Aiag Ppap Manual 4Th Edition Form – Fill Out and Use This PDF

Element Order

PPAP Requirements

Level1

Level2

Level3

Level4

Level5

Required Documents

Additional Comments and Clarity

documents in this order.

AIAG PPAP Fourth Edition

Important: Submit your

1

Part Submission

AR

Cooper PSW only

Cooper PSW is required for all submissions and required on all Cooper designed parts.

Warrant (PSW)

2

Design Records &

AR

Cooper Divisional Part

Include one clean copy of the current approved revision print with all dimensions, applicable specifications, and notes,

Bubbled part print(s).

Print

bubbled (circle with corresponding number) on the print for reference to dimensional report.

3

Approved Engineering

AR

AR

Various engineering

Any formal documentation that is not reflected in the current released print such as un-released marked up prints, formal

Change Documentation

documentation

engineering changes and any pertinent engineering correspondence.

4

Customer Engineering

Not Required for Cooper

Not used with Cooper Industries submissions.

Approvals

Submissions

Can be Cooper FMEA

5

Design FMEA,

AR

AR

AR

Format or an AIAG

Required only if supplier is responsible for part design.

compliant DFMEA.

Any standard flowchart

Identifies all process steps from receiving to shipping/warehouse operations. Must include all offline and in process

6

Process Flow Diagrams

AR

inspections and testing including ongoing routine conformance checks such as annual dimensional layouts. Process steps

format.

must match PFMEA and Control Plan steps.

Can be Cooper PFMEA

FMEA must be AIAG or comparable format that contains the same information as the AIAG form. Process steps must match

Process Flow Chart, Control Plan and address all characteristics associated with each operation. RPN numbers must be in

7

Process FMEA

AR

Format or an AIAG

accordance with AIAG guidelines with critical processes and inspections identified. Recommended Actions for high RPN

compliant PFMEA.

totals are required.

Control Plan must be AIAG or comparable format that contains the same information. Must match the Flow Chart/FMEA

Can be Cooper supplied

process steps and describe the actions of each phase of the manufacturing process from receiving to shipping/warehouse.

8

Control Plan

AR

format or AIAG compliant

All CTQs and SPC items must be addressed within the corresponding process step. Any dedicated check/testing fixtures

format.

that are used will be identified along with the numbered characteristics it measures/verifies/tests on the print. All CTQ's

must be identified in the control plan.

Measurement System

Cooper GRR format or any

Require an analysis of the capability of all measuring tools identified in the Control Plan (in process or offline) used in the

9

AR

AR

statistical package format

decision making process of normal production. As a minimum gauge R&Rs, using percent of total tolerance must be included

Analysis Studies

for gage R&R.

for all process tools used in determining acceptability of equipment measurement capability.

10

Dimensional Results

AR

Must be on Cooper

Cooper Dimensional Data Sheet is only acceptable format.

Dimensional report format

Certificates of Analysis for all primary raw materials such as chemicals, plastic resins and rubber. Chemical composition lab

Industry Standard reports

reports for all metals and controlled substances. Performance life testing results such as salt spray, impact testing, heat,

Material, Performance

humidity, electrical performance, etc, when required either by print, specification or specific request by Cooper representative

11

AR

AR

or test result formats

to be submitted on AIAG forms CFG-1004, CFG 1005, or equivalent. For Catalog Parts Generic or family data maybe

Test Results

designated by Cooper

substituted with prior approval. AEC Qualification testing or equivalent is required for semiconductor devices. Any gaps

Industries.

between supplier qualification testing and AEC qualification testing requirements should be documented and approved by

Cooper Prior to submission.

Process Capability Study

A short term study of process control capability (Cpk), must come from one continuous significant production run. At least

Initial Process Study

100 individual samples must be used for Cpk calculations. Multi-cavity tools would require a separate study per cavity.

using any statistical

12

(Cpk)

AR

AR

Supplier must have minimum Cpk value of 1.33 on all CTQs. No attribute data will be accepted for any PPAP submissions

package or Cooper

Capability Studies

for Initial Process Study. If CTQs are NOT identified on the print, the supplier will identify a minimum of two characteristics

Capability Data Forms.

that have a direct affect on fit, form, or function and perform Initial Process Studies on them.

