Phased PPAP Requirements Handbook
Ford
GLOBAL PURCHASING
Supplier Technical Assistance
Phased PPAP
Requirements
Handbook
XOFRD004 - Rev. Date 12/04 - Eff. 5/5/2005
Phased Production Part Approval
Process
Phased PPAP Requirements Handbook
 Ford Motor Company
Supplier Technical Assistance
December 2004
Acknowledgements: The Phased PPAP development represents the efforts of Ford and its suppliers. Acknowledgement
should be made to the core team which comprised of: Erin Bates, Chris Burford, Volker Domdei, Matthias Duex, Timo Golzio,
Brian Grandstaff, Russ Hopkins, Tim Jolly, Debra Keller, Tom Miller, Jim Polman, Ranga Rajan, Aricka Long, Hans
Pettersson, Julian Taylor and Steve Walsh. This core team gratefully acknowledges the contributions made by employees at
Ford and its suppliers who have developed and continue to support effective implementation of Phased PPAP.
XOFRD004 - Rev. Date 12/04 - Eff. 5/5/2005
Phased PPAP Requirements Handbook
Ford
Table of Contents
Page
Phased PPAP Introduction
3
Phased PPAP Overview
4
Process Flow Overview
5
Phased PPAP Key Definitions
6
Phase 0 PPAP – Run–at-Rate
7
Phase 1 PPAP – Quality Verification
8
Phase 2 PPAP – Production Verification
9
Phase 3 PPAP – Capacity Verification
10
Customer Approval of Phased PPAP
11
Expectations
12
Appendix A - STA Roles & Responsibilities
13
Appendix B – Exception Management Process
14 – 17
Appendix C – Phased PPAP Submission Warrant
18
Appendix D – PPAP Requirements Listing
19
Appendix E - Acronym List
20
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Phased PPAP Requirements Handbook
Ford
Phased PPAP Introduction
In order to improve launch performance, Ford has structured the Production Part Approval
Process (PPAP) into a phased approach that will require an organization to demonstrate
manufacturing capability, product quality and production capacity prior to Job #1. Phased PPAP
will provide Ford and the supplier with an improved understanding of supplier manufacturing
process and part readiness.
Phased PPAP organizes the Production Part Approval Process into four phases:
‰ Phase 0: 'Run-at-Rate'
‰ Phase 1: 'Quality Verification'
‰ Phase 2: ‘Production Verification'
‰ Phase 3: ‘Capacity Verification’.
Benefits of Phased PPAP
Phased PPAP will benefit Ford and its Suppliers by:
• Dividing PPAP activities into more manageable segments
• Providing a structured approach aligned with manufacturing process development
• Providing a program team with earlier and additional measures to forecast
program/product readiness
• Providing a consistent mechanism for a supplier to demonstrate their ability to
support Ford production volume requirements/capacity
Teamwork
Ford Motor Company and its Suppliers must work together to deliver a quality part, produced ontime, that meets all Ford engineering requirements. To drive flawless execution in launching and
delivering products that surpass customer expectations, Ford and its suppliers must place trust,
integrity and accuracy above all else in the Production Part Approval Process.
What Phased PPAP Means to Ford Motor Company
Successful completion of Phased PPAP:
• Confirms that all customer engineering design record and specification requirements are
properly understood by the supplier, and that ALL production streams have the potential
to produce product consistently meeting these requirements during an actual production
run at the quoted production rate.
AND
•
Verifies that the supplier's production system can support the Daily Production Volume
declared by the customer.
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Phased PPAP Requirements Handbook
Ford
Phased PPAP Overview
Scope
• Phased PPAP must be completed for any of the situations already specified by the
current edition AIAG PPAP Manual. In addition, any increase in the Daily Production
Volume declared by the customer above the verified declared DVP will require the
supplier to re-complete any affected Phased PPAP phases.
Summary
Phase 0: Run-at-Rate
Objectives: To confirm that all production input requirements are available and understood,
and can support a limited production run.
To provide an early indicator that the design of the process/tool/facility has the potential to
produce at rate the required number of acceptable parts as determined by the pre-launch
control plan.
Phase 1: Quality Verification
Utilizes parts produced during Phase 0.
Objectives: To confirm all customer design record and specification requirements are
properly understood by the supplier.
To provide an early indicator that the design of the process/tool/facility has the potential to
produce product consistently meeting these requirements during an actual production run at
the quoted production rate by operating a minimum of one selected production stream.
Phase 2: Production Verification
Objectives: To confirm all customer engineering design record and specification
requirements are properly understood by the supplier, and that ALL production streams
have the potential to produce product consistently meeting these requirements during an
actual production run at the quoted production rate.
