Ford's PPAP Customer Specific Requirements Updated: Keeping up with PPAP CSR Changes with PPAPQuest

On July 5th, 2023, the International Automotive Task Force (IATF) announced updates to Ford’s Customer Specific Requirements (CSR) for IATF 16949 and the Production Part Approval Process (PPAP). While these updates encompass various changes and clarifications, the focus here is on the changes made to the Initial Process Studies in the PPAP CSRs. Particularly, we will delve into the clarifications made to capability studies for samples with quantities less than 125, as being able to appropriately conduct studies with 125 samples for each studied characteristic is a frequent challenge for Tier-1 firms.

Unpacking the Changes

In our view, the most significant update for PPAP CSRs lies in the clarification of the ‘Initial Process Study,’ or what is commonly known as the capability study. The guidelines maintain that an organization is required to complete measurement system analysis of all gauges prior to initiating the process capability study and the characteristics being studied should be in a state of statistical control – talk to us about our GageQuest and InspectionQuest products, if you need help in these areas. The focus, however, is on how Ford has handled the process capability with a sample size of less than 125.

Previously, the Initial Process Study required a data set of at least 25 subgroups and a subgroup size of at least 5 for a minimum of 125 measurements, with the subgroups of 5 being evenly distributed throughout a significant run (meaning at least 300 pieces) and representing all tools, cavities, machines, etc. In scenarios where the part size, launch timing, tooling availability, or other factors prevented the collection of 25 subgroups, there were no defined conditions articulated for STA approval. Under such conditions, concessions might often be discussed with an STA on a case-by-case basis, but there were no clearly defined process requirements, such as the implementation of 100% inspection or error-proofing, that were necessary to get STA approval.

With the updated CSR, requirements have been articulated in that exceptions to the minimum number of parts can be aligned with the Site STA, and the rationale for the exception should be documented in the PPAP package. Until the organization can determine process capability utilizing data from a 125-piece sample, the requirement for 100% inspection or mistake proofing integrated into the process has been added, however, a later demonstration of process stability and acceptable capability can remove the need for 100% inspection down the road – with an updated Control Plan approved by the customer, of course.

The document also provides guidance on how to conduct process capability studies when the requirements for the Ppk data set are not met. This includes specific examples and advice on adjusting measurements for variables and tolerances, including one-sided and two-sided tolerances, when using 100% inspection gauges.

The emphasis of these updates is on ensuring that a high degree of quality and consistency is maintained throughout the manufacturing process, regardless of the size of the sample.

Keeping up with CSRs with PPAPQuest

While keeping up with ever-changing customer-specific requirements might seem daunting, they can be navigated effectively with the right tools. That’s where PPAPQuest comes in. It’s a comprehensive module designed to streamline the PPAP process, making it easier to manage all PPAP requirements, including up-to-date CSRs.

Our PPAPQuest module integrates easily with your existing processes and our other modules in our automotive suite, allowing users to define pre-set PPAP levels, submission requirements, guidance on CSRs, etc. to guide your cross-functional teams step-by-step through the process to ensure that all requirements are met.

Perhaps even more valuable, PPAPQuest integrates seamlessly with our Collaboration Portal so that you can manage and enforce your own requirements or cascade CSRs downstream to ensure that your received parts and components from your suppliers consistently meet all PPAP requirements as well.

Try PPAPQuest Today

Why not see for yourself? We’re so confident in the utility and user-friendliness of the PPAPQuest module that we’re offering a 30-day Proof-of-Concept (POC) trial. This gives you a risk-free opportunity to see how PPAPQuest can streamline your processes and ensure you’re compliant with the latest requirements.

Don’t let the PPAP changes leave you feeling overwhelmed. Reach out today for a demo of PPAPQuest and experience how we can simplify and streamline your path to PPAP compliance.

Key Challenges Addressed

• No dashboards for overview and management of all PPAPs in one place
• Suppliers slow to respond or not responding, creating production delays
• Multiple errors and rework due to lack of consistency and discipline
• All communication with suppliers managed through emails and impossible to track and very time consuming to manage
• No alerts for resubmissions of PPAPs on annual basis
• Time consuming to manage and track PPAP process with suppliers
• Lack of real time transparency and visibility of information and communication with suppliers