PPAP_Process-Guide_Example

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					                                PPAP Review Process Guide                                                        Purchasing Representative ____________________

      Supplier:                                                                                       Part Number:
      Sent to Tech Rev ________________: Rev Comp'l            ________________                                  Sent to Engr Review____________ : Rev comp'l ___________
      Number Open FMEA Actions ________________                                                                  Risk:   Low           Moderate          High
                                                Audit Items                                           Result                           Comments
      GENERAL                                                                                         Yes   No
1.    Are all applicable elements, as required by the submission checklist, included?
2.    Is customer PPAP checklist included and complete?
3.    Is Part #, Description, and Revision level documented and correct?
4.    Do elements submitted correlate to submission level requested?
5.    Submitted in a timely manner per purchasing instructions?

      1. WARRANT                [PSW]                                                                 Yes   No
1.    Are all required sections filled in by supplier?
2.    Is appropriate submission level checked?
3.    Are submission results marked?
4.    Is production rate indicated in the Declaration?
5.    Is warrant signed by appropriate supplier quality representative?

      2. DESIGN RECORDS                                                                               Yes   No
1.    Are customer print(s) included to correct revision level?
2.    Are prints of components and details included?
3.    Is CAD/CAM math data submitted?
4.    If there is no customer print, are supplier prints included?
5.    Are all print dimensions (including specs., mtl., & notes) numbered?
6.    For an Aluminum or Zinc Casting, are "Casting Production Specification"
      forms E06M001A or E06M001B included.

      3. AUTHORIZED ENGINEERING CHANGE DOCUMENTS                                                      Yes   No
1. If submitting to design records undergoing engineering change not yet officially
   incorporated, are authorized engineering change documents included?

      4. ENGINEERING APPROVAL                                                                         Yes   No
1. Is engineering approval provided where required?
     Note: Only applies when required on HD part drawing or specification.




     S06A001C Rev. 3 4/3/2001                                                           Page 1 of 5                                                      2/10/2010 4:58 PM
                                 PPAP Review Process Guide                                                  Purchasing Representative ____________________

       Supplier:                                                                                 Part Number:
       5. DESIGN FAILURE MODE & EFFECTS ANALYSIS [DFMEA]                                         Yes   No
 1.    If supplier is responsible for design is DFMEA included?
 2.    If customer did DFMEA, is it included for reference?
 3.    Are potential failure modes included?
 4.    Are potential effects of failure recorded?
 5.    Are potential cause(s)/mechanism(s) of failure recorded?
 6.    Are current process controls recorded?
 7.    Are severity / occurrence / detection levels assigned (rank 1-10)?
 8.    Are RPN numbers calculated (severity x occurrence x detection) and noted?
 9.    Are recommended action(s) and results recorded for high RPN numbers?
10.    Are dates and person responsible noted for each recommended action?
11.    Are all KPC(s) and KCC(s) (special characteristics) included?
12.    Are part number and revision level noted ?

       6. PROCESS FLOW DIAGRAMS [PFD]                                                            Yes   No
1.     Is process graphically shown?
2.     Are all steps of process included (outside services)?
3.     Are part number and revision level noted?
4.     Are machine names and/or numbers included?

       7. PROCESS FAILURE MODE & EFFECTS ANALYSIS                   [PFMEA]                      Yes   No
 1.    Does FMEA follow process flow and are all process steps included in FMEA?
 2.    Are potential failure modes included?
 3.    Are potential effects of failure recorded?
 4.    Are potential cause(s)/mechanism(s) of failure recorded?
 5.    Are current process controls recorded?
 6.    Are severity / occurrence / detection levels assigned (rank 1-10)?
 7.    Are RPN numbers calculated (severity x occurrence x detection) and noted?
 8.    Are recommended action(s) and results recorded for high RPN numbers?
 9.    Are dates and person responsible noted for each recommended action?
10.    Are all KPC(s) and KCC(s) (special characteristics) included?
11.    Are part number and revision level noted?




      S06A001C Rev. 3 4/3/2001                                                     Page 2 of 5                                             2/10/2010 4:58 PM
                                PPAP Review Process Guide                                                         Purchasing Representative ____________________

      Supplier:                                                                                        Part Number:
      8. DIMENSIONAL RESULTS                                                                           Yes   No
          Note: Can be tabulated for ballooned print or shown on drawing check print.
1.    Are actual results recorded for two samples (or for # of samples requested)?
2.    Are specification and tolerance included to compare to result?
3.    Are results recorded for all dimensions, specifications, and notes?
4.    Do results fall within specification limits?
5.    Is part # and revision level documented?
6.    Are KPC & KCC dimensions identified?

