PPAP Templates

PPAP Submission

Date Initiated:

Part Name

Part Number

Purchase Order #

Engineering Change Level

Engineering Change Level Date

Supplier Name

Street Address

City

State

Zip

Phone Number

Supplier Contact

PPAP Submission Level GuideQuick reference

Level 4 - Will be defined by ACTIA during the PPAP request

Level 4a - Predetermined by ACTIA

Level 4b - Predetermined by ACTIA

The additional comments below are only an ACTIA summary of AIAG manual.Refer to AIAG Manual current edition for complete information.

Lev

el 1

Lev

el 2

Lev

el 3

Lev

el 4

Lev

el 4

a

Lev

el 4

b

Lev

el 5 Additional Comments

1 X X X * X X X ACTIA PSW only

2 X X * X X X

3 X X * X X X

4 X * X X

5 Design FMEA, X * X

6 X * X X

7 Process FMEA X * X

8 Control Plan X * X X

Ele

me

nt

Ord

er

PPAP RequirementsAIAG PPAP Fourth Edition

Required Documents

Part Submission Warrant (PSW)

Upon completion of all PPAP requirements, the organization shall complete the Part submission warrant (PSW).

If production parts will be produced from more than one cavity, mold, tool die, pattern, or Production process e.g., line or cell, the organization shall complete

a dimensional evaluation on one part from each . These specifics cavities, molds, line, etc..., shall then be identified in the "Mold/Cavity/Production

Process" line on a PSW, or in a PSW attachment. A responsible official of the organization shall approve the PSW and provide contact information.

Design Records & Bubbled part print(s).

ACTIA design record bubbled

The organization shall have the design record for the saleable product/part, including design records for components or details of the saleable product / part. Where the design record is in electronic format, e.g., CAD/CAM math data, the organization shall produce a hard copy (e.g., pictorial, geometric

dimensioning & tolerancing (GD&T) sheets, drawing) to identify measurements taken.

Authorized Engineering Change

Documentation

Various engineering documentation

The organization shall have any authorized engineering change documents form those changes not yet recorded in the design record but incorporated in

the product, part or tooling.

Customer Engineering Approvals

Customer engineering approval proof

Where specified by the customer, the organization shall have evidence of customer engineering approval.

Can be ACTIA DFMEA Format or an AIAG compliant DFMEA.

The product design-responsible organization shall develop a Design FMEA in accordance with and compliant to, customer specified requirements.(e.g.,

potential Failure Mode and Effects Analysis reference manual)

Process Flow Diagrams

Any standard flowchartformat.

The organization shall have a process flow diagram in an organization-specified format that clearly describes the production process steps and

sequence, as appropriate, and meets the specified customer needs, requirements and expectations (e.g., Advanced Product Quality Planning and Control Plan reference manual). For bulk materials, an equivalent to a process

Flow Diagram is a Process Flow Description.

Can be ACTIA PFMEA Format or an AIAG compliant PFMEA.

The organization shall develop a process FMEA in accordance with and compliant to, customer-specified requirements, (e.g., Potential Failure Mode

and Effects Analysis reference manual)

Can be ACTIA format or AIAG compliant format.

The organization shall have a control plan that defines all methods used for process control and complies with customer-specified requirements (e.g., Advanced Product Quality Planning and Control Plan reference manual).

9 X * X Not required by ACTIA

10 Dimensional Results X X * X X X

11-1 X X * X X X

11-2 X X * X X X

12 X * X

13 X X * X X X

Measurement System Analysis

Studies

The organization shall have applicable Measurement System analysis studies, e.g., gage R&R, bias, linearity, stability, for all new or modified gages,

measurement, and test equipment.( see the Measurement Systems Analysis reference manual)

Can use ACTIA Format or an AIAG compliantformat

for dimention report

The organization shall provide evidence that dimensional verifications required by the design record and the Control Plan have been completed and result

indicate compliance with specified requirements. The organization shall have dimensional results for each unique manufacturing process, e.g., cells or production lines and all cavities, molds, patterns or dies. The organization

shall record , with the actual results : all dimensions (except reference dimensions), characteristics, and specifications as noted on the design record

and Control Plan. The organization shall identify the parts measured.

Material Test Results and Performance test

result and related design notes

Industry Standard reports or test result formats

designated by ACTIA.

