sonnen PPAP Production Process and Product Release User Guide
- June 1, 2024
- sonnen
Table of Contents
Guideline for Production Process and
Product Release / PPAP
PRODUCTION PART APPROVAL PROCESS [PPAP]
INTRODUCTION
The “Production Process and Product Release” or “PPAP” guideline is aimed at
suppliers of the sonnen GmbH who develop and manufacture series parts for
sonnen, as well as suppliers who manufacture series parts for Sonnen according
to specifications. The basis for requirements are product specifications,
drawings, referenced and generally accepted standards, procedures, and norms.
This guideline aims to ensure that the supplier demonstrates the necessary
capabilities to produce a series part for sonnen GmbH in a process-secure and
error-free manner as per their requirements.
The necessary documents and procedures for production process and product
release are outlined in this document and must be submitted prior to the start
of series production according to the part’s risk classification.
This process concludes with the final production process and product release
by sonnen, which remains in effect until changes occur in the production
process and/or the product – changes are thus bilateral!
Once the case arises, the PPAP must be partially revised or newly created due
to altered conditions.
WHEN IS A PPAP TO BE CONDUCTED?
PPAPs are to be conducted under the following conditions:
- New or modified parts/materials
- Changed subcontractor
- Changed specifications
- Changed manufacturing conditions / process changes
- Changed production sites
- Longer suspension of production (t > 1 year)
DOCUMENTATION REQUIREMENTS
The issuance of PPAP documentation must occur under series conditions with production tools and fixtures, and it serves as the basis for production process and product release.
PPAP SUBMISSION LEVELS
PPAPs are to be conducted according to the specifications of sonnen GmbH. They are generally classified into two types:
- Series parts that are developed and manufactured by the supplier for sonnen
- Series parts that are developed by sonnen and manufactured by the supplier
Refer to Appendix Submission Levels
PPAP ELEMENTS
5.1 TEAM FEASIBILITY COMMITMENT [TFC]
The Feasibility Commitment (TFC) team aims to provide a team statement that
assesses and confirms the feasibility of a product or process.
The TFC is typically based on a multidisciplinary team decision made by
representatives from various departments such as design, engineering,
manufacturing, quality assurance, and supply chain management.
The team collectively discusses whether all aspects of the product in terms of
quality, cost, availability, and customer satisfaction can be met in the form
demanded by customers.
5.2 DESIGN FAILURE MODE & EFFECT ANALYSIS [DFMEA]
The Design Failure Mode and Effects Analysis (Design-FMEA) is an effective
tool used to identify, assess, and mitigate potential failures in the design
process.
By systematically examining and evaluating design features and their potential
impacts, the Design-FMEA allows for early detection and rectification of
potential weaknesses, enhancing the quality, reliability, and safety of a
product.
It encourages a proactive mindset and contributes to minimizing costs, rework,
and recalls during the later stages of product development and production.
The Design-FMEA is thus a crucial step to ensure that a product’s design
aligns with customer requirements and expectations, guaranteeing a high level
of quality and customer satisfaction.
5.3 PART HISTORY
The Part History provides an overview of the revision history of a component
over time. It includes information about all relevant changes made during the
component’s lifecycle.
The Part History typically includes details such as:
- Date and description of changes made to the component
- Reasons for the changes, e.g., error corrections, enhancements, design adjustments, etc.
- Approval and authorization of changes by responsible individuals or committees
- Updated technical drawings, specifications, or other documents reflecting the changes
- Information about the impacts of the changes on other aspects of the product or the manufacturing process
The Part History allows all involved parties to trace and understand the
change history of a component. This is particularly crucial to ensure that all
changes are properly documented, approved, and implemented.
Documenting change revisions in the Part History provides transparency and
traceability. It’s of significant importance for effective communication and
collaboration among the involved parties in the PPAP process.
5.4 CUSTOMER ENGINEERING APPROVAL [CEA]
Customer Engineering Approval (CEA) is the consent obtained from the customer
for specific engineering aspects of a product. It ensures that the product
aligns with customer requirements and expectations. The CEA confirms the
customer’s approval for design, technical specifications, and other
engineering parameters.
5.5 PROCESS FLOW CHART
A Process Flow Chart is a graphical representation that illustrates the
sequence of steps in a process or a series of activities.
It offers a visual overview of the chronological order of activities,
decisions, and connections within the process.
The purpose of a Process Flow Chart is to vividly and comprehensively
visualize the process, ensuring that all involved parties share a common
understanding of the steps and their sequence.
It helps identify potential bottlenecks, sources of errors, or inefficient
areas.
Additionally, it serves as a means of communication to share processes with
other teams or stakeholders, facilitating discussions.
