AAR
SAMPLE PARTS
CONTROL PLAN
DIMENSIONAL RESULSTS
MATERIAL, PERFORMANCE &
TEST RESULTS
INITIAL PROCESS STUDY
MEASUREMENT SYSTEM
ANALYSIS STUDIES
DESIGN RECORDS
LABORATORY SCOPE AND
ACCREDITATION
PROCESS FLOW DIAGRAMS
PROCESS FMEA
LEVEL 1
LEVEL 2
LEVEL 3
LEVEL 4
LEVEL 5
DESIGN FMEA
PPAP
LEVEL
PSW
SUPPLIER PPAP CHECKLIST
PART SUBMISSION WARRANT
PSW
To clearly state to the Customer the reason for your submission.
Take special note of the following:
Record part revision level to the right of the part# (Dwg revision & Part revisions may be different)
Supplier Must mark yes or no to meeting all Dwg. Requirements & sign the PSW.
Part Weight to be expressed in kilograms to four significant decimal places (0.0000).
Reminder- Part weight is determined by an average of ten randomly selected parts.
Identify whether the part does or does not contain Reportable/Restricted Substances
Suppliers are encouraged to mark plastic parts with the appropriate ISO symbols to designate
type of polymer & filler used in the part. Identify on the PSW ("Yes" or "No")
The specific Molds/Cavities/Prod. Process' pertaining to the PPAP shall be ID'd on the PSW.
Record the Production Rate at which the PPAP samples were produced on the PSW.
All checking aides used in the everyday processing of a part shall be identified on the PSW.
APPEARANCE APPROVAL REPORT
AAR
For Appearance Items ONLY
Submitted with PPAP and sample parts for the customer to sign, verifying parts are verifying that the parts
meet all aesthetic criteria.
-
Must have Spectrophotometer data readings. (Dl*, Da*, Db*, DE*, CIE LAB)
SAMPLE PARTS
SAMPLES FROM PPAP RUN
Submitted for Appearance and Functional evaluation. Six samples are required with each PPAP submission
-
Supplier PPAP Checklist
A few of the parts used for dimensional verification shall be submitted. These shall be labeled
with part#,cavity, revision,tool#, etc. & with a sample number that corresponds to the Dimensional
Report. Suppliers shall submit samples that represent each unique cavity, mold, line, etc.
Sample parts sent in shall be from a significant "production" run as outlined in the AIAG PPAP
Manual.
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PPAP-ABG.xls
PROCESS/PRODUCT CONTROL PLAN (C.P.)
CONTROL PLAN
To aid in the manufacture of quality products according to customer requirements. A structured approach for the
design, selection, and implementation of value-added control methods for the total system. It provides a written
summary description of the systems used in minimizing process and product variation.
-
All Special Characteristics (e.g., critical, key, significant, etc.) must be ID'd/addressed on the CP
The CP is a living document that should be utilized/updated for the life of the product.
ANY CHANGES MADE TO THE PRODUCT CONTROL PLAN MUST HAVE "WRITTEN"
CUSTOMER APPROVAL.
The Control Plan MUST be signed/dated by the Supplier and the Customer.
In some cases ABG will allow Family Group PFD's, FMEA's and Control Plan - When this is agreed
upon, the supplier shall have a reference attachment for all part numbers and individual part
differences of the parts in the Family Grouping.
The inspection frequency MUST be defined in quantifiable terms. ( i.e.- What is a "Lot"?)
DIMENSIONAL RESULTS
FIRST ARTICLE DIMENSIONAL LAYOUT RESULTS
This record is used to verify the parts meet all of the dimensional requirements called out on the Drawing and Control Plan.
-
If production parts will be produced from more than one cavity, mold, tool, die, pattern, or
production process, the supplier shall complete a dimensional evaluation on a minimum of one
part from each unique process/variation (Including color, if applicable, for certain process')
The specific cavities, molds, line, etc. shall then be identified on the PSW & on the Dimensional
Results Report.
All dimensions, characteristics and specifications noted on the Drawing and Control Plan should
be listed in a convenient/organized format with the actual results recorded.
All records shall be submitted on the ABG Dimensional Results Form.
LAB & FUNCTIONAL RESULTS
MATERIAL, PERFORMANCE TEST RESULTS
This record is used to verify that the parts meet all of the Material and/or performance
requirements/specifications called out on the Drawing and Control Plan.
