Production Part Approval Process (PPAP) Manual: Rev Date Originator Section(s) Change Description

QA3525
Production Part Approval Process (PPAP) Manual

Level 2 Document
Rev Date Originator Section(s) Change Description
1.0 01/29/2016 Kevin Powers All Initial Release

2.0 02/11/2016 Kevin Powers 04, 1.13, Added definition for PPAP (04), specified
1.15, 5.2.1, Tolerance method for GR&R studies and
5.2.6 changed 20% to 30% (1.13), reworded section
(1.15), included revised PRF and DCE forms
(both rev 2.0)
3.0 10/26/2016 Kevin Powers 02, 1 Reworded Section 02 – Scope; Reworded
Section 1 – PPAP Requirements: added
reference to MC015, expanded upon the
factors that determine the requirements for a
specific PPAP
4.0 10/26/2016 Kevin Powers N/A Edited footer to show Revision 3
5.0 12/05/2016 Kevin Powers 01, Added PPAP Process Flow Chart, Suppliers
Append. A, (Appendix B); the previous Appendix B (PPAP
Append. B, Related Forms) is now Appendix C; renamed
Append. C Appendix A to PPAP Process Flow Chart,
Hypertherm  Supplier
6.0 09/07/2017 Kevin Powers 1, 1.1, 1.2, Added note that suppliers must not modify the
1.4, 1.9, PRF (1.1); added statement regarding pre-
1.11, 1.13 PPAP activities (1); re-wrote for better clarity
(1.4, 1.13); added document numbers (1.1,
1.2, 1.4, 1.9, 1.11)
7.0 04/xx/2018 Kevin Powers 03, 04, 1.4, Added two references in 03; added PPAP+
1.7, 1.12, definition in 04; rewrote sections 1.4, 1.7, 1.12,
1.13, 5.1, 1.13 to reflect current practice; update
5.3.1, 5.3.3 flowchart in 5.1 to reflect current practice;
updated two forms in 5.3 to reflect current
practice
8.0 12/23/2019 Kevin Powers 1.1, 1.4, Updated the PPAP Conditionally Approved
1.10, 1.12, disposition; updated the copy of the KFE Form
3.1, 3.2, in the Appendix; minor verbiage updates
4.2, 5.3.4 throughout to better reflect actual practice
QA3525 Page 1 of 19 Revision 8.0

Please be advised if using a paper copy of this document - it is uncontrolled unless otherwise identified and it is the user’s
responsibility to verify the latest revision.
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TABLE OF CONTENTS
FOREWARD ................................................................................................................... 3
INTRODUCTION ............................................................................................................. 4
01 PURPOSE ...................................................................................................................................... 4
02 SCOPE .......................................................................................................................................... 4
03 REFERENCES ................................................................................................................................. 4
04 DEFINITIONS/ACRONYMS ................................................................................................................ 4
1 PPAP REQUIREMENTS ......................................................................................... 5
1.1 PPAP REQUIREMENTS FORM (PRF) .............................................................................................. 5
1.2 PART SUBMISSION WARRANT (PSW) ............................................................................................. 5
1.3 DRAWING(S) .................................................................................................................................. 6
1.4 KEY FEATURES CONTROL (KFC) FORM.......................................................................................... 6
1.5 PROCESS FLOW CHART ................................................................................................................. 6
1.6 PROCESS FAILURE MODES AND EFFECTS ANALYSIS (PFMEA) ....................................................... 6
1.7 PROCESS CONTROL PLAN.............................................................................................................. 6
1.8 MATERIAL TESTS/CERTIFICATES .................................................................................................... 7
1.9 PACKAGING METHOD DATASHEET (PMD)....................................................................................... 7
1.10 SAMPLES....................................................................................................................................... 7
1.11 DIMENSIONAL AND COSMETIC EVALUATION .................................................................................... 7
1.12 PROCESS CAPABILITY EVALUATION................................................................................................ 7
1.13 MEASUREMENT SYSTEM EVALUATION ............................................................................................ 8
1.14 PERFORMANCE TESTS ................................................................................................................... 8
1.15 CHECKING AIDS ............................................................................................................................. 8
2 PPAP EXECUTION AND SUBMISSION ................................................................. 8
3 PPAP SUBMISSION EVALUATION ....................................................................... 9
3.1 EVALUATION OF THE PPAP PAPERWORK ....................................................................................... 9
3.2 EVALUATION OF THE PPAP SAMPLES .......................................................................................... 10
4 PPAP DISPOSITION ............................................................................................. 10
4.1 PPAP APPROVED........................................................................................................................ 10
4.2 PPAP CONDITIONALLY APPROVED .............................................................................................. 10
4.3 PPAP REJECTED ........................................................................................................................ 11
5 APPENDICES ........................................................................................................ 12
5.1 APPENDIX A. PPAP PROCESS FLOW CHART, HYPERTHERM  SUPPLIER ..................................... 12
5.2 APPENDIX B. PPAP PROCESS FLOW CHART, SUPPLIER ............................................................... 13
5.3 APPENDIX C. PPAP RELATED FORMS .......................................................................................... 14

