Production Part Approval Process (PPAP) Manual Procedure · PDF fileProduction Part Approval...

Number: OPS-PROC-0106

Name: Production Part Approval Process (PPAP)

Manual Procedure

Revision: 1 Last Saved: 27-JAN-2016 of 24

Confidential © 2016 Polaris Industries Inc.

POLARIS INDUSTRIES INC.

2100 HIGHWAY 55

MEDINA, MN 55340

Production Part Approval Process (PPAP) Manual Procedure

OPS-PROC-0106

WRITTEN BY: Kevin O’Brien DATE: 15-Dec-15

APPROVED BY: Brad Clark DATE: 29-JAN-2016



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REVISION HISTORY

REV DATE AUTHOR APPROVER(S) DESCRIPTION OF CHANGES

1 14-Dec-15 Kevin O’Brien Brad Clark Initial Document Release



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1. PURPOSE/SCOPE ............................................................................................................................................. 5

2. TERMS & SYMBOLS ....................................................................................................................................... 5

3. PRODUCTION PART APPROVAL PROCESS (PPAP) .............................................................................. 6

3.1. PREAMBLE ..................................................................................................................................................... 6 3.2. APPLICABILITY ............................................................................................................................................... 7 3.3. WHEN IS A PPAP SUBMISSION REQUIRED? .................................................................................................... 7 3.4. 18 ELEMENTS OF A PPAP ............................................................................................................................... 8

3.4.1. Design Record ....................................................................................................................................... 9 3.4.2. Engineering Change Document ............................................................................................................. 9 3.4.3. Customer Engineering Approval ......................................................................................................... 10 3.4.4. Design Failure Mode and Effects Analysis (DFMEA) ........................................................................ 10 3.4.5. Process Flow Diagrams ....................................................................................................................... 10 3.4.6. Process Failure Mode and Effects analysis (Process FMEA) .............................................................. 10 3.4.7. Control Plan ......................................................................................................................................... 11 3.4.8. Measurement System Analysis (MSA) Studies ................................................................................... 12 3.4.9. Dimensional Results ............................................................................................................................ 12 3.4.10. Material, Performance Test Results ..................................................................................................... 14 3.4.11. Initial Process Studies .......................................................................................................................... 14 3.4.12. Qualified Laboratory Documentation .................................................................................................. 16 3.4.13. Appearance Approval Report .............................................................................................................. 16 3.4.14. Sample Production Parts ...................................................................................................................... 16 3.4.15. Master Sample ..................................................................................................................................... 17 3.4.16. Checking Aids ..................................................................................................................................... 17 3.4.17. Customer-Specific Requirements ........................................................................................................ 17 3.4.18. Part Submission Warrant (PSW) ......................................................................................................... 18

3.5. PPAP SUBMISSION LEVELS .......................................................................................................................... 20 3.6. ELECTRONIC SUBMISSION REQUIREMENTS .................................................................................................. 21 3.7. SIGNIFICANT PRODUCTION RUN ................................................................................................................... 22 3.8. PART SUBMISSION STATUS ........................................................................................................................... 22

4. REFERENCES ................................................................................................................................................. 23



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1. PURPOSE/SCOPE

The purpose of this document is to define expectations and provide guidance for

proper PPAP submission by the supplier. This Polaris document takes precedence

over any differences/discrepancies that may exist between the AIAG reference

manuals/materials referenced below.

2. TERMS & SYMBOLS

TERM DEFINITION

AAR Appearance Approval Report

AIAG Automotive Industry Action Group

APQP Advanced Product Quality Planning

CMM Coordinate Measuring Machine

DCR Drawing Change Request

DFMEA Design Failure Mode and Effects Analysis

ECL Engineering Change Level

FAIR First Article Inspection Report

GD&T Geometric Dimensioning and Tolerancing

KPC Key Product Characteristic

MSA Measurement System Analysis

NIST National Institute of Standards and Technology

PCR Product/Process Change Request

PDI Pre-delivery Inspection

PFMEA Potential Failure Modes and Effects Analysis

PPAP Production Part Approval Process

PQR Part Qualification Request (Obsolete Polaris Term)

PSW Part Submission Warrant

QA Quality Assurance

QE Quality Engineer

SDE Supplier Development Engineer

SPC Statistical Process Control

SQE Supplier Quality Engineer

SQAM Supplier Quality Assurance Manual

SYMBOL DEFINITION



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3. PRODUCTION PART APPROVAL PROCESS (PPAP)

Polaris does not accept separate charges for the cost of PPAP development and

should be factored in with the overall cost of doing business.