-
All dimensions, characteristics, and specifications noted on the Drawing and control plan should
be listed in a convenient/organized format with the actual results recorded.
Material Testing Results, Performance Testing Results, and other engineering requirements on the
design record shall be less than one year old at the time of the initial submission. This data shall
be updated for engineering changes that affect the original data. The supplier shall also maintain
and update all testing data for each lot of material. When PPAP is requested for an engineering
change, the supplier shall submit the testing data that corresponds to the material for the change.
CAPABILITY (CpK/PpK) STUDIES
INITIAL PROCESS STUDY
The purpose of this record is to determine if the production process will produce product that meets
the Customer's requirements.
The raw data (data points)
The results
(CPK, PPK, CP, etc.)
Supplier PPAP Checklist
Suppliers must submit with their Cpk results at least 30 data results that the Cpk results
were derived from or the PPAP will not be considered for approval. Also include a copy
of the histogram (Graphs).
Supplier MUST submit Initial Process Study for all Special Characteristics (e.g., critical, key,
significant, etc.) that are called out on the Drawing or Control Plan. Studies must be submitted that
are representative of each unique production process, e.g. duplicate assembly line and/or work
cell, each position of a multiple cavity die, mold, tool, or pattern, etc.
The acceptance criteria for Capability Studies is as follows:
* SHORT TERM STUDY- MUST meet
> or = to 1.67 Cpk
* LONG TERM STUDY- MUST meet
> or = to 1.33 Cpk
If CPK falls between 1.33 and 1.67 (Short Term Study), a corrective action plan and interim revised
Control Plan (normally providing for 100% inspection) must be developed by the supplier and
approved by the customer prior to approval. New studies MUST be performed after corrective
action is implemented and must be included in a revised PPAP submission.
ALL Initial Process Studies must be accompanied by Measurement System Analysis Studies.
>>> Initial process studies must be performed for ALL engineering changes that could have an
Page 2
PPAP-ABG.xls
effect on the Special Characteristics (e.g., critical, key, significant, etc.) that are called out on the
Drawing or Control Plan. If it is unclear please contact ABG Engineering.
GAGE R&R, BIAS, LINEARITY, & STABILITY
MEASUREMENT SYSTEM ANALYSIS STUDIES
The purpose of this record is to verify that the Gage or measurement system is capable of accurately
assessing the quality of the parts.
-
Measurement System Analysis Studies must be submitted with ALL Initial Process Studies.
Gage R&R, Bias, Linearity, & Stability must be submitted when applicable.
Definitions: Please reference the Measurement Systems Analysis manual.
Acceptance Criteria:
Gage R&R- <10 is Acceptable,
10 to 20 may be Acceptable based on importance,
and >20 is Rejectable
Corrective action is necessary for all Rejectable items.
-
>>> Measurement System Analysis Studies must be included with all Initial Process Studies for
ALL engineering changes that could have an effect on the Special Characteristics (e.g., critical,
key, significant, etc.) that are called out on the Drawing or Control Plan. They must also be
submitted if the gage is modified for any reason. If it is unclear please contact ABG Engineering.
Attribute Studies (If Applicable) will be performed on 20 parts, with 2 operators
and 2 trials. To meet acceptance criteria all results from the study must "PASS".
DRAWINGS
DESIGN RECORDS
Suppliers MUST submit a ballooned copy of the drawing that corresponds to the Dimensional,
Material, and Performance Results.
The drawing MUST be the official engineering released design record.
The PPAP MUST meet ALL drawing requirements to be considered for approval.
-
When the design records, e.g. CAD/CAM math data, part drawings, specifications, are in electronic
format, e.g. math data, the supplier shall produce and submit a hard copy (e.g. pictorial, GD&T
sheets, drawing, specification pages, etc.) to identify measurements taken.
LABORATORY SCOPE AND ACCREDITATION
The purpose of this record is to verify that the supplier has used an Accredited Laboratory/Testing Facility
to perform all Material, Functional, and Performance testing called out on the Drawing and Control Plan.
-
This Record must be submitted with ALL testing data.
This includes ALL standards and specifications called out on the Drawing and C.P.
Records must be submitted by the Laboratory that actually performed the testing.
