PPAP Workbook

This workbook is to be used for Production Part Approval Process (PPAP) submissions to Jacobs Vehicle Systems (JVS). Separate tabs are included for each section of the PPAP (as shown in the AIAG PPAP Manual, Fourth Edition). For Ease of Use with the forms, you should enter all relevant information in the "Data" tab to avoid having to retype it. The "Submission Plan" defines what sections are applicable for each level of PPAP. Supplier shall complete each tab. Included are check boxes to be used if the tab is "not applicable". If a document cannot be attached into the designated tab, please indicate in the designated tab and add a separate tab or submit as a separate .pdf document. Supplier shall fill in areas shaded "yellow". JVS uses sections shaded "blue". On tab #18 (Part Submission Warrant), be sure to check off applicable boxes. "Data" information auto fills, but other information requires your input, including reportable substances, for example. The JVS Reportable substance list is available in the Supplier section at http://www.jacobsvehiclesystems.com/suppliers/jvs-ppap-workbook/. Upon completion, please submit your PPAP to JVS_PPAP@jakebrake.com or as requested in the PPAP purchase order or instruction from JVS Purchasing or Quality.

Workbook Rev: 23-MAY-12

Part Information
Part Name Part Number Revision Supplier Part Number (if applicable) Supplier Part Rev or Date (if applicable) Additional engineering changes Additional engineering change rev/date Shown on drawing number Deviation Deviation Approval Date Weight Application Purchase Order No Tooling Purchase Order JVS Buyer Name

Submission Information
Submission Date Submission Level (see submission plan)

Reason for PPAP submission

Supplier Information
Supplier Name Street Address City State Postal Code Person responsible for PPAP submission Title Phone Fax e-mail

PPAP Submission Plan

Supplier Part Number Reason for submission 0 0 0
Part Name

Revision

0 0

Date of Submission PPAP Level

0 0

JVS normally requires PPAP level 3, unless otherwise specified. The PPAP P.O. takes precedence. JVS requires PPAP level 4* (see below) for commercially available product such as fasteners. Item 10 should include material certs, grade certs, mechanical properties, unless otherwise specified. The PPAP P.O. takes precedence. This form represents a plan for the submission of requirements. Not all requirements may be applicable in every case. Key: R - Retain at Supplier S - Submit to JVS W - Waived Refer to AIAG PPAP Manual, Fourth Edition, for further clarification. PPAP Level

Requirement
1 2 Design Record Ballooned JVS Part Print Engineering Change Documents, if any JVS Supplier Change Request or evidence of engineering approval (e.g. e-mail) Customer Engineering Approval JVS Supplier Deviation Request Design FMEA Required, if design responsible. Process Flow Diagram Process FMEA Control Plan Measurement System Analysis Studies Required for measurement devices used for special characteristics. Dimensional Results Clearly identify dimensional data to the part(s) submitted in # 14. Material, Performance, Test Results Transfer data to form from certifications, including the specification limits, and attach copy of material and test certifications. Initial Process Study Required for all special characteristics. Include raw data, histogram, control chart and capability indices (PpK and CpK). Qualified Laboratory Documentation Include copies of certifications (e.g. ISO9000, TS16949, A2LA), as appropriate Appearance Approval Report Not applicable to JVS product Sample Product Clearly identify part(s) used for the results submitted in # 9. A minimum of 2 parts to be submitted (one for dimensional analysis and one for possible destructive testing), unless otherwise specified. Master Samples Sample must be retained at the supplier. Dimensional data for this piece should also be included in #9. Checking Aids List the checking aids with calibration status, as appropriate. JVS Specific Requirements Packaging & Preservation Coatings (MSDS) Process Chemicals Outside processes Part Submission Warrant

4*

Submitted Y/N

Supplier Comments

JVS Comments

Acceptable Y/N

R S S R R R R R

S S S R R R R R

S S S S S S S S

* * * * * * * *

S S S W W W W W

R R R R R R R R

4 5 6 7 8

Date

Date

Date Commodity Mgr/Buyer Planner

JVS Layout R S S * S R

10

Met Review Other Testing -

11

12

R W

S W

S W

* W

S W

R W N/A Waived Waived N/A

13 14

15

N/A

To be retained at supplier

To be retained at supplier

N/A

16

R Process Quality Engineer

17

18

S W

S W

S W

S W

S W

R W N/A Waived Waived N/A

19 Bulk Material Checklist Not applicable to JVS product

Product Engineer

Supplier Quality Engineer

Date

Interim/ Conditional

Approved

Rejected

Comments

Design Record
Ballooned JVS print (required for PPAP level 2, 3, 4, and 4*) Attached below Submitted under separate cover Supplier print Attached below Submitted under separate cover

Engineering Change Document (Supplier Change Request)

Identify approved change(s) not yet recorded on the design drawing, but which are incorporated in the product.
Not Applicable Approved Supplier Change Request Attached below Submitted under separate cover Other evidence of engineering approval (e.g. e-mail) Attached below Submitted under separate cover Supplier Change Request included (form available at www.jakebrake.com) Attached below Submitted under separate cover

