SUPPLIER

BAE Systems PPAP Guide

Doc #: B45157

May 24, 2018

Page 1 of 28

Author: Pete Trainor

SUMMARY

The purpose of the PPAP Submission Guide is to assist the supplier to

complete the various aspects of the Enhanced First Article (PPAP).
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Revision History
Rev Date Description
- 24 May 2018 Initial release per DCR DRB31135

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Table of Contents
BAE Systems PPAP Guide......................................................................................................................................1
1.0 Purpose.....................................................................................................................................................4
2.0 Scope - When is PPAP Submission Required?...........................................................................................4
3.0 Reference Documents..............................................................................................................................4
4.0 Terms and Definitions.....................................................................................................................................5
5.0 Requirements for PPAP Submission:........................................................................................................8
5.1 Supplier PPAP Checklist............................................................................................................................9
5.2 Submission Method..................................................................................................................................9
5.3 Submission Status...................................................................................................................................10
5.4 Ongoing Requirements.......................................................................................................................10
6.0 Instructions for completing a PPAP Submission.....................................................................................10
6.1 Part Submission Warrant (PSW).........................................................................................................10
6.2 Design Records and Ballooned Drawings...........................................................................................12
6.3 Approved Engineering Change Documentation..................................................................................13
6.4 Customer Engineering Approvals.......................................................................................................13
6.5 Design Failure Mode and Effects Analysis (DFMEA).......................................................................14
6.6 Process Flow Diagrams......................................................................................................................15
6.7 Process Failure Mode Effects Analysis (PFMEA)..............................................................................16
6.8 Control Plan........................................................................................................................................18
6.9 Measurement System Analysis (MSA)..............................................................................................20
6.10 Dimensional Results...........................................................................................................................22
6.11 Material and Performance Test Results..............................................................................................25
6.12 Initial Process Study (Cpk, Ppk).........................................................................................................25
6.13 Qualified Laboratory Documentation.................................................................................................26
6.14 Sample Parts.......................................................................................................................................26
6.15 Checking Aids....................................................................................................................................27
6.16 Customer Specific Requirements........................................................................................................27

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1.0 Purpose
The purpose of the PPAP Submission Guide is to assist the supplier to complete the various aspects
of the Enhanced First Article (PPAP) as part of a process in accordance with AS9145.

The purpose of the Production Part Approval Process (PPAP) is:

A. To provide the evidence that all engineering, design record and specification requirements
are properly understood and fulfilled by the manufacturing organization.
B. To demonstrate that the established manufacturing process has the potential to produce
consistently conforming product which meets all requirements during an actual production
run at the quoted production rate.

2.0 Scope - When is PPAP Submission Required?

BAE may require a PPAP submission per purchase order requirements, when any of the following
occur:

New parts, process or suppliers

A. New part or product

B. New process or technology
C. New supplier

Changes to existing product

A. Change to design including material, construction or component.
B. New, additional or modified tools
C. Refurbishment of current tools
D. Production or equipment transfer to a different location
E. Change of sub supplier or material source
F. New source of raw material
G. Change in production process or method
H. Product when tooling has been inactive for 12 months or greater.
I. Major environmental impact affecting fit, form or function of the product.

3.0 Reference Documents

SAE International AS9145™ – Requirements for Advanced Product Quality Planning
and Production Part Approval Process
SAE International AS9103 – Variation Management of Key Characteristics
AIAG FMEA Manual- 4th Edition
AIAG APQP Manual
AIAG PPAP Manual- 4th Edition
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AIAG SPC Manual

AIAG MSA Manual-3d Edition
IEEE 1490:2011 Adoption of the Project Management Institute (PMI(R)) Standard; A
Guide to the Project Management Body of Knowledge
BAE Supplier Variation Request (SVR)

4.0 Terms and Definitions

Bill of Material (BOM):

Total list of all components and materials contained in the design record of a product required to
manufacture the product.

Containment:
Recognition, identification and where possible, the segregation of the entire population affected by the
condition of nonconformance. Containment includes raw material, stock inventory, kits, work-in-
process, product in sell-off, finished goods inventory, goods in transit, and goods at BAE.

