Apqp & Ppap PDF

Driving Change - Building Leaders
ADVANCED
PRODUCT QUALITY PLANNING
&
PRODUCTION PART APPROVAL PROCESS
Presented by: ANURAG SRIVASTAVA
Quality Growth Services Pvt. Ltd.

H-13, Kirti Nagar, New Delhi – 110 015
Phone: +91-11-25431737 / 25918332 / 41425273
E-mail: qgs@qgspl.com Website: www.qgspl.com
Objective of Session
To provide
To explain
Basic To facilitate
APQP & PPAP
understanding Value added
methodology
of APQP & APQP & PPAP
in detail
PPAP process
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New Product Development
Customer
Core focused
Engineering QUALITY
ENGINEERING
Two
Aspects
APQP relates to Customer focused Quality Engineering
What is Quality Planning ?
To To ensure
understand that all the
the customer requirements
requirements are met
Systematic
approach
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What is Advanced Product Quality Planning
A structured method of defining and establishing

the steps necessary to assure that a product
satisfies customer.
The goal is to facilitate communication with
everyone involved to assure that all required
steps are completed in time.
What is Advanced Product Quality Planning :

Now A Process Model (i.e. P-D-C-A in Each Phase)
 The four stages of

the planning cycle
are Plan, Do, Check
(Study) and Act.
 Provides specialized
tools to offer the
opportunity to get
ahead of problems
and solve them
before the problems
affect the customer
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Benefits…
“Promote early identification of

required changes”
“Avoid late changes”
“Provide quality product on time at

lowest cost”
“..Designed to be a ‘before-the-event’
action, not an ‘after-the-fact’ exercise”
When is APQP appropriate?
• For development of “New Products”

• Incorporating major changes in
“Existing Products”
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Phase-1: Define the Scope
A process Cross
owner for Functional
APQP Team
•Representatives from
Organize •Engineering,
the •Manufacturing,
•Quality,
Team •Materials,
•Sales,
•Service,
•Suppliers and
•Customers, as
appropriate
Preparatory Step
Define Scope:
 Team must meet to decide
- Project Team Leader
- to over see the planning process
- Rotating team members
permissible
- Their Roles and Responsibilities,
- Customers (Internal / External),
- Customer Requirements,
- Additional Members, when required
- Feasibility Assessment ,
- Cost , Timings, Constraints etc.
- Customer Assistance, when required
- Documentation process or method
- Review Frequency
- Periodic
- Gate
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Fundamentals of Product Quality Planning
(New Addition)
Consider
Critical Path Customer
Method (CPM) may Requirements
be appropriate. while deciding
Timings
Chart to have
Shall list tasks, “Start” and
Assignments “Completion”
and/or other dates with
events
Timing actual point of
progress
Plan
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Actual
Planned Planned Ready Status Actual
# Activity Supplier Resp. Completion- Follow-up / Comments / References
Start-Date Due Date Start-Date
(YYYY-MM-DD) (YYYY-MM-DD) (YYYY-MM-DD)
Date
20% 40% 60% 80% 100% Status (YYYY-MM-DD)
Red Yellow Green Completed
1 Project Team
2 Feasibility Study and Action Plan

completed
4 Serial Order and Drawings /

Specification release
5 Prototype delivery schedule
6 Sub-supplier (material and sub-

components) APQP and assessment
8 Special characteristics
14 Lot Traceability Plan
15 Process flowchart
16 Process FMEA
17 Control Plan
18 AS2 Process Audit
19 Facilities and Process Equipment
20 Measuring and Control Equipment
21 Production tooling procurement
Typical Product Quality Planning Timing Chart

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22 Work instructions / Inspection
instructions
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Five Phases of APQP 3
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Concept
Initiation / ApprovalProgramme Prototype Pilot Launch
Approval
PLANNING
PLANNING
PRODUCT DESIGN AND DEV.
PROCESS DESIGN AND DEVELOPMENT
PRODUCT AND PROCESS VALIDATION
PRODUCTION
FEEDBACK ASSESSMENT AND CORRECTIVE ACTION
Product Process Product

Plan and design and design and and Feedback
define development development process assessment and
programme verification verification validation corrective action
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Five Different Phases of Planning –

Process Approach
Customer Requirements
Input
Plan & Define
Common to All 4 Phases
Program
Feed Back, Assessment
Phase I
Output & Corrective Action
Phase V
Input
Product Design &
Development Output
Phase II Input Product & Process
Output Validation
Input
Phase IV
Process Design &
Development
Phase III Output
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Product Quality Planning Responsibility Matrix
(New Addition) Design Manufacturing Service Org.
Responsible Only i.e. H/T,
W. House,
X – Means “Required” Transport etc
Define the Scope X X X
Phase I
Plan & Define Program X Not Reqd. Not Reqd.
Product Design &
Development X Not Reqd. Not Reqd.
Phase II
Feasibility Section X X X
Process Design &
Phase III Development X X X
Product & Process
Phase IV
Validation X X X
Feedback, Assessment &
Phase V Corrective Action X X X
Control Plan Methodology
X X X
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Phase I : Plan and Define
Objective
• To understand customer requirements (Needs &
Expectations)
• To establish design intent
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Phase I : Plan and Define
Inputs of Phase I Outputs of Phase I
Plan & Define Inputs of Phase II & V
Program
Phase I
•Design Goals
•Customer Requirements
•Voice of Customer •Reliability & Quality Goals
•Business Plan •Preliminary Bill of Material
•Product / Process Bench •Preliminary Process Flow Chart
Mark Data •Preliminary List of Special Product
•Product / Process Assumptions & Process characteristics
•Product Reliability Study •Product Assurance Plan

•Translate design goal into design
•Customer Inputs requirements
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Plan and Define: Key questions (Inputs)
 Customer requirements: How to know?

