u",,",

II

2'T~

It~

I,j

,j_,

~I

_lj

~ ,)

a .L

I~

,IF.,5, ,D'esiigln IFM~EA I(see 2:.2.41

F .. .1 Effects of Faillln'\e and Se,!!lcrity Ra:nkings 5 The following two s:~epsprovide an alternative method for identifying the Poiential Effects of Failure and assign]ng a Severity Ran.kirl\g. List Effects of'Failure
Consumer Effects- General terms jdelltify1ng the loss experienced by the ultimate user of the product [e.g., the vehicle buy:er).. '. Customer Effect') - General terms identifying the [ass experienced by the intermediate user of your product (e... the vehicle manufacmrer), g., Assign a Severity Ra11ki1lg to each Bffect • See the Severity Definition aed Evaluation Criteria in'! the Potential Faihae Mode and Effects •

Analysis reference manual.

.. The goal for each of the Items that multiply to arri ve at the Risk Priority Number is to differentiate between the items in that category. The following figure provides a guideline for severity rankings, U YOIlT situation only uses a small portion of the scale then develop your own scale to improve the differentiation. If your situation is greater thantwo tiers back from the final consumer, then the guideline figure should be adjusted to reflect the effects that will be felt by your customer's elastomer"

Effects of f:aihJlliea.nd Sev,erUy. Ranlic:iingl Tablle

Consumer
(e.g., vehicle buyer)
0\11' ner Safety Problem

Mai Or Owner Dlssarisfaction (Loss of Owner Lovaltv) Moderate Owner Dlssac sfactiou
(1nconvenience)

8 6
4

Minor Owner Dissatisfaction (Annoyance)

'Customer _. (e.g., vehicle
[11<'1.111.1 facturer)

Plant Safety Problem Pessible RecaU

7 7 Rezulatorv Penaltv Moderaie Rework (e.~. < 20% or moderate renair) 7 5

I
,I

Plant Dissatisfaction Minor Rework fe-:g-,< 10% or simple repair)

F .S.l Potential Ca uS1e( s)fI\ilech anlsms of FaUu reand

Desig,n Matrix
as the Potential

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

Mechanismsare generally described as over or under a certain threshold, These thresholds define the boundaries of the product approval and subsequent requirements for change notification,
'i
, I I

F .S 3 LJik~Liiboad of Oejculr:r'em:eRankjng~
.e

The foUQwing step provides en ~Memate method for Bssigni.l1lg Oeesrtence ~tings. the ranking scale ~[11 the r!J)t,c'u:tiaJ FaUure MoiiiJ.~andEfftlc:ts: Ana.~ys;i.s manual is d~ffic~]l to relate to bufkmateriets and gene:m]lyreSIJIUs ~1:11 very hJ<wnumbers, with. htU.e di fferemJUauion III Rank Occurrencethe ultimate ris,kTne foHow]Rg matrix is recommended, as a Iepb.ce:meffi[t It. evaluates the frequency of

ODCUUOOCJe OMOOupon. observed evidence the fonn~~at:or basin the design, Occunence Matrix Formulation
.LOW

FREQUENCY
. UDKRA.'1E M

HIGH .
7

Actual Experience
2 3

10

Actua I Experience:
S.imiIat lExperience: A ssumpt ion: Frequmcyraflkjn,g • ,. .'

Obtained from appropriate experim:enbti on on the speci flc~ nal produet eud the
poteFIJlia!fllilme Based
UPCJiIl

lmodJe·.

similar prodnets or precesses and t1~epotential faUure model.

Based upon. a clear u]l!derstand]ng potentia!] failure mode" clarifications:

of U>tG: ehemiea! impact of tbematerial and the

H~ghis dell ned as - Repealed f<lJ]ll!.m~s Mode:rate is defined as. - Occasional failures Low is defiaed as - RJe;lative]y few failures

F .5 ..4

,e !II rrent

Design. Co wtIr'"Q·~s·

Design Control: Supplementing the FdlU"1il M.ode EffecttS and An3~.ysis manual, bulk material design oO:l1lt.mls may alse ~[!IdUl:k • ,. DesignedlEx.perime[IJts (DOE's) ~ Listeaperiment #'s C ustorner validafian tests ruldlidaJ~ runs - e.g, grave]om1e$e:r pandii. fender customer reference #' s). Test p'w~oe.o]s- list Test Met]]oos. Stan.d!ard OperafiagPsoeednres, ere. Variation of supplier specifications. formulating p'fadice robust ranges. sprn.you,ts (Iist

•
,. •

Design controls rude:!lltifi·ed bya number should be aval.La:M.eso ~halUle relevant coneent of that control cali'!
be understeod,

F .5,.5 J..EkieUboid of IDet.ecttiOin. Ra.n.kWgl!i The next step provides an alternate me~fuod for as8~gnj'l.'JigDetection ramri.ngs. Rank Detection - the ran_k~[i1gseale in tjne r(!!'~e:liJda]. Failil.!lll!'eM.ode a.ndEfteds Analysis maanal is difficult to .re:late~o bulk materials andgeaerally results ]]]J very low numhers with r itde d.i.ffer.l;:nti.at]on in. ~he ultimate risk. TWe<folLowing. matriix maybe used. It evaluates the; Detectiorn as the abHity of the current Desi.g[l Cont.TlilIl~oactua:ny detect a cause ·of faUIillJ~e ndlforfuilure mode based upon Ute assessed a

40

Testing Method R&R'spercenl of speeificatian range (see the M'euureUlent manual) and the quality o f ev idence. Deteetion by Design
COll't~0~ •

System .Analysis reference

T esti ng Meltho d R&'R <30% 1 ]0% -100% 2

Q uaUtv of .Evililenee DOE (Response Surface

>100% 7
9 10

Analysis)
Screening Experiments

:5 No Evidence

DOE (Response Surface Analysis): Symmetric design spaceanalyzed with appropriate statistical tools. Screening Experiments: Screening desD.gJ1 (If ladder evaluation srraregically set to develop DOE_ Assumption/Experience: Informadon/data based upon si milar products or processes. Note: The above R&R limits are suggested unless. otherwise agreed. I!1pon by the customer and organization. R&Rcal.cul<ltions can i.ilhia]1y be based using design nmt.rix~lfrres.hj{)kls. .

F.6 Process IFMEA l(see.2.2: .. J 6

p recess FMEA Ila nki.ng Ta.bl.es

Severity Rankings
, Severity of Effect
Very High: Potential failure mode may result in a field failure (9). or censtjtute a safety

Ranking
9-10
7&8

hazard or noncompliance with a government regulation nO). disseaisfactios dUlL: tu t~e nature of the failure. May cause serious disruption to .subsequeru processing of the product or result in the prodact failing to meet its. sales specifications. Willresult ill 3! customer complaint and product rerum. Failure is likely 10 be detected during the customer's final product testing.
High.: High degree of custemer

Moderate: F ai lure C£Lll'SeSsome eustomer dissatisfact~o[l OIiI1d may result in a customer complaint or limitation on shelf Hfe. The custemer may need to make modifications or adJm;tmenl:s to their process to accommodate the material Tile problem is likely to be detected as part of an incoming inspectiOlil or prior to use (4). The problem will be detected duringprocessing (5)_ The problem wi,Ube detectedin subsequent processing steps (6). Low: Failure causing only 11 slight customerennoyence. Customer will notice only slight dererioratien or iilleollvcni.·cncewith tiheprod'Il. cl or processing of the product.
l

4·<1)

3!

2-3

Minor: Reasonable 1(.0 expect tharihe miner nature oflhis failure would not cause' filly rea] effect on. the product or its processing by the customer _ Customer will probably not even notice the failure.

4]

Frequency of Failure
VeryHigh~
fan.h.m:s.

Fa~lurei$ almost inevi~ble.

Add!ih'oil<l.~.rroccss StepS i!1rt:developoo to deal w~1!h the p

9 - 10

Moderw,'c :8imilar

p;rocesse;; h<!!\I,e ;.;:penefl~ed oceasienal e

faulmes. but .not iII 1lIl1ljmpWfl'OrI:tons.

Process is, in. sl:albtkaJ ,eon1!rnL

~m~e'Ss ism stalislio,1I Q(I!!Itro~_

Remote:

Failure is I!Inlike!.:!_ No faill!lreS ,ever assoclated

wHfu almost irleillica~prQCesses. The

VerylLow:

O;rgafli~4ttOn. cantrols j):robab!y will not dateettbe exlstenee

o£lectiO:I1

(lflthe ddeC't, bat the defect

OCCUlf lIitnu~pacbging

may be dtelJl..-etc!:lby th.e CuSroIUI~r,

Low: Controls may detect the existence of the defect, but

1!I~d.ef\v;:l!y •

may

l10ti

is

7-3

Modemte: CO:I:I~15hke~y to dC'te"Cl the e;.llste!!lctof !he r<lihue, bllll n(U lJJlhl .hn 1It.'t:CplllIle.t: testing .ha&beelll O®ffip!eted_ TeMS whh !lh~:ghe:rdegree of Yariabul.itywiU h!lJ\I'ethe hug!ler rnnklng. High: ,Controls have a good ehence of dletecH!ilg ~he exls~'ell'Ce(lht\e defect before the fll!:!nu.facturilJg process has been cerapleted, ][l.Pro~ess~esfing is used to monitor t!ie malllufactuInll ..g process.. J ,4 1-2

Very HighfEarly.: Co:nmro:1.~ ~m almost cerlaiflly

moves <Ink! lb:~ l1eld:~!ep m.ilS
!iI'hall!':!

dsteet the eX·~s.1J.ent:elfl~~ defeet be:foll>e theprorlm:1 { f~cWj'ing pro.oe£~. ]mpona.11l FciW l'rIIl1~e'rials <Irecentre U~d "'1:8

erganizanon

5pecuf1JiGa~j.o[l~.

42

F.1 SDec~al CtJ!cu'j3,derisUcs

F,,".1 I nt1J'1odudl,on
If prod!uctch~racteri$t~.cs1ath~ibnwe;s. can have normal v:t1:ri;ationres-ulting ~,nmovement outside their designintended mIDus:tmn:ge whieh resuhsim significm'Jiti:rnpact" they are deslgnared special, and must be controlled by spec ial contrels,

:1

Spec~al Ch<!rati'e"i sties

F,or Bulk Materl als, a frequent

oecurreneeis a 'tl1msfo.-rrtatioIl :m:.m bu.~k matc:rii.lllO flioo~ p-rodlilct_

IIhl'StMiO{lS ofltte nOA\I of mil[e:riill;s.fhrou~. fillal prodJllIC~ foHDW (~.g., ~o.~im Res~1l A, % % U V A intended). are lil.Qt. [le(:~sa:lli!yirnteilld'~d te be Spec lal (:haracl:er~stic-s~

nese

The di f:fewn~s between blllLk p.rodlilC:1 ch!l!r:llc~.eri:Sitic~(fearurlllS ohhe sU!P'plied. md~(:n and the p firml !I~.Hilbutcs (fetltmes of the transformed product) ~hDUld be !m(krsw(1o(l. Duril1g the d~iWl phase, the prud,ll~"t ~l:U:U-'-I~~~I~S~lICS be C-iU:!, CQJ]tr-o~s for fina! prodlllct! iluribu~es. (ltt:Ls doesoo[ imply tool ~hcy :1m:cuntw.~ chm:aoterislics}. ThiIril!l;g i't'l anufaemre ofl:he bulk material, proces.sp~fiI!me~ers are the coneol characteristics. i):uri~g -~l1JJiIsformi"nij)[1 from bulk. :IlMducl teflnal pr-oduct, both bulk

Examples. of prod!llct 'c<'hcarncteri~tics are: \fiscosity. NV Solids, % RfZsin "A". Examples of fLna~ product buil.dl. f'MVSS

attribute~~:Qe,: a~pe-arnnce. film :saf.i;~. durabi]ity.