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FOREWARD
Perhaps nothing, when done properly, helps a business prevent future quality problems, and all
the costs and disruptions that go with them, more than PPAP. Both the Supplier and the
Customer benefit.
The key to success with the PPAP process is to embrace the fact that it is a tool for you, the
Supplier(*), and not just a requirement imposed by the Customer. By adhering to the principles
of the PPAP process and doing all of the due diligence, the Supplier benefits from the
assurance that its process is ready and capable of meeting all of its Customers’ requirements
consistently throughout all future production runs, not just the first run.
Equally important, the Supplier can benefit from knowing when the process is not ready for
consistent quality production. When the Supplier believes it has sufficient evidence that the
process is ready, the PPAP run is initiated. The PPAP is the final validation that the production-
intent process is ready. If, however, any non-conformances are encountered after PPAP parts
have gone through the normal (intended) production and inspection process, it is negated. The
PPAP should be terminated, root cause determined, corrective action implemented and the
PFMEA and Control Plan updated. After validating the improvements, another PPAP run is
initiated.
The Supplier is free to do additional PPAP related activities above and beyond what is required
per the PPAP Requirements Form (PRF) that is issued by Hypertherm. The Supplier should not
seek to do the minimum amount of effort; it should seek to do the optimum amount of due
diligence for the purpose of preventing future problems.
(*) The general focus here is on PPAPs performed by external Suppliers to Hypertherm. However, the principles,
expectations and benefits of PPAP outlined in this manual would apply internally to Hypertherm as well.

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INTRODUCTION
01 Purpose
The purpose of production part approval is to determine if all Hypertherm engineering
design/specification requirements are properly understood by the Supplier and that the
Supplier’s process has the ability to produce product meeting these requirements
during an actual production run at the quoted rate. This applies to not only the first
production run but to all future production runs.
This procedure defines PPAP related terms and all aspects of the PPAP process,
including when a PPAP submission is required, what the general PPAP submittal
requirements are and what the possible outcomes and consequences of a PPAP
submission are. In addition to the description provided in the Manual’s sections, PPAP
process flow charts are included in Appendix A and B, and PPAP-related forms are
shown in Appendix C for reference purposes(*).
This document is not meant as a training primer on PPAP or any of the many activities
associated with it, such as Process FMEAs, capability studies, etc. There are
numerous training resources available that the Supplier can take advantage of as
needed.
02 Scope
The PPAP process defined in this manual applies to the production of items
(components, parts, materials, products, assemblies, sub-assemblies, etc) for which it
has been determined that a PPAP is warranted per Supplier Management Program
MC015, Section 6.3 – Purchased Part Qualification.
03 References
a. QA3524: PPAP Workbook (forms)
b. MC015: Supplier Management Program (SMP) – for Hypertherm use only
c. QA3531: Supplier-Part Risk Assessment
d. QA4106: Risk-Rigor Design Review
04 Definitions/Acronyms
a. PPAP: Production Part Approval Process. Originally developed by the American
Automotive Industry, the PPAP process defined in this Manual has been tailored to
Hypertherm’s specific needs, industry and business environment. PPAP is a
standardized approach that helps ensure the supplier understands all Hypertherm
requirements and that the process is capable, repeatable, and sustainable over the
long-term.
b. PPAP+: If the outcome of the Supplier-Part Risk Assessment is high risk, the
Hypertherm team shall determine the appropriate risk mitigating activity(ies), if any,
to complement PPAP. If the outcome is specifically high part risk, the ‘plus’ shall
entail risk-rigor design review (Ref.: 03d)
c. PFMEA: Process Failure Modes and Effects Analysis
d. Beta Build: pre-production (Beta) build using production-level processes