Control Plan:
A written description of the systems for controlling production parts, materials and processes. Control
plans identify the important characteristics and engineering specifications of the product and how they
are controlled to assure quality of the product. The control plan should be linked to the process flow
diagram and the process failures modes and effects analysis.

Critical Item (CI):

Those items (e.g., functions, parts, characteristics, processes) having significant effect on the product
realization and use of the product; including safety, performance, form, fit, function, producibility,
service life, etc.; that require specific actions to ensure they are adequately managed. Examples include:
safety CIs, fracture CIs, mission CIs, Key Characteristics (KCs), and maintenance tasks critical for
safety (reference AS9103 standard).

Correction:
Action taken to eliminate a detected nonconformity

Customer:
The recipient of the supplier’s or organizations products or service.

Deliverables:
Outputs completed as part of the APQP/PPAP process.

Design Failure Mode and Effects Analysis (DFMEA)

An organized methodology used to assure that potential design risks are mitigated through mistake
proofing and design/process enhancements. Potential risks are ranked and prioritized for improvement.

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Design Records:
The records of the engineering definition/specification, that fully define the product (system, part,
component, or assembly), including physical or electronic/digital drawings, electronic/digital models,
software, or other associated information. This includes records of authorized engineering changes
(Approved via SVR) not yet incorporated into the released engineering definition/specification.

Design Risk Analysis:

Analytical techniques used by the design responsible organization to identify, to the extent possible,
potential failure modes related to product performance (i.e., fit, form, and function), durability,
manufacturability, and cost.

Design Validation
The assurance that a product, service, or system fulfills the needs of the customer and other identified
stakeholders. It often involves acceptance with external customers (defined in IEEE 1490:2011).
Relevant types of validation include: – Confirmation through the provision of objective evidence, that
the requirements for a specific intended use or application have been fulfilled. Testing and/or analysis to
ensure the product design conforms to defined user needs and/or requirements. Design validation
follows successful design verification and may involve preproduction product (e.g., development,
prototype) [reference AIAG Advanced Product Quality Planning and Control Plan].

Design Verification
Testing to assure that all design outputs meet the requirements of the design inputs with objective
evidence that the specified product requirements have been fulfilled. Testing and/or analysis to ensure
that all design outputs satisfy requirements may include activities such as: design review, performing
alternate calculations, understanding tests and demonstrations, and review of design stage documents
before release (reference AIAG Advanced Product Quality Planning and Control Plan).

Key Characteristic (KC)

An attribute or feature whose variation has a significant influence on product fit, performance, service
life, or producibility; that requires specific action for the purpose of controlling variation (reference
AS9103 standard).

Measurement Systems Analysis (MSA)

A study of the effects of selected elements (repeatability and reproducibility) of a measurement process
on accuracy, precision, and uncertainty of measurement.

Nonconformance:
The failure or potential failure of a characteristic to conform to the requirements specified in a contract,
purchase order, drawing, specification or other approved product description. Potential/suspect non-
conformances include improper handling, storage, transport, and exposure to out-of-tolerance
environmental, test or process conditions.

Nonconforming Material:
Any item, part, or product containing one or more nonconformance

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Preliminary Capacity Assessment:

An assessment performed early in the process planning and development phase to determine resources
(e.g., people, equipment, facilities) necessary to produce product at the customer demand rate.

Preventive Action:
Action to eliminate the cause of a potential nonconformity or other undesirable condition. If a
nonconformance has not occurred, but an action is taken to proactively reduce the risk of a
nonconformance, the action is preventive.

Process Capability:
Comparing actual process performance with process specification limits using measure e.g.: Cpk, CP,
Sigma Level and parts defective parts per million.
Failure Mode and Effects Analysis (FMEA)
An organized methodology used to assure that potential design and manufacturing risks are mitigated
through mistake proofing and design/process enhancements. Potential risks are ranked and prioritized
for improvement.

Process Failure Mode and Effects Analysis (PFMEA)

An organized methodology used to assure that potential manufacturing risks are mitigated through
mistake proofing and design/process enhancements. Potential risks are ranked and prioritized for
improvement.