Phase 3: Capacity Verification
Objective: Verify the supplier's production system can support customer declared DPV
while meeting Phase 2 requirements.
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Ford
T h e p ro c e s s b e lo w is n o t to s c a le b e tw e e n tim in g p o in ts
START
C o m p le te s s o u rc in g
o f s u p p lie r s ite p e r
P u rc h a s in g
P ro c e d u re 2 .1 o r
lo c a l p ra c tic e
H a v in g c o m p le te d P S W 0 0 9 , a g re e s H ig h Im p a c t
P a rts d e s ig n a tio n w ith
S ite E n g in e e r. In fo rm s
a ffe c te d s u p p lie rs o f H I
p a rt s ta tu s a n d
d e s ig n a tio n o f P P A P
S u b m is s io n L e v e l 5
A s s ig n s P P A P
le v e l to S u p p lie r
S ite (p e r P S P -0 1 1 :
T a b le 1 ). A g re e s
w ith P ro g ra m
e n g in e e r o n H ig h Im p a c t P a rts
N o te : In s o m e re g io n s
th e P ro g ra m m e E n g in e e r
m a y b e re s p o n s ib le fo r
a s s ig n in g s ite P P A P
s u b m is s io n le v e l a n d
m a y b e th e re s p o n s ib le
P a rt A p p ro v a l A c tiv ity .
In p u ts P h a s e d P P A P
P ro m is e d a te s in to
V PP per Phased
P PA P H andbook
< P le a s e re fe r to P h a s e d P P A P H a n d b o o k fo r T im in g E x p e c ta tio n s b y P h a s e >
P h a s e 0 - C a p a c ity
A n a ly s is R e p o rt
P h a s e 1 - W a rra n t
P h a s e 2 - W a rra n t
P h a s e 3 - W a rra n t &
C a p a c ity A n a ly s is
R e p o rt
C o m p le te s P h a s e d
P P A P R e q u ire m e n ts
(P h a s e 0 , 1 , 2 o r 3 ) &
D o c u m e n ta tio n d e fin e d
fo r P h a s e b e lo w
P hase 0
W e re
a ll re q u ire m e n ts
o f th e P h a s e
m e t?
No
R e q u ire m e n ts
Yes
<1PP>
Phase 1
D o c u m e n ta tio n
d e fin e d fo r
Phase
E n te r "Y " c o d e in
V P P fo r P h a s e &
s u b m it
d o c u m e n ta tio n
d e fin e d fo r
P h a s e to S T A
a c tiv ity th a t m u s t b e c o m p le te d to m e e t P h a s e 1
T im in g o f P h a s e 0 is d e te rm in e d b y lo n g e s t le a d
5
T h e p ro c e s s b e lo w is n o t to s c a le b e tw e e n tim in g p o in ts
No
W a s th e
D o c u m e n ta tio n
A p p ro v e d ?
Yes
S ig n e d -o ff
D o c u m e n ta tio n
a s d e fin e d b y
P hase
E n te rs "R "
(R e je c te d ) in
V P P w ith in
2 4 h o u rs
R e fe r to th e P h a s e d
P P A P E x c e p tio n
M a n a g e m e n t P ro c e s s ,
e le m e n t 4 .2 .3 in th e
P hased PP AP
H andbook b)
R e je c t
R e c o rd s
S T A D e c is io n
in V P P
< P le a s e re fe r to P h a s e d P P A P H a n d b o o k fo r T im in g E x p e c ta tio n s b y P h a s e >
R e v ie w &
S ig n
D o c u m e n ta tio n
d e fin e d fo r P h a s e
N o te s
a) R e fe r to R o le s a n d R e s p o n s ib ilitie s M a tric e s to d e te rm in e m in im u m e x p e c ta tio n s b y s u b m is s io n le v e l a n d p h a s e .
b) P ro d u c t D e v e lo p m e n t (C re a tio n ) h a v e th e a u th o rity to a u th o ris e a n A le rt (o r re g io n a l e q u iv a le n t) w h e re a d e v ia tio n to s p e c ific a tio n e x is ts , a n d In te rim A p p ro v a l is re q u ire d .
c ) L a u n c h te a m ty p ic a lly c o n s is ts o f S T A , P u rc h a s in g , P ro d u c t D e v e lo p m e n t (C re a tio n ), N e w M o d e l L a u n c h a n d M a te ria l P la n n in g & L o g is tic s (M P & L ).
