Generic PPAP Self Assessment?

PPAP Submission Assessment

General criteria is element specific, to drive robus detail and
understanding etc.

Is there evidence of APQP execution?

Is there evidence of Supplier team engagement?

Is there evidence of Organized team engagement?

Are all documents controlled?

Are all documents legible and understandable?

Design Record
There should be complete drawings for components, including
but not limited to dimensions, characteristics, specifications,
attributes, customer specific requirements, etc. Should be
accessible and easy to share when requested.

Is a copy of the drawing included that supports the part and/

or assembly?

Is a list of specificaation supporting the production of the

part provided?

Is change level verification assured or available so that the

supplier has the latest revisions of specifications?

Is the form of dimension throughout the PPAP identical in all

documentation? I.e English, metric, etc.

Have dimensions that affect fit, function, and durability been

identified?

Are reference dimensions identified to minimize inspection

time?

Are control poins and datum surfaces sufficiently identified

to design functional gauges?

Are any tolderances compatible with current manufacturing

standards?

Are there any requirments specified that cannot be

evaluated using known inspection techniques?

Authorized Engineering Change Documents

Change documents are for the changes not yet recorded in the
design record, but are incorporated in the product, part, or
tooling. Such as written and approved deviation for anything
that deviates from the design record.

If applicable is the approved deviation accessible?

Completely filled out?

Properly approved?

Does the deviation clearly identify the number of pieces,

time limit, change forthcoming, etc, for the proper PPAP
disposition?

Design Failure Mode and Effects Analysis (Design

Responsible Organization)
A single design FMEA may be applied to a family of similar parts
and/or materials. All characeristics must be addressed. The
highest risk(s) must be identified/addressed. There should be a
current design detailed FMEA in place for each component or
family of components.

Is there design FMEA of saleable part number(s) and

components?

Are there cascading FMEA to fully address the product, i.e

- Product Vehicle

- System / Group Level

- Assembly Level

- Component Level

Does the FMEA drive design improvements as the primary

objective?

Does the FMEA address all high-risk failure modes, with

executable action plans?

Does Analysis/Development/Validation, and/or Design

Verification Plan and Report (DVP&R) consider the failure
modes from the design FMEA?

Does the FMEA scope include integration and interface

failure modes in both block diagram and analysis?

Does the FMEA consider all major "lessons" (High warranty,

campaigns, etc.) as input to failure mode identification?

Does the FMEA identify appropriate special characteristic

candidates as input to the SC selection process?

Were similar part FMEA's considered?

Has customer reliability data been utilized in preparing the

FMEA?

Is there evidence the FMEA is a living document?

Have customer product problems and/or rejections been

included, with appropriate counter measures?

Have these appropriate counter measures been planned

and/or taken for high-risk numbers?

Is the FMEA data being used in continuous quality

improvement programs?

Were customer plant problems used as an aid in developing

the FMEA?

Have the causes of problems been described in terms of

something that can be fixed or controlled?

Are the criteria used to determine Special Characteristics

documented?

Have all dimensional tolerances and material properties

been considered?

Was the design FMEA used to determine these?

Have SC been identified for all products?

Has warranty and reliable data been included to determine

the characteristics?

Is there evidence that all known special characteristics were

included?

Were attribute characteristics included?

Are New Product instructions and design changes included

in identifying SC?

Are there clear links to PFMEA and other APQP documents

(My Job)

Are historical DFMEA's recorded? (Me)

Are historical campaign and warranty data recorded? (Me)

If applicable are all special required characteristics

identified and listed?

If applicable are the special design characteristics identified

and listed?

If app. are the Special process characteristics identified and

listed?

Process Flow Diagram Assessment

"Process Flow Diagram is a representation of the process flow"
the "diagram" accurately reflects process, rework, and
inspection. All stations identified that create required, design,
and process characteristics match the design record, FMEA,
Control Plan, Work instructions and all APQP documentation.
Flow diagrams may be used once for parts that are in similar
familts as long as the flow is revised with the new parts added.
Each distinct manufacturing process should have a Process
flow chart, A schematic representation of the current or
proposed process flow. Any rough, intermediate, and finishing
operations should be included as well as material handling
techniques, inspection steps, and if applicaple any sub-
contracted products and/or processes. The flow should also
demonstrate any cleaning, packaging or other logistics stpes
until the product is used by the customer, any alternate or
backup processes should be documented as well.

Is the chart in place that identifies all manufacturing

operations, handling techniques, inspection steps, alternate/
backup processes and sub-contract suppliers?

Is the method of handling rework and scrap clearly

illustrated?

Does the process layout reflect planning, so that a logical

flow of material can occuring during the manufacturing
process?

Is the sequence of production illustrated?

