PPAP Audits – Production Plan Approval Process

Production Plan Approval Process (PPAP) is used extensively in Automotive industry especially applicable to tier 1 and tier 2 suppliers.

PPAP is an essential part of the 7 Core tools used in Automotive industry the other six being Advanced production Quality Plan (APQP), Control Plan. (CP) Design Failure Mode Effects Analysis (DFMEA), Process Failure Mode Effects Analysis (PFMEA), Measurement System Analysis (MSA), and Statistical Process Controls (SPC)

Essentially the plan must include the Design requirements of the Part, Addition of any special customer’s design requirements, functional requirements of the product, and the production process which includes ensuring the safety of the product while in use. In other words, the plan must include requirements of “Fit” “Form” “Function” and “Safety” of the part under approval.

Approval by customer is required for implementing PPAP.

This approval of the customer is obtained on a document called Part Submission Warrant (PSW).

There can be 5 levels of PSW submissions

Level 1. PSW directly submitted to customer where the part has low risk and has single controllable process with open tolerance dimensions and is a simple part.

Level 2. PSW with product sample with some supportive data. This also is used for low risk low significance on the performance of the product

Level 3. PSW submitted with product samples and complete supporting data

Level 4. PSW submitted with product samples, complete supporting data and other requirements of the Customer such as PFMEA.

Level 5. PSW submitted with Product Samples, Complete production and process data along with DFMEA and PFMEA records available at the location for customer review and approval.

There are about 9 elements to be taken care while submitting PSW:

1. Design Records: A print or copy of the part drawing along with design considerations taken in to account in as much detail as possible.
2. Authorized Engineering Change Documents: Associate documents to show any corrections or improvements done based on trial production and approved by engineering personnel designing the product and communicated to all concerned to effectively incorporate changes.
3. Customer Approval: Before submission of PSW the drawing changes must be approved by customer before incorporating in to engineering change notices. Temporary approval for changes alone is obtained and appended to PSW.
4. Design Failure Mode Effects Analysis (DFMEA): This will be required if the Part supplier is also designed of the part based on fit form function and safety requirements stated by the customer. Normally this is a feature done by OEM automotive manufacturers and not shared with part suppliers.
5. Process Flow Diagram: The path followed by the parts as per the processes from start to finish in a schematic diagram to determine where PFMEA is to be applied.
6. Process Failure Mode Effects Analysis: (PFMEA): These are the details of all possible failure mode analyses, and results of process variations brain stormed by part manufacturers’ PFMEA team along with acceptable norms and final confirmed process to be submitted for approval by Customer.
7. Control Plan: Complete Plan of how and where control measures will be applied during process along with acceptance criteria needs to be submitted to Customer. This will become a living document for the manufacturer and control document for customer till the life of the product. Any change or re start requires re run of the control plan to ensure that process is being followed as per plan.
8. Measurement System Analysis Studies:  Results of an analytical study on the repeatability and reproducibility of the measuring instruments needs to be submitted along with PSW for approval.
9. Dimensional Results: A comprehensive report of all dimensions recorded during trial production of the part along side the acceptance limits and the status of acceptance must be recorded and submitted along with PSW
10. Records of Material Performance Test:  The certificates of conformance for the materials used in production of the part is to be submitted along with all above referred documents for PPAP approval.

 

QSE Difference:  Quality Systems Enhancement is can conduct a thorough audit on PPAP and have the plan approved by Customer on first submission. We can assist in creating the documentation conduct PFMEA team brain storming sessions.  Create and up date documentation and make the dossier ready for customer approval, along with finalization on Risk priority number for each of the processes in the process flow diagram. Contact for immediate assistance (770)-518-9967 or e mail:info@qsebackup.atlcreative.co for further details.