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POLARIS INDUSTRIES INC.
2100 HIGHWAY 55
MEDINA, MN 55340
Production Part Approval Process (PPAP) Manual Procedure
OPS-PROC-0106
WRITTEN BY: Kevin O’Brien DATE: 15-Dec-15
APPROVED BY: Brad Clark DATE: 29-JAN-2016
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REVISION HISTORY
REV DATE AUTHOR APPROVER(S) DESCRIPTION OF CHANGES
1 14-Dec-15 Kevin O’Brien Brad Clark Initial Document Release
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1. PURPOSE/SCOPE ............................................................................................................................................. 5
2. TERMS & SYMBOLS ....................................................................................................................................... 5
3. PRODUCTION PART APPROVAL PROCESS (PPAP) .............................................................................. 6
3.1. PREAMBLE ..................................................................................................................................................... 6 3.2. APPLICABILITY ............................................................................................................................................... 7 3.3. WHEN IS A PPAP SUBMISSION REQUIRED? .................................................................................................... 7 3.4. 18 ELEMENTS OF A PPAP ............................................................................................................................... 8
3.4.1. Design Record ....................................................................................................................................... 9 3.4.2. Engineering Change Document ............................................................................................................. 9 3.4.3. Customer Engineering Approval ......................................................................................................... 10 3.4.4. Design Failure Mode and Effects Analysis (DFMEA) ........................................................................ 10 3.4.5. Process Flow Diagrams ....................................................................................................................... 10 3.4.6. Process Failure Mode and Effects analysis (Process FMEA) .............................................................. 10 3.4.7. Control Plan ......................................................................................................................................... 11 3.4.8. Measurement System Analysis (MSA) Studies ................................................................................... 12 3.4.9. Dimensional Results ............................................................................................................................ 12 3.4.10. Material, Performance Test Results ..................................................................................................... 14 3.4.11. Initial Process Studies .......................................................................................................................... 14 3.4.12. Qualified Laboratory Documentation .................................................................................................. 16 3.4.13. Appearance Approval Report .............................................................................................................. 16 3.4.14. Sample Production Parts ...................................................................................................................... 16 3.4.15. Master Sample ..................................................................................................................................... 17 3.4.16. Checking Aids ..................................................................................................................................... 17 3.4.17. Customer-Specific Requirements ........................................................................................................ 17 3.4.18. Part Submission Warrant (PSW) ......................................................................................................... 18
3.5. PPAP SUBMISSION LEVELS .......................................................................................................................... 20 3.6. ELECTRONIC SUBMISSION REQUIREMENTS .................................................................................................. 21 3.7. SIGNIFICANT PRODUCTION RUN ................................................................................................................... 22 3.8. PART SUBMISSION STATUS ........................................................................................................................... 22
4. REFERENCES ................................................................................................................................................. 23
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1. PURPOSE/SCOPE
The purpose of this document is to define expectations and provide guidance for
proper PPAP submission by the supplier. This Polaris document takes precedence
over any differences/discrepancies that may exist between the AIAG reference
manuals/materials referenced below.
2. TERMS & SYMBOLS
TERM DEFINITION
AAR Appearance Approval Report
AIAG Automotive Industry Action Group
APQP Advanced Product Quality Planning
CMM Coordinate Measuring Machine
DCR Drawing Change Request
DFMEA Design Failure Mode and Effects Analysis
ECL Engineering Change Level
FAIR First Article Inspection Report
GD&T Geometric Dimensioning and Tolerancing
KPC Key Product Characteristic
MSA Measurement System Analysis
NIST National Institute of Standards and Technology
PCR Product/Process Change Request
PDI Pre-delivery Inspection
PFMEA Potential Failure Modes and Effects Analysis
PPAP Production Part Approval Process
PQR Part Qualification Request (Obsolete Polaris Term)
PSW Part Submission Warrant
QA Quality Assurance
QE Quality Engineer
SDE Supplier Development Engineer
SPC Statistical Process Control
SQE Supplier Quality Engineer
SQAM Supplier Quality Assurance Manual
SYMBOL DEFINITION
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3. PRODUCTION PART APPROVAL PROCESS (PPAP)
Polaris does not accept separate charges for the cost of PPAP development and
should be factored in with the overall cost of doing business.