Engineering Approval (Supplier Deviation Request)

Identify any deviation(s) from the design drawing (characteristics which do not meet the design requirement).
Not Applicable Approved Supplier Deviation Attached below Submitted under separate cover Other evidence of engineering approval (e.g. e-mail) Attached below Submitted under separate cover Supplier Deviation Request included (form available at www.jakebrake.com) Attached below Submitted under separate cover

Design Failure Mode & Effects Analysis (DFMEA)

Not Applicable per Submission Plan Not Applicable - Not design responsible DFMEA attached below DFMEA submitted under separate cover DFMEA included as separate tab in this workbook

Process Flow Diagram

Not Applicable per Submission Plan Process Flow attached below Process Flow submitted under separate cover Process Flow included as separate tab in this workbook

Process Failure Mode & Effects Analysis (PFMEA)

Not Applicable per Submission Plan Other (Explain) PFMEA attached below PFMEA submitted under separate cover PFMEA included as separate tab in this workbook

PROCESS FAILURE MODE AND EFFECTS ANALYSIS

Item Potential Failure Mode Potential Effect(s) of Failure S e v C l a s s O c c u r Current Process Controls Prevention Current Process Controls Detection D e t e c t Action Results R P N Responsibility & Recommended Action(s) Target Completion Date S e v O c c D e t R P N

Process Function/ Requirements

Potential Cause(s)/ Mechanism(s) of Failure

Actions Taken

00-039626 PFMEA Rev 11/6/11

Page 11 of 29

Control Plan
Not Applicable per Submission Plan Control Plan attached below Control Plan submitted under separate cover Control Plan included as separate tab in this workbook

CONTROL PLAN Control Plan

Key Contact / Phone: Prepared By: Revised by:
Characteristics Part / Process Number Process Name/Operation Description Machine, Device, Jig, Tools for Mfg. Special Char. Class Specification / Tolerance Evaluation / Measurement Technique

Control Plan Number: Part Number / Latest Change: Orig Date: Rev Date:
Methods Sample Frequency Reaction Plan Control Method

No.

Product

Process

Sample Size

00-039626 Control Plan

Rev 11/6/11

Page 13 of 29

Measurement System Analysis Studies

Not Applicable per Submission Plan Not Applicable - No Special Characteristics MSA evaluated Total GRR < 10% 10% < Total GRR < 30% Total GRR > 30% - Action plan attached MSA attached below MSA submitted under separate cover MSA included as separate tab(s) in this workbook

Dimensional Results
PART NAME PART NUMBER PART REV

0
SUPPLIER

0
NAME OF SUPPLIER INSPECTOR

0
DATE OF SUPPLIER INSP DATE OF JVS INSP

0
PURCHASE ORDER NAME OF JVS INSPECTOR

Inspection Method
C=Calipers, DI=Drop Indicator, G=Gage Pins, I=Indicator, M=Micrometer, P=Profilometer, R=Rockwell Hardness Tester, S=Shadowgraph

Supplier
Item Dimension / Specification Inspection Method Results Pc. 1 Pc. 2 Pc. 3
(Retained at Supplier)

Jacobs
A/R Inspection Method Results A/R

Page 15 of 29

Supplier
Item Dimension / Specification Inspection Method Results Pc. 1 Pc. 2 Pc. 3
(Retained at Supplier)

Jacobs
A/R Inspection Method Results A/R

Page 16 of 29

Material Test Results

Not Applicable

Complete form and attach material certification below. Blanket statements of conformance are unacceptable for any test results.
SUPPLIER PART NAME PART NUMBER REV

0
NAME OF LABORATORY

0
MATERIAL SPEC./ CHARACTERISTIC

0
SPECIFICATION LIMITS TEST DATE QTY TESTED SAMPLE DATA SUPPLIER TEST RESULTS (DATA)

0
NOT OK

MATERIAL SUPPLIER

OK

METAL CO HT SUPPLIER

METAL CO. HT SUPPLIER

42CrMoS4 %C Core Hardness

0.38 - 0.45 56 - 60 HRC

6/6/10 6/10/10

Heat 425880 (2000 lbs) 1

0.44 57.70

OK OK

Performance Test Results

Not Applicable

Applies to performance tests such as fatigue testing, breakaway torque and mechanical properties. Complete form and attach test certification below (if applicable). Blanket statements of conformance are unacceptable for any test results.
SUPPLIER PART NAME PART NUMBER REV

0
TEST SPEC./ CHARACTERISTIC

0
SPECIFICATION LIMITS TEST DATE QTY TESTED SAMPLE DATA SUPPLIER TEST RESULTS (DATA)

TEST LABORATORY

OK

AAA TEST LAB

Cycle test per ABC SPEC 1234

100,000 cycles without failure

6/6/10

1 pc broke at 214,000 cycles, 2 pcs test stopped at 250,000 cycles without failure

