Supplier (AIAG) PPAP / (VDA) PPA Book Checklist

This Checklist / Sheet applies to Supplier (AIAG) PPAP. Please refer to other worksheet for (VDA 2) PPA requirements as needed.

Date
JTEKT Part Number Revision Revision Date

Part Name JTEKT APQP Contact:

Program: FSQM-080
Supplier: IMDS submission required to Site: 57229

Supplier JTEKT
Preliminary Preparations OK N/G N/A OK N/G References

Are All re-PPAP orders (Off Tool and/or Off Process) shipments accompanied by 100% inspection data on at
A least 3 pieces, and properly labelled with DELIVERY LABEL of SAMPLES form on the BOX? FORM # FSQM-013 SQAM 2.2.1, 2.2.2, 2.2.3, 2.3.1, 2.3.2

B Blue PPAP Binder prepared, with Labelled Dividers, per JTEKT SQAM. SQAM 2.2.3, FSQM-017

C Supplier Production Readiness complete? SQAM 2.1.2, FSQM-011, FSQM-012, FSQM-012 pg2

D Are Packaging and IMDS approvals obtained prior to PPAP submission? SQAM 1.8

E PPAP Production Run scheduled (minimum 300 pieces or 8 hours of production) SQAM 2.2, AIAG PPAP 4th ed.

Section 1 JTEKT Internal Approval Section OK N/G N/A OK N/G

1 Section left blank for JTEKT internal use. SQAM 2.2.3

Section 2A Part Submission Warrant (must use AIAG format) OK N/G N/A OK N/G

2 Correct Part Name (from Print)? SQAM 2.2.3, AIAG PPAP 4th ed.

3 Correct JTEKT part number (not drawing number)? SQAM 2.2.3, AIAG PPAP 4th ed.

Is this a safety and/or government regulation, in other words, are there any Safety Characteristics on the print?
4 SQAM 2.2.3, AIAG PPAP 4th ed.

5 Correct part engineering drawing change level/date? SQAM 2.2.3, AIAG PPAP 4th ed.

6 Additional engineering changes noted and dated? SQAM 2.2.3, AIAG PPAP 4th ed.

7 Correct drawing number? SQAM 2.2.3, AIAG PPAP 4th ed.

8 Correct P.O. Number, Include copy of pg.1 of JTEKT PO in PPAP? SQAM 2.2.3, AIAG PPAP 4th ed.

9 Correct weight to 4 decimal places and referenced in kilograms? (0.0000kg) SQAM 2.2.3, AIAG PPAP 4th ed.

10 Was part weight calculated using ten randomly selected parts and based on a ten piece average? SQAM 2.2.3, AIAG PPAP 4th ed.
11 Are checking aids referenced? SQAM 2.2.3, AIAG PPAP 4th ed.

12 Correct checking aid engineering change level/dated? SQAM 2.2.3, AIAG PPAP 4th ed.

13 Has the supplier manufacturing information section been completed, including supplier code? SQAM 2.2.3, AIAG PPAP 4th ed.
14 Has the submission information section been completed? SQAM 2.2.3, AIAG PPAP 4th ed.

15 Proper reason for submission been entered correctly? SQAM 2.2.3, AIAG PPAP 4th ed.

16 Proper PPAP submission level entered correctly? SQAM 2.2.3, AIAG PPAP 4th ed.

17 Has the declaration completed and were parts produced per 8 Hr. shift? SQAM 2.2.3, AIAG PPAP 4th ed.

18 Have the submission results been submitted? SQAM 2.2.3, AIAG PPAP 4th ed.

19 Are the results from all mold/cavities/production process, etc.? SQAM 2.2.3, AIAG PPAP 4th ed.

20 Explanation completed (Include ECR, if applicable) SQAM 2.2.3, AIAG PPAP 4th ed.

21 Has the supplier signed the warrant? SQAM 2.2.3, AIAG PPAP 4th ed.

22 Are the approved PSW's from sub-suppliers included in the PPAP? SQAM 2.2.3, AIAG PPAP 4th ed.

Section 2B Certifications OK N/G N/A OK N/G

23 Current Certificate of Registration to ISO9001 or ISO/TS16949? On file in supplier GASL is acceptable.

24 Customer Requirements for PPAP reviewed, requested, and included in PPAP submission.
Section 2C Design Records of Saleable Product OK N/G N/A OK N/G