Material test results shall indicate and include :1) The design record change level of the parts tested;

2) Any authorized engineering change documents that not yet been incorporated in the design record;

3) The number, date, and change level of the specification to which the part was tested;

4) the date on which the testing took place;5) the quantity tested; 6) the actual results;

7) The material supplier's name and, when required by the customer, the customer-assigned supplier/vendor code.

Performance Test Results

Industry Standard reports or test result formats

designated by ACTIA .

The organization shall perform tests for all part(s) or product material(s) when performance or functional requirements are specified by the design record or

Control Plan. Performance test results shall indicate and include : 1) The design record change level of the parts tested;

2) Any authorized engineering change documents that not yet been incorporated in the design record;

3) The number, date, and change level of the specification to which the part was tested;

4) the date on which the testing took place;5) the quantity tested; 6) the actual results;

Initial Process Study (Cpk) Capability

Studies

Process Capability Study using any statistical package or ACTIA Capability Form.

The level of initial process capability or performance shall be determined to be acceptable prior to submission for all Special Characteristics designated by

the customer or organization. The organization shall obtain customer concurrence on the index for estimating initial process capability prior to

submission.- Where no special characteristics have been identified, the customer reserve

the right to require demonstration of initial process capability on other characteristics.

Index > 1.67 : the process currently meets the acceptance criteria.1.33=< Index =< 1.67 : the process may be acceptable. Contact the authorized

customer representative for review of the study results.Index <1.33 : Process does not currently meet the acceptance criteria. Contact

the authorized customer representative for a review of study results.

Qualified Laboratory Documentation

Lab Scope and outside labproof of accreditation.

Inspection and testing for PPAP shall be performed by qualified laboratory as defined by customer requirements (e.g. an accredited laboratory). the qualified

laboratory (internal or external to the organization) shall have a laboratory scope and documentation showing that the laboratory is qualified for the type

of measurements or tests conducted.When an external/Commercial laboratory is used, the organization shall

submit the test results on the laboratory letterhead or the normal laboratory report format. The name of the laboratory that performed the tests, the date(s)

of the tests, and the standards used to run the tests shall be identified.

14 X X X * X X X

15 X X * X X X Upon ACTIA requirements The organization shall provide sample product as specified by the customer.

16 Master Samples * X X X Uppon Actia requirements

17 Checking aids * X X X

18 * X X

Appearance ApprovalReport

ACTIA format or AIAG format

A separate Appearance Approval Report (AAR) shall be completed for each part or series of part if the product/part has appearance requirements on the

design record.Upon satisfactory completion of all required criteria, the organization shall

record the required information on the AAR. The completed AAR and representative production product/part shall be submitted to the location

specified by the customer to receive disposition. AARs (complete with part disposition and authorized customer representative signature) shall then

accompany the PSW at the time of final submission based upon the submission level requested.

Sample Product Parts

The organization shall retain a master sample for the same period as the production part approval records, or a) until a new master sample is produced

for the same customer part number for customer approval, or b) where a master sample is required by the design record, Control Plan or inspection

criteria, as a reference or standard. The master sample shall be identified as such, and shall show the customer approval date on the sample. The

organization shall retain a master sample for each position of a multiple cavity die, mold tool or pattern, or production process unless otherwise specified by

the customer. When part size , sheet volume of parts, etc. makes storage of a master

sample difficult, the sample retention requirements may be modified or waived in writing by authorized customer representative.

Part specific assembly or checking aids

If requested by customer, the organization shall submit with the PPAP submission any pert specific assembly or component checking aid.

Customer specific requirements

To submit for PCA suppliers only

The organization shall have records of compliance to all applicable customer-specific requirements. For bulk materials, applicable customer-specific requirements shall be documented on the Bulk Material Requirement

Checklist.

PPAP SAMPLE PARTS - LABEL

PPAP SAMPLE PARTSINSPECTION VERIFICATION REQUIRED

Purchase Order#: 0

Part Number: 0

Revision Level: 0

Supplier Name: 0

Send identified sample(s). Each sample used for PPAP must be clearly identified with their identification number corresponding with data.

Please complete, print in color and attach this page on the outside of each package in plain view of a fork lift/material handler/operator. Put the Packing slip pocket near the label.

In the event parts are “Loose” shipped, a label should be placed on each part. This would apply to parts laying on pallets also. Label on a Painted Part must be wire tied or attached in a way painted surface is protected from label adhesion.

of 28

Part # 0 FMEA NumberPart Name 0 Prepared ByRev # 0 FMEA Date (Orig.)

