Production Part Approval Process

(PPAP) Training – SQE/SDE Department

Agenda

Learning Objectives

Purpose

Table of Contents Overview

PPAP Overview / Expectations

References / Resources

Learning Objectives Recap

Wrap Up (FAQ / Q&A / Feedback)

Learning Objectives
At the end of this training, participants will be able to:
• What is the Purpose of PPAP?
• When is PPAP Required?
• What are the Elements of the submission?
• How are the Levels of PPAP applied?
• Details on successful PPAP submission to Polaris’ facilities

3
Document Purpose
• The sole purpose of this document is to provide additional information, training
and guidance to Polaris’ supply base to ensure all PPAP documentation is
provided in a manner consistent with expectations.
• This document is not intended to be all encompassing. PPAPs are to be created
and submitted on the basis of AIAG standards.
Additional resources:
• Automotive Industry Action Group (AIAG)
26200 Lahser Road, Suite 200
Southfield, MI 48034
Phone 248-358-3570
[Link]
Training options available:
• Courses at AIAG’s headquarters in Southfield, MI
• Onsite training
• Webcasts
• Quality-One
Detroit, MI USA
1333 Anderson Road
Clawson, Michigan 48017
Phone: 248-280-4800
Online training courses available for purchase at [Link]
• Production Part Approval Process (PPAP)
• Process and Design Failure Mode and Effects Analysis (PFMEA & DFMEA)
• Measurement System Analysis (MSA)
• Eight Disciplines of Problem Solving (8D)
• Advanced Product Quality Planning (APQP)
• Six Sigma Black, Green, White and Yellow Belt training

• It is the supplier’s responsibility to reach out to a Polaris representative if there

are questions or concerns regarding PPAP preparation/submission. If you are
unsure of anything, please ask.
4
Table of Contents
PPAP Overview Slide 6
18 Elements of PPAP Slide 13
Submission Requirements Slide 14
Submission Status Slide 16
Element 1 - Design Record Slide 17
Element 2 - Authorized Engineering Change Documents Slide 21
Element 3 - Customer Engineering Approval Slide 23
Elements 4 & 6 - Design and Process FMEAs Slide 24
Element 5 - Process Flow Diagram Slide 32
Element 7 - Control Plan Slide 38
Element 8 - Measurement Systems Analysis Studies Slide 46
Element 9 - Dimensional Results Slide 50
Element 10 - Records of Material/Performance Test Results Slide 54
Element 11 - Initial Process Studies Slide 56
Element 12 - Qualified Laboratory Documentation Slide 64
Element 13 - Appearance Approval Report Slide 66
Element 14 - Sample Production Parts Slide 70
Element 15 - Master Sample Slide 73
Element 16 - Checking Aids Slide 77
Element 17 - Customer-Specific Requirements Slide 79
Element 18 - Part Submission Warrant Slide 80

Note: Hyperlinks only work in presentation mode

5
What is PPAP?
Production Part Approval Process
– Rigorous and structured process for part qualification
used to formally reduce risks prior to product or service
release, in a team oriented manner using well
established tools and techniques.
– Initially developed by AIAG (Auto Industry Action
Group) in 1993 with input from the Big 3 - Ford,
Chrysler, and GM.
– All AIAG forms are acceptable
Contact AIAG At:
Automotive Industry Action Group
26200 Lahser Road, Suite 200
Southfield, MI 48034
Phone 248-358-3570
[Link]

6
Purpose of PPAP
• Provide evidence that all customer engineering design records
and specification requirements are properly understood by the
organization and achievable.
• To demonstrate that the manufacturing process has the potential
to produce product that consistently meets all requirements
during an actual production run, at the quoted production rate.
• All PPAP submission data/documentation shall be based on a
significant production run as defined as any time period/quantity
used to establish process capability, with all normal process
variation accounted for.

PPAP manages change and ensures product conformance!

7
When is PPAP Required?
• PPAP submission required when:
– New part released for production
– Engineering change order (ECO)
– Correction from previous submission discrepancy
– Process Change Request (PCR) – any change to product or
process. Note: Reference the Polaris PCR Training Guide for
further details / guidance. Some examples:
– Alternative construction or materials
– Tooling or equipment refurbishment, replacement, transfer or
additional
– Production at new or additional location
– Change of or at a subcontractor or material source change
– Product or process changes to component

Note: At the discretion of Polaris, a PPAP submission may be

requested at any time.

PPAP is required for any new or changed part/process!!

8
Benefits of PPAP Submission
• Forces formal part conformance and approval
• Ensures formal quality planning
• Helps to maintain design integrity
• Identifies issues early for resolution
• Reduces warranty charges and prevents costs of poor
quality
• Assists with managing supplier changes
• Prevents use of unapproved and nonconforming parts
• Identifies suppliers that need more development
• Improves the overall quality of the product & customer
satisfaction

9
Importance of Attention to Detail
• In the last three months an analysis was completed on rejected PPAP
submissions.
• The majority of the rejected submissions were easily preventable (not filling
out forms properly and/or not following simple directions/requirements).
PQR Submittals

Documentation
Missing or
• 62% Approved
Discrepancy
27%
• 38% Rejected
• Majority due to documentation
Approved
missing or discrepancy
62%
Dimensional
Discrepancy
8%

Inadequate
Controls
3%

~ 70% of PPAP submission failures due to documentation

10
Top Documentation Related PQR Failures
60
Frequency of Failures
50
40
30
20
10
0
Missing Missing/Incorrect Language Print Not Polaris Missing Polaris Outdated
Dimensions question answers Released PN/Rev Revisions
Submitted
Failure Category

Missing Missing/Incorrect Language

Dimensions Question • Documents not
• Dimensions and Answers submitted in English Outdated
KPCs missing on Print not PII Missing Polaris
• PSW missing Revisions
required documents responses or not Released PN/Rev
• Balloon drawings not
Submitted
pertaining to the
submitted question
• Variable data missing

27% 43% 57% 59% 65% 70%

These are EASILY preventable!!