d) D a ta in p u t in to V P P m a y b e c o n d u c te d b y a n a d m in is tra tio n te a m c o n s is te n t a s d e fin e d b y lo c a l p ro c e d u re . If S T A d e c is io n o n P h a s e d P P A P W a rra n t is e n te re d b y th e s u p p lie r, S T A m a y o v e rrid e s u p p lie r
V P P e n try a t a n y tim e . T h is a ls o a p p lie s in th e c a s e s o f P P A P S u b m is s io n L e v e l 1 ("S u p p lie r S e lf C e rtific a tio n "), w h e re A p p ro v a l is re g is te re d in V P P a u to m a tic a lly w h e n th e s u p p lie r e n te rs "Y " c o d e
e) D o c u m e n ta tio n is n o t lim ite d to th a t d e fin e d in th is P ro c e s s F lo w c h a rt. T h e F o rd P h a s e d P P A P 4 -P a n e l P ro c e s s M a p (s e e P h a s e d P P A P H a n d b o o k ) d e fin e s th e d o c u m e n ta tio n th a t is re q u ire d to b e c o m p le te d
a t e a c h P h a s e . S u b m is s io n to th e C u s to m e r A p p ro v a l A u th o rity (S T A ) is d e fin e d in th e A IA G P P A P M a n u a l.
Buyer
S T A P ro g ra m
E n g in e e r
S T A S ite
E n g in e e r a ),d ),
e)
S u p p lie r d ),e )
Launch
Team c)
FPDS
T im e lin e
A p p ro v e
E n te rs "A "
(A p p ro v e d ) in
V P P w ith in
2 4 h o u rs
<FEU>
P hase 2
No
A re a ll
P hases
c o m p le te ?
Yes
END
<Job #1>
Phase 3
This process flow (an extract from Ford Internal Procedure PSP-011) is intended to link the activities in Phased PPAP to include 4-Panel Process
Flow, Roles & Responsibilities Matrices & Exception Management Process with the AIAG PPAP Reference Manual and any related Ford Internal
procedures.
Process Overview
Phased PPAP Requirements Handbook
Phased PPAP Requirements Handbook
Ford
Definitions:
Production Stream
A single production stream is a sequence of a minimum of one line, machine, tool, cavity,
facility, equipment, gage, operator and other required items at the intended location and
with the intended layout that will be used to produce parts that meet Ford specifications.
All production streams must include any additional items not included in the single
production stream that are required to meet the Ford Capacity Planning Volume (CPV)
requirements of the intended program being launched (e.g. additional tools, cavities, lines,
conveyors, machines)
Line
Stream
Conveyor
Cavity
Gages
Others
EOL Tester
Tool
Facilities
Operators
CPV (Capacity Planning Volumes)
Capacity Planning Volumes are the volumes for which Ford requires suppliers to facilitize
and tool-up for. CPV's are approximately 10 percent higher than "production planning
volumes," in order to cover spares (service requirements) and volume spikes. The CPV is
communicated to Suppliers on a part level basis through the Ford Purchasing “Request for
Quotation” (RfQ).
CPV's are typically expressed as weekly volumes. Suppliers are expected to satisfy the
production weekly demand based on a maximum 5 days/3 shifts manufacturing operating
pattern.
DPV (Daily Planning Volume)
DPV's are the maximum planned requirement for this part per day and are broken down by
plant and Brand (e.g. Volvo).
Acceptable Parts (referenced in Phase 0 objectives)
Acceptable Parts are defined as parts produced using the required PPAP inputs for Phase 0
as identified on the Process Map and manufactured in conformance with the relevant
control plan, either Pre-Launch or Production.
Interim Accepted
Part meets customer specifications and includes valid Temporary Engineering Specification
for temporary exception.
Temporary Engineering Specification
Temporary specification provided by the customer engineering release organization. The
Ford Brand specific method for communicating these specifications is as follows:
• WERS Alert (Ford/Jaguar);
• Temporary Part Change Management (Land Rover);
• Temporary Part Deviation (Volvo).
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Phased PPAP Requirements Handbook
Ford
Process Map Phase 0 Run-at-Rate
Objectives: To confirm that all production input requirements are available and
understood, and can support a limited production run.
To provide an early indicator that the design of the process/tool/facility has the potential to
produce at rate the required number of acceptable parts as determined by the Pre-Launch
control plan.
Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity Analysis
Report and supporting documentation.
Phase 0
Run-at-Rate
START
INPUTS
Trained
supplier
production
operators
Are the
Run-at-Rate input
requirements in place
for the production
stream?
Outputs from
the event
Required Inputs
STATUS:
Phase 0
Completed
No
Sub-supplier(s)
material status
from Tier-x
Run-at-Rate
Supplier
EVENT:
Conduct Runat-Rate
Yes
No
Quantity of
parts required
as defined by
customer
(default 300
consecutive
parts)
Was the
Pre-Launch
Control Plan
followed?