 Who are the competitors?
 Where we are as compared to competitors?
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Plan and Define - Inputs
VOICE OF THE CUSTOMER

 Encompasses complaints, recommendations, data and information
obtained from Internal or External customers. It can be found
through:
• Critical Path Method
• Quality Function Deployment
• Bench Marking
• Market Research
• Historical Warranty
• Team Experience
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Plan and Define – Inputs (Cont’d.)
MARKET RESEARCH
 Team obtains data and information reflecting the voice of customer to
identify concerns, wants for translating into product process
characteristics. Can be in the form of
• Customer interviews
• Customer questionnaire and surveys
• Market test and positioning reports
• New product quality and reliability studies
• Competitive product quality studies
• Things Gone Right (TGR) reports
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HISTORICAL WARRANTY AND QUALITY INFORMATION

 List of historical customer concerns / wants to assess the potential for
recurrence during design, manufacture, installation and use. The
following item can be used:
• Things Gone Wrong (TGW) reports
• Warranty reports
• Capability indicators
• Supplier plant
• Internal quality reports
• Problem resolution reports
• Customer plant returns and rejections
• Field return product analysis
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TEAM EXPERIENCE
 The team may use other source of information such as:
• Input from higher system level or past Quality Function Deployment (QFD) projects
• Media commentary and analysis: magazine and newspaper reports, etc.
• Customer letters and suggestions
• TGR / TGW reports
• Dealer comments
• Fleet Operator’s comments
• Field service reports
• Internal evaluations using surrogate customers
• Road trips
• Management comments or direction
• Problems and issues reported from internal customers
• Government requirements and regulations
• Contract review
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BUSINESS PLAN / MARKETING STRATEGY

 Customer business plan and marketing strategies will set the frame
work for APQP. Issues like timing, cost, investment, product
positioning, R&D may put constraints. The marketing strategies will
define the target customer, key sales point and key competitors
PRODUCT / PROCESS BENCHMARK DATA
 Benchmarking provides input for product / process performance
targets. R&D may provide benchmark and concept ideas. Methods to
successful benchmarking are:
• Identify appropriate benchmark
• Understanding the reasons for gap between current status and the benchmark
• Develop a plan to either close the gap, match the benchmark or exceed the
benchmark
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PRODUCT / PROCESS ASSUMPTION

 Certain assumptions about product feature, design or process concept
become inputs for planning. These includes:
• Technical innovations
• Advanced Materials
• Reliability assumptions and
• New Technology
PRODUCT RELIABILITY STUDIES
 Data related to frequency of repair, replacement of components within
specified period, long term reliability / durability tests
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Plan and Define – Inputs
CUSTOMER INPUTS
User of product provides valuable information relating

to the needs and expectations of customers.
Additionally, user may have conducted various studies
and reviews on the product. Should be used to
develop agreed upon measures of customer
satisfaction
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Plan and Define – Output
DESIGN GOALS
 A translation of the voice of customer into tentative and measurable
design objectives. Assures that voice of customer is not lost
RELIABILITY AND QUALITY GOALS

 Reliability goals are established based on customer wants and
expectations, programme objectives and reliability benchmarks. Should
be expressed in terms of probability and confidence limits
 Quality goals are targets based on continual improvement
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Design Goals Example
Stop Fast
Long Life
Low Vibration
Improved Fuel efficiency
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Plan and Define – Output (Cont’d.)
PRELIMINARY BILL OF MATERIAL

 Include bill of material based on product / process assumptions and early sub-
contractors list
PRELIMINARY PROCESS FLOW CHART
 Described anticipated manufacturing processes. Use preliminary BOM and
product / process assumptions
PRELIMINARY LISTING OF SPECIAL PRODUCT & PROCESS
CHARACTERISTICS
 Customer and team identify based on knowledge of product and process. List
could be developed from
• Product assumptions based on the analysis of customer needs and expectations
• Identification of reliability goals / requirements
• Identification of special process characteristics from the anticipated manufacturing
process
• Similar part FMEAs
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Plan and Define - Output (Cont’d.)
PRODUCT ASSURANCE PLAN (Optional)

