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PPAP Workbook
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 fill in areas shaded "yellow". JVS uses sections shaded "blue".
Workbook Rev: 23-MAY-12
This workbook is to be used for Production Part Approval Process (PPAP) submissions to Jacobs Vehicle Systems (JVS).
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.
On tab #18 (Part Submission Warrant), be sure to check off applicable boxes. "Data" information auto fills, but other information requires your input, including reportable substances, for example. The JVS Reportable substance list is available in the Supplier section at http://www.jacobsvehiclesystems.com/suppliers/jvs-ppap-workbook/.
Upon completion, please submit your PPAP to [email protected] or as requested in the PPAP purchase order or instruction from JVS Purchasing or Quality.
Part InformationPart NamePart NumberRevisionSupplier Part Number (if applicable)Supplier Part Rev or Date (if applicable)Additional engineering changesAdditional engineering change rev/dateShown on drawing numberDeviationDeviation Approval DateWeightApplicationPurchase Order NoTooling Purchase OrderJVS Buyer Name
Submission InformationSubmission DateSubmission Level (see submission plan)
Reason for PPAP submission
Supplier InformationSupplier NameStreet AddressCityStatePostal CodePerson responsible for PPAP submissionTitlePhone Faxe-mail
PPAP Submission PlanSupplier 0 Part Name 0 Date of Submission 0
Part Number 0 Revision 0 PPAP Level 0
Reason for submission 0
RequirementPPAP Level
Supplier Comments JVS Comments1 2 3 4 4* 5
1R S S * S R
Com
me
nts
2S S S * S R
3S S S * S R
App
rove
d
Rej
ecte
d
4R R S * W R
5 Process Flow DiagramR R S * W R
6 Process FMEAR R S * W R
7 Control PlanR R S * W R
8R R S * W R
9R S S * S R
Dat
e
Dat
e
Dat
e
Dat
e
10
R S S * S R
11
R R S * W R
12R S S * S R
13W W W W W W N/A Waived Waived N/A
14
R S S * S R
15
R R R * R R N/A To be retained at supplier To be retained at supplier N/A
16R R R * W R
Pro
duct
Eng
inee
r
Pro
cess
Qua
lity
En
gin
eer
Com
mo
dity
Mgr
/Buy
er P
lann
er
Sup
plie
r Q
ualit
y E
ngin
eer17
S S S S S R
18 Part Submission WarrantS S S S S R
19W W W W W W N/A Waived Waived N/A
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 - WaivedRefer to AIAG PPAP Manual, Fourth Edition, for further clarification.
SubmittedY/N
AcceptableY/N
Design RecordBallooned JVS Part Print
Engineering Change Documents, if anyJVS Supplier Change Request or evidence of engineering approval (e.g. e-mail)
Customer Engineering ApprovalJVS Supplier Deviation Request
Inte
rim/
Con
ditio
nal
Design FMEARequired, if design responsible.
Measurement System Analysis StudiesRequired for measurement devices used for special characteristics.
Dimensional ResultsClearly identify dimensional data to the part(s) submitted in # 14. JVS Layout -
Material, Performance, Test ResultsTransfer data to form from certifications, including the specification limits, and attach copy of material and test certifications.
Met Review - Other Testing -
Initial Process StudyRequired for all special characteristics.Include raw data, histogram, control chart and capability indices (PpK and CpK).
Qualified Laboratory DocumentationInclude copies of certifications (e.g. ISO9000, TS16949, A2LA), as appropriate
Appearance Approval ReportNot applicable to JVS product
Sample ProductClearly identify part(s) used for the results submitted in # 9. A minimum of 2 parts to be submitted (one for dimensional analysis and one for possible destructive testing), unless otherwise specified.
Master SamplesSample must be retained at the supplier. Dimensional data for this piece should also be included in #9.
Checking AidsList the checking aids with calibration status, as appropriate.
JVS Specific RequirementsPackaging & PreservationCoatings (MSDS)Process ChemicalsOutside processes
Bulk Material ChecklistNot applicable to JVS product
Design RecordBallooned JVS print (required for PPAP level 2, 3, 4, and 4*)
Attached below
Supplier print
Submitted under separate cover
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
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)
Approved Supplier Change Request
Attached below
Submitted under separate cover
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
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)
Approved Supplier Deviation
Attached below
Submitted under separate cover
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
DFMEA included as separate tab in this workbook
Process Flow DiagramNot 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
PFMEA attached below
Other (Explain)
PFMEA submitted under separate cover
PFMEA included as separate tab in this workbook
PROCESSFAILURE MODE AND EFFECTS ANALYSIS
00-039626 PFMEA Rev 11/6/11 Page 11 of 27
Item
Potential Failure Mode Recommended Action(s)
Action Results
Actions Taken
Potential Effect(s) of Failure
Sev
Class
Potential Cause(s)/ Mechanism(s) of Failure
Occur
Current Process Controls
Prevention
Current Process ControlsDetection
Detect
RPN
Responsibility & Target Completion DateProcess Function/
Requirements
Sev
Occ
Det
RPN
Control PlanNot 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
00-039626 Control Plan Rev 11/6/11 Page 13 of 27
Control Plan Control Plan Number:
Key Contact / Phone: Part Number / Latest Change:
Prepared By: Orig Date:
Revised by: Rev Date:
Characteristics Methods
Reaction PlanNo. Product Process Sample Size Control Method
Part / Process Number
Process Name/Operation
Description
Machine, Device, Jig, Tools for Mfg.
