PPAP Checklist

• Manufacturer

• Address
  Address

• Customer

• Address
  Address

• Part Name & Number

• Quality Manager

• Conducted on

  Date

1. Design Records

• Is a copy of the drawing included to support the part or assembly (both manufacturer and customer drawings)?

  Yes

  No

• Is a list of specification supporting the production of this part provided?

  Yes

  No

• Is change level verification assured or available that the supplier has the latest revisions of specification?

  Yes

  No

• Is the form of dimension throughout the PPAP identical in all documentation?

  Yes

  No

• Is the form of reporting dimensions throughout the PPAP per customer drawing?

  Yes

  No

• Have dimensions that affect fit, function and durability been identified?

  Yes

  No

• Are reference dimensions identified to minimize inspection layout time?

  Yes

  No

• Are sufficient control points and datum surfaces identified to design functional gages?

  Yes

  No

• Are tolerances compatible with accepted manufacturing standards?

  Yes

  No

• Are there any requirements specified that can’t be evaluated using known inspection techniques?

  Yes

  No

2. Authorized Engineering Change Documents

• Are authorized engineering changes applicable?

  Yes

  No

• Is approved deviation attached?

  Yes

  No

• Is deviation completely filled out?

  Yes

  No

• Are proper approvals in place?

  Yes

  No

• Does deviation clearly identify number of pieces, time limit, change forthcoming, etc. information for proper PPAP disposition?

  Yes

  No

3. Customer Engineering Approval

• Is customer engineering approval required?

  Yes

  No

• Is there a formal controlled document for customer engineering approval?

  Yes

  No

• Is there a formal controlled document of engineering waiver?

  Yes

  No

4. Design FMEA

• Does the FMEA drive Design Improvements as primary objective?

  Yes

  No

• Is a statement attached that DFMEA is available to be presented to the customer upon request?

  Yes

  No

• Does FMEA consider all major “lessons learned” (such as high warranty, campaigns, etc.) as input to failure mode identification?

  Yes

  No

• Has all dimensional tolerances and material properties been considered?

  Yes

  No

• Have customer reliability and warranty data been utilized in preparing FMEA?

  Yes

  No

• Have the causes been described in terms of something that can be fixed or controlled?

  Yes

  No

• Were attribute characteristics included?

  Yes

  No

• Does FMEA identify appropriate Special Characteristics candidates, as input to the Special Characteristics selection process?

  Yes

  No

• Are New Product Introductions and design changes included in identifying Special Characteristics?

  Yes

  No

• Does Analysis/Development/Validation (A/D/V) and/or Design Verification Plan and Report (DVP&R) consider the failure modes from the Design FMEA?

  Yes

  No

• Does FMEA address all high-risk Failure Modes, as identified by the FMEA team, with executable Action Plans?

  Yes

  No

• Have appropriate countermeasures been planned or taken for high-risk numbers?

  Yes

  No

• Were customer plant problems used as an aid in developing the FMEA?

  Yes

  No

• Have customer product problems and/or rejections been included with countermeasures?

  Yes

  No

• Does submission include action list from Design Review?

  Yes

  No

5. Process Flow Diagram Assessment

• Is the Process Flow Chart in place and identifies all manufacturing operations, handling techniques, inspection steps, alternate/back-up processes, and sub-contract suppliers?

  Yes

  No

• Does the process layout shall reflect planning so that a logical flow of material can occur during manufacturing of the product?

  Yes

  No

• Does the flow chart illustrate the sequence of production?

  Yes

  No

• Has the pull system/optimization been considered for this process?

  Yes

  No

• Are steps in the process where product is stored and/or staged clearly identified?

  Yes

  No

• Does the flow chart describe how the product will move, i.e. roller conveyor, slide containers, tubs, etc?

  Yes

  No

• Are the sequences identified (operation or sequence number) so as to follow through to other PPAP documents?

  Yes

  No

• Are inspection/quality assurance steps, data recording, attribute checks and/or functional testing included for each process step?

  Yes

  No

• Does the flow chart indicating the material flow and control for handling rework and scrap?

  Yes

  No

• Does the material flow consider potential quality problems due to handling and subcontracted operations?

  Yes

  No

• Does the flow chart include all assembly and packaging operations?

  Yes

  No

• Does the flow chart illustrate shipment to the customer and steps to consumption?

  Yes

  No

• Is the process flow chart controlled, updated and reviewed for completeness?

  Yes

  No

• Does the flow chart identify in detail all in-house alternate or back-up processes and sub-contract alternate or back-up sources of supply for products or services provided?

  Yes

  No

• Have alternate or back-up processes or sub-contract suppliers been validated?

  Yes

  No

6. Process FMEA

• Does FMEA drive Process Improvements as the primary objective, with emphasis on Error/Mistake Proofing solutions?

  Yes

  No

• Is a statement attached that PFMEA is available to be presented to the customer upon request?

