PPA Supplier PPAP Expectations Production Part Approval Process

PPA Supplier PPAP Expectations Production Part Approval Process An AIAG* standard used in the automotive supply chain for establishing confidence in component suppliers and their production processes. * Automotive Industry Action Group – 4 th edition is currently released.

Supplier PPAP Expectations The intent of this presentation is to give the supplier a brief overview of the Production Part Approval Process and guide them to a successful PPAP submission to JTEKT.

Supplier PPAP Expectations PPAP belongs to YOU!!! (the SUPPLIER) It is confirmation that the supplier’s planning & processing is sufficient enough to meet the customer’s continuous expectation of quality product.

Supplier PPAP Expectations There are 3 distinct sections to PPAP… 1. Guarantee/Warranty – PSW (Parts Submission Warrant) 2. Quality Planning – Design Record, Process Flow Diagrams, PFMEA, Control Plan, Inspection Standard, Safe Launch plan, MSA (Gage R&R), Laboratory certifications and facility certifications, special checking aids and Supply Chain Map. 3. Quality Data/Quality Evidence – Dimensional Results, Capability Studies, Material & Test Performance Results, IMDS submission to correct JTEKT ID#, Sample product and records of compliance with any other JTEKT requirements.

Supplier PPAP Expectations There a various “Levels” of PPAP depending on what step of the approval process is needed by the customer. As an automotive supplier, your company is expected to know the minimum requirements to satisfy various PPAP levels and when to apply them. Level 2 Level 3 Level 1 Level 4 Level 5

Supplier PPAP Expectations Level 1 – PSW Only This level is generally used for – • Corrections (use comments section in PSW). • Adding additional application (programs or platforms) to an existing production part. • May be requested when being asked to ship already PPAP’ed parts to another location. PLEASE NOTE: All PSW’s MUST INCLUDE an approved IMDS Submission Number And submitted to the appropriate site ID of the customer.

Supplier PPAP Expectations Level 2 – PSW, Sample Parts & Limited Data This level is generally used for – • Minor revision changes to parts that have existing approved PPAP’s. • Minor changes in the method of production of parts with existing approved PPAP’s. • “Limited Data” would be determined by your customer.

Supplier PPAP Expectations Level 3 – PSW, Sample Parts & Complete Data This level is generally used for – • All new parts being PPAP’d for the 1 st time. • Major engineering changes where part configuration or manufacturing method deems necessary. • Must include ALL elements of quality planning. (i. e. : PFMEA, Control Plan, Flow) and evidence of PV Testing acceptance.

Supplier PPAP Expectations Level 3 – Continued Data collection requires supplier to – • Complete a 300 pc. production run. • Ensure process capability of 1. 67 Ppk on features deemed key or critical on drawing (N=50 pcs. sampling). • 100% Layout verification of all dimensions and drawing notes (ballooned drawing). • Submit 3 sample parts* tagged to layouts. • Material certifications for all components. • Gage R&R (repeatability & reproducibility). • Other JTEKT requirements per SQAM * Multi-Cavity tooling requires samples from each cavity.

Supplier PPAP Expectations Level 4 – PSW and Other Customer Requirements This level is generally used for – • Significant revision changes to parts that have existing approved PPAP’s. • Significant changes in the method of production of parts with existing approved PPAP’s. • And where quality planning is unchanged.

Supplier PPAP Expectations Level 4 – Continued Data collection requires supplier to – • Complete a 50 pc. production run. • Ensure process capability as deemed by the customer. (i. e. : 1. 67 Ppk or as noted) • 100% Layout verification of all dimensions and drawing notes (ballooned drawing). • Submit 3 sample parts* tagged to layout. • Material certifications for all components. * Multi-Cavity tooling requires samples from each cavity.

Supplier PPAP Expectations Level 5 – PSW & Sample Parts, but Data on Record This level is generally used for – • Same expectations as a Level 3, but with onsite verification at the supplier. • Performed when there is proprietary information involved or when special processes require to be validated.

Supplier PPAP Expectations Example of PPAP document package Ref: FSQM-017

Supplier PPAP Expectations Remember Ø PPAP Document package is to ship WITH the tagged PPAP sample parts. Ø In a well packed box that is labeled with the JTEKT sample parts label. GOOD EXAMPLE

Supplier PPAP Expectations Successful PPAP submission relies on YOU! üKNOW THE JTEKT SQAM!!!! ü Ship the PPAP samples AND paperwork package TOGETHER! ü Label PPAP shipment properly to ensure receipt (use FSQM-013). ü Don’t forget IMDS, it’s required for final PPAP approval on all levels. ü Use a checklist (FSQM-080) to ensure all requirements are addressed. ü Use early shipments (ITO, TTO, OTOP) to prepare for PPAP. ü Include plans for Safe Launch to ensure Zero Defects for 90 days. Thank You!

Pre-Production Part Requirements A few notes about Pre-Production samples… Prototype > Off-Tool Off-Process • • • All sample shipments need to be labeled per the SQAM using FSQM-013. (SQAM 2. 3) All sample shipments must have specified dimensional & test data. (SQAM 2. 2) Various sample shipments require capability studies on key features. (SQAM 1. 5 & 2. 2)

Lessons Learned The following are examples of incomplete or improper PPAP shipments that resulted in parts being put on hold, or worse yet…lost! No PPAP sample label applied to box. No PPAP documentation included with parts. PPAP sample parts not tagged inside of box. No PSW submitted in PPAP package. IMDS number not listed on PSW. Critical characteristics not addressed in control plan. Capability studies not performed. No Inspection Standard submitted. “Safe Launch” plan not submitted. Ballooned drawing does not address ALL characteristics on drawing.

Information Location JTEKT Supplier Quality Assurance Manual (SQAM) Is available on the JTEKT Supplier Portal… https: //portal. koyobearings. com/portal/ Do not hesitate to contact your JTEKT Buyer or SAE for assistance. Automotive Industry Action Group (AIAG) – 4 th edition PPAP guideline publication is available at… https: //www. aiag. org/productslist/product-details? Product. Code=PPAP-4