11
The Basics of PPAP

Submission requirements are called

Elements

Any element not submitted MUST be retained

Which element is required is determined by the

submission
Level

12
18 Elements of PPAP
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1. Design Record
2. Authorized Engineering Change Documents, if any
3. Customer Engineering Approval, if required
4. Design FMEA
5. Process Flow Diagrams
6. Process FMEA
7. Control Plan
8. Measurement System Analysis Studies
9. Dimensional Results
10. Records of Material / Performance Test Results
11. Initial Process Studies
12. Qualified Laboratory Documentation
13. Appearance Approval Report, (AAR) if applicable
14. Sample Production Parts
15. Master Sample
16. Checking Aids
17. Customer–Specific Requirements
18. Part Submission Warrant (PSW)

13
PPAP Levels – Submission & Retention Requirements
Requirement Level 1 Level 2 Level 3 Level 4 Level 5
1. Design Record R S S *P R
2. Authorized Engineering Change Documents, if any R S S * R
3. Customer Engineering Approval, if required R R S * R
4. Design FMEA R R S *P R
5. Process Flow Diagrams R R S *P R
6. Process FMEA R R S *P R
7. Control Plan R R S *P R
8. Measurement System Analysis Studies R R S *P R
9. Dimensional Results R S S *P R
10. Records of Material / Performance Test Results R S S *P R
11. Initial Process Studies R R S *P R
12. Qualified Laboratory Documentation R S S * R
13. Appearance Approval Report, (AAR) if applicable S S S *P R
14. Sample Production Parts R S S *P R
15. Master Sample R R R * R
16. Checking Aids R R R * R
17. Customer–Specific Requirements R R S * R
18. Part Submission Warrant (PSW) S S S S R
S = The organization shall submit to the customer and retain a copy of records or documentation items at appropriate locations (AIAG std. requirement)
R = The organization shall retain at appropriate locations and make available to the customer upon request (AIAG std. requirement)
* = The organization shall retain at the appropriate location and submit to the customer upon request (AIAG std. requirement)
*P = Polaris default submission level - subject to modification
NOTE: Level 5 PPAP may be reviewed at supplier's manufacturing location

Level 4 is Polaris’ default and the most common level requested

14
Submission Requirements (cont.)
• Polaris requests that all PPAPs be submitted
electronically or scanned / uploaded into electronic
PPAP system.
• Submissions must be in English.
• Submission must be received prior to the PPAP due
date in order to allow for processing time at Polaris.
• Review and Approval Process:
‒ Samples are received into PPAP request system when package is
delivered to the designated Quality Lab.

Note: Reference the Polaris PQR System

Guide for further submission details / guidance.
All submissions to be done electronically
15
PPAP Submission Status

Notification through PPAP request system

‒ Must be Approved or have Interim Approval granted prior to
shipping product
• Full Approval
‒ Meets requirements
‒ May ship product
• Interim Approval
‒ Approved until specified date
‒ Must meet condition by specified date
‒ May ship product
• Rejected
‒ Submission does not meet specifications
‒ Do not ship product

Production quantities may not be shipped without approval

16
Design Record – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• The Design Record is what the supplier has contracted to

provide per the Polaris Purchase Order (PO). Examples
would include, but not limited to:
‒ Polaris drawings (as defined by a unique Polaris part number) to the
latest Engineering Change Level (ECL) or Rev Level as defined on the
Purchase Order (PO).
‒ Engineering specifications
‒ Special notes added to the PO (i.e., paint it black or special packaging)
• The engineering drawing portion of the Design Record is
often used to provide a ballooned drawing when submitting
Element 9 – Dimensional Results.
• Supplier drawings (if defined on the Polaris drawings or PO)
would also be part of the Design Record.

17
Design Record – Ballooned Print Requirements
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• Bubble print supports the dimensional

report
− Must have all notes and
specifications circled and
numbered
− Must be clear and legible
− Must include any reference
dimensions
− Ideally, start numbering in upper-
left and continue clockwise
(maintain a logical pattern)

• Any additional supporting information:

− Reference prints
− Sub-Assembly prints
− Component prints with a different part number
− Applicable material specifications
− Applicable reference specifications
− Customer specified workmanship standards

All submissions should have one copy of the Polaris print

18
Design Record – Ballooned Print Example
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Print balloon number must correspond to the “Item” number on the Dimensional Report
19
Design Record – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
Must be a Polaris print
Ballooned drawing must be clean and legible
Must be correct part number and revision
Every requirement must have a separate balloon
Dimensions
Notes
Special Characteristics
Referenced specifications
Verify that no other prints need to be submitted
Sub-assemblies
Component level detail

Attention to detail!!
20
Authorized Engineering Change Documents (if any) – Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Purpose:
• To provide any pertinent change information for reference
• This is a placeholder for all authorized engineering change documents
not yet recorded in the design record but incorporated in the product,
part or tooling:
− Engineering Change Orders (ECOs)
− Approved deviations
− Approved Process Change Requests (PCRs)
− Specifications
− Feasibility studies
− Sub-assembly drawings
− Life or reliability testing requirements

Note: PPAPs may be approved with approved engineering change documents.

This element is typically used when changes occur to the design documentation
21
Authorized Engineering Change Documents – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
ECOs must be approved, not pending
Marked up prints are not acceptable for PPAP
Feasibility studies included (if applicable)
Life or reliability testing requirements included (if applicable)
Submission must include copies of approved change requests

Attention to detail!!
22
Customer Engineering Approval (if required)
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• If required, customer Engineering Approvals are used to

demonstrate pre-approval of a supplier’s design/testing by
Polaris.

23
FMEA – Tool Interaction
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

The interaction of these three elements is the CORE of PPAP!!

