PPAP Workbook

This workbook is to be used for Production Part Approval Process (PPAP) submissions to Jacobs Vehicle Systems
(JVS).

Separate tabs are included for each section of the PPAP (as shown in the AIAG PPAP Manual, Fourth Edition).

For Ease of Use with the forms, you should enter all relevant information in the "Data" tab to avoid having to retype it.

The "Submission Plan" defines what sections are applicable for each level of PPAP.

Supplier shall complete each tab. Included are check boxes to be used if the tab is "not applicable". If a document
cannot be attached into the designated tab, please indicate in the designated tab and add a separate tab or submit as a
separate .pdf document.

Supplier shall fill in areas shaded "yellow". JVS uses sections shaded "blue".

Upon completion, please submit your PPAP to JVS_PPAP@jakebrake.com or as requested in the PPAP purchase order
or instruction from JVS Purchasing or Quality.

Workbook Rev: 11-NOV-11

 Part Information
Part Name
Part Number
Revision
Supplier Part Number (if applicable)
Supplier Part Rev or Date (if applicable)
Additional engineering changes
Additional engineering change rev/date
Shown on drawing number
Deviation
Deviation Approval Date
Weight
Application
Purchase Order No
Tooling Purchase Order
JVS Buyer Name

Submission Information
Submission Date
Submission Level (see submission plan)

Reason for PPAP submission

Supplier Information
Supplier Name
Street Address
City
State
Postal Code
Person responsible for PPAP submission
Title
Phone
Fax
e-mail
 PPAP Submission Plan
Supplier 0 Part Name 0 Date of Submission 0
Part Number 0 Revision 0 PPAP Level 0
Reason for submission 0

JVS normally requires PPAP level 3, unless otherwise specified. The PPAP P.O. takes precedence.
JVS requires PPAP level 4* (see below) for commercially available product such as fasteners. Item 10 should include material certs, grade certs, mechanical properties, unless otherwise specified. The PPAP
P.O. takes precedence.
This form represents a plan for the submission of requirements. Not all requirements may be applicable in every case.
Key: R - Retain at Supplier S - Submit to JVS W - Waived
Refer to AIAG PPAP Manual, Fourth Edition, for further clarification.

PPAP Level Submitted Acceptable

Requirement 1 2 3 4 4* 5 Y/N Supplier Comments JVS Comments Y/N
1 Design Record

Comments
R S S * S R
Ballooned JVS Part Print
2 Engineering Change Documents, if any
JVS Supplier Change Request or evidence of S S S * S R
engineering approval (e.g. e-mail)
3 Customer Engineering Approval

Conditional
S S S * S R

Approved

Rejected
JVS Supplier Deviation Request

Interim/
4 Design FMEA
R R S * W R
Required, if design responsible.
5 Process Flow Diagram
R R S * W R

6 Process FMEA
R R S * W R

7 Control Plan
R R S * W R

8 Measurement System Analysis Studies

Required for measurement devices used for R R S * W R
special characteristics.
9 Dimensional Results
Clearly identify dimensional data to the part(s) R S S * S R

Date

Date

Date

Date
submitted in # 14. JVS Layout -
10 Material, Performance, Test Results
Transfer data to form from certifications,
including the specification limits, and attach R S S * S R
Met Review -
copy of material and test certifications. Other Testing -
11 Initial Process Study
Required for all special characteristics.
Include raw data, histogram, control chart and R R S * W R
capability indices (PpK and CpK).
12 Qualified Laboratory Documentation
Include copies of certifications (e.g. ISO9000, R S S * S R
TS16949, A2LA), as appropriate
13 Appearance Approval Report
W W W W W W N/A Waived Waived N/A
Not applicable to JVS product
14 Sample Product
Clearly identify part(s) used for the results
submitted in # 9. A minimum of 2 parts to be
submitted (one for dimensional analysis and R S S * S R
one for possible destructive testing), unless
otherwise specified.
15 Master Samples
Sample must be retained at the supplier.
Dimensional data for this piece should also be R R R * R R N/A To be retained at supplier To be retained at supplier N/A
included in #9.
16 Checking Aids
List the checking aids with calibration status, R R R * W R

Commodity Mgr/Buyer Planner

as appropriate.
17 JVS Specific Requirements

Supplier Quality Engineer

Process Quality Engineer
Packaging & Preservation
Coatings (MSDS) S S S S S R
Process Chemicals

