SDN. BHD.

APPROVED APPROVED
ORIGINATOR REVIEW BY REVISIONS
BY BY
RELEASED RELEASED
REV.
DATE BY
00

TITLE

PRODUCTION PART APPROVAL PROCESS

(PPAP)

SDN. BHD.
, MALAYSIA
CLASS DOCUMENT NO:
QMS PROCEDURE SOP-QA-7.3.6.3-001

FOR REFERENCE ONLY. LATEST REVISION REFER TO DOCUMENT CONTROL.

SDN. BHD.

PRODUCTION PART APPROVAL PROCESS (PPAP) REV: 00 Page 1 of 6

CHANGE CONTROL

REV NO. ECN NO. DESCRIPTION OF CHANGES REV DATE

New release to reflect ISO9001 Clause 8.3
0 Nil 09.08.21

FOR REFERENCE ONLY. LATEST REVISION REFER TO DOCUMENT CONTROL.

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PRODUCTION PART APPROVAL PROCESS (PPAP) REV: 00 Page 2 of 6

1.0 PURPOSE
The Production Part Approval Process (PPAP) is intended to validate customer’s engineering
requirements and that the production process has the potential to meet these requirements during an
actual production run at the quoted production rate.

2.0 SCOPE
This procedure applies to customers requiring PPAP submission.

3.0 DEFINITION
3.1 Disciplined Change Control
Engineering change control requires approval before the shipping of product.

3.2 Verification
The output of any change must be congruent in the form of drawing, specification or sample
configuration.

3.3 Validation
The output of any change must be congruent to customer’s intended use.

3.4 Engineering Change Notice

Engineering Change Notice (ECN) requires feasibility study to meet customer requirements by
appropriate testing.

3.5 Type Of Change

Type 1 - Tier 1 – Supplier conforming to PPAP submission for Engineering Change to BIG 3 –
FORD, GM, Daimler Chrysler and automotive related customers.

Type II - Tier 2 supplier conforming to specific submission Engineering Change not directly to
BIG 3 and non-automotive customers.

Type III - No PPAP required for Adding additional test or add/delete operators due to line
balancing.

4.0 REFERENCE
4.1 Production Part Approval Process (PPAP) Manual
4.2 Advanced Product Quality Plan (APQP) Manual

5.0 RESPONSIBILITY
5.1 QA Manager is responsible for signing the Warrant indicating that the report is complete, is
submitted to the proper submission level, the proper supporting information is attached and that
all customer requirements are met.

5.2 Quality Engineer prepares corrective action request for non – conforming production part
approval results. Each submission failure requires a 8D report

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PRODUCTION PART APPROVAL PROCESS (PPAP) REV: 00 Page 3 of 6

5.3 Quality Engineer prepares Part Submission Warrants and assures that all production part
approval requirements are met. In the case of non-approval of PSW, QA Engineer shall stop
the implementation in production

5.4 QA Engineer prepared PPAP documentation for each customer and ensures the submission is
according to requirements

5.5 QA Engineer maintains the PPAP record and the master sample for infinite period or until a
new master sample is made to meet customer requirements.

6.0 ATTACHMENT

6.1 Attachment 1 – PPAP Process Flow

7.0 PROCEDURE

7.1 Significant Production Run

7.1.1 Product for PPAP shall be taken from significant production run. This production run
shall be from one hour to eight hours for production and with the specific production
quantity to total a minimum of 300 consecutive parts, unless otherwise specified by the
authorised customer quality representative.

7.1.2 This run shall be manufactured at the production site during the tooling, gauging,
process, materials and operators from the production environment. Part from each
unique production process, e.g. duplicate assembly line and/or work cell, each position
of a multiple cavity die, mould, tool or pattern, shall be measured and representative
parts tested.

7.2 PPAP Submission

7.2.1 QA Engineer is responsible for co-ordinating the PPAP using Tier 1 submission matrix
according to Production Part Approval Process manual.

