PPAP

Readiness Review Checklist

Process
APQP
Documents

Molding

Debinding

Sintering

Process Requirements
1
2
3

PFD, Control Plan, PFMEA available and up to date.

Product KC's are identified and capability summary is presented.
All customer specs are identified and available.

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2
3
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5
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9
10
11
12

Work instruction(s) available and clearly describes the process?

Specs for green weight and validation evidence for how it was arrived at?
Run chart created in iQS for all trials starting from first off?
Injection peak pressure/packing pressure curves optimized? (will tool last for 30K shots?)
Mold set-up parameter sheet- specification for all key parameters in place?
Staging blocks/trays - Poke yoke In place so that parts will be placed right every time the same way?
Are there clear visual quality standards? Are limit samples required and if yes present?
Is the MHC signed off properly?
Is there a mold water line map?
Cycle time/day, per year. Will we meet customer's peak demand?
How many operators required to run the part per day?
Direct staging or indirect staging? Are adequate fixtures available to run the PPAP?

1 Work instruction(s) available and clearly describes the process?

2 Are specs for weight loss identified and previous run data in the system?
3 Output per day and will we meet customer's peak demand?
4 Capacity consumption of this part. How much strain does it cause on capacity?
1 Work instruction(s) available and clearly describes the process?
2 Route card is complete and meets standard?
3 Specs for sintering cycles are identified?
4 Regular material or new material? If new material has it been well validated?
5 Staging blocks/trays - Poke yoke In place so that parts will be placed right every time the same way?
6 Any special material handling after destaging necessary and if yes,available?
7 Output per day and will we meet customer's peak demand?
8 Capacity consumption of this part. How much strain does it cause on capacity?
9 Are adequate staging fixtures available to run the PPAP?
10 Manpower required for restaging?

Product:
Pass

Fail

Comments

Process

Process Requirements
1 Work instruction(s) available and clearly describes the process?

PSA (Dimn)

PSA (Lab)

ISP 1

2 iQS templates for all dimensions are created?

3 Capability data on dimensions that are achieved as-sintered?
4 Poke-yoke for avoiding mix-ups, bad parts etc in PSA
5 Review of actual measurements on parts in PSA stage with PPAP review committee
6 Review of defects seen in sample stage with PPAP review committee
7 Gages are in calibration system and calibrated? MSA studies evidence?
1 Density, carbon mapping of last samples?
2 Microstructural analysis available?
3 Any internal void,crack observed?
4 Density specs set and do they match with capability required for meeting dimensions?
5 Any special test requirements identified and documented?
1 Work instruction(s) available and clearly describes the process?
2 Is cell layout documented and being followed?
3 Are jigs, fixtures, tools identified and the set-up procedure is clear?
4 Gages are in calibration system and calibrated? MSA study eveidence?
5 Capability data on dimensions achieved at ISP1? First pass yield?
6 Demonstration of ISP1 operations and show actual measurements?
7 SPC being used and can be demonstarted? iQS setup where applicable?
8 Any poke yoke and source inspections on fixtures identified?
9 Is single piece flow followed? How will missed operations or mix-ups be avoided?
10 In-process material handling identified and available? Will it prevent product damage?
11 NC material handling is clear and will stop any mixups? Yellow and red bins present?
12 Visual quality criteria is clear and limit samples available if required?
13 Adequte lighting for the task? Operator ergonomics considered?
14 Output per day and will we meet customer's peak demand?
15 Capacity consumption of this part. How much strain does it cause on capacity?
16 Manpower required per day. Does it meet the iMIM 1000 pcs per shift/person target?
17 Special training if required is completed and can be verified?
1 Work instruction(s) available and clearly describes the process?
2 Is cell layout documented in WI and being followed?
3 Are jigs, fixtures, tools identified and the set-up procedure is clear?

Pass

Fail

Comments

Process

OSP

ISP2

Process Requirements
4 Gages are in calibration system and calibrated? MSA study eveidence?
5 Capability data on dimensions achieved in the process(es) being run?
6 Demonstration of OSP operations and show actual measurements?
7 Any poke yoke and source inspections on fixtures identified?
8 Is single piece flow followed? How will missed operations or mix-ups be avoided?
9 In-process material handling identified and available? Will it prevent product damage?
10 NC material handling is clear and will stop any mixups? Yellow and red bins present?
11 Visual quality criteria is clear and limit samples available if required?
12 Adequte lighting for the task? Operator ergonomics considered?
13 Output per day and will we meet customer's peak demand?
14 Capacity consumption of this part. How much strain does it cause on capacity?
15 Manpower required per day and does suppler have a plan to meet it?
16 Special training if required is completed and can be verified?
17 OSP supplier system audit score and process audit results acceptable?
1 Work instruction(s) available and clearly describes the process?
2 Is cell layout documented and being followed?
3 Are jigs, fixtures, tools identified and the set-up procedure is clear?
4 Gages are in calibration system and calibrated? MSA study eveidence?
5 Capability data on dimensions achieved at ISP1?
6 Demonstration of ISP2 operations and show actual measurements?
7 Any poke yoke and source inspections on fixtures identified?
8 Is single piece flow followed? How will missed operations or mix-ups be avoided?
9 In-process material handling identified and available? Will it prevent product damage?
10 NC material handling is clear and will stop any mixups? Yellow and red bins present?
11 Visual quality criteria is clear and limit samples available if required?
12 Adequte lighting for the task? Operator ergonomics considered?
13 Output per day and will we meet customer's peak demand?
14 Capacity consumption of this part. How much strain does it cause on capacity?
15 Manpower required per day. Does it meet the iMIM 1000 pcs per shift/person target?
16 Special training if required is completed and can be verified?

Pass

Fail

Comments

Process

Packaging

Audit Team:

Process Requirements

Pass

Fail

Work instruction(s) available and clearly describes the process?

Packaging burst/drop test done? Will it survive transit and prevent product damage?
Does packaging address any cleanliness or rust prevention requirements?
Part specific trays if required are avaoibale and adequate supply for PPAP?
Customer labeling and document requirements considered?
Packaging cost meets product budget?

Date(s):

Comments