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e. Resourced Part: an existing Hypertherm part that is transferred (resourced) from a
current supplier to another one
f. RPN: Risk Priority Number
(*) The use of Hypertherm forms, where provided, is preferred. However, the Supplier may choose to use its own
forms. In that case, the information on Hypertherm’s forms, at a minimum, must be included in the Supplier’s forms.
1 PPAP REQUIREMENTS
A PPAP is Supplier-Part Number-Revision Level specific. When PPAP is deemed to be

warranted per Supplier Management Program MC015, Section 6.4 - Purchased Part
Qualification, a part number-rev must be PPAP approved (fully or conditionally) in
order for a Supplier to make production shipments of that part number-rev to
Hypertherm.
The requirements for a specific PPAP will depend on the reason for the PPAP (the
trigger) and the item’s complexity and criticality, annual volume or usage, level of
customization and whether or not it falls within a family of similar parts. Below is a list
of all possible PPAP items that could be required, while supporting PPAP forms can be
found in Ref.: 03a. A PPAP Requirements Form (PRF) will be issued by Hypertherm
that will define the actual required items for a specific PPAP. Every PPAP must have a
Hypertherm issued PRF associated with it.
Many activities may be performed and several tools utilized in the process of
establishing an acceptable process. Among them are design for manufacturability
(DFM), risk-rigor design review (RRDR), sample runs, measurement correlation for key
features, capability studies, etc. These efforts will culminate in a successful PPAP, one
that validates the readiness and capability of the process. Although these 'pre-PPAP'
efforts may tend to be sequential in nature, there may be many circumstances where
that is not the case. But whatever has to be done and regardless of how and when
they are done, the PPAP run must come after all the pre-PPAP activities are
completed. It is possible that some of the pre-PPAP activities may not need to be
repeated for PPAP as long as proper PPAP protocol was followed for the pre-PPAP
run (refer to Section 2 - PPAP Execution and Submission) and no subsequent
changes were made to the part drawing or the process.
1.1 PPAP Requirements Form (PRF) – QA3519

A PRF will be created and issued by an appropriate Hypertherm associate. It will
identify the required items for a specific PPAP and is the official trigger for the Supplier
to begin execution of the PPAP. A copy of the PRF should be included in the PPAP
paperwork as well as in each carton of PPAP samples shipped to Hypertherm. Note: A
supplier must not mark up or modify the PRF in any way. If you believe something
should be added, deleted, modified or corrected, please contact the appropriate
Hypertherm Quality associate.
1.2 Part Submission Warrant (PSW) – QA3520

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The Warrant contains important information regarding the part being PPAP’d. It must
be signed and dated by an appropriate representative of the Supplier.
1.3 Drawing(s)
The drawing defines the engineering design requirements of the part being PPAP’d.
The drawing and the PPAP are Part Number and Revision Level specific; the PPAP
submission must correspond to a specific Drawing Revision, which must match the
Revision called out on the PRF. All appropriate dimensions, notes and other such
callouts on the drawing should be numerically indexed (ballooned) and correlate with
the results on the PPAP dimensional layout form.
1.4 Key Features Evaluation (KFE) Form – QA3521

This item will be required only for new parts, and then only if the new part is designated
by Hypertherm as high risk per the Supplier-Part Risk Assessment. The form will be
provided to the supplier in the PPAP Workbook with the key features identified. The
PPAP Measurement Method field is to be populated for each key feature listed based
on agreement reached between the Supplier and Hypertherm. However, before any of
this can be completed, correlation between the two parties must be demonstrated (as
shown on the KFE Form). The completed form must be submitted with the PPAP and
the production control methods must also be reflected in the Supplier’s Process Control
Plan.
1.5 Process Flow Chart

The Process Flow Chart depicts the flow of materials through the process, from
incoming inspection through packaging, including all processing and inspection steps
in-between. It provides a picture of the separate steps of a process in sequential order
and should be in alignment with the Process Control Plan. Any outsourced operations
must be clearly identified as such and must include the name of the company
performing the operation. The Process Flowchart must be a controlled document. In
addition to its own date/rev control, it should always reflect the latest Revision Level of
the part that it was PPAP Approved to.
1.6 Process Failure Modes and Effects Analysis (PFMEA)

