DRAFT Attachment 0164 - JLTV PPAP Requirements(3).docx

JPO JLTV CUSTOMER-SPECIFIC REQUIREMENTS DOCUMENT - PPAP

JPO JLTV CUSTOMER-SPECIFIC REQUIREMENTS DOCUMENT - PPAP

UNCLASSIFIED

Draft Attachment 0164

JPO-JLTV

PRODUCTION PART APPROVAL PROCESS

(PPAP)

CUSTOMER-SPECIFIC REQUIREMENTS

DOCUMENT

October 2021

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

UNCLASSIFIED

Scope:

The requirements herein provide additional guidance for the minimum requirements of the Fourth Edition of the Automotive Industry Action Group (AIAG) Production Part Approval Process (PPAP) manual as required by the Joint Light Tactical Vehicle (JLTV) Production and Development contract. Unless specifically stated herein, all requirements of the AIAG PPAP Manual Fourth Edition apply.

When applying the requirements and definitions of the AIAG PPAP Manual (Fourth Edition), “the customer” refers to the Government and “the organization” refers to the Contractor. The contractor shall assume the role of “authorized customer representative” when flowing down the JLTV Level 3 PPAP requirements to its supply base, but the Government remains the “customer” and retains the authority to specify the requirements for all Level 3 PPAP submission content, regardless of who the manufacturer of the component is.

The Contractor is authorized to issue Interim or Full Approval for all Level 3 PPAPs which meet the requirements specified herein and any applicable requirements specified in the AIAG PPAP manual Fourth Edition if not specifically discussed within this document (as described above), with the exception of parts that are manufactured by the contractor or contain Component First Article Test (CFAT) specified on the drawing. For parts that are manufactured by the contractor or contain CFAT requirements on the component drawing, the Government retains the approval authority for the corresponding PPAPs.

All parts shall achieve Interim or Full PPAP Approval to the requirements specified herein prior to the introduction of parts at the point of assembly or fabrication into the end item. The Contractor is not authorized to waive or modify any PPAP requirement without Government approval.

Submission Requirements:

Level 3 PPAP submissions are required for all parts, including subcomponents if the part or assembly is purchased at a higher level than the lowest level defined in the JLTV Technical Data Package and Computer Software Package. Submission requirements for each PPAP level are found in Table 4.2 of the PPAP Manual (Fourth Edition).

Detailed PPAP Requirements:

1. Design Record (Reference AIAG PPAP Manual 2.2.1)

a. Engineering Drawings (and 3D Models where appropriate) shall accompany each PPAP submittal.

2. Authorized Engineering Change Documents (Reference AIAG PPAP Manual 2.2.2)

a. If authorized by a Government-approved Request for Deviation (RFD), the Government approved redlined drawing shall accompany the PPAP submittal.

3. Customer Engineering Approval (Reference AIAG PPAP Manual 2.2.3)

a. Only fully-released and approved drawings shall be utilized for PPAP unless a Government approved RFD is in place.

4. Design Failure Mode and Effects Analysis (Design FMEA) (Reference AIAG PPAP Manual 2.2.4)

a. DFMEA is required at the component level for all parts where the manufacturer is design responsible. This includes product built by the Contractor at the Contractor’s facilities.

5. Process Flow Diagram(s) (Reference AIAG PPAP Manual 2.2.5)

a. No additional guidance is required.

b. Process Flow Diagrams are required for all PPAP submittals.

6. Process Failure Mode and Effects Analysis (Process FMEA) (Reference AIAG PPAP Manual 2.2.6)

a. No additional guidance is required.

b. PFMEAs are required for all PPAP submittals.

7. Control Plan (Reference AIAG PPAP Manual 2.2.7)

a. No additional guidance is required.

b. Control Plans are required for all PPAP submittals.

8. Measurement Systems Analysis (MSA) Studies (Reference AIAG PPAP Manual 2.2.8)

a. The contractor shall implement and comply with the MSA requirements of the contract.

b. MSA is required for all measurement devices as identified in the PPAP manual.

c. All measurement tools shall be properly calibrated.

9. Dimensional Results (Reference AIAG PPAP Manual 2.2.9)

a. 100% dimensional inspection is required for a minimum of three (3) parts for each PPAP submittal, including subcomponents if the part or assembly is purchased at a higher level than the lowest level defined in the JLTV Technical Data Package and Computer Software Package. In the event that less than three parts are ordered, all parts shall be subject to 100% dimensional inspection.

b. Additional requirements shall be in accordance with PPAP Manual (Fourth Edition) Appendix H.

c. Dimensional inspection shall include evidence of conformance to all dimensions (to include basic dimensions), tolerances, and Geometric Dimensioning and Tolerancing (GD&T) requirements found on the applicable component drawing.

d. If the product drawing relies upon the 3D CAD model to fully define the part, the PPAP shall include evidence that all measured samples conform to the geometry and associated GD&T requirements defined by the 3D CAD model.