7.2.2 The master sample is stored and make with PPAP label which includes the customer’s
approval date.

7.3 Submission Requirements

7.3.1 PPAP package is submitted according to the customer required submission level.
Customer will choose the submission level, and depending on the level, some have to
be submitted and others retained and be readily available to customer representatives
on request.

7.3.2 Level 3 is to be utilised for all PPAP submissions unless specifically advised by
customer.

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PRODUCTION PART APPROVAL PROCESS (PPAP) REV: 00 Page 4 of 6

7.3.3 Reports are required to demonstrate conformance to the customer’s requirements and
the following job title shall be responsible for part approval.

PPAP Document Responsible Employee

1. Warrant QA Engineer
2. Appearance Approval Report R & D / Product Engineer
3. Sample Product – Master sample R & D / Product Engineer
4. Design Records – for details R & D Engineer
5. Change Documents (if any) R & D / Product Engineer
6. Dimensional Results IQA Engineer
7. Checking Aids Industrial Engineer
8. Test Results Test Engineer
9. Process Flow Diagrams Industrial Engineer
10. (a) Process FMEAs Product Engineer
(b) Design FMEAs (if any) R & D Engineer
11. Control Plan Product Engineer
12. Process Capability Studies Process Engineer
13. Measurement System Studies QA Engineer
14. Design Engineering Approval R & D Engineer
15. Qualified Laboratory Documentation QA Engineer

7.4 Part Submission Status – Interim Approval

7.4.1 If interim approval is granted by the customer, QA Engineer work with the project team
leader to ensure the action plan is followed to rectify the issue highlighted by the
customer

7.4.2 QA Engineer requests from the customer if an extension to the interim approval is
needed. Product will only be shipped to the customer that is covered by the interim
approval allowances

7.4.3 QA Engineer is responsible for obtaining corrective action on product, tests and
processes that do not meet customer requirements

7.4.4 Process Engineer identifies the root cause of the non – conformities identified, if the
interim approval is granted by customer.

7.4.5 Manager approves the interim approval action report

7.4.6 QA Engineer tracks the status of corrective action.

7.5 Rejected PPAP Submittals

7.5.1 QA Engineer work with the project team leader to initiate a discussion with project team
to investigate and identify the cause of rejection

7.5.2 QA Engineer re-submit PPAP once the rectification taken place and the product met
all customer requirements

FOR REFERENCE ONLY. LATEST REVISION REFER TO DOCUMENT CONTROL.

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PRODUCTION PART APPROVAL PROCESS (PPAP) REV: 00 Page 5 of 6

7.5.3 Corrective action for rejected or non – conformance PPAP submittals will be done
using 8D problem solving procedures

7.5.4 Production quantities will not be shipped on rejected PPAP submittals until approval of
the PPAP is obtained from the customer

7.6 Customer notification is required

7.6.1 ASEM shall notify the responsible Customer product approval activity of any design
and process changes as indicated in the PAPP manual table I.3.1. The Customer
may subsequently select to require a submission for PPAP approval

7.7 Customer Notification is not required

7.7.1 Customer notification and submission is not required for the situation described in
PPAP manual table I.3.3

7.8 Submission to Customer

7.8.1 ASEM shall submit for PPAP approval prior to the first production shipment in the
situation describe in PPAP manual table I.3.2 unless the responsible product approval
activity has waived this requirement

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PRODUCTION PART APPROVAL PROCESS (PPAP) REV: 00 Page 6 of 6

ATTACHMENT 1 – PPAP PROCESS FLOW

Flow Description Process References
Owner

PPAP Submission PPAP Submission Team PPAP package

No Follow up on customer KAE & QA N/A

Approved?
Approval status Engineer

Yes

Obtain the full or interim KAE & QA PPAP approval

Full Approval Interim Approval
approval from customer Engineer Sheet

Corrective Brainstorm for the Team 8D report

Action corrective actions

PPAP re-submission
Re-submit the whole Team PPAP package
PPAP to customer for
approval

FOR REFERENCE ONLY. LATEST REVISION REFER TO DOCUMENT CONTROL.