Process Responsibility FMEA Date

Notes : Please refer to the worksheet "DFMEA & PFMEA list 4th edition" to fill up SEV, OCC and DET"

Item

Nu

mb

er

Requirements

Current Product Controls Action Results

Prevention Detection Actions Taken

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

Potential Failure Modes and Effects AnalysisDesign FMEA

Item/Function

Potential Failure Mode

Potential Effects of Failure

SEV

Class

Potential Cause(s)/Failure Mechanisms

OCC

DET

RPN

RecommendedAction(s)

Responsibility and

Completion Date

SEV

OCC

DET

RPN

C3

Actia Part Number as stated on Actia Print.

J3

Insert DFMEA Document Number

C4

Name of the System or component for which the process is being analyzed.

J4

Company and person responsible for preparing DFMEA

C5

Most recent revision off of Actia Print

J5

Enter the date the original DFMEA was compiled.

C6

Department group or supplier name responsible for the process.

J6

Insert date of latest revision to DFMEA

A10

The item number is may be referenced from the process flow chart or control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B10

Enter a description of each item number here.

C10

Enter the requirements of each item/function being analyzed.

D10

In what ways might the product/function potentially fail to meet the part requirements and/or funtion intent? List each potential failure mode. There can be multiple failure modes for each process step.

E10

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user. Typical failure should be stated in terms of part performance.

G10

How Severe is the effect to the customer? Identified product characteristics!

H10

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try to identify the causes that directly impacts the failure mode, i.e., root causes.

J10

What are the existing controls and procedures (inspection and test) that either prevent failure mode from occurring or detect the failure should it occur? The preferred approach is always prevention!

M10

SEV x OCC x DET

N10

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Prevention actions are preferable to detection actions.

O10

Enter the name of the person who is responsible for the recommended action and the target date for completion.

J11

Eliminate the cause of the mechanism of failure from occuring or reduce its occurrence.

K11

Identify the existence of a cause, the resulting mechanism of failure either by analytical or physical methods before the item is released for production

P11

List the completed actions that are included in the recalculated RPN. Include the implementation date for any changes.

Q11

What is the new severity based on the action applied.

R11

What is the new Occurrence numbers based on the action taken.

S11

What is the new detection ranking based on the action taken. Has the detection improved?

T11

Recompute RPN after actions are complete.

of 28

Part # 0 FMEA NumberPart Name 0 Prepared ByRev # 0 FMEA Date (Orig.)

Process Responsibility FMEA Date


Item

Nu

mb

er

Requirements

Current Product Controls Action Results


Potential Failure Modes and Effects AnalysisDesign FMEA

Item/Function



SEV

Class


OCC

DET

RPN


Responsibility and

Completion Date

SEV

OCC

DET

RPN

0 0

C3


J3

Insert DFMEA Document Number

C4


J4

Company and person responsible for preparing DFMEA

C5


J5

Enter the date the original DFMEA was compiled.

C6


J6

Insert date of latest revision to DFMEA

A10

The item number is may be referenced from the process flow chart or control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B10

Enter a description of each item number here.

C10

Enter the requirements of each item/function being analyzed.

D10

In what ways might the product/function potentially fail to meet the part requirements and/or funtion intent? List each potential failure mode. There can be multiple failure modes for each process step.

E10

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user. Typical failure should be stated in terms of part performance.

G10

How Severe is the effect to the customer? Identified product characteristics!

H10

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try to identify the causes that directly impacts the failure mode, i.e., root causes.

J10


M10

SEV x OCC x DET

N10

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Prevention actions are preferable to detection actions.

O10

Enter the name of the person who is responsible for the recommended action and the target date for completion.

J11

Eliminate the cause of the mechanism of failure from occuring or reduce its occurrence.

K11

Identify the existence of a cause, the resulting mechanism of failure either by analytical or physical methods before the item is released for production

P11


Q11


R11


S11


T11


Process flowPart # 0 Control plan NumberPart Name 0 Prepared ByRev # 0 Control plan Date (Orig.)

Control plan Date

Operation Transport Inspect Store Idle

10

20

30

40

50

60

Process ResponsibilityProcess

No.

