Pre-Production Inspection Report (PPIR)

Process Overview
Forward Model Quality Programmes
Last update: 21 July 2015

PPIR
Process Overview

Introduction - What is PPIR?

PPIR in Relation to Project Timing

>

Underbody (UN)

>

Upperbody (UP)

Measurement Requirements

Expectations within Submission

Role of JLR Engineering

Role of Supplier

Role of JLR Programme Management Team

Role of Forward Model Quality (FMQ)

Auditing

PPIR
Introduction - What is PPIR?
Purpose
To confirm parts are to design intent, suitable for build and engineering sign-off
Equivalent of PPAP for any non-PSW parts in M1, VP and HTFB build phases
> Parts with new tooling or modifications both come under this category
> Software revision without physical changes will also require a PPIR
Timing
Distributed 4 weeks / 20 working days before MRD by Programme Team through
PPIR Tool
Must be returned & approved, before parts are shipped to JLR (and before MRD)
High Level Process
Engineering
Inform
Programme
Team of parts
requiring PPIRs
Agree
measurements
with suppliers

Programme
Team
Maintenance
and input of
data.
Send PPIR pro
forma through
tool

GSI Team /
ODEC
Support the
PPIR process
and manage
tool support

Supplier
Receive PPIR via
email
Complete PPIR
Return
completed
PPIRs to JLR to
PPIR@jaguarlan
drover.com

Engineering
Review PPIRs
for approval
Feedback any
issues to
supplier

PPIR
Introduction - What is PPIR? (cont.)
Approving a PPIR
The PPIR approval tool, managed by the GSI team, is only accepted method for JLR
engineering to confirm the status of a reviewed PPIR.
Whilst supplier do not have visibility of this tool, they will receive email
communications when:
> An approval status is allocated to a PPIR, or
> The PPIR has been rejected
The PPIR approval acts as a OK to ship for supplier, to send the parts to JLR

Rejected PPIR
A PPIR may be rejected because:
> Part deemed not fit for purpose due to deviations
> Submission failing PPIR audit, ie. minimum requirements not achieved
If a PPIR is rejected, the supplier is expected to make the necessary corrections and
re-submit

PPIR
In Relation to Project Timing - UN
PS

PSC

PTCC

PTC

iDJ
ATV 1
FMA
Plan

ATV2

PA

M1DJ
UNV1

Boundary Diagram
Interface Analysis

UNV2

M1 Dwg
M1DC

MRD
DJ

DJ

M1 Build

M1 Vehicle

Quality History
Functional Analysis

S-Rel

P-Rel

Parameter Analysis
Failure
Modes

Causes & Countermeasures

Identified

Actions Closed

YC/YS on SCSS &

Cascaded (Supplier & AME)

Supplier & AME Reviews

YC/YS Requirements

Notes
All activities are responsibility of Engineering
Forward Model Quality will coach, report and help facilitate
SCSS = Special Characteristic Summary Sheet (Supp K)
YC/YS = Potentially Critical / Significant characteristics

Final FM Risk
Assessment

Agree PPIR Content & Reqs with

Suppliers (all NTEI)

PPIRs required
for UNV

CC/SC Confirmed
Controls Identified (Supplier & AME)

4 Weeks

PPIR Template Issued to Supplier

PPIR Received & Approved by Eng

PPIR
In Relation to Project Timing - UP
PS

PSC

PTCC

PTC

iDJ
Virtual Series
Pre-VS (iDJ)

PA
FDJ

M1DJ

UPV0

UPV1

UPV2

Boundary Diagram

VP
DRAW

UPV3

MRD

DJ

DJ

VP Build

Interface Analysis
Quality History

T-Rel

P-Rel

Functional Analysis
Parameter Analysis
Failure Modes

Countermeasures
Identified

Causes Identified

Internal YC/YS on SCSS

& Cascaded to AME

AME Reviews
YC/YS Requirements
External YC/YS on SCSS
& Cascaded to Supplier

Notes
Discussions with AME and Suppliers to review FMEA,
special characteristics and measurement requirements,
should be regular and on-going
Although not shown here, the requirement and process
for PPIR repeats for HTFB

Actions Closed

Final FM Risk
Assessment

AME CC/SC Confirmed

Controls Identified
Supplier Reviews
YC/YS Requirements

Supplier CC/SC Confirmed

Controls Identified

Agree PPIR Content & Reqs with

Suppliers (all NTEI)