24
FMEA – Definition
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Failure Mode and Effects Analysis

• Industry accepted process to assess risk before completing design of product
and processes.
– DFMEAs shall be complete before tooling PO is launched (ideal state)
– PFMEAs shall start upon handoff of DFMEA driven KPCs
– PFMEAs shall be completed in time to have a control plan in place before product ramp-
up (run at rate or pulse order)
– Control Plans shall be derived from KPC and other risks identified through the PFMEA
• FMEAs are generated for:
– New designs, technology or processes
– Modifications to existing design or process
– New environment, location or application
– Root cause analysis
• FMEAs are generated by:
– Cross-functional team from Polaris and Supplier, consisting of Design Engineers,
Process/Manufacturing Engineers, Project Leaders, etc.
• Reference AIAG FMEA Manual and/or SAE J1749

25
FMEA – Benefits
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• A 3 phase approach to proactively identify and prioritize potential

risk and drive corrective actions before production launch.
– Design risk out by implementing robust design solutions
– Process risk out by implementing robust process solutions (i.e. mistake-proofing)
– Control risk by developing a control plan to audit Design (KPC) and Process risk
• Reduce costly design changes by catching errors and oversights up-
front before capital investments are launched.
• Improved safety
• One safe source for historical issues, lessons learned, warranty,
etc.

26
FMEA – Proactive Quality Tools/Process
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CSR V Build PI Build PB Build SOP

Process risk Design risk

DFMEA Development
out

Product Design Risk Reduction

PPAP Element #4
Proposed KPCs ID’d

Process Flow
PPAP Element #5
PFMEA: Development
out

PPAP Element #6
Process Design Risk Reduction

Control Plan (with KPCs) PPAP Element #7

Control risk

3 phases of risk mitigation

27
DFMEA – Procedure
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• Reference AIAG FMEA Manual for process and category definitions.

• DFMEA is only required if designed by the supplier.
• Must address all KPCs from previous designs with similar requirements. For new
designs KPCs should be developed by the DFMEA.
• Document is reviewed by a team not a single engineer.
• Severity, Occurrence and Detection must be compliant with AIAG or Polaris
guidelines.
• Must take the technical/physical limits of the manufacturing/assembly process into
consideration.
• Use RPN or Severity vs. Occurrence (red, orange, yellow, green) to drive action to
reduce risk.

28
PFMEA – Procedure
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• Reference AIAG FMEA Manual for process and category definitions.

• Requirements, Effects of Failure, Severity and KPCs should be directly linked to the
DFMEA. If DFMEA is not available, Polaris Product Engineering may develop these
categories.
• Must address all KPCs from previous designs with similar requirements.
• Document is reviewed by a team not a single engineer.
• Severity, Occurrence and Detection must be compliant with AIAG or Polaris
guidelines.
• Control Plan should be generated by PFMEA Risk.
• Use RPN or Severity vs. Occurrence (red, orange, yellow, green) to drive action to
reduce risk.

29
 FMEA – Tips
• Forming the team is critical, the team should be comprised of design, test, quality, manufacturing engineers and subject matter experts.
Make sure the right skillset of people are in the meeting to encourage brainstorming.

• Pre-work drives efficiency and accuracy. The first meeting should start by reviewing the pre-work prepared for the FMEA sessions.
Process flow charts, boundary diagrams, parameter diagrams, warranty and supplier quality data are a few examples of pre-work that will
assist in FMEA development.

• Debating Severity, Occurrence and Detection ratings. In most cases there will be very little difference in rankings that are 1 point apart. To
keep the FMEA moving it is a best practice to just take the higher of the 2 rankings if the team can not agree after a short period of time.

• A Recommended Action shall be defined for all items with a severity of 9/10 regardless of occurrence or detection and should be defined for
all items with a high severity x occurrence or RPN

• Don’t set an RPN threshold. If RPN Is used to prioritize work, the actions should be sorted and worked from highest to lowest.

• If possible, have many short sessions (1-1.5 hours) rather than one or two all day sessions.

• Before a design or process change occurs, the FMEA should be used to ensure no other risks are being introduced.

How How
Bad? Often? How
` well?

What can go What is What could What tools help How can
What is
wrong with effect to cause the to proactively the failure
the
the function the failure prevent the mode be How can risk
function
(anti-function) customer mode? failure mode? detected? be reduced?

LRP June 2013 30

FMEA – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
All KPCs have been addressed and labeled in the FMEA.
Make sure action is being taken on high severity and higher
RPN line items and the outlined action will actually have an
impact.
Make sure that high RPN process concerns and KPCs are
carried over into the control plan.
Make sure that all critical failure modes are addressed:
Safety
Form, fit, function
Material concerns
Severity, Occurrence and Detection must be compliant with
AIAG guidelines and scored within reason.

Attention to detail!!
31
Process Flow Diagrams (PFD) – Tool Interaction
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

The interaction of these three elements is the CORE of PPAP!!

32
PFD – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

What is it?
• A visual diagram of the entire process from receiving through shipping, including
outside processes and services.
Purpose:
• To help people “see” the real process
Receive Order

When to Use It:

• To understand how a process is done In Stock? Distributor Not Available

• Prior to completing the PFMEA

Guidance – Process Flow Must Include: Print Invoice To Shipping
• All manufacturing and key processes to be included
• All offline activities (such as measurement, inspection and handling)
• Identification of areas containing nonconforming material
• Scrap, defective and rework parts
• Process steps must match both the Control Plan and the PFMEA
• PFDs for ‘families’ of similar parts are acceptable if the new parts have been
reviewed for commonality by the supplier and/or Polaris.
• Reference PFD Checklist (A-6 of the AIAG APQP Manual) for additional guidance

33
PFD – Benefits
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Benefits for Supplier:

• Provide a system overview allowing the study of an entire process at once
• Illustrates relationships between and dependencies of process steps
• Display all process inputs and outputs
• Expose process or system inefficiencies and problem areas. Document a
process or system.
• Planning tool to aid in design of new products
Benefits for Polaris:
• Supplier identifies and resolves gaps in quality component of process
– Higher quality parts
• Supplier identifies and eliminates areas of inefficiency
– Lower cost parts
• Serves as formal documentation of the process
– Decreases chance for variation
• Clearly displays all steps in process and provides consistent frame of
reference
– Improves communication
Conclusion:
• A Process Flow Diagram (PFD) provides a pictorial description of all the
major steps in a process
• If used properly, it can result in a higher quality, lower cost part

