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, covering paint, film, coating checks, gloss and texture assessments, and mechanical tests to prove spec compliance.
Customer appearance requirements and AARsPaint, film, and coating performance testsGloss, color, and texture evaluationsMechanical and functional test methodsPhotographic and sample board evidenceLesson 2Packaging, labelling, and shipping documentation to include in PPAPCovers packaging, labelling, and shipping docs for PPAP, including specs, label content, tracking, and proof that logistics protect part quality across the supply chain.
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 includeExplains when engineering change docs are needed, referencing ECNs and deviations, and design failure modes to address in PPAP to show risks from changes are fully checked and managed.
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 includeDetails including supplier and sub-contractor docs in PPAP, passing down requirements, gathering sub-PPAPs, and checking supplier performance for the part.
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 formatOutlines reporting dimensional layouts and material tests, covering sample sizes, layout plans, formats, links to drawings/specs, and handling non-conformities or re-checks.
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 pointsExplains building control plans for process and product controls, matching PFMEA, setting inspection points and reaction plans, with risk-to-control tracking across production.
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 gaugesCovers planning and recording MSA for dimensional and visual gauges, including GRR studies, attribute checks, acceptance rules, and matching scope to critical characteristics.
Selecting gages 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 referencesDetails PSW as the official approval doc, filling fields right, referencing drawings/tests, and linking to PPAP evidence and levels.
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 initial process study needs, short vs long-term data, control charts, stability/capability checks, and sampling to reflect real production.
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 partSets required design records like drawings, BOM, material/performance specs, and customer standards, controlling revisions to match released design in PPAP.
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 criteriaCovers capability needs for special characteristics, Cp/Cpk calcs, data plans, sample sizes, stability, and interpreting against customer criteria.
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 operationsGuides building process flow diagrams with standard symbols, mapping moulding and follow-on steps, linking to PFMEA/control plan, covering all value-add and checks.
Standard symbols and notation rulesDefining process boundaries and scopeDetailing molding 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 modesOutlines PFMEA structure for trim parts, functions/failures, severity/occurrence/detection scales, and actions linking to control plan and docs.
Defining process steps and functionsIdentifying failure modes and effectsRating severity, occurrence, detectionAction prioritization and follow-upAligning PFMEA with control plan