PPIRs required
for UNV & UPV

4 Weeks

PPIR Template Issued to Supplier

PPIR Received & Approved by Eng

PPIR
In Relation to Project Timing - Overall
PS

PSC

PTCC

PTC

iDJ

ATV 1
10

FMA
Plan

ANA 5

FDJ

M1DJ

Vehicle Phase
UNV1

ATV2

PA

10

ANA 5

M1
Dwg

UNV2

11

ANA 5

11

ANA

Boundary Diagram

M1DC
6

Interface Analysis

DJ

M1 Parts/Build

DJ

M1 Vehicle

Quality History
S

Functional Analysis
Parameter Analysis
Failure
Causes &
Modes
Countermeasures ID
YCYS
Cascade

Virtual Series Pre-VS (iDJ)

SCSS Controls
Confirmed
Completed PPIRs submitted
by supplier for approval

Vehicle Phase
UPV0
ANA 5

Final FM
Risk Assess

Actions Closed

11

PPIRs issued
to suppliers

UPV1
ANA 5

VP Build

UPV2
11

ANA 5

UPV3
14

ANA 5

VP Dwg
12

ANA 5

12

Boundary Diagram
Interface Analysis

DJ

DJ

Quality History
P

Functional Analysis
Parameter Analysis
Failure Modes

Causes Identified
Internal YCYS
Cascade

Countermeasures Identified
External
YCYS Cascade

Actions Closed

Final FM Risk Assess

Whole Vehicle
SCSS Confirmed
Completed PPIRs submitted
by supplier for approval

PPIRs issued
to suppliers

PPIR
In Relation to Project Timing - Overall
PS

PSC

PTCC

PTC

PA

PPIRs are driven by preceding activities

iDJ

ATV 1

Vehicle Phase
UNV1

ATV2
10

ANA 5

FDJ

M1DJ

10

ANA 5

M1
Dwg

UNV2

11

ANA 5

11

ANA

M1DC
6

The Special Characteristic Summary Sheet (SCSS)

should direct decision-making behind measurement
strategy and activities
FMA
Plan

Boundary Diagram
Interface Analysis

DJ

M1 Parts/Build

DJ

M1 Vehicle

Quality History

Functional Analysis

Parameter Analysis
Failure
Causes &
Modes
Countermeasures ID
YCYS
Cascade

Virtual Series Pre-VS (iDJ)

SCSS Controls
PPIRs issued
Confirmed
to suppliers
Completed PPIRs submitted
by supplier for approval

Vehicle Phase
UPV0
ANA 5

Final FM
Risk Assess

Actions Closed

11

UPV1
ANA 5

VP Build

UPV2
11

ANA 5

UPV3
14

ANA 5

VP Dwg
12

ANA 5

12

Boundary Diagram
Interface Analysis

DJ

DJ

Quality History
P

Functional Analysis
Parameter Analysis
Failure Modes

Causes Identified
Internal YCYS
Cascade

Countermeasures Identified
External
YCYS Cascade

Actions Closed

Final FM Risk Assess

Whole Vehicle
SCSS Confirmed
Completed PPIRs submitted
by supplier for approval

PPIRs issued
to suppliers

PPIR
Measurement Requirements
The following requirements relate to the minimum sample size for all sections of the
PPIR, including the Declaration of Mass.
JLR engineering may supersede these 2 requirements, on the proviso that:
1. This is agreed between PD and the supplier, and
2. The agreement is documented in the PPIR, as part of the submission
Sampling Requirements
A new PPIR must be submitted for any new batch of parts
Sampling size requirement:
Consignment quantity / batch size
as shipped

Sample size

6 parts

100%

6 to 150 parts

Minimum of 6 parts and 20%

150 parts

30 parts

PPIR
Measurement Requirements (cont.)
Declaration of Mass
It is required to declare the actual mass of the components manufactured, to supply
any given build.
Suppliers are expected to weigh the parts, in accordance to the sampling
requirements, and record them in the PPIR submission
Mass (weight) is to be measured on equipment calibrated with Weights traceable to
National Standards, and quoted within the following range of tolerances:
Components / assemblies mass (weight)
according to the released drawing

General Tolerance (to be applied only

when not stated in Drawing / CAD)

<0.100 kg

+/- 5 g

0.100 to 0.999 kg

+/- 10 g

1.000 to 4.999 kg

+/- 20 g

5.000 to 20.999 kg

+/- 25 g

>20.000 kg

+/- 50 g

This forms part of Section 3 of the PPIR submission (see slide 18).

