SUMMER 2016

102
THE DISTRIBUTOR’S LINK
LAURENCE CLAUS PPAP FOR FASTENER DISTRIBUTORS from page 14
One of the most often misunderstood requirements of
PPAP is when a PPAP submission is required. The answer
to this will likely depend on the source of the request. If
the requestor is outside of the automotive industry (and
there are a growing number of nonautomotive customers
requesting PPAP), a request is likely to come only when
a new part is being proffered.
However, if the customer is within the automotive
industry, the requirement for PPAP submission casts
a much broader net. In addition to new part numbers,
PPAP is likely to be requested when there is an
engineering change, change in supplier, utilization of
new tooling, change in manufacturing location, change
in raw material, and change in testing methods to name
a few. Therefore, for automotive customers, the diligent
distributor must be prepared to update and submit a new
PPAP if any of these changes occur.
A PPAP must be submitted against what is called a
“significant production run”. This is defined as a run
that is able to make up at least 300 consecutive parts
and lasts a minimum of one hour and, in some cases,
up to eight hours. For fasteners, the one hour minimum
usually nets far more pieces than the required 300 but
assemblies and more complicated components may
take longer to get to 300 consecutive pieces. For the
distributor it is important that this is coordinated with
their supplier as the receiving customer is expecting that
at least 300 consecutive parts were made and could
request these parts or a greater quantity for early plant
trials or validation. These parts should be available to
the customer if they request them. In addition, the 300
parts must be produced under production conditions.
Generally this means that all parameters related to serial
production must be embodied in these parts. In other
words, they must be produced off of production tooling,
on the production equipment, with the material (and
material supplier) they will later be produced with, and,
where possible, with the production operators and gaging
that will later be utilized in serial conditions. Again, as
a distributor, the customer will be expecting that the
distributor’s supplier has been made aware of these
requirements and that they are abiding by them.
In a nutshell, there are 18 required elements that
the supplier must meet, as well as any additional or
special requirements of the customer. In most cases,
not all 18 will be applicable, but if they are, they must
be completed. The 18 different required elements are:
[1] Design Record (Usually a print or other set of
engineering documents describing the details of
the part. This might also include proof of an IMDS
(International Material Data System) submission.)
[2] Authorized Engineering Change Documents
[3] Customer Engineering Approval
[4] DFMEA (Design Failure Modes & Effects Analysis)
[5] Process Flow Diagram
[6] PFMEA (Process Failure Modes & Effects Diagram)
[7] Control Plans
[8] Measurement System Analysis (MSA) Studies
[9] Dimensional Results
[10] Records of Material/Performance Test Results
[11] Initial Process Studies
[12] Qualified Laboratory Documentation
[13] Appearance Approval Report
[14] Sample Production Parts
[15] Master Sample
[16] Checking Aids
[17] Customer Specific Requirements
[18] Part Submission Warrant (PSW)
Each of these 18 elements may have multiple
requirements and nuances that need to be met.
Those newly tasked with PPAP submission will need to
understand each of these requirements to assure that
they are supplying all of the proper material with their
submissions. Submissions that are incomplete, more
often than not, will not receive approval by the customer.
The last item on this list, the Part Submission
Warrant (PSW), merits a special explanation. In a few
rare instances, the PSW may be all that is required
for submission. The PSW is essentially a cover sheet
where the supplier provides some basic information
and descriptions, but most importantly identifies that
all requirements are met or where there might be
deficiencies. When deficiencies occur, the PSW allows
the supplier to communicate how it is being addressed
and any interim actions that are occurring until a
permanent remedy can be found.
CONTINUED ON PAGE 142