PPAP documents specific to P.O./Sample?

Fender1

Involved In Discussions
#1
We are a custom steel fabrication company trying to develop a quality system to meet ISO 9001. I’m looking for suggestion on how to properly handle the following scenario.
This summer one of our customers ordered a “widget” recently revised. Customer is design responsible and PPAP level 4 required. I measure/approve weldment prior to machining process, then rejected product after machining due to some hole locations NC to drawing. Our plant-supervisor (my boss and quality coach), who not long ago worked for same customer and believed that he knew widget application and critical requirements, instructed NCP to ship ASAP- stating that NC doesn’t affect fit and function, customer needs the “widget” now. NCP shipped without prior customer knowledge of NC.

Upon receipt of above NC, customer rejected “widget”, asking my company for expedited replacement. Replacement was produced and plant-supervisor hand delivered replacement product WITHOUT quality verification/record. Customer utilized replacement widget soon after receiving.
Above plant-supervisor no longer works here.

Customer recently alerted/reminded me of open/required PPAP doc for above widget.
3 of same widget have been supplied under a different customer p.o. since above replacement was delivered. Is PPAP docs specific to p.o./product sample: is verification record for one of these recent 3 valid for above PPAP?

Educate me nicely please...
 
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Jim Wynne

Staff member
Admin
#3
We are a custom steel fabrication company trying to develop a quality system to meet ISO 9001. I?m looking for suggestion on how to properly handle the following scenario.
This summer one of our customers ordered a ?widget? recently revised. Customer is design responsible and PPAP level 4 required. I measure/approve weldment prior to machining process, then rejected product after machining due to some hole locations NC to drawing. Our plant-supervisor (my boss and quality coach), who not long ago worked for same customer and believed that he knew widget application and critical requirements, instructed NCP to ship ASAP- stating that NC doesn?t affect fit and function, customer needs the ?widget? now. NCP shipped without prior customer knowledge of NC.

Upon receipt of above NC, customer rejected ?widget?, asking my company for expedited replacement. Replacement was produced and plant-supervisor hand delivered replacement product WITHOUT quality verification/record. Customer utilized replacement widget soon after receiving.
Above plant-supervisor no longer works here.

Customer recently alerted/reminded me of open/required PPAP doc for above widget.
3 of same widget have been supplied under a different customer p.o. since above replacement was delivered. Is PPAP docs specific to p.o./product sample: is verification record for one of these recent 3 valid for above PPAP?

Educate me nicely please...
Ultimately your customer will decide what's acceptable in this regard, but in general PPAP is specific to a single "significant production run." It sounds like your lot sizes are very small, so what you do regarding provision of PPAP samples and your own master sample should be discussed with the customer.
 

Fender1

Involved In Discussions
#4
True Position,
Due to custom nature of customer product, very low yearly volume and very quick delivery, our PPAP docs sometimes arrive to customer similar time as product, thus completion is soon after customer receives/inspect at their location and sometimes after product is implemented.

Jim,
Thank you for your reply.
Prior to my post, I wanted to discuss lack of verification/record issue with customer, however I felt if not handled right may give my company a black-eye. Your reply got me moving forward.

I contacted customer and discussed post scenario issue. Customer is allowing us to use a later shipment verification record. Thanks again.
 
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