  Yes

  No

• Did the right people participate as part of the FMEA team throughout the analysis, and are adequately trained in the procedure?

  Yes

  No

• Is the correct part number, engineering change, and other information documented?

  Yes

  No

• Is there evidence that all print, specification, purchase order, attribute, etc. characteristics are included?

  Yes

  No

• Are adequate controls in place for all characteristics?

  Yes

  No

• Are special controls/actions in place for all Special Characteristics?

  Yes

  No

• Are there measurable quality improvement projects in place for Special Characteristics?

  Yes

  No

• Is Process FMEA integrated and consistent with the Process Flow Diagram, Process Control Plan and other PPAP documents?

  Yes

  No

• Is there evidence of Statistical Process Control for all Special Characteristics or controls as identified and approved in the Control Plan?

  Yes

  No

• Are quality performance indicators provided as evidence that sufficient methods are in-place to monitor and control all characteristics?

  Yes

  No

• Are the top RPNs addressed with recommended actions and the actions are implemented?

  Yes

  No

• Have capability studies been performed to validate the control of the characteristics?

  Yes

  No

• Is FMEA completed during the “window of opportunity” where it could most efficiently impact the design of the product or process?

  Yes

  No

• Is there evidence that the failure modes with action are carried over to the Process Control Plan?

  Yes

  No

7. Control Plan

• Are Control Plans and input criteria reviewed with manufacturing personnel?

  Yes

  No

• Are all sections filled out including evidence of cross-functional team involvement?

  Yes

  No

• Are detailed and complete Process Control Plans in place to purchase, manufacture, inspect, test, assemble, package, and ship product for each operation performed?

  Yes

  No

• Does the Control Plan provide detail methods of correcting out of control processes, handling nonconforming products, and corrective action program on all quality problems including attribute variables?

  Yes

  No

• Are Special Characteristics and other major, significant, features of special interest, etc. process variables identified?

  Yes

  No

• Are there Process Control Plans in place for all customer part numbers?

  Yes

  No

• Are Engineering Test and Performance requirements identified?

  Yes

  No

• Is there a documented program for establishing sample sizes and test frequencies?

  Yes

  No

• Are gage methods compatible and are they traceable to national standards?

  Yes

  No

• Does the Control Plan provide detail on: machine make & model, machine type, machine number/identification, etc.?

  Yes

  No

• Is all manufacturing equipment identified i.e. press type, paint booth type, etc.?

  Yes

  No

• Is Receiving Inspection, Process Inspection, and Final Inspection included in Control Plan?

  Yes

  No

• Have all known customer concerns been identified to facilitate the selection of Special Required/Design/Process Characteristics?

  Yes

  No

• Is there evidence of feedback from customer problems or rejections?

  Yes

  No

• Are appropriate reaction plans included in the Control Plan?

  Yes

  No

• Are Control Plans completed and readily available for alternate or backup process?

  Yes

  No

• Are Process Control Plans completed/updated for new product or design changes?

  Yes

  No

8. Measurement System Analysis

• Are MSAs for all (including attribute, process controls, etc.) gages listed on the control plan provided?

  Yes

  No

• Do all MSAs refer to the correct part number and/or gage family

  Yes

  No

• Did the supplier submit an acceptable MSA as above and documented in the AIAG MSA Manual?

  Yes

  No

• Have correlation concerns been addressed?

  Yes

  No

• Have results been reviewed and approved by the customer?

  Yes

  No

9. Dimensional Results

• Are the dimensions references on a ballooned customer drawing or documented within a characteristics library?

  Yes

  No

• Is there evidence that all specification and other requirements were documented?

  Yes

  No

• Are the correct numbers of parts laid out?

  Yes

  No

• Do all requirements, including drawing notes have a response (pass/fail statement is unacceptable)?

  Yes

  No

• Are all Special Characteristics highlighted?

  Yes

  No

• Do results meet all Design Record Requirements?

  Yes

  No

• Is any nonconformance highlighted in the report?

  Yes

  No

• Is layout result legible and understandable?

  Yes

  No

• Are the inspection sheets approved and signed?

  Yes

  No

• Is all reporting against customer specification?

  Yes

  No

10. Records of Material / Performance Test Results

• Are material and performance test results provided for chemical, physicals or metallurgical to the customer specification and compliance confirmed?

  Yes

  No

• Does the submission include correct part and engineering change level, specification numbers, date and change level, authorized engineering change documents not yet incorporated into the design, test date, quantity tested, the actual results, the material supplier’s name and, when required by the customer, the customer-assigned vendor code, special requirements for approved steel, heat treatment, plating, etc., other relevant information specifically required by the customer?

  Yes

  No

• Is any nonconformance highlighted in the report?

  Yes

  No

• Is product testing to be done in-house?

  Yes

  No

• Are all testing results less than one (1) year old?

  Yes

  No

• Is all testing summarized with actual criteria and data (pass/fail statement is unacceptable)?

  Yes

  No

• Is test loading sufficient to provide all conditions, i.e. production validation and end use?