Enml>~e~ OiF mar)l;Ifa'C~l.uing process pHrnrrne~ers (OOliltro~ eharaereristies) a~e':lemperat_ure,
lJ~e:!isl!~.miix r<!te, !est IJIWtocol.

pimlu~l.ch<lr~,c~eri~tic5 final and

product ami bllll:!;;sesn 00 c~otmUed hr eustomer pr-oceS'~ control ~tJ.;arncte>r~sh,(s. Symbols for clIIskm:ter-ld!e!1tifLed Special Characteristics OrgaTliZlltion~ may d:es!gnate theur own hUtrmd s}'moo~8l(I desiJ.gn<l~ Sp6Ci.a~ Chl3imc~gri_s,ticsin. their ",,"ooon" dloe-uments: . .;;,; Fer cllr;.DIiR!:N~.csigru~tedJ identi tied Speci~.I Charac:!erhtics, tfilc cusllI)mer-spcc~fic symbols wiUIoo '!lI5eO,fo.r reqlll:ur'ro C-llS~OJ]}!;ir dlx--IJ:menlalioll and. r-.Bqlllired

Exampks. of eustomer 1T:alllsfo.m1ation process pal"1llll,B<te~ (cmltro] ~.h_(lwcte:r~s~iCi>} are; l:1ui.d flow, tm:lilpCrn~lJreflILIrIlUd iI:)', air
P:w,i:S;Uf'e_

use "8" (SaleM.

The organizalLOIll

may cheese to
Of "sp" {specut!.~)\

m "'[(,. fK£y). d'C.

Thecll5~omcr d~signatcd sbidd, inverted delta, dlianu:md, etc, will be used wla requiredper 'C'lli!il~omt:r i.dcmifiCiiiltion.

smppuilg l~boeiLs,

F ..7 .2 Special C bancter1.sde:s .- EI.ab!lil.mtion .

For c~al~.ifi.ca~.i.on pUIp05es. the following figure is inl:end.edito demonstrate the now of potential special

cheracieristiesthrough

the supply chai n,

I~~lI stli'at~o:n,of the Fl,ow of· Mlater~alis ·tlhlliOlUg 111 ina II Produ et: 1 F Item A (Pain~) Hem 18(Paint) Item C {Sea.h1!nt),
Supplier (rEm- [[) I'l.l.Ilk I!·roducl Cha:racte:ds~ic (Raw M<!~erial) Sup;pli.er (fiel' Il) Btllk Pmi!lm::tCh.!lmRel:eristic (Raw M".:!reri::d) Suppli.er (Ti.er II) BIl~k Prodllle~Chlmlcter~s~ic fbw M,Merbl) P-olyme\l' Vis!IlosHy SuppliG.f {Tic:r U} Mfg_ Control Ch=Dteris~ic

Sup,pH~r 'TIe~ ( Mr;g. Ceatrol nllllJrracrerristie

fIDn:J:~Jte3ctiolil Hold 1f:im.e

Suwlier (TIe; U)
M:fg. Gon~rrd.1 Characteristic

Org<rni:o:atioFl Crier [)
Bun. Produ~~Ciharac..elistic

0fll.1lnizalUOl) {Ti.ei!' [)
D'UIl: ProdU~l Chamcreristic

OI~im~i()lil (Trer [) BuJk r~OdUCl(:haracter;stic

Org<l!f1lz<:i;ti.on (lierl) MIg, eOTI1trolCharacteristic

Orga:nizalicUl (T'ier

OrganizatioIl

M:fg,. Cal1~rol Ch~rncterisHe-

Oier 1) Mfg- CODlrol Cb'I!'flt!.eristic

Cus~:omef Transfermation Co~tr,oJ Characteristic

OU!:>~(lma TrsirlsfQm'I!O!ttolli C(m~ro~haraclcris;tie C .~luIDd~I.{I1I.v (for film. build)

C'U~tO!'f\'ermnlsfo:rtn~,tion Control Charaerenstic

Finilll Product

ffttrribule

44

f .8,_Cmttol

P:lan {see 2.2Jr)

F.B.t Introduction
The Bu lk Material ControJ Plan serves as a mechen ism to: ..
•

Higb Iight Special Product/Process Characteristics and their controls

Link together sonrces of control methods; instructions and specificadon/mlerance reference them ill one document limits and

Addhi onal]y, this cOli1rtroI plan is not intended to recreate specification and/or tolerance limits that exist in (lither control sources such as batch tickets WOIik instructi ens and testing protocols,

F,.S.2 Control. Plan.:" Elabora.tion

R:e:felio the customer's specified eontrol plan format (e.g., that found in the Advanced rrodu:ct Quanty t
Planning and 'CO"tIi'O~P~9n reference manual) ..

..

Prototype (when

required) - A listing of tests, evaluations and their associated specificationsrtolerances used to assess an experimental or developmental formnlericn, This may be tile only eontrol plan that 'us product spec ifie. Pre-launch - Documentati oncf the product/process control characteristics, process controls affecting Special Characteristics, associated tests" and measurement systems employed during product scale up and prior te normal production.

Production> Do cumentation of 'the product/process control characteristics, process controls

affecting Special Characteristics. associated. tests. and measurement systems employed du ring normal production. Additional items may be included <It the Organization's discretion.

Pre-launch and production eonrrol plans ma~ be applied to a family of products or specific processes .

•
45

Bulk ~teIiab; Measureraems

Ofileillil require further processing are often destructive ~

]8 jt

a:l.leJis~ttilpling 1n onl,eK to make a measurement. same sample:.

hi! nature OiIillJd prevents [etest]]]g~he this measured

jn

Measurement

variabiliiy

ofte:I'JJ uch I~r,ge!ifor pro,erilies important in thepraeess m

is fOFpmpeirties

industries (e.g .•

viscosity and pmi.ty} thaa

mechanical industries (e,g,., di mension s). Mea.surem.ent may account for 51J'k or more of the total ebserved vanatiolDi. ISO) are often fonowed. The organizstioa need not re-

Smndru:d]zed test methods (e.g., AS n.t, ~S. 'Ve:ri~ bias. 1inearfuty. s~:<Ib.i.~.]I:y. Gage: R&R. and

MSA sludies arenot required where standardiaed tests are used, however ~t is sti.n ~llID]pm1antfor the' organizanon to uaderstand the measurement component of variation lID llfue~e.stmetheds used,

Customer aJgreem;ell~ Oil! the actul3!W requi:!:ern.eijts for MBA fer either aon-standard
supp~ier" test methods should be ,obtained. during tile p]arto.ing phase.

test methods or "new-to-

Amry MSA studies :s:hou]d,be app]ied to each test m.e~boo. assoc;iail:eo with Specia~ C~ar:acrejri.sti.c:s, and not to each individual pmduc; measured by the test method, Therefore. the MSA studies sh.ould be conducted as broadly as po:ssib]e across all products wh ich use a particu I,IT lest method. If the resulting variO'lbiHty is

unacceptable.then
be taken

eitherthe studies should be eoadaeted on a narrcwer elass of products or action should

test method.

t~, imp[i~I"ethe

The uUnJufacmre of bulk materials consists of indastries wh~ch Spii3!1il !3IV3:]'"iety'0'( product~Qn processes. from high volume P[O~ucts ~o spedaity prooll]:ctsproduced in small quannries nomore than caee or twice per year, Often me production process is completed or already in place before sufficient samples CIIn be re;s.~oo, By the time the product is madeagain, personnel andJoiI equ~pnli.enm Hlay ~ave ehaeged, Also, these processes have mm:l!eroij$ .~npul variables, many C!ontro~W1r.iaJb]es> and a variety (Of prodll:lct variations, There <Irenon-lineaeities - meaningfor example tha:tdouhl ing the change in aparticu lar inp;![:!t The effeetsand rdl!!tiQ:t1l!ships behveen all these vaeiables and conltTds <Ire <I.~SO net U:!;UiIUy '.krn:town without error. MM~ti.p;l.ep:n)cesses are usually interconnected, sOMe:tti:mes w~th feedback ~,[)QPs. There are also timing eonsideratiousend delays in reacnon fime, Furtber, measueements 'of component v<l!ri<lol,e:s <Ire generally ~e5S p'fec ise than measerements of ccmpeaent parts, suc:l1~ha:ltil many cases correlated variables m~st be: used.

does not aecesserily double the ehenge i~the output.

,Fr.1,1 Master S_,amJlle l(seel.2,,1SJ

F.ll.l Intf0d.u.ct'ion
The requiremems fer nliBStersample or equivalent shall be agreed by the customer and organi.Z<l.tion. Phy,s;kal S9.pl~e: Some bulk materials are stah le and Ill!nchangi ng evet aln exrel1lded period of time (e.g., they dtl, net slgllJflcairrUy change pby:sica~ Of ehemiea! compesition, if properly st(Dred,fQr decades).~11 th is COISie:, III physica~s:anlip'le will serve as !!I Mas:ler Sall1pk.
A:n3.l(ytic9'~ S<lIimiJIll!i~ .R.coon): O~lm:eFulk ma~eri<lils ch;1I:[Ige with time, but can be precisely quantifled by b approprieee analytical techltiq1!l:es. III tills ease the analytical reeord ,~e.g",.mtrn,-Vi.QIJ;:1: or Infra-Red s,pectra '"finge:rpri nl:, Atom ic Abs.orption or 0<1$ Chron1;amgraphio-Mass Spectrometric analysis) is am a,pp:fopda:~eMaster Sampl.{~,.
YO

MaDu[adurillll:g Sa,!mp~e RecJord: Wheflll:l'~Lk. aterials can not be disfincjly idel!l!llfied OI change over m t]me~ a mal1iufa.ctllu~ng samlP~e[eo~m shouldbe generated, The record should mchMle the informaUon required rolllimuf:ac~~re "ncrmal pmducUoJiID size" rua (let or ba:tch), according tothe final "Preducticn a O;lI~trQ] P]<In" suppO.rtitl,@: the: PSW" Tbis record. provides an "audit trai~]"rothe inf'om!aJt.ionwhich may be steredinvarieus documen:ts and Or electronic sys~eMs. The foll!Owingis the basic irnfo<rmatiO!1 sug.gesred to aeeempl ish thistask: .'
• ..

UJ,e quarltHy~f produd produced.

Thei mportant performance reselts, Tl'D:eraw mcf:llterials utm~zed (inchxdingnvlliImJufac.u.lJer, Lot '# and ~mpO[1J;aifit preperties The critical equipment [-equ~[iedto manufacture the bulk materiel .. Analyl:i!c:al. sample records. as desccibed above. ,O:ml the taaterial asprodueed .. Balch Hekel used to menufaemre the bulk material, records),

..
•

.,

47

F.U.lraint

Mauufaduring M:astef'Samnp~e ecord - Examples R

The: f'O~lo\"I!i'lngflgm"eshow e~imip1es 'of pai~t m~n~fa:cturing master records: s

IPai:nt: Mf'g MasterS,ampleRecord

MFG. lOCAT~'ON:~~P~.I::m~:~t tiI~I_. ~_~MF(3,.