34
PFD – Common Flow Chart Symbols
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

This slide illustrates some of the most commonly used symbols in a flow chart.
However, hundreds of symbols exist and companies can actually create there own
symbols to meet their needs. PFD Example

PFD Example
Check for
Leave the Check Time Weather Before Rout e Take Primary
Yes Yes congestion on congest ed?
No
Office and Weather Clear? 5:00 pm? Route
primary route

Yes

Divert to
No No
Alternate "B"

Divert to
Alternate "A"

Arrive Home

35
PFD - Examples
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

This process flow diagram utilizes

these symbols to clearly identify
each step in the process

More process flow diagram examples

36
PFD – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
Process Flow must identify each step in the process
Match both PFMEA and Control Plan
Should include abnormal handling processes
Scrap
Rework
Extended Life Testing
Process Flow must include all phases of the process
Receiving of raw material
Part manufacturing
Offline inspections and checks
Assembly
Testing
Shipping
Transportation

Attention to detail!!
37
Control Plan – Tool Interaction
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

The interaction of these three elements is the CORE of PPAP!!

38
Control Plan – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

What is it?
• A document that defines the operations, processes, materials, equipment,
methodologies and special characteristics integral to the manufacturing process.
Purpose:
• To communicate the supplier’s decisions during the entire manufacturing process
(materials purchase through final packaging).
– It does not replace the information contained in detailed operator instructions.
• Reflects methods of monitoring, control, and the measurement system used.
Guidance:
• Identify Key Product Characteristics (KPCs) and their source of variations.
• Develop using a cross-functional team.
• Generate using the PFD, FMEA, design reviews, special characteristics, and
knowledge of process.
• The Control Plan is a living document reflecting the current product and process
designs, control methods, and measurement systems.
– As these change and/or improvements are made, the control plan needs to be updated.
• Reference Control Plan Checklist (A-8 of the AIAG APQP Manual) for additional
guidance

39
Control Plan – Benefits
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• Quality Improvement
– Identify, monitor, & control variation
– Reduce rejects and waste
– Provides a structured approach towards control methods
• Customer Satisfaction
– Focuses on characteristics important to the customer
• Cost Reduction
– Reduce scrap, rejects, and waste
• Communication

40
Control Plan – Form Details
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

CONTROL PLAN
Prototype Pre-Launch Production
Control Plan Number Key Contact/Phone Date:(Org.) Date (Rev.)
002 T. Smith / 313-555-5555 11/29/2009 2/20/2010
Part Number/Latest Change Level Core Team Customer Engineering Approval/Date (If Req'd.)
54321231 / D Erin Hope, Alan Burt, Ken Light
Part Name/Description Supplier/Plant Approval/Date Customer Quality Approval/Date(If Req'd.)
Electronic Circuit Board
Supplier/Plant Supplier Code Other Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
ACR Control 439412
Characteristics Methods
Machine,
Part / Process Name Special Sample
Device, Product/Process Evaluation / Reaction
Process / Operation Char. Control
Jig, Tools, No. Product Process Specification/ Measurement Plan
Number Description Class Size Freq. Method
for MFG. Tolerance Technique

Automated
Wave Wave Sensor inspection
Soldering solder solder continuity (error Adjust and
2 Connections machine height 2.0 +/- .25 mc check 100% Continuous proofing) retest
Flux Test sampling
concen - lab Segregate
tration Standard #302B environment 1 pc 4 hours x-MR chart and retest

3. Production – a comprehensive documentation of Administrative Section

product/process characteristics, process Identifies part number and
controls, tests, and measurement systems that description, supplier, required
will occur during mass production. approval signatures, and dates.
Note: Must submit a Production
Control Plan for PPAP approval
Reference Section 6 of AIAG’s APQP Manual for in-depth instruction
41
Control Plan – Form Details (cont.)
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Part/Process Product Characteristics Specifications/Tolerance

Use this area to define Use this area to define
Define the characteristics of the
part/process number upper/lower spec limits for
product. There may be several
and description. each control element or a
for each operation. Can be
visual criteria not listed in the
dimensional, performance or
engineering documentation.
visual criteria.

Special Characteristic
Process Parameters Classification
Process parameters that are important.
Use as required to designate
A process parameter is a setting made
“Critical”, “Key”, “Safety”,
within a process that effects the
“Significant” classifications
Machine/Tools variation within the operation.
List the machine, Examples include:
device, jig, or tools that •Temperature (molding, heat treat, etc.)
will be used in the •Pressure
manufacturing process •Fixture settings
•Speed
•Torque

42
Control Plan – Form Details (cont.)
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Sample Size Control Method

What is the size of Method that will be used to control the
the sample you process.
should gather data Examples:
from? • Xbar/R Chart • Log sheet
• Mistake proofing • NP Chart
• Pre-control Chart • 1st piece inspection
• Lab report • Checklist
Measurement Technique
How is the characteristic or
parameter going to
measured? Examples include:
caliper, visual, fixture, test
equipment, etc.

Reaction Plan
Frequency Actions to be taken if controls fail.
Define number of parts and What happens when the characteristic
the frequency for which the or parameter is found to be out of
measurement will be taken. control.
Examples: Must include:
Final testing, visual criteria • Segregation of nonconforming product
• 100% • Correction method
SPC, Audit, May include (as appropriate):
• The sample size/frequency • Sorting
• Rework/Repair
• Customer notification

43
Control Plan – Common Pitfalls
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• One time document

– Must be continuously reviewed and updated - what if the latest change or
revision has a significant impact?
• Not consistent with process flow or PFMEA
• Reaction plan not specific enough to tell an operator or supervisor
what to do
• Process characteristics not identified
• Evaluation measurement / detection tools not specifically identified
• Critical and/or special characteristics not identified
• Family based control plan is not all inclusive
• Inspection frequency/gaging not appropriate for inspected feature

44
Control Plan – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer's Checklist
Use PFD and PFMEA to build the control plan; keep them
aligned
“Process Number” should cross reference with PFMEA and PFD
Keep it simple but robust. Controls should be effective.
Such as SPC, Error Proofing, Inspection, Sampling Plan
Cannot be excessively dependent on visual inspection
Ensure that the control plan is in the document control system
and matches the current design record revision.
Good control plans address:
All testing requirements - dimensional, material, and performance
All product and process characteristics at every step throughout the
process
All rework loops
All Special Characteristics as independent line items
Control plans should reference other documentation
Specifications, tooling, etc.

