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1 |
Part Submission |
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Cooper PSW only |
Cooper PSW is required for all submissions and required on all Cooper designed parts. |
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Warrant (PSW) |
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2 |
Design Records & |
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Cooper Divisional Part |
Include one clean copy of the current approved revision print with all dimensions, applicable specifications, and notes, |
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Bubbled part print(s). |
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Print |
bubbled (circle with corresponding number) on the print for reference to dimensional report. |
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3 |
Approved Engineering |
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Various engineering |
Any formal documentation that is not reflected in the current released print such as un-released marked up prints, formal |
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Change Documentation |
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documentation |
engineering changes and any pertinent engineering correspondence. |
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4 |
Customer Engineering |
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Not Required for Cooper |
Not used with Cooper Industries submissions. |
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Approvals |
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Submissions |
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Can be Cooper FMEA |
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5 |
Design FMEA, |
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Format or an AIAG |
Required only if supplier is responsible for part design. |
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compliant DFMEA. |
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Any standard flowchart |
Identifies all process steps from receiving to shipping/warehouse operations. Must include all offline and in process |
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6 |
Process Flow Diagrams |
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inspections and testing including ongoing routine conformance checks such as annual dimensional layouts. Process steps |
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format. |
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must match PFMEA and Control Plan steps. |
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Can be Cooper PFMEA |
FMEA must be AIAG or comparable format that contains the same information as the AIAG form. Process steps must match |
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Process Flow Chart, Control Plan and address all characteristics associated with each operation. RPN numbers must be in |
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7 |
Process FMEA |
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Format or an AIAG |
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accordance with AIAG guidelines with critical processes and inspections identified. Recommended Actions for high RPN |
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compliant PFMEA. |
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totals are required. |
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Control Plan must be AIAG or comparable format that contains the same information. Must match the Flow Chart/FMEA |
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Can be Cooper supplied |
process steps and describe the actions of each phase of the manufacturing process from receiving to shipping/warehouse. |
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8 |
Control Plan |
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format or AIAG compliant |
All CTQs and SPC items must be addressed within the corresponding process step. Any dedicated check/testing fixtures |
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format. |
that are used will be identified along with the numbered characteristics it measures/verifies/tests on the print. All CTQ's |
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must be identified in the control plan. |
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Measurement System |
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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 |
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9 |
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statistical package format |
decision making process of normal production. As a minimum gauge R&Rs, using percent of total tolerance must be included |
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Analysis Studies |
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for gage R&R. |
for all process tools used in determining acceptability of equipment measurement capability. |
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10 |
Dimensional Results |
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Must be on Cooper |
Cooper Dimensional Data Sheet is only acceptable format. |
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Dimensional report format |
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Certificates of Analysis for all primary raw materials such as chemicals, plastic resins and rubber. Chemical composition lab |
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Industry Standard reports |
reports for all metals and controlled substances. Performance life testing results such as salt spray, impact testing, heat, |
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Material, Performance |
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humidity, electrical performance, etc, when required either by print, specification or specific request by Cooper representative |
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11 |
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AR |
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or test result formats |
to be submitted on AIAG forms CFG-1004, CFG 1005, or equivalent. For Catalog Parts Generic or family data maybe |
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Test Results |
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designated by Cooper |
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substituted with prior approval. AEC Qualification testing or equivalent is required for semiconductor devices. Any gaps |
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Industries. |
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between supplier qualification testing and AEC qualification testing requirements should be documented and approved by |
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Cooper Prior to submission. |
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Process Capability Study |
A short term study of process control capability (Cpk), must come from one continuous significant production run. At least |
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Initial Process Study |
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100 individual samples must be used for Cpk calculations. Multi-cavity tools would require a separate study per cavity. |
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using any statistical |
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(Cpk) |
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Supplier must have minimum Cpk value of 1.33 on all CTQs. No attribute data will be accepted for any PPAP submissions |
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package or Cooper |
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Capability Studies |
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for Initial Process Study. If CTQs are NOT identified on the print, the supplier will identify a minimum of two characteristics |
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Capability Data Forms. |
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that have a direct affect on fit, form, or function and perform Initial Process Studies on them. |
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A Quality Record that contains the specific tests/evaluations/calibrations that your facility performs, a list of your personnel's |
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13 |
Qualified Laboratory |
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Lab Scope and outside lab |
competency to perform these tests/evaluations/calibrations, a list of all measuring equipment used during production, and a |
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Documentation |
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proof of accreditation. |
list of methods and standards used to calibrate those tools. NOTE: All outside calibration or testing labs are required to |
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show proof of certification. |
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Appearance Approval |
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Needed only if part has color, grain, or some other cosmetic appearance requirement specified on the part print, or if |
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14 |
AR AR |
AR |
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AIAG format AAR |
specifically requested by Cooper to clarify a cosmetic requirement not clearly identified on a print. Format is AIAG form CFG- |
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Report |
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1002. |
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Parts tagged in |
The organization shall provide 3 sample parts WITH EVERY submission unless otherwise requested. Multi-cavity tools |
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15 |
Sample Product Parts |
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accordance with Cooper |
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require 1 part per cavity. |
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PPAP reference manual |
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16 |
Master Samples |
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Required only for level 5 |
Not required for submission but must be maintained by the supplier. |
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Checking aids |
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Checking aid design prints |
Any part specific fixture, gauge, model or template. Tooling/gauges/fixtures must include design prints and a 3rd party layout |
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17 |
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and GRR for checking |
confirming conformity to print. |
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fixtures. |
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18 |
Customer Specific |
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Documents as specified by |
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Requirements |
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Cooper Industries |
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a |
Tooling Information |
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Specific Cooper Document |
Applies to all Cooper owned tooling. Typical application includes information and pictures on production tools such size, |
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Form |
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maximum cycles, ownership etc… |
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b |
Packaging Form |
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Specific Cooper Document |
Used to outline and verify both external and internal packaging requirements including any related testing. |
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c |
Inspection Plan |
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Specific ASC Format |
Specific format used by many ASC suppliers to document quality inspections |
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(ASC Suppliers only) |
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Specification Deviation |
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Used for any requirement that is non-conforming and requires review by Cooper to provide for approval of the PPAP |
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d |
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Specific Cooper Document |
submission. The supplier must provide a recommended action plan for any issue identified on the Specification Deviation |
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Form |
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Form. |
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e |
Supplier PPAP |
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Specific Cooper Document |
To be submitted with every submission level except level 1 and must be signed by supplier representative. Used as both a |
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Checklist |
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reference/checklist tool as well as a verification that the right documentation is provided at the time of submission. |
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Cooper Industries PPAP Submission Levels (In compliance with AIAG Fourth Edition PPAP March 2006 release) |
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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 |
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applications and re-certification of existing parts previously approved by Cooper at levels 3, 4 or 5. Also used for Self Certification. |
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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 |
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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. |
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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 |
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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. |
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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 |
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divisional Cooper Quality PPAP representative. |
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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 |
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