10. Records of Material / Performance Test Results (Reference AIAG PPAP Manual 2.2.10)

a. Compliance to the following are required to be documented, as applicable:

i. Raw Material Certifications

ii. Performance Test Reports which identify that all specified performance requirements on the Design Record have been demonstrated.

iii. Surface Finish Requirements

iv. Marking/Labeling Requirements

v. Paint/Plating Requirements

vi. Welding Documentation necessary to demonstrate conformance to specified weld requirements. (Welding Procedure Specifications, Welder Certifications, Weld Procedure Qualification Requirements, etc)

b. Compliance information for any other material or material process (e.g. heat treatment) or performance test requirement specified in the Design Record but not included in the list above shall be included.

11. Initial Process Studies (Reference AIAG PPAP Manual 2.2.11)

a. The requirements for significant production runs (PPAP Manual 2.1) and Quality Indices (PPAP Manual 2.2.11.2) shall be in accordance with PPAP Manual (Fourth Edition) Appendix H. All other PPAP Manual 2.2.11 requirements apply as written in the PPAP Manual (Fourth Edition).

b. Initial Process Studies shall be performed on all special characteristics.

i. All Critical Characteristics shall demonstrate a minimum CpK of 1.67.

ii. All Significant Characteristics shall demonstrate a minimum CpK of 1.33.

12. Qualified Laboratory Documentation (Reference AIAG PPAP Manual 2.2.12)

a. No additional guidance is required.

13. Appearance Approval Report (AAR) (Reference AIAG PPAP Manual 2.2.13)

a. Required when appearance requirements are specified in the Design Record.

14. Sample Production Parts (Reference AIAG PPAP Manual 2.2.14)

a. PPAP must be performed on production parts.

15. Master Sample (Reference AIAG PPAP Manual 2.2.15)

a. Photo documentation of conforming part shall be included.

b. A master sample is not required to be retained by the supplier.

16. Checking Aids (Reference AIAG PPAP Manual 2.2.16)

a. Required when aids are utilized to determine conformance with specified requirements.

17. Customer Specific Requirements (Reference AIAG PPAP Manual 2.2.17)

a. Component First Article Test (CFAT) Documentation shall be included. CFAT Documentation shall include a matrix summary of the results of each test performed, test procedures and test equipment utilized, detailed results of each test (to include raw data), and any applicable calibration or certification documentation. Labs certified to ISO 17025 are exempt from the requirement to furnish calibration information. Supplier certification cannot be used to fulfill CFAT requirements unless otherwise specified.

18. Part Submission Warrant (Reference AIAG PPAP Manual 2.2.18)

a. Required for all PPAP submissions.

b. Contractor format is acceptable provided all required elements are included

Commercial Off The Shelf (COTS) Components Commercial off the Shelf (COTS) Components are items sold in the commercial marketplace. These parts are commercially available, unaltered, and may be procured through distributors. The contractor shall always request the production process documentation prior to receiving the PPAP submittal from vendor. At times the contractor may be unable to attain the data for all 18 elements specified above to include within the PPAP package for COTS components. In these cases the supplier shall provide the minimum PPAP elements (1, 2, 3, 9, 14, 15, 17, and 18). The sub tier supplier is expected to demonstrate / affirm conformance with supporting PPAP documents or Certificates of Conformance (C of C). In cases when the sub tier supplier does not have the remaining PPAP elements, a C of C shall be attained. The C of C letter shall; affirm the article is commercially available, be on the supplier’s company letterhead, include the part number, include the part revision level, be signed by a representative within the contractor’s organization that has decision making authority. The C of C letter shall positively affirm that the part meets the requirements within the print.

“COTS Plus”: Parts that are commercially available, but have additional performance requirements, or parts that are deemed important to the JLTV system design (because of the part’s application). If the suppliers catalog page does not include all print specifications, the contractor is responsible to complete the remaining testing.

Interim and Full PPAP Approval (Reference AIAG PPAP Manual 5.2) Interim Approval for parts without CFAT requirements, granted by the Contractor to its supplier, shall be given prior to introduction of parts at the point of assembly or fabrication into the end item once the PPAP has achieved all of the requirements identified herein. Full PPAP approval is required no later than 120 days after interim approval is issued. In the event that the PPAP fails to reach full PPAP approval within this 120 day period, the Contractor shall alert the Government and request approval for continued use.

Interim Approval for parts with CFAT requirements and all parts that the contractor manufactures itself, for which the Government is the exclusive approval authority, must be received by the contractor from the Government prior to the introduction of parts at the point of assembly or fabrication into the end item. Full PPAP approval from the Government is required no later than 120 days after the interim approval for the corresponding part number is issued. In the event that the PPAP fails to reach receive PPAP approval within this 120 day period, the Contractor shall alert the Government and request approval for continued use of the parts in question.

The following table depicts the minimum required elements necessary for Interim and Full PPAP Approval:

Level 3 Full Level 3

X

X

X

X

X

X

X

X

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