Process Validation:
Confirmation through physical demonstration that a process consistently produces a result or product
fulfilling its predetermined specifications, including key product or process characteristics which are
stable and capable at the desired level.

Production Process Verification (PPV):

A review of the manufacturing process (e.g., equipment, operator training, manufacturing
documentation, control plan, associated measurement tools) by a multi-disciplinary team to verify that
the production processes are appropriately defined, documented, and ready for production.

Rework:
A procedure applied to a nonconformance that will completely eliminate the nonconformance, and result
in a characteristic that conforms completely to the drawing, specification or contractual requirement.

SCAR:
Supplier Corrective Action Request

Scrap:
Nonconforming material that is not usable for its intended purpose that cannot be economically
reworked.

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Supplier:
The entity or party that supplies product or services to a customer in accordance with contract
requirements.

5.0 Requirements for PPAP Submission:

BAE Systems PPAP requirements are based on the existing AIAG "Production Part Approval
Process" standard. Depending on the level of submission one or more of the following elements
may be required:

A. Part Submission Warrant

B. Samples of Part
C. BAE Systems Approved Drawing of Revision level being submitted. The drawing must
also be labeled for cross - reference with dimensional layout.
D. Dimensional Layout
E. Material Analysis
F. Design Verification Plan and Test Results, If Applicable
G. Approved Appearance Approval Form, If Applicable
H. Process Capability Studies with Ppk > 1.67 and data of Key Significant Characteristics
I. Control Plan
J. Process FMEA
K. Process Flow Diagram
L. Gage Repeatability and Reproducibility Studies

Note: BAE Systems provides suggested templates of all forms for the PPAP submittal, however
Supplier generated forms meeting the requirements of SAE INTERNATIONAL AS9145™ or AIAG
may also be utilized.

Completion and submission of PPAP records conveys no additional data rights to BAE Systems than
that defined in the respective Procurement Agreement.

The documents to be submitted are determined by which level of submission BAE Systems requests.
If not specified the supplier must submit level 3, which is the BAE Systems default submission level.

Note: The PPAP Supplier Checklist found in the BAE PPAP forms package is interactive and will
identify the forms required for each submittal after typing the submittal level on the top right hand
box.

Those documents not submitted will be kept on file at the supplier's location and be readily available
if needed. For more details about levels of submission or PPAP requirements the AIAG manual
"Production Part Approval Process", is a good reference guide.

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5.1 Supplier PPAP Checklist

The level of PPAP submission is determined by BAE Systems, the default submission will be PPAP
level 3 unless specifically notified by BAE Systems.

To assist the Supplier to ensure all relevant documentation / evidence is submitted BAE Systems
have developed a Supplier PPAP Checklist. This document can also be used by the Supplier to
document concerns, comments and questions against the relevant PPAP elements. All concerns,
comments and questions will be reviewed by BAE Systems during PPAP submission review and
will take the appropriate actions.

PPAP Submission Requirements Submission Level

Production Part Approval Process Supplier Checklist (Please Type 1-5) 3

BAE Part Number Part Description Supplier Name

Revision Level BAE Purchasing Rep. Submission Date
Primary Manufacturing Site Purchasing Rep Phone # PPAP Due Date

PPAP Requirements

Included
Element

Analogic Check Applicable Requirements

Level 1
Level 2
Level 3
Level 4
Level 5
Order

Important: Submit your

documents in this order.
Comments/Concerns/Questions

Part Submission Warrant

1 S S S S R YES
(PSW)

Customer Approved
2 Drawings of Revision Level R S S * R YES
being submitted.

3 Process Flow Diagrams R R S * R YES

4 Process FMEA R S S * R YES

YES
5 Control Plan R R S * R

Measurement System YES

6 R R S * R
Analysis Studies

Please note that the checklist is to be included during the PPAP submission.

5.2 Submission Method

PPAPs ARE NOT TO BE SENT VIA REGULAR, UNSECURE EMAIL!!!