The Production Part Approval Process (PPAP) is a rigorous and structured process
for part qualification. PPAP is a method used for evaluating the complete
manufacturing process which was developed by the domestic auto industry as part of
QS 9000 and TS16949. A PPAP package is composed of several elements. These
elements are tools that focus on the manufacturing process and the prevention of
defects. Five different levels of documentation and submission requirements have
been identified and standardized. All of them include a Part Submission Warrant.
The PPAP package, if requested, is a significant component of the PPAP Request –
which is defined by the Polaris Supplier Quality Assurance Manual (SQAM). A
PPAP is typically required on a PRODUCTION PART for new part submissions and
implemented product change orders, but may be required in whole or in part for
other qualification events. Polaris will request various elements of PPAP for
submission as defined in the PPAP Request. As a default, Polaris requires
submission and retention of PPAP records per Tables 4.1 and 4.2 contained in the
AIAG 4th Edition PPAP manual unless otherwise specified.
3.1. PREAMBLE
Effective June 2006, PPAP 4th Edition replaced the PPAP 3rd Edition manual.
Polaris PPAP requirements are based on the PPAP 4th Edition.
To understand the PPAP process you must obtain a copy of the AIAG 4th Edition
PPAP manual from either www.aiag.org or www.Amazon.com.
Production Part Approval Process (PPAP) is updated to the 4th edition to incorporate
the customer focused process approach associated with ISO/TS 16949:2002 and
other changes.
PPAPs purpose continues to be to provide the evidence that all customer engineering
design record and specification requirements are properly understood by the
organization and the manufacturing process has the potential to produce product
consistently meeting these requirements during an actual production run, at the
quoted production rate, using production tooling and production personnel.
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3.2. APPLICABILITY
PPAP shall apply to supplier internal and external organization sites (Tier I, II, etc.)
supplying production parts, service parts, production materials or bulk materials to
Polaris.
Service parts, standard catalog production or service parts, production
materials or bulk material requirements will be at the sole discretion of the
Polaris Quality Assurance representative.
The word “shall” indicates mandatory requirements.
The word “should” indicates a recommendation.
Note: At the sole discretion of the Polaris quality assurance representative
when requested, PPAP submissions are required as a condition of doing
business with Polaris Industries.
3.3. WHEN IS A PPAP SUBMISSION REQUIRED?
The organization shall obtain approval from a Polaris QE, SQE, SDE or other
authorized representative for the items below (prior PCR approval may also be
required):
1. A new part or product.
2. Correction of a discrepancy on a previously submitted part.
3. Any changes to materials used in the previously approved part or
product.
4. Production from new or modified tools (except perishable tools), dies,
molds, patterns, etc. including additional or replacement tooling.
5. Production following an upgrade or rearrangement of existing tooling
or equipment.
6. Production from tooling and equipment transferred to a different plant
site, from an additional plant site or from a manufacturing/assembly
line move within the plant.
7. Change in the supplier for parts, non-equivalent materials or services
(i.e., heat treating, plating).
8. Product produced after the tooling has been inactive for volume
production for twelve months or more.
9. Product and process changes related to components of the production
product manufactured internally (supplier) or manufactured externally
(Tier II).
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10. Change in test/inspection method – new technique (no effect on
acceptance criteria).
11. New source of raw material from new or existing supplier.
12. Change in product appearance attributes.
The key words are “new” or “change”.
Check with the QE, SDE or SQE if in doubt.
For Polaris initiated changes, a PPAP Request will be created and defined in the
Polaris system by a Polaris authorized quality assurance representative.
The PPAP Request is the vehicle used by Polaris to control quality
submissions.
A FAIR by definition (First Article Inspection Report) cannot
be PPAPd since it is not part of a production run as defined in
Significant Production Run section.
The PPAP Request will be communicated to the supplier quality assurance
representative as designated by the supplier.
PPAP requirements will be defined in the PPAP Request with regard to submission
levels and due dates as well as the Polaris quality assurance representative contact
for electronic submissions.
Supplier initiated changes will be submitted to their SQE/SDE by way of a PCR.
See the Polaris PCR instructions for completing/submitting the PCR.
An approved PCR will define the PPAP requirements, which will then be entered
into the PPAP Request system.
The approved PCR should be submitted in Element 2 of the PPAP.
See the Polaris PPAP Training Aid for more information about PPAP
Requests.
