Global PPAP Checklist ver.

3/29/15

Goals
·         Supports the AIAG Service PPAP manual
·         Supports the Ford Customer Specific Requirements for PPAP
·         Provide guidelines to the supplier of appropriate support documents for element sections
·         Can be used as a tool between the STA and the supplier to define required elements prior to a PPAP submission
·         Can be submitted by the supplier to the STA as a Table of Contents for the PPAP
·         Provides a section for the STA to identify requirements supporting regional or special needs
·         Global Checklist to be used by all regions to support various PPAP scenarios

When to PPAP to a Service STA

All unique service parts (as compared to the production end item) require PPAP documentation prior to shipment. When a
service part number directly crosses with an engineering number shipping into production, the approved production PSW can
be
used. For PPAP notification suggestions, reference the PPAP 4.0 or Service PPAP 1.0 manual sections 3.1 and 3.2.
Below are typical scenarios.

1.       Is this part a current production Part/Assembly which is supplied to FCSD exactly as it is supplied to Production?
       Yes – FCSD STA is not required to PPAP. The Production warrant will suffice provided the service part
number appears on the warrant with the corresponding engineering part number.
2.       Is this part a component of a current production part which is unique to FCSD (not shipped to production at this level)?
       Yes – FCSD STA must PPAP the service process used to manufacture this component. The approved production PPAP
can be used to support the service PPAP for areas that are common to production and service.
3.       Is this Part/Assembly/Component out of production?
       Yes – FCSD STA must PPAP
4.       Is this Part/Assembly/Component a Vehicle Personalization part?
       Yes – FCSD STA/Vehicle Personalization STA must PPAP
5.       Is this a service Kit?
       Yes – FCSD STA must PPAP

Definitions
Element Number: Requirement number directly related to the AIAG Service PPAP Manual
PPAP Element Name: Requirement name directly related to the AIAG Service PPAP Manual
Ford Requirements: Required PPAP document/evidence that the supplier must provide in the PPAP as listed and defined in the
Service Production Part Approval Process (Service PPAP) manual First edition (June 2014) and the Ford Motor Company
Customer-Specific Requirements (for use with PPAP 4.0)
Supplier / STA - Agreed upon Requirements (Required / Not Required): Used by the Supplier or STA to document which items
shall be prepared and submitted by the Supplier for review.
STA - Confirms Requirement (Accepted / Rejected /Alert Required): Used byt the STA to determine at the time of PPAP review
if the requirements have been met by the supplier.

Guidelines: Documents that have been identified as the supporting details to the Ford Requirements. One or multiple guidelines
can be used to support a Ford requirement.
Supplier - Check all that Apply to Submission (Yes/No): Indicates which document the supplier submitted to support the Ford
Requirement.
Comment: Additional information provided by the STA or supplier

Introduction 1 Version 1.0, Dec 2014

FCSD General PPAP Checklist
When parts fall within one of the tabs below (3rd Party Packager, Chemicals, Remanufacturing and Vehicle Personalization) additional requirements may apply,
reference the applicable tab. For Bulk materials use only the Bulk tab.

Supplier -
Supplier / STA - STA - Confirms
Agreed upon Requirement Check all
Element Number PPAP Element Ford Requirements Requirements (Accepted / Guidelines for Requirements that Apply Comments
Name (Required / Not Rejected /Alert to
Required) Required) Submission
(Yes/No)

2.1 Significant PPAP Production runs less than 300 pieces and an 8 hour run When requirements for a 300 consecutive part run or 8
Run must be derived from a statistically significant sample hours of production may not be practical for low-volume
of a one year service release quantity or as determined service parts the quantity of parts needed for service PPAP
by the STA shall be a statistically significant sample of a one year
service release quantity or defined by the STA