The Production Part Approval Process (PPAP) is a rigorous and structured process

for part qualification. PPAP is a method used for evaluating the complete

manufacturing process which was developed by the domestic auto industry as part of

QS 9000 and TS16949. A PPAP package is composed of several elements. These

elements are tools that focus on the manufacturing process and the prevention of

defects. Five different levels of documentation and submission requirements have

been identified and standardized. All of them include a Part Submission Warrant.

The PPAP package, if requested, is a significant component of the PPAP Request –

which is defined by the Polaris Supplier Quality Assurance Manual (SQAM). A

PPAP is typically required on a PRODUCTION PART for new part submissions and

implemented product change orders, but may be required in whole or in part for

other qualification events. Polaris will request various elements of PPAP for

submission as defined in the PPAP Request. As a default, Polaris requires

submission and retention of PPAP records per Tables 4.1 and 4.2 contained in the

AIAG 4th Edition PPAP manual unless otherwise specified.

3.1. PREAMBLE

Effective June 2006, PPAP 4th Edition replaced the PPAP 3rd Edition manual.

Polaris PPAP requirements are based on the PPAP 4th Edition.

To understand the PPAP process you must obtain a copy of the AIAG 4th Edition

PPAP manual from either www.aiag.org or www.Amazon.com.

Production Part Approval Process (PPAP) is updated to the 4th edition to incorporate

the customer focused process approach associated with ISO/TS 16949:2002 and

other changes.

PPAPs purpose continues to be to provide the evidence that all customer engineering

design record and specification requirements are properly understood by the

organization and the manufacturing process has the potential to produce product

consistently meeting these requirements during an actual production run, at the

quoted production rate, using production tooling and production personnel.

http://www.aiag.org/

http://www.amazon.com/



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3.2. APPLICABILITY

PPAP shall apply to supplier internal and external organization sites (Tier I, II, etc.)

supplying production parts, service parts, production materials or bulk materials to

Polaris.

Service parts, standard catalog production or service parts, production

materials or bulk material requirements will be at the sole discretion of the

Polaris Quality Assurance representative.

The word “shall” indicates mandatory requirements.

The word “should” indicates a recommendation.

Note: At the sole discretion of the Polaris quality assurance representative

when requested, PPAP submissions are required as a condition of doing

business with Polaris Industries.

3.3. WHEN IS A PPAP SUBMISSION REQUIRED?

The organization shall obtain approval from a Polaris QE, SQE, SDE or other

authorized representative for the items below (prior PCR approval may also be

required):

1. A new part or product.

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

3. Any changes to materials used in the previously approved part or

product.

4. Production from new or modified tools (except perishable tools), dies,

molds, patterns, etc. including additional or replacement tooling.

5. Production following an upgrade or rearrangement of existing tooling

or equipment.

6. Production from tooling and equipment transferred to a different plant

site, from an additional plant site or from a manufacturing/assembly

line move within the plant.

7. Change in the supplier for parts, non-equivalent materials or services

(i.e., heat treating, plating).

8. Product produced after the tooling has been inactive for volume

production for twelve months or more.

9. Product and process changes related to components of the production

product manufactured internally (supplier) or manufactured externally

(Tier II).



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10. Change in test/inspection method – new technique (no effect on

acceptance criteria).

11. New source of raw material from new or existing supplier.

12. Change in product appearance attributes.

The key words are “new” or “change”.

Check with the QE, SDE or SQE if in doubt.

For Polaris initiated changes, a PPAP Request will be created and defined in the

Polaris system by a Polaris authorized quality assurance representative.

The PPAP Request is the vehicle used by Polaris to control quality

submissions.

A FAIR by definition (First Article Inspection Report) cannot

be PPAPd since it is not part of a production run as defined in

Significant Production Run section.

The PPAP Request will be communicated to the supplier quality assurance

representative as designated by the supplier.

PPAP requirements will be defined in the PPAP Request with regard to submission

levels and due dates as well as the Polaris quality assurance representative contact

for electronic submissions.

Supplier initiated changes will be submitted to their SQE/SDE by way of a PCR.

See the Polaris PCR instructions for completing/submitting the PCR.