OK

results.
REV

0
NOT OK

Initial Process Studies

Process Studies are required for all special (Critical and Major) characteristics. Process Studies should be included, if possible, for all KCC/KPC Include raw data, histogram, control chart and capability indices (PpK and CpK)
Not Applicable per Submission Plan Not Applicable - No Special Characteristics Process Studies conducted Min Capability Requirements met (Critical 1.67 CpK and Major 1.33 CpK) Min Capability Requirements not met - Action plan attached Process Studies attached below Process Studies submitted under separate cover Process Studies included as separate tab(s) in this workbook

Qualified Laboratory Documentation

Not Applicable Certificate(s) previously submitted (no changes) Certificate(s) attached Certificate(s) submitted under separate cover Issue Date TS 16949 Certification ISO 9001 Certification ISO 14000 Certification A2LA Certification ISO/IEC17025 Certification Other Certification (Please specify)

Issue Date Issue Date Issue Date Issue Date

Expiration Date Expiration Date Expiration Date Expiration Date Expiration Date

Checking Aids
Not Applicable SUPPLIER PART NAME PART NUMBER REV

0 Complies with revision above? Y/N

0 Date of last calibration / verification

Checking aid number

Description of checking aid

Packaging and Preservation

Quantity per individual package/box Weight per individual package/box Packaging Material Type Outer packaging NOTE: Over 25 pounds requires formal JVS approval

Returnable bin or crate (Specify type) Wooden bin or crate (Specify type) Gaylord container (Specify size) Cardboard box (Specify size and test rating) Other (Please specify)
Inner packaging (Idenfify all applicable)

Plastic Bag (Non-VCI) VCI Bag Plastic Sheet (Non-VCI) VCI Sheet

Bubblewrap Dessicant Bag

VCI Chip RP applied (Specify type; complete separate tab) Cardboard dividers Plastic or other dividers (Please describe) Other (Please specify)

Coating MSDS
List any coatings on the product and attach MSDS
Not Applicable MSDS(s) previously submitted (no changes) MSDS(s) attached MSDS(s) submitted under separate cover Oil (Please specify type and include MSDS) Rust Preventative (Please specify type and include MSDS) Black Oxide (Please include MSDS) Plating (Please specify type and include MSDS) Loctite or similar (Please specify type and include MSDS) Other (Please specify and include MSDS)

Process Chemicals
Not Applicable

List any chemicals used for cleaning, degreasing, descaling, etching, acids or bases used in vibratory fi Attach manufacturer's chemical specification for any such chemicals, as appropriate.

Brand Name and Manufacturer of Chemical

Process Chemicals

cleaning, degreasing, descaling, etching, acids or bases used in vibratory finishing, etc.. ical specification for any such chemicals, as appropriate.

Process where chemical is used

Outside Services
Identify supplier for any outside processes or services (e.g. coating application, shot peen, grinding)
Not Applicable

Outside Service / Operation

Supplier Name

Supplier Location

Certifications and expiration dates (e.g. ISO 9001, TS16949, A2LA, ISO/IEC 7025)

Part Submission Warrant

Part Name Supplier Part Number Additional Engineering Changes Tooling P.O. Number

0 0 0 0

JVS Part Number

Rev. Rev. Rev. / Date

0 0 0 0.0000

Purchase Order No. SUBMISSION INFORMATION

Weight (kg)

ORGANIZATION MANUFACTURING INFORMATION

0
Supplier Name

JACOBS VEHICLE SYSTEMS 0

JVS Purchasing or Buyer/Planner Contact

0
Street Address

0
City

0
State

0
Zip

0
Application

Does this part contain any restricted or reportable substances? Yes (explain below) No Verified by: JVS Restricted and Declarable Substance List (available at www.jacobsvehiclesystems.com)

GADSL EPA List of Lists

REACH Chemicals including Candidate List

IMDS (provide number below)

Other (explain below)

Explanation Are plastic parts identified with appropriate ISO marking codes? REASON FOR SUBMISSION Initial submission Engineering Change(s) Tooling: Transfer, Replacement, Refurbishment, or Additional Correction of Discrepancy Tooling inactive > than 1 year REQUESTED SUBMISSION LEVEL (Check one) Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer. Level 2 - Warrant with product samples and limited supporting data submitted to customer. Level 3 - Warrant with product samples and complete supporting data submitted to customer. Level 4 - Warrant and other requirements as defined by customer. Change to Optional Construction or Material Sub-Supplier or Material Source Change Change in Part Processing Parts produced at Additional Location Other - please specify

Yes

No

N/A

1
(check)

9 10 11 12 13 14 15 16 17 18 19

Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location. DECLARATION I affirm that the samples represented by this warrant are representative of our parts and have been made to the applicable customer drawings and specifications and are made from specified materials on regular production tooling with no operations other than the regular production process. I also certify that documented evidence of such compliance is on file and available for review. EXPLANATION/COMMENTS:

List Molds / Cavities / Production Processes Organization Authorized Signature Print Name Title 0 0 Phone No. E-Mail FOR JVS USE ONLY PPAP Warrant Disposition Customer Signature Print Name Date 0 Date Fax No.

0 0

Approved

Interim Approval

Rejected

Comments

Dispositioned PSW
For JVS use only