C2


C3


C4


C5


of 28

Part # 0 FMEA NumberPart Name 0 Prepared ByRev # 0 FMEA Date (Orig.)Process Responsibility FMEA Date


Pro

cess

Nu

mb

er

Requirements

Current Process Controls Action Results


0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

Potential Failure Modes and Effects AnalysisProcess FMEA

Process/StepFunction



SEV

Class


OCC

DET

RPN


Responsibility and

Completion Date

SEV

OCC

DET

RPN

C3


J3

Insert PFMEA Document Number

C4


J4

Company and person responsible for preparing PFMEA

C5


J5

Enter the date the original PFMEA was compiled.

C6


J6

Insert date of latest revision to PFMEA

A10

The item number is may be referenced from the process flow diagrams and/or the control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B10

List the process function that corresponds to each process step or operation being analyzed. .

C10

List the requirements for each process/step. Requirements are the inputs to the process specified to meet the design intent. There can be multiple requirements per function.

D10

In what ways might the process potentially fail to meet the process requirements intent? List each potential failure mode. There can be multiple failure modes for each process step.

E10

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user.

G10

How Severe is the effect to the customer? Identified product or process characteristics!

H10

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try identify the causes that directly impacts the failure mode, i.e., root causes.

J10


M10

SEV x OCC x DET

N10

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Should have actions only on high RPN's or easy fixes.

O10

Who is responsible for the recommended action? What is the target completion date.

J11

List the methods used that eliminate or prevent the cause of failure.

K11

List the methods of detection control that identifythe cause of process failure leading to corrective actions.

P11


Q11


R11


S11


T11


of 28

Part # 0 FMEA NumberPart Name 0 Prepared ByRev # 0 FMEA Date (Orig.)Process Responsibility FMEA Date


Pro

cess

Nu

mb

er

Requirements

Current Process Controls Action Results


Potential Failure Modes and Effects AnalysisProcess FMEA

Process/StepFunction



SEV

Class


OCC

DET

RPN


Responsibility and

Completion Date

SEV

OCC

DET

RPN

0 0

C3


J3

Insert PFMEA Document Number

C4


J4

Company and person responsible for preparing PFMEA

C5


J5

Enter the date the original PFMEA was compiled.

C6


J6

Insert date of latest revision to PFMEA

A10

The item number is may be referenced from the process flow diagrams and/or the control plan. If multiple part numbers exist (assembly) list the individual part numbers and their functions

B10

List the process function that corresponds to each process step or operation being analyzed. .

C10

List the requirements for each process/step. Requirements are the inputs to the process specified to meet the design intent. There can be multiple requirements per function.

D10

In what ways might the process potentially fail to meet the process requirements intent? List each potential failure mode. There can be multiple failure modes for each process step.

E10

What is the effect of each failure mode on the outputs and/or customer requirements? The customer could be the next operation, subsequent operations, another division or the end user.

G10

How Severe is the effect to the customer? Identified product or process characteristics!

H10

How can the failure occur? Describe in terms of something that can be corrected or controlled. Be specific. Try identify the causes that directly impacts the failure mode, i.e., root causes.

J10


M10

SEV x OCC x DET

N10

What are the actions for reducing the occurrence, or improving detection, or for identifying the root cause if it is unknown? Should have actions only on high RPN's or easy fixes.

O10

Who is responsible for the recommended action? What is the target completion date.

J11

List the methods used that eliminate or prevent the cause of failure.

K11

List the methods of detection control that identifythe cause of process failure leading to corrective actions.

P11


Q11


R11


S11


T11


of 28

Control Plan

Control Plan Number Key Contact / Phone Date (Orig.) Current Release Level Current Release Date

Part Number Latest Change (Rev) Level Part Description Plant Location0 0 0

Core Team Supplier Name Quality Department Approval

0

CHARACTERISTICSMETHODS

CONTROL METHOD REACTION PLAN

SAMPLE

NO. PRODUCT PROCESS SIZ

E

FR

EQ

PA

RT

/

PR

OC

ES

S

NU

MB

ER PROCESS

NAME / OPERATION

DESCRIPTION

MACHINE DEVICES / JIG / TOOLS FOR

MANUFACTURINGSPECIAL

CHAR. CLASS

PRODUCT / PROCESS /

SPECIFICATION / TOLERANCE

EVALUATION/MEASUREMENT

TECHNIQUE

Prototype Pre-Launch Production

A4

This is the internal document number used to track and control the Control Plan.

D4

This is the key quality person responsible for developing and leading the control plan strategy.

H4

This is the date of original release of the control plan for the part number.

