Example of documentation template for Production Part approval Process (PPAP) in IATF

The following document templates (tool kits) are provided totally complimentary, free of charge to use as a starting point for Advanced Product Quality Planning (APQP) in IATF. As each business is different, additional documents or revisions would be required to meet your organization’s specific needs, requirements, context, risk profile, etc. ​​If after reading through all of these documents, you feel like you still need a consulting partner to help you develop your new documents – Contact Us. We’re always looking for interesting new clients and projects.

1.0 Process Approach for Production Part approval Process (PPAP)

2.0 Turtle Diagram of Production Part approval Process (PPAP)

Example of Production Part Approval Process of SHAFT COMP., GEAR SHIFT

List of documents submitted

Part Name : SHAFT COMP, GEAR SHIFT                                              Part No. & Rev:                     N8080530  Rev No : L4/d Customer :                                                                                                      Plant Location:   PPAP Submission Level :                                                                             Initial
Sr No.Document TitleApplicable Y/NSubmitted / RetainedRemarks
1List of documents submittedY  
2Design Records Bill Of Material Drawing Test Standards  Y Y N  
3Engineering Change DocumentsN  
4Customer Engineering ApprovalN  
5Design FMEAN  
6Process Flow Diagram Overall Process Flow (for Assembly)  Y  
Process Flow Chart (for Feeder shop & Assembly)
7Process FMEAY  
8Dimensional ResultsY  
9Material Performance Test ResultsY  
10Initial Process Study Control Chart Pp, Ppk Calculation Sheet  Y Y  
11Measurement System Analysis Studies MSA for variable characteristics MSA for attribute characteristics  Y Y  
12Qualified Laboratory DocumentationN  
13Control PlanY  
14PSW Weight Calculation SheetY  
Y
15Appearance Approval ReportN  
16Bulk Material Requirements ChecklistN  
17Sample ProductY  
18Master SampleY  
19Checking AidsY  
20Records of Compliance With Customer-Specific Requirements List of approved TIER 2 suppliers Process Qualification Records   
Y
N

Prepared by:xxxx                                                                                 Date:xx.xx.xxxx

Checked by:xxxx                                                                                          Date:xx.xx.xxxx

Approved by:xxxx                                                                                        Date:xx.xx.xxxx

CONTROL PLAN
 Prototype                   Pre-launch            ProductionKey contact/phone : xxxxDate (Orig.) : xx.xx.xxxxRev No.02/.Date : xx.xx.xxxx
 
Control plan Number :CP/SGS/28
    Part Number/Latest change level : N8080530                   Rev No : L4 / f    Core Team :A,B,C,D,E,F,G,H,I,J    Customer Engineering approval:
Part Name : Shaft Comp, Gear Shift ( Star )Plant approval/ date :Customer Quality approval:
Customer: TVS MOTOR COMPANY LTDOther approval / date (if reqd) :Other approval:
    OPN No.  Process Name/ Operation Description    Machine, device, Jigs & Fixtures for Mfg.CharacteristicsSpec ial Char . Clas sMethods    Reaction Plan
  No .  Product  Process  Product/ Process Specification / ToleranceEvaluation / Measurement Technique  Error proofingSample  Control Method
Size n  Freq.
 
                                                                          0                                                                      Incoming Inspection (Bought out Materials)                                                                        1) Inspection of Shaft, Gear Shift (N8080549)  1  Distance    8.7 -0.15  Height gauge                                                                         As per Receiving Inspection Sampling Plan                                                                        Receiving Inspection Report (QA/FM/01)                                                                    Reject / Segregation / Rework / Send back to supplier
  2  Chamfer    1 x 30°  Visual 
  3  Surface roughness    6.3 Ra  Roughness tester 
  4  Outer dia    Ø10.1 -0.02  Micrometer 
  5  Radius    R0.2/0.4  Visual 
  6  Outer dia    11.5 -0.05  Micrometer 
  7  Outer dia    12e8 (-0.032/-0.059)  Micrometer 
  8  Surface roughness    6.3  Roughness tester 
  9  Surface roughness    1.6 Ra  Roughness tester 
  10  Groove Width    4.2 +0.5  Digital vernier caliper 
  11  Distance    192  VHG 
  12  Distance    183  VHG 
  13  Distance    17.5  VHG 
  14  Groove dia    9.7 -0.25  Digital vernier caliper 
  15  Distance    157.5 +0.15  VHG 
  16  Groove width    1.15 +0.15  Digital vernier caliper 
    OPN No.  Process Name/ Operation Description    Machine, device, Jigs & Fixtures for Mfg.CharacteristicsSpec ial Char . Clas sMethods    Reaction Plan
  No .  Product  Process  Product/ Process Specification / ToleranceEvaluation / Measurement Technique  Error proofingSample  Control Method
Size n  Freq.
 
