Welcome to Training Programme on

Production Part Approval Process

WHAT IS PPAP?
• PPAP - Production Part Approval Process

Standard used to formally reduce risks prior to

product or service release, in a team oriented
manner using well established tools and
techniques.

Initially developed by AIAG (Auto Industry

Action Group) in 1993 with input from the Big
3 - Ford, Chrysler, and GM
PURPOSE OF PPAP
• Provide evidence that all customer engineering
design record and specifications and requirements
are properly understood by the organization.

• To demonstrate that the manufacturing process has

the potential to produce product that consistently
meets all requirements during an actual production
run at the quoted production rate

PPAP manages change and ensures

product conformance!
WHEN IS PPAP REQUIRED?
 New part
 Engineering change(s)
 Tooling: transfer, replacement, overhaul
 Correction of discrepancy
 Tooling inactive for long time
 Change of material
 Sub-supplier or material source change
 Change in part processing sequence
 Parts produced at a new or additional location

PPAP is required with any significant

change to product or process!
BENEFITS OF PPAP SUBMISSIONS
• Helps to maintain design integrity

• Identifies issues early for resolution

• Reduces warranty charges and cost of poor quality

• Assists with managing supplier changes

• Prevents use of unapproved and nonconforming parts

• Identifies suppliers that need more development

• Improves the overall quality of the product &

customer satisfaction
PRODUCTION RUN

• PPAP data must be submitted from a production run

using:

 Production equipment and tooling

 Production employees

 Production rate

 Production process
PPAP REQUIREMENTS
1. Design Records
2. Authorized Engineering Change Documents
3. Customer Engineering Approval, if required
4. Design Failure Modes and Effects Analysis (DFMEA) applied in
special situations
5. Process Flow Diagram
6. Process Failure Modes and Effects Analysis (PFMEA)
7. Control Plan
8. Measurement Systems Analysis (MSA)
9. Dimensional Results
10. Records of Material / Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report (AAR)
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer-Specific Requirements
18. Part Submission Warrant (PSW)
 PPAP SUBMISSION LEVEL TABLE(SAMPLE)
PPAP Levels for Submission & Retention

Submission Level
Requirement Level 1 Level 2 Level 3 Level 4 Level 5
S = Supplier shall
1. Design Records of Saleable Product
a. For proprietary components/details
R
R
R
R
R
R
*
*
R
R
submit to customer&
b. For all other components/details
2. Engineering Change Documents, if any
R
R
R
S
R
S
*
*
R
S retain a copy of records
3. Customer Engineering approval, if required
4. Design FMEA
R
R
S
R
S
R
*
*
S
R
or documentation items
5. Process Flow Diagrams
6. Process FMEA
R
R
R
R
S
S
*
*
S
S
at appropriate locations
7. Dimensional Results S S S * S
8. Material, Performance, Test Results R S S * S
9. Initial Process Study R R R * R
10. Measurement System Analysis Studies R R S * S
11. Qualified Laboratory Documentation R R S * S
12. Control Plan R R S * S
13. Part Submission Warrant (PSW) S S S * S
14. Appearance Approval Report, (AAR) if applicable S S S * S
15. Bulk Material Requirements Checklist (for bulk
material only) R R R * R
16. Sample Product R S S * S
17. Master Sample R R R * R
18. Checking Aids R R R * R
19. Records of compliance with Customer-Specific
Requirements (DVP&R) R R R * R R = Supplier shall retain
S = The supplier shall submit to NCR and retain a copy of records or documentation items at appropriate locations. at appropriate locations
R = The supplier shall retain at appropriate locations and make readily available to NCR upon request. and make readily
* = The supplier shall retain at appropriate locations, and submit to NCR upon request. NCR will identify what is available to customer
needed for submission.
upon request
.
PRODUCTION WARRANT
PRODUCTION WARRANT
Production Warrant What is It?
Part Name NCR Part Number • Document required for all newly
tooled or revised products in which
Shown on Drawing no. Supplier Part Number

