Production Part Approval Process

RBAU

SUPPLIER INSTRUCTION ISSUED BYPUR

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AUTHORPUR Section 9. Supplier PPAP ED./AMEND.

3/0ISSUE DATE15/06/01

Effective Date Change History

15/06/01 Reviewed & revised18/09/00 Adjustments to 2.2 Submission of PPAP04/12/98 New procedure

If printed, document is uncontrolled and is the user’s responsibility to check that this document reflects the latest revisionlevel. Print Date: 26/07/01

CONTENTS

1. INTRODUCTION 2

1.2 Purpose 2

1.3 Applicability 2

1.4 Definitions 2

2 PROCEDURE

2.1 When Submission is Required 3

2.2 Submission of PPAP 3

2.3 Approval Process 4

2.4 Delivery Types Summary 5

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If printed, document is uncontrolled and it is the user’s responsibility to check that this document reflects the latest revisionlevel. Print date: 26/07/01

1 Introduction

Production part review and approval is required for each part before the first shipmentof production quantities to RBAU. Review of the Purchased parts at RBAU is inaccordance with the requirements of the QS9000 PPAP (Production Part ApprovalProcess).

1.2 Purpose

The purpose of Production Part Approval Process is to determine if all RBAUProduction drawing and specification requirements have been met by the supplier, andto ensure that the manufacturing process has the potential to meet these requirementson an ongoing basis.

Production parts are only to be delivered to RBAU after the PPAP has been approved,or with a prior approved RBAU concession to authorise shipment from supplier.

The Concession number must be quoted on the delivery documentation for all stockshipped under Concession.

The Supplier has the responsibility to ensure that Concession authorised quantitiesand expiry dates are not exceeded.

1.3 Applicability

All direct production materials supplied to RBAU.

1.4 Definitions

RBAU : Robert Bosch (Australia) Pty. Ltd.PGQP: Purchased Goods Quality PlanPLP: Purchasing Launch PlanPPAP: Production Part Approval ProcessPUR: Purchasing – RBAU Dept.RFQ: Request For QuotationQS9000: Quality System as defined by GM, Chrysler & Ford.

Automotive Industry StandardOOPT: Out of Present Tooling

QS9000 Manuals available from:

AIAG (USA): 26200 Lahser Road, Suit 200 Southfield, MI 48034Ph.(248) 358 3003 Fax: (248) 358 3253

FAPM (Aust): GPO Box 295, Canberra ACT 2601,Ph. (612) 6247 4177 Fax (612) 6257 4651E-mail: [email protected]

mailto:[email protected]

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2 Procedure

2.1 When Submission is Required

Production Part Approval Process by RBAU is always required before the firstproduction shipment of product for situations specified in “When Submission isRequired” section of the QS9000 PPAP Manual.

Make sure to contact your RBAU Buyer or Supplier Quality Engineer if there is anyquestion concerning the PPAP.

The Supplier will be requested by RBAU to prepare a PPAP submission for any ofthese situations.

It is the responsibility of the Supplier to notify the RBAU Supplier Quality Engineerwhen any of the changes requiring submission in the QS9000 PPAP Manual, will occuror have occurred without prior instruction from RBAU. The supplier will be advised byRBAU of the resulting obligation for PPAP submission.

2.2 Submission of PPAP

2.2.1 New Projects/Parts/Suppliers:

Once RBAU has selected the supplier, a PLP (refer PLP Instruction) is sent to thesupplier stating PPAP submission requirements.

If specified in the PLP, a PGQP (refer PGQP Instruction) is to be agreed upon byRBAU & Supplier to ensure the necessary controls are in place for the qualitymanufacture of production stock.

The PPAP Submission is to be compiled by the supplier in accordance with the PLPChecklist.

If the samples or documentation do not comply fully with RBAU specifications and/orthe PLP Checklist, the supplier must correct or obtain a written acceptance from RBAUvia the Supplier Quality Engineer. This acceptance must be submitted with PPAP.

The supplier is to pack PPAP Samples & Documentation together but separate fromother deliveries. This package is to be clearly marked “PPAP Submission”, and thePPAP Order Number is to be quoted on all delivery documentation.

The PPAP will be assessed by RBAU and the supplier advised of the disposition.

PPAP Re-submission:

The Re-Approval of a part may be initiated by either RBAU or the supplier.

When the Re-Submission is initiated by RBAU, the supplier will be instructed to re-submit PPAP, and will be provided a PLP to nominate the requirements for the PPAP.

If there is a change at the suppliers premises that necessitates Re-Submission, asspecified by the QS 9000 guidelines, this must be advised to RBAU Purchasing buyeror the relevant Supplier Quality Engineer.

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RBAU will advise the supplier of the PPAP requirements, and provide the supplier witha PLP to specify the requirements for the PPAP submission.

2.3 Approval Process

Confirmation of the PPAP disposition will be via letter from PUR. The supplier PPAPsubmission will be evaluated for conformance to the requirements specified in the PLPand PPAP order.

The following table shows the options for the disposition of the PPAP. The scoresallocated to each PPAP are also shown. These scores are used for evaluation thesuppliers PPAP performance.

Approved Fully Approved (Part Fully Conforms to RBAU Requirements). 0

Approved Fully Approved (Drawing to be updated with OOPT waivers). 0

Approved Fully Approved but Submission Delivered Late 1

Approved Fully Approved but Submission Documents Incomplete 2

Approved Fully Approved but Submission Delivered Late and ProductionAffected

5

Provisional PPAP Parts used on Concession 1

Rejected Parts are non conforming 3

Rejected Parts are non conforming and Production Affected 5

Rejected Parts are non conforming and rejected on Re-Submission 6

Rejected Parts are non-conforming and Rejected on Re-Submission andProduction Affected

8

Rejected Parts conforming to specification, functionally non conforming 0

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1.4 Delivery Types Summary:

This Matrix clarifies the different types of part deliveries to RBAU:

Production DeliveriesEngineering Samples PPAP Submission

PPAP Approved Concession

Order Type: Engineering SamplesOrder

PPAP Order Production Order Approved Concession +Production Order

PartsOrdered for:

Engineering PrototypeSamples

RBAU processevaluation

RBAU Part Evaluation

PPAP ApprovalSubmission Only

RBAU Production RBAU Production

DeliveryInstructions:

Pack Separately fromother parts.

Separate DeliveryDocuments.

Identify delivery as“EngineeringSamples”.

PPAP Order exclusivelyused for PPAPsubmissions includingall documents.

Pack samples and alldocuments together butseparate from otherdeliveries.

Package labelled as“PPAP Submission”

PPAP deliverydocuments to quotePPAP Order Number.

Part must be PPAPApproved by RBAU.

Ship stock toProductionschedule.

If part is not PPAPapproved by RBAU,stock must not beshipped unless aconcession has beenauthorised.

Quote ConcessionNumber on deliverydocuments for allshipments.

Supply to productionschedule but concessionquantity/date limits mustnot be exceeded.

SupplierInstruction:

Engineering Samples PPAP, PLP, (PGQP) PPAP, Delivery PPAP, Delivery

Production Part Approval Process

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