An approved PCR will define the PPAP requirements, which will then be entered

into the PPAP Request system.

The approved PCR should be submitted in Element 2 of the PPAP.

See the Polaris PPAP Training Aid for more information about PPAP

Requests.

3.4. 18 ELEMENTS OF A PPAP

1. Design Record (Polaris drawings only with released Polaris part numbers).

2. Engineering Change Documents, if any.

3. Customer Engineering Approval, if required.

4. Design FMEA – Failure Modes and Effects Analysis (DFMEA).

5. Process Flow Diagrams.

6. Process FMEA - Failure Modes and Effects (PFMEA).

7. Control Plan.



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8. Measurement System Analysis (MSA) Studies – if applicable for KPCs.

9. Dimensional Results (previously referred to as FAIR).

10. Material, Performance Test Results.

11. Initial Process studies – Cpk (if applicable for KPCs).

12. Qualified Laboratory Documentation.

13. Appearance Approval Report (AAR) - if applicable for appearance items.

14. Sample Product.

15. Master Sample.

16. Checking Aids.

17. Records of Compliance (with customer-specific requirements).

18. Part Submission Warrant (PSW).

3.4.1. Design Record

The Design Record is what the supplier has contracted to provide per the Polaris

Purchase Order (PO). Examples would include, but not limited to:

Polaris drawings (as defined by a unique Polaris part number) to the latest ECL

(Rev level) as defined on the PO.

Engineering specifications.

Special notes added to the PO (i.e., paint it black or special packaging).

The engineering drawing portion of the Design Record is often used to provide a

ballooned drawing when submitting Element 9 – Dimensioned Results (as required

in the Polaris Supplier Quality Assurance Manual).

Supplier drawings (if defined on the Polaris drawings or PO) would also be part of

the Design Record, but only if defined.

Polaris purchases to Polaris drawings.

3.4.2. Engineering Change Document

For changes not yet recorded in the design record but incorporated in the product,

part or tooling. Examples would be:

o Approved DCR.

Compliant PPAPs can be approved with approved DCRs.

o Approved Deviations.

Compliant PPAPs can be granted Interim Approval with

approved Deviations.



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See details in the Interim Approval section.

o Approved PCR.

Polaris approved PCR can be retained with the PPAP

submission.

3.4.3. Customer Engineering Approval

Where specified by Polaris, the supplier shall have evidence of customer

engineering approval.

o Note on Emails:

Emails can only clarify requirements, not define them.

Emails cannot re-define a requirement in lieu of a drawing

change.

3.4.4. Design Failure Mode and Effects Analysis (DFMEA)

When requested the product design-responsible organization shall develop a

Design FMEA in accordance with, and compliant to, Polaris-specified

requirements.

The purpose of a DFMEA is to identify all possible failure modes and the effects

they would have on the end product or customer. Subsequently, the necessary

changes to minimize those effects should be implemented and documented on the

DFMEA.

3.4.5. Process Flow Diagrams

Suppliers 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.

o Process Flow Diagrams for ‘families’ of similar parts are acceptable if

the new parts have been reviewed for commonality by the supplier

and/or Polaris.

3.4.6. Process Failure Mode and Effects analysis (Process FMEA)

Suppliers shall develop a PFMEA in accordance with and compliant to Polaris-

specified requirements.

o KPCs shall be identified in the “classification” column of the FMEA.

o A single Process FMEA may be applied to a process manufacturing a

family of similar parts or materials if reviewed for commonality by

the supplier and/or Polaris.



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3.4.7. Control Plan

Suppliers shall have a Control Plan that defines all methods used for process

control and complies with Polaris-specified requirements.

Control Plans for “families” of parts are acceptable if the new parts have

been reviewed for commonality by the supplier and/or Polaris.

The Process Control Plan is a comprehensive document that provides the details

to ensure delivered product is compliant with the design records, engineering

specifications and quality standards. The Process Control Plan does not take the

place of operator or workplace instructions, but may refer to them and their use

where appropriate.

Polaris does not require a supplier to submit a standard Process Control Plan

form; this allows suppliers to utilize their own internal documentation system to

provide this plan. The Polaris Process Control Plan however, can be used in lieu

of, or as a supplement to a supplier's.

A submitted Process Control Plan shall include the following information:

o Part Number and Revision Level.

o Part Description.

o Supplier Name and Plant.

o Polaris Supplier Number.

o Key Supplier Contact and Phone Number.

o Control Plan Date and Revision Level.