Attention to detail!!
45
Measurement System Analysis (MSA) – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

What is MSA?
• MSA is a method used to assess the quality of a measurement
system, and make judgment of fitness for its intended use.
Purpose:
• Quantify the amount and sources of variability in the
measurement system.
• Assess whether the measurement system is usable for its
intended application.
When to use it:
• On critical inputs and outputs prior to collecting data for analysis.
• For any new or modified process in order to ensure the quality of the data.
• When KPCs are identified and an Initial Process Study (Element #11) is required.
Further Guidance:
• Providing detailed guidance on conducting and analyzing GR&R studies is beyond
the scope of this document. For further information:
• Refer to AIAG’s Measurement Systems Analysis manual
• See an example at [Link]‘s link:
[Link]

46
MSA Terms
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Repeatability: Variation in measurements obtained with one measuring instrument when used several
times by an appraiser, while measuring the identical characteristic on the same part (this is often
referred to as Equipment Variation, or EV).
Reproducibility: Variation in the average of the measurements made by different appraisers, using
the same gage when measuring a characteristic on one part (this is often referred to as Appraiser
Variation, or AV).
Gage Repeatability and Reproducibility (GR&R): The combined estimate of measurement system
repeatability and reproducibility. GR&R is typically expressed as “% Tolerance” when the
measurement process is used to judge compliance to specifications.
GR&R Study: A study where multiple parts are measured repeatedly by multiple appraisers. In a
typical study, 5-10 parts are measured 2-3 times each by 3 appraisers (people that actually make
these measurements).
Discrimination, Resolution: The smallest unit of output for a measurement instrument. 10 to 1 rule of
thumb: there should be at least 10 units of measurement contained in the specifications, and in ±2
standard deviations of measurement.
Reference Value: Accepted value of a standard.
Bias: Difference between the observed average of measurements and the reference value.
Stability: A stable measurement process which is in statistical control.
Linearity: Change in bias over the normal operating range. A measurement process with good
linearity will operate consistently across the range of values.

47
MSA – Polaris Specific Requirements
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• Polaris requires an analysis of the capability of all

measurement processes identified in the Control Plan
required to assess KPCs.
• Minimum requirement for Polaris suppliers are:
– Gage R&R study using total tolerance on each measurement tool used to
assess a KPC.
– Percentage of R&R should strive to be less than 10%.
– Gage R&R results between 10% and 30% are considered marginal,
meaning the supplier has to take or suggest action to improve.
– If greater than 10%, an explanation of why the measurement tool is used
shall be included.
• Every effort shall be made to include samples that represent
the full range of process variation.

48
MSA – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer's Checklist
If the gage/inspection measures a KPC or other important feature, then conduct a Gage
R&R. The gage used must be the same gage specified in the Control Plan.
Make sure the study is recent - less than 1 year
Gage R&R results must follow the approval %
Gages >30% cannot be used on Polaris product
Gages between 10% and 30% require highlighted actions
Make sure discrimination vs. tolerance makes sense
Rule = 1 level MORE than the tolerance (i.e. tolerance = .01, gage should measure
to .001)
Does Study provide data on the %GRR, %EV, %AV?

Attention to detail!!
49
Dimensional Results – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

What is It?
• Provides evidence that dimensional verifications required by the design
record and the control plan have been completed and results indicate
compliance with specified requirements.
Purpose:
• To show conformance to the customer part print on dimensions and all
other noted requirements.
When to Use It:
• For each unique manufacturing process
− Each cell, production line and all cavities, molds,
patterns and dies require a Dimensional Result
submission.

50
Dimensional Results – Requirements
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Dimensional Results Report Must Include:

• Date of the design record
• Change level
• Authorized engineering change documents
Sample Production Part (see Element 14):
• Supplier must send the part measured (and specified as such) in the Dimensional
Results Form.
• Send to Polaris Quality Assurance Representative (as designated in the PPAP request).
• Must be clearly labeled as the sample part with the Polaris part number.
Additional Guidance:
• All dimensions (except reference dimensions), characteristics, specifications, material
types, all notes, and any corresponding color or length dash codes should be listed in a
convenient format, with actual variable results recorded.
• Nonconforming Measurements:
– If any dimensions / characteristics do not meet the specifications, interim approval
may be granted if additional documentation is submitted and approved prior to the
PPAP submission (i.e. approved deviation or drawing change request).
– Must be identified on PSW

The dimensional report is evidence of conformance to print

51
Dimensional Results – Example
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

52
Dimensional Results – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
Make sure the dimensional report addresses all print requirements.
Ensure “Method” is noted for every measurement and it makes sense for
the dimension.
If requested, the agreed upon number of parts from the production run
must be shipped to Polaris for verification of form, fit and function.
The same parts will be used to verify both critical and non-critical
dimensions.
Supplier must send the part measured (and specified as such) in the
Dimensional Results Form.
Supplier should make every effort to ship parts that represent the normal
process variation.

Attention to detail!!
53
Records of Material / Performance Test Results – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Definition:
• The supplier shall have records of material and/or performance test
results for tests specified on the Design Record or Control Plan.
Purpose:
• The test reports shall include:
− Design record revision and the specifications to which the part was tested
− Any authorized engineering change documents
− Date the tests were performed
− Indication of pass or fail
− The actual results of each test
• Material test result examples:
• Chemical
• Physical
• Metallurgical
• Performance test result examples:
• Fuel pump flow and pressure
• Regulator voltage or current capacity
• Seat bun dynamic fatigue test

Confirm the data and format with Polaris Quality Representative

54
Records of Material / Performance Test Results – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
Performance test documents should include confirmation of:
Any formal specification referenced
Any formal life testing
Any specific functional test
Sometimes performance is not directly addressed via the part print but it
may be:
Referenced through a specification or a drawing note
Implied through a requirement
Always ask about the need to demonstrate performance if it is not listed on
the print.
Material results should be compared against a known standard. Do not
assume the test specification is correct.
Verify the correct specification (i.e. ASTM D2000 Rev 2015)
Verify the composition breakdown
Verifying composition is NOT just for PPAP, it should be a periodic check
that is identified in the Control Plan.