Yes
No
Job 1 Location
(final site &
line)
Capacity
Analysis
Report
Were the
prescribed number
of acceptable parts
produced?
Submit to
Customer
Yes
Production
process
including
control plan,
flow diagram
instructions &
Process
parameters
[#5,6 & 7]
No
Planned
production
cycle times
required to
support Daily
Production
Volume
Were the
parts produced
in the defined
period?
Status Tracking
Database
Yes
Production
Tools, Facilities
& Gauging
[#8,16 & 17]
No
Implement
Corrective
Action on Input
Did all
operations
meet their planned
cycle time
?
1
Proceed to next page
Released
design
[#1,2,3 & 4]
Yes
4
Note: refer to Appendix D which lists the PPAP requirements
number (#x) noted in the 4-Panel Process Map
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Phased PPAP Requirements Handbook
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Process Map Phase 1 Quality Verification
Objectives: To determine if all customer engineering design record and specification
requirements are properly understood by the supplier. To provide an early indicator that the
design of the process/tool/facility has the potential to produce product consistently meeting
these requirements during an actual production run at the quoted production rate by
operating a minimum of one selected production stream.
Phase 1 Quality Verification
Continue Production Part
Approval Process (PPAP) using
parts from Phase 0
1
-
Dimensional measurements [#9]
Material Tests [#10]
Statistical process package [#11]
Performance Tests [#12]
Appearance criteria [#13]
Sample parts [#14]
Master samples [#15]
Customer Specific Requirements[#17]
as defined by PPAP
Have the
PPAP requirements
been
satisfied?
Yes
STATUS:
Phase 1
Completed
2
No
Phase 1
Warrant
[#18]
Proceed to next page
Submit to
Customer
Status Tracking
Database
Important notes:
For suppliers with only one
production stream completion of
Phase 1 & 2 occur at the same
time utilizing the Production
Control Plan.
It is required that prior to Phase 1
submission that sub-supplier(s)
material status from Tier-x has
also achieved Phase 1.
Return to
Phase 0 for
corrective
action
4
4
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Phased PPAP Requirements Handbook
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Process Map Phase 2 Production Verification
Objectives: To determine if all customer engineering design record and specification
requirements are properly understood by the supplier, and that ALL production streams
have the potential to produce product consistently meeting these requirements during an
actual production run at the quoted production rate.
Note: The approach adopted for PPAP of multiple production streams is scenario-specific and must
be agreed between the Supplier and STA. In general terms each production stream should be
assessed for Run-at-Rate and Quality Verification separately. Consideration should also be given to
the risk that the introduction of further production streams may impact the validity of the Phase 1
approval. (e.g. Phase 1 achieved on cavity #1 of a four cavity tool - the introduction of cavity #2, 3 &
4 may impact the cavity #1 part and it may no longer be to specification).
P h ase 2 P ro d u ctio n V erificatio n
2
Have Run-at-Rates
(Phase 0) been conducted
and Q uality Verifications
(Phase 1) been satisfied for
ALL production
stream s ?
Y es
STATUS:
Phase 2
Com pleted
3
No
S u b m it to
C u stom er
Status Tracking
Database
Im porta nt note :
Pha se 2 a nd Pha se 3 c a n ha ppe n
c onc urre ntly if a ll Inputs a nd
Outputs a re sa tisfie d.
E x pe c ta tion tha t the Produc tion
C ontrol Pla n is follow e d during
this Pha se .
4
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Proceed to next page
Phase 2
W arrant
[#18]
Phased PPAP Requirements Handbook
Ford
Process Map Phase 3 Capacity Verification
Objective: Verify the supplier's production system can support customer declared DPV
while meeting Phase 2 requirements.
Update process flow with latest version to include nomenclature 'Capacity Analysis Report'
Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity Analysis
Report and supporting documentation.
Phase 3
C a p a c ity V e rific a tio n
A re the
C V input
requirem ents in plac e
for all produc tion
s tream s ?
A ll pers onnel
for all s hifts ,
trained
Q uantity
required is
c us tom er DP V
for one full day
Required Inputs
3
Y es
No
E V E N T:
Conduc t
C apac ity
V erific ation R un
S TA TUS :
P has e 3
C om pleted
W as the
P roduc tion c ontrol
plan follow ed &
ac c eptable parts
produc ed?
P has e 3
W arrant
[#18]
& Capac ity
A naly s is
R eport
Y es
P has e 2
W arrant
S c heduled
down tim e
defined (TP M ,
c hange over,
B reak s etc .)
No
D id th e
vo lu m e o f a c c e p ta b le
p a rts p ro d u c e d m e e t o r
e xc e e d th e re q u ire d
D P V?