Translate design goal into design requirements. Should include:
• Outlining of program requirements
• Identification of reliability, durability and apportionment / allocation goals
and / or requirements
• Assessment of new technology, complexity, materials, application,
environment, packaging, service and manufacturing requirements or any
other factor that may place the program at risk
• Development of Failure Mode & Effects Analysis (FMEA)
• Development of preliminary engineering standards requirements
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Management Commitment & Support
Management commitment, interest & support is key of

success- Get it
• Update management at the conclusion
• Should be formal
 with the opportunity for questions and answers
MUST DO at the end of every

phase
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Phase II
Product Design and Development :
Objective
A thorough and robust review of engineering or

service requirements
To develop design features and characteristics
into near final form
• Should consider all design factors to ensure the final
product will satisfy the “Voice of the Customer”
Design Factors should be considered, even if the
responsibility for design is owned by the customer
or shared
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Product Design and Development – Phase II

Inputs of Phase II Outputs of Phase II
Prod Design & Inputs of Phase III & V
Development Phase II
•Design Goals Outputs of •DFMEA

•Design for Manufacturing & Assembly
Phase I
•Reliability & Quality Goals •Design Verification
•Design Reviews
•Preliminary Bill of Material •Prototype Build - Control Plan
•Engineering Drawing
•Preliminary Process Flow Chart •Engineering Specification
•Materials Specification
•Preliminary List of Special Prod. •Drawings & Specification Changes
•New Equipment, Tooling & Facilities
& Process characteristics Requirement
•Special Product & Process Characteristic
•Product Assurance Plan-Optional •Gage / Testing Equipment Requirements
•Translate design goal into •Team Feasibility Commitment
design requirements & Management Support
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Product Design and Development :
Key Features
Feasible design must permit

• Meeting production volumes,
• Schedules,
• Ability to meet engineering requirements with
 Quality,
 Productivity,
 Reliability,
 Investment cost,
 Unit Cost and
 Timing Objectives
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Product Design and Development - Outputs
Design for Manufacturability and Assembly (DFMA)

• DFMA is a simultaneous engineering process to optimize the
relationship between design function, manufacturability and ease
of assembly
• The scope of customer needs and expectations determine the
extent of the activity. The following shall be considered:
 Design, concept, function and sensitivity to manufacturing variation
 Manufacturing and / or assembly process
 Dimensional tolerances
 Performance requirements
 Number of components
 Process adjustments
 Material Handling
 Teams knowledge, experience, the product / process, government regulations
and service requirements are other factors
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Design Verification
• Verifies that product design meets the customer requirements
Design Review
• Regularly scheduled meeting led by design engineering activities
and must include other affected area
• An effective method to prevent problems, misunderstandings and
provide mechanism to monitor progress
• Design reviews are a series of verification activities that are more
than an engineering inspection
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Design Review (Contd.)

• Shall evaluate
 Design / Functional requirement(s) considerations
 Formal reliability and confidence goals
 Component / subsystem / system duty cycles
 Computer simulation and bench test results
 DFMEA(s)
 Review of the Design for Manufacturability and Assembly effort
 Design of Experiments (DOE) and assembly build variation results (Refer
to Appendix B)
 Test failures
 Design Verification progress
 A major function of design review is the tracking of design verification
progress
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Prototype Build - Control Plan

• Prototype control plan describe the dimensional measurements,
material and functional tests that will be carried out during
prototype build
• The manufacturer of prototype parts provide an excellent
opportunity to compare the product with voice of customer
• Prototype should be reviewed to
 Assure that product or service meets specifications report data
 Ensure that particular attention has been given to special product and
process characteristics
 Use data and experience to establish preliminary process parameters and
packaging requirements
 Communicate any concerns, deviations and/or cost impact to the customer
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Engineering Drawings
• Customer design do not preclude the responsibility to review the
following in the engineering drawings
 Special characteristics (Governmental, Regulatory and Safety)that must
be shown on the control plan
 In case customer drawings do not exist, review which characteristic affect
fit function durability and/or governmental, regulatory and safety
requirements
 Drawing should be reviewed to determine
 adequacy of informations for dimensional layout of the individual part
 control / datum services / locators clearly identified
 dimensional evaluation to assure feasibility and compatibility with
manufacturing and measuring standards
 In case of math data, it has two way communication compatibility
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Engineering Specifications
• Specification review helps to identify functional durability and
appearance requirements
• Sample size frequency and acceptance criteria generally
identified in the specifications otherwise establish in the control
plan
• Determine which characteristics affect or control the results that
fulfill functional durability and appearance requirements
Material Specifications
• Material specifications should be reviewed for special
characteristics relating to physical properties, performance,
environmental, handling and storage requirements
• These characteristics should be included in control plan
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Drawing and Specification Changes

• Where changes required in drawings & specifications, team must
ensure that the changes are
 promptly communicated to all affected areas and properly
documented
New Equipment, Tooling and Facilities Requirements
• DFMEA, product assurance plan, design reviews may identify
new equipment and facilities requirements
• Should address the items in the timing chart
• Ensure new equipment, tooling is capable and delivered on time
• Facilities progress should be monitored to assure completion to
surpass planned production tryout
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Special Product and Process Characteristics

• Preliminary special characteristics identified through voice of
customer
• Team should build on this listing and reach consensus during
the review and development
• Special characteristics must be documented in the control plan
Gauge / Testing Equipment Requirements
• Gauge / Testing equipment requirements is also identified and
added in the timing chart
• Monitor progress to assure the meeting of required timings 23
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Product Design and Development – Outputs
Feasibility & Management Support