Accreditation certification must NOT be out-dated.
Testing facilities that are strictly Laboratory facilities by nature must submit Laboratory Scope
and Accreditation because they are not able to acquire QS9000 Registration.
PROCESS FLOW CHARTS
PROCESS FLOW DIAGRAMS
This record is used to verify that the supplier has thoroughly evaluated and analyzed the total manufacturing
or assembly process, from start to end, for all possible causes of variation (i.e. machines, materials, methods,
etc. ) and has organized the process in such a way as to eliminate/reduce the effect these variations will have
on the overall quality system.
-
Supplier PPAP Checklist
This document shall flow smoothly into the supplier Control Plan and FMEA. Part/Process
Numbers and Process Name/Operation Descriptions should carry over and be consistent on all
three documents.
Title blocks must be complete and must reference all, unique, ABG information.
Please use the standard ABG Process Flow Diagram Forms or an approved AIAG Form.
In some cases ABG will allow Family Group PFD's, FMEA's and Control Plan - When this is agreed
Page 3
PPAP-ABG.xls
upon, the supplier shall have a reference attachment for all part numbers and individual part
differences of the parts in the Family Grouping.
PROCESS FMEA
PROCESS - POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
To assure that all potential failure modes and the effects they have on a process have been considered
and eliminated/addressed. Please note the following:
-
If there are no recommended actions you must state none in the recommended actions column.
Do not use Operator Error as a potential failure. The failure is rooted to a process or system.
A PFMEA should be created by a team which has representation from every area of the process.
All Special Characteristics (e.g., critical, key, significant) must be ID'd/addressed on the PFMEA.
Any issue, customer or internal, will require review/adjustment of R.P.N. numbers.
The PFMEA is a living document that should be utilized/updated for the life of the product.
In some cases ABG will allow Family Group PFD's, FMEA's and Control Plan - When this is agreed
upon, the supplier shall have a reference attachment for all part numbers and individual part
differences of the parts in the Family Grouping.
DESIGN - POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS
DESIGN FMEA
ONLY applicable when the supplier has design responsibility.
A tool used when designing a component, system, process, etc. to assure, to the extent possible,
that all potential failure modes (Design related) and their associated causes/mechanisms have been
considered and addressed.
-
Supplier PPAP Checklist
Retain at supplier facility. Must be available for customer review at any time.
Page 4
PPAP-ABG.xls
PART SUBMISSION WARRANT
Part Name
Part Number
Safety and/or
Government Regulation
Yes
No
Engineering Drawing Change Level
Additional Engineering Changes
Dated
Shown on Drawing No.
Purchase Order No.
Checking Aid No.
Engineering Change Level
SUPPLIER MANUFACTURING INFORMATION
Dated
Weight (kg)
Dated
SUBMISSION INFORMATION
Dimensional
Supplier Name & Supplier Code
Materials/Functional
Appearance
Customer Name/Division
Buyer/Buyer Code
Street Address
Application
City
State
NOTE:
Zip
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
Engineering Change (s)
Change to Optional Construction or Material
Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional
Correction of Discrepancy
Tooling Inactive > 1 year
Change in Part Processing
Change in Part Processing
Parts Produced at Additional Location
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.
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
SUBMISSION RESULTS
The results for
dimensional measurements
material and functional tests
appearance criteria
statistical process package
(If "NO" - Explanation Required)
Yes
No
These results meet all drawing and specification requirements:
Mold / Cavity / Production Process
DECLARATION
I hereby affirm that the samples represented by this warrant are representative of our parts, have been made to the applicable
Production Part Approval Process Manual 3rd Edition Requirements. I further warrant these samples were
produced at the production rate of
/ 8 hours. I have noted any deviations from this declaration below.
Explanation/Comments:
Print Name
Title
Phone No.
Supplier Authorized Signature
FAX No.
Date
FOR CUSTOMER USE ONLY (IF APPLICABLE)
Part Warrant Disposition:
Customer Name
Part Functional Approval:
Approved
Approved
Rejected
Waived
Customer Signature
Date
Dim.
Loc.