     17  Radius    R0.2Max  Visual    
  18  Groove dia    11.3 -0.2  Blade micrometer 
  19  Appreance    free from burr  Visual 
  20  Surface treatment    ZnFe Alloy plating  Verify Supplier Report 
  21  Appreance    Free from rust  
  22  Hardness    24±4  Hardness tester 
  23  Distance    2  Digital vernier caliper 
  24  Angle    45°  Bevel protactor 
                                                                        0 Cont.                                                                      Incoming Inspection (Bought out Parts)                                            2) Inspection of ARM (N5080959)  1  Thickness    3.2 +0.1/-0.2  Micrometer                                                                         As per Receiving Inspection Sampling Plan                                                                        Receiving Inspection Report (QA/FM/01)                                                                    Reject / Segregation / Rework / Send back to supplier
  2  Hole dia    7 H9 (+0.036)  Plug gauge 
  3  Height    3.5 ±0.1  VHG 
  4  Hole dia    10.2 ±0.1  Plug gauge 
  5  Distance    95  VHG 
  6  Flatness    0.15 max  VHG / Dial gauge 
  7  CD    107±0.15  Digital vernier caliper 
  8  Position    0.15 WRTB  CMM 
  9  Symmetry    0.15 WRT B  CMM 
  10  Height    12 -0.5  VHG 
  11  Appreance    Free from crack, Dent, burr  Visual 
  12  Case Depth    0.1/0.3  Verify supplier report 
  13  Hardness    80-91 HR15N  Verify supplier report 
  14  Appreance    No buldeg ouward allowed  Visual 
    OPN No.  Process Name/ Operation Description    Machine, device, Jigs & Fixtures for Mfg.CharacteristicsSpec ial Char . Clas sMethods    Reaction Plan
  No .  Product  Process  Product/ Process Specification / ToleranceEvaluation / Measurement Technique  Error proofingSample  Control Method
Size n  Freq.
 
     15  Chamfer    0.5×45°  Visual    
                          3) Inspection of Pawl. ( N8080969 )  1  Distance    4.84 -0.05  CMM 
  2  Angle    35.34 +0.50°/  CMM 
  3  Distance    5 -0.5  CMM 
  4  Distance    61.55 +0.15  CMM 
  5  Distance    37.87 -0.15  CMM 
  6  Hole dia    5 +0.1  Plug gauge 
  7  Flatness    0.2  Dial 
  8  Appreance    Free from crack, Dent, burr  Lever Dial 
  9  HArdness    45 ±3  Hardness tester 
                                        4) Inspection of Rivet (N2080499)  1  Outer dia    Ø8.5 -0.1  Micrometer    
  2  Radius    R0.3 Max  Visual 
  3  Outer dia    Ø7 e9 (-0.025/-0.061)  Micrometer 
  4  Outer dia    Ø5 -0.02/-0.07  Micrometer 
  5  Inner Dia    2.5  Digital vernier caliper 
  6  Surface roughness    N9  Visual 
  7  Depth    2.5  Dial 
  8  Distance    8  VHG 
  9  Distance    3.35 ±0.05  VHG 
  10  Depth    1.5  Digital vernier caliper 
  11  Hardness    78±4  Hardness tester 
  12  Case Depth    0.5/1.0  Supplier Report 
    OPN No.  Process Name/ Operation Description    Machine, device, Jigs & Fixtures for Mfg.CharacteristicsSpec ial Char . Clas sMethods    Reaction Plan
  No .  Product  Process  Product/ Process Specification / ToleranceEvaluation / Measurement Technique  Error proofingSample  Control Method
Size n  Freq.
 