3.4. 18 ELEMENTS OF A PPAP
1. Design Record (Polaris drawings only with released Polaris part numbers).
2. Engineering Change Documents, if any.
3. Customer Engineering Approval, if required.
4. Design FMEA – Failure Modes and Effects Analysis (DFMEA).
5. Process Flow Diagrams.
6. Process FMEA - Failure Modes and Effects (PFMEA).
7. Control Plan.
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8. Measurement System Analysis (MSA) Studies – if applicable for KPCs.
9. Dimensional Results (previously referred to as FAIR).
10. Material, Performance Test Results.
11. Initial Process studies – Cpk (if applicable for KPCs).
12. Qualified Laboratory Documentation.
13. Appearance Approval Report (AAR) - if applicable for appearance items.
14. Sample Product.
15. Master Sample.
16. Checking Aids.
17. Records of Compliance (with customer-specific requirements).
18. Part Submission Warrant (PSW).
3.4.1. Design Record
The Design Record is what the supplier has contracted to provide per the Polaris
Purchase Order (PO). Examples would include, but not limited to:
Polaris drawings (as defined by a unique Polaris part number) to the latest ECL
(Rev level) as defined on the PO.
Engineering specifications.
Special notes added to the PO (i.e., paint it black or special packaging).
The engineering drawing portion of the Design Record is often used to provide a
ballooned drawing when submitting Element 9 – Dimensioned Results (as required
in the Polaris Supplier Quality Assurance Manual).
Supplier drawings (if defined on the Polaris drawings or PO) would also be part of
the Design Record, but only if defined.
Polaris purchases to Polaris drawings.
3.4.2. Engineering Change Document
For changes not yet recorded in the design record but incorporated in the product,
part or tooling. Examples would be:
o Approved DCR.
Compliant PPAPs can be approved with approved DCRs.
o Approved Deviations.
Compliant PPAPs can be granted Interim Approval with
approved Deviations.
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See details in the Interim Approval section.
o Approved PCR.
Polaris approved PCR can be retained with the PPAP
submission.
3.4.3. Customer Engineering Approval
Where specified by Polaris, the supplier shall have evidence of customer
engineering approval.
o Note on Emails:
Emails can only clarify requirements, not define them.
Emails cannot re-define a requirement in lieu of a drawing
change.
3.4.4. Design Failure Mode and Effects Analysis (DFMEA)
When requested the product design-responsible organization shall develop a
Design FMEA in accordance with, and compliant to, Polaris-specified
requirements.
The purpose of a DFMEA is to identify all possible failure modes and the effects
they would have on the end product or customer. Subsequently, the necessary
changes to minimize those effects should be implemented and documented on the
DFMEA.
3.4.5. Process Flow Diagrams
Suppliers shall have a Process Flow Diagram in an organization-specified format
that clearly describes the production process steps and sequence, as appropriate
and meets the specified customer needs, requirements and expectations.
o Process Flow Diagrams for ‘families’ of similar parts are acceptable if
the new parts have been reviewed for commonality by the supplier
and/or Polaris.
3.4.6. Process Failure Mode and Effects analysis (Process FMEA)
Suppliers shall develop a PFMEA in accordance with and compliant to Polaris-
specified requirements.
o KPCs shall be identified in the “classification” column of the FMEA.
o A single Process FMEA may be applied to a process manufacturing a
family of similar parts or materials if reviewed for commonality by
the supplier and/or Polaris.
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3.4.7. Control Plan
Suppliers shall have a Control Plan that defines all methods used for process
control and complies with Polaris-specified requirements.
Control Plans for “families” of parts are acceptable if the new parts have
been reviewed for commonality by the supplier and/or Polaris.
The Process Control Plan is a comprehensive document that provides the details
to ensure delivered product is compliant with the design records, engineering
specifications and quality standards. The Process Control Plan does not take the
place of operator or workplace instructions, but may refer to them and their use
where appropriate.
Polaris does not require a supplier to submit a standard Process Control Plan
form; this allows suppliers to utilize their own internal documentation system to
provide this plan. The Polaris Process Control Plan however, can be used in lieu
of, or as a supplement to a supplier's.
A submitted Process Control Plan shall include the following information:
o Part Number and Revision Level.
o Part Description.
o Supplier Name and Plant.
o Polaris Supplier Number.
o Key Supplier Contact and Phone Number.
o Control Plan Date and Revision Level.