PPAPs are considered Technical Data and therefore must be controlled in accordance with contractual
requirements specified in the special provisions of the Purchase Order / Subcontract or incorporated
Terms and Conditions. Such requirements may include ITAR, Export Control, and Proprietary
Information Agreements. Unclassified technical data shall be submitted through BAE Systems
approved methods including but not necessarily limited to Secure File Transfer System (SFTS),
Exostar, or physical mail.

Classified technical data shall be specially handled as specified in the Purchase Order or Subcontract.

Contact your BAE Systems procurement representative to confirm the approved transmittal method.
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5.3 Submission Status

The PPAP approval process will be carried out by BAE Systems. The PPAP submission will be
reviewed and dispositioned one of the following ways:

APPROVED: A formal acceptance of the submission which has met all of the criteria set by BAE
Systems.

REJECTED: The submission is not acceptable and does not meet the criteria set by BAE Systems.

INTERIM: An interim approval can be given if it is deemed by BAE Systems that product is
useable. The interim status is a temporary approval for a specified time-frame which is determined
by BAE Systems. The supplier must implement the required corrective actions and re-submit PPAP
for full approval during this time frame. If a re-submission does not occur within the required time-
frame the PPAP will be rejected.

5.4 Ongoing Requirements

BAE Systems reserves the right to request any information you have provided in any data or
document in any element of approval, at any time, including after the approval has been granted.

6.0 Instructions for completing a PPAP Submission

6.1 Part Submission Warrant (PSW)

The purpose of the Part Submission Warrant (PSW) is to document the submission and the approval
or rejection of purchased parts prior to production. BAE Systems has developed its own PSW
document and is a required part of the PPAP submission.

Completing the Part Submission Warrant

The PSW form must be filled out and signed by the supplier.

The part number must match the Purchase Order issued by BAE Systems.

The correct revision level and submission level must be entered.

Any fields that do not apply to your submission should be filled in with “N/A” (Not Applicable).

It is important that the PSW is filled out correctly and contains accurate and legible information.
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PPAP Approval
1. Part Number:
2. Part Name:
3. Part Revision Level: 6. Additional Changes:
4. Drawing Number 7. Customer Purchasing Rep:
5. Drawing Revision Level: 8. Purchase Order Number:
Supplier Information
9. Organization Name: 10. Supplier Number
11. Address (Street, City, State, Country, Postal Code):
12. Submission
Full Submission Initial Submission
Partial Submission Resubmission PPAP Level: (1-5) _____ Reason:
13a. PPAP Elements Provided 13b. Customer PPAP Element Acceptance (Customer U
Yes No N/A Element Description Yes No Customer Comments
1. Design Records
2. Design Risk Analysis (e.g., DFMEA)
3. Process Flow Diagram
4. Process FMEA
5. Control Plan
6. Measurement System Analysis
7. Initial Process Studies
8. Packaging, Preservation, and Labelling Approvals
9. First Article Inspection Report (Including all material certs)
10. Customer Specific PPAP Requirements
Note: "No" selections in Section 13a require an Action Plan item documented in Section 14 below
14. Action Plan Element #

15. Declaration
I, the supplier, submit this PPAP Approval form as declaration of having met all applicable requirements of the AS9145 standard, except as noted a
having implemented the requirements at the sub-tier level where applicable. I further certify that our production process meets all defined product
engineering and quality requirements. I understand that the approval of this form by the customer does not release me from responsibility or liabil
conformances.

Name (clearly print and sign) Title Email Address

16. Approval (Customer Use Only)
Approved Interim Approval Rejected

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6.2 Design Records and Ballooned Drawings

The purpose of designed records and ballooned drawings is to document and provide a copy of the
formal print and to provide any additional engineering records for reference.

A ballooned drawing shows the parts or assemblies in a part print with numbered “balloons” that
point to individual requirements of the part. The numbers on the ballooned drawing correlate with
the numbers found on the Dimensional Data Sheet. A ballooned drawing must be submitted as part
of the PPAP for every submission when dimensional results are required.

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Completing the balloon drawing

All part requirements on the BAE Systems or Supplier print must be ballooned and numbered for
reference and measurement. These may include:

A. Dimensions and tolerance of parts

B. Electrical requirements (performance data, functional tests, etc)
C. Visual features (color, texture, etc)
D. Chemical characteristics (cure time, etc)
E. Physical and mechanical properties (tensile strength, plating thickness, heat treat hardness, etc)
F. Any other specified requirement that you have the capability to measure or that is described in
the print notes or reference specifications.