Attention to detail!!
55
Initial Process Studies – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

What is it?
• Statistical tools are applied to data from a production run to provide
an early assessment of process stability and capability.
Purpose:
• To determine if the production process is likely to produce product
that will meet Polaris requirements.
When to use them:
• In the development process, initial process studies are conducted for
all KPCs (and other characteristics as identified by Polaris), based on
a significant production run.

Initial Process Studies: Section 2.2.11 in AIAG’s PPAP, Fourth Edition

56
Initial Process Studies – Approach
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Gather Analyze Calculate Apply

For each KPC and/or identified dimension:

• Perform measurement system analysis (MSA) to
understand how measurement variability affects the study
measurements.
1. Gather data for the study.
2. Analyze the data in the order produced using control charts.
3. Calculate the appropriate quality indices and create a
histogram from the data.
4. Apply acceptance criteria and determine next steps.

57
Initial Process Studies – Gather Data for the Study
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Gather • Polaris requires at least 30 observations gathered from the

production process for initial process studies.
– Although the PPAP manual calls for a minimum of 25 subgroups
containing at least 100 readings, we have reduced this because of
our lower volumes versus the automotive industry.
• Data should be gathered and recorded in the order of production.
• The intent of initial process studies is to identify the amount and
sources of variation present in the production process. The data
requirements may be replaced by longer-term historical data from
the same or similar processes, with Polaris concurrence, if it is
judged that the longer-term historical data will better achieve that
intent.

58
Initial Process Studies – Analyze the Data
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Analyze • Data should be plotted in the order produced,

preferably using control charts.
– With small data sets, we cannot make conclusions about long-term
process stability (effects of time and variations in people, materials,
methods and environment), but we can understand whether the
process is stable over the short time involved, and possibly identify
key sources of variation for control and improvement.
• Look for signals of instability (special causes of
variation)
– With small data sets, we cannot make conclusions about long-term
process stability (effects of time and variations in people, materials,
methods and environment).
• If there are signs of instability, the supplier shall
identify, evaluate and wherever possible, eliminate
special causes of variation prior to PPAP submission.

For details about process control charts, see AIAG’s SPC manual,
Chapter I-Section G through Chapter II
59
Initial Process Studies – Quality Indices
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• Cpk - The capability index for a stable process

Calculate – Cpk is a measure of process capability based on process variation
within each subgroup of a set of data.
– It does not include the effect of process variability between
subgroups.
– It provides a prediction of what the process might deliver if the
process is in statistical control.
• Ppk - The performance index
– Ppk is an indicator of process performance based on process variation
throughout the full set of data.
– It does include all sources of process variability in the data set, and
provides a summary of what the process has done during generation
of the data.
– If a process is in statistical control Cpk and Ppk will have similar
values.
• The quality indices are designed to provide a numerical indication
of how the process performs compared to specifications.
However, a histogram of the data, with specification limits
indicated, should accompany the indices to provide a visual sense
of how the data in the study relate to the specification limits.

For details about quality indices, see AIAG’s SPC manual, Chapter IV
60
Initial Process Studies – Acceptance Criteria
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Apply Cpk or Ppk will be chosen as the Index, as appropriate.

Results Interpretation
Index > 1.67 The process currently meets the acceptance
criteria.
1.33 ≤ Index ≤ 1.67 The process may be acceptable. Contact the
authorized Polaris representative for a review
of the study results.
Index < 1.33 The process does not currently meet the
acceptance criteria. Contact the authorized
Polaris representative for a review or the study
results.

61
Initial Process Studies – Miscellaneous
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

• Unstable (out of statistical control) processes may not meet Polaris

requirements. The supplier shall notify the authorized Polaris
representative of an unstable process and submit a corrective action
plan prior to submission.
• Action to be taken when acceptance criteria are not satisfied:
– The supplier shall contact the authorized Polaris representative if acceptance
criteria cannot be attained by the required PPAP submission date.
– The organization shall submit to the authorized Polaris representative for approval a
corrective action plan and a modified Control Plan normally providing for 100%
inspection.
– Variation reduction efforts shall continue until the acceptance criteria are met, or
until customer approval is received.
• The quality indices are designed to provide a numerical indication of
how the process performs compared to specifications. However, a
histogram of the data, with specification limits indicated, should
accompany the indices to provide a visual sense of how the data in
the study relate to the specification limits.

62
Initial Process Studies – Process Capability
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
Ensure the supplier has evaluated measurement processes and they are
adequate.
Review control charts to assess statistical process control.
Review histogram to evaluate distribution of the data.
Is the measure centered in the specification? (Note: This isn’t
absolutely necessary, but if the process is not centered, have a
conversation with the supplier about why it isn’t centered and whether
they intentionally run the process centered at the location indicated by
the data.)
Does it show a coherent distribution (i.e. are there multiple modes or
clear “flyers” that raise questions about using the data to represent the
ongoing process)?
Review reported quality indices to ensure they meet requirements.

63
Qualified Laboratory Documentation – Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Purpose:
• Inspection and testing for PPAP shall be performed by a qualified laboratory
as defined by Polaris requirements (i.e. an accredited laboratory).
• The qualified laboratory (internal or external to the supplier) shall have a
laboratory scope and documentation showing that the laboratory is qualified /
accredited for the type of measurements or tests conducted.
– When an external laboratory is used, the supplier shall submit the test results on the
laboratory letterhead or the normal laboratory report format.
– The name of the laboratory that performed the tests, the date(s) of the tests, and the
standards used to run the tests shall be identified.
Internal / External Recommendations:
• Recommendation for performing testing or measurement (INTERNAL)
– Record/Scope that identifies the testing to be done and it must include a list of all
test equipment, methods and standards used to calibrate the equipment.
• If you are sending out for measurement and testing (EXTERNAL)
– Provide a copy of the company’s THIRD PARTY accreditation
– Results must be on company letterhead and include:
• The name of the Lab
• Date of testing
• Standards used for testing are identified

64
Qualified Laboratory Documentation – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer's Checklist
Third party labs that measure parts for performance, material or
dimensional must be accredited.
If any testing is performed to measure or monitor part quality the test
organization must have:
Lab scope
Evidence of calibration (in-process)
Lab Scope: Make sure internal labs have a “system” defining what can
be measured, method, training, etc.