I4

This is the Revision level of the most current CONTROL PLAN release.

L4

Date the current control plan was released or became effective.

A6

Enter the part number and the most current revision level.

E6

Enter the description of the part on the Actia print.

A8

List all key team members involved in the process and the control plan. List names, numbers and other contact information.

F8

Full Name of Supplier

I8

Signature of author or quality approval of control plan.

A10

The item number is usually referenced from the process flow chart. If multiple part numbers exist (assembly) list the individual part numbers and their processes accordingly.

B10

All steps in the manufacturing of a system, subsystem or component are described. Identify the process/operation that best describes the activity on each line.

C10

For each operation that is described, identify the processing equipment, machine, device, jig or other tool for manufacturing as appropriate.

D10

A distinguishing feature, dimension or property of a process or it's output on which variable or attribute data can be collected.

G10

Use the appropriate characteristic.

H10

Systematic plan for controlling a process.

L10

Brief description of how the operation will be controlled, including procedure numbers where applicable. Should be based on effective analysis of the process. Various methods can be used from additional inspection to SPC or error proofing. The method of control should be clinically evaluated for effectiveness of process control.

M10

The reaction plan specifies the corrective actions necessary to avoid producing nonconforming products or operating out of control. The actions should normally be the responsibility of the people closest to the process.

H11

Specification/tolerance may be obtained from various engineering documents such as drawings, specifications etc..

I11

Measurement system being used to check the specification or tolerance. This could include gages, fixtures, tools and or test equipment required to measure the part/process/manufacturing equipment. A measurement system analysis should be done to ensure control of monitoring and measuring devices prior to relying on a measurement system.

J11

When sampling is required list the corresponding sample size and frequency.

D12

Cross reference number from all applicable documents such as FMEAS, process flows etc..

E12

Product characteristics are the features or properties of a part that are described on the drawings or other primary engineering information. The Core Team should identify the special Product Characteristics from all sources. All special characteristics should be listed on the Control Plan.

F12

Process Characteristics are the process variables that have a cause and effect relationship with the identified Product Characteristic. A Process Characteristic can only be measured at the time it occurs. The Core Team should identify Process Characteristics for which variation must be controlled to minimize variation. There could be one or more Process Characteristics listed for each Product Characteristic. In some processes one Process Characteristic may affect several Product Characteristics.

DIMENSIONAL RESULT

Part name 0 Tooling num

Part number: 0 Cavity #

Revision # 0 Sample size :

Cavity number: Check by:

Total # of measurements taken = 0Total # of measurements within in spec = 0

% of measurements meeting spec = #DIV/0!

Bu

bb

le #

SpecificationActual measurements

Re

su

lt

Sample 1 Sample 2 Sample 3

Gauge Type

Low.tol.

Upp.tol.

Insp Pts

# out of tol

Bu

bb

le #

SpecificationActual measurements

Re

su

lt

Sample 1 Sample 2 Sample 3

Gauge Type

Low.tol.

Upp.tol.

Insp Pts

# out of tol

comment

Part Submission WarrantPart Name 0 Part Number 0Safety and/orGovernment Regulation Yes No Engineering Drawing Change Level 0 Dated

Additional Engineering Changes Dated

Shown on Drawing no. Purchase order No. 0 Weight (kg)

Checking Aid No. Engineering Change Level Dated

ORGANIZATION MANUFACTURING INFORMATION CUSTOMER SUBMITTAL INFORMATION0 Customer Name / Division

Supplier Name Buyer Name/Code0 Application

Street Address0 0 0

City State Zip

Note: Does this part contain any restricted or reportable substances Yes No N/A

Are plastic parts identified with appropriate ISO marking codes Yes No N/A

REASON FOR SUBMISSION

Initial Submission Change to Optional Construction or MaterialEngineering Change(s) Sub-Supplier or Material Source ChangeTooling: Transfer, Replacement, Refurbishment, or additional Change in Part processingCorrection of Discrepancy Parts Produced at Additional LocationTooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant, only (and for designated items, an Appearance Approval Report) submitted to customer.

Level 2 - Warrant with product samples and limited supporting data submitted to customer.

Level 3 - Warrant with product samples and complete supporting data submitted to customer.

Level 4 - Warrant and other requirements as defined by customer. Include Level (4a) and (4b) predefined in ACTIA procedure.