Does the chart start with and detail the actual beginning
process, including purchased material and process, and the
movement of material throughout all manufacturing
operations?

Has the pull system/optimization been considered for this

process? (If applicable)

Is the process flow chart controlled, updated, and reviewed

for completeness?

Does the flow chart include all assembly and packaging

operations?

Are the sequences identified (operation or sequence

number) so as to follow other APQP requirements?

Were all appropriate FMEA's available to use as aid to

develop the process flow chart? Are inspection/quality
assurance steps, data recording, attribute checks and/or
functional testing included for each process step if
applicable?

Does the flow chart indicate the material flow for handling
rework and scrap?

Does the flow consider potential quality problems due to

handling and sub-contracted operations if applicable?

Does the flow chart illustrate all the way to shipment and
customer consumption?

Does the flow describe how a product will move, i.e roller
conveyor slide containers, tubs, etc...?

Are the steps clearly identified where and when a product is

stored and/or staged?

Does the chart illustrate special handling requirments if

applicable (green pre-heat, post grind, assembly)

Does the diagram identify all in-house alternate and/or

backup processes?

Does the the chart identify in detail sub-contract alternate or

back-up sources of supply for products or services provided,
if applicable.

Have the processes that identify special characteristics

been charted?

Process Failure Mode and Effects Analysis

Will comply with the AIAG FMEA Manual with appropriate
rankings, all special characteristics identified. Highest risk(s)
addressed, the supplier will have reviewed the DFMEA or
special characteristics list. Typical and/or historical failures will
be addresed. THe PFMEA shows connection to the flow chart,
control planm and/or other APQP documentation.

Do other design FMEA's properly cascade a products

- Product Vehicle

- System / Group Level

- Assembly Level

- Component Level

• My job to ensure properly linked

Are other tier supplier(s) PFMEA's accesible/recorded?

If proprietary is the statement that DFMEA is available at the

supplier or at the organization able to be produced upon
request? (My job)

Is there a list of recomended actions from the PFMEA? (My

job to link)

Is there a list of Special Required/Design/Process

characteristics ? (My job to link)

Are correct part numbers, engineering changes and other

info documented?

Are top severity and occurances addressed with proper

recommended actions?

Is the PFMEA provided in English, or with translations (If

applicable)

Is there evidence that all print, specification, purchase order,

attribute, characteristics recorded?

Are adequate controls in place for all characteristics?

Are special controls / actions in place for all special

characteristics?

Does FMEA drive process improvements as the primary

objective, with emphasis on Error/Mistake proofing
solutions?

Does FMEA address all high-risk failure modes with

executable action plans?

Are all other failure modes considered?

Is there evidence that the failure modes with action are

carrier over to the process control plan?

Is the Process FMEA integrated and Consistant with the

Process Flow Diagram, Process Control Plan, andother APQP
documents?

Is the FMEA completed within the "window of opportunity"

where it could most efficiently impact the design of the
priduct, part, and/or process design?

Is the FMEA document completely filled out "by the book"

including "action taken" and new RPN (Risk Priority Number)
values? (How can we make sure of this?)

Are recommended actions recorded and identified as

required and are the actions implemented or going to be?

Are the criteria used to determine Special Characteristics

documented?

Have all dimensional tolerances and material properties

been considered?

Was the design FMEA used to determine the special

characteristics?

Have SC been identified for all products?

Has warranty and reliability ddata been recorded/included

to determine the characteristics?

Is there evidence that all known special characteristics are

considered?

Were attribute characteristics recorded/included?

Are New Product Introductions and design changes included

in identifying special characteristics if applicable?

Is PFMEA clearly linked to APQP documents (my job)

Have all process dimensional tolerance and material

properties been considered?

Are all special characteristics documented?

Where SC established for assembly and packing operations?

Have the Special Characteristics been included in all other

PPAP documents? (Maybe my job? If I know what exactly to
look for i.e format)

Is there evidence of Statistical Process Control for all

Special Characteristics or controls as identified and
approved in the control plan?

Have capability studies been performed and documented to

validate the control of the characteristics?

Are there measurable quality improvement projects in place

for Special Characteristics where required / applicable?

Have any applicable SC affected by sub-contract suppliers

been identified / documented?

Control Plan
Process control plan should be developed for every process
step. To identify all actions and reactions necessary to assure
product and process variables are being controlled.

Is there a detailed and completed Process Control Plan in

place for ordering, manufacturing, inspecting, testing,
assembling, packaging, and shipping for each product /
operation being performed?

Is there evidence that a Process Control plan is a working

document, including any NPI (New Product Introduction)
products?

Does the control plan provide detailed methods for handling

nonconforming products and corrective action programs for
all quality problems including any attribute variables?