~ Batch/lot Mfg., Re,con'l

IDArE:
l2/5f97

Number
Dade':

1 :1;97'

Produ ct Code:

XXR';1iTI'YBa5~ooat

Formula
tI I.8191 _

lbsJGalls. Req'~":,_]O_O_O_G_<J]_'s. IEqu~, liD.: p Mix.e'i#2:

I TESTING IINIFORMATION

INarn,e
WVGallr,on % ~on Volatile ViiS:cosity

Tle~t Meti'loo llM:001 l1M'OQ4, TM003

SPBcmcations 10.50 ~ 10_10 57 - 61%

30 - 40 Sees
Da1te1Time
°iP€ir8ilOir
Inili<li~s

log redlierhts Add in or-der, willil mixi1nt9

Amt

Amt
Loaded

I Lotrfan'k #

12151979:35 ,AM
iResillii B

501 l.bs.

CD 618

~~~'~n~~~ ~ __
l. r- -~.---~ ~'-'-.

.~ _.

1~:~~ __ l~o:~:-1~~:--1~2~5~9~~::5_~ _
:11

._.

__ ~-

~ -_._

-'_'-,'

~ -._ -~.

.. _ . _

~. __

'~

fltUNG

INSTRUCT~ONS
250 GallTote

COrlitalns'ffi Filile lfing

25-Mi.cmn Bag

Lai!l:le~l Per CO.lll.tiract ngl

48

Product Code: Date

Paint: Mig !Master Sample Recanl .: Product Test Results, xxR -yyyy Product Name: White Basecoat MarmJacmring location: Plant # 1
Batch '# Batch S.ize
~

WtJGaUon
TM[lOl
W_50-

%non~

Vo~a)tile

Gallons
1215/97

lMD04
10.70

Vi~c:osity TM003

Ijlni'ial'

30-40 Sees 34
OK

Certificate of Analysis
Material Na:me:Filmfonne:r Material Code; Resin A Resin lot/Ba:~ch #: AB345

. Specification Requirements
Property M:U[l._

Result
% Non Volatile (TM004)

:51% '7

61'% 7.3

58.. % 8 7.2

ph
(IM005)

Certification

Signature:

Date: ------------------

APart Subm.i.s.s.ion Warrant sb;a]] be prepared andsabmlned for apprcval when required by thecnstomer _ ~f a customer agrees dlSltP.PAP ]S ]]JOlt required, no warrant needs to be prepared. The information required by the Snbmission Wam:nt whicl"l does not appLy to bulk msterial (e.g., part w,ei.gM, dimensional measureruent) does [lot Heed ttO be fll1Ovided.
I ,I

For those organizatioes that have been classified as "self oertifying" by a specific customer, submission. of a warrant signed ooly by the organizationsball be evidence of PPAP approval, unless the organization is advised otherwise. F or a]1 other Q<rg~nizati!on-s,evidence of PPAP approval shall be a warrant signed by both the authorized customer .r'errese:nMl.M:ve nd orgamizll.tioi.l1om: ether customer approval documents, a

49

Most ~;II:00Il,lCtS w~U aeh ieve approval prior to initial. use. I.Ii1I 'cases where approval CiUl!110t be ebtained, a "Bulk M,a1ieriaJ Interim Approval" may be granted. A form is shown on the faeing pege; other forms !.1I,1!ay

be used.
t.

•
BULK MATERIAL INTER.[M AI"PROVAL .FORM
N8m~ IIl5sj!WlOO to T[![)N NAME:

COMPLETION OF mE
ORGANI:L4 PRODUCT
Doeuments.

OI;8lU1i7..l!!ti!lllo's, 1I\I1i!L!lr\!lC!W'IDg

1~lioiL id.lefillifietiin !he CusromN'~

IIllaflur~ri~ location
.itS

2. J.
'It .5. 6. 7. 8.

NAME::

Tb~ Orsami7~~ioo·~~igl1!l.wd
CODE:. Coo.c' (DUNS, number

n~!D!l for ~~ prod'u~t---,as,

8'r

lEn~[neoJiillg

R,~!~8S~

S~:J:I"PLlE]~!VENDOR pliltba~ 08Ll~r, :ENG. SPEC.: MANIJIF" PAR,]"~:

cquuvaknl'

8S!>igll.~d~o~lte

S:bowmJ 1:)0 the Cu~'mncx'5,

CuS[WllI~['S

iOO:n!iffud :Spc~ifi(iiltion ofdte

lJut!i.I~ whiebtb~

pmmu::~ is IIt'pPrQved gJli!

fe~C:!I!S~(!,

SITE.:

Pbysicaliltl.drt:ss

milnuf:iJclurirrng ]mOil!ti[}J18~~Imwm. o:~ the Cl5W~(S

Plll:!l;llall~ ordee,

Custtl1m:['S

Par! Num'ber.
er nlJjrTi\~r

ENG. CHANGE #:~Qnn\l!!l R.cvi~k~~~'d roRMUL.o\I)),>H!E: .~ngjncmltgltd= ~

ldi:<nlif'yin_gtbG fQmlula.

~fthG fQmt!Jb i:d~Qlifi~

in

i!cmil7.

9.
10.

!l:ECIWVED D.n.E:

CII!llt~IIlCr

Us.: ()Q1y.
Reprcs.m~i~.'~), OrggliZllltioo expJres,

H ECEIV ED B,\': 'CUS~(II1Nr ru~ On:l)! (l"m[~

I! •
12.

SUBMISS[ON

LEVU, ~ Submission L~\Il!!

noS) I~

is required

.1) ~ll.bmit

to as d~fHMd hy the

Cusloll1!lCr.

IX[,:nRA TIO:-.l DATI: Dl!.te ihlIt Ute Interim Ap~o"'.al

13.
14. I j. 16.

,[MCK[NG

CODE: QjsWme~ U~ OI1~Y,

DATE: Date O~gal'tizalioo wilnresubDiit if!:!.- prOOoot~n ~pprov<ll. 1rllt~rum). 3. sp~rfic

RE-SUBMIS:5[ON ST AruS:

for each Jrum. enter .approptiate coo.r: (NR - Nat .ReCjl1ited -.'\lfPruvro, •.A
OF MA TIREAL AUTIlDRnZHD~

SPECIFIC 'QUAI'-ITIn product.

UtlUirted when n:nlt:rim A[ppl:OV81 ~iXiliit'S

aUllttlfizins

qLll![ntityof \roh~me ot·

1i'.PR!D:Dl'Cl~0}.1 r~eilit)'.

TRIAL .AtlllHORtZA.nON:

ClJiS[(!m.~r's Et\:f!;iocering R~k.asc

Ih~ U!i.C of th~prOOlil~J;C't in ~til'C Cl.l5toJ]m·s

Ul. 19.
20.

REASON(S) FORUNT6RilM APPROVAl...: fudicMe rcasen for InLieiim Reques.~ iSSUES TO .B[ RESOl.VED', EXP.EC"I"iD COMPJ.,ET~O~~ DA1iE: rn:g,p:i:dim_g pn;:t!blem iml~~ andfl!JJllL<lh a d2ltoc for pmb<l~m :~s.ol~.ti,on,
F'm eachitem

m;:r~,oo. ~~ "I" ill #:15. provide

~J[pI8IWJ!b[}.TY d>=lail~

ACTIONS TO BE ACL"OM fLrSIiIED IJlJRmG O<Il'ER.1M PERIOD, HFECfIVIE DA'il'E: Wb.ilJ(i~ bei:rng; cl!cne kI ensure ,or[~!iv,c pr'OOl!JA:t i~cOOllllin~d, .~ ·\¥:rn~n the 8E~iI;Jf!Wi·1l$ im,pI~nn(>nt~.!lllC E:><h trit~ri:aJ n~o;ssat'}' .~ ~n.(j need .fOf ~Gnl[nliimg theaeticn '00" it's r ndividua] elernems, PROGRESS REVI!EW io.tOOmperiod, [lAn· WHAT .DATI: Updalte 11m proW~!i of problem reselution,

2:1. 21. 23. 24.

SJ=m.c<rl!Uy ~

mldpooint

[tOO'! ~ss~ce

00' ~~!pjrn~io[lJ (!if the

MA TERrAL- DUtE TO .PLANT: Al'UONS 110'1'4: ARE

futt: I'J1Iiltm81 is clue to CI!B.1ormds

site, SU6MWS~ONS
8g<1i:rn?

REQUrn.EME:'NTS BY THE SAMPLE [,RO:M:ISE DATE? Why w~rn't ll;;i~h8~p~!1J

ORGANllZA R~5i.b!c

'r A K~~O

PLACE TO m-rSUll!E ll-IA TFunJRE

W~I...L CO~iFORI\,II. TO ,\1..[, PPM

and A~lru:mm:dI OrgaEl!iGr<J.titmll!f:liiciaJ~ ensure rompli.axmc l'IJ'toe 8bQ.".,Cm~U\ttcnc-d 8clions~n(i! 1:0 phenenurnber, :mdJ da~. 2l!ndi dat~.

dll!.ws.

25. 2J6..
27.

FRQi[)tTcrffiG.,P:n;.d~c~ !;ng;inc.oc"~ ~isn<i1Ju~', ,pruDledmmme.

M~ T1!FI.IA 1L,s Iri'oi:v.= Mmt;:;nal, En$io~r'~ 'QUAUTY !E"~G.: Qualily :~~mlturc, pcinltd

mmlC, p:h.o:ruilliurribcr:,

En.jl.im.eer'~ ~~1Jure,

pciJiit~dI name, poooernur:rnMr. ~n-d dtL1.e..

28.

INTERIM APfROVA.L 'NU~1BER: Customer Use

Onb·

511

BULK lMTERllAL IliNTEIRIM APP'ROIVAL~ 'ORMI

SUPPLIER Ir>4AME; ~..,_

PR.o.[)UCT

NftJME: -----7'-.;-:""'""'------

SUPPLIER COD:E,:
MA~I!J~., SI1~:
----"'"7""",..---',.._ ~

ENG. SPiEC,: __
FORMI!JlILA DA

~?---'--~~~

__

PART #: ----l.".___.L:,~~-----

I:: NG_ CHANIG E #:

rs.

~-d~~~

__

RECEIVED DAT~: SlJBM1SS.ION lEVE,l;.

lRACKllNG OODE,:.

RECICM~[)i BY: --------->..-A'""""'"---EXPllRATIONDAll:: __ -=~.-'__ ~

RE-SUBMIISSIOND,ATE:

ST'ATUS~, (NR - INo~IR,equired " .A - .Appn)v'e:d" ~- Interim)

Desijgn MatrilX; ContrrQ~ Plans: Test Resu1ts: M'ea$iLlrement [Hf'MEA: ,PF'MEJI.:__

(~
A;pprolV:a.t_

Special Prod'ud Cllii~lracteri'Sti;os:~'E,li1ginooring

SpeGiaI 1?~()Qess Clhlall<l.ote~iis<t[C$;~Prooe$is R~w Diagram:

.Process Stud'ie$;;_Dlmension:al Sys:tems, Studles:. __ Appear:ance

~sl!!lts:.__

-,Masferr' Sem;p~~:_~~_

Ap:p:rovaIRepCItt;

SPECIFIC QUANllTY

air

M~1"E.R.IAl AUTHORII.ZI~D OFAPPLICABt~

1:----"'(W)._,,_~6"'_··

IPRODUCTIION TIR~IA!l AUTHOiRIZArlON iREASONI(S) FOR. INTERIM .AJIPPROVAL:

tt:~~~~_~~_~L~~

ISSU~S TO BIE RESOLVED', EXPECTED COMPLEIUJN D.AT~ (;;\ (CLASSU::Y AS ENGIIINEERING .• DESIGN, PROCESS, OR. OTHIER):_O~19,-··' ..

ACTIONlS TO BE ACCOMPUSHED

DUR.~NGINTERIM PE'R~OD,EFFECT~VE :D. -

PROGRESS R:EVU~WDATE: 21 'DATE MAIERJAJl DUE. TO. PLANT: 22 WHAT ACTIONS ARE lAKUNG P ~-E TO E:NSUR.~.THAI FUTURE SU:8M~.sSI "s, Will CONFORM TO BU~K MATEiRi,Al. PPAP REQU~IREMENlIIS.BY THE SAMPLE ,P,ROMISE DATE.?

S'l!J~I?'PILIER tA.llfTHClR!ZEDSIGNATURE)\....-_..J".
(PRINT rN!AME)

PHON~;, _ _

MTE.._:

CUS,lOMER APPR.OlVALS (as l'Ielld8d)~ PRODUCT IENG. {SIGNATUIRi:.)b

_____"V~~"-

... l

PHO:ME

BULIK MATE,R~A'LIINTERIM APPROVAL

SUPPLIER NAME: --PROID1!JCT ~AME:,

FORMI
~ __

SUPPUER CODE MANUF" SIlE:,

~lrNlG" CIHAN:G'E

ENG. SPiEe.; ~ PA~:n#;~ __ . ~~~~

_ _

it.:.

ORMULA DAlE:
RECI:.IIVI~D BY: EXIi'IRATIUJ:N 11[)1A1E.~ RIE~SUE!MISSION

_
_ _ _

REC!::~VH) DATE: SUBM~SS~ON ILEVEJL.:

TRACKING CODE:

DATE:

STATUS:
Controll

(!N:R.- No~ IRequired, .A.··Approved." II -Interim)

IJFMEA: __ P~ME.A: Specia1 Prodlual. Ciharnrnerislioo:_Engii l'lIeerin91.Approva:1 : _ Fil@wDiag ram:

Dei!l1gn MaJllib:::. PllaJ~5:

Special Process C!haraGterislics,~_Process. S.wdie'.s;_Pi!T1.eilm$io~l~$ult$:~~_Ma500r

t,est Res~lts:~~~Process

Samp!e:~~~~

SIPECllflC QUANTffY

OF M~TIEIRIIIAlAU1HOIR~Z'EID(IF .APPLICABLIE},:

~~~

IPRODUC"fIION TRIAL AUlliHORi~ZA'fION RIEASON(S)I FOR ~INTERIM APPROVAL:

#:

---------------_

ISSUES TO BE RESOLVED, liEXlPECTlElD COMPLETION DATE

{CLASSifY A.S ENGINE.E.RIN'G, DESIGN .•PROCESS, DR. OTHER):

ACTIONS TOoBEACCOMPUSI~IED

OUR.ING INTE.RIM PERIOD, EFF"IECTIVE.DATE.:_~_ .

PIROGRJESS iREVIEW DATE: DATE MATERIAL DUE TO PLAJINT= _ WH~:r ACTIONS ARE TAKING PLACE TO IENSURIETHAT FUTURE SUBMIISSIONS WILL COtNi"ORM TO ,BUllK MlAIER~Al PPAP REQUI~IREMENTS BY THE SAMPLE IPIROMISE

DAlE?

SUPiPlllli1R (AtmHORIZED C'UISTOMEIR IPRJ!)[)UCT

SM]'f'ilAThliRlE)..__ ,(PR.lNT NAMlE)

---,PFtOHE:---iDA1iE:· PiFiONE

_ _

APPiR(JVA!!.S (liS 'neOOed~: ENG_ (S:IGNAruRE),~~~~ -

MATIEIR~.A!L:S ENG" ,(SIGNATIJiRE):_, _~~~~ QUAIJifY

tF'R1NT NAME)._~~_~ ENG_ (SIIGNATlJjREJL_ __ ~_~

(PRINT NAME)' __ ~_~ ----~~-_ API?RDVAIL NUMBJEJl::

----

ImEIRIM

:52
• • 0' ~ .-_., -..... -' ...I.' _,. _ _ __~I
r_ •••• --

iF.I~tl C USIllHUer 's Re~pondlbiljt~es

The custornen planr eonnectien isa sha.red responsibility between rhe org;uJJ]zation su:pp~yil1J.,g:. bulk material and the customer. This connection defines tbe interacticn of specific customer planrprecessing steps with Special Charaeteristicsaad final product attributes of the bWiU;: ~Thll.te:rrn<lit This interactionis es.peciaHy SJ~m;I]fl.caililt when bulk.lmIltenaJ]su]J;dergo chemiealer p~ysjcal traI'lsfom1iat~o]l;(s). Three key CJ@mpQ.ne~ts'of the Cl.IStQm:er PlantConaectien <lire the devdopment of a Customer P>rocessMaltrix (SEE FOlLOMNG EXA.1tIP'LE), deJtem:]][lI,atiolilii Special Characooristics. frem the Custom.er Process Matrix, of and the preparation of a Control Plan which systematically directs eerreetive actions" For bulk materials, conducting the steptiio~t]ined lilllills, "Cusromer Plaer Conneetioa" is highly tecommeaded, t NOTE; U.is not the iDle!li~ur rp'AP ~o comJPfflmis('l ~I'l)prie1aryml!o:~tion_

1i'.14.:2CustomerPlaRt 'Cmlliledion ~ Cladfication

Tile following. is epplicable b) msterials that are transforrnedfi"om bull: (e.g., wet cen 'Of P@l$lit)te final product (e.g., c~ruredpai nt film), This. may Mot be <I!ppl.i.t:aIMe~o bulk materials (i.e, washer t1~~d. a.U em~gi!:le oil, ete.), It: is recognized by tlle orgaoizatiolli that ]t istheir respousibiliry to ddiverlbe product tothe
customer with the characteristics onhe bu]k:material per OIg.arniz;a.~~Oin customer and agreement, The impact of the trandonll'JiatioIi.of bllWlik m.:atenals by the ,cllsto:ro.e:rplO'lnt .on final pmduet a.nrrnbute~ .may be aooouillIted for in ~fie customer's appl!ii:cati@]lJj process. During tine transformaticn from b'-IlLk producrto final product, both bulk product: characteristies and final product altiibliles may be impacted by customer

process controls. 'PAP does no& require a PoooessFMlEA or Co~trol.f]f1[!1 ilDorth:e CIl~sto~eTpr(u;:eSJ;_ Since thep'f{uiu.c"[ is t frequently two products (bu]k and fini shed).tjh_e:.re I:S.lI shared responsibility for~befi[Ja~ pWduct attribute,
FQ]'example, percent solids and viscosity ofa bulk coa~i~,g which impacts the final oOiHltiug's film build a~tribut:e. may be affected by the customer's mix roorn peH:e]]ls~)l\!ent redll.l:~lion. The percent reduction process parameter may therefore, be controlled to aid in ccntrol of film build. The process stepsat CUS;W'I'l'iLer p lants !H<ly be matrixed v,eFSUS the Special Characteristics [determined jioimt]y by the organization and theeustomer), Wl\te:rebi.gh impact is evident, those precess steps m.ay be analyzed by the ProcessfMEA mctbodo[ogyThe Special Cha;racteristics maytJhen be determined, and beiacluded in a Control f]an for the, CllS~Oi[fiet process. These special control charaeterlstic itemsmay be moaitoredand oonUIDIuo1!lsly improved .

.F .14 .•3 Cus.tnmerPla:n·ft OI!lnn!eetioEl. - GiI1ideiLines

The following is a reoommended se,t ofgJll!idelines jinl the cuS,klmer pT<'lIllt wfuen impleme]]ting process

CJ~ntro~s bu lk materials. for l , Assernble cress- funct]Om'li~le-am.g, of customer Include apP.fOp:r:ialte@FgaO]zati.onepresesuatives r 2.. Seleet Ciwmpi Ol1lS for each team -these'<lirelhe engineer, area superviser, ete.),
4. Reviewthe attributes 5.
On

pe.rs>01iIDe] each 'cust:Qn_~:iprocess for each team,

area"

customer process owners (i.e .• chief precess

3" lDefirnecrllitiC;aJ~ustomer kaIldling, ~p:p]icartjol]ste:ps and pro~ess parameters in each area .. c

~1i'ganjzat~on'sDesigfl Matr.ix. and. Design FMEA items fm applicatirm functions which have been dcs]gn<lted. <IS Special Charaereristics, Alsereview the desired final product
for ]~eiIDs. eed]figc.o[[1trl].I . n
<I

fr1;Dm#4. develop

Ust of Special Caaracterisnes aJ~dAttributes.

53

6. 7.

Construct a Customer Precess M.a;lri.ll:., using #3 asthe KiP. aad #5 as the side ef a matrix. Performa Customer Process fNffiA, focl!sing on the b.i.gh impact customer precess areas whicl.lI.impact the Special Charaeterisfics, (Do the .PFMEA per Appendix FJ.

8. Determine Sp~dal Cfuara.cteristi.c-s from the CustomerPlrooes;s. fluid now, gum. distance, etc.). 9.

Matliix.:.md PFMEA (e.g., paint

Prepare a Control Plan foreach affected customer process area- The plan (~tiIi:z!ecurrent Oa.im.lerCh.rys~e:r,FQrd" GM A.PQP gu]d!eHnes)mig:ht eontain at a minimum aU process steps containing Speda~ Charaeteristies, and recm:daU Special Ch~racteristics, bya:ppr@priate means (control

10. Monitor

cham,

eheckl ists, etc.),

l L Easure stabHity of Special Charocter:isHos and contlauously jmprovle where possible.

Special Ch:ll]" &; Attributes

Painl%

reduetion
I

Paint I:luid flow

]

Gun
atQm8!]t

G.!:R
f,aJ1l

Gun

Gun
distance 1

ca:p
;3 2

tnr 2
22,

DirtC];['eck FUm Build Sags

PODPil11!l: Peel

OWl wash bax J,

]

Booth lem.]) 1 1

900th hUmJ.idhy

Bake
temp

3
:1

3 :2

J.
3 .3
2

2 3 3
1 I

2 2-

l
~ 2-

2
2.
]

:3
!.

.3 3 :2 2: 3
l
II

I
I I 1 l

l 3

.~
I 2:
]

54

•
of30 tires ..

-'

An organizati 0]] s.upplying tires shan omn!p~y with the reqllir-em.e]]!ts ·offP'AP.