  Yes

  No

• Have parts manufactured at minimum and maximum specification been tested?

  Yes

  No

• Can additional samples be tested when a reaction plan requires it?

  Yes

  No

• Is the specified test sampling size and/or frequency feasible?

  Yes

  No

11. Initial Process Studies

• Is there preventive maintenance, gage and fixture calibration, tooling verification needed to maintain an acceptable level of capability?

  Yes

  No

• Were results utilized in determining preventative maintenance schedules?

  Yes

  No

• Was a study performed on the packaging of products for shipment, assembly operations, and final product conformance?

  Yes

  No

• Is the method utilized to perform studies and calculate capability level documented along with evidence that results are within customer requirements?

  Yes

  No

• Is the measurement method/device noted?

  Yes

  No

• Were correlation studies required and performed?

  Yes

  No

• Are results for standard deviation and the distribution noted?

  Yes

  No

• Is variable data reporting preferred for process capability reporting?

  Yes

  No

• Is the attribute data indicating zero (O) defects found?

  Yes

  No

• Does the data indicate that the process is under control?

  Yes

  No

• Is the sample size according to the agreed upon criteria and documented within the submission?

  Yes

  No

• Are capability studies performed on new product and/or design changes and when process changes are implemented?

  Yes

  No

• Is there evidence of capability results feedback to management and production personnel?

  Yes

  No

• Is a mechanism in place to feedback the product testing results to the capability study?

  Yes

  No

• Is there a program to update the studies on a routine basis?

  Yes

  No

12. Qualified Laboratory Documentation

• Is a complete, signed and dated lab scope available?

  Yes

  No

• Does the lab scope (as defined on the certification or addendum to the certification) list all tests performed by the lab?

  Yes

  No

• Are qualified independent laboratory checks defined?

  Yes

  No

• Is the quantity tested identified?

  Yes

  No

• Are all Special Characteristics from the drawing (and drawing notes) included?

  Yes

  No

• Has testing specification been identified on all tests?

  Yes

  No

• Are results reported on the letterhead?

  Yes

  No

• Are performance test results and material test (chemical, metallurgical, etc.) results included?

  Yes

  No

• Is any nonconformance highlighted in the report?

  Yes

  No

• Has customer approval been obtained for the test?

  Yes

  No

13. Appearance Approval Report

• Are appearance items identified on the engineering drawing?

  Yes

  No

• Is the standard AAR form filled out completely?

  Yes

  No

• Is a formal, approved, controlled waiver submitted?

  Yes

  No

• Is formal approval in place from the proper organization (engineering, marketing, met lab)?

  Yes

  No

• Was submission according to customer specification?

  Yes

  No

14. Sample Production Parts

• Are the formal requirements for samples documented?

  Yes

  No

• Is there a formal, approved, controlled waiver for samples attached?

  Yes

  No

• Are the samples shipped before PPAP Submission with documentation of the parts included?

  Yes

  No

• Were the samples measured from taken from the Production Trail Run or a production run?

  Yes

  No

15. Master Sample

• Is there evidence of a master sample as per standard?

  Yes

  No

• Is there a formal, approved, controlled waiver in place for master sample or documentation to consume master sample in production?

  Yes

  No

• Are master samples controlled for life of PPAP records or until a new sample is approved and disposition of old sample?

  Yes

  No

• Is the master sample approved by the customer and identified as a master sample?

  Yes

  No

• Are master samples available for multiple dies, cavities, molds, impressions, etc.?

  Yes

  No

16. Checking Aids

• Is submission according to customer specific requirements?

  Yes

  No

• Were prints copies and duplication gages submitted?

  Yes

  No

• Are all Checking Aids numbered, calibrated, included in the Control Plan and provided for preventive maintenance plans?

  Yes

  No

• Do all Checking Aids have acceptable Measurement Systems Analysis studies?

  Yes

  No

17. Customer Specific Requirements

• Is a list of “Specific Requirements” along with compliance documentation provided or a waiver that none exist?

  Yes

  No

• Does reporting take place for those requirements listed and all others identified by PPAP approver representative plus other process partners (met lab, engineering, logistics, etc.)?

  Yes

  No

18. Part Submission Warrant

• Is the warrant compliant to the AIAG PPAP standard?

  Yes

  No

• Is proper detail provided for “Reason for Submission”?

  Yes

  No

• Are all fields completed as per PPAP instructions?

  Yes

  No

• Is a completed bulk material checklist and warrant in place for all bulk material used in production parts? (See page 36 of AIAG PPAP 4th edition Manual)

  Yes

  No

• Submission Level

  1

  2

  3

  4

  5

• Are specific elements clearly identified for the submission?

  Yes

  No

• Are specific elements clearly identified for the submission?

  Yes

  No

• Are all 16 elements provided along with full explanation of any that are not provided in full?

  Yes

  No

Completion

• Additional Comments

• Quality Manager Name & Signature

  Sign