Special Char. Class
Specification / Tolerance
Evaluation / Measurement Technique
Sample Frequency
Measurement System Analysis StudiesNot 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 submitted under separate cover
MSA included as separate tab(s) in this workbook
MSA attached below
Page 15 of 27
Dimensional ResultsPART NAME PART NUMBER PART REV
0 0 0SUPPLIER NAME OF SUPPLIER INSPECTOR DATE OF SUPPLIER INSP
0PURCHASE ORDER NAME OF JVS INSPECTOR DATE OF JVS INSP
0
Item
Supplier JacobsResults
A/R Results A/RPc. 1 Pc. 2
Inspection MethodC=Calipers, DI=Drop Indicator, G=Gage Pins, I=Indicator, M=Micrometer, P=Profilometer, R=Rockwell Hardness Tester, S=Shadowgraph
Dimension / Specification
Inspection Method
Inspection Method
Pc. 3 (Retained at Supplier)
Page 16 of 27
Item
Supplier JacobsResults
A/R Results A/RPc. 1 Pc. 2Dimension /
SpecificationInspection
MethodInspection
MethodPc. 3
(Retained at Supplier)
Material Test Results
SUPPLIER PART NAME PART NUMBER REV
0 0 0 0
MATERIAL SUPPLIER QTY TESTED OK
SAMPLE DATA
METAL CO METAL CO. 0.38 - 0.45 6/6/10 0.44 OK
HT SUPPLIER HT SUPPLIER Core Hardness 56 - 60 HRC 6/10/10 1 57.70 OK
Complete form and attach material certification below. Blanket statements of conformance are unacceptable for any test results.
NAME OF LABORATORY
MATERIAL SPEC./ CHARACTERISTIC
SPECIFICATION LIMITS
TEST DATE
SUPPLIER TEST RESULTS (DATA)
NOT OK
42CrMoS4% C
Heat 425880 (2000 lbs)
Not Applicable
Performance Test Results
SUPPLIER PART NAME PART NUMBER REV
0 0 0 0
TEST LABORATORY QTY TESTED OK
SAMPLE DATA
AAA TEST LAB 6/6/10 3 OK
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.
TEST SPEC./ CHARACTERISTIC
SPECIFICATION LIMITS
TEST DATE
SUPPLIER TEST RESULTS (DATA)
NOT OK
Cycle test per ABC SPEC 1234
100,000 cycles without failure
1 pc broke at 214,000 cycles, 2 pcs test
stopped at 250,000 cycles without failure
Not Applicable
Initial Process StudiesProcess Studies are required for all special (Critical and Major) characteristics. Process Studies should be included, if possible, for all KCC/KPCInclude raw data, histogram, control chart and capability indices (PpK and CpK)
Not Applicable per Submission Plan
Not Applicable - No Special Characteristics
Process Studies attached below
Min Capability Requirements met (Critical 1.67 CpK and Major 1.33 CpK)
Min Capability Requirements not met - Action plan attached
Process Studies submitted under separate cover
Process Studies included as separate tab(s) in this workbook
Process Studies conducted
Qualified Laboratory Documentation
Issue Date Expiration DateIssue Date Expiration DateIssue Date Expiration DateIssue Date Expiration DateIssue Date Expiration Date
Not Applicable
TS 16949 Certification
ISO 14000 Certification
A2LA Certification
ISO/IEC17025 Certification
Other Certification (Please specify)
ISO 9001 Certification
Certificate(s) previously submitted (no changes)
Certificate(s) attached
Certificate(s) submitted under separate cover
Checking Aids
SUPPLIER PART NAME PART NUMBER REV
0 0 0 0
Description of checking aidChecking aid
number
Complies with revision above?
Y/N
Date of last calibration / verification
Not Applicable
Packaging and PreservationQuantity per individual package/box
Weight per individual package/box NOTE: Over 25 pounds requires formal JVS approval
Packaging Material Type
Outer packaging
Inner packaging (Idenfify all applicable)
Returnable bin or crate (Specify type)
Other (Please specify)
Gaylord container (Specify size)
Cardboard box (Specify size and test rating)
Other (Please specify)
Plastic or other dividers (Please describe)
Dessicant Bag
Cardboard dividers
Plastic Bag (Non-VCI)
VCI Bag
Bubblewrap
Plastic Sheet (Non-VCI)
VCI Sheet
Wooden bin or crate (Specify type)
RP applied (Specify type; complete separate tab)
VCI Chip
Coating MSDSList any coatings on the product and attach MSDS
Oil (Please specify type and include MSDS)
Black Oxide (Please include MSDS)
Other (Please specify and include MSDS)
Plating (Please specify type and include MSDS)
Loctite or similar (Please specify type and include MSDS)
Rust Preventative (Please specify type and include MSDS)
Not Applicable
MSDS(s) previously submitted (no changes)
MSDS(s) attached
MSDS(s) submitted under separate cover
Process Chemicals
Brand Name and Manufacturer of Chemical Process where chemical is used
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
Outside ServicesIdentify supplier for any outside processes or services (e.g. coating application, shot peen, grinding)
Supplier Name Supplier LocationOutside Service / Operation
Certifications and expiration dates
(e.g. ISO 9001, TS16949, A2LA, ISO/IEC 7025)
Not Applicable
Part Submission WarrantPart 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 SYSTEMSSupplier Name
0 0Street Address JVS Purchasing or Buyer/Planner Contact
0 0 0 0City State Zip Application
Does this part contain any restricted or reportable substances?
Verified by:
Explanation
Are plastic parts identified with appropriate ISO marking codes?
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.
(check)
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
DECLARATION
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 Comments
Customer Signature
Print Name Date
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.
Approved RejectedInterim Approval
Yes (explain below) No
Yes No
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
JVS Restricted and Declarable Substance List (available at www.jacobsvehiclesystems.com)
GADSL
IMDS (provide number below)
N/A
REACH Chemicals including Candidate List
EPA List of Lists
Other (explain below)
Dispositioned PSWFor JVS use only