The PFMEA is a systematized technique which identifies and ranks the potential failure
modes of a process in order to prioritize improvement actions. The PFMEA has many
benefits – it is vital input into the Control Plan; it is a communication tool – but its
greatest benefit, when done properly, is in the prevention of problems. It must be a
controlled document. In addition to its own date/rev control, it should always reflect the
latest Revision Level of the part that it was PPAP Approved to. It should also be
reviewed for potential revision in response to any process changes as well as any
quality issues. Ultimately, the PFMEA must continue to be a living, dynamic document.
1.7 Process Control Plan

A Process Control Plan is a written description of the system for controlling production
parts and processes; it describes the actions that are required at each phase of the
process. The Process Control Plan must address the key features of the product as
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well as the key parameters of the process so as to minimize product and process
variation. It must be a controlled document. In addition to its own date/rev control, it
should always reflect the latest Revision Level of the part that it was PPAP Approved
to. It should also be reviewed for potential revision in response to any process changes
as well as any quality issues. Ultimately, the Process Control Plan must continue to be
a living, dynamic document.
1.8 Material Tests/Certificates

The Supplier must perform the tests as required on the PRF. If the Supplier cannot
perform the required tests, services must be procured from a qualified source or, upon
special arrangement, from Hypertherm’s laboratory. When third party laboratory
services are used, the results (often in the form of a Material Certificate of Analysis or,
for some non-metals, a Certificate of Compliance) should be submitted on their
letterhead or normal report format. The name of the laboratory that performed the
tests, part number, revision level and the date the testing took place must be indicated.
Any report submitted should be signed and dated by an appropriate representative of
the Supplier; this is in addition to a signature/date on the third-party laboratory report.
1.9 Packaging Method Datasheet (PMD) – MC3440

The Packaging Method Datasheet (MC3440) communicates the Supplier’s intended
packaging method and shipment mode to Hypertherm facilities in compliance with all
Hypertherm requirements (refer also to MC3439). These requirements include, but are
not limited to, the protection of the product, environmental restrictions and operational
productivity.
1.10 Samples
The typical requirements for the number of parts to run and the number of samples to
draw for evaluation are described in Section 2 of this Manual. Exceptions can be made.
The PRF will define the number of parts to run, the number of samples to draw, the
number of samples to submit to Hypertherm and to whom they should be sent. When
samples are drawn from the PPAP run, they must be identified with the appropriate
sequential processing number (e.g., 1, 2, 3,… 40).
1.11 Dimensional and Cosmetic Evaluation – QA3523

The results on the PPAP dimensional layout form should correlate to numerically
indexed (ballooned) dimensions on the drawing. A complete evaluation includes
verification of all dimensions, places and notes specified on the drawing as well as
cosmetic acceptability. This evaluation shall be performed on a specific set of samples
(from each cavity, die mold, etc., if applicable) as specified on the PRF. The PRF will
also define the sample numbers to be sent to Hypertherm.
1.12 Process Capability Evaluation

The Supplier must perform capability studies on select key features as specified on the
PRF. The typical requirements include capability and/or performance indices (Cp, Pp,
Cpk and/or Ppk); the minimum acceptable limits will be shown on the PRF. In addition,
requirements may include a histogram and/or a control chart associated with the data.
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Applicable requirements will be specified on the PRF. As stated in 1.4 above, if this is a
new part with high part risk, correlation between Hypertherm and the Supplier must be
demonstrated prior to the capability evaluation.
1.13 Measurement System Evaluation

The Supplier must develop or obtain gages and measurement instruments and
standards to control their processes and to determine product conformance to
specifications with confidence. The Supplier will perform measurement system analysis
such as correlation, gage repeatability & reproducibility (GR&R), etc., for all key
features listed in Item 12 on the PRF.
Whenever performing a variable measurement GR&R, using the Tolerance method,

the following values apply:
• <10%: desirable, the goal
• 10 – 30%: acceptable, Supplier is encouraged to improve
• >30%: unacceptable, do not submit PPAP, improvement action required
1.14 Performance Tests