25 JTEKT Print, matches what is released / on Purchase Order SQAM 2.2.3

26 Each Characteristic is ballooned, including notes. SQAM 2.2.3

Section 2D Engineering Change Documents, if any OK N/G N/A OK N/G

27 Engineering Change not yet recorded FSQM-003

28 Supporting Documents w/ approval, if required FSQM-003

Section 2E Customer Engineering approval OK N/G N/A OK N/G

29 Reason for change defined, using Engineering Change Request form? FSQM-003

30 Approval signed by JTEKT, with E.C.R. number assigned and noted on PSW? FSQM-003

Section 3A Process Flow Diagram OK N/G N/A OK N/G See

31 Up to date process flow diagram? SQAM 2.2.3, FSQM -008

32 Do all process steps noted in PFMEA, Control Plan, and Flow Chart match? AIAG PPAP 4th Ed.

Section 3B Control Plan (must use AIAG format) OK N/G N/A OK N/G

34 Is part number correct? AIAG PPAP 4th Ed.

35 Is revision number correct? AIAG PPAP 4th Ed.

36 Is the header filled out correctly AIAG PPAP 4th Ed.

37 Is engineering change addressed in control plan? AIAG PPAP 4th Ed.

38 Have predictive maintenance procedures or predictive maintenance plan been included in PPAP? AIAG PPAP 4th Ed.

39 Do control plan steps follow the Flow chart, & FMEA? AIAG PPAP 4th Ed.

40 Special Characteristics match FMEA and Flow? AIAG PPAP 4th Ed.
41 Diamond C critical characteristics either Poke-Yoked or controlled via statistical methods? SQAM 1.5.1, AIAG PPAP 4th ed.

42 Safety critical characteristics either 100% inspected or Poke-Yoked? SQAM 1.5.1, AIAG PPAP 4th ed.

43 Heat / Lot Number of raw materials matching certification is verified? SQAM 1.4

44 Traceability and identification, including inspection results, are controlled from Raw Material to Finished goods SQAM 1.4, 3, 11.5

45 Is New Product Containment Control Plan / Safe Launch Identified for new products? SQAM 1.7.4

46 Is the annual layout defined in the Control plan? SQAM 2.4

Section 3C Checking Aids/Inspection standards OK N/G N/A OK N/G

47 Has Inspection Standard been included in the PPAP?

48 Documentation showing JTEKT engineering sign-off on all JTEKT funded tooling and gauging?
Does Inspection Standard include use of JTEKT form or equivalent, showing linkage to control plan, gaging
49 practices, frequencies, sample sizes, etc.
Section 4A Design FMEA, If Required - Design Responsible OK N/G N/A OK N/G

50 Is part number correct? AIAG FMEA 4th Ed.

51 Is revision number correct? AIAG FMEA 4th Ed.

52 Has the supplier identified recommended actions for Severity rankings of 9 & 10? Are they also Safety Critical? AIAG FMEA 4th Ed.

53 Is "NONE" in recommended actions if no action? AIAG FMEA 4th Ed.

54 Is DFMEA to 4th Edition? AIAG FMEA 4th Ed.

55 Is Severity, Occurrence, & Detection criteria to 4th Edition? AIAG FMEA 4th Ed.

Section 4B Process FMEA (Must use AIAG format) OK N/G N/A OK N/G

56 Is part number correct? SQAM 2.2.3, AIAG FMEA 4th ed.

57 Is revision number correct? SQAM 2.2.3, AIAG FMEA 4th ed.

58 Is the DFMEA and Flow Chart available for developing the PFMEA? SQAM 2.2.3, AIAG FMEA 4th ed.
59 Have the DFMEA Special Characteristics and Severities been carried over to the PFMEA? SQAM 2.2.3, AIAG FMEA 4th ed.

Review and gain approval of Supplier's PFMEA with Subject Matter Experts - JTEKT Product Engineering,
Project/Process Engineering, and Quality Engineering - to ensure supplier controls are appropriate, Lessons
60 Learned Failures identified, with all controls in place both at the supplier and JTEKT. SQAM 2.2.3, AIAG FMEA 4th ed.

61 Has the supplier identified recommended actions for Severity rankings of 9 & 10 (if design responsible)? SQAM 2.2.3, AIAG FMEA 4th ed.