Engineering Drawing Change Level Dated

the supplier confirms that

Additional Engineering Changes Dated

Safety and/or Government Regulation Yes No Purchase order No. Weight (kg)

inspections and tests on production

Checking Aid No. Engineering Change Level Dated

SUPPLIER MANUFACTURING INFORMATION NCR SUBMITTAL INFORMATION

parts show conformance to

Supplier Name Supplier Code NCR Location

Street Address Buyer

customer requirements
Buyer Code

City Region Postal Code Country Model Name / Number

Note: Does this part contain any restricted or reportable substances? Yes No

Objective or Purpose
Are parts identified with appropriate UL/CE/ISO marking codes if applicable? Yes No

REASON FOR SUBMISSION

Initial Submission Change to Optional Construction or Material

Used to :
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part processing
Correction of Discrepancy Parts Produced at New or Additional Location

• document part approval

Tooling Inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one based on NCR requirements)

• provide key information

Level 1 - Production Warrant and Appearance Approval Report (if applicable) submitted to NCR

Level 2 - Production Warrant, product samples, and dimensional results submitted to NCR

Level 3 - Production Warrant, product samples, and complete supporting data submitted to NCR

Level 4

Level 5
-

-
Production Warrant and other requirements as defined by NCR

Production Warrant, product samples, and complete supporting data reviewed at supplier's manufacturing location
• declare that the parts meet
SUBMISSION RESULTS

The results for dimensional measurements material and functional tests appearance criteria statistical process package
specification
These results meet all drawing and specification requirements: Yes No (If "No" - Explanation Required)

When to Use It
Mold / Cavity / Production Process:

DECLARATION

• Prior to shipping production parts

I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all of NCR's
Production Part Approval Process requirements. I further affirm that these samples were produced at the production rate of
_____ pieces / _____ hours. I also certify that documented evidence of such compliance is on file and available for review. I have noted
any deviations from this declaration below.
EXPLANATION/COMMENTS:

Supplier Authorized Signature Date

Print Name Title

Email Phone No.

FOR CUSTOMER USE ONLY (IF APPLICABLE)

PPAP Warrant Disposition: Approved Rejected Other ____________________________________________________
NCR Signature _____ Date
Print Name NCR Tracking Number (optional)
PRODUCTION WARRANT
Production Warrant

Part Name NCR Part Number

Shown on Drawing no. Supplier Part Number

Engineering Drawing Change Level Dated

Part Name / NCR Part Number

Additional Engineering Changes Dated

Shown on Drawing Engineering

Safety and/or Government
Number
Regulation released
Yes No finished
Purchase order No. Weight (kg)
Engineering Supplier
Change Part
Level & DateNumber
The design end item
record thatpart name and
specifies number
Checking Aid No.
Part
Engineering
number
Change Level
Show the change level and date defined
of by
Dated
the customer part number being the supplier, if any INFORMATION
the Design Record
submitted
SUPPLIER MANUFACTURING INFORMATION NCR SUBMITTAL

Supplier Name Supplier Code NCR Location

Purchase Order Number
Street Address Enter this number as found on
Buyer Buyer Code
the contract / purchase order
Checking Aid Number, Change Level, & Date
City Region
Enter if requested
Postal Code Country
by the customer
Model Name / Number

Note: Does this part contain any restricted or reportable substances? Yes No

Are parts identified with appropriate UL/CE/ISO marking codes if applicable? Yes No
PRODUCTION WARRANT
Production Warrant

Part Name NCR Part Number

Shown on Drawing no. Supplier Part Number

Engineering Drawing Change Level Dated

Additional Engineering Changes Dated

Safety and/or Government Regulation Yes No Purchase order No. Weight (kg)

Checking Aid No. Engineering Change Level Dated

SUPPLIER MANUFACTURING INFORMATION NCR SUBMITTAL INFORMATION

Supplier Name Supplier Code NCR Location

Street Address Buyer Buyer Code

City Region Postal Code Country Model Name / Number

Note: Does this part contain any restricted or reportable substances? Yes No

Are parts identified with appropriate UL/CE/ISO marking codes if applicable? Yes No
 PRODUCTION WARRANT
Reason For Submission
REASON FOR SUBMISSION
Check the appropriate box(es)
Initial Submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part processing
Correction of Discrepancy Parts Produced at New or Additional Location
Tooling Inactive > than 1 year
Requested Submission Level
Other - please specify