The Supplier must perform the tests as required on the PRF. If the Supplier cannot
perform the required tests, services must be procured from a qualified source or, upon
special arrangement, from Hypertherm’s laboratory. When third party laboratory
services are used, the results should be submitted on their letterhead or normal report
format. The name of the laboratory that performed the tests, part number, revision level
and the date the testing took place must be indicated. Any report submitted should be
signed and dated by an appropriate representative of the Supplier; this is in addition to
a signature/date on the third party laboratory report. Blanket statements of
conformance are unacceptable.
1.15 Checking Aids

The PPAP submittal must provide evidence that there are controls in place for any part
specific inspection or testing devices or checking aids. Standard inspection instruments
such as bore, ring, pin, plug and thread gages, calipers, micrometers, etc are not
included.
The following checking aid documentation must be included in the PPAP:

• Checking aid design prints
• Dimensional layout confirming conformity of the checking aid to the print
• Measurement system studies for the checking aids
• Callout of the checking aid in the Control Plan with sample size and frequency
of checks on product characteristics or process parameters
2 PPAP EXECUTION AND SUBMISSION
Parts produced for a PPAP must be manufactured at the production site and at the
production rate using the intended normal production tooling, process, equipment,

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materials, inspection/testing methods, gaging, operators, environment and process
settings, e.g. feeds, speeds, cycle times, pressures, temperatures, etc. Nothing
special should be done during the PPAP run. The intent of the PPAP run is not to find
out if the process is ready; it should be the final validation that it is ready.
A PPAP run must begin only after the process is deemed by the Supplier to be stable.
Once process stability is reached, a PPAP run is executed from which samples are
drawn. The samples are to be drawn per instructions on the PRF after the completion
of the normal production and inspection/testing process. These samples will be utilized
for the dimensional and cosmetic evaluations, capability studies, measurement system
studies and testing as specified on the PRF. The minimum PPAP run quantity and
sample size will also be specified on the PRF.
If non-conformances are encountered in the drawn samples, the PPAP is negated. The
Supplier shall not submit the PPAP to Hypertherm. Root cause must be determined
and corrective action implemented. After confirming the improvements, another PPAP
run can be initiated. The Supplier must communicate the issue to Hypertherm and
advise the new target PPAP submission date.
If the Supplier wishes to propose a change to the Hypertherm design, a request needs
to be processed through the appropriate Hypertherm contact. If Hypertherm approves
the request, the Drawing will be revised and a new PRF will be issued. All appropriate
Supplier PPAP documents must reflect the new part revision level prior to submittal of
the PPAP.
All required PPAP paperwork should be aggregated, preferably in the order of the PRF,
and sent electronically in one file. There are two acceptable ways to do this: either in
one pdf file or using the PPAP Workbook (Excel) file provided by Hypertherm, with
each required item in its own tab. Each carton of samples being sent to Hypertherm
should have a copy of the PRF in it; no other paperwork should be in the cartons. The
samples and paperwork should be sent at the same time; if either of the two is not
ready, then the PPAP is not ready.
3 PPAP SUBMISSION EVALUATION
The evaluation of a PPAP submission consists of the evaluation of the paperwork and
the evaluation of the samples if, and as, required per the PRF.
3.1 Evaluation of the PPAP Paperwork

An appropriate associate of the Hypertherm team will review the submitted
documentation as follows:
• The PPAP paperwork file contains all required documentation as prescribed on
the PRF
• All process documents (Flowchart, PFMEA, Control Plan)
‒ demonstrate acceptable depth and comprehensiveness
‒ indicate the correct part revision level, which must match the revision
level on the drawing and on the PRF
‒ have Date/Revision controls of their own
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‒ match each other in terms of the basic sequence of process steps
• The PFMEA shows reasonable risk numbers for Severity, Occurrence and
Detection, and preventive actions with estimated new, lower risk numbers
shown to the right are provided for the higher RPNs
• All data/results in the PPAP file demonstrate conformance to requirements
(dimensional layout results, Cpk’s, Gage R&Rs, Material Cert, Packaging
Method Datasheet, etc)
• The Material Cert is a Certificate of Analysis if required per the PRF, and not a
Certificate of Conformance. In addition, the copy of the Material Cert provided
should show evidence that the Supplier reviewed and confirmed that the
information on the Material Cert is in fact conforming. This can be done with
check marks, signature and date.
3.2 Evaluation of the PPAP Samples