Trois Appendix ]SI!O be used as glllid;am:,Oe for- darificatlon of requireme,nt5 the authorized OEM custemer representative.

unless etherwise

specified by

Performance testing. based uffi.loTII. design req;ui~remenrl:s used by eaeh OEM b) select Ike construction (technical approval), reducestheneedje repea,t all tests dUf.ing PPAr. Specific I'P,,"P confirmation tests ~re speeified by each OEM.

Ie; ,,2 G'1lII iideUE1Ies for P'AIP' Reg Uli fiem,ents, (Refe!~erlce Secti £1 [lL2 jJ
J

S~lnifican.tr'r,dud~~)nR.u (2.» n Unless otherwise specified by t!h.eOEM, the size of

me producriontun

fOf

'the PPAr parts is a minimum

NOTE I: The' ebove definitioa applies to all uses of''s~gllificamp.ooduotuolJJ rua" wfutillinlPFAP.
NOl'iE :!: The typical deve·.~op.lillf!in.lof a new tire des~~:ninvolvesmul.tipre builds of iii. s~:lf.IU qMal1!liliy of tires, Most designs axe basic to the o:rganiZ<lt]O!lJ'S precess. for the tire ][Id!ustry. ~PAP is tylP~ca.Hy complewd wdh om !1Ilih!!~mold fir molds. and well in ;wv;l!l]ce of castotaer feq1l!'ir-emellts for large vO~lIme

prOOl)ic'l.iol1NOTE 3; "The rpAP fOlr tte tireindustry typically 18 derived from. 1 to 8110ms of tire curing f'romtbe appr;(}ved, pr.oo.uct:i:O!lJprocess as 5.~jf~ediI! the mg,m~zat~:o:~.'·s ,oon:lro~plan. prA:IJis not required fo.r1.td.ditio[Ja~ molds tb<Iftare bmugl1!t on line in the approved production process, An additional molds shall be certified by erganisation's ~~te:rnal cernficadon criteria. 3!1'1d docu me O!UIt i0 r1,

m.e

NOT.E 4: F or tires, tOQ:~i.ng is d!efl.n.ed. s jhe tire meld; Tbi.s deli'in:iltlo[l of~ooH[lg spplies to .a.~~ a uses of "wo~ing" within P.PAP ..

Materia1 Test Resutts (R.e:fef'\euce 2.2.10.1)1

Testing is <Ipplkab~e only to finished tiresaad not eo FaW materials. Tireind[lsrny practice does not require c~emieal, physical. or meiUl[~~:rgjcaJl oostmg. Materialtest resultsare not required forrrAP,

Sp,ec~~.d baraderis:ucs fRdennCle 1.:2.1l..1) C

Tire UH~foriTIiry (foreevariation) and balanee are de-sig[1:ll.ted Special Characteristics,
Grit

Appearanc!e: Ap,r'lIIa~ Re,

I(AAR) (Beferen.ce 2.2.13)

The MR reqJuireme:lllt s notapplieable. i .Ma:st,er Samp,le (see' 1·.2.t5 and. 2:.•2,.')

Master samples. are not retained.

Pro cess Flow Diagrams

See FilP 2.25. AP'

eheckiw.g Aids ('see .2.2.] 6)1

Checking aids are netrequired.

rPM $ubmissio.D \\larr:a,lDt (see 2.1.18:) ,

R.epo[t]1l:Ig mulUple ea vities, molds, lines, etc, on Ole fSW is not required for tires. of

Part Weight (1'la$$,) (Rder'ellce 2.2.1 S.l)

PPAF tires iilFewei.gfue;d to two (2) si~ificant fou~ (4) dedma~8(.xx.xxxx). decimals
(XX.XX)I.

Th~ ,ave.rnge ~s reported On the

rsw

to

G.a Submiissh:nll to CustDmer

R:et,ention/Subm~ssion
erganizafion.

Lervels of Ev~dence t(Referenc~ Seclb:m.--,4_)

Requ.il'le1'lr!l.el1llts: (Re:'e:ren.ce T9ib~e 4..,2)

Re'Cords ofirems submitted (8) and retained {R} are maJ~~taJwneda:t eppropriate Iocanons des~gllaJtedby the

A[l oIgaffi1liza:t]on sll(llplymg~o s:l[:IiJ:sc:ribh:l:g tneek OEMs shan o@mply wit/h. tili\!e requiremeats J]] this Appe:[!)dix or use guidance herein for clarification of p'r AI. Toe requiremeets ~rnthis Appendix are

minimums and may be :s~pp].emei.ltedat&e discretion ,of tbe '@F-gll[l]zalt~@lnand!for eustomer, the Ap'pUe:ability
•

(seePege I)
[We

The foUowing additienal reqairemems

<lidded:
ill

The' Customer has the right to request compm!Lent

PP Ar at any time to re..quali.i)' a production

Feature BasePrecess or Part N1:l!mber Generated compOW6:nlt;s1.tJit'i r,'AP' qualified using the highest eontent configuration to' qual i.:fy the master P'8!rt: umber, AU other configumtion:s.may n be approved with the submissiQIl ofaPSW link:img,(be Jflewpart number with the ma;swer part
Humber. f 0:1 bulk mll.teTial and standard cataJog pans'j the Qrg~n izatiO<[!J sl1aU formaUy q~aJi.fy the]F product totaeir desigareeord and submit aPSW when requested by the customer;
ltlll 0

Sig,n~fi(;ant Prod~etiolil!

(see 2.1)

It isimportant that adequaee quantities of pans be manulaemred dll1nng this mn to confirm tibequai.ity <lind clIp13Jbi]iry of production pmcess at: rate prier to full preduction. U is recog.z~dthal in low volume app]icaJtkD~S,.sample sizes as small as 3,0pieces may be ll~inzed forpreliminary prooess capalb~]if1y studies. When perform ing the S~glliflc:;i!m Production Run. sholLl]d be considered and tested wherepracticsble, related issuesidentified within the PFMEA.

am .a:s.pec:ts of '\{,aTI<'lIbmuywldliin me

the production process e_g., &et~upvariability or osher potential process

Sample sizes m~~$tbe discussed and agreed (0 early in APQPprocess. UpIOjected volumes <lire low SIO that 30 samples <Ire no,t attainable p.ri.o:rto pT(lductiol],i~terinl rpAP' approv.al may be granted. A dimensional report witih I00% inspection On special eharacteristiesis required dillri.ng theinterim period"

Oaeetbe 30 consecutive prodnenon samples Me produced, measured accepted, then the interim appl1Qvalis changed to approved_ llimel!l.siional. ResuUs, (see 2..2.9)

and tlIe q'1U'JUty index. cakulab':d and

The Oi[-,ganizat~.ollshan snbmit, as part oHhe r.p'A._[) palicl:age,. a copy of the d:mw.ing w~flh each dimension,

test. and er s'pedfl.caJUon Identlfied w~tIDi aunique number. These WiD.iql1.le numbers shall be e,noored on~~J'llle dimensional or test results sheet asap:p~kable> and actual resultseatered onto the appropriate sheets. The o'[_g1l!nizati.o!1 shal] abo identi.fy tifue print zone [OF each. D.lIJImbered chM<I!creT.ist]c1l;5, <I!ppi icable,

57

.,-

-_

.... -- - - - . - -- -

M.a.lerial1' est (see 2 .2. 11. 0

TtJteoi.rg3lillil~za:t±on shal! also 8UlJrym:it a oomp:leted Design Verificart:ion 1'1<1[\ liJjd Report tlat summarizes H appropriateperfonnance ~lld5:lncti.ona~ test results.

QuaUty Indices (see 2.2 .JJ .2)1

\Vhen the c'W!stOl:nev .spec~fiesspecial chta:r.3!cte:rist~csaJ~d tlle ,eshillatied armual usage is less than ,5 00 pieces, the organizatio» sball dOC1UTJJliellli in their eontrol plan that they willeither: • perform] OO%inspe>c:ti.on and reeord the results

or ,. conduct an ]liLiUalprocess cap~bi~]ty swdy wiuha. m[[IJ.[m.1ll:m 30 producti.on pieces end maintain of SPC connol charts of the characte'Fjstics during production,

F Olf s:pecruOlJ] characteristics thateaa be studied using variables dat~>the o[ggiza,t~():IIlishall unlize oneef the following techniquesto study the slabiUtyof the process:

..

X~Bar and R Ch3i[1!S,0.=5. plot m~~im1a!m6

SUbgr01rupS.

_, Individual X ~ Mov]mgRamige, plot liiIDiil.nlnr~m3,0 data points

When. performingthe initial precess study > data. shaU be plotted nom. eonseeutive paris taken from the pwiJl!udion trial mil. These studies couh!. be augrneated OiI replaced by ]Qng~termres.ults from the same or

simUar process run on the same equipment wifh prior customer concurrence. Muster Sample (see 2.2,.15)'

The mask', sl:Iil'Wlpl sfulal~be retai ned afiler PPAP approval whecmls'f,leci ~,ed by the customer. e

Part S'UlJ)l1riliss~,w \Varr:a.~U (see 2.2.18)' When specified by jhe custemer, orgasuzations shall use the Truck liil~;b.l!stryPSW (see the Truck Industry
PSWf
Orin

thatfollows),

Part \Veilg,b.t fmass) (see 2:..2,.18.1)

The orgaaizadonmay record the part. wdgh~ of tnJepart submitted. 0:0 the PSW measured and expressed in kilograms m four significant fl:gures '(e.g., IOOOKg., lOO.OlK_;g. lO.OOKg. :and I.OOOKg) unless otheswise specified by the customer. To deternsiae plllli weight. the m-ga:nirnti.on snaUindiv]d!ually weigh [en raadomly selected parts. amd ca[c'l.li~a.wnd r,epmt the average wejpt. At ]eas,toIl.e part shall be merurillred a from each eaviry, too~>line, or ~n'Ocess used in prodect realizatien,

Custemer NodfkatiJ~R (see 3.l)

De o["g~[![iza.tion s~aU notify ~e customer ef a:.n:y phm!o!edd'es·ip :aIlidprocess changes. ne customer may su])sequ.enUy elect to require a subrnission fOFPr AI' approval. Org"nizat~Oins sUiPp~yi[![g to SUihSlcEibing
truck .oEMs are Ie'1lnire~to complete ehe Preduct Process C~an;ge notification fOml~~)advise of

fonliLoom:ing process orproprietaryprodact

cilla:!l~es-

58
•.• , .... ~_.I.I •• ··•-_. ~--.. ••• _, ...... -----•••• ••• -.-.... , ,--

eompl'ctiQn 'Of 'the Part Submission Warr,ant.

PART INFORJ\'IATION I. Pan Name: Engineeringreleased 2. fimisbed end irternll art. name. p enditem part nl!]~ber.

Customer Part Numbb{s}: E~gineedngre]easedflni$bed

3_
4"

PS!!itRev ision Levd:ihpp~icab]eTool. Purchase Order Numbe[:

if applicable,
[)'<ite,:

:5.
6. 7. 8_ 9.

Enghileedfig

Dr,;'J,wiog eb~nge Level & Appwval.