When dimensions are specified at multiple location on the drawing, the data for each location should
be numbered separately.

6.3 Approved Engineering Change Documentation

This section is used to cover anything that is not addressed in a part print such a Supplier Variation
Request for Deviation (SVR).

A. BAE Systems ECOs must be approved and not pending.

B. Print change submissions must have current prints.
C. All supplier initiated changes must have a copy of the approved BAE deviation form.

The Supplier Variation Request (SVR) must be approved by BAE Systems. The supplier must not
proceed with the change until an approved SVR has been provided by BAE Systems.

6.4 Customer Engineering Approvals

The supplier submission is to include BAE Systems Engineering Approval documentation when
requested. This will only be requested if the supplier has design authority of the parts/products.

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6.5 Design Failure Mode and Effects Analysis (DFMEA)

Note: BAE Systems only requires a Design Failure Mode and Effects Analysis (DFMEA) to be
included if the supplier has design authority.

A Design Failure Mode and Effects Analysis (DFMEA) shows evidence that potential failure modes
and their associated risks have been addressed in order to eliminate or minimize their effects through
product design changed and improvements.

The DFMEA is only required when the supplier has design authority of the product. The DFMEA
must address all Critical Items (CI).

Severity, Occurrence and Detection ratings are used when performing FMEA activities. These
rating scales must be compliant with the AIAG guidelines for FMEA.

Any potential failure mode not mitigated in the DFMEA should be included in the PFMEA.

When completing the FMEA an action plan must be established in line with the risk analysis table
shown below:

Green area - no actions needed

Yellow area - no mandatory actions required, but corrective and preventative actions should be
defined and communicated to BAE Systems to reduce the risk to both parties

Red area - mandatory corrective and preventative actions are required and shall be communicated to
BAE Systems to reduce the risk to both parties

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Completing the DFMEA

The DFMEA supports the design process by reducing the risk of failures. The DFMEA should be
initiated before the design concept is finalized. Each item / function needs to be addressed. Any
potential failure mode of the item / function should be defined as completely as possible.
Recommended actions should be recorded.

Prevention is the preferred method to address the design failure mode. If prevention is not possible,
then highlight detection controls. The DFMEA is not a standalone document and should also be
linked to the PFMEA and Control Plans.

BAE Systems has developed a DFMEA form which can be utilized by suppliers. The form uses
embedded ratings which will automatically produce the initial Risk Priority Number (RPN)
Severity x Occurrence x Detection = RPN

Example of BAE Systems DFMEA form –

DESIGN FAILURE MODE ANALYSIS
(DESIGN FMEA)
FMEA number
Item Process Responsibility No. of Pages
Part Number Key dates Prepared by
Core Team FMEA date (Orig.) Rev. Date
C O D
PROCESS Actions Results
S L Potential Cause(s) / C E R Responsibility &
FUNCTION Potential Failure Potential Effect(s) of Current Process Controls Current Process Controls Recommended S O D R
E A Mechanism(s) of C T P Target Completion E C E P
REQUIREMENTS Mode Failure V S U Prevention Detection E N Action(s) Actions Taken
S
Failure R C
Completion Date Date V C T N
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0

6.6 Process Flow Diagrams

The purpose of Process Flow Diagrams is to document and clarify all the steps required in the
manufacturing of a part. The primary process steps must match both the PFMEA and the Control
Plan. Process flows must include the entire manufacturing process, receiving through shipping.

The Process Flow Diagram must also include key steps in the process and all offline activities (such
as measurement, inspection and handling). The flow of the nonconforming material such as scrap
parts, non-conforming parts and rework parts should also be included The supplier is not authorized
to perform a repair on a part. Note: Suppliers may utilize their own Process Flow Diagram format.
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6.7 Process Failure Mode Effects Analysis (PFMEA)

The Process Failure Mode Effects Analysis (PFMEA) is used to show evidence that any potential
failure modes and risks have been addressed at the manufacturing level.