An appropriate associate of the Hypertherm team will evaluate the submitted samples
as follows:
• The correct number of samples were received
• The samples are appropriately identified/numbered
• The samples are in acceptable condition cosmetically
• Measure selected dimensions on selected samples as deemed appropriate
• Perform appropriate tests on selected samples as applicable
• Distribute samples to other associates for evaluation as appropriate
4 PPAP DISPOSITION
Suppliers will be notified of the PPAP disposition. There are three possible outcomes:
PPAP Approved, PPAP Conditionally Approved and PPAP Rejected.
4.1 PPAP Approved

PPAP Approval indicates that the part and documentation fully meet all specifications
and requirements. The Supplier is therefore authorized to build and ship production
quantities as directed by Hypertherm, including conforming parts built from the
approved PPAP run.
4.2 PPAP Conditionally Approved

PPAP Conditional Approval indicates that the PPAP submission, whether because of
an issue with the samples or with the documentation or both, does not meet all
Hypertherm specifications and requirements. However, the Hypertherm team has
determined, after carefully weighing the need for the parts versus risk to the Customer,
that use of the parts in production is the best course of action. PPAP Conditional
Approval permits shipment of product for a specified period of time, quantity of parts or
some other condition. Parts made from the PPAP run can be used in production orders
to Hypertherm provided they fall within the specified condition. The Supplier must
determine root cause and corrective action to address the non-conformities preventing
full PPAP Approval. A new PRF will be issued by Hypertherm for PPAP resubmission.
PPAP disposition to Approved status is required for full authorization of production
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shipments. If the condition set for this status is about to expire, it may be extended by
the appropriate Hypertherm associate. Or, if there is no longer any interest in pursuing
Approval, the status is to be changed to PPAP Closed. Once the conditional has
expired, the Supplier is not authorized to ship production lots of this specific Part
Number-Rev. Conditional status is not meant to be a permanent status; it must
eventually be brought to conclusion, either as Approved or Closed.
4.3 PPAP Rejected

PPAP Rejection indicates that the PPAP submission, whether because of an issue with
the samples or with the documentation or both, does not meet all Hypertherm
specifications and requirements. All parts made from the failed PPAP run should be
segregated as nonconforming and cannot be shipped to Hypertherm, unless otherwise
agreed upon between Hypertherm and the Supplier. The Supplier must determine root
cause and implement correction action to address the non-conformities. A new PRF
will be issued by Hypertherm for PPAP resubmission. The Supplier is not authorized to
build and ship production parts until PPAP Approval is achieved.

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5 APPENDICES
5.1 Appendix A. PPAP Process Flow Chart, Hypertherm  Supplier
PPAP Manual Section # Process Step Activities/Requirements/Expectations
Need for
PPAP has
been • Refer to MC015, Section 6.3
identified
STEP 1
Issue PPAP
Workbook • Issue the PPAP Workbook (Ref.: 03a)

Hypertherm
STEP 2
Execute PPAP • Execute requirements of PRF per PPAP Manual
 And Submit • Submit PPAP to Hypertherm electronically (in one PDF file)
Supplier
• The PPAP paperwork file contains all required
documentation as prescribed on the PRF
• The process documents are comprehensive, indicate
the correct part revision level, are themselves date/rev
Step 3A
controlled, and match each other in terms of the basic
Evaluate process steps
PPAP • The PFMEA shows reasonable risk numbers and
Paperwork preventive actions for the higher RPNs
• All data/results in the PPAP file demonstrate
STEP 3 conformance to requirements
Evaluate PPAP • The Material Cert is appropriate and clearly shows
 conformance to requirements
Hypertherm
• Correct number of samples received
• Samples are appropriately identified/numbered
Step 3B
Evaluate
• Samples are in acceptable condition
PPAP • Measure select dims/samples as appropriate
Samples • Perform tests on select samples, if applicable
• Distribute samples to other Associates for evaluation as
appropriate
STEP 4
Disposition and Store • Approve, Conditionally Approve or Reject per PPAP Manual
 PPAP • Update PPAP status and store files/records per MC015, Section 7
Hypertherm

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5.2 Appendix B. PPAP Process Flow Chart, Supplier

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5.3 Appendix C. PPAP Related Forms
5.3.1 QA3519: PPAP Requirements Form (PRF)
PPAP Requirements Form (PRF)