62 Has the supplier self identified Special Characteristics if the Severity = 5-8 AND Occurrence = 4-10? SQAM 2.2.3, AIAG FMEA 4th ed.

63 Has the supplier self identified KC's if the Severity = 5-8 AND Occurrence = 3 or less? SQAM 2.2.3, AIAG FMEA 4th ed.
64 Is "NONE" in recommended actions if no action? SQAM 2.2.3, AIAG FMEA 4th ed.

65 Recommended actions include responsible person/department & completion date present SQAM 2.2.3, AIAG FMEA 4th ed.

66 Recommended action follow up is not past due SQAM 2.2.3, AIAG FMEA 4th ed.
67 Process descriptions match flow and control plan steps SQAM 2.2.3, AIAG FMEA 4th ed.

68 All potential failure modes are present & appropriate SQAM 2.2.3, AIAG FMEA 4th ed.
69 S, O, D, RPNs calculated correctly SQAM 2.2.3, AIAG FMEA 4th ed.

70 Is PFMEA to 4th Edition? (Inc: Identification of Prevention/Detection Controls) SQAM 2.2.3, AIAG FMEA 4th ed.
71 Is engineering change addressed in PFMEA? SQAM 2.2.3, AIAG FMEA 4th ed.

FSQM-080 Page 1 of 14 2/11/2011 Revision: 3

 Supplier (AIAG) PPAP / (VDA) PPA Book Checklist

This Checklist / Sheet applies to Supplier (AIAG) PPAP. Please refer to other worksheet for (VDA 2) PPA requirements as needed.

Date
JTEKT Part Number Revision Revision Date

Part Name JTEKT APQP Contact:

Program: FSQM-080
Supplier: IMDS submission required to Site: 57229

72 Are detection and prevention addressed in PFMEA? (incl new 4th ed detection rankings) SQAM 2.2.3, AIAG FMEA 4th ed.

73 Is Severity, Occurrence, & Detection criteria to 4th Edition? SQAM 2.2.3, AIAG FMEA 4th ed.

Section 5 Capabilities Studies OK N/G N/A OK N/G

74 Have capability studies been performed on all special characteristics listed on print? SQAM 1.5, SQAM 2.2.3, AIAG PPAP 4th ed, AIAG SPC 2nd ed.

75 PPK greater than 1.67 on a normal distribution (P > 0.05) for special characteristics? SQAM 1.5, SQAM 2.2.3, AIAG PPAP 4th ed, AIAG SPC 2nd ed.
Pp & Ppk results shall taken from a minimum of 30 pieces of data from each cavity of a multiple die or mold,
76 each process, and tooling? SQAM 1.5, SQAM 2.2.3, AIAG PPAP 4th ed, AIAG SPC 2nd ed.

Section 6A Dimensional Results / Analysis OK N/G N/A OK N/G

77 Are all dimensions ballooned on print and all documented on layout? (include results of basic dimensions) SQAM 2.2.3, AIAG PPAP 4th ed
78 Is all information on layout report, including notes? SQAM 2.2.3, AIAG PPAP 4th ed

79 At least 3 parts measured AND submitted (delivered) with PPAP? SQAM 2.2.3, AIAG PPAP 4th ed
80 At least 1 part per cavity measured AND submitted (delivered) with PPAP? SQAM 2.2.3, AIAG PPAP 4th ed

81 Part number correct? SQAM 2.2.3, AIAG PPAP 4th ed

82 Revision level correct? SQAM 2.2.3, AIAG PPAP 4th ed

83 Date correct? SQAM 2.2.3, AIAG PPAP 4th ed

Have out of tolerance dimensions been properly noted as out of tolerance on layout and PSW?
NOTE: Do Not submit PPAP if parts are out of tolerance, unless special arrangements and approvals have been
84 made with S.A.E. or S.Q.E. SQAM 2.2.3, AIAG PPAP 4th ed
85 Is the report marked Approved or Rejected? SQAM 2.2.3, AIAG PPAP 4th ed

86 Does the report have a approval signature? SQAM 2.2.3, AIAG PPAP 4th ed
87 Part name on layout? SQAM 2.2.3, AIAG PPAP 4th ed
88 Customer part number layout? SQAM 2.2.3, AIAG PPAP 4th ed
89 Date of layout? SQAM 2.2.3, AIAG PPAP 4th ed
Section 6B Performance Test Results OK N/G N/A OK N/G

90 All testing completed? SQAM 2.1, 2.2.1, 2.2.2, 2.2.3

91 Tests have Results noted Pass/Fail criteria? (Statement of conformance only is not acceptable) AIAG PPAP 4th ed.

92 Test Results Signed and Dated? AIAG PPAP 4th ed.

93 Are copies of test specifications included in PPAP? SQAM 2.1, AIAG PPAP 4th ed.
94 All documentation complete to match all specifications? SQAM 2.1, AIAG PPAP 4th ed.