• A joint statement of commitment by the
team
MUST DO at the end of This

Phase
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Phase III
Process Design and Development : Objective
To develop a comprehensive manufacturing

system and its related control plans
to achieve quality products
Must assure that customer requirements, needs

and expectations are met.
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Process Design and Development:
Inputs of Phase III Outputs of Phase III
Process Design & Inputs of Phase IV & V
Development Phase III
Outputs of
•DFMEA PhaseII Packaging Standards (Customer
•Design for Manufacturing & Assembly Defined)
•Design Verification Process Flow Chart
•Design Reviews
•Prototype Build-Control Plan
Floor Plan Layout
•Engineering Drawing Characteristics Matrix (Optional)
•Engineering Specification PFMEA
•Materials Specification
Pre-launch Control Plan
•Drawings & Specification Changes
•New Equipment, Tooling & Facilities Work Instructions / Work Standards
Requirement Measurement System Analysis Plan
•Special Product & Process Characteristic Capability Study Plan
•Gage / Testing Equipment Requirements
•Team Feasibility Commitment Packaging/Transportation Specifica-
& Management Support tions etc..
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Process Design and Development -

Ouputs
Packaging Standard
• Incorporate customer packaging standard into packaging
specifications for the product. If not provided packaging design
should ensure product integrity at point of use
Product / Process Quality System Review
• Team should review the quality system. Additional controls /
procedural changes should be updated. Also an opportunity to
improve the existing quality system based on customer input,
team expertise, previous experience
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Outputs
Process Flow Chart

• Process flow chart is a schematic representation of current /
proposed process flow
• Used to analyze sources of variation of machines, materials,
methods and manpower from the beginning to end
• Used to emphasize impact of sources of variation on the
processes
• Help to analyze the total process rather than individual steps
• Assist to focus on process when conducting PFMEA and
designing control plan
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Outputs
Floor Plan Layout

• The Floor Plan should be developed and reviewed to determine the
acceptability of inspection points, control chart location, applicability of
visual aids, interim repair stations, and storage areas to contain defective
material. All material flow should be keyed to the process flow chart and
control plan.
• Use of value stream mapping and identifying the wastes to make plans
for their reduction
Characteristics Matrix (Optional)

• Recommended analytical technique for displaying the relationship
between process parameters and manufacturing stations
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Outputs
Process Failure Mode and Effects Analysis (PFMEA)

• Should be conducted during product planning and before
beginning production. A disciplined review and analysis of a
new / revised process and conducted to anticipate, resolve, or
monitor potential process problems. Is a living document and
needs to be reviewed and updated as new failure modes are
discovered
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Outputs
Pre-launch Control Plan

• A description of the dimensional measurements, material and
functional tests that will occur after prototype and before full
production. Should include additional product / process
controls to be implemented until the production process is
validated. The purpose is to contain potential non-
conformances during or prior to initial production runs.
Examples
 More frequent inspection
 More in-process and final check points
 Statistical evaluations
 Increased audits 29
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Outputs
Process Instructions / Work Standards

• Ensure that understandable process instructions, provide sufficient
detail for all operating personnel who have direct responsibility for
the operation of the processes. These should be developed from
the following sources:
 FMEAs
 Control plan(s)
 Engineering drawings, performance specifications, material
specifications, visual standards and industry standards
 Process flow chart
 Floor plan layout
 Characteristics matrix
 Packaging standards
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Outputs
Process Instructions / Work Standards (Contd.)

 Process parameters
 Producer expertise and knowledge of the processes and products
 Handling requirements
 Operators of the Process
• Should include set-up parameters such as: machine speeds,
feeds, cycle times, etc., and should be accessible to the
operators and supervisors.
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Outputs
Measurement Systems Analysis Plan

• Ensure that a plan to accomplish the required
measurement systems analysis is developed. This should
include, at a minimum; the responsibility to ensure gage
linearity, accuracy, repeatability, reproducibility.
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Outputs
Preliminary Process Capability Study Plan

• Ensure the development of a preliminary process capability
plan. The characteristics identified in the control plan will
serve as the basis for the preliminary process capability
study plan.
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Outputs
Packaging Specifications
• Ensure that individual product packaging (including interior
partitions) is designed and developed. Customer
packaging standards or generic packaging requirements
should be used when appropriate. In all cases the
packaging design must assure that the product
performance and characteristics will remain unchanged
during packing, transit and unpacking. The packaging
should have compatibility with all material handling
equipment including robots
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Phase IV
Product and Process Validation
Objective
To validate the manufacturing process through

an evaluation of a production trial run.
Additional concerns should be identified for

investigation and resolution prior to regular
production runs.
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Product and Process Validation: Phase IV
Inputs of Phase IV Outputs of Phase IV
Product & Process
Inputs of Phase V
Validation Phase IV
Packaging Standards (Customer • Production Trial Run