(Check)Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

SUBMISSION RESULTS

The results for dimensional measurements material and functional tests appearance criteria statistical process packageThese results meet all drawing and specification requirements: Yes No (If "No" - Explanation Required)Mold / Cavity / Production Process:

DECLARATION

I hereby affirm that the samples represented by this warrant are representative of our parts and have been made to the applicableProduction Part Approval Process Manual 4th Edition Requirements. I further warrant these samples wereproduced at the production rate of / 8 hours. I have noted any deviations from this declaration below.

EXPLANATION/COMMENTS:

Print Name Title Phone No. FAX No.

Supplier Authorized Signature Date

Part Warrant Disposition:Rejection/Other Comments:

Customer Name Customer Signature Date

FOR ACTIA USE ONLY (IF APPLICABLE)

APPROVED REJECTED OTHER

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

Production Part Approval Material Test Results and Related Design Record Notes

PART NUMBER: 0 DESIGN RECORD CHANGE LEVEL: 0

PART NAME: 0 ENGINEERING CHANGE DOCUMENTS date: 12/30/1899

NAME of LABORATORY:

MATERIAL SPEC. NO. / REV / DATESUPPLIER TEST RESULTS (DATA) OK

Blanket statements of conformance are unacceptable for any test results.

SIGNATURE TITLE DATE

Bubble #

SPECIFICATION / LIMITS

TEST DATE

QTY. TESTED

NOT OK

Production Part Approval Performance Test Results and Related Design Record Notes

PART NUMBER: 0 DESIGN RECORD CHANGE LEVEL: 0

PART NAME: 0 ENGINEERING CHANGE DOCUMENTS DATE: 12/30/1899

TEST SPECIFICATION / REV / DATE SUPPLIER TEST RESULTS (DATA) / TEST CONDITIONS OK

SIGNATURE TITLE DATE

Bubble #

SPECIFICATION / LIMITS

TEST DATE

QTY. TESTED

NOT OK

INITIAL SAMPLES CAPABILITY REPORT

Part Name : 0Part number : 0 Revision #

Drawing number : 0Tool number :

Cavity number :Check by :

Inspection date :

Gauge type

0 030 10

N° Data Cp Cpk Average

1

234

Maxi. Mini Range56 0.00 0.00 0.000 0 789

101112131415161718192021222324252627282930

Comments :

Nominal.dim.

Low.tol.

Upp.tol.

Low.dim.

Upp.dim.

Samplesize

Cat. nbr.

OkOut

Std.deviation

Out of spec.

#D

IV/0

!#D

IV/0

!#D

IV/0

!#D

IV/0

!#D

IV/0

!#D

IV/0

!#D

IV/0

!#D

IV/0

!#D

IV/0

!#D

IV/0

!0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0%

200%

400%

600%

800%

1000%

1200%

0

Histogram

Inch

QT

Y

K15

Do not change

Comments :

ACTIA Corporation APPEARANCE APPROVAL REPORT

Part Name 0 Part number 0

Revision level 0 0

Supplier name 0

PPAP ELEMENTSA

PP

LIC

AB

LE

AC

CE

PT

ED

COMMENTS

1 COLOR N/A

2 BRILLANCE N/A

3 GLOSS N/A

4 GRAIN N/A

5 TRANSPARENCY N/A

6 SINK MARK N/A

7 WELDING LINES N/A

8 INJECTION GATE N/A

9 KNIT LINE MARK N/A

10 EJECTOR MARKS N/A

11 PAINT N/A

12 MARKING AND DECORATION (Silk-screen printing, Pad printing) N/A

14 Approved Sample Matched N/A

ECN change level date

Supplier 0 Part name 0

Part # 0 Revision level 0

ACTIA Special requirement Bill Of Material review (Applicable for PCA only)

Bubble Number on

BOM

Is component present?

Is component orientation correct?

Bubble Number on

BOM

Is component present?

Is component orientation correct?

Form 4.7.19 Revision C 6-23-10

Document Number:

SUPPLIER DEVIATION REQUEST ACTIA SUPPLIER TO COMPLETE

Supplier Name: Part Number: Part Name:

0 0 0

Date: P.O.# P.O Qty Qty Produced Scheduled Delivery Date Contact Name:

EMAIL:

Type of deviation:

Quantity: PO's affected:

From: To: PO's affected:

How does this deviation affect the scheduled delivery date of the product?

Date approval needed to meet scheduled delivery date?

