Lesson 1Appearance and Functional Testing Evidence — Paint/Film/Coating, Gloss, Texture, Mechanical TestsExplains how to doc appearance and functional tests for trim, coated parts, including paint, film, coating tests, gloss, texture checks, mechanical performance tests to show spec match.
Customer appearance needs, AARsPaint, film, coating performance testsGloss, colour, texture checksMechanical, functional test waysPhoto, sample board proofLesson 2Packaging, Labelling, and Shipping Documentation to Include in PPAPExplains packaging, labelling, shipping docs needed in PPAP, including pack specs, label content, tracking, proof that logistics ways protect part quality through supply chain.
Packaging specs, approvalsLabel content, barcode rulesTracking, lot IDTransit tests, damage stopLogistics controls, work guidesLesson 3Engineering Change Documentation and Design Failure Modes to IncludeCovers when engineering change docs needed, how to ref ECNs, deviations, which design failure modes to handle in PPAP to show risks from design changes fully checked, controlled.
Triggers for engineering change recordsDoc ECNs, waivers, deviationsUpdate DFMEA, design recordsTell changes to customersTracking from change to validationLesson 4Supplier Performance and Subcontractor Submittals to IncludeCovers how to put supplier, subcontractor docs in PPAP, set flow-down needs, get sub-supplier PPAPs, check supplier performance signs for submitted part.
Find critical suppliers, servicesFlow-down customer needsSub-supplier PPAP, approvalsWatch supplier performance KPIsHandle supplier risks, escalationsLesson 5Dimensional Results and Material Test Reports — Sample Sizes, Reporting FormatDescribes how to report size layouts, material test results, including sample size pick, layout plan, report formats, link to drawings, specs, handle bad fits, re-measure.
Pick parts, sample sizesBallooned drawings, dimension mapDimensional report formats, unitsMaterial, performance test summariesHandle out-of-tolerance sizesLesson 6Control Plan — Format (Process and Product Controls), Linkage to PFMEA and Inspection PointsDetails how to build control plan for process, product controls, match PFMEA, set check points, reaction plans, keep tracking from risks to controls across making process.
Control plan types, needed columnsLink PFMEA causes to controlsSet product, process featuresCheck frequency, sample planReaction plans for out-of-controlLesson 7Measurement System Analysis (MSA) — Plan for Dimensional and Visual Inspection GaugesDescribes how to plan, doc MSA for size, visual gauges, including GRR studies, attribute agree analysis, accept rules, match MSA scope to critical, special features.
Pick gauges for MSA studiesVariable GRR study planningAttribute agree for visual checksRead MSA indices, rulesDoc MSA in PPAP fileLesson 8Part Submission Warrant (PSW) — How to Complete Fields and Attach ReferencesExplains PSW role as formal customer okay doc, how to fill each field right, ref drawing, test reports, link PSW to support PPAP proof, submit levels.
PSW aim, link to PPAP okayKey PSW fields, fill rulesRef drawings, tests, reportsSubmit levels, customer specificsCommon PSW errors, avoid themLesson 9Initial Process Studies (Short-Term and Long-Term) — Stability, Control Charts, Sample CollectionMakes clear hopes for initial process studies, split short-term, long-term data, use control charts, stability, capability check, pick sampling points for real production.
Aims of initial process studiesPick features, locationsX-bar, R, I-MR chart pickCheck stability, special causesDoc study results in PPAPLesson 10Design Records (Drawing Revisions, BOM, Material Specs) — Required Content for This PartSets needed design records for part, including drawings, BOM, material, performance specs, customer standards, explains control revisions, ensure PPAP proof matches released design.
Customer drawings, 3D modelsBill of materials, component trackingMaterial, performance specsRevision control, change historyMatch records to PPAP proofLesson 11Capability Studies (Cp, Cpk) — Data Collection Plan, Sample Size, Interpreted Acceptance CriteriaLooks at capability study needs for special features, including Cp, Cpk calcs, data collect plans, min sample sizes, stability checks, read results vs customer accept rules.
Pick features for capabilityShort vs long-term capability dataSample size, subgroup setCalc Cp, Cpk, PpkRead results, improvement plansLesson 12Process Flow Diagram — Symbols, Mapping for Moulding and Downstream OperationsExplains how to build process flow diagram with standard symbols, map moulding, downstream ops, link to PFMEA, control plan, ensure all value-add, check steps clear.
Standard symbols, notation rulesSet process limits, scopeDetail moulding, secondary stepsLink flow to PFMEA, control planVersion control, change updatesLesson 13PFMEA — Structure, Severity/Occurrence/Detection Scales, Examples for Trim Part Failure ModesDetails how to build PFMEA for trim part, set functions, failure modes, apply severity, occurrence, detection scales, make effective actions link to control plan, process docs.
Set process steps, functionsFind failure modes, effectsRate severity, occurrence, detectionAction priority, follow-upMatch PFMEA to control plan
