Lesson 1Appearance and Functional Testing Evidence — Paint/Film/Coating, Gloss, Texture, and Mechanical TestsDescribes how to record appearance and working tests for trim and coated parts, including paint, film, and coating tests, shine and texture checks, and mechanical performance tests to show spec matching.
Customer appearance needs and AARsPaint, film, and coating performance testsShine, colour, and texture checksMechanical and working test methodsPhoto and sample board proofLesson 2Packaging, Labelling, and Shipping Documentation to Include in PPAPDescribes packaging, labelling, and shipping papers needed in PPAP, including packaging 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 avoidanceLogistics controls and work guidelinesLesson 3Engineering Change Documentation and Design Failure Modes to IncludeCovers when engineering change papers are needed, how to reference ECNs and deviations, and which design failure modes must be handled in PPAP to show that risks from design changes are fully checked and managed.
Triggers for engineering change recordsRecording ECNs, waivers, and deviationsUpdating DFMEA and design recordsSharing changes with customersTracking from change to validationLesson 4Supplier Performance and Subcontractor Submittals to IncludeCovers how to add supplier and subcontractor papers in PPAP, set flow-down needs, gather sub-supplier PPAPs, and check supplier performance signs relevant to the submitted part.
Finding vital 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 how to report size layouts and material test results, including sample size pick, layout plan, report forms, links to drawings and specs, and handling faults and re-measures.
Picking parts and sample sizesBallooned drawings and size mappingSize report forms and unitsMaterial and performance test summariesHandling out-of-tolerance sizesLesson 6Control Plan — Format (Process and Product Controls), Linkage to PFMEA and Inspection PointsDetails how to build a control plan for process and product controls, match it with PFMEA, set check points and reaction plans, and keep tracking from risks to controls across making.
Control plan types and needed columnsLinking PFMEA causes to controlsSetting 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 how to plan and record MSA for size and visual gauges, including GRR studies, trait agreement review, okay rules, and how to match MSA scope with vital and special traits.
Picking gauges for MSA studiesVariable GRR study planningTrait agreement for visual checksReading MSA indexes and rulesRecording MSA in the PPAP fileLesson 8Part Submission Warrant (PSW) — How to Complete Fields and Attach ReferencesExplains the PSW role as the formal customer okay document, how to fill each field right, reference drawing and test reports, and how to link the PSW to support PPAP proof and submission levels.
PSW aim and link to PPAP okayKey PSW fields and fill rulesReferencing 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 CollectionMakes clear hopes for initial process studies, splitting short-term and long-term data, use of control charts, stability and ability check, and how to pick sampling points that show real making conditions.
Aims of initial process studiesPicking traits and spotsX-bar, R, and I-MR chart pickChecking stability and special causesRecording 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 how to manage revisions and ensure PPAP proof matches the released design.
Customer drawings and 3D modelsBill of materials and part trackingMaterial and performance specsRevision management and change historyMatching records with PPAP proofLesson 11Capability Studies (Cp, Cpk) — Data Collection Plan, Sample Size, and Interpreted Acceptance CriteriaLooks at ability study needs for special traits, including Cp and Cpk counts, data gather plans, min sample sizes, stability checks, and how to read results against customer okay rules.
Picking traits for abilityShort-term vs long-term ability dataSample size and group setupCounting Cp, Cpk, and PpkReading results and improvement plansLesson 12Process Flow Diagram — Symbols, Mapping for Moulding and Downstream OperationsExplains how to build a process flow diagram using standard signs, mapping moulding and follow-up steps, linking to PFMEA and control plan, and ensuring all value-add and check steps are shown clearly.
Standard signs and note rulesSetting process edges and scopeDetailing moulding and secondary stepsLinking flow to PFMEA and control planVersion management and change updatesLesson 13PFMEA — Structure, Severity/Occurrence/Detection Scales, and Examples for Trim Part Failure ModesDetails how to build PFMEA for the trim part, set functions and failure modes, apply severity, occurrence, and detection scales, and create effective actions that link to the control plan and process papers.
Setting process steps and functionsFinding failure modes and effectsRating severity, occurrence, detectionAction focus and follow-upMatching PFMEA with control plan