S ub m it to
C us to m e r
S tatus Trac k ing
Databas e
Y es
S ub s upplier
m aterial s tatus
from Tier-x
P has e 3
C om plete
C apac ity
A naly s is
W ork s heet
D eterm ine
Root Caus e &
P lan Correc tive
A c tion
Return to
affec ted phas e
and s tart
c orrec tive ac tion
P has e 0
P has e 2
P has e 1
P has e 3
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E ND
Phased PPAP Requirements Handbook
Ford
Customer Approval of Phased PPAP
Phased PPAP Approval
Phase 0 does not require a Phased PPAP Submission Warrant, however a Capacity Analysis
Report (Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity
Analysis Report and supporting documentation) must be submitted with the Run-at-Rate box
ticked indicating Phase 0. In addition, the supplier should have results from Run-at-Rate readily
available for STA Engineer review and approval where required (see roles & responsibilities
section, appendix A).
Phase 1, 2 and 3 each require a Phased PPAP Submission Warrant and customer approval in
line with the AIAG PPAP submission level requirements or as otherwise specified by STA (see
roles & responsibilities section, appendix A).
Phase 3 requires Suppliers to complete the Capacity Analysis Report in addition to the Phased
PPAP Submission Warrant.
Suppliers to Ford and its affiliates will utilize the Phased PPAP warrant (Appendix C). For
suppliers designated as non-Q1 and suppliers/parts identified as High-Impact, STA will review
and either approve or reject the PPAP submission warrant within 48 hours of the supplier
indicating the PPAP is "Ready-for-STA-Inspection" in the Vehicle Parts Progress (VPP)
database. Once STA has determined the PPAP status and signed the Warrant (Phase 1, 2 and
3) and Capacity Analysis Report (Phase 0 and 3), the supplier or STA's designate will enter the
PPAP decision status in the Vehicle Parts Progress (VPP) database within 24 hours of receiving
a STA's signed copy of the warrant.
Any temporary exception due to non-compliance with a PPAP element or build timing
requirement is handled in line with the Exception Management Process (refer to Appendix B).
Transition: Phase 1 Approval to Phase 2 Approval - Status and Part Supply
In cases where more than two production streams are to be used to support Ford's capacity
requirements, the degree of complexity regarding the declaration of Phased PPAP Status
and the ability to supply parts during the transition from Phase 1 to Phase 2 inevitably
increases. In order to illustrate how this should be managed please consider the following
example:
• A supplier will be introducing a total of four production streams. In line with Phased
PPAP methodology, the supplier will only be ready to submit the Phase 2 Warrant
when they are able to prove that the PPAP requirements have been met for all 4
production streams.
• 3 months prior to 1PP the supplier has achieved Phase 1 Warrant approval for one
production stream.
• As 1PP approaches the PPAP requirements for the second and third production
streams have been satisfied, and the supplier wants to supply parts for 1PP from the
three streams.
• In order to supply these parts the supplier must have an approved, updated, Phase 1
Warrant, that declares that the PPAP requirements for the 3 production streams
have been met (plus supporting data as per submission level requirements). The
date for which Phase 1 requirements were achieved is not affected in reporting
metrics.
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Expectations
Phased PPAP Achievement by Build Milestone
1PP (PV1)
Phase 1
100% Completed
FEU (PV2)
Phase 2
100% Completed
Job #1
Phase 3
100% Completed
The decision to progress through the FPDS Milestones is determined by the Global Launch
QOS; refer to New Model Launch Team for latest version. Note: Phased PPAP achievement by
Volvo build event is Phase 1: Tryout, Phase 2 and Phase 3: Job 1.
Phased PPAP Reporting Expectations
The preferred system to track and report Phased PPAP is VPP (Vehicle Parts Progress in
CMMS3).
Phased PPAP now requires suppliers to track and report on multiple promise dates. Suppliers
operating in VPP must enter any remaining open Phased PPAP promise dates (Phase 0 – 3)
within one full working day of the part appearing in the supplier work queue. Supplier's Approval
submission via VPP is the electronic equivalent to a signed PPAP Warrant.
Tier 1 Suppliers shipping to Ford must use a production part approval process for their subsuppliers. Additionally, suppliers are required to verify their sub-supplier can meet required
volumes at the required time; suppliers and/or sub-suppliers may use the Ford Capacity
Analysis Report and documentation.