Defined)
Process Flow Chart
Outputs of • MSA result
Floor Plan Layout Phase III • Capability result
Characteristics Matrix (Optional) • Product Approval Process
PFMEA
Pre-launch Control Plan (PPAP)
Work Instructions / Work Standards • Production Control Plan
Measurement System Analysis Plan • Quality Planning Summary
Capability Study Plan
Packaging/Transportation Specifica-
Sign-off
tions etc..
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Product and Process Validation :

Phase IV
Production Trial Run

The validation of the effectiveness of the manufacturing process
begins with the production trial run. The minimum quantity for a
production trial run is usually set by the customer but can be
exceeded by the Product Quality Planning Team. Output of the
production trial run (product) is used for:
 Preliminary process capability study
 Measurement system evaluation
 Final feasibility
 Process review
 Production validation testing
 Product Approval Process
 Packaging evaluation
 First time capability (FTC)
 Quality Planning Summary sign-off
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Product and Process Validation –
Phase IV
Production Trial Run (Contd.)

• Conduct Trial Run by using:
 Production Tooling
 Equipment
 Environment
 Operators
 Facilities
 Cycle Time
Same as to be used for regular production
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Phase IV
Measurement Systems Evaluation

• Evaluate the measurement devices and methods used to
check the characteristics specified in the Control Plan
Preliminary Process Capability Study
• Perform preliminary process capability studies on the
characteristics specified in the control plan (Preliminary
process capability study plan). This assessment help to
evaluate process readiness for production
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Phase IV
Product Approval Process

• The intent of product part approval is to validate that products
made from production tools and processes, meets
engineering requirements.
Production Validation Testing
• Production validation testing refers to engineering tests that
validate that products made from production tools and
processes meet engineering standards.
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Phase IV
Packing / Transportation Evaluation

• Assess the protection of the product from normal transportation
damages and adverse environmental factors. Use test
shipments & methods where feasible
Production Control Plan
• A written description of the systems for controlling parts and
processes.
• A living document and should be updated to reflect the addition
/ deletion of controls based on experience gained by producing
parts (Approval of the procuring organization(s) may be
required).
• Logical extension of the pre-launch control plan.
• Mass production provides the producer the opportunity to
evaluate output, review the control plan and make appropriate
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Phase IV
Quality Planning Summary Sign-off

• Ensure that all control plans and process flow charts are being
followed. It is suggested that the Product Quality Planning Team
performs its review at the manufacturing location(s) and
coordinates a formal sign-off. A review of the following items prior
to first production shipment is required:
 Control Plans. Exist and be available at all times for all affected
operations
 Process Instructions. Verify that these documents contain all the Special
Characteristics specified in the control plan and that all PFMEA
recommendations have been addressed. Compare the process
instructions and process flow chart to the control plan
 Gage and Test Equipment. Where special gages, fixtures, or test
equipment are required per the control plan, verify gage repeatability
and reproducibility (GR&R) and proper usage
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Product and Process Validation – Phase IV

Key Features
Must ensure that

 The process has ability to satisfy product
requirements
 Production Control Plan is prepared after
successful validation
 A formal APQP Sign-off is done after
PAP / PPAP
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Product and Process Validation
What is APQP Sign-off
A formal and documented review to ensure that

• All planning requirements are met or
• concerns documented and
• schedule a management review.
• Higher Management is informed of program status and
gain their commitment to assist in any open issues.
Review Must be performed by the TEAM

at the manufacturing Location(s)
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Feedback, Assessment & Corrective Action : Phase V
Objective:
 A Parallel (Common) Phase with all Phases

 To review the effectiveness of total quality
planning system outputs
 To initiate improvement action
 To confirm all customer requirements are met
(or exceeded) and documented.
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Feedback, Assessment & Corrective Action : Phase V

Inputs of Phase V
Feedback, Assessment Outputs of Phase V
& Corrective Action –
Phase V
• Production Trial Run

Reduced unwanted
• MSA result Outputs of variation
Phase I-IV
• Capability result Confirmed customer
• Product Approval Process
(PPAP) satisfaction / delight
• Production Control Plan Meeting Delivery &
• Quality Planning Summary
Sign-off
service requirements
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PRODUCTION PART
APPROVAL PROCESS
Why PPAP
To determine if the supplier has understood all Customer engineering
design record & specification requirements and the suppliers’ process
has the potential to produce product consistently meeting these
requirements during an actual run at the quoted production rate
IATF 16949:2016 Clause Number 8.3.4.4 requires Product Approval