      9. MATERIAL, PERFORMANCE, & DURABILITY TEST RESULTS                                              Yes   No
1. Are test results included for all tests required by the design record and related specifications?
2. Do actual results meet requirements?
3. Is material what is specified on design record?
4. Are performance & durability results included as specified?
5. Do reports show who performed tests, date of test, number parts tested, change level of
   parts tested, and change level of specification parts were tested to?
6. Are there tests for all GES, ASTM, and other referenced specifications?
7. If applicable, is "Foundry Trial Plan Summary' attached. [E06M001C]

      10. INITIAL PROCESS CAPABILITY RESULTS                                                           Yes   No
1. Are control charts submitted which show a stable, in-control, process?
   Note: Histograms do not show stability and are not acceptable unless agreed to in writing prior to submission.
2. Are capability results reported for all KPCs & KCCs?
3. Do results equal 1.67 or greater for first time capability?
4. If results represent ongoing results is CpK 1.33 or greater?

      11. MEASUREMENT SYSTEM ANALYSIS STUDIES                                                          Yes   No
1.    Are results reported for each KPC & KCC measurement tool?
2.    Are R&R results >10%?
3.    If R&R results >10% to < 30%, is there documented evidence of review for acceptability?
4.    Are R&R results > 30%?
5.    Are attribute studies reported for attribute gauging?
6.    Was Measurement Systems Analysis performed on all checking aids?




     S06A001C Rev. 3 4/3/2001                                                           Page 3 of 5                                              2/10/2010 4:58 PM
                              PPAP Review Process Guide                                                          Purchasing Representative ____________________

    Supplier:                                                                                         Part Number:
    12. QUALIFIED LABORATORY DOCUMENTATION (as required)                                              Yes   No
1. Is A2LA certification provided of accreditation to ISO/IEC Guide 25.
2. Is laboratory accredited for tests conducted.

    13. CONTROL PLAN                                                                                  Yes   No
 1. Does control plan follow the process flow and PFMEA, are all process steps included?
 2. Are all KPC(s) & KCC(s) listed with control method, including capability
    tracking and reporting where possible?
 3. Are KPCs specially marked (highlighted) within Control Plan?
 4. Are product / process specification / tolerance reported for each control step?
 5. Are evaluation/measurement techniques reported?
 6. Is sample size and frequency reported for each characteristic?
 7. Are control methods recorded?
 8. Are reaction plans recorded?
 9. Are part number and revision level noted?
10. Are all special gages and/or fixtures noted?
11 Are "Checking Aids" identified on control plan by gage number as shown on warrant?

    14. COSMETIC VALIDATION REPORT                                                                    Yes   No
1. Is part cosmetic (cosmetic zones defined)?
       If no, cosmetic validation report not required.
2. Is cosmetic validation from completed and acceptable?

    15. BULK MATERIAL CHECKLIST (Bulk Material PPAP only)                                             Yes   No
1. Are Bulk Material requirements and Checklist applicable?
2. Are target dates entered for each item with customer / supplier responsibility identified?
3. Is there an approval date for each item?

    16a. SAMPLE FOR LAYOUT                                                                            Yes   No
1. Was sample(s) provided in accordance with submission level?
2. If submission level 2 or 3, was part(s) sent to specified site for customer layout and approval?
3. Was layout submission acceptable?




   S06A001C Rev. 3 4/3/2001                                                          Page 4 of 5                                                2/10/2010 4:58 PM
                                PPAP Review Process Guide                                                        Purchasing Representative ____________________

      Supplier:                                                                                       Part Number:
      16b. COSMETIC / STYLING SAMPLE(S)                                                               Yes   No
1. Was sample(s) provided in accordance with submission level?
2. If submission level 2 or 3, was part(s) sent to specified site for customer layout and approval?
3. Was cosmetic / styling submission acceptable?

      17. MASTER SAMPLE TO BE RETAINED BY SUPPLIER

      18. CHECKING AIDS SPECIFIC TO THE PART BEING SUBMITTED                                          Yes   No
1.    See Part Submission Warrant to verify checking aids are noted.
2.    Are correct Engineering Change Level and date shown on Warrant?
3.    See Control Plan to verify checking aids are noted.
4.    Is there evidence "all aspects of the checking aid agree with part dimensional requirements"?

      19. CUSTOMER-SPECIFIC REQUIREMENTS                                                              Yes   No
1. Are there Customer-Specific requirements (must be specified on attachment
   to Submission Checklist)?
2. Do records indicate supplier has complied with these requirements?




     S06A001C Rev. 3 4/3/2001                                                        Page 5 of 5                                                2/10/2010 4:58 PM

				
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