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Appendix A
STA Phased PPAP Roles & Responsibilities
Minimum STA Review Requirements a, b)
Site Status
Regardless of
Site Status d)
Non-Q1 Site
Q1 Site f)
PPAP
Part
Phase 0
Submisssion
Run-At-Rate
Status
c)
Level
Review must
be
on site
Phase 1
Quality
Verification
Phase 2
Production
Verification
Phase 3
Capacity
Verification
Review must
be
on site
HighImpact
5
Non
HighImpact
3
Phase 0, 1, 2 and 3 must be at least a desktop review
Non
HighImpact
1
None
Documentation
Capacity
Analysis
Report
At least a desktop review
PPAP
submission
Warrant (Phase
1), Supporting
Documentation
and Sample
Parts
PPAP
submission
Warrant (Phase
2), Supporting
Documentation
and Sample
Parts
Capacity
Analysis
Report and
PPAP
Submisssion
Warrant
(Phase 3)
PPAP
Outcome d, e)
Approve or Reject
Warrant
requiring an
Temporary
Engineering
Specification
No change to the assessment requirements as defined in table
above.
a) For Programs utilizing Supply Base launch Teams (SBLT's) 100% of STA Tier 1 reviews will be conducted
On Site for a minimum of 3 of 4 Phases. Any deviation from the minimum requirements listed above
must receive STA management authorization.
b) For ongoing running changes, MCR, or resourcing action: Phase 0 (Run-at-Rate), Phase 1 (Quality Verification),
Phase 2 (Production Verification) and Phase 3 (Capacity Verification) will follow the minimum STA review
requirements stated in the table.
c) PPAP submission level is assigned per STA procedure PSP-011.
d) Site may be designated Q1 or Non-Q1.
e) Input into VPP is executed by the Supplier, or their Ford internal administrator, upon receipt of a signed warrant.
f) Submission Level 1 suppliers self approve submission
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Appendix B
Exception Process
Purpose
The purpose of this instruction is to identify the supplier and customer responsibilities when PPAP is
not complete and approved material is required to support customer manufacturing. Also, this
instruction defines the process steps for achieving Interim Accepted of a part with a valid Temporary
Engineering Specification.
Process Flow -- Deviations to PPAP Element(s) or Timing
Team
Supplier
New Model Launch /
Manuf. Plant
Product Development
STA
Deviation to PPAP Element(s) or
PPAP Timing requirements
Develop, Agree and Implement Corrective action Plan
Correctable
prior to Build
need?
Consider risks that affect
successful completion and
monitor accordingly
Implement Corrective Action Plan
No
Is there a
deviation to
PPAP
Elements?
Yes
Raise Temporary Engineering Specification*
No
Does Local Practice
require Temporary
Engrg. Spec. for
part status that fails
to support customer
Timing
requirements?**
Approve or
Reject
Temporary
Engrg. Spec.?
Yes
No
Yes
Update control plan &
implement process control
changes accordingly
No
Complete PPAP process and
address Temporary
Engineering Specification
No
Does this
Temporary Engrg.
Spec. apply to
parts required for
Integrated Build
***?
Consider risks that affect
successful completion
and monitor accordingly
No
Yes
Approve
Warrant
per PPAP
Submission
Level?
Submit Warrant to the
Temporary Engineering
Specification with
Documentation
Yes
Supplier develops
Support/Containment Plan and
submits to NML
Approve
Support Plan in
'Open-to-Go'?
NML & Chief
Engineer
Supplier inputs plan information into
VPP
Yes
Permission to Ship for Build
* Notes: Temporary EngineeringSpecification:
Ford = WERS Alert
Land Rover = Temporary PCM
Volvo = Temporary Part Deviation
**Notes: If Phased PPAP timing has not been achieved as per customer requirements (normally specified in the Launch QOS)
refer to NML Team for clarification on requirement for Temporary Engineering Specification.
***Notes: For programs following FPDS this refers to IB build and after.
Refer to web-link: https://web.qpr.ford.com/sta/Exception_Management.pdf
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No
Phased PPAP Requirements Handbook
Ford
Appendix B
Definitions
"Approved Material" – parts with Warrant declaring "Approved" in the customer use block of the
PPAP Warrant.
"Temporary Engineering Specification" – temporary specification provided by the customer
engineering release organization. The Ford Brand specific method for communicating these
specifications is as follows:
• WERS Alert (Ford/Jaguar);
• Temporary Part Change Management (Land Rover);
• Temporary Part Deviation (Volvo).
"Full Approval" – part meets all customer specifications and requirements.
"Interim Accepted" – part meets customer specifications and includes valid Temporary
Engineering Specification for deviation.