     13  Hardness    247 BHN Max  Supplier Report    
                          5) Insp.of Spacer (N2080970 )  1  Inner Dia    Ø11.58 / Ø11.53  Plug gauge  
  2  Chamfer    0.5 x 45°  Visual 
  3  Outer dia    20.0 -0.15  Micrometer 
  4  Run out    0.05 WRT B  Dial 
  5  Thickness    24.5 -0.15  Micrometer 
  6  Surface roughness    N9  Visual 
  7  Surface roughness    N9  Visual 
  8  ID chamfer    0.3 x 45°  Visual 
  9  Surface roughness    N9  Visual 
                                                                         Welding                                                                        Shaft & Arm Welding   Machine Code:  M/c 1 : W003                              Check Sheet 
  1   Current   150 – 170 Amps  Ammeter   1  Daily  a,b,c
  2   Voltage   22 – 26 Volts  Voltmeter   1  Daily  a,b,c
  3   Gas Flow   15 – 20 LPM  Flow meter   1  Daily  a,b,c
  4 Rotary Welding Speed   H – Full Speed  Stop Watch   1  Daily  a,b,c
  5 Welding Wire Diameter   0.8 mm  Micrometer   1  Daily  a,b,c
  6   Nozzle Cleaning   No Weld Spatters on Nozzle  Visual   Once  Every 5 Piece  a,b,c
  7 Openning the Nozzle & Cleaning   No Weld Spatters on Nozzle  Visual   Once  Every 30 Piece  a,b,c
  8   Liner Cleaning   No Weld Spatters on Nozzle  Visual   Once  Every 1 Week  a,b,c
  9Weld Blow Holes, Incomplete Weld    No Weld Spatters & Incomplete Weld  Visual   100%  Daily        Setup cum In process Inspection Report(QA/FM/0  a,b,c
  10  Rust    Not allowed  Visual   100%  Daily  a,b,c
  11  Knurling Damages    Not allowed  Visual   100%  Daily  a,b,c
    OPN No.  Process Name/ Operation Description    Machine, device, Jigs & Fixtures for Mfg.CharacteristicsSpec ial Char . Clas sMethods    Reaction Plan
  No .  Product  Process  Product/ Process Specification / ToleranceEvaluation / Measurement Technique  Error proofingSample  Control Method
Size n  Freq.
 
10Shaft & ARMMachine : W003  12  Groove Pressence    Not allowed  Visual   100%  Daily2) & Gauge Frequency check sheet(QA/FM/14) .  a,b,c
  13  Bush Float    Not allowed  Visual   100%  Daily  a,b,c
  14  Arm Flatness    Not allowed  Visual   100%  Daily  a,b,c
  15  Arm Height    18.2 + 0.2  Position Gauge / VHG                   Setup approval first 5 nos Inprocess 1 no / every 2 hrs by QA (Inspector), Gauge frequency check 5 nos/ every one hour by Operator & also by Final Inspector.                  Setup cum In process Inspection Report(QA/FM/0 2) & Gauge Frequency check sheet(QA/FM/14) .  a,b,c,d
  16  Perpendicularity    0.25 WRT F  CMM   a,b,c,d
  17  Arm to Shaft Height    5.5 ± 0.2  Position Gauge / VHG  
  18  Welding fillet    3mm  Digital vernier caliper   a,b,c,d
  19  Serration angle    5° ± 1°  CMM/ Position gauge   a,b,c,d
  20  Welding strength    >150 NM  UTM / once in a month   a,b,c,d
  21  Spacer rotation    Free Movement  Manual  
              20              Riveting            Riveting Machine : RM002  1   Air Pressure   5 – 6 Bar  Pressure Gauge   1  Daily  Check Sheet  a,b,c
  2   Pawl Bend & Twist   Pawl to be Freely Entry to Acc. Gauge  Acceptance Gauge   100%  DailySetup cum In process Inspection Report(QA/FM/0 2) & Gauge Frequency check sheet(QA/FM/14) .  a,b,c
  3   Pawl Free Rotation   Pawl to Freely Rotate on Axis  Visual   100%  Daily  a,b,c
    4     Pawl Float     Not allowed    Visual     100%    Daily    a,b,c
     I  Appearance  Inspection    Visual    
    1    Damages, Rust, Burr      Not allowed    Visual       a,b,d,e
  2Wrong parts,Child Parts & Operations Missed    Not allowed  Visual   a,b,d,e
  3  Dent    Not allowed  Visual   a,b,d,e
    OPN No.  Process Name/ Operation Description    Machine, device, Jigs & Fixtures for Mfg.CharacteristicsSpec ial Char . Clas sMethods    Reaction Plan
  No .  Product  Process  Product/ Process Specification / ToleranceEvaluation / Measurement Technique  Error proofingSample  Control Method
Size n  Freq.
 