Do all results come from suppliers internal lab with scope defined/submitted or external lab with ISO/IEC 17025
95 lab cert?
Section 7A Measurement System Analysis R & R OK N/G N/A OK N/G

96 New R&R for any changes to gage? SQAM 1.5, SQAM 2.2.3, AIAG PPAP 4th ed, AIAG MSA 2nd ed.

97 R&R / MSA present for ALL gauges shown on control plan? AIAG PPAP 4th ed, AIAG MSA 2nd ed.

98 R&R / MSA performed on product/parts being PPAP'd rather than surrogate product/parts? AIAG PPAP 4th ed, AIAG MSA 2nd ed.

99 3 Appraisers, 3 Trials, 10 parts for variable gauges on parts that represent the maximum variation seen? AIAG PPAP 4th ed, AIAG MSA 2nd ed.

3 Appraisers, 3 Trials, 50 parts for attribute gauges on parts/product being PPAP'd that represent the maximum
100 variation seen? AIAG PPAP 4th ed, AIAG MSA 2nd ed.

101 Action plan REQUIRED for R&R ³ 10% and £30% AIAG PPAP 4th ed, AIAG MSA 2nd ed.
102 Is percent study variation and ndc (discrimination) included? AIAG PPAP 4th ed, AIAG MSA 2nd ed.
103 Corrective action issued for failed gage R&R? AIAG PPAP 4th ed, AIAG MSA 2nd ed.

Section 7B Material Performance Test Results OK N/G N/A OK N/G

104 All testing completed? SQAM 2.1, 2.2.1, 2.2.2, 2.2.3

105 Tests have Results noted Pass/Fail criteria? (Statement of conformance only is not acceptable) AIAG PPAP 4th ed.

106 Test Results Signed and Dated? AIAG PPAP 4th ed.
107 Are copies of specifications included in PPAP? SQAM 2.1, AIAG PPAP 4th ed.

108 All documentation complete to match all specifications? SQAM 2.1, AIAG PPAP 4th ed.
109 All material Certs. for all sub components/materials, with results? SQAM 2.1, AIAG PPAP 4th ed.

110 Materials purchased from OEM approved sources, with approval evidence included in PPAP? Customer Specific Requirements
111 Do all material Certifications contain specification as noted per drawing? SQAM 2.1, AIAG PPAP 4th ed.
Do all results come from suppliers internal lab with scope defined/submitted or external lab with ISO/IEC 17025
112 lab cert? SQAM 2.2.3
Has complete restricted substance and IMDS information been included in PPAP, showing proof of submission to
113 the correct facility? SQAM 2.2.3
Have Norms and References (for raw materials) been included in the IMDS submission, using existing materials
114 in IMDS whenever possible? SQAM 2.2.3
Section 8 Tooling OK N/G N/A OK N/G

Has supplier submitted tooling record (FSQM-005) to purchasing for each item or assembly classified as
115 Customer and/or JTEKT owned tooling? SQAM 2.2.3
Sample Product OK N/G N/A OK N/G

116 Has a minimum of 3 PPAP sample pieces, 100% dimensionally inspected (see section 6) been provided? SQAM 2.2.1

Have PPAP samples been properly labelled/tagged with DELIVERY LABEL of SAMPLES on the BOX? FORM #
117 FSQM-013 SQAM 2.2.2. 2.3.1

118 Does the same container of samples also contain the required Blue PPAP Binder? SQAM 2.2.3
119 Are these 3 (minimum) samples the same samples that were used for the dimensional analysis? AIAG PPAP 4th ed.

