Lesson 1Appearance and Functional Testing Evidence — Paint/Film/Coating, Gloss, Texture, and Mechanical TestsThis lesson outlines documenting appearance and functional tests for trim and coated parts, covering paint, film, coating evaluations, gloss and texture assessments, and mechanical tests to confirm adherence to specifications in PPAP submissions.
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 documents required for PPAP, including specs for packaging, labelling details, traceability, and proof that logistics safeguard part quality throughout the supply chain for reliable delivery.
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 to include engineering change documents, referencing ECNs and deviations, and essential design failure modes in PPAP to show that design change risks are thoroughly assessed and managed for ongoing compliance.
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 incorporating supplier and subcontractor documents into PPAP, cascading requirements, gathering sub-supplier PPAPs, and assessing performance metrics pertinent to the part for a complete supply chain validation.
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 tests, covering sample selection, layout approaches, formats, alignment with drawings and specs, and managing discrepancies or re-measurements for accurate PPAP evidence.
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 elaborates on formatting control plans for process and product controls, synchronising with PFMEA, specifying inspection points and response plans, and ensuring traceability from risks to controls throughout manufacturing.
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 recording MSA for dimensional and visual gauges, including GRR studies, attribute agreement, criteria for acceptance, and matching MSA scope to critical and special characteristics for PPAP validity.
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 clarifies the PSW's role as the official approval form, guiding correct completion of fields, referencing drawings and reports, and connecting the PSW to PPAP evidence and submission levels for seamless approvals.
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 specifies requirements for initial process studies, differentiating short-term and long-term data, applying control charts, evaluating stability and capability, and choosing sampling that mirrors actual production for reliable PPAP data.
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 necessary design records for the part, such as drawings, BOM, material and performance specs, and customer standards, plus managing revisions to ensure PPAP evidence aligns precisely with the approved design.
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 investigates capability study needs for special characteristics, including Cp and Cpk computations, data plans, minimum samples, stability verification, and interpreting outcomes against customer criteria for PPAP success.
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 teaches constructing process flow diagrams with standard symbols, mapping moulding and follow-on operations, connecting to PFMEA and control plan, and clearly depicting all value-adding and inspection activities.
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 PFMEA structure for the trim part, outlining functions and failure modes, using severity, occurrence, and detection ratings, and creating actions that tie into the control plan and process docs for risk mitigation.
Defining process steps and functionsIdentifying failure modes and effectsRating severity, occurrence, detectionAction prioritisation and follow-upAligning PFMEA with control plan