        30        Final Inspection      Inspection Area with Measuring Instruments and Gauges  4  Weld spatters    Not allowed  Visual           As per sampling plan (QA/FM/03)        Final Inspection report (QA/FM/05)  a,b,d,e
  5  Rotation of Pawl    Free Rotation  Manual  
  6  Sharp corners    Not allowed  Visual   a,b,d,e
  II  DIMENSIONAL  INSPECTION      
  1  Perpendicularity    0.25 WRT F  CMM   a,b,d,e
  2  Symmetry    0.15 WRT  CMM   a,b,d,e
  3  Rivet Height    1.3 (ref)  Digital vernier caliper   a,b,d,e
  4  Serration angle    5°±1°  CMM   a,b,d,e
    40  Layout Inspection  Inspection Area with Measuring Instruments and Gauges  As per drawing Dimensions to be checked, as per layout inspection plan – Layout Inspection report.(QA/FM/12 / QA/FM/13)    a,b,d,e
  50  Dispatch  Dedicated crates – 16 Nos / Crate ( Photo attached )
  a – Stop Production,  b – Notify Supervisor,  c – Re-adjustment,  d – Segregate previous batch,  e – Quarantine non-conforming parts,  f – Tool Rectification
  Prepared By :Mohan raj         Approved By : Ashokkumar  
  Revision History
  Sl.no  Rev.No  Date  Details of Revision  Revised by
  1  01  xx.xx.xxxx  Inspection Details with Qty  xxxx
  2  02  xx.xx.xxxx  Dimension 5.5 ± 0.2 Parameter Added and also Gauge Inspection Added in Final Inspection Stage  xxxx

FINAL INSPECTION REPORT

VENDOR CODE : 20686VENDOR NAME :
CUSTOMER :Part No : N8080530                        Rev No : L4 / dPart Name : Shaft comp Gear shift
Invoice No :Date :Lot Size :Sample Size:
SL. #PARAMETERSSpecial Char. ClassSpecificationMethod of InspectionOBSERVATION BY TAL  Cp  CpKOBSERVATION AT TVS M
12345678910
IAPPEARANCE  INSPECTION   
  1  Damages, Rust, Burr   Not allowed  Visual             
  2Wrong parts,Child Parts & Operations Missed   Not allowed  Visual             
3Dent Not allowedVisual             
4No Weld spatters Shall presentVisual             
  5  Sharp corners   Not allowed  Visual             
IIDIMENSIONAL  INSPECTION    
1Perpendicularity yes0.25 WRT FCMM             
2Symmetry yes0.15 WRT FCMM             
3Rivet Height 1.3 RefVHG             
4Serration angle 5°±1°CMM/Position Gauge             
INSPECTED BY: Sign. / xxxxVerified at TVS Sign. / Dt.If RW/SG Job Order No:LAB / ETR NO:Acceptance Status DP / RW / SG / RJGRN NO: DATE:
For previous lot Rejection / RT/Segregation & Field failure parameters check double the Sampling Quantity.Sampling PlanLot Size0 – 50                  51 – 100                101 – 500                     501 – 2000            > 2000
Sample sizeAppearance/Dimensional3                             5                            10                               20                          40
Performance1                             1                             1                               2                             3

Product Weight Details

Part Name: Shaft comp gear shift                           Part No. & Rev : N8080530 Rev No :L4 /d Customer :                                                                         Plant Location : xxxx
Sr No.Weight in Kgs (upto 3 decimels)Remarks
  1  0.32 
  2  0.300 
  3  0.33 
  4  0.310 
  5  0.3 
  6  0.320 
  7  0.32 
  8  0.3 
  9  0.32 
  10  0.310 
Average0.313kg

Prepared by:xxxx                                                            Date.xx.xx.xxxx

Checked by.:xxxx                                                            Date.xx.xx.xxxx

Approved by.:xxxx                                                          Date.xx.xx.xxxx