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Gage
Customer
ABG P/N
Supplier P/N
Tool #
Access Business Group
Revision
Rev. Date
Inspection Purpose
Date
Inspector
Engineer
Initial Submission
A = Calipers
D = Drop Gage
G = Height Gage
K = MicroVu
N = Radius Gage
R = Thread Gage
B = CMM
E = Feeler Gage
H = Micrometer
L = Protractor
P = Ring Gage
S = Smartscope
C = Comparator
F = Gage Block
J = Microscope
Dimensional
Nominal + Tol.
- Tol.
Sample
1
Sample
2
Sample
3
M = Pin Gage
Sample
4
Sample
5
Q = Micro Vu - CMM
Sample
6
Sample
7
Sample
8
T = Other
Out of Tolerance
+ Max Dev
- Max Dev
Dim.
Loc.
#
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Gage
Customer
ABG P/N
Supplier P/N
Tool #
Comments:
Access Business Group
Revision
Rev. Date
Inspection Purpose
Date
Inspector
Engineer
Initial Submission
A = Calipers
D = Drop Gage
G = Height Gage
K = MicroVu
N = Radius Gage
R = Thread Gage
B = CMM
E = Feeler Gage
H = Micrometer
L = Protractor
P = Ring Gage
S = Smartscope
C = Comparator
F = Gage Block
J = Microscope
Dimensional
Nominal + Tol.
- Tol.
Sample
1
Sample
2
Sample
3
M = Pin Gage
Sample
4
Sample
5
Q = Micro Vu - CMM
Sample
6
Sample
7
Sample
8
T = Other
Out of Tolerance
+ Max Dev
- Max Dev
Customer:
Part Number:
Part Description:
Tool Number:
Revision:
Inspected By:
Material Used:
Date Sampled:
Date Inspected:
Measurement Method:
No of Samples Measured:
Unit of Measure:
Cavity #
Gage Used
Description
Tolerance Upper Limit(s)
Tolerance Lower Limit(s)
Sample #
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
AVERAGE 0.0000
STD
0.0000
Cp
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
Ppu
Ppl
Ppk
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
MIN
MAX
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
Recommended Limits Based on Sample Data (from Sheet 1)
3 sigma limits:
(PpK = 1.00)
4 sigma limits*:
(PpK = 1.33)
5 sigma limits:
(PpK = 1.67)
6 sigma limits:
(PpK = 2.00)
MIN
MAX
MIN
MAX
MIN
MAX
MIN
MAX
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
*Minimum limits required for long term capability per ABG procedures.
Histogram Bin Ranges based on the above data:
Min
1
2
3
4
5
6
7
8
Max
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
PROTOTYPE
PRE-PRODUCTION
Project #:
Part #:
Part Rev. Level:
Part Name:
Customer:
Customer Contact/Phone:
ACCESS BUSINESS GROUP
Original Date:
Revision Date:
Revision #:
BP Rev Date/ BP Revision:
Drawing #:
Customer Approval Sign/Date:
Supplier Approval Sign/Date:
Inspect
Store
SYMBOLS
Move
Operation
Process:
Company:
Contact/Phone:
Core Team:
Step
PROCESS FLOW DIAGRAM
PRODUCTION
Operation Description
Product and Process Characteristics:
Control Methods:
Page 10 of 27
PROCESS POTENTIAL FAILURE MODE AND EFFECTS ANAYLYSIS
(PFMEA)
Project #:
Part #:
Part Rev. Level:
Part Name:
Customer:
Customer Contact/Phone:
PROTOTY
PE
PRODUCTION
Original Date:
Revision Date:
Revision #:
BP Rev Date/ BP Revision:
Drawing #:
ACCESS BUSINESS GROUP
Process:
Company:
Contact/Phone:
Core Team:
Process Function /
Requirements
PREPRODUCTION
Customer Approval Sign/Date:
Supplier Approval Sign/Date:
Potential
Failure
Mode
Potential Effect(s)
of Failure
S
e
v
S
C
O
Potential Cause(s) /
c
Mechanism(s) of Failure
c
Current Process Controls
Prevention
Current Process Controls
Detection
D
e
t
R.
P.
N.
Recommended
Actions(s)
Responsibility
Target
Completion
Date
Action Results
Actions Taken
S
e
v
O
c
c
D
e
t
R.
P.
N.
