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, coating tests, gloss and texture checks, and mechanical performance tests to show spec compliance.
Customer appearance needs and AARsPaint, film, and coating performance testsGloss, colour, and texture checksMechanical and functional test waysPhoto and sample board proofLesson 2Packaging, Labelling, and Shipping Documentation to Include in PPAPExplains packaging, labelling, and shipping papers needed in PPAP, including packing specs, label content, tracking, and proof that logistics ways protect part quality through the supply chain.
Packaging specs and approvalsLabel content and barcode rulesTracking and lot IDTransit tests and damage stopLogistics controls and work guidesLesson 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 must be handled in PPAP to show risks from design changes 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 including supplier and subcontractor papers in PPAP, setting flow-down needs, gathering sub-supplier PPAPs, and checking supplier performance signs relevant to the submitted part.
Finding key suppliers and servicesFlow-down of customer needsSub-supplier PPAP and approvalsWatching supplier performance KPIsManaging supplier risks and raisesLesson 5Dimensional Results and Material Test Reports — Sample Sizes, Reporting FormatDescribes reporting size layouts and material test results, including sample size pick, layout plan, report formats, link to drawings and specs, and handling faults and re-checks.
Picking parts and sample sizesBallooned drawings and size mappingDimensional report formats and unitsMaterial and performance test summariesHandling out-of-tolerance sizesLesson 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 check points and reaction plans, and keeping tracking from risks to controls across making.
Control plan types and needed columnsLinking PFMEA causes to controlsDefining product and process traitsCheck frequency and sample planReaction plans for out-of-control resultsLesson 7Measurement System Analysis (MSA) — Plan for Dimensional and Visual Inspection GaugesDescribes planning and documenting MSA for size and visual gauges, including GRR studies, attribute match analysis, acceptance 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 PPAP fileLesson 8Part Submission Warrant (PSW) — How to Complete Fields and Attach ReferencesExplains PSW role as formal customer okay document, how to fill each field right, cite drawing and test reports, and link 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 errors and avoidanceLesson 9Initial Process Studies (Short-Term and Long-Term) — Stability, Control Charts, and Sample CollectionClarifies needs for initial process studies, splitting short-term and long-term data, use of control charts, stability and ability check, and picking sample points that show real production conditions.
Aims of initial process studiesPicking traits and spotsX-bar, R, and I-MR chart pickChecking stability and special causesDocumenting study results 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 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 calculations, data gather plans, min sample sizes, stability checks, and reading results against customer acceptance rules.
Picking traits for abilityShort-term vs long-term ability dataSample size and group setupCalculating Cp, Cpk, and PpkReading results and improvement plansLesson 12Process Flow Diagram — Symbols, Mapping for Moulding and Downstream OperationsExplains building process flow diagram with standard signs, mapping moulding and follow-on operations, linking to PFMEA and control plan, and ensuring all value-add and check steps are clear.
Standard signs and notation rulesSetting process edges 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 trim part, defining functions and failure modes, applying severity, occurrence, detection scales, and making effective actions that link to control plan and process papers.
Defining process steps and functionsFinding failure modes and effectsRating severity, occurrence, detectionAction priority and follow-upMatching PFMEA with control plan