Are all Print, specification, attribute, purchase order

requirements, etc. included on the control plan?

Are all of the right part numbers and current engineering

plans identified?

Is the original and version date noted?

Is the document controlled?

Are control plan processes keyed to the Process Flow Chart,

PFMEA and other APQP documents? (I can check and help
link if not?)

Is there recieving inspection, process inspection, and

financial inspection included in the control plan?

Are there special characteristics noted from the FMEA and

PFMEA included in the control plan?

Are applicable performance testing requirements, identified

at the proper intervals?

Are all manufacturing equipments identified? (I.e press type,

paint booth type, etc. etc.)

Is the control method for special characteristics identified?

(X chart? if applicable?)

Are all inspection gages, techniques, and equipment

identified?

Are appropriate reaction plans included in the control plan?

Is the control plan available in English or translated where

applicable?

Have all known customer concerns been identified in order

to facilitate the selection of Special Required/Design/
Process Characteristics?

Are all Special Required/Design/Process Characteristics

included in the control plan?

Were SFMEA, DFMEA, PFMEA used to prepare the control

plan?

Are the material specifications requiring inspection

identified?

Are there copies of any procedure, work instruction,

specification, etc. available if any of such are referenced in
the control plan?

Is there evidence for attribute control, and other non-print

requirments?

Are there process control plans in place for all organization

part numbers?

Is there a process control plan for each manufacturing

operation?

What methodology was used preparing the control plan?

Were there any DFMEA's, PFMEA's, flow chart's, initial

capability and/or any other APQP documents used in the
construction of the control plan? (My job, if so, make sure
there is adequate navigation/linking)

Is there a documented program for establishing sample sizes

and test frequencies?

Does the control plan adequately state in detail specific data

such as progress steps from flow charts, process
descriptions, organization part numbers, individuals
responsible for plan, date, revisions?

Are SC's and other major, significant, features of special

interest, etc. process variables identified/recorded?

Does the Control plan provide detail on: Machine make &
Model, machine type, machine number/identification?

Does the plan contain reference supporting documents that

detail setup, process, inspection, and operator instructions?

If applicable are there control plans ready for any alternate /

backup processes?

Does the control plan include all attribute characteristics?

Does the control plan include specific controls for

assembling and packaging products?

Is there evidence that the plan is effective and a living

document?

Does the plan provide a method for handling nonconforming

products?

Does the plan provide a method for handling out of control

processes?

Is and has the control plan been updated when process

changes are made?

Is there any applicable evidence from customer feedback on

probjems, or rejections?

Are process control plans completed/updated for new

product or design changes?

Are engineering Test and performance requirments

identified if applicable?

Are gage methods compatible and traceable to national

standards?

Control Plan shall also include Operator Process

Instructions:
All aspects of the process should be documented in sufficient
detail for all personnel who have direct responsibility for
operation of the process. A variety of support documentation
that may inclue Design / Process FMEA's, engineering
requirments, visual standards, process flow charts, special
characteristics, capability studies, etc.

Does each process step have sufficient written instructions

to describe all actions required to manufacture, inspect, test,
assemble, package, and ship products?

Are corrective action, problem solving, and handling of

quality issues defined with proper evidence of compliance?

Are customer quality results documented and traceable to a

process control procedure?

Are manufacturing personnel and their qualification and

training requirments documented in detail?

Is the documentation controlled?

Does the document include operation #, equipment #,

description of operation, product characteristics produced,
process characteristics monitored / controlled, person(s)
responsible for control, revision date with applicable
signatures and / or all other information defined in the
control plan?

Is the documentation readily available with all information

needed for operators and setup personnel? (My job, link and
make clear)

Is there documentation for operator instructions, setup

instructions, trouble shooting guidelines, visual aids,
machine operating manuals, statistical process checks, and
inspection instructions for each step?

Are all machine settings and tolerances documented in

detail for each process step?

Does the documentation include any applicable alternate /

backup processes?

Does the process documentation provide a method for

tracking applicable pilot or prototype products? (If at all)

Is there a preventative mainentenance program for each

process step?

Is there a documented program for validating fixturing,

tooling, and gaging where applicable?

Is there detailed documentation for all assembly and

packaging operations?

Are special characteristics clearly communicable to the

operator?

Is there a procedure to identify, separate and control

nonconforming products to prevent shipment?

Is there a specific document stating the course of action to

be followed when known nonconforming products have
been shipped to the customer?

Do operators have written procedures for documenting any

required corrective action if applicable?

Is there a documented training program that lists all

employees who are trained to do all aspects of a specific
process are?

Is there any detailed program for applicable cross-training of

employees?

Are there any applicable and defined operator qualifications

for each process step, (i.e special training, education level,
experience, etc.)