PPIR
Expectations within Submission
Each section of the PPIR submission is set out in such a way that it informs the end user
about the pedigree of the part in question:
Section 1 Summary
Documents the part details and summarises the key findings of the PPIR
Section 2 Geometry
Confirms the form of the part is as per design
Section 3 Laboratory
Verifies the parts physical properties are in accordance to specification
> This includes the measured part mass of the components
Section 4 Functional
Demonstrates the part is able to function as intended
Section 5 In-Vehicle Software (IVS)
Shows the software compatibility between the part and the vehicle system
> Only required for parts containing software

PPIR
Expectations within Submission (cont.)
Embed all additional documents supporting the PPIR submission in the appropriate
section(s). This includes agreements with JLR to:
Neglect a specific section, or to deviate from the PPIR template
Supersede measurement requirements with part / commodity-specific requirements
In sections 2, 3 & 4:
Features shall include, but are not limited to, characteristics marked CC or SC in the
SCSS, and identify them in the section where the measurement is recorded
Enter numeric values into the OK, NOK and NI columns, to confirm the quantity of
parts within tolerance, outside of tolerance and not inspected respectively
> This is irrespective of any agreements to deviate from the template
Record all non-conformances in Details of Non-Conformances, within Section 1 Summary

PPIR
Section 1 - Summary
This section is in 2 parts, which outlines the part, the build it is intended for, the key
features and its conformance to specification

Summary
> Provide overview of the part in the submission
> Summarise all non-conformances identified in the process
Non-conformances, in this instance, are features identified as outside of
specification, or were not inspected
State actions and timings to bring non-conformances back to specification

SCSS
> Outlines the key requirements agreed between supplier & JLR, which are
fulfilled within the PPIR submission
> Fulfilled by attaching existing Special Characteristics Summary Sheet (SCSS)

PPIR
Section 2 - Geometry
This section is in 3 parts, which in its entirety is intended to demonstrate the parts
manufactured are geometrically conforming to design specifications.

Geometry
> Record the outcome of the measurement activities in this page.
> It is acceptable to use gauges / checking fixtures / reference samples as part of
the geometry confirmation
Any objective output / measurements should be recorded as a value to
provide a verification to conformance to specification
Only if the measurement output is an absolute, ie. pass / fail, is it
acceptable to record this as a measurement outcome

Measurement Plan
> Using suitable visuals, illustrate where datums and measurement points are
Include co-ordinated cut planes when required
It is acceptable to use a 2D drawing to satisfy this requirement

PPIR
Section 2 - Geometry (cont.)

PPIR
Section 2 - Geometry (cont.)

PPIR
Section 2 - Geometry (cont.)

Gauging
> Where gauges / checking fixtures are used to verify conformance to design,
attach the relevant instructions to this section
> For CMM, provide visual which illustrates how the part is held for measurement

PPIR
Section 2 - Geometry (cont.)

PPIR
Section 3 - Laboratory
This section verifies that the parts manufactured fulfils the requirements relating to:
Physical properties
Appearance / finish requirements
Measured parts mass

PPIR
Section 4 - Functional
This section relates to any testing and/or functional analysis on the parts manufactured
to verify conformance.

Should contain outcomes of end of line tests / assessments, for example load tests
and continuity checks
This differs from design verification (DV)
Embed test reports for confirmation as necessary

PPIR
Section 5 - In-Vehicle Software
This section should contain information which shows the software and hardware
supplied are to the level intent at each build phase, and as such compatible with the
relevant production systems.

