Lesson 1Appearance and Functional Testing Evidence — Paint/Film/Coating, Gloss, Texture, and Mechanical TestsShows how to record appearance and functional tests for trim and coated parts, including paint, film, coating tests, gloss and texture checks, and mechanical performance tests to prove compliance with specs in local manufacturing.
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 PPAPCovers packaging, labelling, and shipping papers required in PPAP, including packaging specs, label content, tracking, and proof that logistics ways protect part quality through the supply chain in Botswana logistics.
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 IncludeDiscusses when engineering change papers are needed, how to cite ECNs and deviations, and which design failure modes must be handled in PPAP to show risks from design changes are fully checked and managed locally.
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 IncludeCovers including supplier and subcontractor papers in PPAP, setting flow-down needs, gathering sub-supplier PPAPs, and checking supplier performance signs relevant to the submitted part in regional supply networks.
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 FormatDescribes reporting dimensional layouts and material test outcomes, including sample size choice, layout plan, report styles, link to drawings and specs, and dealing with nonconformities and re-checks in Botswana quality labs.
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 PointsDetails structuring a control plan for process and product controls, matching it with PFMEA, setting inspection points and reaction plans, and keeping tracking from risks to controls across making in local processes.
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 GaugesDescribes planning and recording MSA for dimensional and visual gauges, including GRR studies, attribute agreement check, acceptance rules, and matching MSA scope with critical and special traits for PPAP in Botswana.
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 ReferencesExplains the PSW's role as the official customer approval paper, how to fill each field right, cite drawings and test reports, and link PSW to supporting PPAP proof and submission levels in regional submissions.
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 CollectionClarifies hopes for initial process studies, separating short-term and long-term data, use of control charts, stability and capability check, and picking sampling points that show real production conditions in Botswana plants.
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 PartDefines needed design records for the part, including drawings, BOM, material and performance specs, and customer standards, and explains controlling revisions and ensuring PPAP proof matches the released design locally.
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 CriteriaLooks at capability study needs for special traits, including Cp and Cpk calculations, data gathering plans, minimum sample sizes, stability checks, and interpreting results against customer acceptance rules in the region.
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 OperationsExplains building a process flow diagram with standard symbols, mapping moulding and follow-up operations, linking to PFMEA and control plan, and ensuring all added-value and check steps are shown clearly for local flows.
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 ModesDetails structuring PFMEA for the trim part, defining functions and failure modes, applying severity, occurrence, and detection scales, and creating effective actions that link to the control plan and process papers in Botswana.
Defining process steps and functionsIdentifying failure modes and effectsRating severity, occurrence, detectionAction prioritization and follow-upAligning PFMEA with control plan