Process as per Customer defined Procedure / Manual.
• e.g. MSIL have defined specific requirements and submission of
samples & docs. in their Supplier Manual
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Applicability
 Covers generic requirements for PPAP applicable to internal and

external sites of
• Bulk Materials
• Production Material
• Production or Service Parts
 PPAP not required for Bulk Material unless requested by the
customer
 Applicable to standard catalogue production or service parts, unless
formally waived off by the customer.
 Tooling to be maintained as long as items are offered
NOTE: Customer can waive PPAP requirements for an item - however the documented
evidence of waiver is required
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Applicability
Note 1: Refer Customer Specific Requirements for

additional information
Note 2: Customer can formally waive PPAP requirements
for organization.
Note 3 : Supplier requesting waiver of PPAP requirements
to obtain documentation of waiver from authorized customer
representative
Note 4 : Catalogue parts (e.g. Bolts) are identified and/or
ordered by functional specifications or by recognized
industry standards
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Section 1 - General
1.1 Submission of PPAP
Full Product Approval Process is required from Customer

product approval activity in the following situations:
• A new part or product (i.e. a specific part, material, or color
not previously supplied to the specific customer)
• Correction of a discrepancy on a previously - submitted part
• Product modified by an engineering change to design
records, specifications, or materials
• Any situations required by Section 3
NOTE: FOR ANY QUESTION CONCERNING THE NEED FOR
PRODUCTION PART APPROVAL, CONTACT THE AUTHORIZED
CUSTOMER REPRESENTATIVE
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Section 2 - PPAP Requirements
2.1 Significant Production Run (cont’d)

Parts from each unique production process e.g.
duplicate assembly line and / or work cell, each
position of a multiple cavity die, mold, tool or pattern
be measured & representative parts tested
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2.2 PPAP Requirements

 Meet all specified PPAP requirements listed in 2.2.1 to 2.2.18 including all
customer-specific PPAP requirements
 Production Part to meet customer engineering design and specification
requirements (including safety & regulatory requirements).
 If unable to meet, document problem solving efforts & contact authorized
customer representative for concurrence in determination of appropriate
corrective actions
Note : Items from 2.2.1 to 2.2.18 may not necessarily apply to every
customer part number from every organization e.g. Appearance
& color requirements; plastic parts may have Polymeric part
marking requirements
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2.2.1 Design Records

 Shall have design records for saleable products, their components
 When design record is in electronic format (e.g. CAD/CAM math data, Catia),
produce a hard copy to identify the measurements taken
NOTE:
 Regardless of design responsibility there may be only one design record
 Design record may refer other documents making them part of design record
2.2.1.1 Reporting of Part Material Composition
 Provide evidence that Material / substance composition reporting as required by

customer has been completed and it complies with all customer-specific
requirements
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2.2.2 Authorized Engineering Change Documents
 Any authorized engineering Change documents not yet incorporated in the design
record but incorporated in the product, part or tooling to be included (e.g. ECN etc)
2.2.3 Customer Engineering Approval
 Where specified by Customer, show evidence of customer engineering approval
2.2.4 Design FMEA – For Product Design Responsible only
 DFMEA to be prepared in compliance with Customer-specific requirements
2.2.5 Process Flow Diagrams (PFD)
 Prepare Process flow diagram detailing production process steps and sequence, as
appropriate that meets the specified customer needs, requirements and expectations
 PFD for family of similar parts are acceptable, if new parts are reviewed for
commonality
2.2.6 Process FMEA
 A single Design or Process FMEA in compliance with customer-specific
requirements is acceptable to a process manufacturing a family of similar parts or
materials
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2.2.7 Control Plan
 Have a Control Plan defining all Methods used for Product & Process Control and
complies with Customer-specific requirements
Note: 1. Control Plans for Family of parts are acceptable
if new parts have been reviewed for commonality
2. Approval may be required by customer.
2.2.8 Measurement System Analysis Studies
 Shall have applicable Measurement System Analysis Studies (Gauge R&R, Bias,
Linearity, Stability) for all new or modified gauges, measurements and test
equipment
2.2.9 Dimensional Results
 Carryout complete dimensional verification, record actual results and ensure
compliance with specified requirements (given in Design Record and Control Plan)
 Dimensional Evaluation required for each unique manufacturing process e.g. cell or
production lines and all cavities, molds, patterns or dies
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 Indicate Date of design record; change level and any authorized Engineering change
document, drawing date on auxiliary documents
 Tracing to be included when optical comparator is necessary for inspection
 Identify one of the parts measured as the master sample and retain the same
2.2.10 Records of Material / Performance Test

Results
 Maintain records of materials and / or performance test results for tests specified in
Design Record or Control Plan
2.2.10.1 Material Test Results

 Perform tests for all part(s) and product material(s) when chemical, physical or
metallurgical requirements specified in Control Plans
 Keep record of quantity tested and actual results of each test
 Material Test Report to include material supplier’s name, date of testing and design
record change levels, number, date and change level of specifications, customer
assigned supplier code when required
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2.2.10.2 Performance Test Results
 Carryout performance test as specified in the design record or control plan
 Keep actual test results in understandable format and include quantity tested, design
record change level, date of testing; number date and change level of specification
2.2.11 Initial Process Studies

2.2.11.1 General
 Before submission of PPAP, Process Capability / Performance results must meet the
customer requirements for all “Special Characteristics”
 Shall obtain customer concurrence on the Index for estimating initial process capability
prior to submission
 Perform measurement system analysis to understand how measurement error affects the
study measurements
NOTE 1: Where no special characteristics are identified, customer reserves the right to
demonstrate initial process capability on other characteristics
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2.2.12 Qualified Laboratory Documentation
 Inspection & Testing to be performed by a qualified laboratory as defined by customer.
 Qualified Laboratory (internal or external) to have Laboratory Scope and documented

evidence showing the laboratory is qualified for type of measurements or tests
conducted,
 When an external / commercial Lab. is used, test results to be on Lab. letter head or
normal Lab Report Format containing name of Lab which performed the tests, date of
testing and the standards used to run the test
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2.2.13 Appearance Approval Report (AAR)
 Prepare separate Appearance Approval Report for each part or series of part for
appearance item
 Submit AAR and representative parts to specified customer locations