REQUESTED SUBMISSION LEVEL (Check one based on NCR requirements) Identify the submission level
Mold / Cavity / Production Process requested by customer
If production
Level 1 - parts will
Production be
Warrant andproduced from
Appearance Approval Report (if applicable) submitted to NCR

more than
Level 2 one mold,Warrant,
- Production cavity, tool,
product samples,die,
and dimensional results submitted to NCR
pattern, or
Level 3 production process,
- Production Warrant, Submission
product the and
samples, supplier
Results
complete supporting data submitted to NCR
shall complete
Level 4 a dimensional
- Production Warrant andCheck evaluation on
the appropriate
other requirements as defined by NCR boxes
one part from
Level 5
each. The specific molds,
- Production Warrant, product samples, and complete supporting data reviewed at supplier's manufacturing location
lines, etc. shall then be identified here.
SUBMISSION RESULTS

The results for dimensional measurements material and functional tests appearance criteria statistical process package
These results meet all drawing and specification requirements: Yes No (If "No" - Explanation Required)
Mold / Cavity / Production Process:
PRODUCTION WARRANT
Explanation / Comments Declaration
Entercommentsthe
Declaration
Affirmation
number that the samples represented
Provide any explanatory onof the pieces
submission results or manufactured by the during
any deviations warrant the are representative and
Supplier Authorized Signature
significant were made by run
production a process that meets NCR’s
from the Declaration. Attach additional
A DECLARATION
responsible supplier official,
and the PPAP time (inafter verifying
requirements
hours) taken
information as appropriate.
that the results show for the significantto
conformance all NCR
production run
I affirm that the samples represented by this warrant are representative of our parts, which were made by a process that meets all of NCR's
requirements and that all required documentation
Production Part Approval Process requirements. I further affirm that these samples were produced at the production rate of
is _____
available, shall
pieces / _____ hours. Iapprove
also certify that the declaration
documented evidence of such compliance is on file and available for review. I have noted
any deviations from this declaration below.
EXPLANATION/COMMENTS:

PPAP Warrant Disposition

Approved, Rejected,
Supplier Authorized Signature Other Date

Print Name Title

Email Phone No.

FOR NCR USE ONLY

PPAP Warrant Disposition: Approved Rejected Other ____________________________________________________
NCR Signature _____ Date
Print Name NCR Tracking Number (optional)
AUTHORIZED ENGINEERING
CHANGE DOCUMENTS
AUTHORIZED ENGINEERING CHANGE DOCUMENTS

 The supplier shall provide authorized change

documents for those changes not yet recorded in the
design record, but incorporated in the product, part or
tooling, such as:

 ECNs (must be approved, not pending)

 Specifications

 Feasibility studies

 Supplier change requests

 Sub-assembly drawings

 Life or reliability testing requirements

PROCESS FLOW DIAGRAM
PROCESS FLOW DIAGRAM
What is It?
Operator
Separate Cutting Evaluate for
• A visual diagram of the entire
process from receiving through
Tags Corrective Action
(31)

shipping, including outside

Yes
Operator Operator Operator Operator
Operator
Get Traveler and Operator Download Cutting Program Observe Cutting
Load Machine with Cutting Error?
Nest from Holding Prints Cut Tags Infomation Command Operation for

processes and services

Blanket (33)
Shelf (27) (2s to 2m) "Ready to Cut" Errors
(28)
(26) (29) (30) (32)

No

Operator
Remove Small
Plies from the
Cutting Table
Operator
Move to Kitting
Table
(37)
Operator
Tag Small Plies
(38)
Objective or Purpose
(36)

Small Plies

Large Operator Operator

No
To help people “see” the real process.
Process maps can be used to
Operator Operator
Tag while Laying Remove Plies Traveler Operator
Cutting Operation Large or Small Plies Piies Move Plies to Yes
on the Cutting from the Cutting Complete? Stamp Traveler
Complete or Test Coupons? Kitting Table
And Table Table (42) (43)
(34) (35) (41)
Coupons (39) (40)

understand the following

characteristics of a process:
• Set-by-step process linkage
• Offline activities (measurement,
6 Sigma Project Project Idea Department/Group Project
High Level Process Map High Level Process Map

Fill Out Master

inspection, handling)
Form
with Initial
Information

Other Required Other Required

Signatures: Signatures:
6 Sigma Assigns Segment CEO Champion: Group Assigns Get DLN
Get WO Assigned
Project Number Champion Process Owner Project Number Assigned
Process Owner Prefer to work Project Owner