5.6 FACTORY FLOOR PLAN
The Factory Floor Plan is a crucial LEAN activity within the scope of PPAP.
Through its visualization, the production flow can be optimized, and
bottlenecks can be identified. It contributes to waste elimination and
efficiency enhancement within the production process.
It enables efficient utilization of factory space, aligning with the
principles of LEAN management.
The plan also considers safety and environmental aspects, ensuring that LEAN
principles such as safety and sustainability are integrated.
Through clear communication across departments, the Factory Floor Plan
supports collaboration and fosters the continuous improvement process, which
is an essential component of LEAN.
Therefore, within the context of PPAP, the Factory Floor Plan contributes to
the implementation of LEAN practices, aiming to enhance efficiency, quality,
and productivity.
5.7 PROCESS FAILURE MODE & EFFECT ANALYSIS [PFMEA]
Therefore, within the context of PPAP, the Factory Floor Plan contributes to
the implementation of LEAN practices, aiming to enhance efficiency, quality,
and productivity.
The Process Failure Mode and Effects Analysis (Process-FMEA) is a powerful
tool used to identify, assess, and mitigate potential errors and their impacts
within a process.
It enables the development of preventive measures to enhance process quality,
increase efficiency, and reduce costs.
The Process-FMEA is a crucial component of a robust quality management system
and supports the continuous improvement of processes.
5.8 CONTROL PLAN
A Control Plan is an essential tool for ensuring product quality within a
comprehensive quality management system.
It serves to establish the necessary control measures to ensure that a product
or process meets the specified requirements.
The Control Plan provides detailed descriptions of the measurement and testing
methods to be used, the frequency of checks, responsibilities, and acceptable
tolerance limits.
By implementing an effective Control Plan, deviations can be identified and
corrected early, leading to consistent product quality and customer
satisfaction.
The Control Plan supports process control, traceability, and contributes to
continuous improvement by ensuring the required quality standards are adhered
to.
5.9 PERFORMANCE TEST REPORT
A Performance Test Report is a document that summarizes the results and
insights from performance tests conducted on a product or a system component.
The report provides detailed information about the tests performed, the
testing methods, the test results, and the resulting performance data.
The Performance Test Report is of significant importance to assess the
capability of a product and ensure that it meets the required performance
criteria. The report provides objective data and enables an evaluation of
performance against established specifications. Furthermore, the Performance
Test Report aids in identifying potential weaknesses, bottlenecks, or areas
for improvement concerning the product’s performance. It assists in deriving
targeted measures for performance enhancement or issue resolution.
5.10 MATERIAL TEST REPORT
A Material Test Report is a document that summarizes the results of material
tests and examinations. The report provides detailed information about the
tests conducted, the testing methods applied, the test results, and the
specific properties and quality of the material.
The Material Test Report is important to ensure that the used material meets
the required quality standards. It provides objective data about the
material’s chemical composition, physical properties, mechanical strength, and
other crucial characteristics.
The Material Test Report enables the early detection of potential material
defects, deviations, or quality issues. It allows for a comprehensive
assessment of material quality and supports decision-making regarding the
material’s use in a product or process.
5.11 DIMENSION TEST REPORT
A Dimension Test Report is a document that summarizes the results of dimension
tests and examinations. The report provides detailed information about the
tests conducted, the measurement methods used, the measurement results, and
the specific dimensions of the tested object. The Dimension Test Report is
important to ensure that the dimensions of a product align with the drawing
requirements and specifications. It provides objective data about the actual
measurements of the product and allows for the verification of conformity with
the requirements.
5.12 APPEARANCE APPROVAL REPORT
An Appearance Approval Report is a document that describes the visual
acceptance of a product or component. The report provides detailed information
about the appearance, surface quality, and other visual characteristics of the
tested object. The Appearance Approval Report is important to ensure that the
appearance of a product meets aesthetic requirements and customer
expectations. It includes the assessment of surface texture, colors, finishes,
or other external features.
5.13 PACKAGING TEST REPORT
The Packaging Test Report is a crucial document that summarizes the results of
tests and examinations related to the packaging of a product.
By providing detailed information about the conducted tests, applied testing
methods, and results, the report offers valuable insights into the packaging’s
performance regarding requirements.
The Packaging Test Report assesses important aspects such as protection,
safety, handling, storage, and transportation. This ensures that the product
is adequately safeguarded and arrives undamaged at the customer’s location.