 Submit AAR along with PSW at the time of PPAP submission
2.2.14 Sample Production Parts

 Provide sample product in quantity as per details required by the customer
2.2.15 Master Sample
 Retain a master sample until a new master sample is produced where specified in the
control plan as reference or acceptance criteria
 Provide identifications and approval date after approval from customer on the master
samples
 Retain master sample from each production stream
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2.2.16 Checking Aids
 Submit parts specific (assembly or component) checking aids along with PPAP, if
required by the customer
 Certify that all aspects comply with part dimensional requirements
 Document all released engineering changes incorporated in checking aid at the time of
submission
 Carryout preventive maintenance & MSA as per customer requirements
2.2.17 Customer Specific Requirements

 Maintain records of compliance to all applicable “Customer Specific Requirements”
either as per their Manual or specifically desired by them
 For Bulk Materials, maintain in Bulk Materials Requirements Check List.
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2.2.18 Part Submission Warrant (PSW)

 Complete PSW on completion of PPAP requirements
 Separate PSW be completed for each customer part number unless agreed by authorized
customer representative
 If production parts are from more than one cavity, mold, tool, die, pattern or production
process e.g. line or cell, complete a dimensional evaluation on one part from each.
Specific cavities, molds, lines etc. be identified on a PSW or in a PSW attachment
 Verify that all measurements and test results show conformance to customer
requirements and documentation available for specified levels of submission.
Note : PSW may be submitted electronically with customer requirements
2.2.18.1 Part Weight

 Record on PSW the part weight in Kilograms to four decimal places (0.0000) unless
otherwise specified by customer.
 To determine Part Weight, weigh 10 randomly selected parts and calculate & report
average weight.
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Section 3 - Customer Notification &

Submission Requirements
3.1 Customer Notification

 Notify any design, process and site changes listed below in Table to Authorized
Customer Representative. The customer may subsequently elect to require a
submission for PPAP approval
Note: Organizations are responsible for notifying the authorized customer representative of
any changes to part design and/or the manufacturing process
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Examples of Changes requiring Clarifications

Notification
1. Use of other construction or For example, other construction as documented
material than was used in the on a deviation (permit) or included as a note on
previously approved part or the design record and not covered by an
product. engineering change as described in Table 3.2,
# 3.
2. Production from new or This requirement only applies to tools, which
modified tools (except due to their unique form or function, can be
perishable tools), dies, molds, expected to influence the integrity of the final
patterns, etc. including product. It is not meant to describe standard
additional or replacement tools (new or repaired), such as standard
tooling measuring devices, drivers (manual or power),
etc.
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Notification
3. Production following upgrade or Upgrade means the reconstruction and / or
rearrangement of existing tooling modification of a tool or machine or to increase the
or equipment capacity, performance, or change its existing
function. This is not meant to be confused with
normal maintenance, repair or replacement of parts,
etc., for which no change in performance is to be
expected and post repair verification methods have
been established.
Rearrangement is defined as activity that changes
the sequence of product / process flow from that
documented in the process flow diagram (including
the addition of a new process).
Minor adjustments of production equipment may be
required to meet safety requirements such as,
installation of protective covers, elimination of other
environmental, safety and damages potential risks.
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Notification
4. Production from tooling and Production process tooling and/or equipment transferred
equipment transferred to a different between buildings or facilities at one or more sites.
plant site or from an additional plant
site.
5. Change of supplier for parts, non- The organization is responsible for approval of supplier
equivalent materials, or services (e.g. provided material and services.
heat-treating, plating)
6. Product produced after the tooling has For product that has been produced after tooling has been
been inactive for volume production inactive for twelve months or more:
for twelve months or more. Notification is required when the part has had no change in
active purchase order and the existing tooling has been
inactive for volume production for twelve months or more.
The only exception is when the part has low volume, e.g.,
service or specialty vehicles. However a customer may
specify certain PPAP requirements for service parts.
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Notification
7. Product and process changes Any changes, including changes at the suppliers to
related to components of the the organization and their suppliers, that affect
production product manufactured customer requirements, e.g., fit, form, function,
internally or manufactured by performance, durability.
suppliers.
8. Change in test / inspection For change in test method, the organization should
method – new technique (no have evidence that the new method has
effect on acceptance criteria) measurement capability equivalent to the old
method.
Additionally, for bulk materials: These changes would normally be expected to have
9. New source of raw material from an effect on the performance of the product
new or existing supplier
10. Change in product appearance
attributes
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Submission Requirement Clarifications
1. A new part or product (i.e. Submission is required for a new product (initial release) or a
a specific part, material, or previously approved product that has a new or revised
color not previously product / part number (e.g., suffix) assigned to it. A new part /
supplied to the customer) product or material added to a family may use appropriate
PPAP documentation from a previously approved part within
the same product family.
2. Correction of a Submission is required to correct any discrepancies on a
discrepancy on a previously submitted part.
previously submitted part. A “discrepancy” can be related to:
 The product performance against the customer
requirements
 Dimensional or capability issues
 Supplier issues
 Approval of a part replacing an interim approval
 Testing, including material, performance, or engineering
validation issues
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Submission Requirement Clarifications