Service parts associated with the production parts

must be included in the PPAP process and meet all
OEM requirements
2.2 PPAP Requirements
Service part samples submitted as part of PPAP must
be run from tooling intended for service volume
production. Organizations shall not ship parts until
service organization quality has approved the
dimensional reports and/or samples per OEM specific
approval process
All service PPAP submissions shall provide evidence of NA - 'T' (manufacture and package) role suppliers must
a packaging approval with the submission provide a copy of the IMS3 packing specification. 'M'
(manufacture) role suppliers this requirement is not
applicable. Reference the FCSD NA Packaging and Shipping
Guide. (See 2.17a)
APA- None
EU- None
SA- None

2.2.1 Design Record Released and authorized Ford design record (drawing, Ballooned print with Ford title block
CAD/CAM) in appropriate system (WERS, Teamcenter,
Ford Doc)
Hard copy pictorial to identify measurements taken when
design record is Ford CAD/CAM math data
Design record is at the latest level and matches Notice in
WERS
Bill of Materials (BOM) Ford released print
Required for Service Kits and Packages WERS BOM
CAD/CAM BOM
Approved Instruction Sheet (I-Sheet) NA - Created by Creative Data and release in
Required when listed within a kit's BOM Teamcenter/Ford Doc
APA - None
EU - None
2.2.1.1 Reporting of Part Material reporting entered into the International SA -None
Service parts for vehicles produced prior to July 1, 2003
Material Materials Data System (IMDS). are exempt.
Composition
2.2.1.2 Marking of Polymeric parts properly marked with the ISO symbols Part markings meet the requirements identified in the
Polymeric Parts when required. Design Record
2.2.2 Authorized Support document for those changes not yet recorded Copy of the Ford Engineering Release Notice (WERS)
Engineering in the design record but incorporated in the product,
Change part or tooling Approved SREA
Approved Alert - 'C' Status
2.2.3 Customer Ford Product Development or FCSD (out of warranty Signed copy of PV test results by either the Ford Product
Engineering only) Engineer approval of PV (Production Validation) Development or FCSD engineer
Approval tests results
2.2.4 Design FMEA Design FMEA Ford Product Development Engineer is required to approve
Required when the supplier is design responsible the D-FMEA
Ford Product Development Engineering authorization is
required to create a single DFMEA for a family of similar
parts or material.
2.2.5 Process Flow Process Flow Diagram Service parts with unique processes that are different from
Diagram(s) production parts require a service Process Flow Diagram
including part processing handling, packaging and
labeling.
Characteristics are traceable to the DFMEA (when supplier
is design responsible)
A Family Process Flow Diagram is acceptable if approved by
the STA.
2.2.6 Process FMEA Process FMEA Characteristics are traceable to the Process Flow Diagram
Process FMEA(s) for safety and regulatory (inverted delta)
components require the Ford Product Development or
Service Engineer and STA approval.
A single PFMEA may apply to a process manufacturing a
family of similar parts or material if approved by the STA.

2.2.7 Control Plan Control Plan Characteristics are traceable to the Process Flow Diagram
The organization submitting the PPAP shall submit a
control plan as it applies to the service process PFMEA and
flowchart
Control Plan(s) for safety and regulatory (inverted delta)
components require the Ford Product Development or
Service Engineer and STA approval.
All SC, CC and HI must be identified in the Control Plan
Shall include provisions for on-going monitoring of process
capability, stability and control
Annual Dimensional Layout requirement shall be included
in the Control Plan
A Family Control Plan is acceptable if approved by the STA.

2.2.8 Measurement Measurement System Analysis Studies Preferred method for calculating Gage R&R is using the
System Analysis Required for all new or modified gages, Analysis of Variance (ANOVA) method.
Studies measurement and test equipment.
Meets the requirements of the Measurement Systems
Analysis and Statistical Process Control manuals from AIAG
and the Ford Motor Company Customer-Specific
Requirements
2.2.9 Dimensional Evidence that dimensional verifications required by the Dimensional results traceable to ballooned drawing,
Results design record and the Control Plan have been including reference dimensions.
completed and results indicate compliance with
specified requirements. Dimensional results traceable to hard copy pictorial to
identify measurements taken (when design record is
CAD/CAM math data)
A minimum of 5 parts (or as approved by STA) shall be
measured and documented
2.2.10 Records of Material Evidence of material and/or performance test results Production Part Approval Material/Performance Test
/ Performance Test for tests specified on the design record and Control Results - Reference CFG-1004 and CFG-1005
Results. Plan