• Rework, scrap
BB or GB No this project Dept GB/BB/MBB
within your
area?
Monitor Progress
Begin/Work Yes Monitor Progress Begin/Work
through Power
Project through Bi- Project
Steering and Finance Approval
Weekly Updates
Monthly and Signature Finance Approval
Follow DMAIC or and Monthly Follow DMAIC or
Financial and Signature
DFSS process Do you Reviews DFSS process
Reviews
No have BB/GB to
Assist/Work the
project?
Master Form Will
Complete Project Generate Yes Complete Project
(Has to be fully Contract Master Form Will (Has to be fully
Documented Generate Documented)
Contract

When to Use It
Yes Is Hard
Savings > $???

Enter Remaining
Final Project 6 Sigma Final Project
Information on No
Review Project Review
Master Form

Does the Department

Yes Enter Remaining

• To understand how a process is

Project Involve
Only Your
or Group Information on
Project Master Form
Group?
Finance Approval Finance Approval
and Signature and Signature
No

Does the

done
Other Required Other Required
Project Involve No
Signatures: Signatures:
Champion: Dir T&E >2 Groups in Champion: Dir T&E
Process Owner Eng? Process Owner
Project Owner Project Owner
Dept BB or MBB Yes Dept BB or MBB

Complete all Complete all

Does the
Documentation Documentation

• Prior to completing the PFMEA

Close Yes Project Involve No Close
including a including a
Project >3 Depts. Project
(1) Page Close- (1) Page Close-
outside Eng?
out Sheet out Sheet
PROCESS FLOW DIAGRAM - EXAMPLE
LEO PROCESS FLOW DIAGRAM F/QA/05/0
Part No. : 484 -0100264 Customer Name : NCR Doc. No. : PFD/NCR/0264
Shaft Pressure
Part Name : : Page : 1 of 1 Rev. No. / Date : O / 10.08.09
Paddle

Incoming CNC Sliding Deburring & Cleaning

Final Isnpection
Inspection Machining
10 15 20
05

**RM receiving Patrol Insp.

Insp. report report Final Inspection
register
Pre delivery
Pre shipment Oiling, Packing & Layout
Despatch Inspection
audit Preservation Inspection

70 60 50 40 30

Pre shipment Layout Inspection Self Inspection

audit report Report Report

Not ok , Rejected
** Inspection as per 100%
Inspection as If Rejected If rework
Opertion layout Re-inspection
per RIQP possible Rework

Not ok , Rejected
Return to Note : Not ok Ok
supplier Tags to be provided
for OK, Rework, Inspection Scrap Next
& Rejection operation

PREPARED BY & DATE APPROVED BY &

- MOVEMENT - PATROL INSPECTION - STORAGE
DATE
- SUPPLIER END OPERATION - PROCESS - INSPECTION T T Arul V Raja
PROCESS FLOW DIAGRAMS – REVIEW CHECKLIST

 Process Flow must identify each step in the

process
 Should include abnormal handling processes
 Scrap
 Rework
 Process Flow must include all phases of the
process
 Receiving of raw material
 Part manufacturing
 Offline inspections and checks
 Assembly
 Shipping
CONTROL PLAN
CONTROL PLAN
What is It?
A document that describes how to
control the critical inputs to
continue to meet customer
expectations of the output.

Objective or Purpose
• Primary reference source for
minimizing process and product
variation.
• Description of how teams should
react to out-of-control situations.
NOTE
Since processes are expected to be continuously When to Use It
updated and improved, the control plan
• Implementation of new process
is a living document!
• Following a process change
NCR’S CONTROL PLAN
CONTROL PLAN
Prototype Pre-Launch Production

Control Plan Number Key Contact/Phone Date:(Org.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)

Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date(If Req'd.)

Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique
 CONTROL PLAN
3 Distinct Phases

CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date:(Org.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)

Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date(If Req'd.)

Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique

3 Distinct Phases 3 Distinct Phases 3 Distinct Phases

1. Prototype – a2.description
Pre-Launchof3.the
– aProduction
description
– of
a comprehensive
the
dimensionaland
dimensional measurements measurements
documentationand of product/process
material and
material and performance testsperformance
characteristics,
that will tests
process
that will
controls, tests,
occur build.
occur during Prototype after Prototype
and measurement
and before full
systems that will
Production. occur during mass production
 CONTROL PLAN
Administrative Section

CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date:(Org.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)

Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date(If Req'd.)

Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique

Administrative Section
Identifies part number and description,
supplier, required approval signatures, and
dates.
 CONTROL PLAN
Process, Machine/Tools, Characteristics

CONTROL PLAN
Characteristics
Part/Process Define the characteristics
Use this area to define
Prototype Pre-Launch Production
of the product or process
Controlpart/process
Plan Number number and Key Contact/Phone Date:(Org.) Date (Rev.)
description.
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)

Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date(If Req'd.)

Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique

Machine/Tools
List the machine, device, jig, or tools
that will be used in the
manufacturing process
 CONTROL PLAN
Specifications, Measurement, Sample Size & Frequency
Sample Size
What is the size of the
sample you should gather
data from?
CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number
Specifications/Tolerance
Key Contact/Phone Date:(Org.) Date (Rev.)
Use this area to define upper/lower
Part Number/Latest Change Level spec limits for each
Core Team control element. Customer Engineering Approval/Date (If Req'd.)

Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date(If Req'd.)

Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique

Measurement Technique
For each line in the control plan, list the
measurement procedure that will be
Frequency
used (may list R&R Gage Plan or Poka- Define the frequency for
Yoke). which the measurement
will be taken.
 CONTROL PLAN Control Method
Control Method, Reaction Plan Method that will be used
to control the process

CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date:(Org.) Date (Rev.)

Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)

Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date(If Req'd.)

Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)

Characteristics Methods
Machine,
Process Special Evaluation Sample
Part/Process Device, Product/Process Reaction
Name/Operation Char. /Measure Control
Number Jig, Tools, No. Product Process Specification/ Plan
Description Class ment Size Freq. Method
for MFG. Tolerance
Technique

Reaction Plan
Actions to be taken if
controls fail
 CONTROL PLAN – EXAMPLE
A supplier manufactures a circuit board with electronic components soldered on the
board. Properly soldered connections are the major product characteristics. Two major
process characteristics for the wave solder machine are solder level and flux
concentration. An automated feeder controls the solder level by sensing the level of
solder and feeding in additional solder as the level is reduced. This characteristic is
measured 100% by checking electrically for continuity. The flux must be sampled and
tested for the concentration level. Control
Sample SizeMethod
Frequency
Product
Product==Automated
100% inspection
Product = Continuous
Characteristics
CONTROL PLAN Process
Process = x-MR chart
= 1 pc= 4 hours
Process
Product = Wave solder height
Prototype Machine/Tools
Part/Process Pre-Launch Production
Process = Flux concentration Reaction Plan
Specifications/Tolerance
Soldering
Control Plan Number
Wave solder machine Smith /mc
Connections Key Contact/Phone
002 Product = 2.0 +/-T.0.25 313-555-5555
Product = Adjust and
Date:(Org.)
11/29/2009
Date retest
(Rev.)
2/20/2010
Process
Part Number/Latest Change Level = Standard
Core Team #302B Process = Segregate
Customer and retest
Engineering Approval/Date (If Req'd.)
54321231 / D Erin Hope, Alan Burt, Ken Light
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date(If Req'd.)
Electronic Circuit Board
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
ACR Control 439412
Characteristics Methods
Machine,
Part / Process Name Special Sample
Device, Product/Process Evaluation / Reaction
Process
Number
/ Operation
Description
Jig, Tools, No. Product Process 3 Distinct Phases
Char.
Class
Specification/ Measurement
Size Freq.
Control
Method
Plan
for MFG. Tolerance Technique
Production
Automated
Wave Wave Sensor inspection
Soldering solder solder continuity (error Adjust and
2 Measurement Technique
Connections machine height 2.0 +/- .25 mc check 100% Continuous proofing) retest
Product = Sensor continuity check
Flux Test sampling
Process = Test sampling lab environment
concen - lab Segregate
tration Standard #302B environment 1 pc 4 hours x-MR chart and retest
CONTROL PLAN – REVIEW CHECKLIST
 Use process flow diagram and PFMEA to build the control plan;
keep them aligned
 Controls must be used to be effective. Keep it simple.
 Ensure that the control plan is in the document control system of
the business
 Good control plans address:
 All testing requirements - dimensional, material, and performance
 All product and process characteristics at every step throughout the process
 The control method should be based on an effective analysis of the
process
 Such as SPC, Error Proofing, Inspection, Sampling Plan
 Control plans should reference other documentation
 Specifications, tooling, etc.
DIMENSIONAL RESULTS
DIMENSIONAL RESULTS
What is It?
Non-Critical Dimensions
Date: Supplier Name: Date Code:

Evidence that dimensional

Part Number: Facility Location: Inspected By:

Revision: Supplier Code: Verified By:

The number of non-critical data points required for part qualification is 5. The non-critical data points
must be taken from the same 35-piece sample as the critical data points. Five partsfrom a production verifications have been completed
and results indicate compliance with
run must be shipped to NCR for verification of form, fit, and function. The same 5 parts will be used to
verify both critical and non-critical dimensions. The supplier must clearly identify which of the 35 parts
are being shipped. Non-critical dimensional results for the 5 parts being shipped must be entered
below. Critical dimensional results must be entered into the "FAI Critical Dimensions" worksheet. The
supplier should make every effort to ship 5 parts that represent both the low and high ends of the specified requirements.
specifications for the non-critical dimensions.
Cpk less than 1.33 will require action for improvement
Print zone or Nominal
spec note Value Tol + Tol - Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Cp Cpk Pass/Fail
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Objective or Purpose
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• To show conformance to the

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customer part print on dimensions

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and all other noted requirements.

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When to Use It
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• For each unique manufacturing

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process (e.g., cells or production

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lines and all molds, patters, or
List Gage R&R value: Name and ID of gage(s) used for measurement: dies
ACCEPTANCE CRITERIA - SAMPLE

Acceptance criteria for critical vs. non-critical characteristics

Critical Non-Critical Decision

Red (Bad) <1.33 <1.00
Yellow (OK) 1.33-1.67 1.00-1.33

Green (Good) >1.67 >1.33

Cpk must be greater than or equal to

1.67 for critical processes

Cpk must be greater than or equal to

1.33 for non-critical processes
RECORDS OF MATERIAL
/ PERFORMANCE TEST
RESULTS
RECORDS OF MATERIAL/PERFORMANCE TEST RESULTS

Material Test Results

 The supplier shall perform tests for all parts and product
materials when chemical, physical, or metallurgical
requirements are specified by the design record or Control
Plan

Performance Test Results

 The supplier shall perform tests for all parts or product

materials when performance or functional requirements are
specified by the design record or Control Plan
MATERIAL RESULTS
Production Part Approval - Material Results

Supplier Part Number Revision Level

Laboratory Outside laboratory Name of Laboratory Part Name

In-house testing

Type of
Material Spec. No./Date/Specification Supplier Test Results OK Not OK
Test

Material Results shall include:

 The name of the laboratory that conducted the test
 The type of test that was conducted
 The number, date, and specification to which the part was tested
 The actual test results

Signature Title Date

INITIAL PROCESS STUDY
QUALIFIED LABORATORY
DOCUMENTATION
QUALIFIED LABORATORY DOCUMENTATION
• Inspection and testing for PPAP shall be performed by a
qualified laboratory as defined by customer(e.g., an
accredited laboratory).

• The qualified laboratory (internal or external to the

supplier) shall have a laboratory scope and documentation
showing that the laboratory is qualified for the type of
measurements or tests conducted
 When an external laboratory is used, the supplier
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.
APPEARANCE APPROVAL
REPORT
 APPEARANCE APPROVAL REPORT
Appearance Approval Report What is It?
Part Number

Part Name
Drawing Number

Buyer E/C Level

Application

Date
• A report completed by the supplier
Supplier Name Manufacturing Location Supplier Code containing appearance and color
criteria
Reason for Part Submission Warrant Special Sample Re-Submission Other
Submission
Pre Texture First Production Shipment Engineering Change

Appearance Evaluation
Pre-Texture Customer Representative
Supplier Sourcing and Texture Information

Objective or Purpose
Evaluation signature and Date

Correct and Proceed

Correct and Resubmit

Approved to Texture
• To demonstrate that the part has
met the appearance requirements
Color Evaluation
Color
Color Master Master Material Material Metallic Part

on the design record

Tristimulus Data Hue Value Chroma Gloss Shipping
Suffix Number Date Type Source Brilliance Disposition
Suffix
DL* Da* Db* DE CMC Red Yel Grn Blu Light Dark Gray Clean High Low High Low