A PFMEA should be performed for every part, piece or equipment or process involved in
manufacturing. The PFMEA is a cross functional activity and should not be conducted in isolation.
POTENTIAL FAILURE MODE ANALYSIS
(PROCESS FMEA)
FMEA number
Item Process Responsibility No. of Pages
Part Number Key dates Prepared by
Core Team FMEA date (Orig.) R

PROCESS C O D Acti
S L Potential Cause(s) / C E R Responsibility &
FUNCTION Potential Failure Potential Effect(s) of Current Process Controls Current Process Controls Recommended
E A Mechanism(s) of C T P Target Completion Completion
REQUIREMENTS Mode Failure V S U Prevention Detection E N Action(s)
Failure Date Date
S R C
0
0
0
0
0
0
0

When calculating the Risk Priority Number (RPN) for the PFMEA the following rating mechanism
should be utilized to assess Severity, Occurrence, and Detection: (Severity x Occurrence x Detection = RPN)

Severity: An assessment of how serious the Failure Effect (due to the Failure Mode) is to the customer:

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Occurrence: An assessment of the likelihood that a particular cause will happen and result in the
Failure Mode:

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Detection: An assessment of the likelihood that the current controls will detect the cause of the Failure
Mode or the Failure Mode itself, should it occur, thus PREVENTING the Failure Effect from reaching
your customer. The customer in this case could be the next operation, subsequent operations, or the end
user:

The PFMEA worksheet is a tool used to identify and show potential process risks associated with the
manufacture of each part. It also highlights the controls at each stage of the manufacturing process;
this detail should read across to the Control Plan.

6.8 Control Plan

A Control Plan defines the operation, processes, materials, equipment, methodologies and CIs for
controlling variations in key product or process characteristics integral to the manufacturing process.
Its purpose is to communicate the supplier’s decisions during the entire manufacturing process from
material purchase through to final shipping. Specifically the control plan should address the
following:

A. Methods of production
B. Identification of CI characteristics
C. Secondary or Outsourced Operations
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D. Materials and their physical and chemical characteristics

E. Types of process equipment at each operation
F. Types of test equipment used to measure each characteristic
G. Specifications, sampling strategy, control and reaction methods used.
H. Periodic conformance testing and product verification

All processes must have a control plan that defines all methods used for process control and
complies with BAE Systems specified requirements. The control plan must clearly state each step in
the process; the specification and all CI characteristics must be addressed for product and process.
The Process Flow Diagram, PFMEA and Control Plan should be linked. Each major process step in
the process flow diagram should correlate with PFMEA steps and there should be documented
control plan actions for each of the steps.

Completing the Control Plan

This is a process whereby the Supplier simply documents all materials and processes involved in the
manufacturing process from start to finish. The process flow diagram, ballooned drawing, and
PFMEA all provide inputs to the Control Plan. All CIs identified as Process, First-Piece or Safety
Related by the supplier or BAE Systems must be listed on the Control Plan.

A control plan should address all testing requirements, inspection and measurements that are
required to verify product quality and conformity. The control plan should not be excessively
dependent on visual inspection and should always target prevention techniques wherever possible.

The control plan should be developed in stages, from Prototype to Pre-Production and then into
Production. The control plan is a “living” document and should be updated to reflect any changes to
the manufacturing process and its controls.

BAE Systems has developed a Control Plan format which is available for suppliers to utilize if
required.

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Example of Control Plan document

BAE CONTROL PLAN

Proto-Type Pre-Launch Production Key Contact / Phone Date of Origination Date of Latest Revision - ref.
Control Plan Number M/DD/YY
M/DD/YY
Part Number / Latest Revision Change Core Team Customer Engineering Approval / Date (If Required)

Part Name / Description Supplier / Plant Approval / Date (If Required) Customer Quality Approval / Date (If Required)

Supplier / Plant Supplier Code Other Approval / Date (If Required) Other Approval / Date (If Required)

Part / Process Name / Machine, Device, Characteristics Special Methods

Process Operation Jig, Tools Char. Product / Process Measurement Sample Reaction Plan
No. Product Process Control Method
Number Description for Mfg. Class Specification / Tolerance Technique Size Freq.

