Lesson 1Appearance and Functional Testing Evidence — Paint/Film/Coating, Gloss, Texture, and Mechanical TestsThis lesson explains documenting appearance and functional testing for trim and coated parts, including paint, film, and coating tests, gloss and texture assessments, and mechanical performance tests to prove compliance with specifications in Australia.
Customer appearance requirements and AARsPaint, film, and coating performance testsGloss, colour, and texture evaluationsMechanical and functional test methodsPhotographic and sample board evidenceLesson 2Packaging, Labelling, and Shipping Documentation to Include in PPAPThis lesson covers packaging, labelling, and shipping documentation required in PPAP, including specifications, labelling content, traceability, and proof that logistics methods safeguard part quality through the supply chain in Australian contexts.
Packaging specifications and approvalsLabel content and barcoding rulesTraceability and lot identificationTransit testing and damage preventionLogistics controls and work instructionsLesson 3Engineering Change Documentation and Design Failure Modes to IncludeThis lesson addresses when engineering change documentation is needed, how to reference ECNs and deviations, and which design failure modes must be covered in PPAP to show that risks from design changes are thoroughly assessed and managed in Australia.
Triggers for engineering change recordsDocumenting ECNs, waivers, and deviationsUpdating DFMEA and design recordsCommunicating changes to customersTraceability from change to validationLesson 4Supplier Performance and Subcontractor Submittals to IncludeThis lesson explains including supplier and subcontractor documentation in PPAP, defining flow-down requirements, gathering sub-supplier PPAPs, and assessing supplier performance indicators relevant to the submitted part in Australian supply chains.
Identifying critical suppliers and servicesFlow-down of customer requirementsSub-supplier PPAP and approvalsMonitoring supplier performance KPIsManaging supplier risks and escalationsLesson 5Dimensional Results and Material Test Reports — Sample Sizes, Reporting FormatThis lesson describes reporting dimensional layouts and material test results, covering sample size selection, layout strategy, formats, correlation to drawings and specs, and managing nonconformities and re-measurement in Australian reporting standards.
Selecting parts and sample sizesBallooned drawings and dimension mappingDimensional report formats and unitsMaterial and performance test summariesHandling out-of-tolerance dimensionsLesson 6Control Plan — Format (Process and Product Controls), Linkage to PFMEA and Inspection PointsThis lesson details structuring a control plan for process and product controls, aligning it with PFMEA, defining inspection points and reaction plans, and maintaining traceability from risks to controls across manufacturing in Australia.
Control plan types and required columnsLinking PFMEA causes to controlsDefining product and process characteristicsInspection frequency and sample strategyReaction plans for out-of-control resultsLesson 7Measurement System Analysis (MSA) — Plan for Dimensional and Visual Inspection GaugesThis lesson covers planning and documenting MSA for dimensional and visual gauges, including GRR studies, attribute agreement analysis, acceptance criteria, and aligning MSA scope with critical and special characteristics in Australian practices.
Selecting gauges for MSA studiesVariable GRR study planningAttribute agreement for visual checksInterpreting MSA indices and criteriaDocumenting MSA in the PPAP fileLesson 8Part Submission Warrant (PSW) — How to Complete Fields and Attach ReferencesThis lesson explains the PSW's role as the formal customer approval document, how to fill each field accurately, reference drawings and test reports, and link the PSW to supporting PPAP evidence and submission levels in Australia.
PSW purpose and link to PPAP approvalKey PSW fields and completion rulesReferencing drawings, tests, and reportsSubmission levels and customer specificsCommon PSW errors and how to avoid themLesson 9Initial Process Studies (Short-Term and Long-Term) — Stability, Control Charts, and Sample CollectionThis lesson clarifies expectations for initial process studies, differentiating short-term and long-term data, using control charts, assessing stability and capability, and selecting sampling points that reflect real production in Australian settings.
Objectives of initial process studiesChoosing characteristics and locationsX-bar, R, and I-MR chart selectionAssessing stability and special causesDocumenting study results in PPAPLesson 10Design Records (Drawing Revisions, BOM, Material Specs) — Required Content for This PartThis lesson defines required design records for the part, including drawings, BOM, material and performance specifications, and customer standards, and how to manage revisions to ensure PPAP evidence matches the released design in Australia.
Customer drawings and 3D modelsBill of materials and component traceabilityMaterial and performance specificationsRevision control and change historyAligning records with PPAP evidenceLesson 11Capability Studies (Cp, Cpk) — Data Collection Plan, Sample Size, and Interpreted Acceptance CriteriaThis lesson explores capability study requirements for special characteristics, including Cp and Cpk calculations, data collection plans, minimum sample sizes, stability checks, and interpreting results against customer criteria in Australian contexts.
Selecting characteristics for capabilityShort-term vs long-term capability dataSample size and subgroup definitionCalculating Cp, Cpk, and PpkInterpreting results and improvement plansLesson 12Process Flow Diagram — Symbols, Mapping for Moulding and Downstream OperationsThis lesson explains building a process flow diagram using standard symbols, mapping moulding and downstream operations, linking to PFMEA and control plan, and representing all value-added and inspection steps clearly in Australia.
Standard symbols and notation rulesDefining process boundaries and scopeDetailing moulding and secondary stepsLinking flow to PFMEA and control planVersion control and change updatesLesson 13PFMEA — Structure, Severity/Occurrence/Detection Scales, and Examples for Trim Part Failure ModesThis lesson details structuring PFMEA for the trim part, defining functions and failure modes, applying severity, occurrence, and detection scales, and developing actions that link to the control plan and process documentation in Australian standards.
Defining process steps and functionsIdentifying failure modes and effectsRating severity, occurrence, detectionAction prioritisation and follow-upAligning PFMEA with control plan