5.14 PRODUCT AND MASTER SAMPLE
A Product and Master Sample is a representative specimen or example of a
manufactured product that serves as a reference for product quality, design,
and other specific attributes. It is used to ensure that serial production
aligns with established standards and specifications. The Product and Master
Sample plays a critical role in the quality management process as it serves as
a benchmark for reviewing and assessing serial products. It allows for
comparison between manufactured products and the accepted reference sample to
ensure they are identical or within defined tolerances.
5.15 PART SUBMISSION WARRANT [PSW]
A Part Submission Warrant (PSW) is a crucial document within the context of
the PPAP process.
It serves as the supplier’s formal confirmation that the delivered parts or
components meet the agreed specifications and requirements.
5.16 PART SUBMISSION WARRANT, DEVIATION SHEET
The Deviation Sheet is a supplementary document to the PSW within the
framework of the PPAP process.
It is used to record and document deviations from the established
specifications. The purpose is to capture the nature of the deviation, its
impacts, and the corrective or compensatory measures taken. This sheet serves
as the basis for the customer’s decision to approve or reject the deviation
and may result in requesting adjustments.
5.17 SAFETY DATA SHEET
Safety Data Sheets (SDS) are important within the context of PPAP for
assessing the safety of materials used.
They provide information about potential hazards and necessary protective
measures. These data sheets ensure compliance with safety standards and
support the protection of employees, customers, and the environment.
5.18 FORM, FIT AND FUNCTION
“Form, Fit, and Function” are crucial in the context of PPAP to ensure that a
product meets design requirements, compatibility, and functionality. This
ensures that the physical characteristics, dimensional compatibility, and
intended purpose of the product are aligned with the specifications and
expectations.
- Form refers to the appearance of the component
- Fit refers to the accuracy of fit of the component and
- Function refers to the performance of the component Assessing these aspects ensures product conformity and performance to meet customer requirements.
5.19 QUALIFIED LABORATORY DOCUMENTATION
Qualified Laboratory Documentation is crucial in the PPAP process to ensure
that tests are conducted by recognized laboratories.
The documentation confirms the laboratory’s competence and provides accurate
and reliable test results.
5.20 LIST OF CHECKING AIDS
The “List of Checking Aids” is a compilation of tools, fixtures, or
instruments used to perform inspections and tests within the scope of the PPAP
process.
This list includes the necessary testing equipment required for verifying
product quality, conformity, and performance.
5.21 SUB SUPPLIER SOURCE DETAILS
Sub Supplier Source Details play a crucial role in the PPAP process to ensure
transparency and traceability of the supply chain.
In the context of PPAP, Sub Supplier Source Details are crucial to ensure that
the materials or components used come from trusted and qualified suppliers.
They help identify potential risks, bottlenecks, or quality issues in the
supply chain and take appropriate actions.
PRODUCTION PROCESS AND PRODUCT APPROVAL
Formal series deliveries may only take place once an explicit production
process and product approval of the PPAP has been granted by sonnen GmbH.
Any special releases are to be defined based on quantity or time and must be
approved in writing by sonnen.
Under certain circumstances, sonnen reserves the right to conduct a process
audit at the supplier’s premises for decision-making purposes.
The supplier will provide the best possible support to sonnen in this regard
and commits to addressing any discrepancies identified in the audit report in
a timely manner.
The approval of samples does not release the supplier from the responsibility
for the quality of their products, nor does the approval of samples constitute
a purchase order.
PARTIAL SAMPLING IN CASE OF CHANGES
Only the characteristics/specifications affected by the change and, if applicable, the inspection and functional dimensions on the drawing need to be submitted for approval. The formal procedures for initial submissions described earlier apply in this case.
EXEPTIONS
Deviations from the specifications and requirements mentioned in this document can be granted by mutual agreement between the SUPPLIER and sonnen’s Quality Assurance. Exceptions are to be documented in writing as part of the Initial Sample Inspection Report.
NON-COMPLIANCE
In case of non-compliance with the agreed provisions according to the PPAP guideline, the following consequences are possible:
- Delays in Approval: Failure to meet the agreed-upon requirements can result in delays in product approval for mass production. Further actions and corrections will be necessary to ensure product quality and conformity.
- Rework or Recall: If the non-compliance is significant and affects product quality or safety, it may be necessary to perform rework or even recall products to address potential risks or issues.
- Contractual Penalties: In case of serious non-compliance with the agreed provisions, contractual penalties or financial sanctions may be imposed. These serve as incentives to ensure compliance with the agreed conditions.
- Loss of Trust: Non-compliance with the agreements can lead to a loss of trust between the parties involved. This can affect the business relationship and future engagement.
It’s important to note that the exact consequences of non-compliance with the agreements can vary from case to case. Careful review and compliance with the agreed provisions is of utmost importance to avoid possible negative consequences.
APPENDIX
