2.2.2 Quality – PPAP

Purpose:

To explain Veoneer specific instructions concerning the AIAG PPAP requirements

Input from Veoneer:

• PPAP request
• Veoneer released drawings and specifications
• PPAP checklist, if required by Veoneer.

Requirements:

General:

• The default level for PPAP submissions is 3, unless specified otherwise by the responsible part approving body. The supplier is responsible for ensuring all PPAP elements are kept up to date to reflect the current approved part and process whenever required to be submitted.
• All documents shall be in English.
• Laboratory data in the original PPAP submission must be less than 12 months old.
• Traceability for PPAP parts shall meet the same requirements as serial parts
• Additional elements may be added to the PPAP process due to Veoneer's specific customer demands
• The PPAP approval is not a production nor a delivery signal. The supplier shall wait for further delivery information/schedules from the Veoneer receiving plants. Reference VSM-Quality Requirements/"PPAP"
• In the event that another Veoneer plant plans to place orders for a part which already has an Veoneer PPAP approval, the PPAP release process shall not be repeated. A supplier PPAP approval by one Veoneer plant is also valid for all other Veoneer plants. The (approved) PPAP documentation may be requested by Veoneer just to confirm the original approval.
• Re-submitted samples following rejection must be accompanied by all relevant documentation as required for the original PPAP samples.

PPAP basic requirements for each item:

1. Design Records of Saleable Product

The supplier shall include 2-dimensional controlled copies of the design records. The records include component drawings, product specifications and hardware / software specifications.

1.1 IMDS-Declaration of Material (done in IMDS database)

Documentation of an approved IMDS declaration. Material composition is declared within IMDS and sent to Veoneer through the IMDS system. Documentation of an approved IMDS declaration shall be included within the PPAP package. As a consequence, the supplier shall complete the IMDS entry in the IMDS database a reasonable time period before the agreed PPAP submission date. This procedure will give Veoneer the opportunity to approve the IMDS entry prior to the supplier's PPAP submission date. In case Veoneer does not respond to the IMDS declaration before supplier's PPAP submission date, it is sufficient for the supplier to submit only the IMDS entry confirmation with the PPAP package. PPAP approval can only be done with an approved IMDS Declaration. (IMDS Reporting Guideline)

Since the IMDS declaration is a full declaration of materials, the absence of forbidden substances will be confirmed by the IMDS declaration. (Ref. VS005 and VSM General Requirements/General/Environment).

2. Engineering Change Documents

The supplier shall include any authorized engineering change documents not yet recorded in the design records but implemented in the product, part or tooling. (Supplier Change Request)

3. Customer Engineering Approval

If samples are evaluated by Veoneer e.g. form, fit or function, the approval and comments shall be documented. Samples shall be delivered to Veoneer for approval (Ref. AIAG PPAP Manual - ESA form)

4. DFMEA

If the supplier is design responsible, the supplier shall include their reviewed and approved D-FMEA.

Ensure all CC/SC characteristics have been identified and included from the design records and that actions have been defined and implemented during design phase. (Ref. VS052)

5. Process Flow Diagram

Flow diagrams that clearly describe the production process, steps and sequence. All steps in the manufacturing process shall be identified and keyed to the PFMEA and Control Plan. Traceability requirements confirmed by a traceability specific flow chart, (Ref. See VS004, VS244)

6. Process FMEA

Reviewed and approved P-FMEA for actual process, all steps shall be keyed to Flow Chart and Control Plan. Ensure all CC and SC characteristics have been identified and included from the design records and D-FMEA, including manufacturing process Special Characteristics and that actions have been defined and implemented. (Ref. VS052)

7. Control Plan

Production Control Plan, keyed to Process Flow Diagram and the P-FMEA. CC/SC and process special characteristics shall be identified and methods to control defined on the Control Plan. Any rework/repair operations shall be approved by Veoneer and included. Layout Inspection shall be included in control plan.

8. Measurement Systems Analysis Studies

Reports of MSA analysis performed on all test and measuring methods used for serial production as referenced in the Control Plan. Gauge R&R and measuring data shall be reported for all measuring methods used to accept product, and noted on control plan, including operators, material and environmental variations. Special attention shall be paid on methods used for verifying special characteristics CC/SC. Gauges funded or directed by Veoneer to be included. ( Reference AIAG Manual MSA )

9. Dimensional Results

Reports of all dimensions and parameters documented in the design records for all cavities and each unique manufacturing process. The dimensional report must be keyed to the design record (ballooned).

The supplier shall respond to each drawing note and specification item and blanket statements are not allowed, test results and a “pass / fail” statement is required. Number of samples unless otherwise agreed is five (5).

10. Material / Performance Test Results

When design records or Control Plans specify chemical, physical, metallurgical performances and / or functional requirements the supplier shall be responsible to ensure that the tests are performed for all parts and product materials:

a) Functional measurement; Report of the products functional characteristics, e.g. electrical measurements, sensitivity, force etc.

b) Material performance; Report of the products material characteristics, e.g. structural strength, retention force, composition etc.

c) Validation results; Report of the products performance/reliability qualification, e.g. vibration, moisture, ESD, temperature etc.

For semiconductor devices and electronic components, tests according to AEC Q-standards is required. e.g. Q-100.

d) Characterization; Reports of characterization according to AEC Q-003 is required for semiconductor devices.