Show change leve] and dai.oofor submlssion. and

Additional Englneerlng Changes:bldydeaH authorized engineering cb<l[ru!W decumests approval dates not yetincorporated on the draw:ing but wh ich are iaeorporated inthe part. Shown on Drawing submitted.
Part weight

Number:

The design reeordthat

Q~!

specifies the cllst:omJerpart

the purebase order,
fOiI

]]u.m1oer being

Purchase Order N umber:

~n~ie;[the

Enter th is number as found

]E1 k]]OgrnMSliQ

actual weiglJit

[rim significant p]<Ioesdimensional inspection,

lO. Checking Aid Number: Earuterhe eheeking aid number, if one is used t and
] I. ]2. lts ~ngineering Change Level and Approva] .Date. Orpniz:'uion purchase order ..
WEIS

ORGANIZATION

1\,:1lANUF.A!CTUlUl'lG INfORMATIO Name and Code: Show the eodc ruls]gnedto

ihe manutacturing

b::ati.(m on the

] 3. Orga[llzam:lOJiili Manu fa.cru.ring Address: Show tJae: complete address of the .loc;1.I,t[on where theproduct
manufactured.
Or

SlTIIJNnSS~ON~.NFIORI\1iA 1'ION

14. Customer NamefDlvision: Show U'1ecorporate name arid division

'15_ Contact Name: Enter the l.mn1,e of your customer eoutact,

eperationsgtoup,
etc.

1.6" Appl ication: Enrer l:fuemodel year, vehicle name. Or engine, transmission, l1,

ChBCkthe appropriate box 00 indicate Snbsrances of ConcemtISO marking reporting.

REASON FOR SLTBl\iHSSION

1,8, Check the appropriate box, Add explanatory detail.s in the "other" section.

REOlJEST.~O SlfB.M""ESSION LE''El. 19.. Id!entify the sUOro.iSSlOIDIevel requested by your cusiomer. l
requested, DECLARATION

Check the submissicn ]tems if a level 4 is

20.. Exp]anatlm:a!Conm:lent:s: Prov ide any explan:.uory details om the; submission ]'esu]ts ;additk:rtm! Inforrm:aUon D1;3!Ye attad.lod as apprQpri<lte_ b 21. Enter t(he u1llImber or eede tJ1llia,t ~deIDtifie"sthe specific mo.~d, cavity, aiirnd/or production precess used ~D manufacmre the semple parts. 22. The respong~ble supplier officia.1. afl:e:1iverifying ~hat the res"WID[show confonnance [0 an eustorne» s reqjuirenlJJenrnlIm:d that a]l required documentafica ]8 available. shall. appreve the declarsden and
provide l'ide,Phone Nlllmber. Email Address, <lnd fax. NlLI![i]!1.be[·. FOR, CUSTiO!\.'lEIt. USti: ONt Y: Leave blank.

59

Part. Subm:issiofl Wan"ant

'Tool PG l'b!1!;.sr __

__,Q)._;_.'._. .

Engi~

O-.ii'ig ()~;j,I.t!<d

__;~~~

(5"'\..• .

Ih'IBd

__ ~-""""'0) ...... ~:''''' .. ·

___ B:...~~~.L·. ••• E~~

__~--~,~~6~··~.---------------~~----n~~-~ ~ (7) (9)

Pur,cfnase.Ord:erND. W.eig'M [lkgj
.

Change Lavel. :SUElMISSION

.::.A~11..1l· •.;". •

031£!d _~

__

IIH:FOru.tATT.ONI

O!W'Lf1iUliO~ f\!ljrT!~ ~!"!d CQ(!e

Customer

~I!IoOO

OlllStomer COOtact

~Ion

®
~QH

Dyes

o D o o

fO'R SUaMISiSiION r~1Ei1 S~bmis5ian

E;~I~~)

(~~k.

~ I~a$tolilt!')

D DO

~,to,

O~

Goo;;iJ1jJJ;;~OO

or Mat!3ilial

Ooo-ectlan d Dr3CIBpGOOl' T~I!~"~·lye~r

o o

:ilyb-Sy~ O!l' M(I'!e~ Source ~"Se Q~ 1~ p.aIi i?roc.;;$'Slng

p<!~.

p,!§!'w~

al A.ddiOOmII

!l.OC<!t!oo

Otht?l,~~~~if:!'-I;Ie!Dw

~ ~~

2 • J,'If~nt

Wiln

lMQduc.lsamples ~nd Ilml~1 ~u~~ng 8I1d ~t9

data srubmflted ~Q cusmmar,

9 - WlIII1'8ntMih podUGI =pl£<s

~upporur'1gdata w\lmi:it9d iii

to GU'5\J;!r:Mf.

(chectO;) Uwi?l :!i - Wa!T~

D .DD 10D 0 DODO

1M!ll prWitil ~il!m~~. and 0I;m~.~

:2

4.

:5

Il

910
~~

DOD
~~

11

12 ·13 14
;.'!!

0 01.00 0 0
~i~ no flPer~ljJn~ ravi8Tll'_
al:~

15 HI 17

18

19

$yppW$,m~n~~duri!'!!:lIOC<'iliO!'l,

~eCbAA;i!!,TI!QNI

ilafllrm·II1!8IIbe s,am;:!le!s.~l3IihId dr:avoingl; and ~roea1iorilS protlLI!C5!):n pr.;<;e~. ~d I arse ~

Ir; (!lis; ~
~fe ,"~~.fI:'Om ,~~ 1m documented at

;jr·e~i,..-e¢l_·~.atJlI male_
1M}

~~,~~()tlie is an file and! av<IialtilBD

~~er 1I103J!l1he, ~l

r'E\gIiIar IlfOOUMB too4i!ig din

e'MBOOB of 5-IJjjh complii!ooS

(ii')

Ol'fl~nlzalJooAuthofiz.ed,~ru[B,;_,

--,,"®_· ... ~ :"".

PhDI'I8 Nh, _ ~~i! ~~~~ ~~~

_
FaJ(

O'Jle

~""--iI1

-iI
~ ~

I'ot!;):!;!"

CI!IIS.TOMSR.

O5lE: ONLY

DAppf'rl"\!Ed

DR~
Data_
I

Dlmlmm~1

Prlnt~B MafiCI'! 2000

THE·l001

I I

60

TIUct; lndus1Iy
_____________

Part SUlbmission W,anrant

CUstomerPari Nw;rtber

___________

Rav.

Ei.ee~1ng i)r;;rhll1ng ChallQlll.i!!l\'~'I _ _______ ~ ~ !P'un:rn:s:e Order No. ___________________ SI!iBMISSf.ON INFORMATlOiN

Dllbsd ' Elated

_ _

W.~(kllI
~t~ __

Customer iNamelDi'li8iDJl

dm;10meli Contact

DN'o REASON! FOR SUBMISSION

o o

(cll;o!:ik il!1Ig.l!l;t QIf!!;')

I!!ilial :Sllbmill~ =~gi~~9IC~~s, fcdl!lfl: TraJSfer, Replecernen!, Cooac1ian of rusc;rep81lC)' T~I Imaelhtl ~ llian 1 ~r RaMbishmcnt. ~diLiOlIII!l

I
,

D D

o o
o
o o

Gnanll9

to Op.1iofla! 'C;onsirLittioo
proce9Blng

01 M'a~aiial

Sub-SuPPlier or fI'la~11 Ctlange In ~rt Parts Prod(jtaD

Souree CI1~nge

at A;:kiliollEi'l LDCattoo

othar - p!Eas8 spg;;fify below

SUBMU,SIO,N IL5\i'E:L, '[Che~~ O~;~

o o o

L.c,,~ 1 • W~fI'IInt only [and for des{gneb3i:l 8pps3l13Il1;lit ~8ms; an ~ranc~

Le!.'!!'J

~'!<')!

i'l~~

~bmii~>iJ

'Ib ¢uSlom(l1\'.

2 - Warrant ,'lith produ!::t sampj~s am! !imil(:;i! wppo:of.-.g ~n.:! !Xim~e

~~

t.Uibml~ed ID ~U!j=er,

leve1 3 - War;ranll"ith PHldu:.;;t ~~ lC'>'c14 - W;c;~t

!Wpporillf"l1l dataaubmated to customer.

and Qltoelr requirements as d9flned by customer,

~DDDDDDDDDDDDDDDDDDD
Level 5 . Warrarn ."ojh produ<:l ~p!es
~i'i~

'1

of

is

S9

III 1-1

12 '13, 1,4 15 '16 11 18 19

mamlfactwWig Iooaiion.

~plel'!!

8~rting

data fll,,1sYted a~ BIqlIlar's

CECI..ARAlilON ! ,~!lin[il ~ plOlb:tiom Ihe semplas re;pi!eS£fliEll!l by 'lt1i811!'8rrili1~ arc ~pr,~(;'!'iI~io;e, ,and ,ilr", ~ 'froM,
$~i~

(!II' OIiJrPIlI't$, , ~oo

h~e been made to !M spp\ol:aMs 009'tomer toolilljj \..tth no ape-Ja1.ions,oihBr ~'J,;a., 't!tM rB1Jul~f'

df:8Yilng~ ,and specift:aiians prncess.

,matemEils,00 regular prodLdkm e\i'ldence of soclTJ ~p

I <!1M'ooiili~ Ittm ~~mell1ed

IaIlOS is an flIe and av-ajral;il~ klr mviow,

Organization

AIllh~e>(!

$lfl~lUre::.

~~

l)ate

-1

'Pdim IN811M TrtlB

Phone No.
5-i'n~il

Fa~__ -------~

"'PAP W3lIT'8nt o"spasib;;Xi;

o D

APPfCl\'-edI Inte!'d!111 A.P~'r.!1

0 fIi~eDte!iI

f'OR CWiSitiM

EIfI USE: ONL'I"

Comment:

Pr1ntName' M~fCft ;JOGS

6]

I.
2,

To: Customer
Customer:

O()illll~ct name,

Customer n<"liim!e.

3 4. 5:.
,6.

Org:amb':a:Uon Pert Number: The salable part mlumber to undergoa product or process c~ange. E:n_gi]J!eerin.g Roevisio~ Level: The Org<lnizatio<n,dial'!N~q revision le-.... and. date, e]
Customer Engineering Part NUimJher:
CI!i:!llome'F

part number (if <lIppliceble).

Rev]s]onLeve]:

Tfue Customer drawing revision level and. date.

r.
8. 9.

Purehase Order N~!nnber:Customer's Purehase Order Dumber.

Appli.cati.oin: Ente<1F the model y,ear. vehiele name, or engine, transmissioa, etc, Safety and Olf gov,ernm.e]]Jt: :regJ.ll]a!ticUl.:Does component as-sodaJt.ed? (Yes I No). .INF'ORMlAnON have sll.fe,ty a:!1dfOf governmenc r,e:gllliatioml

ORGANlfZA.'fJON MANUFACTURING

10" Name; ]npn~ t:heMme andaddress of the oompany thatis/wi U manufacture the component

l 1. Code: Customerassigned
12. [4. U5. .~6"

nUn:lber fO:l: orga.n.lzation sel Ung the (;om!ponernt.

CugrorniLerP~a:Ilt(s)a:ffected:Ust Design Responsibility; Expec:ledP'PAP

customer plants where product is used.

