Supplier PPAP Expectations

Production Part Approval Process

An AIAG* standard used in the automotive supply
chain for establishing confidence in component
suppliers and their production processes.
* Automotive Industry Action Group – 4th edition is currently released.
Supplier PPAP Expectations

The intent of this presentation is to

give the supplier a brief overview of
the Production Part Approval Process
and guide them to a successful PPAP
submission to JTEKT.
Supplier PPAP Expectations

PPAP belongs to YOU!!!

(the SUPPLIER)
It is confirmation that the supplier’s planning &
processing is sufficient enough to meet the customer’s
continuous expectation of quality product.
Supplier PPAP Expectations

There are 3 distinct sections to PPAP…

1. Guarantee/Warranty – PSW (Parts Submission Warrant)

2. Quality Planning – Design Record, Process Flow Diagrams,

PFMEA, Control Plan, Inspection Standard, Safe Launch plan,
MSA (Gage R&R), Laboratory certifications and facility
certifications, special checking aids and Supply Chain Map.

3. Quality Data/Quality Evidence – Dimensional Results,

Capability Studies, Material & Test Performance Results,
IMDS submission to correct JTEKT ID#, Sample product and
records of compliance with any other JTEKT requirements.
Supplier PPAP Expectations

There are a various “Levels” of PPAP depending on

what step of the approval process is needed by the
customer. As an automotive supplier, your company
is expected to know the minimum requirements to
satisfy various PPAP levels and when to apply them.
Level 2 Level 3

Level 1 Level 4

Level 5
Supplier PPAP Expectations

Level 1 – PSW Only

This level is generally used for –
• Corrections (use comments section in PSW).
• Adding additional application (programs or
platforms) to an existing production part.
• May be requested when being asked to ship
already PPAP’ed parts to another location.
PLEASE NOTE:
All PSW’s MUST INCLUDE an approved IMDS Submission Number
And submitted to the appropriate site ID of the customer.
Supplier PPAP Expectations

Level 2 – PSW, Sample

Parts & Limited Data
This level is generally used for –
• Minor revision changes to parts that have
existing approved PPAP’s.
• Minor changes in the method of production
of parts with existing approved PPAP’s.
• “Limited Data” would be determined by your
customer.
Supplier PPAP Expectations

Level 3 – PSW, Sample

Parts & Complete Data
This level is generally used for –
• All new parts being PPAP’d for the 1st time.
• Major engineering changes where part
configuration or manufacturing method
deems necessary.
• Must include ALL elements of quality
planning. (i.e.: PFMEA, Control Plan, Flow)
and evidence of PV Testing acceptance.
Supplier PPAP Expectations

Level 3 – Continued
Data collection requires supplier to –
• Complete a 300 pc. production run.
• Ensure process capability of 1.67 Ppk on
features deemed key or critical on drawing
(N=50 pcs. sampling).
• 100% Layout verification of all dimensions
and drawing notes (ballooned drawing).
• Submit 3 sample parts* tagged to layouts.
• Material certifications for all components.
• Gage R&R (repeatability & reproducibility).
• Other JTEKT requirements per SQAM
* Multi-Cavity tooling requires samples from each cavity.
Supplier PPAP Expectations

Level 4 – PSW and Other

Customer Requirements
This level is generally used for –
• Significant revision changes to parts that
have existing approved PPAP’s.
• Significant changes in the method of
production of parts with existing approved
PPAP’s.
• And where quality planning is unchanged.
Supplier PPAP Expectations

Level 4 – Continued
Data collection requires supplier to –
• Complete a 50 pc. production run.
• Ensure process capability as deemed by
the customer. (i.e.: 1.67 Ppk or as noted)
• 100% Layout verification of all dimensions
and drawing notes (ballooned drawing).
• Submit 3 sample parts* tagged to layout.
• Material certifications for all components.

* Multi-Cavity tooling requires samples from each cavity.

Supplier PPAP Expectations

Level 5 – PSW & Sample

Parts, but Data on Record
This level is generally used for –
• Same expectations as a Level 3, but with on-
site verification at the supplier.
• Performed when there is proprietary
information involved or when special
processes require to be validated.
Supplier PPAP Expectations

Example of PPAP document package

Ref: FSQM-017
Supplier PPAP Expectations

Remember
 PPAP Document package is to ship WITH the
tagged PPAP sample parts.
 In a well packed box that is labeled with the
JTEKT sample parts label.

GOOD EXAMPLE
Supplier PPAP Expectations

Successful PPAP
submission
relies on YOU!
KNOW THE JTEKT SQAM!!!!
 Ship the PPAP samples AND paperwork package TOGETHER!
 Label PPAP shipment properly to ensure receipt (use FSQM-013).
 Don’t forget IMDS, it’s required for final PPAP approval on all levels.
 Use a checklist (FSQM-080) to ensure all requirements are addressed.
 Use early shipments (ITO, TTO, OTOP) to prepare for PPAP.
 Include plans for Safe Launch to ensure Zero Defects for 90 days.

Thank You!
Pre-Production Part Requirements

A few notes about Pre-Production samples…

Prototype > Off-Tool > Off-Tool Off-Process
• All sample shipments need to be labeled
per the SQAM using FSQM-013. (SQAM 2.3)
• All sample shipments must have specified
dimensional & test data. (SQAM 2.2)
• Various sample shipments require capability
studies on key features. (SQAM 1.5 & 2.2)
Lessons Learned

The following are examples of incomplete or improper PPAP

shipments that resulted in parts being put on hold, or worse yet…lost!
No PPAP sample label applied to box.
No PPAP documentation included with parts.
PPAP sample parts not tagged inside of box.
No PSW submitted in PPAP package.
IMDS number not listed on PSW.
Critical characteristics not addressed in control plan.
Capability studies not performed.
No Inspection Standard submitted.
“Safe Launch” plan not submitted.
Ballooned drawing does not address ALL
characteristics on drawing.
Information Location

JTEKT Supplier Quality Assurance Manual (SQAM)

Is available on the JTEKT Supplier Portal…
https://portal.koyobearings.com/portal/
Do not hesitate to contact your JTEKT Buyer or SAE for assistance.

Automotive Industry Action Group (AIAG) – 4th edition

PPAP guideline publication is available at…
https://www.aiag.org/products/products-
list/product-details?ProductCode=PPAP-4