Attention to detail!!
65
Appearance Approval Report (AAR) – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

What is It?
• A Polaris supplied form: OPS-FORM-0151,
completed by the supplier containing
appearance and performance criteria.

Purpose:
• To demonstrate that the part has met the
coating cosmetic and performance
requirements in the design record.

When to Use It:

• Testing completed on production level parts.
• AARs only required for cosmetic parts.

Note:
Typically only applies for parts with color,
grain, or surface appearance requirements.
The use of limit samples help to distinguish
acceptable vs. unacceptable parts.

66
AAR – Form Breakdown
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Form Breakdown:
• Pretreatment Process Information
– Defines the cleaning and preparation process including details of the process type,
chemical composition and product identification.
• Coating Specifications
– Provides the coating brand and details as well as the substrate conditions.
Substrate conditions are identified by Polaris and are to be found in the design
record.
• Performance Tests
– Location for documenting all test results pertaining to coating performance, broken
down into chrome and paint.
– Performance requirements will come from the appropriate Polaris standard as found
in the design record.
– Examples: adhesion, hardness, and corrosion testing are a few of the results
reported here.
• Cosmetic Surface Criteria
– Cosmetic sections are broken down into Liquid Paint, Powder Paint, Colored
Plastic, and Chrome.
– Documents pass/fail for the supplied part on defects such as blisters, scratches,
fibers, waviness, etc.

67
AAR - Instructions
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Supplier MUST understand the cosmetic expectations & provide specifications or standards for inspection
68
AAR – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
Are all green areas on the form populated as outlined in the AAR
procedure?
Is the information provided on the Appearance Approval Report directly
tied to the design record?
Alltesting is complete per the Polaris standard referenced on the print.
Testing results are acceptable and passing according to the Polaris
standard.

Attention to detail!!
69
Sample Production Parts – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

What is it?
• Product sent by the supplier as
defined by the customer on the
submission request.
Purpose:
• Sample of Process Output
– Sample parts should be
representative of a process
and taken from a significant
production run (as discussed
elsewhere in this document).
• Needs to be the same part
measured when creating the
dimensional report submitted in
response to PPAP request.
• Verify inspection techniques.

Sample parts to be selected at random from the production run

70
Sample Production Parts – Submission Guidelines
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Address the following when submitting Sample:

• Sample sizes for PPAP reporting purposes should be of at least 5
parts.
• Samples provided for Polaris approval can be a minimum of 1
part.
• Ship sample part(s) to the attention of the responsible Polaris
quality assurance representative and to the location noted in the
PPAP Request.
• Include method of shipment (i.e. UPS, FedEx, etc.) and the
shipper’s tracking number in the PPAP Request.
• Sample parts are to be shipped shortly after the electronic data is
submitted to the Polaris quality assurance representative.
• The Sample Part Label (found in the Polaris Supplier Quality
Assurance Manual and shown here) must be affixed to the
OUTSIDE of shipping containers…not enclosed inside.
• Samples are to be shipped free of charge – DO NOT send
sample parts with inventory/production shipments – samples must
be separate.
• Do not ship the sample(s) against any purchase order.
• The bill of lading, invoice or packing slip must clearly state the
parts are “sample” at no cost to Polaris.
• If samples are shipped against a purchase order they will be
received into inventory and will not be considered as PPAP
samples – subject to an RMO.

Sample production parts MUST be properly identified

71
Sample Production Parts – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
Sample Parts should be received with every PPAP submission
and examined and must be the same part measured and
documented in the Dimensional Results paperwork.
Shipment method and tracking information must be referenced in
PPAP submittal.
Sample parts must be properly tagged, if they are not, they may
be REJECTED!!

Attention to detail!!
72
Master Sample – Definition/Guidance
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Definition:
• A sample of the material retained by the supplier from the significant production
run which is representative of the yield of the process.
Guidance:
• The Master Sample is retained at the supplier’s facility, NOT AT POLARIS.
– Material must be retained by the supplier until such a time a new PPAP is submitted
OR a change is made to the material.
– In some cases, suppliers maybe required to retain parts for seven years after the end
of the build. This condition usually relates to critical operation parts (brakes, drive
system, vehicle safety systems, etc.).
• The Master Sample may be used to:
– Confirm fit up and dimensional conformity
– Confirm acceptance to cosmetic criteria
– Used for development of gaging and creation of inspection criteria
– Used for assembly and inspection training
– Verification of production tooling

Master samples aid in referencing revision differences

73
Master Sample – Types
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Three types of Master Samples:

• Physical sample - A part or sample taken from the initial pre-
production run and kept in a secure area.
• Analytical Sample Record - For materials that breakdown over
time (plastics, rubber compounds, chemicals, etc.), a master
analysis (test records) along with the test protocol, are kept on
file. These records are for baseline comparison in the event the
current material fails to perform.
• Manufacturing Sample Record - Test records from bulk
material produced in the pre-production run (paint, welding shield
gases, chemicals).
– In some applications, bulk materials are supplied which may contain
several different lots of material. To create a master sample:
• Record quantity of product produced
• The important performance results
• The raw materials utilized (including lot numbers used)
• Critical equipment used to produce bulk material
• An analytical sample record
• Batch ticket used to make bulk material

74
Master Sample - Requirements
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Master Sample Requirements

• The supplier maintains a minimum of one part or applicable
records
– Exception: If a supplier is unable to safely retain samples due to size or
storage constraints, the customer may grant a waiver to the entire
master sample requirement.
– A sample from each tool, mold, cavity, etc. must be retained.
– Any differences in the process require sample parts be maintained for
future comparison (i.e. injection molding barrel temperature).
• Each part labeled with the customer part number and PPAP
approval date.
• Parts storage
– Parts are organized so they are easily locatable.
– Parts are protected from elements that may cause damage (rain, wind,
sunlight, etc.), to preserve original production condition.

