Looking for PPAP help for newbie

[Bob_M]

OK small company, ISO 9001:1994 upgrading to 2000, inexperienced Quality person (me), little to no budget, no copy of PPAP manual (that I know of), one major customer that is QS and requires PPAPs.

Besides combing thru all the posts here can anyone point me to some beginners info for PPAP processing and submissions (preferably for free).

Our company and I have submitted some simple level 1 and 2 PPAPs. I basically copied the work our last QA guy did.

We just got a Level 3 PPAP for a simple part we make out of basic steel. The new part is the same except it now is spring steel.

I will probably call the customer and verify what info they want/need today or tommorrow.

On paper the PPAP states:
Level 3 - Warrant with product samples and complete supporting data submitted to customer
Retention/Submission Requirements: 1,2,3,4,5,6,7,8,9,10,11,12,13,14,16,19

I know how to do part layouts, control plans, inspection reports, Gage R&R, and we have software to verify the cpk stuff (?).
But what is this retention/submission stuff?????

I'm at a loss.

Any specific or general help will be greatly appreciated.

[Randy Stewart]

Bob,
Can you get a copy of the manual??? On page 16 there is table I.4.1 that sets up what you have to retain on site (ready for review) and what you have to submit. It is just too big to reproduce here and I don't have an electronic copy of the table to send. But in a nut shell, level 3 PPAPs you submit everything except proprietary components, Master Samples (must be controlled) and check Aids.

[IceZebra]

Bob,

You can order the manual through www.aiag.org, if you can't find a copy of it laying around. The current revision is the 3rd Edition.

The thing to remember about PPAP's is that you are required to do all the applicable requirements (Items 1-19). The only difference between the submission levels is what you submit to your customer and what you retain for review, if requested.

[Bob_M]

Randy Stewart said:

Bob,
Can you get a copy of the manual??? On page 16 there is table I.4.1 that sets up what you have to retain on site (ready for review) and what you have to submit. It is just too big to reproduce here and I don't have an electronic copy of the table to send. But in a nut shell, level 3 PPAPs you submit everything except proprietary components, Master Samples (must be controlled) and check Aids.

Considering the non-member price is only $36 I probably CAN get it...

Can someone sum up what the items I listed are...
Retention/Submission Requirements: 1,2,3,4,5,6,7,8,9,10,11,12,13,14,16,19

I realize this is most of them...
Considering my lack of knowledge of FEMAs and similar items, I have a feeling this PPAP package is gonna be a pain to complete.

Considering THIS part is a round/flat washer i think the excessive work i'm about to do, is just that EXCESSIVE.

(Like I don't have enough to do
)

[IceZebra]

I can email you a scanned copy of Table I.4.1, if you like or do you already have that and now need a brief description of each?

I don't think this will be that excessive. Most of the items in the table you will probably have anyway (Design record, ECN's, etc.). Some of the items that you will need to provide (FMEA, Control Plan, etc.) will be very small due to the nature of your product. I would imagine that you could get all the items into a duo-tang.

Email me if you want the scanned copy of the table.

Good luck.

[Bob_M]

I would appreciate a copy of the table.

I do believe we have most if not all of the FORMS that I will need for a full blown out Level 3 PPAP. (Control Plans, Inspection Records, ECN forms, FMEA, etc).
We even have some SPC software so I can plug in numbers and get the CPK stuff.

Besides not having the "required" manuals, I personally don't have the experience with the FMEA and CPK stuff.

Oh and we did not design this part, simply given a print which we quoted against (existing die new material, new thickness).

Hopefully between checking out the COVE and talking with our last Quality Guy I can stumble through this. (Probably gonna have a few more similar ones soon )

Thanks Bob_M

[Randy Stewart]

Bob,
Your FMEA should be simple. Keep it brief and to the point. Depending on what it takes to produce one washer it could be as simple as 1 page with 5 entries on it. Receive raw material, form, heat treat (?), inspect, ship.

See if the attached table helps.