Product Engineer
Outside processes

18 Part Submission Warrant

S S S S S R

19 Bulk Material Checklist

W W W W W W N/A Waived Waived N/A
Not applicable to JVS product
 Design Record
Ballooned JVS print (required for PPAP level 2, 3, 4, and 4*)
Attached below
Submitted under separate cover
Supplier print
Attached below
Submitted under separate cover
 Engineering Change Document
(Supplier Change Request)
Identify approved change(s) not yet recorded on the design drawing, but which are
incorporated in the product.
Not Applicable
Approved Supplier Change Request
Attached below
Submitted under separate cover
Other evidence of engineering approval (e.g. e-mail)
Attached below
Submitted under separate cover
Supplier Change Request included (form available at www.jakebrake.com)
Attached below
Submitted under separate cover
 Engineering Approval
(Supplier Deviation Request)
Identify any deviation(s) from the design drawing (characteristics which do not meet the
design requirement).
Not Applicable
Approved Supplier Deviation
Attached below
Submitted under separate cover
Other evidence of engineering approval (e.g. e-mail)
Attached below
Submitted under separate cover
Supplier Deviation Request included (form available at www.jakebrake.com)
Attached below
Submitted under separate cover
 Design Failure Mode & Effects Analysis
(DFMEA)
Not Applicable per Submission Plan
Not Applicable - Not design responsible
DFMEA attached below
DFMEA submitted under separate cover
DFMEA included as separate tab in this workbook
Process Flow Diagram
Not Applicable per Submission Plan
Process Flow attached below
Process Flow submitted under separate cover
Process Flow included as separate tab in this workbook
 Process Failure Mode & Effects Analysis
(PFMEA)
Not Applicable per Submission Plan
Other (Explain)
PFMEA attached below
PFMEA submitted under separate cover
PFMEA included as separate tab in this workbook
 PROCESS
FAILURE MODE AND EFFECTS ANALYSIS

Item D Action Results

C O
e
S l c Current Process Current Process R
Potential Effect(s) of Potential Cause(s)/ t Responsibility &
Potential Failure Mode e a c Controls Controls P Recommended Action(s) S O D R
Process Function/ Failure Mechanism(s) of Failure e Target Completion Date
v s u Prevention Detection N Actions Taken e c e P
Requirements c
s r v c t N
t

00-039626 PFMEA Rev 11/6/11 Page 11 of 27

 Control Plan
Not Applicable per Submission Plan
Control Plan attached below
Control Plan submitted under separate cover
Control Plan included as separate tab in this workbook
 CONTROL PLAN
Control Plan Control Plan Number:
Key Contact / Phone: Part Number / Latest Change:
Prepared By: Orig Date:
Revised by: Rev Date:

Characteristics Methods

Part / Process Special

Machine, Device, Jig,
Process Name/Operation Char. Specification / Evaluation / Measurement Sample Reaction Plan
Tools for Mfg. No. Product Process Sample Size Control Method
Number Description Class Tolerance Technique Frequency

00-039626 Control Plan Rev 11/6/11 Page 13 of 27

 Measurement System Analysis Studies
Not Applicable per Submission Plan
Not Applicable - No Special Characteristics
MSA evaluated
Total GRR < 10%
10% < Total GRR < 30%
Total GRR > 30% - Action plan attached
MSA attached below
MSA submitted under separate cover
MSA included as separate tab(s) in this workbook
 Dimensional Results
PART NAME PART NUMBER PART REV
0 0 0
SUPPLIER NAME OF SUPPLIER INSPECTOR DATE OF SUPPLIER INSP
0
PURCHASE ORDER NAME OF JVS INSPECTOR DATE OF JVS INSP
0

Inspection Method
C=Calipers, DI=Drop Indicator, G=Gage Pins, I=Indicator, M=Micrometer, P=Profilometer, R=Rockwell Hardness Tester, S=Shadowgraph

Supplier Jacobs
Results
Dimension / Inspection Pc. 3 Inspection
Item Specification Method Pc. 1 Pc. 2 (Retained at Supplier) A/R Method Results A/R

Page 15 of 27
 Supplier Jacobs
Results
Dimension / Inspection Pc. 3 Inspection
Item Specification Method Pc. 1 Pc. 2 (Retained at Supplier) A/R Method Results A/R

Page 16 of 27
 Material Test Results
Not Applicable
Complete form and attach material certification below. Blanket statements of conformance are unacceptable for any test results.

SUPPLIER PART NAME PART NUMBER REV

0 0 0 0

NAME OF MATERIAL SPEC./ SPECIFICATION SUPPLIER TEST NOT

MATERIAL SUPPLIER LABORATORY CHARACTERISTIC LIMITS TEST DATE QTY TESTED RESULTS (DATA) OK OK
SAMPLE DATA

42CrMoS4 Heat 425880

METAL CO METAL CO. %C 0.38 - 0.45 6/6/10 (2000 lbs) 0.44 OK
HT SUPPLIER HT SUPPLIER Core Hardness 56 - 60 HRC 6/10/10 1 57.70 OK
 Performance Test Results
Not Applicable

Applies to performance tests such as fatigue testing, breakaway torque and mechanical properties.
Complete form and attach test certification below (if applicable). Blanket statements of conformance are unacceptable for any test results.