2.2.11 Initial Process Initial Process Studies Ford designated special characteristics (CC, SC or HI) as
Studies For Special Characteristics designated by the defined in the design record.
customer or supplier
Supplier designated special characteristics (CC, SC or HI) as
defined in the Control Plan
Meets the requirements of the Service Production Part
Approval Process 1st Edition from AIAG and the Ford Motor
Company Customer-Specific Requirements
2.2.12 Qualified Internal or external laboratory shall be in compliance When an external laboratory is used test results shall be on
Laboratory with the latest ISO/IEC 17025 the laboratory letterhead.
Documentation Accreditation to ISO/IEC 17025 is not required

General FCSD PPAP Checklist 2 Version 1.0, Dec 2014

FCSD General PPAP Checklist
When parts fall within one of the tabs below (3rd Party Packager, Chemicals, Remanufacturing and Vehicle Personalization) additional requirements may apply,
reference the applicable tab. For Bulk materials use only the Bulk tab.

Supplier -
Supplier / STA - STA - Confirms
Agreed upon Requirement Check all
Element Number PPAP Element Ford Requirements Requirements (Accepted / Guidelines for Requirements that Apply Comments
Name (Required / Not Rejected /Alert to
Required) Required) Submission
(Yes/No)

2.2.13 Appearance Appearance Approval Report (Form CFG-1002) All parts having appearance criteria shall be reviewed and
Approval Report approved by Ford Design Quality
(ARR)
The completed and approved AAR shall be submitted with
the PPAP.
2.2.14 Sample Production Sample Parts The organization shall provide sample product as specified
Parts by the customer
If it is not feasible to ship a sample part, multiple detailed
pictures of the part(s) with distinctive features among parts
within the same part family identified and highlighted.

General FCSD PPAP Checklist 3 Version 1.0, Dec 2014

FCSD General PPAP Checklist
When parts fall within one of the tabs below (3rd Party Packager, Chemicals, Remanufacturing and Vehicle Personalization) additional requirements may apply,
reference the applicable tab. For Bulk materials use only the Bulk tab.

Supplier -
Supplier / STA - STA - Confirms
Agreed upon Requirement Check all
Element Number PPAP Element Ford Requirements Requirements (Accepted / Guidelines for Requirements that Apply Comments
Name (Required / Not Rejected /Alert to
Required) Required) Submission
(Yes/No)

2.2.15 Master Sample Master Sample Master parts shall be identified with the part number and
Retained by supplier show the PPAP approval date
When part size, sheer volume of parts, etc. makes storage
of the master sample difficult, the sample retention
requirements may be modified or waived in writing by the
authorized customer representative.

Master parts shall be retained for each position, cavity,

mold, tool or pattern unless waived by the customer
2.2.16 Checking Aids Checking Aids Certification of all aspects of the checking aid agrees with
Part-specific assembly or component if requested the part dimensional requirements.
Checking aid identified with the proper released
engineering design level
Measurement Analysis Studies (MSA) completed
Preventative maintenance has been identified
2.2.17 Ford Customer- Records of compliance to all applicable customer- Ford Motor Company Customer- Specific Requirements
Specific specific requirements June 2013, Ford use with the PPAP 4.0 and SPPAP 1.0
Requirements
Evidence of compliance to E-108 Branding or Branding
Exception number
2.2.17a FCSD Customer- Records of compliance to all applicable customer- Packaging
Specific specific requirements Must meet FCSD packaging requirements outlined in
Requirements region specific Packaging and Shipping Guidelines
Provide a sample label