Submit this deviation request to ACTIA Purchasing

ACTIA PURCHASING TO COMPLETE

Date product needed to meet order dates?

Quantity needed to meet order dates?

ACTIA ENGINEERING AND QUALITY TO COMPLETE

Approved by: Name: Date:Engineering:

Quality:

By: Date:

ACTIA customer approval/PPAP submission required.

Submitted: **Add reason below:

Approved by: Name: Date:** Please provide the customer approval for this deviation. Engineering:

Quality:

ACTIA ENGINEERING TO COMPLETE

Reason:

By: Date:

Quantity: PO's affected:

From: To: PO's affected:

ECN #:

Comments:

Return this completed document to ACTIA Purchasing.

ACTIA PURCHASING FORWARD THIS COMPLETED DOCUMENT TO THE SUPPLIER

Reason: (Please include a physical sample or picture depicting the deviation to be approved.)

Add the document number and forward to ACTIA Engineering and Quality.

No ACTIA customer approval required - No customer specification or drawing requirements.

* This approval is granted upon the understanding that it is advisory in nature and in no manner changes the Sellers original responsibility for insuring that all characteristics, designated in the applicable engineering specifications

and/or inherent in the samples as originally tested and approved, are maintained.

Limited QtyLimited TimePermanent

APPROVED*

REJECTED

Limited QtyLimited TimePermanent

Yes No

PFMEA LISTS 4th Edition DFMEA LISTS 4th EditionSEVERITY SCALE SEVERITY SCALE 10 Noncompliance to a government regulation 10 Affects safe vehicle operation and/or noncompliance to a government regulation without warning. 9 A safety hazard 9 Affects safe vehicle operation and/or noncompliance to a government regulation with warning. 8 Will result in customer complaint and return of product 8 Loss of primary function (vehicle inoperable but does not affect safe vehicle operation. 7 May cause production disruption or failure of sales specification. 7 Degradation of Primary function (vehicle operable but at a reduced level of performance) 6 Will be caught at subsequent processing. 6 Loss of secondary function (vehicle operatable but comport/ convenience functions inoperable. 5 Will be caught during processing 5 Degradation of secondary function (vehicle operatable but comfort/ convenience functions inoperable. 4 Likely to be caught by customer at incoming inspection 4 Appearance of audible noise, vehicle operable, item does not conform, and noticed by most customers (75%). 3 Only a slight inconvenience with product or processing noticed 3 Appearance of audible noise, vehicle operable, item does not conform, and noticed by many customers (50%). 2 Likely to cause only a slight customer annoyance 2 Appearance of audible noise, vehicle operable, item does not conform, and noticed by discriminating customers (25%). 1 Not likely to cause any effect or to be noticed by customer 1 No discernible affect.OCCURRENCE SCALE OCCURRENCE SCALE10 High frequency, No Background 10 New technology/new design with no history. 9 High frequency, Assumption 9 Failure is inevitable with new design, new application, or change in duty cycle/operating conditions. 8 High frequency, Similar Experience 8 Failure is likely with new design, new application, or change in duty cycle/operating conditions. 7 High frequency, Actual Experience 7 Failure is uncertain with new design, new application, or change in duty cycle/operating conditions. 6 Moderate Frequency, Assumption 6 Frequent failures associated with similar designs or in design simulation and testing. 5 Moderate Frequency, Similar Experience 5 Occasional failures associated with similar designs or in design simulation and testing. 4 Moderate Frequency, Actual Experience 4 Isolated failures associated with similar designs or in design simulation and testing. 3 Low Frequency, Assumption 3 Only isolated failures associated with almost identical design or in design simulation or testing. 2 Low Frequency, Similar Experience 2 No observed failures associated with almost identical design or in design simulation or testing. 1 Low Frequency, Actual Experience 1 Failure is eliminated through preventative control.DETECTION SCALE DETECTION SCALE10 Absolute certainty of Non-detection. 10 No current design control; Cannot detect or is not analyzed. 9 Very low likelihood of detection. 8 Controls may detect at end of customer production. 7 Controls may detect existence during customer production. 6 Controls likely to detect defect in lot inspection but higher variability. 5 Controls likely to detect defect in lot inspection. 4 Controls have a good chance of detecting defect at end of current process step. 3 Controls have a good chance of detecting defect before end of current process step. 2 Controls almost certainly defect before next process. 1 Controls detect defect before next process. 1 Not Applicable. Failure is fully prevented through design solutions (e.g. proven design standard, best practices, or common material, etc.)