"Process Flow Diagram" – Deviation to PPAP Element(s) or Timing
Process Flow Description
Deviation to PPAP Requirements:
It is the responsibility of the supplier to complete the 19 requirements of PPAP prior to the date
when the customer requires approved material. Typically, there are four situations that prohibit
PPAP completion:
• Incomplete PPAP Element – e.g. PV testing not complete;
• Deviation to requirement – e.g. dimension out of tolerance;
• Parts not produced using intended production flow – e.g. rework due to urgent change,
use of temporary tooling/facility, not all equipment on home-line.
• Deviation to required cycle time.
The team should develop, agree and implement a corrective action plan. If this plan is not
complete prior to the build requirements then a Temporary Engineering Specification is needed.
Deviation from PPAP Timing:
It is the responsibility of the supplier to complete the appropriate Phase by the required timing as
determined by the customer. If this timing is not achieved then the team should develop, agree
and implement a Corrective action plan.
If this plan is not complete prior to the build requirement then a support plan should be
developed. Local practice determines whether a Temporary Engineering Specification is required
for Deviations to PPAP Timing.
Corrective Action Plan:
It is the responsibility of the supplier to develop a corrective action plan that achieves Approved
Material status by the required part submission date. The supplier should seek input from the
customer's product development, manufacturing, and launch management to assure their
concurrence with the planned corrective actions.
Support Plan:
If the PPAP is not complete on time a Support Plan must be developed that identifies how the
supplier will support the build volume requirements, as well as, the activities to support Full
Approval
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Appendix B
Temporary Engineering Specification:
Shipment of production level parts with an incomplete PPAP requires a supplier's PPAP Warrant
consistent with the requirements stated in a Temporary Engineering Specification. The
Temporary Engineering Specification must describe the specific PPAP Element(s) (or timing
deviations per local practice) that are not completed, the modified specification(s) that the part
satisfies and the justification why the modified specification is acceptable.
Additionally, the Temporary Engineering Specification shall describe how the supplier will assure
quality of parts (e.g. extra ordinary controls/inspection process and robust measurement system)
to the modified specification. The Temporary Engineering Specification is effective for a limited
period of time, typically reflected in terms of days, quantity, or specific launch build event.
Examples of Temporary Engineering Specifications:
• Geometry – expanded tolerance or mean shift
• PV Testing – partial completion
• Functional Testing - Use of surrogate test results
The Temporary Engineering Specification processes and originators differ by brand as follows:
Brand
Process
Originator
Ford
Worldwide Engineering
Release System
(WERS) Alert
Ford Product
Development or
Supplier with WERS
access
Jaguar
Worldwide Engineering
Release System
(WERS) Alert
Ford Product
Development or
Supplier with WERS
access
Land Rover
Temporary Product
Change Management
(Temporary PCM)
Land Rover Product
Development
Volvo
Temporary Part
Deviation (TPD)
Volvo Research &
Development,
Purchasing, or
Manufacturing
Approve/Release Temporary Engineering Specification:
The customer is responsible to approve and release engineering deviations. Typically, the
customer's Product Development, Launch Management, and Manufacturing will (electronically)
sign-off on the deviation, and it will be approved by the releasing activity. This approval is
authorization to the supplier to proceed with the corrective actions necessary to achieve
Approved Material status on a time-limited basis.
Update quality control documents:
Upon receiving the approved Temporary Engineering Specification from the customer, the
supplier is responsible to update all affected quality control documents. The PFMEA shall be
updated to determine if there are any new or changed failure modes. Additionally, items such as
Gage R&R, Controls Plans, Operator Instructions and Visual Aids shall be reviewed.
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Appendix B
Provide PPAP Warrant:
It is the responsibility of the supplier to complete a PPAP Warrant per the specifications provided
in the Temporary Engineering Specification. The purpose of this Warrant is for the supplier to
declare that inspections and tests on production parts show conformance to customer
specifications including the Temporary Engineering Specification.
The supplier must indicate the following on the PPAP Warrant section addressing Interim Status:
• In the Interim Status section, check the box indicating Interim Submission
• Enter the Temporary Engineering Specification number against Engineering Authorization
• Provide a brief description of the reason(s) for the Temporary Engineering Specification
Approve or Reject Warrant:
If the Temporary Engineering Specification applies to parts to parts required for Integrated Build
and subsequent builds (or Brand equivalent Build Phase) then the customer approval authority is
required to either Approve or Reject the submission. Prior to this build phase the customer
approval authority may choose to review the documentation at their discretion. Approval of the
Warrant is the supplier's permission to ship products for a specified time period or quantity.
Rejection of the Warrant means customer requirements were not fulfilled and requires the
supplier to make corrections and submit a new warrant.
Upon review of the Warrant and supporting evidence, the Customer Part Approval Activity
completes the Customer Use section of the Warrant.