A submitted Process Control Plan shall include the following minimum

information for each Key Product Characteristic (KPC) specified and Key

Process Characteristic used by the supplier (and should be used for all process

steps). Supplier Key Product and Process Characteristics shall be included.

o Process Name/Operation Description.

o Product Characteristic.

o KPC Identifier.

o Product Specification.

o Measurement Technique.

o Sampling Plan.

o Control Method.

o Reaction Plan.



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3.4.8. Measurement System Analysis (MSA) Studies

Suppliers shall have applicable MSA studies (i.e., gage R&R, bias, linearity,

stability, for all new or modified gages, measurement, and test equipment).

A measurement system analysis is a mathematical method of determining how

much the variation within the measurement system contributes to the overall

measured process variability. An MSA is required for all KPC’s that require a

capability analysis. Detail on the MSA can be found in the AIAG manual. The

suggested method to analyze the measurement system is a Gage R&R study.

Gage R&R studies are required for PPAP submittal.

A Gage R&R (repeatability and reproducibility) study is used to understand how

consistent the gage’s measurements within a process are, regardless of the

operator. Using total tolerance, the percentage of R&R should strive to be less

than 10%. Gages are considered marginal if between 10% and 30%. If greater

than 10%, an explanation of why the gage is to be used shall be included.

Every effort shall be made to include samples that represent the full range of

process variation.

3.4.9. Dimensional Results

The dimensional results (previously referenced as FAIR – first article inspection

report) are a comprehensive inspection report of a production intent part(s).

Suppliers shall provide evidence that dimensional verifications required by the

Design Record and Control Plan have been completed and results indicate

compliance with specified requirements. This includes ANY functional

requirement as defined by the Design Record.

Suppliers shall record, with actual results: all dimensions (except reference

dimensions), characteristics and specifications as noted on the Design Record

and Control Plan.

Suppliers shall indicate the date of the Design Record, ECL and any authorized

engineering change document not yet incorporated in the Design Record

(Element 2) to which the part was made.

This information will also be included with all auxiliary documents (i.e.,

supplementary layout results sheets, sketches, tracings, cross sections, CMM

inspection point results, scanning, GD&T sheets or other auxiliary drawings used

in conjunction with the part drawing).

Per the Polaris Supplier Quality Assurance Manual, ballooned drawings

corresponding to the dimension results will also be provided.

When a “changes only” dimensional result is required, every change made to the

drawing as defined in the most current revision shall be analyzed. A ballooned

drawing reflecting only those changes shall also be submitted.



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When a tool has multiple cavities, stations, etc., one sample from each

cavity/station shall be measured.

Polaris does not require a supplier to submit a standard dimensional results form;

this allows suppliers to utilize their own internal documentation system to

provide this report.

For positional tolerances, the basic dimensions used to determine the location

must be listed on the dimension results report.

IMPORTANT: The parts measured for the dimensional results should be the

same part(s) submitted as formal samples in Element 14. All drawing

requirements shall be conforming to specs prior to submission, or an approved

deviations or DCR must accompany the submission.

A submitted dimensional result shall include the following information:

o Supplier Name.

o Polaris Part Number.

o Revision Level.

o Part Name.

o Date Inspected.

o A listing of all measuring equipment used.

o A listing of each characteristic measured including:

Nominal dimension call out.

Upper specification limit call out.

Lower specification limit call out.

Actual measurements taken with indication of pass/fail.

o A listing of all engineering material call outs with verification of

actual materials used.

o Verification of any specific engineering test call out (i.e. hardness,

surface finish, color, gloss, etc.).

o Name of inspector(s).

o Submit the actual part(s) measured with the dimensional result report.



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3.4.10. Material, Performance Test Results

Suppliers shall have records of material and/or performance test results for tests

specified on the Design Record or Control Plan.

Suppliers shall perform tests for all parts and product materials when chemical,

physical or metallurgical requirements are specified by the Design Record or

Control Plan.

Material test results shall indicate and include:

o The Design Record change level of the parts tested.

o Any authorized engineering change documents that have not yet been

incorporated in the Design Record.

o The number, date and ECL of the specifications to which the part was

tested.

o The actual results.

o The material supplier’s name.

o For products with Polaris-developed material specifications and a

Polaris-approved supplier list, the supplier shall procure materials

and/or services (i.e., painting, plating, heat-treating, welding) from

suppliers on that list.