A submitted Process Control Plan shall include the following minimum
information for each Key Product Characteristic (KPC) specified and Key
Process Characteristic used by the supplier (and should be used for all process
steps). Supplier Key Product and Process Characteristics shall be included.
o Process Name/Operation Description.
o Product Characteristic.
o KPC Identifier.
o Product Specification.
o Measurement Technique.
o Sampling Plan.
o Control Method.
o Reaction Plan.
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3.4.8. Measurement System Analysis (MSA) Studies
Suppliers shall have applicable MSA studies (i.e., gage R&R, bias, linearity,
stability, for all new or modified gages, measurement, and test equipment).
A measurement system analysis is a mathematical method of determining how
much the variation within the measurement system contributes to the overall
measured process variability. An MSA is required for all KPC’s that require a
capability analysis. Detail on the MSA can be found in the AIAG manual. The
suggested method to analyze the measurement system is a Gage R&R study.
Gage R&R studies are required for PPAP submittal.
A Gage R&R (repeatability and reproducibility) study is used to understand how
consistent the gage’s measurements within a process are, regardless of the
operator. Using total tolerance, the percentage of R&R should strive to be less
than 10%. Gages are considered marginal if between 10% and 30%. If greater
than 10%, an explanation of why the gage is to be used shall be included.
Every effort shall be made to include samples that represent the full range of
process variation.
3.4.9. Dimensional Results
The dimensional results (previously referenced as FAIR – first article inspection
report) are a comprehensive inspection report of a production intent part(s).
Suppliers shall provide evidence that dimensional verifications required by the
Design Record and Control Plan have been completed and results indicate
compliance with specified requirements. This includes ANY functional
requirement as defined by the Design Record.
Suppliers shall record, with actual results: all dimensions (except reference
dimensions), characteristics and specifications as noted on the Design Record
and Control Plan.
Suppliers shall indicate the date of the Design Record, ECL and any authorized
engineering change document not yet incorporated in the Design Record
(Element 2) to which the part was made.
This information will also be included with all auxiliary documents (i.e.,
supplementary layout results sheets, sketches, tracings, cross sections, CMM
inspection point results, scanning, GD&T sheets or other auxiliary drawings used
in conjunction with the part drawing).
Per the Polaris Supplier Quality Assurance Manual, ballooned drawings
corresponding to the dimension results will also be provided.
When a “changes only” dimensional result is required, every change made to the
drawing as defined in the most current revision shall be analyzed. A ballooned
drawing reflecting only those changes shall also be submitted.
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When a tool has multiple cavities, stations, etc., one sample from each
cavity/station shall be measured.
Polaris does not require a supplier to submit a standard dimensional results form;
this allows suppliers to utilize their own internal documentation system to
provide this report.
For positional tolerances, the basic dimensions used to determine the location
must be listed on the dimension results report.
IMPORTANT: The parts measured for the dimensional results should be the
same part(s) submitted as formal samples in Element 14. All drawing
requirements shall be conforming to specs prior to submission, or an approved
deviations or DCR must accompany the submission.
A submitted dimensional result shall include the following information:
o Supplier Name.
o Polaris Part Number.
o Revision Level.
o Part Name.
o Date Inspected.
o A listing of all measuring equipment used.
o A listing of each characteristic measured including:
Nominal dimension call out.
Upper specification limit call out.
Lower specification limit call out.
Actual measurements taken with indication of pass/fail.
o A listing of all engineering material call outs with verification of
actual materials used.
o Verification of any specific engineering test call out (i.e. hardness,
surface finish, color, gloss, etc.).
o Name of inspector(s).
o Submit the actual part(s) measured with the dimensional result report.
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3.4.10. Material, Performance Test Results
Suppliers shall have records of material and/or performance test results for tests
specified on the Design Record or Control Plan.
Suppliers shall perform tests for all parts and product materials when chemical,
physical or metallurgical requirements are specified by the Design Record or
Control Plan.
Material test results shall indicate and include:
o The Design Record change level of the parts tested.
o Any authorized engineering change documents that have not yet been
incorporated in the Design Record.
o The number, date and ECL of the specifications to which the part was
tested.
o The actual results.
o The material supplier’s name.
o For products with Polaris-developed material specifications and a
Polaris-approved supplier list, the supplier shall procure materials
and/or services (i.e., painting, plating, heat-treating, welding) from
suppliers on that list.