3. Engineering change to Submission is required on any engineering change to the
design records, production product / part design record, specifications or
specifications, or materials materials.
for production product / part
number(s).
Additionally, for Bulk
Materials:
4. Process Technology new
to the organization, not
previously used for this
product.
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4.1 Submission Levels

 Submit the item records specified by the submission level (Refer Table 4.2)
indicated by the customer
LEVEL 1 Submit warrant and Appearance Approval
Report for Appearance Items
LEVEL 2 Submit warrant, product sample and
limited supporting data
LEVEL 3 Submit warrant, product sample and
complete supporting data
LEVEL 4 Warrant and other requirement specified
by the customer
LEVEL 5 Retain warrant product and complete
supporting data at organization manufacturing
location
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 Use Level 3 as default level unless specified by the customer

 Minimum submission requirements for Bulk Materials is PSW and
Bulk Materials Requirements Check List.
NOTE 1: Customer identify submission level

Different location of customer may have
different levels
NOTE 2: All of forms referenced may be replaced
with Computer generated forms
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Section – 5 Parts Submission
Status
5.1 General
 Upon approval of Submission, assure that all customer requirements are met in future,
i.e. after Product Approval Process
NOTE 1: Supplier approval considered as Customer Approval for Self Certified items /
supplier combination unless specifically advised
5.2 Customer PPAP Status
5.2.1 Approved
 Indicates all customer requirements and specifications are met
 Supplier has authority of shipping as per schedule / order
5.2.2 Interim Approval
 Authorize shipment for production requirements on a limited time or piece quantity basis
only granted when
• Root cause of non-conformity preventing approval clearly identified and
• Approval from customer obtained on interim approval with action plans
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Section – 5 Parts Submission

Status
5.2.2 Interim Approval (Contd.)
 Re-submission for obtaining approval required
 Material which fails to meet agreed action plan requirements e.g. expiration date over
• Shipment quantity exceeds shall be rejected
• No additional shipment allowed unless interim approval is extended
5.2.3 Rejected : i.e. PPAP submission does not meet customer
requirements. If the following do not meet the requirements
• Submitted Parts
• Production Lot from which parts selected
• Documentation submitted
 Submit corrected product and document for approval. Obtain approval before
submission
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Driving Change - Building Leaders

Quality Growth Services Pvt. Ltd.

APQP relates to Customer focused Quality Engineering

What is Quality Planning ?

A structured method of defining and establishing

What is Advanced Product Quality Planning :

 The four stages of

“Promote early identification of

“Avoid late changes”

“Provide quality product on time at

When is APQP appropriate?

• For development of “New Products”

Red Yellow Green Completed

2 Feasibility Study and Action Plan

4 Serial Order and Drawings /

5 Prototype delivery schedule

6 Sub-supplier (material and sub-

14 Lot Traceability Plan

18 AS2 Process Audit

19 Facilities and Process Equipment

20 Measuring and Control Equipment

21 Production tooling procurement

Typical Product Quality Planning Timing Chart

PRODUCT DESIGN AND DEV.

PROCESS DESIGN AND DEVELOPMENT

PRODUCT AND PROCESS VALIDATION

FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

Product Process Product

Five Different Phases of Planning –

Phase I : Plan and Define

•Business Plan •Preliminary Bill of Material

•Product / Process Bench •Preliminary Process Flow Chart

Mark Data •Preliminary List of Special Product

•Product / Process Assumptions & Process characteristics

•Product Reliability Study •Product Assurance Plan

Plan and Define: Key questions (Inputs)

 Customer requirements: How to know?

VOICE OF THE CUSTOMER

Plan and Define – Inputs (Cont’d.)

HISTORICAL WARRANTY AND QUALITY INFORMATION

Plan and Define – Inputs (Cont’d.)

BUSINESS PLAN / MARKETING STRATEGY

Plan and Define – Inputs (Cont’d.)

PRODUCT / PROCESS ASSUMPTION

User of product provides valuable information relating

Plan and Define – Output

RELIABILITY AND QUALITY GOALS

Improved Fuel efficiency

PRELIMINARY BILL OF MATERIAL

Plan and Define - Output (Cont’d.)

PRODUCT ASSURANCE PLAN (Optional)

Management commitment, interest & support is key of

MUST DO at the end of every

A thorough and robust review of engineering or

Product Design and Development – Phase II

•Design Goals Outputs of •DFMEA

Feasible design must permit

Product Design and Development - Outputs

Design for Manufacturability and Assembly (DFMA)

Product Design and Development - Outputs

Design Review (Contd.)

Prototype Build - Control Plan