Performance test results shall indicate and include:

o The Design Record change level of the parts tested.

o Any authorized engineering change documents that have not yet been

incorporated in the Design Record.

o The number, date and ECL of the specifications to which the part was

tested.

o The date on which the testing took place.

o The quantity tested.

o The actual results.

3.4.11. Initial Process Studies

The initial process study is a multi-part statistical study of critical and significant

dimensions to determine if the production processes are likely to yield products

that will consistently meet Polaris’ requirements.

The level of initial process capability or performance shall be determined to be

acceptable prior to submission for all Special Characteristics (KPC) designated

by Polaris.



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o 1.33 Cpk is the acceptable level for capability. All KPC’s shall meet

this level at a minimum. If the KPC does not meet a 1.33 Cpk, 100%

inspection shall be implemented in-process until it has been proven

that a 1.33 Cpk can be met, sustained and approved via the PPAP

process. This shall be documented on the process control plan.

Suppliers shall perform measurement system analysis to understand how

measurement error affects the study measurements.

o The part drawing defines the critical and significant dimensions

through the use of KPC’s and the (diamond) symbol. All dimensions

listed as KPC’s shall have a process study performed and have a

known Cpk Index that are tracked and maintained by the supplier or

the supplier must provide evidence of an error-proofed process.

There are certain cases where a non-KPC dimension requires a

process study and that will be detailed in the Polaris PPAP Request

System (such instances may include verification of a corrective

action).

The initial process study is focused on variables, not attribute data.

o Assembly errors, test failures and surface defects are examples of

attribute data, which is important to understand, but is not covered in

this initial study.

o To understand the performance of characteristics monitored by

attribute data will require more data collected over time. Unless

approved by a Polaris authorized quality assurance representative,

attribute data is not acceptable for PPAP submissions.

Cpk – the capability index for a stable process. It is used to predict the

future capability and is a measure of the inherent process variation of a

specific dimension, relative to an engineering specification, expressed in

terms of three standard deviations. A Cpk Index encompasses both process

spread (variation) and process centering and can only be determined from a

process verified to be within statistical control.

Ppk – the performance index. Ppk 1.67 for short term or initial

qualification. Cpk – go back after 3 months and reevaluate. Continual

monitoring required.

Sample Size: The standard sample size for determination of a Cpk Index is

30 unless otherwise specified. Samples drawn for statistical inferences as

well as Cpk calculations are to be selected from a consecutive based

sampling plan unless otherwise specified.

Multiple Tooling/Multi-Cavity Tooling: A separate Cpk analysis may be

required for each tool or cavity used to produce the same part number.



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Polaris Quality Assurance will define requirements via a Part Qualification

Request. Cavity traceability is vital for monitoring quality performance and

shall be considered with tooling design.

3.4.12. Qualified Laboratory Documentation

Inspection and testing for PPAP shall be performed by a qualified laboratory as

defined by Polaris requirements (i.e., an accredited laboratory).

The qualified laboratory (internal or external to the supplier) shall have a

laboratory scope and documentation, traceable to N.I.S.T., showing that the

laboratory is qualified for the type of measurements or tests conducted.

When an external/commercial laboratory is used, the supplier shall submit the

test results on the laboratory letterhead or the normal laboratory report format.

o The name of the laboratory that performed the tests, date(s) of the

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

3.4.13. Appearance Approval Report

An appearance approval report shall be completed for each part (or series of

parts) when appearance requirements exist on the design record. Once the

appearance meets the requirements, a completed AAR and representative

production part(s) shall be submitted using the Polaris AAR Form.

Polaris AARs (complete with part disposition and Polaris quality assurance

representative signature) shall then accompany the PSW at the time of final

submission based upon submission level requested.

3.4.14. Sample Production Parts

PPAP samples must be taken from a Significant Production Run.

Sample sizes for PPAP reporting purposes should be of at least 5 parts.

Samples provided for Polaris approval can be a minimum of 1 part.

Ship sample part(s) to the attention of the responsible Polaris quality assurance

representative and to the location noted in the PPAP Request.

Include method of shipment (i.e. UPS, FedEx, etc.) and the shipper’s tracking

number in the PPAP Request.

Sample parts are to be shipped shortly after the electronic data is submitted to the

Polaris quality assurance representative.