75
Master Sample – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
Ensure there is a system for properly maintaining and periodically
reviewing master samples.
Certain materials may deteriorate over time depending on storage conditions
(i.e. rust, harden, discolor, warp, etc.).
Ensure contingency plans are established to protect samples from loss.
A sample from each tool, mold, cavity, etc. are retained.

Attention to detail!!
76
Checking Aids – Definition/Guidelines
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Definition:
• Fixtures, templates or special gages where used to measure dimensions or functional
integrity of parts.
Guidelines:
• Supplier may be asked to provide gage with PPAP submission.
• Supplier will be responsible for maintenance, calibration and gage R&R.

77
Checking Aids – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewer’s Checklist
If a fixture is referenced in the control plan and used to check physical
print dimensions either in-process or offline, then it is a checking aid and
subject to this review.
Checking aids must have evidence of:
Conformance to a provided print (if requested)
Repeatability
GRR
Preventive maintenance plan

Attention to detail!!
78
Customer Specific Requirements
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Definition:
• Records of compliance to all applicable Polaris-specific
requirements as listed below:
– Packaging Approval form
– Pre-Delivery Inspection (PDI) checklist (when applicable)
– Others as defined
• These requirements would be defined by an authorized
Polaris quality assurance representative as required.

79
Part Submission Warrant (PSW) – Definition/Purpose
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

What is it?
• It is an industry-standard document
required for all newly-tooled or revised
products in which the supplier confirms
that inspections and tests on production
parts show conformance to Polaris
requirements.
Purpose:
• Used to:
– Document part approval
– Provide key information
– Declare that the parts meet
specification
When to Use It:
• Whenever PPAP submission is required
• Prior to shipping production parts

PSW submission is MINIMUM requirement for ALL PPAP levels

80
Part Submission Warrant (PSW) – Elements
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Elements of the Part Submission Warrant

• Part information
• Supplier Manufacturing Information
• Submission Information
• Reason For Submission
• Requested Submission Level
• Submission results
• Declaration
• Documentation for any non-conformance, deviation or
open engineering change requests
• For Customer Use Only (not used – PPAP approval is the
acceptance method)

81
Part Submission Warrant (PSW) – Reviewer’s Checklist
Element 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Reviewers Checklist
Must be completely filled out
Must be signed by the supplier
Part number must match the PO
Product family submissions allowed
Submitted at the correct revision level
Submitted at the correct submission level
Specify the reason for submission
Ensure any deviations and/or change requests are documented

Attention to detail!!
82
PPAP Summary
• The Production Part Approval Process is an extensive approval process
for new or changed designs or processes.
• It is very formalized, so it inevitably causes some administrative work.
• It can be used in both manufacturing and service industries.
• AIAG PPAP expects the supplier to do all design and validation
activities, regardless of PPAP level request.
• Later changes to the product or process can be expensive and time-
consuming!
Standard Response to PPAP Charges
Dear Supplier,

Polaris does not pay one-time PPAP charges because it expects the activities that make up APQP and PPAP will not be one-
time activities. Process design elements such as FMEAs and Control Plans should be living documents and updated
regularly. Process validation activities such as MSAs, Process Capability Studies and part inspections should also be done
regularly to monitor and improve processes. Combined, these activities will help suppliers drive continuous process
improvement and achieve necessary cost targets.

Please review the Polaris Supplier Quality Assurance Manual (SQAM) and the current AIAG APQP and PPAP manuals to
ensure a complete understanding of Polaris’ expectations.

Regards,

83
PPAP – Reviewer’s Checklist

Reviewer’s Checklist
Ensure all required elements have been submitted.
Ensure any non-conformances or concerns have been noted.
Must verify approval status of any sub-assemblies.
Thoroughly review all element details prior to submitting/approving.

Attention to detail!!
84
References / Resources
• Where are the training, references / resources located?
– Refer to the Polaris Supplier Quality Assurance Manual
(SQAM).
• Support/Subject Matter Expert (SME)
– Contact your Polaris quality representative for questions or
additional guidance.
Learning Objectives Recap

At the end of this training, participants will be able to:

Understand Polaris’ expectations regarding the overall
process of PPAP preparation, compilation and submittal.
What is the Purpose of PPAP?
When is PPAP Required?
What are the Elements of the submission?
How are the Levels of PPAP applied?
Details on successful PPAP submission to Polaris’ facilities

86
FAQs
Why will Polaris not accept hard copies of submission data
in lieu of electronic data?
• Hard copies cannot be entered into our system and thus viewed by the
many people who need access to the data.
• Electronic submissions can also be traced verifying date of submission.

Why does the data need to be submitted in .pdf or .tif

format?
• Data must be submitted in acceptable formats which Polaris can open
conveniently.

What if multiple revisions exist in the PPAP submission

system for the same part number?
• Previous revision requirements can be moved forward to the latest
PPAP Submission Request upon supplier request (this is not done
automatically and subject to certain conditions).

What if the due date on the PPAP request cannot be met?

• DO NOT ignore the date – your metrics will be negatively affected.
• Notify the Polaris representative PRIOR to the due date and provide a
reason.

87
FAQs – (cont.)
What happens to submitted samples after auditing at Polaris?
• Samples are scrapped after approval.
• Sometimes samples may be used for destructive testing and could be
destroyed in the process.
Why must the submitted data be against a RELEASED Polaris
drawing?
• Polaris Purchasing Agents and Engineers provide suppliers with pre-released
drawings for quoting purposes or early discussion.
• Preliminary, pre-release or WIP drawings can change at any time with no
notice and are exempt from the Polaris release cycle.
• The released drawing is a contractual agreement as noted on the PO.
• PPAP submission requests are automatically generated after a print is
released.
• Only production POs and production drawings can be PPAP’d.

88
Questions?

89