List of Checking Aid

  Part Name : SHAFT COMP. GEAR SHIFT    Part No. & Rev:N800530& L4 / d
Customer Name :   Plant Location: 
  Sr No.  Characteristics / Specification / RequirementChecking Aid used (Attr/Var)  Checking Aid NameChecking Aid NumberCalibration Due Date  R&R details  Remarks
1Perpendicularity0.25 WRT FVCMMCMM-01xx.xx.xxxx  
2Symmetry0.15 WRT FVCMMCMM-01xx.xx.xxxx  
3Rivet Height1.3 RefVVHG – Dial ind.counter type with Hy.MandrelQA/VHG/01xx.xx.xxxx  
4Serration angle5°±1°ACMMCMM-01xx.xx.xxxx  

Prepared by: xxxx                                Date :xx.xx.xxxx

Checked by: xxxx                                 Date : xx.xx.xxxx

Approved by: xxxx                                Datexx.xx.xxxx

                                                                                                                                                      
                       Customer Specific Requirements
Annexure-07
Rev 01   dated -01.12.2020
Customer Spectific Requirement Matrix
IATF RequirementsCustomer specific additional Requirements for TVS Motor  ( ref. SQAM Supplier Quality Assurance Manual )Customer specific additional Requirements for MultimaticCustomer specific additional Requirements for Jay IndustriesCustomer specific additional Requirements for Lander AutomotivesCustomer specific additional Requirements for JostCustomer specific additional Requirements for Rockman IndustriesCustomer specific additional Requirements for Diado IndiaProcess Name
 (Where this requirement is applicable)
4.1No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
4.2No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
4.3No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
4.4No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
5.1No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
5.2No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
5.3
Organizational roles, responsibilities and authorities
The supplier shall submit an organisation chart including the roles and responsibilities of each function and number of persons (Manager, Executives, and Inspectors) along with the contact information.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsHR
The supplier shall notify TVSM of any changes in their contact information as and when they are made. Revised forms shall be sent within 7 days of such changes.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
6.1No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
6.2No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
6.3No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
7.1.5.1.1
Measurement systems analysis
Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies.Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies.Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies.Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies.Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies.Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies.Supplier shall use MSA reference manual latest edition of AIAG for all attribute and variable gauge studies.Quality
On an on going basis, the supplier shall conduct Gauge R&R (variable and attribute studies) on all types of measurement systems at least once in a year
The types of measurement system shall be identified / grouped based on instrument type, instrument range and resolution, part characteristics, operating environment and skills / competences of personnel using the instrument.
7.2No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
7.3No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
7.4No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
7.5
Documented information
Retention period- 2 Years
Inspection Standards, Inspection Reports, Tooling Maintenance Reports, Control Chart, Material Test Reports, Performance Test Reports, Calibration Records, Machine Capability Study Reports, Audit Reports, QUALITY DEVIATION HIGHLIGHTS, Action Plans, Kaizens, QC Story
No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsControl of documented information
Retention period- Life of the product
Drawings, APQP Documents and Master Samples
Retention period- Life of the product
Drawings, APQP Documents and Master Samples
Retention period- Life of the product
Drawings, APQP Documents and Master Samples
Retention period- Life of the product
Drawings, APQP Documents and Master Samples
Retention period- Life of the product
Drawings, APQP Documents and Master Samples
Retention period- Life of the product
Drawings, APQP Documents and Master Samples
Retention period- Life of the product
Drawings, APQP Documents and Master Samples
8.1No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements 
8.2.3.1.3
Organization manufacturing feasibility
Prepare Manufacturing Feasibility and Risk Analysis format QSF PUR SQAM 002,003 and drawing feedback & agreement form QSF PRG 02 01 018 and feedback / suggestions for QCD improvementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsMarketing & Sale and New Product Development
manufacturing feasibility as per checklist QSF PUR SQAM 003No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
Supplier shall use TVSM format QSF QAD 10 11 05 for preparation of AOINo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
8.3.2
Design and development planning
Readiness Review– This is done by reviewing product and process design documents as per checklist CL QAD 10 11 001No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNew Product Development
IPTR (Initial Production Trial Run)– typically 50 nos. and reviewing the results as per checklist CL QAD 10 11 002No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