The Sample Part Label (found in the Polaris Supplier Quality Assurance Manual)

must be affixed to the shipping containers.

Samples are to be shipped free of charge – Do not send sample parts with

inventory/production shipments – samples must be separate.



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Do not ship the sample(s) against any purchase order.

The bill of lading, invoice or packing slip must clearly state the parts are

“sample” at no cost to Polaris.

If samples are shipped against a purchase order they will be received into

inventory and will not be considered as PPAP samples – subject to an RMO.

3.4.15. Master Sample

The supplier shall retain a master sample for the same period as the production

part approval records (for one year after discontinuation) or:

o Until a new master sample is produced for the same Polaris P/N for

Polaris approval.

o Where a master sample is required by the Design Record, Control

Plan or inspection criteria, as a reference of standard.

The master sample shall be identified as such, and shall show the Polaris

approval date on the sample.

The supplier shall retain a master sample for each position of a multiple cavity

die, mold, tool or pattern, or production process unless otherwise specified by

Polaris.

Master samples are sometimes referred to as “golden parts”.

3.4.16. Checking Aids

If requested by Polaris, the supplier shall submit with the PPAP submission any

part-specific assembly or component checking aid.

The supplier shall certify that all aspects of the checking aid agree with part

dimensional requirements. Evidence can be provided using drawings, pictures,

etc.

The supplier shall document all released engineering design changes that have

been incorporated in the checking aid at the time of submission.

The supplier shall provide preventive maintenance of any checking aids for the

life of the part.

Measurement system analysis studies, i.e., gage R&R, accuracy, bias, linearity

and stability studies, shall be conducted in compliance with Polaris requirements.

Checking aids can include fixtures, variable and attribute gages, models,

templates and mylars specific to the product being submitted.

3.4.17. Customer-Specific Requirements

The supplier shall have records of compliance to all applicable Polaris-specific

requirements.



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Examples may be:

o Tooling information form.

o Packaging form.

o Inspection plan.

o PDI checklist.

o Supplier PPAP worksheet.

This would be defined by an authorized Polaris quality assurance representative.

3.4.18. Part Submission Warrant (PSW)

Upon completion of all PPAP requirements, the supplier shall complete the PSW.

A separate PSW shall be completed for each Polaris P/N unless otherwise agreed

to by an authorized Polaris quality assurance representative.

The specific cavities, molds, line, etc. reported in the Dimensional Results shall

be identified in the “Mold/Cavity/Production Process” line on a PSW, or in a

PSW attachment.

The supplier shall verify that all of the measurement and test results show

conformance with Polaris requirements and that all required documentation is

available and included in the submission as appropriate.

A responsible official of the supplier shall approve the PSW and provide contact

information.

Note: Polaris will not be signing nor returning submitted PSWs.



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Completing the PSW - minimum requirements outlined below:

o Be sure to select at least one box for each section – Reason for

Submission, Requested Submission Level and Submission Results.



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3.5. PPAP SUBMISSION LEVELS

Level 1

o Elements 13 (if applicable) and 18 are submitted to Polaris, balance of

elements retained at supplier.

Used when seeking a PSW and Appearance Approval Report

only, or a current supplier who has provided acceptable

quality and an ECL ‘opens up’ a previous requirement.

Level 2

o Elements 1, 2, 9, 10, 12, 13, 14 and 18 where applicable are submitted

to Polaris, balance of elements retained at supplier.

Typically ECL (Rev changes) to a current supplier for the

same product or low to medium risk products/services.

Level 3

o Elements 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 17 and 18 (where

applicable) submitted to Polaris, balance of elements retained at

supplier.

Should be used on high risk parts or new suppliers.

Level 4

o Used when custom requirements are best suited.

o At a minimum elements 1, 18 and other elements defined by Polaris

in the PPAP Request are submitted, balance of elements retained at

supplier.

Unless otherwise specified, the default elements in a Polaris

Level 4 PPAP include the following items:

1. Design Record (Polaris drawings only with released

Polaris part numbers).

5. Process Flow Diagrams.

6. Process FMEA - Failure Mode Effects Analysis

(PFMEA).

7. Control Plan.



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8. Measurement System Analysis Studies - if applicable for

KPCs (MSA).

9. Dimensional Results (Previously referred to as FAIR)

10. Material, Performance Test Results.

11. Initial Process Study – Cpk (if applicable for KPCs)

13. Appearance Approval Report - if applicable for

appearance items (AAR).

