Lesson 1Appearance and Functional Testing Evidence — Paint/Film/Coating, Gloss, Texture, and Mechanical TestsExplains documenting appearance and functional tests for trim and coated parts, including paint, film, and coating checks, gloss and texture reviews, and mechanical performance tests to prove spec compliance.
Customer appearance needs and AARsPaint, film, and coating performance testsGloss, colour, and texture reviewsMechanical and functional test methodsPhoto and sample board proofLesson 2Packaging, Labelling, and Shipping Documentation to Include in PPAPExplains packaging, labelling, and shipping papers needed in PPAP, including packaging specs, label content, tracking, and proof that logistics ways guard part quality through the supply chain.
Packaging specs and approvalsLabel content and barcode rulesTracking and lot IDTransit tests and damage preventionLogistics controls and work instructionsLesson 3Engineering Change Documentation and Design Failure Modes to IncludeCovers when engineering change papers are needed, how to cite ECNs and deviations, and which design failure modes to handle in PPAP to show risks from design shifts are fully checked and managed.
Triggers for engineering change recordsDocumenting ECNs, waivers, and deviationsUpdating DFMEA and design recordsSharing changes with customersTracking from change to validationLesson 4Supplier Performance and Subcontractor Submittals to IncludeCovers adding supplier and subcontractor papers in PPAP, setting flow-down needs, gathering sub-supplier PPAPs, and checking supplier performance signs relevant to the submitted part.
Spotting key suppliers and servicesFlow-down of customer needsSub-supplier PPAP and approvalsWatching supplier performance KPIsManaging supplier risks and alertsLesson 5Dimensional Results and Material Test Reports — Sample Sizes, Reporting FormatDescribes reporting dimensional layouts and material test outcomes, including sample size picks, layout plans, report styles, links to drawings and specs, and handling faults and re-checks.
Picking parts and sample sizesBallooned drawings and dimension mappingDimensional report styles and unitsMaterial and performance test summariesHandling out-of-tolerance dimensionsLesson 6Control Plan — Format (Process and Product Controls), Linkage to PFMEA and Inspection PointsDetails building a control plan for process and product controls, matching it with PFMEA, setting inspection points and response plans, and keeping tracking from risks to controls across making.
Control plan types and needed columnsLinking PFMEA causes to controlsDefining product and process traitsInspection frequency and sample plansResponse plans for out-of-control outcomesLesson 7Measurement System Analysis (MSA) — Plan for Dimensional and Visual Inspection GaugesDescribes planning and documenting MSA for dimensional and visual gauges, including GRR studies, attribute match checks, okay rules, and matching MSA scope with key and special traits.
Picking gauges for MSA studiesVariable GRR study planningAttribute match for visual checksReading MSA indices and rulesDocumenting MSA in the PPAP fileLesson 8Part Submission Warrant (PSW) — How to Complete Fields and Attach ReferencesExplains the PSW role as the official customer okay document, how to fill each field right, cite drawings and test reports, and link the PSW to support PPAP proof and submission levels.
PSW aim and link to PPAP okayKey PSW fields and fill rulesCiting drawings, tests, and reportsSubmission levels and customer detailsCommon PSW mistakes and avoidanceLesson 9Initial Process Studies (Short-Term and Long-Term) — Stability, Control Charts, and Sample CollectionClarifies hopes for initial process studies, splitting short-term and long-term data, use of control charts, stability and ability checks, and picking sample points that show real production states.
Aims of initial process studiesPicking traits and spotsX-bar, R, and I-MR chart picksChecking stability and special causesDocumenting study outcomes 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.
Customer drawings and 3D modelsBill of materials and part trackingMaterial and performance specsRevision control and change historyMatching records with PPAP proofLesson 11Capability Studies (Cp, Cpk) — Data Collection Plan, Sample Size, and Interpreted Acceptance CriteriaExplores ability study needs for special traits, including Cp and Cpk counts, data collection plans, min sample sizes, stability checks, and reading outcomes against customer okay rules.
Picking traits for abilityShort-term vs long-term ability dataSample size and group setupCounting Cp, Cpk, and PpkReading outcomes and improvement plansLesson 12Process Flow Diagram — Symbols, Mapping for Moulding and Downstream OperationsExplains building a process flow diagram with standard icons, mapping moulding and follow-on operations, linking to PFMEA and control plan, and ensuring all value-add and check steps are shown clearly.
Standard icons and notation rulesSetting process limits 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 building PFMEA for the trim part, defining functions and failure modes, using severity, occurrence, and detection scales, and creating effective actions that link to the control plan and process papers.
Defining process steps and functionsSpotting failure modes and effectsRating severity, occurrence, detectionAction ranking and follow-upMatching PFMEA with control plan