Performance test results shall indicate and include:
o The Design Record change level of the parts tested.
o Any authorized engineering change documents that have not yet been
incorporated in the Design Record.
o The number, date and ECL of the specifications to which the part was
tested.
o The date on which the testing took place.
o The quantity tested.
o The actual results.
3.4.11. Initial Process Studies
The initial process study is a multi-part statistical study of critical and significant
dimensions to determine if the production processes are likely to yield products
that will consistently meet Polaris’ requirements.
The level of initial process capability or performance shall be determined to be
acceptable prior to submission for all Special Characteristics (KPC) designated
by Polaris.
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o 1.33 Cpk is the acceptable level for capability. All KPC’s shall meet
this level at a minimum. If the KPC does not meet a 1.33 Cpk, 100%
inspection shall be implemented in-process until it has been proven
that a 1.33 Cpk can be met, sustained and approved via the PPAP
process. This shall be documented on the process control plan.
Suppliers shall perform measurement system analysis to understand how
measurement error affects the study measurements.
o The part drawing defines the critical and significant dimensions
through the use of KPC’s and the (diamond) symbol. All dimensions
listed as KPC’s shall have a process study performed and have a
known Cpk Index that are tracked and maintained by the supplier or
the supplier must provide evidence of an error-proofed process.
There are certain cases where a non-KPC dimension requires a
process study and that will be detailed in the Polaris PPAP Request
System (such instances may include verification of a corrective
action).
The initial process study is focused on variables, not attribute data.
o Assembly errors, test failures and surface defects are examples of
attribute data, which is important to understand, but is not covered in
this initial study.
o To understand the performance of characteristics monitored by
attribute data will require more data collected over time. Unless
approved by a Polaris authorized quality assurance representative,
attribute data is not acceptable for PPAP submissions.
Cpk – the capability index for a stable process. It is used to predict the
future capability and is a measure of the inherent process variation of a
specific dimension, relative to an engineering specification, expressed in
terms of three standard deviations. A Cpk Index encompasses both process
spread (variation) and process centering and can only be determined from a
process verified to be within statistical control.
Ppk – the performance index. Ppk 1.67 for short term or initial
qualification. Cpk – go back after 3 months and reevaluate. Continual
monitoring required.
Sample Size: The standard sample size for determination of a Cpk Index is
30 unless otherwise specified. Samples drawn for statistical inferences as
well as Cpk calculations are to be selected from a consecutive based
sampling plan unless otherwise specified.
Multiple Tooling/Multi-Cavity Tooling: A separate Cpk analysis may be
required for each tool or cavity used to produce the same part number.
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Polaris Quality Assurance will define requirements via a Part Qualification
Request. Cavity traceability is vital for monitoring quality performance and
shall be considered with tooling design.
3.4.12. Qualified Laboratory Documentation
Inspection and testing for PPAP shall be performed by a qualified laboratory as
defined by Polaris requirements (i.e., an accredited laboratory).
The qualified laboratory (internal or external to the supplier) shall have a
laboratory scope and documentation, traceable to N.I.S.T., showing that the
laboratory is qualified for the type of measurements or tests conducted.
When an external/commercial laboratory is used, the supplier shall submit the
test results on the laboratory letterhead or the normal laboratory report format.
o The name of the laboratory that performed the tests, date(s) of the
tests and the standards used to run the tests shall be identified.
3.4.13. Appearance Approval Report
An appearance approval report shall be completed for each part (or series of
parts) when appearance requirements exist on the design record. Once the
appearance meets the requirements, a completed AAR and representative
production part(s) shall be submitted using the Polaris AAR Form.
Polaris AARs (complete with part disposition and Polaris quality assurance
representative signature) shall then accompany the PSW at the time of final
submission based upon submission level requested.
3.4.14. Sample Production Parts
PPAP samples must be taken from a Significant Production Run.
Sample sizes for PPAP reporting purposes should be of at least 5 parts.
Samples provided for Polaris approval can be a minimum of 1 part.
Ship sample part(s) to the attention of the responsible Polaris quality assurance
representative and to the location noted in the PPAP Request.
Include method of shipment (i.e. UPS, FedEx, etc.) and the shipper’s tracking
number in the PPAP Request.
Sample parts are to be shipped shortly after the electronic data is submitted to the
Polaris quality assurance representative.