Page 11 of 27
CONTROL PLAN
PROTOTYPE
Project #:
Part #:
Part Rev. Level:
Part Name:
PRE-PRODUCTION
PRODUCTION
Customer: ACCESS BUSINESS GROUP
Customer Contact/Phone:
Original Date:
Revision Date:
Revision #:
BP Rev Date/ BP Revision:
Drawing #:
Process:
Company:
Contact/Phone:
Core Team:
Customer Approval Sign/Date:
Supplier Approval Sign/Date:
Part/ Process Number
Process Name / Operation
Description
Machine, Tools for
Conversion
Characteristic
No. Product
Process SC
Methods
Product/Process Spec/Tolerance
Evaluation Meas. Technique
Sample
Size
Sample
Control
Frequency Method
Reaction Plan
Page 12 of 27
Page 13 of 27
PPAP GUIDELINES REFERENCE SHEET
REQUIREMENT FOR NOTIFICATION
Production tools and/or equipment
transferred to a different plant
location.
CLARIFICATION OR EXAMPLES
MINIMUM PPAP
REQUIRED
Ex. If the tool and/or equipment is moved from
one manufacturing site to another
manufacturing site. ABG is still purchasing from
the same supplier.
L5
Ex. Any major tool and/or equipment repair that
may effect any critical dimensions.
Major tool and/or equipment repair
or refurbishment.
Ex. Any major tool and/or equipment repair that
may effect the fit and fuction of the product.
L2
Ex. Any major tool and/or equipment repair that
may effect the reliability of the product.
Ex. DOES NOT include normal preventative
maintenance.
New tool/equipment or new product
previously not supplied to ABG.
Ex. Any new production tool and/or equipment.
Includes replacement tooling.
L3
Ex. Any product that ABG is purchasing for the
first time.
Ex. Moving a mold from the qualified press to
an unqualified press, even if the presses are
the same tonnage, make, and model.
L2 - Minimal, suppliers are
requested to measure the
critical dimensions on 3
pcs.
Change from an ABG approved
process to unapproved process.
Ex. Any process change that effects the
process flow diagram.
Ex. Changing the caviation of approved
production tool.
Ex. Producing product outside the accepted
process/setup parameters.
Ex. Using non-ROHS compliant material.
Ex. Change in the assembly or production
process. Change in the work cell.
Ex. Additonal equipment or removal of
equipment in the production/assembly process.
Ex. Using regrind material for the first time.
L2
Transferring the tool and/or
equipment from one location of the Ex. Moving the tool / equipment from a clean
facility to another location within the room to non-clean room.
facility.
A change in material or component
not approved by ABG.
Ex. The use of substitute material or
components that deviate from ABG
specification.
Ex. Any change in material or components is
required to be approved by ABG.
L1
L3
A change in subcontractor of
material, components, or services
(paint).
Ex. Any sub-supplier change is required to be
approved by ABG. This includes a change in
sub-supplier that is supplying the same material
or component. - L2
Ex. Includes outsourcing assembly, processing,
etc.
L3
Ex. Using material, components, or chemicals
that do not conform to ABG's specification.
Includes dimensional, performance, or any
Use of raw material, components, or characteristics that affects form, fit, function,
chemicals that do not meet
and/or reliability.
specifications.
Ex. Includes materials, components, or
chemicals that are expired.
L3
Ex. Any change in the package quantity, size or
weight.
Ex. Any change to internal package cushioning
and/or protection i.e foam bags, partitions,
corner posts, etc.
Ex. Any change in the pallet size and/or
unitization of cases. Must comply with Supplier
Shipping Requirements Guide.
A change in the approved
packaging.
Ex. Any change in the structure of the package,
i.e. expendable packaging to returnable
Contact ABG Procurement
packaging, corrugated compression strength,
or ABG Packaging
etc.
Engineer
Ex. Any change in the pack method, i.e. layer
pack to bulk pack, bulk bagged to individually
bagged, etc.
Ex. Any packaging change that may affect the
integrity and the appearance of the product, i.e.
ESD Bags (static protection), Class A surface
protection, etc..
Ex. All case labeling must adhere to the
Supplier Shipping Requirements Guide
Any change to the ABG design
specifications or prints.
A change in ABG approved
assembly testing / inspection
method.
Min. L1
Ex. Any change in testing method or testing
equipment.
Ex. A change / upgrade in testing software.
Min. L2
E SHEET
ENGINEERING CHANGE NOTICE
REQUIRED
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