SUPPLIER PART NAME PART NUMBER REV

0 0 0 0

TEST SPEC./ SPECIFICATION SUPPLIER TEST NOT

TEST LABORATORY CHARACTERISTIC LIMITS TEST DATE QTY TESTED RESULTS (DATA) OK OK
SAMPLE DATA

1 pc broke at 214,000
cycles, 2 pcs test
Cycle test per ABC 100,000 cycles stopped at 250,000
AAA TEST LAB SPEC 1234 without failure 6/6/10 3 cycles without failure OK
 Initial Process Studies
Process Studies are required for all special (Critical and Major) characteristics. Process
Studies should be included, if possible, for all KCC/KPC
Include raw data, histogram, control chart and capability indices (PpK and CpK)
Not Applicable per Submission Plan
Not Applicable - No Special Characteristics
Process Studies conducted
Min Capability Requirements met (Critical 1.67 CpK and Major 1.33 CpK)
Min Capability Requirements not met - Action plan attached
Process Studies attached below
Process Studies submitted under separate cover
Process Studies included as separate tab(s) in this workbook
 Qualified Laboratory Documentation
Not Applicable
Certificate(s) previously submitted (no changes)
Certificate(s) attached
Certificate(s) submitted under separate cover
TS 16949 Certification Issue Date Expiration Date
ISO 9001 Certification Issue Date Expiration Date
ISO 14000 Certification Issue Date Expiration Date
A2LA Certification Issue Date Expiration Date
ISO/IEC17025 Certification Issue Date Expiration Date
Other Certification (Please specify)
 Checking Aids
Not Applicable

SUPPLIER PART NAME PART NUMBER REV

0 0 0 0

Complies with Date of last

Checking aid revision above? calibration /
number Description of checking aid Y/N verification
 Packaging and Preservation
Quantity per individual package/box
Weight per individual package/box NOTE: Over 25 pounds requires formal JVS approval
Packaging Material Type
Outer packaging

Returnable bin or crate (Specify type)

Wooden bin or crate (Specify type)
Gaylord container (Specify size)
Cardboard box (Specify size and test rating)
Other (Please specify)
Inner packaging (Idenfify all applicable)

Plastic Bag (Non-VCI)

VCI Bag
Plastic Sheet (Non-VCI)
VCI Sheet
Bubblewrap
Dessicant Bag
VCI Chip
RP applied (Specify type; complete separate tab)
Cardboard dividers
Plastic or other dividers (Please describe)
Other (Please specify)
 Coating MSDS
List any coatings on the product and attach MSDS
Not Applicable
MSDS(s) previously submitted (no changes)
MSDS(s) attached
MSDS(s) submitted under separate cover
Oil (Please specify type and include MSDS)
Rust Preventative (Please specify type and include MSDS)
Black Oxide (Please include MSDS)
Plating (Please specify type and include MSDS)
Loctite or similar (Please specify type and include MSDS)
Other (Please specify and include MSDS)
 Process Chemicals
List any chemicals used for cleaning, degreasing, descaling, etching, acids or bases used in vibratory finishing, etc..
Attach manufacturer's chemical specification for any such chemicals, as appropriate.
Not Applicable

Brand Name and Manufacturer of Chemical Process where chemical is used

 Outside Services
Identify supplier for any outside processes or services (e.g. coating application, shot peen, grinding)
Not Applicable

Certifications and expiration

Outside Service / dates
Supplier Name Supplier Location
Operation (e.g. ISO 9001, TS16949,
A2LA, ISO/IEC 7025)
 Part Submission Warrant
Part Name 0 JVS Part Number 0 Rev. 0
Supplier Part Number 0 Rev. 0
Additional Engineering Changes 0 Rev. / Date 0
Tooling P.O. Number 0 Purchase Order No. 0 Weight (kg) 0.0000

ORGANIZATION MANUFACTURING INFORMATION SUBMISSION INFORMATION

0 JACOBS VEHICLE SYSTEMS
Supplier Name
0 0
Street Address JVS Purchasing or Buyer/Planner Contact
0 0 0 0
City State Zip Application

Note: Does this part contain any restricted or reportable substances? Yes No
Are plastic parts identified with appropriate ISO marking codes? Yes No

REASON FOR SUBMISSION

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 Additional Location
Tooling inactive > than 1 year Other - please specify

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
(check)
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

DECLARATION

I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer drawings and
specifications and are made from specified materials on regular production tooling with no operations other than the regular production process. I
also certify that documented evidence of such compliance is on file and available for review.

EXPLANATION/COMMENTS: 0

List Molds / Cavities / Production Processes

Organization Authorized Signature Date 0

Print Name 0 Phone No. 0 Fax No. 0
Title 0 E-Mail 0

FOR JVS USE ONLY

PPAP Warrant Disposition Approved Interim Approval Rejected Comments

Customer Signature

Print Name Date

Dispositioned PSW
For JVS use only