Rust
Must meet FCSD rust requirements outlined in region
specific Packaging and Shipping Guidelines
Service Kits with Packaged Chemical Components
Labeling must meet the L1794 Label Package Material
Specification
Dry Friction Materials
Labeling must meet the L1853 Package Material
Specification
Sample barcode label
NA - provide a sample label to STA for review
All other Regions - consult your STA for requirement
Part Release Screen
NA - provide a copy of the GPMA, Part Screen
Information from Direct Data Link (DDL) to the STA for
review
All other Regions - consult your STA for requirement

2.2.18 Part Submission Part Submission Warrant (PSW) Separate PSW for each part number unless otherwise
Warrant (PSW) directed
NA - PSW submitted for service unique parts to be
submitted using Phase 3 or Interim. May not apply to VP
parts.
The Customer Part Number shall include the FCSD Service
part number and the corresponding Ford Engineering part
number
At least one part shall be measured from each cavity, tool,
line or process
Report average weight of 10 pieces in Kg to 4 decimal
places
Part weight as shipped - not to include shipping
protectors, assembly aides or packaging material

For service unique PPAPs the FCSD STA shall determine if

the capacity requirement section is required.
The Alert number for an interim status PPAP shall be
provided on the PSW
Additional STA STA to write-in additional requirements based on PPAP
Commodity scenario
Requirements

General FCSD PPAP Checklist 4 Version 1.0, Dec 2014

FCSD 3rd Party Packagers PPAP Checklist
These requirements are in addition to the requirements outlined on the Production Part Approval Process (see General Checklist tab).

Supplier / STA - STA - Confirms

Requirement Supplier -
Agreed upon (Accepted / Check all that
Element Number PPAP Element Name Ford Requirements Requirements Rejected Guidelines for Requirements Apply to Comments
(Required / Submission
Not Required) /Alert (Yes/No)
Required)

2.3.1 Third Party Packager Process Sheet

Procurement / Kits PPAP Submission Bill of Material (BOM)
Parts and/or kit components purchased Material reporting entered into the International
by the third party packager, individually Materials Data System (IMDS).
packed in retails containers and shipped Service parts for vehicles produced prior to July 1,
to Parts Distribution Centers or Dealers 2003 are exempt.

Appearance Approval Report (AAR), when required All parts having appearance criteria shall be reviewed and
approved by Ford Design Quality
The completed and approved AAR shall be submitted with
the PPAP.
Approved Packaging Specification
Sample packaging label for the unitized product
If required for scanning
Approved Instruction Sheet (I-Sheet) NA - Created by Creative Data and release in
Required when listed within a kit's BOM Teamcenter/Ford Doc
APA -None
EU - None
SA -None

Parts Submission Warrant (PSW) utilizing the One supplier PSW for each purchased part or kit component
Manufacture's Data
2.3.1 Third Party Packager Process Sheet
Consigned / Kits PPAP Submission Bill of Material (BOM)
Parts and/or components of assemblies For Kits only
purchased by the customer and
packaged by the third party packager in Approved Packaging Specification
retail containers and shipped to Part Sample packaging label for the unitized product
Distribution Centers or Dealers If required for scanning
Approved Instruction Sheet (I-Sheet) NA - Created by Creative Data and release in
Required when listed within a kit's BOM Teamcenter/Ford Doc
APA - None
EU - None
SA - None

FCSD 3rd Party Pkg Checklist 5 Version 1, Dec 2014

FCSD Remanufacturing PPAP Checklist
These requirements are in addition to the requirements outlined on the Production Part Approval Process (see General Checklist tab).
STA -
Supplier / STA Confirms Supplier -
- Agreed upon Requirement Check all
Element Number PPAP Element Ford Requirements Requirements (Accepted / Guidelines for Requirements that Apply Comments
Name (Required / Rejected to
Not Required) /Alert Submission
Required) (Yes/No)

2.3.2 Remanufacturing Design Record Bill of Material (BOM)

Remanufacturing Products and Released and authorized Ford design record Mandatory Replacement Part List - MRP List
A formal process that recycles and Requirements (drawing, CAD/CAM) in appropriate system (WERS,
salvages core assemblies from the field Teamcenter, Ford Doc Component Reclaim acceptance criteria
to process them into replacement In Process, Component and End of Line Test requirements
assemblies to customer specifications Fastener Torque requirements
Cleanliness requirements
Product Validation requirements
Audit requirements
DFMEA DFMEA shall be approved by the customer defined
When required engineering and quality organization when required
Product and Packaging Labeling US - Federal Trade Commission requirement
Complies with local, national and regional CAN -
requirements for product identification as a MX -
remanufactured product APA -
EU -
SA -

Material reporting entered into the International

Materials Data System (IMDS).