A Quality Record that contains the specific tests/evaluations/calibrations that your facility performs, a list of your personnel's

13

Qualified Laboratory

AR

Lab Scope and outside lab

competency to perform these tests/evaluations/calibrations, a list of all measuring equipment used during production, and a

Documentation

proof of accreditation.

list of methods and standards used to calibrate those tools. NOTE: All outside calibration or testing labs are required to

show proof of certification.

Appearance Approval

Needed only if part has color, grain, or some other cosmetic appearance requirement specified on the part print, or if

14

AR AR

AR

AR

AR

AIAG format AAR

specifically requested by Cooper to clarify a cosmetic requirement not clearly identified on a print. Format is AIAG form CFG-

Report

1002.

Parts tagged in

The organization shall provide 3 sample parts WITH EVERY submission unless otherwise requested. Multi-cavity tools

15

Sample Product Parts

AR

accordance with Cooper

require 1 part per cavity.

PPAP reference manual

16

Master Samples

Required only for level 5

Not required for submission but must be maintained by the supplier.

Checking aids

Checking aid design prints

Any part specific fixture, gauge, model or template. Tooling/gauges/fixtures must include design prints and a 3rd party layout

17

AR

and GRR for checking

confirming conformity to print.

fixtures.

18

Customer Specific

Documents as specified by

Requirements

Cooper Industries

a

Tooling Information

AR

Specific Cooper Document

Applies to all Cooper owned tooling. Typical application includes information and pictures on production tools such size,

Form

maximum cycles, ownership etc…

b

Packaging Form

AR

Specific Cooper Document

Used to outline and verify both external and internal packaging requirements including any related testing.

c

Inspection Plan

IA

IA

IA

IA

Specific ASC Format

Specific format used by many ASC suppliers to document quality inspections

(ASC Suppliers only)

Specification Deviation

Used for any requirement that is non-conforming and requires review by Cooper to provide for approval of the PPAP

d

IA

IA

IA

IA

Specific Cooper Document

submission. The supplier must provide a recommended action plan for any issue identified on the Specification Deviation

Form

Form.

e

Supplier PPAP

AR

Specific Cooper Document

To be submitted with every submission level except level 1 and must be signed by supplier representative. Used as both a

Checklist

reference/checklist tool as well as a verification that the right documentation is provided at the time of submission.

Cooper Industries PPAP Submission Levels (In compliance with AIAG Fourth Edition PPAP March 2006 release)

Level 1

Warrant only and Appearance Approval Report as requested submitted to the customer. Applied to: "Non-critical" parts, "non critical" raw/bulk material or catalog/ commodity parts for electrical

applications and re-certification of existing parts previously approved by Cooper at levels 3, 4 or 5. Also used for Self Certification.

Level 2

Warrant with product samples and limited supporting data submitted to the customer. Applied to: Critical Bulk products such as Plastic/PaintChemicals, critical fasteners, simple material

changes, simple revision level only changes or simple print updates not affecting form-fit-function. This level can also be applied to low and medium risk parts within a product family.

Level 3

Warrant with product samples and complete supporting data submitted to customer. Default Cooper Industries Submission Level Applied to: All new parts on Cooper programs. All changes

affecting form-fit-function, reliability, or performance. All product resourced to new suppliers, serial production parts, existing high risk parts undergoing a part number change.

Level 4

Warrant and other requirements as defined by the customer. This level is reserved for special applications only. Applied to: This level can only be applied with prior approval from the designated

divisional Cooper Quality PPAP representative.

Level 5

Warrant with product samples and complete supporting data reviewed at the supplier's manufacturing location. Applied to: On site review as requested by each Cooper Division