All testing shall be less than one (1) year old at the time of PPAP and serial status on product and process. Blanket statements are not allowed, test results and a “pass / fail” statement is required e.g. CFG 1004/1005.

11. Initial Process Capability Studies

The supplier shall provide a preliminary process capability study (Ppk) on all CC’s and SC's.

Default requirement is Ppk studies required on all CC’s and SC’s as indicated on Veoneer drawings and related specifications. Reports of capability studies performed on defined process steps and product characteristics, > 100 parts from continuous production measured. For unstable processes corrective actions has to be implemented.

Processes to be controlled by statistical methods to be identified and reported in control plan. Special requirements applies for CC/SC. Test results and a “pass / fail” statement is required. See VS052.

12. Qualified Laboratory Documentation

If the supplier uses an external laboratory, this has to be accredited to ISO/IEC 17025 (or equal regional accreditation) and include their ISO/IEC 17025 Certificate in the PPAP. If an internal lab is used the supplier shall provide evidence of ISO/IEC 17025, IATF 16949 or ISO 9001 certification, as well as a lab scope which defines all the tests the lab is able to perform.

13. Appearance Approval Report

If the part has appearance requirements ( i.e. structure and color), the supplier PPAP must include an Veoneer approved AAR. The supplier shall compile all surface data in one report for each part number. The AAR shall represent serial production. In case of required AAR the supplier has to retain released and signed off samples from Veoneer. The specific quality characteristics shall be clearly indicated on the samples or on an attached label. The amount of samples has to be defined with Veoneer.

14. Sample Product Parts

The supplier shall submit sample parts as requested by the using facility.

In case of required AAR the supplier has to retain released and signed off samples from Veoneer. The sample specific quality characteristics shall be clearly indicated on the samples or on an attached label. The amount of samples has to be defined together with Veoneer.

15. Master Sample Parts

Unless specified otherwise, the supplier shall:

• Identify three (3) parts identical to measured parts (see item 7 above), as Master Sample Parts and label them with Master Sample tags.
• retain two (2) Master sample Parts and submit one (1) with the PPAP submission.

16. Checking Aids

If requested by Veoneer, the supplier shall include in the PPAP submittal, any part specific Checking Aids. Checking Aids can include: fixtures, gages, models, templates, and/or mylars used to accept product, as identified in the Control plan. The supplier shall certify that all aspects of the Checking Aid(s) agree with the part dimensional and functional requirements. The supplier shall provide for preventive maintenance for any checking aids for the life of the part.

17.1 Approved VS005-Waiver Request

The submission requirements of this chapter are only applicable, if materials are designed or chosen by the supplier:

For any materials, components and products containing substances classified as forbidden (Ref. VS005: Declarable and Forbidden Substances List) the supplier must make sure that the Veoneer approved Waiver Request (Ref. VS005: Waiver Request Form for Forbidden Substances) is included in the PPAP package.

Note that the inclusion of the approved Waiver Request in the PPAP submission is to show the authorized use. The action to obtain this Veoneer authorization (approved Waiver Request) must take place prior to PPAP. (Ref. VS005 and VSM General Requirements/General/Environment).

17.2 Submission of VS 244 - label samples

The supplier shall submit a sample of serial representative labels properly filled out to verify its compliance to VS244 and any local requirements defined by the receiving plant, if requested by Veoneer. (Ref. AIAG, VS244)

17.3 Manufacturing Lot Traceability

The Supplier shall include a generic flow chart describing the product traceability system per VS004. This flow chart is to include their supplier traceability, receiving of material, production and shipping to Veoneer.

17.4 Special Processes Audits

If the Supplier is responsible for performing any "special process" per VS069 such as heat treating, plating, coating, welding, soldering or crimping, they are responsible to ensure a self audit or an Veoneer sponsored audit is performed each year. Results of the latest audit are to be submitted with the PPAP.

17.5 Packaging Instructions

Include copy of the packaging instructions if required.

17.6 Tool Asset Form

Check if a copy of the Tool Asset Form was sent to the proper party / location (if applicable).

18. Part Submission Warrant (PSW)

Completely filled out PSW, PPAP submission level is 3 unless otherwise directed by the Veoneer using facility. The supplier declares that all product and process requirements are fulfilled, unless otherwise stated. Sub-supplier PSWs to be available for review upon request. The PPAP is approved when the supplier receives a copy of the approved PSW.

19. Bulk Material Requirements (BMR) Checklist:

The supplier shall include a BMR checklist if it is required for bulk material.

Signature Blocks:

The supplier representative responsible for PPAP shall sign the PPAP.

Output from Supplier:

PPAP (Ref. VSM - General Requirements/ PPAP)

Required Documents:

As defined in VSM - General Requirements/ (PPAP)

Reference Documents:

• AIAG manuals
• VSM General Requirements/ Specific Requirements/ Quality - PPAP
• VSM General Requirements/Specific Requirements/ Logistics
• VSM General Requirements/General/Environment
• VS004 (Product Traceability)
• VS004 Appendix 1b - Traceability Flow chart (Supplier Example)
• VS004 Appendix 2 - Traceability Classification Levels
• VS004 Appendix 3 - Traceability Data Requirements Charts
• VS005 (Substance Use Restrictions)
• VS052
• VS 244
• VS 244 Appendices: see VSM Section 6.2 Templates
• Automotive Electronics Council (AEC) Manuals
• Supplier Change Request