Part Number: Rev: Description:
Supplier: PPAP Due Date:
Hypertherm Team: QA: CP/SC:
Project: Part Risk (if new): EAU:
Reason for Submission:
Comments:
Submission Requirements
PPAP Documentation/Items Yes/No Comments
1. Copy of PRF (QA3519)
2. Part Submission Warrant (QA3520)
3. Drawing(s)
4. Key Features Evaluation Form (QA3521)
Process Flow Chart Outsourced operations must be
5. clearly identified, including the name of the company
performing the operation.
6. Process FMEA
7. Process Control Plan
Material Tests/Cert Provide Cert of Analysis for
8.
FOR REFERENCE PURPOSES ONLY
metals & elastomers and Cert of Compliance for other
(consult QA3524 for current revision)
nonmetals. Supplier to show evidence that the Certs were
reviewed for compliance.
9. Packaging Method Datasheet (MC3440)
Samples Unless otherwise specified in the Comments
column to the right, after the process is deemed by the
10.
Supplier to be stable, run 100 pcs and draw 30
consecutive samples from somewhere within the 100 pcs.
Dimensional and Cosmetic Evaluation (QA3523)
Dimensional results should be tied to ballooned
characteristics on the drawing. Unless otherwise
11.
specified in the Comments column to the right, verify all
dimensions, places, notes and cosmetics for sample
numbers 1, 10, 20 and 30 of the 30 consecutive samples.
Process Capability Evaluation of Key Features
Refer to the Comments column to the right regarding the
number of samples to be measured (typically all 30
consecutive), the features to be evaluated, the
capability/performance indexes to be used (Cp, Cpk, Pp,
12.
Ppk) and their requirements (typically Cpk 1.33
minimum), as well as any additional requirements. If this
is a new part and designated as high part risk,
correlation may be required prior to capability
evaluation (refer to Item 4 above).
Measurement System Evaluation For the production
gaging of all key features listed in Item 12 above, GR&R
13.
(Tolerance Method) <10% desirable; 10-30% acceptable
(Supplier is encouraged to improve); >30% unacceptable.
14. Performance Tests
15. Checking Aids
Prepared By: Date:
5.3.2
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5.3.3 QA3520: Part Submission Warrant Form


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5.3.4 QA3521: Key Features Control (KFC) form

5.3.5 QA3522: PFMEA Hypertherm Ranking Scale Guidelines

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5.3.6 MC3440: Packaging Method Datasheet (PMD)

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5.3.7 QA3523: Dimensional and Cosmetic Evaluation


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Production Part Approval Process (PPAP) Manual: Rev Date Originator Section(s) Change Description

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QA3525

Production Part Approval Process (PPAP) Manual

Rev Date Originator Section(s) Change Description

1.0 01/29/2016 Kevin Powers All Initial Release

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A PPAP is Supplier-Part Number-Revision Level specific. When PPAP is deemed to be

1.1 PPAP Requirements Form (PRF) – QA3519

1.2 Part Submission Warrant (PSW) – QA3520

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1.4 Key Features Evaluation (KFE) Form – QA3521

1.5 Process Flow Chart

1.6 Process Failure Modes and Effects Analysis (PFMEA)

1.7 Process Control Plan

1.8 Material Tests/Certificates

1.9 Packaging Method Datasheet (PMD) – MC3440

1.11 Dimensional and Cosmetic Evaluation – QA3523

1.12 Process Capability Evaluation

1.13 Measurement System Evaluation

Whenever performing a variable measurement GR&R, using the Tolerance method,

1.14 Performance Tests

1.15 Checking Aids

The following checking aid documentation must be included in the PPAP:

2 PPAP EXECUTION AND SUBMISSION

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3 PPAP SUBMISSION EVALUATION

3.1 Evaluation of the PPAP Paperwork

3.2 Evaluation of the PPAP Samples

4.1 PPAP Approved

4.2 PPAP Conditionally Approved

4.3 PPAP Rejected

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PPAP Manual Section # Process Step Activities/Requirements/Expectations

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5.3.1 QA3519: PPAP Requirements Form (PRF)

PPAP Requirements Form (PRF)

FOR REFERENCE PURPOSES ONLY

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FOR REFERENCE PURPOSES ONLY

5.3.5 QA3522: PFMEA Hypertherm Ranking Scale Guidelines

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5.3.6 MC3440: Packaging Method Datasheet (PMD)

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FOR REFERENCE PURPOSES ONLY

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