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Quality Assurance by D. H. Stamatis

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449
Appendix II
PPAP Checklist
This appendix provides the reader with a quick check review of a produc-
tion part approval process (PPAP). The anticipated answers are Yes, No, and
Not Applicable or Do Not Know. If the answer is Yes, then there is a good
chance that the section of the PPAP is okay. Of course, this is only a guide
and it is the responsibility of the supplier to make sure that the Automotive
Industry Action Group (AIAG) as well as the customer’s requirements are
followed. Typical concerns that should be addressed (at a minimum) in any
PPAP review should be in the following areas:
1. Design record
a. Released customer drawing in appropriate design system
b. Ballooned prints (including all dimensions, notes, and engineer-
ing specications [ES] and material specications [MS])
2. Authorized engineering change documents
a. Approved supplier request for engineering approval (SREA), if
applicable
b. Approved alert, if applicable
c. Electronic notication, if applicable
3. Customer engineering approval
a. When specied on drawing
b. Part functional trial approval when required
4. Design failure mode and effects analysis (DFMEA)
a. Customer engineering approved DFMEA provided by customer
engineering if customer responsible or from supplier, if supplier
is design responsible
b. DFMEA must align to latest revision of AIAG and customer
requirements
5. Process ow diagram
a. Conrm document linked to process failure mode and effects
analysis (PFMEA) and control plan, including part number/revi-
sion level or process/part name
b. Conrm it ows from receiving to shipping encompassing all
production process steps (including all production and service
steps as applicable)
450 Appendix II
6. PFMEA
a. Conrm PFMEA is linked to DFMEA, process ow diagram, and
control plan
b. If critical characteristics (CC) parts, then customer engineer
and supplier engineer must approve
c. Aligns with AIAG and customer requirements (CC if severity is
9 or 10, or SC if severity is 5–8 and occurrence >3)
d. Aligns with special characteristics requirements of the customer
regardless of the location of the special control in the supply
chain (Tier 1Tier N)
7. Control plans
a. If CC parts, then customer engineer and supplier engineer
must approve.
b. Controls for all special part/product (dimensional and perfor-
mance) and process characteristics are to be documented in the
control plan.
c. Control plan must identify appropriate reaction plan.
8. Measurement system analysis studies
a. All gauges, both production and service, must have gauge repeat-
ability and reproducibility (R&R) study in accordance with cus-
tomer requirements and AIAG MSA handbook
b. ANOVA method preferred, variable study: 10 part, 3 operators,
3 trials; attribute study: 50 parts, 3 operators, 3 trials using cus-
tomer parts
c. Reported in % Study Variation and % Tolerance with 5 distinct
categories
d. Variable gauge: Gauge repeatability and reproducibility (GR&R)
acceptable <10%, >30% is unacceptable. Greater than or equal to 10%
but less than or equal to 30% requires supplier engineer approval
e. Attribute study, kappa value .75
9. Dimensional results
a. Specied measurement results are recorded on APQP/PPAP
evidence workbook, GD&T sheet, checked (ballooned) print, or
another method of recording
b. One part from each cavity/mold/tool/line is measured with a
minimum of ve parts
10. Material/performance test results
a. Test results for test specied on the print/engineering specication
b. Number, date, and change level of specication to which part
was tested

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