6.9 Measurement System Analysis (MSA)

Measurement System Analysis (MSA) is a mathematical method of determining how much variation
within the measurement process contributes to overall process variability. MSA is used to ensure the
right measurement equipment is used to qualify production parts or processes.

BAE Systems requires an MSA study to be conducted on all measurement equipment that is used to
accept or fail the product. This generally covers all measurement tools identified in the control plan.

A Gauge Repeatability and Reproducibility (GR&R) study is used to ensure that measurements
taken in the manufacturing process and reasonably consistent regardless of how many times they are
performed or how had performed them. It is important to select a sample size that encompasses the
full range of parts.

BAE Systems recommends the following acceptance levels to be used:

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1) % R&R should be 10% or less for CIs

2) Marginal gauges (between 10% and 30%) should have an action plan to address and improve
the method of measurement.
3) Gauges with R&R at 30% or more must not be used.

Statistical software, IE: Mini-tab, SPC Excel or equivalent may be utilized to conduct the
measurement study. BAE Systems has also developed at GR&R worksheet for the suppliers to
utilize. Instructions on how to complete the GR&R are included in the worksheet.

Example of GR&R worksheet

GAUGE R&R TEMPLATE

Hold Cursor Here for Directions
Part Number: Comments:
Part Revision:
Part Description: Nominal=
Date Completed: + TOL=
Gage Name: -TOL =
Gage Number:
Cal Date:

Measurements
OPER1 OPER2 OPER3 OPER4 OPER5

Part trial 1 trial 2 Range trial 1 trial 2 Range trial 1 trial 2 Range trial 1 trial 2 Range trial 1 trial 2 Range
1
2
3
4
5
6
7
8
9
10
X-bar X-bar X-bar X-bar X-bar
# persons R-bar R-bar R-bar R-bar R-bar
# parts (n) MaxR MaxR MaxR MaxR MaxR
# trial (m)
LSL 0.000 USL 0.000 Max X-bar 0.0000 R-double bar =

a 0.00 Total Tolerance 0.0000 Min X-bar 0.0000 UCLR = R-double bar x D4
b 0.00 X-bar diff 0.0000 UCLR =
D4 = 0.00 If R values in study are greater
than UCLR, these are statistical
outlier and need evaluation

Repeatability Reproductibility GAGE R&R

2 2 1/2 2 2 1/2
EV=(R-double bar) x a Av=(X-bar diff x b) -(EV) /n/m) R&R = (EV +AV )
EV= AV = R&R =

%EV = 100(EV/tolerance) %AV = 100(AV/tolerance) %R&R = 100(R&R/tolerance)

%EV = %AV = %R&R = 0.0%

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6.10 Dimensional Results

The Dimensional Results are documented in the Dimensional Data Sheet referenced earlier in this
document. The measurements in this form should correlate with your ballooned drawing from Item
6.2.

The parts used for dimensional data must be from production tooling / process and randomly
sampled (if possible) from a run at production rate. The dimensional report must address all of the
following:

A. All dimensions
B. All applicable notes on the drawing
C. Any dimensions contained on reference prints

Note: The parts measured to obtain the dimensional results must be the same parts submitted for
PPAP approval.

Completing the Dimensional Data Sheet

All dimensional requirements on the ballooned drawing must be listed on the dimensional data sheet.
All sections of the dimensional data sheet must be filled out completely. The measurement method
must be documented for every line item.

When a specific feature on the drawing has multiple requirements I.E. GD&T symbols the data must
be recorded on individual line items with the dimensional data sheet.

Example: This call out would require 3 lines of separate data on the dimensional report.

1. Hole diameter (25+/-0.2)

2. True Position (0.05 MMC on datum A,B,C)
3. Cylindricity (0.1)

Dimensional Data and all requirements should be documented via the standard BAE Systems FAI
process per BAE Systems B25279:

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Note: Any concerns identified in the Dimensional Data should be brought to the attention of BAE
Systems before submitting your PPAP.