PPAP deviations Any variations to the PPAP requirements shall be defined

and approved by Ford
Packaging NA - Supplier to package to protect

FCSD Remanufacturing Checklist 6 Version 1, Dec 2014

FCSD Chemical PPAP Checklist
These requirements are in addition to the requirements outlined on the Production Part Approval Process (see General Checklist tab).
STA - Supplier -
Supplier / STA Confirms Check all
- Agreed upon Requirement
Element Number PPAP Element Ford Requirements Requirements (Accepted / Guidelines for Requirements that Apply Comments
Name (Required / Rejected to
Not Required) /Alert Submission
Required) (Yes/No)
2.3.3 Service Chemicals Process Sheet / Part Information Sheet
OEM Production Chemicals PPAP Submission Service parts with unique processes to production require a
Production product packaged for service Process Flow Diagram including part processing
service handling, packaging and labeling.
A Family Process Flow Diagram is acceptable if approved by
the STA.
Characteristics are traceable to the Process Flow Diagram
Control Plan(s) for safety and regulatory (inverted delta)
components require the Ford Product Development or
Service Engineer and STA approval.
All SC, CC and HI must be identified in the Control Plan
A Family Control Plan is acceptable if approved by the STA.
Shall include provisions for on-going monitoring of process
capability, stability and control
Process FMEA Characteristics are traceable to the Process Flow Diagram
Process FMEA(s) for safety and regulatory (inverted delta)
components require the Ford Product Development or
Service Engineer and STA approval.
A single PFMEA may apply to a process manufacturing a
family of similar parts or material if approved by the STA.
Bill of Material (BOM) / Container Size
Material Test Results
Evidence of material and/or performance test results
for tests specified on the design record and Control Plan

Fill Capability Study

Part Submission Warrant (PSW)
Change Notice approval
Drawing approval
Container Size approval
Industrial Hygiene Formulation Submission approval
Hazard Material Submission approval
Material Safety Data Sheet (MSDS) approval
Regulatory Submission approval
Packaging and Graphic approvals
2.3.3 Service Chemicals Process Sheet / Part Information Sheet
OEM Marketed Chemicals PPAP Submission Process Flow Service parts with unique processes to production require a
New product developed for service service Process Flow Diagram including part processing
handling, packaging and labeling.
A Family Process Flow Diagram is acceptable if approved by
the STA.
Control Plan Characteristics are traceable to the Process Flow Diagram
Control Plan(s) for safety and regulatory (inverted delta)
components require the Ford Product Development or
Service Engineer and STA approval.
All SC, CC and HI must be identified in the Control Plan
A Family Control Plan is acceptable if approved by the STA.
Shall include provisions for on-going monitoring of process
capability, stability and control
Process FMEA Characteristics are traceable to the Process Flow Diagram
Process FMEA(s) for safety and regulatory (inverted delta)
components require the Ford Product Development or
Service Engineer and STA approval.
A single PFMEA may apply to a process manufacturing a
family of similar parts or material if approved by the STA.
Bill of Material (BOM) / Container Size
Material Test Results
Evidence of material and/or performance test results
for tests specified on the design record and Control Plan
Fill Capability Study
Part Submission Warrant (PSW)
Application Matrix
DVP&R
Measurement System Analysis
Change Notice approval
Drawing approval
Container Size approval
Industrial Hygiene Formulation Submission approval
Hazard Material Submission approval
Material Safety Data Sheet (MSDS) approval
Regulatory Submission approval
Packaging and Graphic approvals

