Lesson 1Appearance an' functional testing evidence — paint/film/coating, gloss, texture, an' mechanical testsExplain how fi document appearance an' functional testing fi trim an' coated parts, includin' paint, film, an' coating tests, gloss an' texture evaluations, an' mechanical performance tests required fi show compliance wid specifications.
Customer appearance requirements an' AARsPaint, film, an' coating performance testsGloss, color, an' texture evaluationsMechanical an' functional test methodsPhotographic an' sample board evidenceLesson 2Packaging, labelling, an' shipping documentation fi include in PPAPExplain packaging, labelling, an' shipping documentation required in PPAP, includin' packaging specifications, labelling content, traceability, an' evidence dat logistics methods protect part quality through di supply chain.
Packaging specifications an' approvalsLabel content an' barcoding rulesTraceability an' lot identificationTransit testing an' damage preventionLogistics controls an' work instructionsLesson 3Engineering Change Documentation an' Design Failure Modes fi includeCover when engineering change documentation required, how fi reference ECNs an' deviations, an' which design failure modes mus' be addressed in PPAP fi demonstrate dat risks from design changes fully evaluated an' controlled.
Triggers fi engineering change recordsDocumenting ECNs, waivers, an' deviationsUpdating DFMEA an' design recordsCommunicating changes to customersTraceability from change to validationLesson 4Supplier performance an' subcontractor submittals fi includeCover how fi include supplier an' subcontractor documentation in PPAP, define flow-down requirements, collect sub-supplier PPAPs, an' evaluate supplier performance indicators relevant to di submitted part.
Identifying critical suppliers an' servicesFlow-down a customer requirementsSub-supplier PPAP an' approvalsMonitoring supplier performance KPIsManaging supplier risks an' escalationsLesson 5Dimensional Results an' Material Test Reports — sample sizes, reporting formatDescribe how fi report dimensional layouts an' material test results, includin' sample size selection, layout strategy, reporting formats, correlation to drawings an' specifications, an' handling nonconformities an' re-measurement.
Selecting parts an' sample sizesBallooned drawings an' dimension mappingDimensional report formats an' unitsMaterial an' performance test summariesHandling out-of-tolerance dimensionsLesson 6Control Plan — format (process an' product controls), linkage to PFMEA an' inspection pointsDetail how fi structure a control plan fi process an' product controls, align it wid PFMEA, define inspection points an' reaction plans, an' maintain traceability from risks to controls across di manufacturing process.
Control plan types an' required columnsLinking PFMEA causes to controlsDefining product an' process characteristicsInspection frequency an' sample strategyReaction plans fi out-of-control resultsLesson 7Measurement System Analysis (MSA) — plan fi dimensional an' visual inspection gagesDescribe how fi plan an' document MSA fi dimensional an' visual gages, includin' GRR studies, attribute agreement analysis, acceptance criteria, an' how fi align MSA scope wid critical an' special characteristics.
Selecting gages fi MSA studiesVariable GRR study planningAttribute agreement fi visual checksInterpreting MSA indices an' criteriaDocumenting MSA in di PPAP fileLesson 8Part Submission Warrant (PSW) — how fi complete fields an' attach referencesExplain di role a di PSW as di formal customer approval document, how fi complete each field correctly, reference drawing an' test reports, an' how fi link di PSW to supporting PPAP evidence an' submission levels.
PSW purpose an' link to PPAP approvalKey PSW fields an' completion rulesReferencing drawings, tests, an' reportsSubmission levels an' customer specificsCommon PSW errors an' how fi avoid demLesson 9Initial Process Studies (short-term an' long-term) — stability, control charts, an' sample collectionClarify expectations fi initial process studies, distinguishing short-term an' long-term data, use a control charts, stability an' capability assessment, an' how fi select sampling points dat represent real production conditions.
Objectives a initial process studiesChoosing characteristics an' locationsX-bar, R, an' I-MR chart selectionAssessing stability an' special causesDocumenting study results in PPAPLesson 10Design Records (drawing revisions, BOM, material specs) — required content fi dis partDefine required design records fi di part, includin' drawings, BOM, material an' performance specifications, an' customer standards, an' explain how fi control revisions an' ensure dat PPAP evidence match di released design.
Customer drawings an' 3D modelsBill a materials an' component traceabilityMaterial an' performance specificationsRevision control an' change historyAligning records wid PPAP evidenceLesson 11Capability Studies (Cp, Cpk) — data collection plan, sample size, an' interpreted acceptance criteriaExplore capability study requirements fi special characteristics, includin' Cp an' Cpk calculations, data collection plans, minimum sample sizes, stability checks, an' how fi interpret results against customer acceptance criteria.
Selecting characteristics fi capabilityShort-term vs long-term capability dataSample size an' subgroup definitionCalculating Cp, Cpk, an' PpkInterpreting results an' improvement plansLesson 12Process Flow Diagram — symbols, mapping fi moulding an' downstream operationsExplain how fi build a process flow diagram using standard symbols, mapping moulding an' downstream operations, linking to PFMEA an' control plan, an' ensuring all value-added an' inspection steps represented clearly.
Standard symbols an' notation rulesDefining process boundaries an' scopeDetailing moulding an' secondary stepsLinking flow to PFMEA an' control planVersion control an' change updatesLesson 13PFMEA — structure, severity/occurrence/detection scales, an' examples fi trim part failure modesDetail how fi structure PFMEA fi di trim part, define functions an' failure modes, apply severity, occurrence, an' detection scales, an' develop effective actions dat link to di control plan an' process documentation.
Defining process steps an' functionsIdentifying failure modes an' effectsRating severity, occurrence, detectionAction prioritization an' follow-upAligning PFMEA wid control plan