1120 Were these samples randomly collected from the same 300 pieces (minimum) PPAP production run? AIAG PPAP 4th ed.
Master Sample OK N/G N/A OK N/G

121 Has a master PPAP sample (per cavity/process) been measured, evaluated, and retained at the Supplier? AIAG PPAP 4th ed.
122 Does this master sample have the same measurements (range) as the submitted samples? AIAG PPAP 4th ed.

ACCEPTED REJECTED

Reviewed By Date

FSQM-080 Page 2 of 14 2/11/2011 Revision: 3

 Supplier (AIAG) PPAP / (V
Form #:

This Checklist/sheet applies to Supplier (VDA 2) P

The (VDA 2) PPA requires some additional documents and activities, a

documents and activities required in the (AIAG) PPAP. However, JT
PPAP, and will therefore require additional documents (shown below)
such, this checklist is to be used IN ADDITION TO the PPAP (AIAG)
require Supplier PPA instead of PP

See Matrix at bottom of this checklist for applications differences be

Date
Part Number Revision
Part Name APQP Contact:

Program:
Supplier: IMDS submission required to Site:

Additional Section 1
(VDA 2 ref Section 8) Software Test Report

1 Has the Software Validation been documented using the VDA-2 Appendix 6 "So
2 Has the ASPICE level been validated on site by a qualified JTEKT ASPICE assess
3 Has the Software Test Report Form been reviewed and approved by JTEKT's So
Additional Section 2
Tooling List
(VDA 2 ref Section 16)

4 Has the tooling concept been reviewed and approved by JTEKT Process Engine
5 Is a tooling list / final concept included in the PPAP/PPA?
6 Does the Tooling list include the quantity of tools and number of cavities intend
7 Is the tooling design included in the PPAP/PPA submission?
 Additional Section 3 Capacity Confirmation
(VDA 2 ref Section 17)

8 Is there a documented Capacity Confirmation?

9 Was this capacity confirmed over at least 1 shift, or other agreed upon product
10 Is the documented Capacity Confirmation rate also listed on the PSW?
11 Has the purchasing buyer confirmed the capacity matches the quoted capacity?
Additional Section 4 Written self-assessment of criteria as per evaluation matrix for production
(VDA 2 ref Section 17)

12 Has the Production Maturity been evaluated in concert with the Capacity Confir
13 Has the Production Maturity been documented using the 2 page, Appendix 7, P
14 Is the Production Matrix complete, reviewed, and signed by the supplier?
Additional Section 5 Confirmation of Suitability of the product carrying units, including storage.
(VDA 2 ref Section 20)

15 See PPAP AIAG Checklist deliverable Control Plan item for Packaging.
Additional Section 6 PPA status of the supply chain (purchased parts, directed parts, and in-hou
(VDA 2 ref Section 21)

16 Are sub-tier supplier PPA's available and submitted within the supplier's PPA?

Additional Section 7 Approval of Coating Systems in accordance with customer requirements.

(VDA 2 ref Section 22)

19 See PPAP AIAG Checklist deliverable for CQI-12

ACCEPTED

Reviewed By
(AIAG) PPAP / (VDA) PPA Book Checklist
REVISION: #VALUE!
REVISION DATE: #VALUE!

plier (VDA 2) PPA Requirements.

and activities, and in some cases, does not require the

P. However, JTEKT requires ALL suppliers to submit
(shown below) when our customers require PPA. As
e PPAP (AIAG) Checklist when customer specifically
A instead of PPAP.

s differences between PPAP (AIAG) and PPA (VDA).

Revision Date

on required to Site:

Supplier

OK N/G N/A OK N/G

VDA-2 Appendix 6 "Software Test Report" form?

JTEKT ASPICE assessor?
pproved by JTEKT's Software Engineering?
OK N/G N/A OK N/G

JTEKT Process Engineering?

mber of cavities intended for use?

n?
 OK N/G N/A OK N/G

agreed upon production duration?

on the PSW?
s the quoted capacity?
n matrix for production maturity for product and process. OK N/G N/A OK N/G

th the Capacity Confirmation?

2 page, Appendix 7, Production Maturity Matrix?
by the supplier?

nits, including storage. OK N/G N/A OK N/G

Packaging.

ected parts, and in-house parts) OK N/G N/A OK N/G

the supplier's PPA?

tomer requirements. OK N/G N/A OK N/G

REJECTED

Date
Revision History
DATE REV #
3-May-16 1
ion History
REVISION
Initial Draft
Rev By
M. Filley