13" Change Type: Check all the properties that marybe affected by the cbange. Check iftbe oF~a[li.zation Or Customer has d!esig[l respon:si.biUry .. wi U haJve O:rgarni:z;ation Chang.e TI~at May AWed End Item: Check eppl lcable boxes for .aprodm::t change . CompletioIlllS1!1bm]ssionDlI;1!:e: s,timate the date that the Organizeriea E

fheirinternal qualiflcatkms oomplere. ~. . .D:em.ikdDescnplimlJ (If Change: Specific information describing 7

er process change .. ]8. Phtilllned lmplementatiea

the Orgau]zatiom/s product change

rh'lit.e: lllpu~ planned date to be ~n pWducliQn with ehe change. the

O!E,CI..ARATION

] 9" Expla]lJ1lJtionJCQmlI!e[lts:~ndude
20.

lIny additiQnal. exp,1<1l:lationor comments here.

and slJbm~t:lin:g rpCN.,

Name: N anile of person agreeing with ~fu:e' deelaration

2~ " Title: Business tiUe ofthe personsigJ!lin,g the declaration. 22. Business Phone number; TeJephoil)e DUITlbe:i whereperson sigrung the decleranen csn bereacbed,
23. 24. 25. Business Fax m!illm~be!i: Faxnlilllmoe:r of the per;SQD s~gni]]g the deelarafion, Email address:.E~.ma]l address of'jhe person s~gllj]lJcg(Jfiedeelaratica, Dale; Date thePPCN ~sSiigned, clarification is

Ot'her required ttlt=numbeJ'ed document in.f().nl'~(lt.i'o.l2 should be self--.fu"ltpla~atory_ Iffurther necessary, please contact your ,c!~tomef" r-epr-(tSrmta#ve.

62
~ - - _. ~ - _ ... - . .. ..
,

__

• .,...

_.

••

_-

_.

--

-_.

--_

•••

'''---,.

Complete this form .m!! email fp j,l'(Wf CiIS!ofrnlr ,organizatilm whenever Ci1s.~ome,rtIDtmoa,~f()rr is r-equjred by the PPAP Manum in' Tallie' 3" 1. V:our cuS1Mie( wm~'sporr.r1 Meli: m~1l an ,acknowledgement ami may '9q~!ist .uJdilionaS change
ckiriffc-atkm' orlPPAIP' s!!l'bmis;sfQn ,Il8qailfl&m8Jlls_

io:
0I9af'lizatioiil Pari N'u:mber:

CustoriTl,er Pan MUFIloor:

---==,..,0 ...
5

(3)

o
"""-" _ _ -

0)

Appli'catiQn:

_,:0~1I .. ..·~·
-->®-l O""-.>-,
I

'ORGAIN iZATIO;N1 MIANUfACilU RING INro:I1tMA:TJI~ON

~allN:~;
Str1e:et Address,:

Code:

~~~1~1_.

Cily,

St.ale &, Zip:

®
o
1~)Clpecwdl p'PAJP CO\l!Ilipl{llJjo,1Il1,Sl.lbmislSiol'l Da~e:

®
Organization

D D

'ChallIge ly,pe (cneD'kall that apply) lDirmen<slona! Materials

'F'uocti:OIilf31

Appearaf1loe

®;:,,·~.'6;;;...· .

..

~_

~Ei AILED D:E::S:CIRIPTION OF PiR!()[)lJ!Crl,PRQC,~SS, CHANGE:

Pil!l!f1l'1!!d Date of ~'rI1lpI8m~l'Itatiol'l: DEiClARA r~ON: II h.e~,ebycemrytmtrepre6en~alive

where a,pprQpriale,klr

sa!'l1!ple<S \'Ioill be manUiract\! red ~$il'llgl~he revised prodUct andiio:r prooess and v~;ijtiedl. dimell1lsiomlll chaliilge. appearance (m~lIiiIge. physl'cal propelity chan:g€<,~unotiQn811!f rm

peliformance

andl dur.ibDtty.11 ato

ce'Jtify 1l1atdQiCUrn ented evid'~I111~~

or :such

oom~lianoo

is oniire

and' ava~IO!ible, for

ElI~JlSII;N1ESS PHO~E E~MAilL:

INJO:

._~~~®~22"", •• _~~~ ----®_:,,24-·~~~~~~~~ OAJE:~ __~_~~C§)~25~.·~.

b.··. ~~~ _

IIFAX N@: ._~~__;~::..~-~ ~I

__

~_~_

THE-1002

63

Con:tpfete Bl'is fQIiman.d emOlilliO }'Our cU$/omer o.rgarozatiO'll iI'L!.a~.ualin Tab'e 3., 1. YOfurrc~stOiine! respotl'diback w.llh c.larific-olWn or PPAP $Ubmis.sio~ mquire,i'l'J'€Jits.

wit,

wfjl1tll!;l'illW ClJ.. J,om~fffl;)tfflcalroni~ 'equi~d s 01'1'1

:O¥ the PPAP .ac1-ti)()wJ'edgement and m.eYI'7eQ'uestadditifmaJ ch8n~

IOU$lorn~r P"ut Num~r:

I

'Purchase Order INilllmoor.

liNarne:~~~---------------Street Address: ~~~~

City., State

&. Zip:

o o
D Customer D
OrgaimizaiHon

'Chiillilg;e

iype

(chEid all that a,pp~ly)

Desigli1ll R.espollsiblU.'ty:

D D

DimenStofial1 MareriarcS
iFUII1Qjjio:nal

APlpearranoo

InEf;lA~ON;

I mer,eby certify ~hat ,reprresent.alive5ampl~s, Will be manu(aotured u5'lng !I'I~ ~evii5ed product andJ'or process and vermed, where apPMpriale, ror dlmens.10na~ cmngra. appwranc~ dhange, physi:cal propoe~ change,. IUllcliooally lOF pe:rron:rumDe 81ii1[11 urab~ity_ ;13150 certify !hat. d\)oomei'ill~ d evidence ,oj' SiUolfil oompliai'liOO is oi'lfile and avat'abl~ for olls!ome~ rell/tew.

iITLE: .

DATE: ~

~~

Mar'on

2006·

THE-1002

I ......

------~

....

__ •• ,

••.• ,.,,

•• _

•• _.-

,GLOSSARY
A.CCREIDITlE.o

is, one that has been reviewed and approved by a ru,uionall.yalternative, a customer recognized accredisation body, cornf()f!ning to ISOllEe Guide 58 for c~libra~lon OF~eS;l.Ia!borntory aocredrta:lim to ]SOllEe 17025, or national eqnivalerr;
LABORJ\liORY

recognized accreditation body or,

~S:8:]]j

A:CTIVE PART is one currently being sW!pphed (0 the customer for or.igl[]l.<l] equiprneruet
applications,

service

The part .rema]rnn,sOJ:c,tive ntil tooUngSlcrap aUltholjization is given lily th.. aiPPIOpnare u e custom~.r aotivlty.for p~ with no cestomes-owned ®Oo]illg Of sifuati(m:swil.ere multiple pads are maJde fm'm the same tool, written oollfinna!t]on frtDm toe customer PlIrcihasln.g a.ctiv]tyis requiredlo (k~a(;tiva~e a p~rt. NOTE: For bulk Inate:ria], "aetive pil'Iril." refers to the bl!1!]k material contr.ac:~tHl, not the parts that are $ubse{Jjuemltly produced from tbat maooriiat
APPEARANCE ITEl\-~. is a product that is vis~ble, once the vehich~:is, comple,ted. Certain euseomers will ~dej}~ify ~p.pearnfice items onthe engineering d!rawi]~gg, In these cases, spec ial approval for appearance (co,1o]", grain. texture, etc.) is required prior tio produG~ki<rlpari: suhmission.

APPROVED ]8 used in PPAr ro mea]il~hat the parts, lIIa~eF.ials. <lndiGr related documentation (or records submitted to, ()iI" reviewed by, Ule customer) mee~ an custom.er rl?Q!uinm:Jeot<;,After approval or interim
approval, the o.r,gallizatien is apt:hOT.ized to ship product as d irected by Ute customer. DR1\. WINGi:s,an AP'PROVED

'etnginee:ring cl:ra.w]]JJg :sigmed by the engineer and released through the either byindl.llSl[')' standard specifications (e.g .• SAB,

custemer's system.
APf'ROVI1:U MATERIALS <Ire materials gevemed ASTh1. DIN". mSO) or by customer specificetions.

APPROVED

SOURIC!E· LIST isa Jist of the orgenizatiens and suppliersthat

have been found to be

<Icoeptab]e to the customer. Ut~]iz~ng prodiU£ttlrom an approved

supplier does not rei ieve the organization

of .respo]'JJs~bHiryfor the qUaJhty of [hal product, A.1'TRIBUT.E DATA are qualitasive data thal call be counted for recording and analysis, Examples
inelade tile pre,selm:c:e absence of a required label. the wFlsla~.rualiQIliof <1]1equ ired fasteners, or r AUl'HOIUZED

ClfS'TOMIER

R1EPRESEN1'A

T1VE(8}

is the individual. or mdivideals

having

appr,(D'vaJ~ aulhor:l.ty en behalf of the customer. NOTE: The customer's process s~ouid ~de:~tifythe app[l)Va~auUtor:ity.
l,lI.LACKBOX refers ~o a part (e.g., ami<ISSie~b1y, electric-a] device, mechaaical device, orccetrol modnle) where design responsihility m;.longs ttl the otgaliitUa:ti.m1J orjhe s1Jl!pp~]er ..Black Box requirements are g;elI!le:r:aUy limited to those eha!DcwristiCsJj[ern_g [equired for customer interface eonneetions :arid
verifieation effunctional mea![l~ll'Ig. reqlLllrurements. ~'O.D.D." (OlJlts]de .oes~gn and Development] has the

equivalent

BULK MATERIAL

is a substance (e.g, non-dGcl1isioo.al solid, ~lquid.gas} such as adbesives, sealanrs, chemk<l~s. eoetingsfabrics, hibricants. etc. A bulk material may becomeprcduction material. if issu eel a customer pmdllction pm F:llu!ilJibersee P~ODUCT10N IviATERlAI.). ( BULK MATEIUAI.S
CAD/CAlvIMATH
responsible

R_E:.QumEl\ImNl'S
F).
Oil

CH!E'CKLIST

defines the

customer prAf' requirements

information necessary

for
to

bulk. liuilleriiJ<lt (see Appeadix

DATA is

form of design record by whlchall convey results of d imensional

dimensioaal inspection.

define a 'pr-.oductis conveyed

for obtaining

dedronicalWy

_ Vi.Jben th~s desi,~. record is used. the org,lli1ilzatloJili is

a drawingto

65

- _~I·· - _.•• , . - - - ._., ,. - _.- --

---

CAUBRA TION is a set of operatieres which compares values taken froma pieCleof ~ nspection, measuring ilInd.test eqUlipme[U;t 0]" a ~.ge to a known standard under specifi.ed conditions. ,CAPABILITY is fhe total. ram1JigE; ofim:erent varietionina ()Qintr'ot reference manu',) st~b~fl rocess. (see tile Sta.tisticilil. Pmeess p
resu]t;s. recorded
by the

CHECKED PRlN'Ti:s a released mg~neerin.g dnlwi:o:g with <licllhiaJ easurement m organiza:Uon adjac-ent to each dmwlllg dimeasiou and otber rcqui:rem.ents.

CONF'ORl'dANCE
CONTROL

meensthat the part or materiaW meets tll1Le customer's speciflcariensand

requiremeets,

- see g-TATISTICAIL CONTROl._ CHARTS - see the Stli!ti:st~ea~Preeess OJlHtt"oi reference m;;l~u;3!l

CONTROL CONTROL
materials

and p:[iocesse:s,. Theyare writl:el1L by ovga:nizationsto address tbe important characteristics and eWtlgi:neel'iirog ooqJulrlemenLs of theprcdacr, Each p'8!ril must have a Control Plan, but in rrII!l!ly cases, "':fum~ly"ContrQ] Plans can <1\pplylD a number of paets p.WdliDOO using <lIoommcm. prooe:s,s." Refer fLO AJdivanCledl Pf'odillJl,ctQUaJUty Plagging and '€)i1ifth'i(!l1 rlag reference maJiJllHII, ISOffS 16949. and

PLANS are written descr~phons of the system. for OO[]jtrol~~ng pf\oducUon parts or bulk

c1!J!st:om,eT~s.pedfiic requieernests,
'CUSI"OM.ER is the recipient oHhe otrg::l]"1]z<'ltion's supplier's m produc-t
Or

service,

DES:~GN~.IN'F.EN[)ED .ROBUS1r RANG,E are limitswithin lj,\'lliicD.perameters may be aHo\.ved to vary while .stUl ensuring iliat a product complies with fitness for use l1equirements • .DESIGN RE OORD is. the part. drawi~g. spec:ificalions.,mdJQ'i eleettonic {CA Dc} data used to
~nfQfI]lati:~ln necessary ~opro[htl:oe a pwdlJlct.
ICQ]1!vey

.MODE AN.D EFlF.ECM'S ANALYSIS (FMIl:A) is a systemJahc group of activities intended 10: end evaloalle the polel]l~alf<l~h.lirie <I pmduct/process of <lind effects of that failure, (bJI the identify actiens that could elimiaate Of reduce dIe chance of me poie:nUa]faU~r·eoccurring. and (c) doc1ll!mle-nm entire process, It is cOlTlplemen~ry to the process of defin ing what 11. desi gn or process ~he must do to satisfy the customer, Refer to Potentwal F;i1JHun::Modes a nd Effec:ts A 0 ;)j~ysiis,eferenee r
FAlLURE
(a) recognize

ma[iLua~. OOTM.LPROCESS
LAIORA

STUDY - see the 8ta.Iiii:sti:i~a.l.·P·F~c;essCOlIlt[\III~. reference maeual.

metallurgical, dimensional, pbysi.ca.I .•

TORY ls a lest f~e~]ity that H1:3Jjf inelndechemical, electrical, Fe liab.i1ity testing Of rest valida:t]on..
.,
.,

LAlJORA TORY S:COPE is. qua]ity reeord oOif.lita[fiin.g~he f{)UoW'ing:

tiliu:e specific tests, e'Va]~adons and leaJ~~brati©'I]san organ~zatio]"JJ' 8 ~aboratoi'Yhas the :abilily~!nd
o{)imp~tellCy to' perform
ill ~istof the equ~pm.e](t which It useste pe:rf:ornn.the above a list of tillle methods and sta.. dards ~owhich it per:ITo"rms the above. n

l"tIA.RKED PRINT· is an en:ghweenBg dJrawing ~di fied.signed, and! dated by the custemes e:nguFlee:r (the engLIl.eenng change m,llind;u~:r beinelnded], must ORGANIZATIONS a:rep!'QvideiiS 'of: <li) roductio.n materials, b) prodaetien or servi.©eparlS, c) p assembl ies, OF d) heat treating, '!.'\fe]d:ing, aJmtill:g, pLating O[ other finishing services, d irecUy 00 till!;'! p OEM or other customers requiring this docW!m~llt PART SUB-MISSIONW A!FI:RA_NT I(f'S\1V) is <Inind:lill!stry~s.tand,ndoenment required fOJ aU newlyd tooled or revised prndaetsi» ltvhid the organization confirms tbatinspeceices and tests on production p~ sho'l;\" conformance to customer requireraeets.

66

_. ,_. ,•••••••

_.••• -

- _.

I-

••• -

I~

--

••

PEJiUSJIIAml.E

TOOLS ar,e drill bits, cutters, ~nserns,e:tc.used to produce a prodnct and which are inputs into outputs,

consumed ill the process, P'ROCESS is a 8e,'I; f ]~le.rr>elalt:ed iO:llernc'li:ng actwvi:t]es wihlkh traasfomrs o Or PROCESS

FLOW DIAGRAI\f is a.schematic representarion ofthe p.moessf[oll.\I'.

NOTE 1: For PPAP,. the process flow d~~gram should focus npon the maaufacturiag proc~ss, including rework and. repair . NOTEl:Processfl!Ow

diagrams can apply mMily aspect. 'of me business.

is the manil1fac~ri.ng lecation w~~fuJwn U~ep.roduJCtionshe WhlCb includes the pmducUoll tooLing" gagh1Jg,process.neaterials, '()per;a:~ors. environment, and p'rooe:ss settings" e.g., feeds~speed:s. cycle times, pressures, h;Jmp(:rcaJmes"quoted line rate. E:l]VirOflLm.eflf is defined as all of theprocess cOlldlltlOJi'liS s'-luToilinndl~. Or affediflg UIDemal1~faclJ.uJre.1iill].d quality of a pm or product Bnvireement wiH va:ry f'OI eachsile, but ge:l];e:roJUy includes: bousekeep]ng~ Ugh.ling, E1Ci'lSe, HV AC •. IESB controls, and s:a,fe~ hazards relating to lho1l1ook!eep.ing. rRODUCl'lON MlAT.ERI.AL 1:8 material Whl~ hM beenissaed a productieu part number by m~ shipped directlytn theeustomer,

PR01lVCnON E~VIRONM.ENT

customer aud

]5

PROnUC .. ONPAR.T is marusfacteeed at the productioa site I:ilsi.ng the producnan tooLing.gagjng. n process, marerials, operators, env]oonmet'llt,flmdproces8 settings, e.g., feedslspeedslcyde ti!11eslpressuresJtel'ij,pera;tul1e~L
P.R.oDUCTIONPART APPROVAL SUBMISSION is based on specified quantities of production parts 0;[ prodnctioa mat.e:nabtakl!io from tie s~gflmcal'l&pmduc:UoliDJ run made '!-'1 ]lDprodiuctriml tooling, processes, and cyde times. These parts or materials ~5IJ)IDbm[lil::ed production part approvat are to be for verified by the organizadon as meetingall specified requirements from 'the design record,
i

PR:OnUCTION RATE is the agreed t!P~llI number.ofpfI!liil.s.produced]]1 aplaaned time period bJ meet eustomer assembly Of!11a!I1J;li'otctu:r.i[!g plant prodaetion volume requiremeets - with consideration of other product m~x and machineavailability,

NO'l'E: The agreed predueuon rnte is. typlicaHy sped fled in the purchase agreement,
Q UAUl'fYINDIC['S are measures of caJpabiifuty or perfom1ancei"o1i eitherproduct Cpk~r Ppk> S~ U'leSb~tist:i:calrro~es:s(:![Iinh'l(!ll refe:rence m!'lntl~],
Of

.'

process, such as

QUALlfyrLANNING isa s~cttlrod precess for defiflJ~o.,gtae methods (e.g., measnrements, test~.)tha~ WIUbe used in the production of a specific prodiuct or film iLy of'products (e.g., parts. materials). Q1il~~ty i p]aJlm ing embodies the, ~(m:ce1pls of defect prevention <lind eentinual im.pfov,e:ment as eontrastedwith defect detection 1~:fIee dwute!ill Produd 'Quality PJaJ!!ning and CllIlntrl!ll Plain refereuce manual), A 'QUAL1TY RECORD ~sa document stl.ting resu]t:s achieved or providi:!1ig evideIl©e of activities performed.,. e"g., test results, internal audit results, caUbraJl:io~ data,
RiEGULAR.P'ROOOCnON produ.c~ionprl)dl!Jct customer andOi.!:g,<llllli.~ti.Oi.rL SIGNIFil.C.ANT paODUCTION IUJN - seerrAP, 2.·~. TOOLING

is,the toeling with wl]id:l the

([ID1.I~ufad{Jf,eIintends

~iO produce

SALEABLE PROOOCl' I.,AR 'f ,.refers to the prodli.lcllp~rtspecified

00

me eentraet between the

SI.TEis: alocatien at wfu~ch'llaIIle-added manufa.cru.ring processes: Qoc~r"

67

..
... _ I ._, -, .., • ---"" ... _.-

SPECIAL CHAJtACT~R.Is;,'f~CS <Ire pFOO1Uc:t chaeacteristics or manefacturing pmcessparameters wbich can affect safely at ,oompUaJi1cew~tfu regll]atiOTIs, fit, fi.ll[l[ctimll, peeformance (l'rsubsequent precessing of product Rde:r toO cust:onl,er~srecific requi[em.ents.
S:PECIFlfCA"nON
isa decument

st:<lting re[I,11:J]rements.

NOTE: F(DF:rr A' ~every feamre of the PWdilllot s identified by engineerilng specitications must a meet requkemeuts. ActuaJ[ measuremeat "mild tes:~resultsare reqJ1!lj~red. Specifications should not
be confused w.~lh.eontrol ~]miitswhich rep.resent "the voice of the precess,"

STABLE PIR:OCl,SSES, om: pmcesses reference manual,

tfua,t are in ,srn,tristi!cal oontmt

See tilileStatistical.

P'!!0CJesS,

Oll:ntrol

ST Al"ISl'l:CAL CONTROL is thecQltdit:ioll of 81 processftomwhich a]1 special. causes of nri.adoJiJl have been eliminated and only CCUlIIl1O'I1 eansesremaia, See, the Stillfigti1ca.~ .Pf'O[;E::SS CODtr1i)~ reference manaal,
SUBMJ1:SSI0N LEVEL Iefers to the level of e\!id:ellJceequired forPfi'AP subm~ssion (see:P'PA:P, r SUlPL.mRS, OEM orether
treating.w,eld;iug~

4_1),_

are providers of prodaetien materials, (lifprodtllct~OJJiL orservice parts.llssemblies. he~t pa]nring~ 1P~<litingr ather finishing services d~redl.y to ilIO (l!ir~rCl!],iZ'i3ltiQn. s1!l!pplyingthe o
cusiemers .req~~r1:11iglliJJis ocument t d

1'0001. is defiD.ed es the portion ofpr(lcess machinery wlli.c~ is speeiflc 110 a component OF sub-assembly. Tools (or tool ing] are used in precess machinery to transforrn raw material i.nto a finished. part or assembly.
V.ALIDATION is ,ooJIaJfinnatiofi, tkough[be provision ef objective evidence, that the requirements for a. specific intended use ,gra:pp,li.ca.tion have been fulflUeilL DATA are qJu<mt]~:at;ive data,wh.ere measurements <lire used for analysis, Exareples include the dim:neter of 8ibeaJ~ j~1!l1.malinmimmeters> the dosing efIort of~. door hi Newtons. the conceorradon of electrolyte in peroent. or the torque of a fiil:sre]1J:e'l~im1 Newtnn-mete:[~. VARIAJILES

VERIFICAll0N is

cOliIl:llrma'~i@iI!It

through

fieqlL]]rements, have been fuUl!ned

me provision

ofo1iJjeC'tiveevidence, ~hat pecified s

W A:m:r-RAN"r - See, P:3Jn Sl!lllnlilJiss~onW (u'rant

63