• If Interim Accepted, check Interim Accepted against Phased Part Warrant Status
• If Reject, check Reject against Part Warrant Disposition
Warrant disposition is communicated by local practice.
If a submission at any phase is due to be, or has been, rejected the STA Program Manager
should be notified. The STA Program Manager may choose to utilize this Exception
Management process to gain approval for the submission
Actions to achieve Full Approval:
The supplier is responsible to implement the corrective actions necessary to achieve a Full
Approval. If Full Approval is not complete by the next launch build event, the customer should
process a new or updated Temporary Engineering Specification. If the conditions within the
Temporary Engineering Specification are changed, a new Warrant is required from the supplier.
Timing
Approved material requirements vary based upon customer as follows:
• Ford, Jaguar, and Land Rover vehicle programs by the 1PP build event.
• Ford, Jaguar, and Land Rover Powertrain programs by the PV (or "Powertrain 1PP") build
event.
• Volvo Vehicle and Powertrain programs by Try-out.
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Appendix C
Phased PPAP Submission Warrant 1/
Phase 1
Phase 2
PPAP Submission Warrant Status
Phase 3
PART INFORMATION
Part Name
Customer Part Number
Shown on Drawing Number
Organization Part Number
Engineering Change Level
Date
Additional Engineering Changes
Date
Optional Tracking Number
Safety and/or Government Regulation
Yes
Checking Aid Number
Purchase Order No.
No
Weight (kg)
Checking Aid Change Level
Dated
ORGANIZATION MANUFACTURING INFORMATION
Organization Name and Supplier Code
Customer Name/Division
Street Address
Buyer/Buyer Code
State/County/Province
City
Zip
Country
Application
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 below
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.
DECLARATION and SUBMISSION RESULTS
I affirm that the samples represented by this warrant are representative of our parts which were made by a process which meets all
current edition Production Part Approval Process Manual requirements including all Ford-specific requirements. I further affirm that
hours using
these samples were produced at the production rate of ________ /
production streams. I also certify that
documented evidence of such compliance is on file and is available for review. I have noted any exceptions from this declaration below.
EXPLANATION/COMMENTS
List Molds / Cavities / Production Processes:
(Attach a separate page if additional space is necessary)
Supplier Authorized Signature
Date
Print Name
Phone No.
Title
Fax
Email
FOR FORD USE ONLY
PPAP
Phased PPAP
Warrant Status:
Non-PPAP
.
Approved
Rejected
Interim Status (to be completed by Supplier)
a/
.
Interim
Accepted
Interim
Submission:
Engineering
Customer Signature
Print Name
.
Date
.
.
Alert, Temp. PCM, TPD Number
Description:
.
a/ Non-PPAP indicates the part does not satisfy one or more PPAP requirements
and is considered incomplete until all PPAP requirements are satisfied.
1/
Authorization:
.
(Open Issues)
Refer to web-link: https://web.qpr.ford.com/sta/Phased_PPAP_Warrant.xls
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Appendix D
PPAP Requirements as Noted in the Phased PPAP Process Map
#
Requirement
1
Design Records
2
Engineering Change Documents
3
Customer engineering Approval
4
Design FMEA
5
Process Flow Diagrams
6
Process FMEA
7
Control Plans
8
Measurement System Analysis Studies
9
Dimensional Results
10
Records of Material/Performance Test Results
11
Initial Process Studies
12
Qualified Laboratory Documentation
13
Appearance Approval Reports
14
Sample Production Parts
15
Master Sample
16
Checking Aids
17
Customer-Specific Requirements
18
PPAP Warrant
1/
Bulk Material expectations are not addressed within Global Phased PPAP requirements.
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Appendix E
Acronym List
ƒ
STA
-
Supplier Technical Assistance
ƒ
PPAP
-
Production Part Approval Process
ƒ
PSW
-
PPAP Submission Warrant
ƒ
TACT
-
Total Actual Cycle Time
ƒ
EOL
-
End of Line
ƒ
DPV
-
Daily Production Volume
ƒ
CPV
-
Capacity Planning Volume
ƒ
IPD
-
In Plant Date (to a program build event)
ƒ
1PP
-
1st Production Prove-Out Units (at customer plant)
ƒ
FEU
-
Field Evaluation Units (at customer plant)
ƒ
VPP
-
Vehicle Parts Progress
ƒ
AIAG
-
Automotive Industry Action Group
ƒ
FPDS
-
Ford Product Development System
ƒ
WERS
-
Worldwide Engineering Release System
ƒ
PM Parts
-
Part Process Modification
ƒ
TIKO
-
TidsInformationKöpOrder (Part Information and Order System)
ƒ
PTIS
-
Part Tracking Information System
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