9 Design analysis/detection controls have a weak detection capability; Virtual Analysis (e.g. CAE, FEA etc.) is 8 Product verification after design freeze and prior to launch with 7 Product verification after design freeze and prior to launch with 6 Product verification after design freeze and prior to launch with 5 Product validation (reliability testing, development or validation tests) prior to design freeze using 4 Product validation (reliability testing, development or validation tests) prior to design freeze using 3 Product validation (reliability testing, development or validation tests) prior to design freeze using 2 Virtual analysis correlated. Design analysis/ detection controls have a strong detection capability and is

DFMEA LISTS 4th EditionSEVERITY SCALE 10 Affects safe vehicle operation and/or noncompliance to a government regulation without warning. 9 Affects safe vehicle operation and/or noncompliance to a government regulation with warning. 8 Loss of primary function (vehicle inoperable but does not affect safe vehicle operation. 7 Degradation of Primary function (vehicle operable but at a reduced level of performance) 6 Loss of secondary function (vehicle operatable but comport/ convenience functions inoperable. 5 Degradation of secondary function (vehicle operatable but comfort/ convenience functions inoperable. 4 Appearance of audible noise, vehicle operable, item does not conform, and noticed by most customers (75%). 3 Appearance of audible noise, vehicle operable, item does not conform, and noticed by many customers (50%). 2 Appearance of audible noise, vehicle operable, item does not conform, and noticed by discriminating customers (25%). 1 No discernible affect. OCCURRENCE SCALE 10 New technology/new design with no history. 9 Failure is inevitable with new design, new application, or change in duty cycle/operating conditions. 8 Failure is likely with new design, new application, or change in duty cycle/operating conditions. 7 Failure is uncertain with new design, new application, or change in duty cycle/operating conditions. 6 Frequent failures associated with similar designs or in design simulation and testing. 5 Occasional failures associated with similar designs or in design simulation and testing. 4 Isolated failures associated with similar designs or in design simulation and testing. 3 Only isolated failures associated with almost identical design or in design simulation or testing. 2 No observed failures associated with almost identical design or in design simulation or testing. 1 Failure is eliminated through preventative control.DETECTION SCALE 10 No current design control; Cannot detect or is not analyzed.

1 Not Applicable. Failure is fully prevented through design solutions (e.g. proven design standard, best practices, or common material, etc.)

9 Design analysis/detection controls have a weak detection capability; Virtual Analysis (e.g. CAE, FEA etc.) is not correlated 8 Product verification after design freeze and prior to launch with pass/fail testing (Subsystem or system testing with acceptance criteria such as ride and handling , shipping evaluation etc.) 7 Product verification after design freeze and prior to launch with test to failure testing (Subsystem or system testing until failure occurs, testing of interactions etc.) 6 Product verification after design freeze and prior to launch with degradation testing (Subsystem or system testing after durability test e.g. functional test. 5 Product validation (reliability testing, development or validation tests) prior to design freeze using pass/fail testing (e.g.. acceptance criteria for performance functional checks etc.) 4 Product validation (reliability testing, development or validation tests) prior to design freeze using test to failure 3 Product validation (reliability testing, development or validation tests) prior to design freeze using degradation (e.g. data trends, before/after values etc.) 2 Virtual analysis correlated. Design analysis/ detection controls have a strong detection capability and is highly correlated

2 Appearance of audible noise, vehicle operable, item does not conform, and noticed by discriminating customers (25%).

1 Not Applicable. Failure is fully prevented through design solutions (e.g. proven design standard, best practices, or common material, etc.)

9 Design analysis/detection controls have a weak detection capability; Virtual Analysis (e.g. CAE, FEA etc.) is not correlated to expected or actual operating conditions. Not likely to detect at any stagetesting (Subsystem or system testing with acceptance criteria such as ride and handling , shipping evaluation etc.)

testing (Subsystem or system testing until failure occurs, testing of interactions etc.) testing (Subsystem or system testing after durability test e.g. functional test.

pass/fail testing (e.g.. acceptance criteria for performance functional checks etc.) test to failure (e.g. until leaks, yields or cracks etc.)degradation (e.g. data trends, before/after values etc.)

2 Virtual analysis correlated. Design analysis/ detection controls have a strong detection capability and is highly correlated with actual or expected operating conditions.

PPAP Templates

Documents

Transcript of PPAP Templates