The Sample Part Label (found in the Polaris Supplier Quality Assurance Manual)
must be affixed to the shipping containers.
Samples are to be shipped free of charge – Do not send sample parts with
inventory/production shipments – samples must be separate.
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Do not ship the sample(s) against any purchase order.
The bill of lading, invoice or packing slip must clearly state the parts are
“sample” at no cost to Polaris.
If samples are shipped against a purchase order they will be received into
inventory and will not be considered as PPAP samples – subject to an RMO.
3.4.15. Master Sample
The supplier shall retain a master sample for the same period as the production
part approval records (for one year after discontinuation) or:
o Until a new master sample is produced for the same Polaris P/N for
Polaris approval.
o Where a master sample is required by the Design Record, Control
Plan or inspection criteria, as a reference of standard.
The master sample shall be identified as such, and shall show the Polaris
approval date on the sample.
The supplier shall retain a master sample for each position of a multiple cavity
die, mold, tool or pattern, or production process unless otherwise specified by
Polaris.
Master samples are sometimes referred to as “golden parts”.
3.4.16. Checking Aids
If requested by Polaris, the supplier shall submit with the PPAP submission any
part-specific assembly or component checking aid.
The supplier shall certify that all aspects of the checking aid agree with part
dimensional requirements. Evidence can be provided using drawings, pictures,
etc.
The supplier shall document all released engineering design changes that have
been incorporated in the checking aid at the time of submission.
The supplier shall provide preventive maintenance of any checking aids for the
life of the part.
Measurement system analysis studies, i.e., gage R&R, accuracy, bias, linearity
and stability studies, shall be conducted in compliance with Polaris requirements.
Checking aids can include fixtures, variable and attribute gages, models,
templates and mylars specific to the product being submitted.
3.4.17. Customer-Specific Requirements
The supplier shall have records of compliance to all applicable Polaris-specific
requirements.
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Examples may be:
o Tooling information form.
o Packaging form.
o Inspection plan.
o PDI checklist.
o Supplier PPAP worksheet.
This would be defined by an authorized Polaris quality assurance representative.
3.4.18. Part Submission Warrant (PSW)
Upon completion of all PPAP requirements, the supplier shall complete the PSW.
A separate PSW shall be completed for each Polaris P/N unless otherwise agreed
to by an authorized Polaris quality assurance representative.
The specific cavities, molds, line, etc. reported in the Dimensional Results shall
be identified in the “Mold/Cavity/Production Process” line on a PSW, or in a
PSW attachment.
The supplier shall verify that all of the measurement and test results show
conformance with Polaris requirements and that all required documentation is
available and included in the submission as appropriate.
A responsible official of the supplier shall approve the PSW and provide contact
information.
Note: Polaris will not be signing nor returning submitted PSWs.
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Completing the PSW - minimum requirements outlined below:
o Be sure to select at least one box for each section – Reason for
Submission, Requested Submission Level and Submission Results.
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3.5. PPAP SUBMISSION LEVELS
Level 1
o Elements 13 (if applicable) and 18 are submitted to Polaris, balance of
elements retained at supplier.
Used when seeking a PSW and Appearance Approval Report
only, or a current supplier who has provided acceptable
quality and an ECL ‘opens up’ a previous requirement.
Level 2
o Elements 1, 2, 9, 10, 12, 13, 14 and 18 where applicable are submitted
to Polaris, balance of elements retained at supplier.
Typically ECL (Rev changes) to a current supplier for the
same product or low to medium risk products/services.
Level 3
o Elements 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 17 and 18 (where
applicable) submitted to Polaris, balance of elements retained at
supplier.
Should be used on high risk parts or new suppliers.
Level 4
o Used when custom requirements are best suited.
o At a minimum elements 1, 18 and other elements defined by Polaris
in the PPAP Request are submitted, balance of elements retained at
supplier.
Unless otherwise specified, the default elements in a Polaris
Level 4 PPAP include the following items:
1. Design Record (Polaris drawings only with released
Polaris part numbers).
5. Process Flow Diagrams.
6. Process FMEA - Failure Mode Effects Analysis
(PFMEA).
7. Control Plan.
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8. Measurement System Analysis Studies - if applicable for
KPCs (MSA).
9. Dimensional Results (Previously referred to as FAIR)
10. Material, Performance Test Results.
11. Initial Process Study – Cpk (if applicable for KPCs)
13. Appearance Approval Report - if applicable for
appearance items (AAR).