14. Sample Product.

18. Part Submission Warrant (PSW).

Level 5

o Product samples and supporting data is to be retained and reviewed at

the organization’s manufacturing location.

Used when on site approval is the best option.

Note: – Submission levels, individual requirements and purposes are at the sole

discretion of the Polaris quality assurance representative to ensure design

intent, a controlled process and mitigated risk.

3.6. ELECTRONIC SUBMISSION REQUIREMENTS

PPAP submissions need to be in English.

Suppliers must submit PPAP documents electronically to the Polaris quality

assurance representative listed in the PPAP Request system.

Suppliers shall send only one email for each PPAP Request with the part number

in the subject line of the email.

Failure to do so will delay review of the submission and the

submission might be counted as late.

Suppliers shall send all electronic data (.xls, .pdf, .tif or .doc format) to the QE

email link on the PPAP Request.

If the files are ‘zipped’ suppliers must make sure that ‘polaris’ is included in the

name of the .zip file or the file will be quarantined by the Polaris firewall.

Suppliers shall send sample parts to the address listed in the PPAP Request

shortly after the electronic data is sent.

When suppliers send electronic data and sample parts, they shall list the shipper

name (i.e. UPS, FedEx, etc.), tracking number and the date/content/method/to

whom electronic data was sent in the supplier information section of the PPAP

Request.



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3.7. SIGNIFICANT PRODUCTION RUN

Only production parts can be PPAPd.

For production parts, product for PPAP shall be randomly taken from a

significant production run.

This significant production run shall be from one to eight hours of production

and with the specific production quantity, to total a minimum of 30 consecutive

parts (unless otherwise specified by the authorized Polaris quality assurance

representative).

The significant production run shall be conducted at the production site, at the

production rate agreed upon on the Polaris PO (delivery), using production

tooling, production gaging, production process, production materials and

production operators.

Parts from each unique production process, i.e., duplicate assembly line and/or

work cell, each position of a multiple cavity die, mold, tool or pattern, shall be

measured and representative parts tested.

3.8. PART SUBMISSION STATUS

PPAP submissions will be reviewed by the Polaris quality assurance representative

and location noted on the PPAP Request.

PPAP dispositions carry-over for all of Polaris, not just the business unit

dispositioning the PPAP Request.

Approved

o Approved indicates the submitted part, including all sub-components,

meets all customer requirements.

o The supplier is therefore authorized to ship production quantities of

the product, subject to releases from the customer scheduling activity.

Interim Approval

o Interim Approval permits shipment of material for production

requirements on a limited time or piece quantity basis.

o Interim Approval will only be granted when the supplier has:

Clearly defined the non-compliances preventing approval; and

prepared an action plan agreed upon by the customer.

PPAP re-submission is required to obtain a status of

“approved.”



Manual Procedure



o Material covered by Interim Approval that fails to meet the agreed-

upon action plan, either by the expiration date or the shipment of the

authorized quantity, will be rejected.

o No additional shipments are authorized unless an extension of the

Interim Approval is granted.

o In situations where production parts are needed prior to the supplier’s

ability to meet all of the conditions of PPAP (use of temporary

tooling, not run at rate, etc.) the Polaris quality assurance

representative may grant Interim Approval to allow the supplier to

ship product allowing the supplier to resubmit the PPAP when all

aspects of the PPAP are compliant.

The rule of limited time or piece quantity basis still applies as

with all of the conditions of Interim Approval.

Rejected

o Rejected means that the PPAP submission does not meet the customer

requirements, based on the production lot from which it was taken

and/or accompanying documentation.

In such cases, the submission and/or process, as appropriate,

shall be corrected to meet Polaris requirements.

The submission shall be approved before production quantities

may be shipped.

4. REFERENCES

Polaris Supplier Quality Assurance Manual (SQAM).

AIAG (Automotive Industry Action Group) reference manuals (4th Editions) are used

by Polaris Industries and can be purchased at www.aiag.org. They are available in

Chinese, Japanese, Korean, Portuguese, Russian, Spanish & German.

o Production Part Approval Process (PPAP).

o Advanced Product Quality Planning & Control Plan (APQP).

o Potential Failure Modes and Effects Analysis (PFMEA).

o Measurement System Analysis (MSA).

o Statistical Process Control (SPC).

http://www.aiag.org/



Manual Procedure



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