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PPAP Review Process Guide Purchasing Rep ________________________

Supplier: Part Number:


Sent to Tech Rev ________________: Rev Comp'l ________________ Sent to Engr Review____________ : Rev comp'l ___________
Number Open FMEA Actions ________________ Risk: Low Moderate High

Audit Items Result Comments


SUBMISSION CHECKLIST / GENERAL Yes No
1. Is H-D PPAP checklist included and complete?
2. Are all applicable elements, as required by the submission checklist, included?
3. Is H-D Part #, Description, and Revision level documented and correct?
4. Do elements submitted correlate to submission level requested?
5. Submitted in a timely manner per purchasing instructions and target submission date?
6. If "Family PPAP" is a "Primary Part Number" designated?
7. If "Family PPAP" is there a matrix showing related parts?
8. If "Family PPAP" does the matrix show information to be submitted for related parts?
(Supplier should submit information that changes between parts, such as different lengths.)

1. WARRANT [PSW] Yes No


1. Are all required sections filled in by supplier?
2. Is appropriate submission level checked?
3. Are submission results marked?
4. Is production rate indicated in the Declaration?
5. Is warrant signed by appropriate supplier representative?
6. Is Mold / Cavity / Production Process field completed?

2. H-D DESIGN RECORD Yes No


1. Are H-D print(s) included to correct revision level?
2. Are prints of components and details included? [For assembly, records of Dwg. BOM components.]
3. For models, is CAD/CAM math data submitted?
4. If there is no H-D print, are supplier prints included?
5. Are all print dimensions (including specs., matl., & notes) numbered for layout?
6. For an Aluminum or Zinc Casting, are "Casting Production Specification" form EW416-001.

3. AUTHORIZED ENGINEERING CHANGE DOCUMENT(S) if applicable Yes No


1. If submitting to design records undergoing engineering change not yet officially incorporated,
are H-D engineering change documents (ECN's / PCN's) included and referenced on warrant?

4. ENGINEERING APPROVAL if applicable Yes No


1. Is engineering approval provided where required?
Note: Only applies when required on HD part drawing or specification .

HC2.05.04.03 Rev. 5 2007 Page 1 of 4


PPAP Review Process Guide Purchasing Rep ________________________
Supplier: Part Number:

5. DESIGN FAILURE MODE & EFFECTS ANALYSIS [DFMEA] Yes No


1. If supplier is responsible for design is DFMEA included?
2. H-D DFMEA, may be included for reference?
3. Are potential failure modes included?
4. Are potential effects of failure recorded?
5. Are potential cause(s) / mechanism(s) of failure recorded?
6. Are severity / occurrence / detection levels assigned (rank 1-10)?
7. Are RPN numbers calculated (severity x occurrence x detection) and noted?
8. Are recommended action(s) and results recorded for high Severity, Occurrance, or RPN?
9. Are dates and person responsible noted for each recommended action?
10. Are potential KPC(s), KCC(s), or SC's indicated?
11. Are part number and revision level noted ?

6. PROCESS FLOW DIAGRAMS [PFD] Yes No


1. Are process steps listed or process graphically shown?
2. Are process steps included (outside services)?
3. Are part number and revision level noted?
4. Are machine names and/or part numbers included?
5. If rework is part of normal processing, is it included on the flow diagram?

7. PROCESS FAILURE MODE & EFFECTS ANALYSIS [PFMEA] Yes No


1. Does PFMEA follow process flow and are all process steps included?
2. Are potential failure modes included?
3. Are potential effects of failure recorded?
4. Are potential cause(s) / mechanism(s) of failure recorded?
5. Are current process controls recorded?
6. Are Prevention and Detection controls listed and identified separately?
7. Are severity / occurrence / detection levels assigned (rank 1-10)?
8. Are RPN numbers calculated (severity x occurrence x detection) and noted?
9. Are recommended action(s) and results recorded for high Severity, Occurrance, or RPN?
10. Are dates and person responsible noted for each recommended action?
11. Are KPC(s), KCC(s), and SC's (significant characteristics) included if shown on design record?
12. Are part number and revision level noted?

8. CONTROL PLAN Yes No


1. Does control plan follow the process flow and PFMEA, are all process steps included?
2. Are all KPC(s), KCC(s), & SC(s) listed with control method, including capability
tracking and reporting where possible?
3. Are Product and Process characteristics documented?
4. Are special characteristics marked (highlighted) within Control Plan?
5. Are product / process specification / tolerance reported for each control step?
6. Are evaluation/measurement techniques reported?
7. Is sample size and frequency reported for each characteristic?
8. Are control methods recorded?
9. Are reaction plans recorded?
10. Are part number and revision level noted?
11 Are all special gages and/or fixtures noted?
12. Are "Checking Aids" identified on control plan by gage number as shown on warrant?
13. Are machine names and/or process numbers included?