FCSD Chemical Checklist 7 Version 1.0, Dec 2014

FCSD Bulk PPAP Checklist
Bulk material shall comply with the requirements in the AIAG PPAP Bulk Material Appendix F and the Ford Customer Specific Requirements when specified by the customer. The supplier is responsible for applying
PPAP to their suppliers of ingredients which have organization-designated special characteristics. The minimum submission requirement for bulk materials is the PSW and the Bulk Materials Checklist. For Bulk
Material PPAP submissions, check “Other” in the Reason for Submission Section on the PSW form and specify “Bulk Material.” This indicates that the "Bulk Material Requirements Checklist" was used to specify the
PPAP requirements for the bulk material and shall be included in the submission packet.

Supplier / STA - STA - Confirms Supplier -

Bulk Material Agreed upon Requirement Check all that
Element Number / Requirements Ford Requirements Requirements (Accepted / Guidelines for Requirements Apply to Comments
Name Checklist (Required / Rejected /Alert Submission
Not Required) Required) (Yes/No)

F.3 Product Design and Design Matrix See Service Production Part Approval Process Edition 1.0
Bulk Material Development Correlates customer expectations with product F.4.2 Design Matrix Elaboration and example
Requirements Verification design elements
Checklist

Design FMEA See Service Production Part Approval Process Edition 1.0
F.5 Design FMEA
Special Product Characteristics See Service Production Part Approval Process Edition 1.0
F.7 Special Characteristics
Design Records May include identification of raw materials, formulations,
processing steps and parameters, and final production
specifications or acceptance criteria. If dimensional results
do not apply, then CAD/CAM requirements are also not
applicable.

Prototype Control Plan Prototype (when required) - A listing of tests, evaluations

and their associated specifications/tolerances used to
assess an experimental or developmental formulation. This
may be the only control plan that is product specific.

Appearance Approval Report All parts having appearance criteria shall be reviewed and
Appearance Approval Report (Form CFG-1002) approved by Ford Design Quality
The completed and approved AAR shall be submitted with
the PPAP.
Master Sample Physical Sample
Analytical Sample
Manufacturing Sample Record
Test Results Material test results
Evidence of material and/or performance test results Performance test results
for tests specified on the design record and Control
Dimensional Results
Plan Typically does not apply
Checking Aids Typically does not apply
Engineering Approval Satisfied by a signed 'engineering approval' line on the Bulk
Material Requirements Checklist and/or inclusion on the
customer maintained list of approved materials.

Process Design and Process Flow Diagram / Process Flow Description For bulk material, an equivalent to a Process Flow Diagram
Development is a Process Flow Description
Verification
Process FMEA See Service Production Part Approval Process Edition 1.0
F.6 Process FMEA
See Service Production Part Approval Process Edition 1.0
Special Product Characteristics SeeF.6
Service Production
Process FMEA Part Approval Process Edition 1.0
F.7 Special Characteristics
Pre-Launch Control Plan Pre-launch - Documentation of the product/process control
characteristics, process controls affecting Special
Characteristics, associated tests, and measurement systems
employed during product scale up and prior to normal
production.

Production Control Plan Production - Documentation of the product/process

control characteristics, process controls affecting Special
Characteristics, associated tests, and measurement systems
employed during normal production. Additional items may
be included at the Organization’s discretion.

Measurement System Analysis See Service Production Part Approval Process Edition 1.0
F.9 Measurement System Analysis
May not apply. Customer agreement should be obtained
Interim Approval See Service Production Part Approval Process Edition 1.0
F.13 Interim Approval - 'Bulk Material Interim Approval'
form

Product and Initial Process Studies Obtain customer agreement regarding the appropriate
Process Validation technique for initial process studies, if required.
Part Submission Warrant Part weight field is not applicable
Elements to be Customer Plant Connection Develop a list of Special Characteristics and Attributes
completed as Construct a Customer Process Matrix
needed
Customer Process FMEA
Customer Process Control Plan

FCSD Bulk Checklist 8 Version 1.0, Dec 2014