14. Sample Product.
18. Part Submission Warrant (PSW).
Level 5
o Product samples and supporting data is to be retained and reviewed at
the organization’s manufacturing location.
Used when on site approval is the best option.
Note: – Submission levels, individual requirements and purposes are at the sole
discretion of the Polaris quality assurance representative to ensure design
intent, a controlled process and mitigated risk.
3.6. ELECTRONIC SUBMISSION REQUIREMENTS
PPAP submissions need to be in English.
Suppliers must submit PPAP documents electronically to the Polaris quality
assurance representative listed in the PPAP Request system.
Suppliers shall send only one email for each PPAP Request with the part number
in the subject line of the email.
Failure to do so will delay review of the submission and the
submission might be counted as late.
Suppliers shall send all electronic data (.xls, .pdf, .tif or .doc format) to the QE
email link on the PPAP Request.
If the files are ‘zipped’ suppliers must make sure that ‘polaris’ is included in the
name of the .zip file or the file will be quarantined by the Polaris firewall.
Suppliers shall send sample parts to the address listed in the PPAP Request
shortly after the electronic data is sent.
When suppliers send electronic data and sample parts, they shall list the shipper
name (i.e. UPS, FedEx, etc.), tracking number and the date/content/method/to
whom electronic data was sent in the supplier information section of the PPAP
Request.
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3.7. SIGNIFICANT PRODUCTION RUN
Only production parts can be PPAPd.
For production parts, product for PPAP shall be randomly taken from a
significant production run.
This significant production run shall be from one to eight hours of production
and with the specific production quantity, to total a minimum of 30 consecutive
parts (unless otherwise specified by the authorized Polaris quality assurance
representative).
The significant production run shall be conducted at the production site, at the
production rate agreed upon on the Polaris PO (delivery), using production
tooling, production gaging, production process, production materials and
production operators.
Parts from each unique production process, i.e., duplicate assembly line and/or
work cell, each position of a multiple cavity die, mold, tool or pattern, shall be
measured and representative parts tested.
3.8. PART SUBMISSION STATUS
PPAP submissions will be reviewed by the Polaris quality assurance representative
and location noted on the PPAP Request.
PPAP dispositions carry-over for all of Polaris, not just the business unit
dispositioning the PPAP Request.
Approved
o Approved indicates the submitted part, including all sub-components,
meets all customer requirements.
o The supplier is therefore authorized to ship production quantities of
the product, subject to releases from the customer scheduling activity.
Interim Approval
o Interim Approval permits shipment of material for production
requirements on a limited time or piece quantity basis.
o Interim Approval will only be granted when the supplier has:
Clearly defined the non-compliances preventing approval; and
prepared an action plan agreed upon by the customer.
PPAP re-submission is required to obtain a status of
“approved.”
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o Material covered by Interim Approval that fails to meet the agreed-
upon action plan, either by the expiration date or the shipment of the
authorized quantity, will be rejected.
o No additional shipments are authorized unless an extension of the
Interim Approval is granted.
o In situations where production parts are needed prior to the supplier’s
ability to meet all of the conditions of PPAP (use of temporary
tooling, not run at rate, etc.) the Polaris quality assurance
representative may grant Interim Approval to allow the supplier to
ship product allowing the supplier to resubmit the PPAP when all
aspects of the PPAP are compliant.
The rule of limited time or piece quantity basis still applies as
with all of the conditions of Interim Approval.
Rejected
o Rejected means that the PPAP submission does not meet the customer
requirements, based on the production lot from which it was taken
and/or accompanying documentation.
In such cases, the submission and/or process, as appropriate,
shall be corrected to meet Polaris requirements.
The submission shall be approved before production quantities
may be shipped.
4. REFERENCES
Polaris Supplier Quality Assurance Manual (SQAM).
AIAG (Automotive Industry Action Group) reference manuals (4th Editions) are used
by Polaris Industries and can be purchased at www.aiag.org. They are available in
Chinese, Japanese, Korean, Portuguese, Russian, Spanish & German.
o Production Part Approval Process (PPAP).
o Advanced Product Quality Planning & Control Plan (APQP).
o Potential Failure Modes and Effects Analysis (PFMEA).
o Measurement System Analysis (MSA).
o Statistical Process Control (SPC).
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