HC2.05.04.03 Rev. 5 2007 Page 2 of 4


PPAP Review Process Guide Purchasing Rep ________________________
Supplier: Part Number:

9. MEASUREMENT SYSTEM ANALYSIS STUDIES Yes No


1. Are results reported for each KPC, KCC, SC measurement tool?
2. Are R&R results <10%? - OK
3. If R&R results >10% to < 30%, is evidence of management review for acceptability included?
4. Are R&R results > 30%? REJECT, take gage improvement action.
5. Are attribute studies reported for attribute gauging?
6. Was Measurement Systems Analysis performed on all checking aids?

10. DIMENSIONAL RESULTS Yes No


Note: Dimensions can be tabulated for ballooned print or shown on drawing check print.
1. Are actual results recorded for two samples (or for # of samples requested)?
2. Are specification and tolerance included to compare to result?
3. Are results recorded for all dimensions, specifications, and notes?
4. Do all results fall within specification limits?
5. Is part # and revision level documented?
6. Are KPC(s), KCC(s), and SC(s) dimensions identified?

11. MATERIAL / PERFORMANCE TEST RESULTS Yes No


1. Are results included for all tests required by specifications on the design record(s) & control plan?
2. Do actual results meet requirements?
3. Is material what is specified on design record?
4. Are performance results included as specified?
5. Do reports show who performed tests, date of test, number parts tested, change level of
parts tested, and specification & change level parts were tested to?
6. Are there tests for all GES, ASTM, and other referenced specifications?
7. If for castings, is "Foundry Trial Plan Summary' attached. [EW416-001]
8. Is documentation supplied for all Regulatory / "Conformance of Production" /
Homologation compliance requirements identified on the design record?

12. INITIAL PROCESS CAPABILITY RESULTS Yes No


1. Are control charts submitted which show a stable, in-control, process?
Note: Histograms do not show stability and are not acceptable unless agreed to in writing prior to submission.
2. Are capability results reported for all KPC(s), KCC(s), and SC's ?
3. Do results equal 1.33 or greater for SC's?
4. Do results equal 1.67 or greater for KPC's and KCC's?
5. Are actions documented for Cpk <1.67>1.33?
6. Are actions documented for Cpk <1.33?
7. Are acceptance criteria documented for one-sided or non-normal distributions?

13. QUALIFIED LABORATORY DOCUMENTATION Yes No


(required if laboratory testing is not performed by supplier or H-D)
1. Is A2LA or ISO 17025 certification and scope provided for tests conducted?
2. Is laboratory accredited for tests conducted?
3. If part is for PTO, is submitting supplier "layout qualified" to PC2.05.05?
4. Are test results on lab letterhead or laboratory report format?
5. Is name of laboratory, date of tests, and standard and revision level used identified?

HC2.05.04.03 Rev. 5 2007 Page 3 of 4


PPAP Review Process Guide Purchasing Rep ________________________
Supplier: Part Number:

14. COSMETIC VALIDATION REPORT Yes No


1. Is part cosmetic (cosmetic zones defined on H-D design record)?
If no, cosmetic validation report not required.
2. Is cosmetic validation form (HC2.05.05.01) submitted, completed, and approved ?

15. SAMPLES - LAYOUT (15a.); COSMETIC / STYLING SAMPLE (15b.) Yes No


1. Are sample(s) provided in accordance with submission level?
2. If specified, was part(s) sent to specified site for H-D approval?
3. Was layout submission acceptable?

16. MASTER SAMPLE TO BE RETAINED BY SUPPLIER

17. CHECKING AIDS SPECIFIC TO THE PART BEING SUBMITTED Yes No


1. See Part Submission Warrant to verify checking aids are noted.
2. Are correct Engineering Change Level and date shown on Warrant?
3. See Control Plan to verify checking aids are noted.
4. Is there evidence "all aspects of the checking aid agree with part dimensional requirements"?

18. CUSTOMER-SPECIFIC REQUIREMENTS Yes No


1. Are there Customer-Specific requirements (must be specified Submission Checklist)?
2. Do records indicate supplier has complied with these requirements?

18A. Certification of number of pieces run Yes No


1. Were 300 consecutive pieces produced or documentation provided for lesser quantity?
2. Is the declaration signed by appropriate supplier representative?

18B. Tooling Photograph (for H-D owned tooling) Yes No


1. Is photo legible?
2. Is H-D ownership permanently marked with part no., part revision, and tool number?

18C. Capability Summary Reporting Yes No


1. Is Capability reported for all KPC's?

18D. Supply Chain Documentation Yes No


1. Is supply chain structure documented?
2. Is the company name and location shown in a process flow chart?

18E. Additional Requirements Yes No


1. Is documentation provided as required by the submission checklist?

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