SPTR (Significant Production Trial Run)– (8 hours Production or 300 nos ) at planned run-at-rate and reviewing the results as per checklist CL QAD 10 11 003No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
8.3.3.3
Special characteristics
Safety / Statutory / regulatory- severity = 9 or 10.
 Minimum Process Performance index / process capability levels for variable characteristics 1.0 for geometric & 1.67 others
Follow as per DrawingFollow as per DrawingFollow as per DrawingFollow as per DrawingFollow as per DrawingFollow as per DrawingNew Product Development
Fit / Function – Critical- severity = 7 or 8.
Minimum Process Performance index / process capability levels for variable characteristics 1.0 for geometric & 1.67 others
Fit / Function – major- severity = 5 or 6.
Minimum Process Performance index / process capability levels for variable characteristics 1.0 for geometric & 1.33 others
Supplier shall send the of process capability reports on monthly basis for special characteristics, controlled through X-bar, R chart. Action plan to be submitted to improve the process capability, if Cpk is below the norms specified in the manual.Quality & Production
8.3.4.4
Product approval process
Submit the PPAP documents through Collaboration Folder link available on http://www.tradewithtvs.com and Table 1 shows the 19 requirements for the PPAP submissionPilot Lot of 300 nos along with PPAP Documents
Material reports to be uploaded on IMDS If required
Intial 10 nos  nos along with PPAP DocumentsIntial 5 nos  nos along with PPAP Documents
Material reports to be uploaded on IMDS if required
Intial 05 nos  nos along with PPAP DocumentsIntial 10 nos  nos along with PPAP DocumentsIntial 10 nos  nos along with PPAP DocumentsNew Product Development
8.3.5.2
Manufacturing process design output
FMEA shall follow the latest edition of FMEA reference manual published by AIAGNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNew Product Development
High risk in FMEA is defined where severity is high and / or RPN is high for a failure mode / cause. High Severity ³ 7 or High RPN ³ 63 ( action plan required to reduce severity or RPN ).No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
special attention to be given for high severity rankings even if RPN is low. Whenever severity is 9 or 10 and no actions are possible to reduce severity ranking, efforts shall be taken to minimize occurrence and detection ranking.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
8.4
Control of externally provided processes, products and services
Maintain master list of all the T2 suppliers with clear details of the operations carried out and provide a copy to TVSM along with PPAP.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsPurchase & Quality
Carry out special processes like heat treatment, plating, painting, powder coating etc only at the mutually approved sources.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
TVSM may review the PFD, PFMEA & Control Plan of the Tier 2 supplier during part development if required.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
8.4.2.4.1
Second Party Audit
Supplier shall make a plan for Tier 2 audit covering all Tier2 suppliers.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsPurchase, G.M Systems & Quality
Supplier shall verify following areas
– Availability of latest revision of drawing and inspection standard
– Adherence to Control Plan
– Condition & Calibration of Gauges / Instruments / Tool / Equipments
– Part parameter audit
– Condition of jig / fixture / tools / gauges & history maintenance.
– NC products identification and handling
– Deployment of certified operators and inspectors in critical processes
– If a special process is done by Tier 2, then the special process qualification to be verified and approval by TVSM.
– Layout inspection, product audits.
– Supplier may cover additional areas as required
No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
8.5.1
Control of production and service provision
Process Qualification
Supplier shall identify the special processes ie (Heat treatment, Plating, Painting, Powder Coating, Welding, etc) and make a plan for conducting the process qualification, including Tier 2.
No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsQuality, Production & Purchase
The process shall be set at minimum condition for all process parameters as per the Control Plan and produce the product as per the normal batch size. (E.g. Temp: 160 ~ 200 deg Time: 5minutes ~ 8 minutes in a plating process then produce the batch by setting temp at 160 deg and time 5 minutes for minimum condition)No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
8.5.2.1
Identification & Traceability
Batch Number
Supplier Identification
LH / RH designation
Date of manufacture, Month, Year
Cavity no, Mould no, Die no,
Date Code / Heat Code
No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsProduction, New Product Development & Tool Management
8.5.1.6
Management of production tooling and manufacturing, test, inspection
tooling and equipment
Issue Tool Ownership Certificate (QSF PUR SQAM 017) to TVSM, once the tools are proved.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsTool Management
Review the condition of tool when quantity produced reaches 75 % of the agreed life. Thereafter, review the tool condition at incremental 10% production of the agreed tool life quantityNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
8.5.6.1
Control of changes
Supplier shall submit request for engineering changes – format no. QSF PUR SQAM 014, process changes format no, QSF PUR SQAM 013 and obtain necessary clearance from TVSM for going ahead with the change implementation.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNPD
8.6No additional requirementsMaterial TC and Inspection report with each every dispatchMaterial TC and Inspection report with each every dispatchNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
8.7.1.1
Customer authorization for concession
Non-conformance of Minor in nature
If the non conformance is minor in nature and if the supplier feels that it will not affect either the subsequent process at TVSM or the intended functional requirements at TVSM customer’s end, then they shall request TVSM for clearance thro, Deviation Approval Request format (QSF PUR SQAM 007) immediately and explain the non conformance nature.
No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsQuality
The suppliers are notified through Quality Deviation Highlights (QDH) on Web http://www.tradewithtvs.com, the supplier shall ensure corrective actions on receipt of QDH and communicate the causes of failure.
QDH raised for non-conformance shall be replied within 24 hours through E-Mail, Fax, Courier, or in person.
No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements 
8.7.1.6
Customer notification
Non-conforming parts shipped to TVSM and suppler end
Supplier shall send Notification of Suspected Shipment of Non-confirming Product format (QSF PUR SQAM 006) to TVSM Purchase / Quality
No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsQuality
9.1.1.1
Monitoring and measurement of manufacturing processes
SPC shall be in line with latest edition of AIAG manualNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsQuality & Production
Process capability studies shall be carried out over a sample size of minimum 100 nos. (25 subgroups of 4 samples each or 20 subgroups of 5 samples each)No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
If the process becomes unstable or non-capable (as per table), supplier shall introduce 100% inspection for the parameter, till the Corrective Action is taken and normalcy restored.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
Supplier shall send the of process capability reports on monthly basis for special characteristics, controlled through X-bar, R chart. Action plan to be submitted to improve the process capability, if Cpk is below the norms specified in the manual.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirements
9.1.2.1
Customer satisfaction
Quality performance report for each supplier is published on the website http://www.tradewithtvs.com. Quality rating is arrived based on the quality performance covering lot, line rejections, and warranty returns including spare parts supply. If rating is less than 90%, supplier shall forward the action plans proposed / planned along with the time frame to meet the target, the progress of which shall be reviewed by the supplier management on monthly basis and to be presented to TVSM on demand.No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsQuality, Marketing & Sale
9.2.2.4
Product Audit
Supplier shall perform product audit for ready for despatch parts, to confirm dimensions against standard, Functionality, Packaging, Labeling, etcNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsPurchase & Quality
9.3No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
10.1No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA
10.2.5
Warranty management systems
Analyze the failure, using warranty analysis guidelines and warranty analysis summary format QSF PUR SQAM 010 & QSF PUR SQAM 011. It is recommended to check 50 – 100 nos of failed parts randomly and verify the following observations.
– Phenomena of failure, kms etc
– Location of failure
– Bench mark study to identify the improvements
– Simulation of field failure in lab
– Identify the root cause of failure
– Identify the counter measure
– Compare the improvement in lab testing (before & after)
– Implement the action with time plan format
– Monitor the results
No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsQuality, Marketing & Sale
The implemented corrective action score shall be minimum 4
Detection type
Poka Yoke
• Design improvement
(Sev 5 to 7)
• Process improvement
(Cpk 1.33 to1.67)
• 100% additional
test station
• Automation of tool
change frequency
– visual control
No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsQuality
10.2.6
Customer complaints and field failure test analysis
Upon the receipt of complaint (Email / Fax / Quality Deviation Highlights), supplier representative shall visit TVSM to understand the problem within 24 hours.Corrective action required to submit on DMN PortalNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsQuality
M1 action – Immediate action to be taken on stocks at TVSM- Quarantining / segregation / 100% inspection etc.
Target lead time for completion of M1 action -Within 24 hrs
M2 action -Temporary action to be taken at all stages of manufacturing, transit and storage through out the supply chain. to prevent the defect reaching TVSM.Example of means used –100% inspection / switch over from sampling to 100% inspection / Gauge introduction, etc
Target lead-time for completion of M2 action – Within 48 hrs
M3 action – Corrective action through problem solving approach (QC Story/Kaizen sheet/8D- report )
Target lead-time for( i) Submission of corrective action reports –within 7 days
(ii) completion of M3 action – Within 15 days (according to the nature of problem and resolution)
10.3No additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNo additional requirementsNA

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