PPIR
Role of JLR Engineering
Before distribution of PPIR
Identify parts requiring a PPIR
> All parts which are not delivered under PSW
> Generally new parts, or existing parts with major changes, including new tool
Communicate to Programme Team parts requiring PPIR
> UNV2 for underbody & powertrain parts
> UPV3 for upperbody parts
Understand what needs to be measured
> In particular YC/YS characteristics
Consider measuring new features / sections only for reused modified parts
> Review & agree measurement strategy with suppliers
Consider whether the generic measurement requirements will suffice
Once PPIRs are submitted
Review parts for suitability to build
Indicate approval / non-approval of part at http://rads.portsmouth.jlrint.com/ppir/
> Approve in accordance to classification rating guidelines
> GSI PPIR support site
> Training package now in Catalyst, search for PPIR tool

PPIR
Role of Supplier
Before distribution of PPIR
Understand what needs to be measured
> In particular YC/YS characteristics
Consider measuring new features / sections only for reused modified parts
> Review & agree measurement strategy with JLR engineering
Once PPIRs are distributed
Populate the PPIR pro forma with agreed information
Embed all supporting documents to the relevant section
Compress the PPIR into a .zip file to reduce file size if required
Return completed pro formas by emailing to PPIR@jaguarlandrover.com
If PPIRs are rejected
Correct all errors identified and resubmit
If there are non-conformances which cannot be corrected, submit recovery plan and
timing
Note: an automated message will be sent to supplier when a PPIR is reviewed for
approval to indicate outcome

PPIR
Role of JLR Programme Management
The PPIR Tool must be used for all M1, VP and HTFB build events (and the associated
Quality Loops where used), irrespective of size and number of parts due in.
Before distribution of PPIR
BOM creation and validation
> Identify parts which are not delivered under PSW (with support from PD)
> Includes identifying key contacts within suppliers
These are contacts who will receive communications and PPIR templates
Create the programme in PPIR Tool http://rads.portsmouth.jlrint.com/ppir/
> Including administration throughout preparation to the build event
GSI team can provide support and guidance to this activity
> Training package now in Catalyst, search for PPIR tool
Agree timing of PPIR submission with PD and supplier
Consider timing for parts which are not due for first car MRD
Send out supplier communications to prepare suppliers for PPIRs at MRD -8 weeks
Organise supplier and engineering training, if required
> To ensure common understanding across the build event

PPIR
Role of JLR Programme Management (cont.)
At MRD -4 weeks
Issue out PPIR template using PPIR tool
> It may be necessary to issue out template earlier than this for certain suppliers /
systems, PD to advise / request
Before and After MRD / During Build Event
Report out and follow-up on parts due in for MRD
Utilising existing metrics within PPIR tool
Parts Arriving in Plant without PPIRs
Parts should not be shipped without PD approval of the PPIR submission(s)
> The automated notification from the PPIR tool, once the PPIR is approved,
serves as an OK to ship notice to supplier
They should be placed in Impound / Quarantine until approval is given

PPIR
Role of Forward Model Quality (FMQ)
Identify priority parts
Using High Hurts brochure, PAWS, TGW, etc.
Before distribution of PPIR
Facilitate discussions to agree measurement contents
Ensure special characteristics (YS/YC) have been agreed with supplier,
communicated and signed-off via SCSS
Once PPIRs are submitted
Audit PPIRs and respond as necessary

PPIR
Auditing

The purpose is to ensure information contained within approved PPIRs are:

> Reflective of parts manufactured
> Usable for problem solving and concern resolution
> Confirming part pedigree with respect to form, fit and function

Key aspects under scrutiny:

1. Measurement sample size is suitable for batch delivered
2. Special characteristics are identified
3. Drawing (or suitable visuals) identify what was measured
4. Geometric features conform to engineering specifications
5. Physical and appearance requirements are met as appropriate
6. Parts have been proven to function to design as appropriate
7. Non-conformances found have corrective plans to rectify

Audits are carried out by Forward Model Quality Programmes

> Audit failures are raised to engineer responsible for the part
To re-evaluate PPIR approval
Work with supplier to correct points of audit failure

PPIR
Summary

Purpose is to ensure parts are suitable for build

> Confirms parts are made to spec for form, fit and function

Required for all non-PSW parts at prototype build phases, up to HTFB

> Including carryover and reused parts with new tools
> Also includes software updates, with and without physical changes

Measurement requirements are driven by Engineering

> Determined by FMA activities, summarised by SCSS
> FMQ will provide support where required / necessary

JLR Engineering notify Programme Team of parts requiring PPIR by UNV2 / UPV3

Pre-populated templates are distributed 20 working days before MRD

Engineering approval of submitted PPIRs required before MRD

> This approval serves as OK to ship for supplier to deliver parts to plant