I. Purpose
II.
III.
This policy defines Master Lock’s requirements for approving Supplier’s products and processes at any time within the products life.
Scope
This policy applies to all Master Lock Suppliers.
Definitions
PPAP – Production Part Approval Process
FAIR – First Article Inspection Report
Process Control Plan – summary of checks, inspections and test that occur from start to end of a process
CTQ – Critical to Quality, product characteristics are typically defined by Master Lock and process characteristics are typically defined by the Supplier
IV.
V.
Responsibilities
A. Master Lock
•
Provide clear communication of product and quality requirements through requirements listed on the Purchase Order, ECO, PPAP and/or CTQ List.
B. Supplier
•
Provide Master Lock the expected product quality level through controlled processes.
•
Communicate proposed process, subcontractor and product changes to Master Lock before implementation.
•
Complete requested quality documents within project schedule.
•
Use current Master Lock Drawings for each step of this Product and Process quality policy.
Procedures
A. The PPAP Process is used to document all process and product activities supporting the consistent build of quality products and services for Master Lock. A PPAP is initiated for new or existing items for any change that affects fit, form, function or appearance.
B. PPAP consists of the following Requirements:
1. Engineering Requirements a. Project & PPAP Requirement Review b. Master Lock Document Review c. CTQ List Review
2. Marketing Services Requirements a. Packaging Requirement Review b. Master Lock Marketing Services Review
3. Operational Requirements a. Process Flow Diagram b. Process Control Plan c. Quality Work Instructions d. Tooling Build and Qualification e. Gage Build and Qualification f. Assembly Process Qualification
4. Product Quality Requirements a. Master Lock Process Audit b. Product Conformance (FAIR, Test Results, Material Certificates, etc.) c. Post Launch – Ongoing Product Conformance
5. PPAP Approval Section
Revision: February 08, 2010

VI.
C. Master Lock reviews the project and PPAP requirements with the Supplier. A timeline is developed and followed.
D. The Supplier completes all “ ” items listed on the PPAP. Samples used for the PPAP must be made with production tooling and assembly equipment.
E. Supplier reviews the completed items with Master Lock Quality. The Supplier will sign the PPAP form and forward it to Master Lock along with the samples, product results and process documentation.
F. Master Lock Team will evaluate the PPAP and determine final disposition (PASS or FAIL).
Reference Documentation and Instructions
A. PPAP form – see PPAP form.
B. FAIR form - Number each feature measured on the Master Lock Drawing. Quantity of samples stated on PPAP Form.
1.
2.
3.
4.
5.
Part Submission – Part Number & Revision, Supplier’s Name, and reason for Submission
Sample Information – Date Samples ran, Process/Tooling Information, Inspector
Results – Feature Number (item), Measurement Type (dia, rad, etc.), Feature and Tolerance, actual measurements, measurement method, disposition and sign-off.
Supplier Approval and Master Lock Approval.
Submit numbered Master Lock Drawing, Master Lock FAIR Form and numbered samples to Master Lock.
C. Process Flow Chart – it’s a graphical representation of the steps in a process. i.
One step in the process. Sequentially number each process step. ii. iii.
Direction of flow from one step or decision to another.
Decision based on a question. iv. Delay or wait. v. Link to another page or another flow chart. vi. vii.
Input or Output
Document viii. Alternate symbol for start and end points
D.
Process Control Plan – follows process flow chart step-by-step to summarize all inspections and tests.
1.
2.
General information – Product #, Product name, Supplier name, Date originated, Date revised, Document prepared by and Core team.
Process Control Plan – process step #, process step name, Product feature, Process Parameter, CTQ?,
Measurement Technique, sample size, sample frequency, control method and reaction plan.
E. CTQ List forms (2)
1.
2.
Product CTQ’s – typically issued by Mater Lock
Process CTQ’s – created by the Supplier’s team.
Revision: February 08, 2010