When to Use It
Comments: • Prior to tooling for production
Supplier Signature Phone No. Date Customer Representative Signature Date

IMPORTANT!
Typically only applies for parts with color, grain,
or surface appearance requirements
 APPEARANCE APPROVAL REPORT
Administrative Section

Appearance Approval Report

Part Number Drawing Number Application

Part Name Buyer E/C Level Date

Supplier Name Manufacturing Location Supplier Code

Reason for Part Submission Warrant Special Sample Re-Submission Other

Submission
Pre Texture First Production Shipment Engineering Change

Appearance Evaluation
Pre-Texture Customer Representative
Supplier Sourcing and Texture Information
Evaluation signature and Date

Correct and Proceed

Correct and Resubmit

Approved to Texture

Supplier Sourcing & Texture Information

List all first surface tools, graining Pre-Texture Evaluation
Source(s), grain type(s), and grain and To be completed by SQE
Gloss masters used to check part
 APPEARANCE APPROVAL REPORT
Master
Master
Material
Number
DateType
Material Source Color Shipping Suffix
Color Suffix
Enter
Enter
Identify
alphanumeric
the date
first
Identify
on
surface
which
firstfinish
surface
andand Color part number
Alphanumeric or
master numeric
thesubstrate
master
identification
was
substrate
(e.g.
approved
paint
suppliers
/ ABS) suffix or color number
color identification

Color Evaluation
Color
Color Master Master Material Material Metallic Part
Tristimulus Data Hue Value Chroma Gloss Shipping
Suffix Number Date Type Source Brilliance Disposition
Suffix
DL* Da* Db* DE CMC Red Yel Grn Blu Light Dark Gray CleanHigh Low High Low

Tristimulus Data
Part Disposition
List numerical (colorimeter) Hue, Value, Chroma, Gloss, and
To be determined by
data of submission part as Metallic Brilliance
NCR (approved or
compared to the customer- Visual assessment by NCR
Comments:
rejected)
authorized master

Supplier Signature Phone No. Date Customer Representative Signature Date

SAMPLE PRODUCTION
PARTS
SAMPLE PRODUCTION PARTS

What is It?
Actual samples that reflect the parts
documented in the PPAP.

Objective or Purpose
• Confirm cosmetic or functional
part approval.

When to Use It
• Sample parts should be delivered
WITH the PPAP submission
SAMPLE PRODUCTION PARTS

• The sample parts provided should be the same parts

measured for the dimensional results

• Default quantity for all submissions is 3 parts unless

otherwise requested
SAMPLE PRODUCTION PARTS
 Sample production parts MUST be properly identified
Include the following information on the part label:
 Date parts were packed
 Customer part number
 Quantity
 Serial number
 Supplier part number (optional)
 Part description
 Country of origin (optional)
 Approval markings (UL, CE, etc.) where
applicable
MASTER SAMPLE

 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, mould, tool or pattern, or production process.
CHECKING AIDS

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

 The organization shall certify that all aspects of the checking aid agree with
part dimensional requirements.

 The organization shall document all released engineering design changes that
have been incorporated in the checking aid at the time of submission.

 The organization shall provide for preventive maintenance of any checking aids
for the life of the part.

 Measurement System Analysis studies, e.g. gage R&R, accuracy, bias,linearity,

stability studies, shall be conducted in compliance with the customer
requirements
PART SUBMISSION STATUS

 “A” - Approved
 “B” – Interim Approval
 “C” – Rejected

Part Submission Status “A” = Approved

 indicates that the part or material meets all
customer specifications and requirements
 the organization therefore is authorized to ship
production quantities of the product subject to
releases from the customer scheduling activity
PART SUBMISSION STATUS
Part Submission Status “B” = Interim Approval

 Permits shipment of material for production requirements on a limited time or

piece quantity basis.
will only be granted when the organization has:
 clearly defined the non-compliances preventing approval; and,
 prepared an interim approval action plan agreed upon by the customer
 The organization is responsible for implementing containment
 actions to ensure that only acceptable material is being shipped tothe
customer.
 PPAP re-submission is required to obtain a status of “Approved”

Part Submission Status “C” = 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 the customer requirements.
Q&A
Thank You