6.11 Material and Performance Test Results

The purpose of this item is to ensure that the material is verified for its properties and acceptable
performance is demonstrated.

Material test results should be provided in the form of a material composition report also called a
Certificate of Analysis (CofA) from an accredited lab that confirms the material content meets a
known standard, IE: Chemical and Physical Analysis Report.

It is the Supplier’s responsibility to confirm the composition of material not only at PPAP
submission stage but also ongoing during the life of the product / project. This step should be placed
into the FMEA process and the Control Plan.

A Certificate of Compliance (C of C) is acceptable during production shipping but is not acceptable

during PPAP submission as the C of C will not give actual test results.

Performance Test Results should be acceptable, and meet the agreed upon specifications to be
measured. Performance results may include data confirming any referenced specifications in the
part print or specific testing required by BAE.

BAE Systems will communicate specific material, performance and testing requirements either in
the part print, reference specifications or by a specific request prior to PPAP approval. It is the
responsibility of the supplier to confirm the data and format of this requirement with the appropriate
BAE Systems representative.

Test Data should not be submitted with the PPAP unless the purchase order calls out material clause
111 or 111T.

6.12 Initial Process Study (Cpk, Ppk)

The purpose of initial process studies (cp, Cpk, Pp, Ppk) is to determine if the production process is
likely to manufacture product that will meet BAE Systems requirements. Initial process studies
(capability) are highly recommended for all CIs.

There are two primary indexes used in determining process capability.

Cpk predicts future capability and should be used when developing new parts or revising
specifications on a part. Cpk should also be used when materials, processes, manufacturing location,
or equipment have changed or Material suppliers have changed.

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Ppk indicates past performance. Use Ppk when you are a new supplier to BAE Systems but have
already been manufacturing the part which BAE will purchase.

The capability study is to be performed on samples taken from an actual production run at the quoted
production rates. The minimum acceptance capability for all CIs is 1.33 and 1.67 for all safety
related CI’s.

The supplier can submit the Capability data on the format of their choice, and Mini-tab, SPC Excel
or equivalent may be utilized.

6.13 Qualified Laboratory Documentation

The purpose of Qualified Laboratory Documentation is to ensure that the testing for PPAP has been
done by a qualified lab. If your organization is performing testing or measurement internally or
externally at an outside facility, then proof of Scope and accreditation is required.

Internal Labs located at Supplier

All suppliers that have testing or measurement performed on site must provide the following in this
section of the PPAP submission:

A. Record / Scope that identifies the testing to be done and it must include:
B. List of your personnel’s competency and training to perform the testing.
C. List of all test equipment used in process and offline.
D. List of methods and standards used to calibrate the equipment.

External Labs located offsite from the Supplier

If you are sending out for measurement and testing, you must ensure that you use an accredited lab
and can provide proof of accreditation. BAE prefers external labs be accredited to known standards
such as ISO 17025, ISO 10012:2004, or ANSI/NCSL Z540-1-1994.

A. Provide a copy of the lab company’s Third Party accreditation.

B. Results must be on company letterhead and include the following:
 The name of the lab
 Date of testing
 Standards used for testing

6.14 Sample Parts

Sample parts are to be included and are to be the actual samples measured in the dimensional
analysis (Item 6.10). Sample parts are to be delivered with or before the PPAP submission.

The PPAP samples should be delivered with the label identifying them as PPAP Samples.

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This is to avoid the PPAP sample parts being inadvertently misplaced or mixed up with production
parts.

6.15 Checking Aids

The purpose of this item is to provide evidence that the checking aids used to verify product exist
and have been properly validated.

There are many different types of checking aids. Examples of checking aids include but are not
limited to certified check fixtures, un-certified check fixtures, templates, custom gauges and test
equipment.

BAE requires all checking aids to be verified as repeatable through an MSA study. The MSA can be
either attribute or variable depending on the type of checking aid in use.

6.16 Customer Specific Requirements

This item is to address BAE specific requirements during PPAP submission.

BAE will advise during the PPAP process on specific requirements as there may vary depending on
the scope of the project / product being supplied. This item is also utilized to flow down
requirements of BAE’s customers to ensure these elements are captured during PPAP submission.

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